Category Archives: Audi

News about Audi automobile manufacturer. News about Audi recalls, technical service bulletins (TSB), and problems regarding Audi vehicles.

Audi E-Tron Quattro Fire Risk From Overheating Battery Modules

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The Volkswagen Group of America, operating under its Audi brand, has recently identified a critical issue in a range of its electric vehicle models. This issue revolves around the charging system, specifically the high-voltage battery modules, raising concerns about potential overheating and fire safety risks.

Affected Models

The problem affects several Audi models between 2019 and 2024, including the RS e-tron GT, e-tron GT, Q4 e-tron Sportback, Q4 e-tron, Audi A8, e-tron Quattro, e-tron Sportback Quattro, Q5, and A7.

Overheating High-Voltage Battery Modules

The central issue lies in the high-voltage battery modules, which are prone to overheating. This has been especially evident when charging with the industrial 220V/240V plug at a current of 40 amperes. Crucially, Investigations revealed that the charging equipment itself was not at fault. Instead, the issue often stemmed from household power outlets and wiring incapable of handling the required current, leading to overheating of the home infrastructure.

Initial Discovery and Response

The issue first came to light in April 2020, following a fire incident outside the U.S. Audi collaborated with their high-voltage battery supplier, LG Energy Solutions, to investigate. By mid-2023, a noticeable increase in thermal events led to a deeper examination. Despite a service campaign in April 2022 that included a software update for cell module balancing, issues persisted.

Recall and Remedial Actions

In response, Audi initiated a voluntary global safety recall, designated 93U9 by Audi and 23V-867 by the NHTSA. The recall includes installing onboard diagnostic software to monitor battery module performance and replacing affected modules as necessary. Interim notification letters are scheduled for February 2024, with a detailed follow-up expected in the third quarter of the same year.

Charging Cable Replacement

A significant aspect of the recall is the replacement of the power cable used for industrial sockets (220V/240V/NEMA 14-50). The existing cable (part number 7PP971678 ED) will be replaced with a new design (part number 7PP971678GA), featuring temperature sensors. These cables should be available in the second quarter of 2024.

Safety Concerns and User Guidance

Owners of affected models are advised to be cautious, especially when using industrial sockets for charging. The overheating issue can cause not only damage to the charging cable but also pose a risk to household electrical infrastructure. If the problem exists, users may notice the charging cable feeling hot to the touch after use.

This recall underscores the importance of matching electric vehicle charging systems with compatible household wiring. Audi’s proactive steps in addressing this issue highlight their commitment to customer safety and the integrity of their electric vehicle line. Owners of the affected models are encouraged to heed recall notices and ensure their home charging setups are compatible and safe.

The charging issue identified in Audi’s electric vehicles bears notable similarities to the Chevrolet Bolt recall (21V-650). In both cases, the central concern revolves around the battery systems and the associated risk of overheating, which could potentially lead to fire hazards. The Chevrolet Bolt recall, much like Audi’s, involved issues with high-voltage battery packs that were found to be prone to catching fire. Both recalls necessitated substantial corrective actions, including software updates, close monitoring of battery performance, and in some cases, the replacement of battery modules. Furthermore, these incidents highlight a broader challenge in the electric vehicle industry, emphasizing the need for more robust and safe battery technologies and charging infrastructures. Such parallels underline the growing pains of electric vehicle technology and the critical importance of ensuring safety as these vehicles become increasingly prevalent.

Volkswagen Charging Cable Could Overheat

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Volkswagen Group of America, Inc., particularly its Audi division, is facing a significant challenge with its 220V/240V charging cables. Owners of certain 2019-2024 Audi models are being notified due to a defect that could lead to the overheating and potential fire hazard of the outlet or charging cable. This alarming issue affects a range of models, including:

  • 2021-2022 Audi A7
  • 2020-2021 Audi A8
  • 2019-2024 Audi E-Tron
  • 2022-2024 Audi E-Tron GT
  • 2022-2024 Audi Q4 E-Tron
  • 2020-2024 Audi Q5
  • 2022-2024 Audi RS E-Tron GT

The problem first came to light in September 2020 when cases of melting and overheating at the industrial socket (NEMA 14-50) were reported during the use of the industrial 220V/240V plug with 40 amperes. Audi’s thorough investigation, which involved requesting parts from the field and analyzing customer charging behavior, revealed that the vehicles and the provided charging equipment were not at fault. Instead, the cause was often linked to household power outlets and wiring, or circuit breakers not capable of handling the required electrical current.

Understanding that household power outlets and wiring might not be equipped to handle the necessary current, Audi initiated a service campaign that instructed customers to bring their charging equipment to an Audi dealer to modify the charging system control unit to a 50% power level for the industrial plug. Additionally, a warning label was attached to the control unit of the Audi compact charging system, advising on safe usage.

Despite these measures, and the ability to charge at 100% current upon confirmation of adequate home power supply, further incidents of overheating and melting sockets were reported. As a result, in January 2022, Audi launched a safety recall, superseding the service campaign, to replace the affected charging cables with new ones equipped with temperature sensors. For unsold vehicles, the industrial charging cable will be replaced before delivery. As of the latest reports, Audi has identified 615 claims related to this issue from 08/05/2020 to 12/05/2023. Fortunately, there have been no reports of fires, crashes, or injuries connected to this problem.

Audi advises owners of the affected models not to use the 220V/240V compact/portable charging cable. Instead, they should use the 110V home charging cable or public charging stations until the issue is resolved. Owners can expect to receive interim notification letters by February 9, 2024, explaining the safety risks. A second notice will follow, detailing the availability of remedy parts, expected around mid-2024. Audi’s recall numbers are 93U6 and 93U8, with the NHTSA campaign number being 23V-842.

This recall underscores the importance of not only the quality of automotive products but also the compatibility and capacity of home electrical systems. Owners of the affected models are urged to heed the recall notices and take the necessary steps to ensure their safety.

2018-2022 Audi Q5 And SQ5 Sportback Loss Of Engine Power

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In August 2020, Volkswagen / Audi received an inquiry about a gateway control module failure in an Audi Q5 vehicle in China. An inspection of the situation found that the gateway control module had gone into fail safe mode because of liquid entering the module from a rear bench seat spill.

The gateway control module has been programmed to go into a fail-safe mode when an implausible signal is detected in the control unit. If an implausible signal is detected, the gateway switches off its function in order to avoid unwanted vehicle reactions. The vehicle remains steerable and the brake system will work, but the engine will go into emergency mode and remains in operation with reduced power.

Audi performed a safety assessment to evaluate the potential conditions and consequences that could result from a power shutdown of the gateway control module due to liquid ingress. Audi also conducted a risk assessment which indicated that the risk of a liquid spill leading to a failure of the gateway control module is very low and rare over the lifetime of the vehicle. At the time there were only isolated cases in the North American region and all of them happened after an outside influence, mostly after a beverage spill. Audi continued to monitor the problem.

In March 2021, Audi experienced an increase in customer reports related to gateway control module failures on Q5 vehicles after a liquid spill. Audi conducted additional testing and continued to investigate a potential solution to be implemented in production and in the field. Due to single field cases alleging the failure without a liquid spill, an additional investigation was initiated to rule out other root causes for liquid ingress. In August 2021 Audi identified a potential manufacturing issue in the factory in Mexico. “Due to a programming error of a glue bead robot, an underbody seam may not have been sealed sufficiently and therefore allow water ingress from underneath in very rare cases when driving through heavy rain or deep puddles.” The adjustment to the robot was implemented immediately and analysis continued regarding the impact of this additional potential cause for liquid ingress.

The Audi Safety Committee began to issue a service campaign in order to install a protective cover for the gateway control module and to seal the underbody in the area of the insufficient glue bead, but after a meeting with Transport Canada and the Defective Product Administrative Center in China, the Audi Product Safety Committee re-evaluated their decision and decided to conduct a voluntary recall to fix affected vehicles.

The Vehicles Affected Include:
2018-2022 Audi Q5 Sportback
2018-2022 Audi SQ5 Sportback

2020 Audi Q8 Transmission Fluid Leak

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Volkswagen will be contacting owners of certain 2020 Audi Q8 SUVs, regarding a potential problem affecting the transmission in their vehicle.

Due to a manufacturing error, the flanges of certain gearbox oil pipes were made from an uncertified material. Because of this difference in material, a permanent connection could not be created during the welding process and a transmission fluid leak could develop between the transmission oil pipe and the flange. A loss of transmission fluid will result in oil marks on the ground beneath the vehicle and a warning lamp indicator, once the fluid goes beneath a certain level.

Dealers will correct the problem by inspecting the transmission oil pipe welds and replacing it as necessary. Volkswagen’s number for this recall is 38C7 and the NHTSA campaign number is 20V-272.

Audi R8 Spyder & R8 Coupe Transmission Fluid Vent Hose Leak

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If you are the owner of a 2017-2018 Audi R8 Spyder or R8 Coupe, you may be receiving a manufacturer defect notice for the power train of your vehicle. According to the defect report filed with the NHTSA, during extreme maneuvers the transmission fluid could expand and foam up beyond the expansion volume in the gearbox, causing the transmission fluid to leak out of the gearbox ventilation hose. The fluid could contact hot engine parts, causing smoke and a possible fire.

Dealers will correct the problem by adding a double ventilation hose that has a higher oil expansion volume. Volkswagen’s number for this recall is 34J1 and the NHTSA campaign number is 18V-639.

Audi A8 & S8 Fuel Smell

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Volkswagen will be contacting the owners of certain 2013-2015 Audi A8 and S8 vehicles because of a problem affecting the fuel system.

According to the NHTSA defect report, the high pressure fuel pump supply line could become porous and deteriorate from the inside. The resulting fuel leak may lead to a fuel smell withing the vehicle cabin and a potential fire in the presence of an ignition source.

Audi will be asking owners to return to their dealers to have the fuel line replaced. Volkswagen’s number for this recall is 20AV and the NHTSA campaign number is 18V-430.

Audi A4, A5 & Q5 Susceptible To Auxiliary Heater Fires

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Volkswagen will be contacting the owners of certain 2013-2016 Audi A4, A5 & Q5 vehicles regarding a problem affecting the electrical connector to the auxiliary heater. According to the defect report, the connector is susceptible to contact corrosion which may cause the auxiliary heater to fail and/or cause the wires to overheat and melt. The problem could result in an electrical fire.

Owners receiving notices will be asked to return to their dealers to have the auxiliary heater replaced, as necessary. Owners wanting more information about the problem can contact Audi customer service at 1-800-893-5298. Volkswagen’s numbers for this recall are 80C5 and 80C6 and the NHTSA campaign number is 17V-622.

2017-2018 Audi A3 Stalling

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Volkswagen will be asking the owners of certain 2017-2018 Audi A3 vehicles to return to their dealerships to correct a problem affecting the engine control unit (ECU). According to the defect report, the engine air/fuel mixture software is not robust enough. During engine start up or idling, the system may misinterpret the rotation of the dual mass flywheel as a knocking condition. The defect will result in loss of lose motive power when beginning to move from a stop or during a slow acceleration. Drivers will be alerted of a problem through an “Engine Stop While Driving” warning light.

Dealers will correct the problem by reprogramming the ECU software. For more information about the recall, owners may contact Audi customer service at 1-800-253-2834. Volkswagen’s number for this recall is 24DF the NHTSA campaign number is 17V-508.