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March 16, 2022 NHTSA CAMPAIGN NUMBER: 22V162000
Unreliable HV Battery Connection May Cause Stall
An unreliable battery connection may cause a stall, increasing the risk of a crash.
NHTSA Campaign Number: 22V162
Manufacturer Volkswagen Group of America, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 351
Summary
Volkswagen Group of America, Inc. (Volkswagen
) is recalling certain 2021 ID4 vehicles. Incorrect soldering of the flexible printed circuit assembled (FPCA), inside the high voltage (HV) battery, may cause an unreliable connection.
Remedy
Dealers will replace the battery cell modules, free of charge. Owner notification letters were mailed December 6, 2022. Owners may contact Volkswagen customer service at 1-800-893-5298. Volkswagen
’s number for this recall is 9302.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check if your Volkswagen has a Recall
Affected Vehicles
Country | Beginning Model Year | Ending Model Year | Vehicle | Vehicle Count |
USA | 2021 | 2021 | ID4 | 356 |
CAN | 2021 | 2021 | ID4 | 6 |
Problem Description
Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning.
Corrective Action
Replace the affected battery cell modules.
Precautions
If the recall issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, customers are advised to contact an authorized Volkswagen dealer without delay to make arrangements to have the vehicle diagnosed/repaired.
Code Visibility
On April 08, 2022, the campaign code was applied to affected vehicles.
Owner Notification
Owner notification will take place in December 2022. Owner letter examples are included in this bulletin for your reference.
Repair Overview
All vehicles โ perform a test plan to check for cell modules with an increased self-discharge. If a module is identified by the test plan as needing replacement, it will be replaced while the HV battery is open.
Criteria 04 vehicles – replace one, preidentified, cell module inside the high voltage battery.
Criteria 05 vehicles – replace two, preidentified, cell modules inside the high voltage battery.
NOTE
There are three Criteria 04 VINs that have additional pre-identified cell modules. These VINs are included in a future campaign. All of the preidentified cell modules should be replaced under this action.
Chronology of Defect
January 16, 2021: The first known field case occurred outside of the U.S. The claim was related to the vehicle not starting at the beginning of a trip. Analysis into the non-starting condition began.
May 12, 2021: Supplier identified the root cause of the non-starting condition. Given that the claims did not relate to vehicles while driving, the topic was addressed as a quality topic.
May 2021 โ December 2021: Quality and safety departments monitored the field and continued analyzing the nature and frequency of the non-starting condition.
December 16, 2021: The topic was presented to the Volkswagen pre-Product Safety Committee panel, which requested additional details on affected population.
January 13, 2022: A field claim alleging a stall while driving condition was reported in a non-Volkswagen vehicle outside of the U.S. Analysis into the stall while driving condition began.
January 14, 2022: The Volkswagen Product Safety Committee recommended continued field monitoring and requested a follow-up presentation. At this time, the analysis had just begun following the first stall while driving field complaint.
January 14, 2022 โ March 1, 2022: Further analysis of field claims and related diagnosis protocols to identify whether stall while driving issue might also affect Volkswagen vehicles.
March 02, 2022: During a Multi-Brand Clearing committee meeting, impacted brands shared information on analysis of the potential stall while driving cases. Further update to differentiate between vehicles affected by the non-starting condition vs. the stall while driving condition was requested.
March 09, 2022: The Multi-Brand Clearing committee decided to conduct a recall of Volkswagen vehicles in the U.S. that contain the affected parts.
May – August 2022: The battery supplierโs sub-supplier conducted further analysis, and informed Volkswagen about additional potentially affected vehicles. The sub-supplier who had analyzed the solder joints further optimized their detection algorithm and applied this again to all previously taken pictures. During this second review, additional potentially affected parts were finally identified. This included five (5) additional vehicles identified in the U.S. market. Neither Volkswagen
nor the battery supplier were aware of this second review until it had been completed.
September 07, 2022: The information was presented to the Volkswagen Product Safety Committee, who then made the decision to recall the additional five (5) vehicles in the U.S. market.
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
VOLKSWAGEN![]() | ID.4 | 2021 |
18 Associated Documents
Defect Notice 573 Report
RCLRPT-22V162-1029.PDF 215.969KB
Recall Acknowledgement
RCAK-22V162-7624.pdf 706.575KB
Manufacturer Notices(to Dealers,etc) – VOLKSWAGEN Date: April 08, 2022 CORRECTED – Advance Notice โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery
RCMN-22V162-3611.pdf 832.356KB
Manufacturer Notices(to Dealers,etc) – VOLKSWAGEN Date: April 08, 2022 Advance Notice โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery
RCMN-22V162-0125.pdf 833.969KB
Manufacturer Notices(to Dealers,etc) – VOLKSWAGEN Date: April 22, 2022 IMPORTANT โ Safety Recall 93O2 Repair Preparations
RCMN-22V162-2787.pdf 271.216KB
ISSUED Interim Owner Notification Letter(Part 577) – PRI
RIONL-22V162-1435.pdf 627.617KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-22V162-4865.pdf 314.317KB
Recall 573 Report-Amendment 1 – 05/26/2022
RCLRPT-22V162-4053.PDF 216.002KB
Amended Chronology for Volkswagen Recall 93O2/NHTSA 22V-162
RMISC-22V162-4731.pdf 208.563KB
Recall 573 Report-Amendment 2 – 09/14/2022
RCLRPT-22V162-2948.PDF 243.522KB
Remedy Instructions and TSB
RCRIT-22V162-9810.pdf 10914.835KB
ISSUED Owner Notification Letter(Part 577) – PRI
RCONL-22V162-2854.pdf 114.999KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V162-8039.pdf 100.505KB
Manufacturer Notices(to Dealers,etc) – VOLKSWAGEN Date: December 05, 2022 Repair Available โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery
RCMN-22V162-9571.pdf 773.552KB
Remedy Instructions and TSB
RCRIT-22V162-9106.pdf 1728.433KB
Manufacturer Notices(to Dealers,etc) – VOLKSWAGEN Date: December 22, 2022 REVISION โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery
RCMN-22V162-9074.pdf 282.579KB
Recall Quarterly Report #1, 2022-4
RCLQRT-22V162-1713.PDF 211.151KB
Volkswagen – Recall FAQ – February 2023
RMISC-22V162-7933.pdf 634.096KB
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SEOCONTENT-START
NAME Title Department Phone Fax Date Dear Ms. Carlson: Volkswagen hereby submits the following amended chronology associated with the subject recall. Information added to the chronology accounts for the timeframe of May-August 2022 and September 07, 2022. Chronology of Defect January 16, 2021: The first known field case occurred outside of the U.S. The claim was related to the vehicle not starting at the beginning of a trip. Analysis into the non-starting condition began. May 12, 2021: Supplier identified the root cause of the non-starting condition. Given that the claims did not relate to vehicles while driving, the topic was addressed as a quality topic. May 2021 โ December 2021: Quality and safety departments monitored the field and continued analyzing the nature and frequency of the non-starting condition. December 16, 2021: The topic was presented to the Volkswagen pre-Product Safety Committee panel, which requested additional details on affected population. January 13, 2022: A field claim alleging a stall while driving condition was reported in a non-Volkswagen vehicle outside of the U.S. Analysis into the stall while driving condition began. January 14, 2022: The Volkswagen Product Safety Committee recommended continued field monitoring and requested a follow-up presentation. At this time, the analysis had just begun following the first stall while driving field complaint. January 14, 2022 โ March 1, 2022: Further analysis of field claims and related diagnosis protocols to identify whether stall while driving issue might also affect Volkswagen vehicles. March 02, 2022: During a Multi-Brand Clearing committee meeting, impacted brands shared information on analysis of the potential stall while driving cases. Further update to differentiate between vehicles affected by the non-starting condition vs. the stall while driving condition was requested. March 09, 2022: The Multi-Brand Clearing committee decided to conduct a recall of Volkswagen vehicles in the U.S. that contain the affected parts. Ann Carlson, Acting Administrator National Highway Traffic Safety Administration 1200 New Jersey Avenue, S.E. Washington, DC 20590 Subject: Amended Chronology for Volkswagen Recall 93O2/NHTSA 22V-162 Christopher T. Sandvig Director Group Customer Protection 248-754-5000 248-754-5093 September 14, 2022 May – August 2022: The battery supplierโs sub-supplier conducted further analysis, and informed Volkswagen about additional potentially affected vehicles. The sub-supplier who had analyzed the solder joints further optimized their detection algorithm and applied this again to all previously taken pictures. During this second review, additional potentially affected parts were finally identified. This included five (5) additional vehicles identified in the U.S. market. Neither Volkswagen nor the battery supplier were aware of this second review until it had been completed. September 07, 2022: The information was presented to the Volkswagen Product Safety Committee, who then made the decision to recall the additional five (5) vehicles in the U.S. market. Please contact me if you require any additional information or have any questions related to this information. Sincerely, Christopher T. Sandvig Director, Group Customer Protection Group Quality
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TOPIC TYPE RECALL CODE QUESTION ANSWER Safety Recall 93O2 Safety Recall 93O2 What vehicles are included in Safety Recall 93O2? What is the safety concern for Safety Recall 93O2? Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Are there any precautions I should take because my vehicle is part of Safety Recall 93O2? If the recall issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, customers are advised to contact an authorized Volkswagen dealer without delay to make arrangements to have the vehicle diagnosed/repaired. What is the repair for the Safety Recall 93O2? To address this potential issue, your authorized Volkswagen dealer will replace the affected battery cell modules. When will the repair for Safety Recall 93O2 be available? Repairs for this recall have begun. Please contact your authorized Volkswagen dealer without delay to schedule this recall repair. To set up an appointment online, please visit www.vw.com/find-a-dealer.
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Volkswagen of America, Inc., 3800 Hamlin Road, Auburn Hills, MI 48326 If you should have any questions about this communication, please reach out to us using your preferred method of communication at www.vw.com/contact or by calling us at 800-893-5298. If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. To check your vehicleโs eligibility for repair under this or any other recall/service campaign, please visit www.vw.com/owners/recalls and enter your Vehicle Identification Number (VIN) into the Recall/Service Campaign Lookup tool. If you are the lessor and registered owner of the vehicle identified in this action, the law requires you to forward this letter immediately via firstclass mail to the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle, please fill out the enclosed prepaid Owner Reply card and mail it to us so we can update our records. 93O2 USA Form No. F_3.4_AHQ-GQO-CP-C_054 Rev. 5.0 IMPORTANT SAFETY RECALL <MONTH YEAR> <CUSTOMER NAME> <CUSTOMER ADDRESS> <CUSTOMER CITY STATE ZIPCODE> This notice applies to your vehicle: <VIN> <MODELYEAR> <BRAND> <MODEL> NHTSA: 22V162 Volkswagen Recall: 93O2 โ Flexible Printed Circuit Solder for High-Voltage (HV) Battery INTERIM SAFETY RECALL NOTICE FOR YOUR VEHICLE A recall repair is not yet available This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain Volkswagen vehicles. Our records show that you are the owner of a vehicle affected by this action. About this recall: Specific soldering points on the flexible printed circuit assembled inside the highvoltage (HV) battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving, which can lead to a crash without warning. A recall repair is not yet available. We will send another letter as soon as the recall work can be completed on your vehicle. What you can do now: If the recall condition is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high-voltage system. Should this occur, owners are advised to make an appointment with their authorized Volkswagen dealer without delay to have the vehicle diagnosed/repaired. Owners are also advised to review the ownerโs manual so that they are familiar with the warnings that may appear in the instrument panel. Please do not contact your dealer about this recall unless you believe your vehicle has the condition described in this letter. Your safety and that of your passengers is our highest priority, and we are working to make a recall repair available as soon as possible. We apologize for any inconvenience this letter may cause. Sincerely, Volkswagen Customer Protection Volkswagen of America, Inc., 3800 Hamlin Road, Auburn Hills, MI 48326 Si tiene alguna pregunta sobre este comunicado, pรณngase en contacto con nosotros mediante su medio de comunicaciรณn preferido en www.vw.com/contact o por telรฉfono al 800-893-5298. Si aรบn no obtuvo una respuesta satisfactoria, puede presentar una queja en la siguiente direcciรณn: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590. Tambiรฉn puede llamar a la lรญnea directa gratuita de seguridad vehicular al 1-888-327-4236 (TTY: 1-800-424-9153), o bien ingresar a http://www.safercar.gov. Si desea comprobar la elegibilidad de su vehรญculo para una reparaciรณn en el marco de esta o de cualquier otra campaรฑa de llamada a revisiรณn o de servicio, visite www.vw.com/owners/recalls e ingrese el nรบmero de identificaciรณn del vehรญculo (VIN) en la herramienta Recall/Service Campaign Lookup (Bรบsqueda de campaรฑas de llamada a revisiรณn o de servicio). Si usted es el arrendador y propietario registrado del vehรญculo identificado en esta campaรฑa, la ley exige que reenvรญe esta carta de inmediato al arrendatario por correo de primera clase en el plazo de diez (10) dรญas a partir de su recepciรณn. Si cambiรณ su direcciรณn o vendiรณ el vehรญculo, complete la tarjeta prepagada de respuesta del propietario que se encuentra adjunta y envรญenosla para que podamos actualizar nuestros registros. 93O2 EE. UU. Formulario n.ยบ F_3.4_AHQ-GQO-CP-C_054 Rev. 5.0 CAMPAรA DE LLAMADA A REVISIรN IMPORTANTE POR MOTIVOS DE SEGURIDAD <MONTH YEAR> <CUSTOMER NAME> <CUSTOMER ADDRESS> <CUSTOMER CITY STATE ZIPCODE> El presente aviso corresponde a su vehรญculo: <NรMERO DE IDENTIFICACIรN DEL VEHรCULO> <AรO MODELO> <MARCA> <MODELO> NHTSA: 22V162 Campaรฑa de llamada a revisiรณn de Volkswagen: 93O2 โ Soldadura flexible de circuitos impresos para baterรญa de alta tensiรณn (HV) AVISO DE CAMPAรA DE LLAMADA A REVISIรN PROVISIONAL DE SU VEHรCULO POR MOTIVOS DE SEGURIDAD El servicio de reparaciรณn por la llamada a revisiรณn aรบn no estรก disponible El presente aviso se le envรญa de acuerdo con la Ley Nacional de Trรกfico y Seguridad de Vehรญculos Motorizados. Volkswagen determinรณ que existe un defecto relacionado con la seguridad de los vehรญculos motorizados en determinados vehรญculos Volkswagen. Nuestros registros indican que usted es propietario(a) de uno de los vehรญculos afectados por estas medidas. Acerca de esta campaรฑa de llamada a revisiรณn: Es posible que puntos especรญficos de soldadura del circuito impreso flexible montado (FPCA) dentro de la baterรญa de alta tensiรณn (HV) no establezcan una conexiรณn fiable debido a problemas de fabricaciรณn. Las conexiones poco fiables dentro de la baterรญa de HV pueden causar averรญas o paradas mientras conduce, lo que puede provocar un choque sin advertencia alguna. El servicio de reparaciรณn por la llamada a revisiรณn aรบn no estรก disponible. Enviaremos otra carta tan pronto como pueda realizarse el servicio de reparaciรณn en su vehรญculo. Quรฉ puede hacer ahora: Si la condiciรณn de llamada a revisiรณn estรก presente en el vehรญculo, se alertarรก al conductor mediante un mensaje que aparecerรก en el panel de instrumentos que advierte sobre un problema en el sistema de alto voltaje. En caso de que esto ocurra, se recomienda a los propietarios que programen una cita con su concesionario Volkswagen autorizado de inmediato para diagnosticar el problema o reparar el vehรญculo. Tambiรฉn se recomienda a los propietarios que revisen el manual del propietario para que estรฉn familiarizados con las advertencias que pueden aparecer en el panel de instrumentos. No se comunique con el concesionario por esta llamada a revisiรณn a menos que crea que su vehรญculo tenga la condiciรณn descrita en esta carta. Su seguridad y la de sus pasajeros es nuestra prioridad principal, y estamos trabajando para que haya disponible cuanto antes un servicio de reparaciรณn por la llamada a revisiรณn. Nos disculpamos por cualquier inconveniente que esta carta pueda causarle. Atentamente, Defensa del Consumidor de Volkswagen
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The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 1 of 45 Safety Recall Code: 93O2 REVISION Subject Flexible Printed Circuit Solder โ HV Battery Release Date December 23, 2022 REVISION SUMMARY Updated work instructions and SVM information. Service Action 97FY no longer has to be performed before completing the 93O2 repair. Affected Vehicles Country Beginning Model Year Ending Model Year Vehicle Vehicle Count USA 2021 2021 ID4 356 CAN 2021 2022 ID4 6 Check Campaigns/Actions screen in ELSA on the day of repair to verify that a VIN qualifies for repair under this action. ELSA is the only valid campaign inquiry & verification source. ๏ผ Campaign status must show โopen.โ ๏ผ If ELSA shows other open action(s), inform your customer so that the work can also be completed at the same time the vehicle is in the workshop for this campaign. Problem Description Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Corrective Action Replace the affected battery cell modules. Precautions If the recall issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, customers are advised to contact an authorized Volkswagen dealer without delay to make arrangements to have the vehicle diagnosed/repaired. Code Visibility On April 08, 2022, the campaign code was applied to affected vehicles. Owner Notification Owner notification will take place in December 2022. Owner letter examples are included in this bulletin for your reference. Additional Information Please alert everyone in your dealership about this action, including Sales, Service, Parts and Accounting personnel. Contact Warranty if you have any questions. IMPORTANT REMINDER ON VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS New Vehicles in Dealer Inventory: It is a violation of federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must correct, prior to delivery for sale or lease, any vehicle The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 2 of 45 that fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety. Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their inventory which are involved in a safety or compliance recall until the defect has been remedied. Dealers must ensure that every affected inventory vehicle has this campaign completed before delivery to consumers. Fill out and affix Campaign Completion Label (CAMP 010 000) after work is complete. Labels can be ordered at no cost via the Compliance Label Ordering portal at www.vwhub.com. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 3 of 45 Parts Information Parts Control Type: VIN to Order If parts are needed to support a vehicle repair: ๏ท US Dealers – use AVA ๏ท CAN Dealers – contact the Parts Specialists via phone (800-767-6552), email (VWoAPartsSpecialists@vw.com), or chat/text with the VIN to order Parts Control Type: Free Order Parts will be managed by Free Order Initial Allocation: NO There will be no parts allocation. Please reference the Repair Projection Tool (below) to view your potential VIN population. Repair Projection Tool: (right click to open) Criteria Quantity Part Number P.O.C. Part Description Ordering Method 04 1 0Z1-915-599-H CELL MOD. VIN to Order 05 2 04 or 05 4 per cell module N -912-809-01 SCREW Free Order 1 per cell module D -G00-018-M2 PASTE 1 per cell module 0Z1-998-474 SEP. FILM 1 D -316-000-A1 UNDER COAT 1 D -454-300-H2 SEALANT 1 11A-998-844 Parts Kit VIN to Order As needed G -12E-100-1L DSP G12 EVO Coolant Concentrate Free Order NOTE The specified part numbers reflect the status at the start of this action. Interim updates made in ETKA can cause a listed part number to become unavailable. In this case, the new part number specified in ETKA should be used. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 4 of 45 Claim Entry Instructions The labor times listed here may differ from the labor operations and labor times listed in ELSA. After campaign has been completed, enter claim as soon as possible to help prevent work from being duplicated elsewhere. Attach the ELSA screen print showing action open on the day of repair to the repair order. If customer refused campaign work: ๏ผ U.S. dealers: Submit request via WISE under the Campaigns/Update/Recall Closure option. ๏ผ Canada dealers: Upload the repair order [signed by customer] to Volkswagen WIN/Operations/Campaign Closure. Service Number 93O2 Damage Code 0099 Parts Vendor Code WWO Claim Type Sold vehicle: 7 10 Unsold vehicle: 7 90 Causal Indicator Mark CELL MOD* as causal part Vehicle Wash/Loaner Do not claim wash/loaner under this action U.S.A.: Loaner/rental coverage cannot be claimed under this action. However, loaner/rental may be covered under the Alternate Transportation Program. Please refer to the Volkswagen Warranty Policy and Procedures Manual for loaner claims information and reimbursement details. Canada: Loaner/rental coverage cannot be claimed under this action. Please refer to t Volkswagen Service Loaner Program to determine loaner eligibility. Criteria I.D. 04 Replace one cell module according to the affected serial number list LABOR Labor Op Time Units Description 9301 55 99 635 Replace one cell module 9305 01 99 10 Check and measure HV battery cover (if necessary) 9329 01 99 120 Clean HV battery cover (if HV battery cover is reused) 2706 89 50 10 Connect battery charger (if necessary) 0150 00 00 Time stated on diagnostic protocol All GFF Operations NOTE: Multiple GFF logs can be added together Continued on next page The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 5 of 45 PARTS Quantity Part Number Description 1.00 0Z1915599H CELL MOD* 4.00 N 91280901 SCREW 1.00 D G00018M2 PASTE 1.00 0Z1998474 SEP. FILM 1.00 D 316000A1 UNDER COAT 1.00 D 454300H2 SEALANT 1.00 11A998844 Parts Kit Up to 20.00 G 12E100S0 COOLANT CONCENTRATE 1.00 1EA804841AC HV battery cover (if HV battery cover required replacement) Criteria I.D. 05 Replace two cell modules according to the affected serial number list LABOR Labor Op Time Units Description 9301 56 99 815 Replace two cell modules 9305 01 99 10 Check and measure HV battery cover (if necessary) 9329 01 99 120 Clean HV battery cover (if HV battery cover is reused) 2706 89 50 10 Connect battery charger (if necessary) 0150 00 00 Time stated on diagnostic protocol All GFF Operations NOTE: Multiple GFF logs can be added together PARTS Quantity Part Number Description 2.00 0Z1915599H CELL MOD. 8.00 N 91280901 SCREW 2.00 D G00018M2 PASTE 2.00 0Z1998474 SEP. FILM 1.00 D 316000A1 UNDER COAT 1.00 D 454300H2 SEALANT 1.00 11A998844 Parts Kit Up to 20.00 G 12E100S0 COOLANT CONCENTRATE 1.00 1EA804841AC HV battery cover (if HV battery cover required replacement) Continued on next page The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 6 of 45 Add the following for each additional cell module being replaced due to results from cell module equalization test plan. EXAMPLE: A criteria 04 vehicle also requires 2 additional cell modules replaced as directed by the test plan: ๏ท You will combine the total quantity of parts replaced (i.e. 3.00 cell modules, 12.00 screws, etc.) ๏ท For the two additional cell modules, you will claim a single labor operation of 360 TU under LO 9301 19 99 LABOR Labor Op Time Units Description 9301 19 99 180 (per additional cell module) Battery module remove+reinstall PARTS Quantity Part Number Description 1.00 0Z1915599H CELL MOD. 4.00 N 91280901 SCREW 1.00 D G00018M2 PASTE 1.00 0Z1998474 SEP. FILM Add the following if the cell module equalization test plan identified a module with increased self-discharge LABOR Labor Op Time Units Description N/A Time stated on diagnostic protocol Reset balancing time counters via SVM and carry out necessary test plans (if an additional module required replacement) All GFF operations will be claimed under ONE labor operation. The time it takes to complete the additional SVM and test plans will be accounted for under labor operation 0150 00 00, which is outlined in the Criteria 04 and 05 claiming instructions. DO NOT enter the labor operation more than once. Add all GFF operations/logs together and claim them once. 9668 25 99 25 Perform bus sleep (if an additional module required replacement) The following can be added as needed in the event of breakage during the repair. PARTS Quantity Part Number Description As required WHT003491 NUT As required WHT009733 BOLT As required 8E0825267 PUSH PIN As required N 0385494 RIVET The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 7 of 45 Customer Letter Example (USA) <MONTH YEAR> <CUSTOMER NAME> <CUSTOMER ADDRESS> <CUSTOMER CITY STATE ZIPCODE> This notice applies to your vehicle: <MODEL YEAR> <BRAND> <CARLINE>, <VIN> NHTSA: 22V162 Subject: Safety Recall 93O2 – Flexible Printed Circuit Solder โ HV Battery Dear Volkswagen Owner, This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2021 model year Volkswagen ID.4 vehicles. Our records show that you are the owner of a vehicle affected by this action. What is the issue? Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. What will we do? To correct this defect, your authorized Volkswagen dealer will replace the affected battery cell modules. This work will take at least one day to complete and will be performed for you free of charge. Please keep in mind that your dealer may need additional time for the preparation of the repair, as well as to accommodate their daily workshop schedule. What should you do? Please contact your authorized Volkswagen dealer without delay to schedule this recall work. To set up an appointment online, please visit www.vw.com/find-a-dealer. Precautions you should take If the recall issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, customers are advised to contact an authorized Volkswagen dealer without delay to make arrangements to have the vehicle diagnosed/repaired. Lease vehicles and address changes If you are the lessor and registered owner of the vehicle identified in this action, the law requires you to forward this letter immediately via first-class mail to the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle, please fill out the enclosed prepaid Owner Reply card and mail it to us so we can update our records. Can we assist you further? If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable time, or if you should have any questions about this communication, please reach out to us using your preferred method of communication at www.vw.com/contact or by calling us at 800-893-5298. Checking your vehicle for open Recalls and Service Campaigns To check your vehicleโs eligibility for repair under this or any other recall/service campaign, please visit www.vw.com/owners/recalls and enter your Vehicle Identification Number (VIN) into the Recall/Service Campaign Lookup tool. If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your safety and continued satisfaction with your vehicle. Sincerely, Volkswagen Customer Protection The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 8 of 45 Customer Customer Letter Example (Canada) Example (USA) <MONTH YEAR> <CUSTOMER NAME> <CUSTOMER ADDRESS> <CUSTOMER CITY STATE ZIPCODE> This notice applies to your vehicle: <MODEL YEAR> <BRAND> <CARLINE>, <VIN> Transport Canada Recall: 2022-123 Subject: Safety Recall 93O2 – Flexible Printed Circuit Solder โ HV Battery Dear Volkswagen Owner, This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person. Our records show that you are the owner of a vehicle affected by this action. What is the issue? Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. What will we do? To correct this defect, your authorized Volkswagen dealer will replace the affected battery cell modules. This work will take at least one day to complete and will be performed for you free of charge. Please keep in mind that your dealer may need additional time for the preparation of the repair, as well as to accommodate their daily workshop schedule. What should you do? Please contact your authorized Volkswagen dealer without delay to schedule this recall work. Precautions you should take If the recall issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, customers are advised to contact an authorized Volkswagen dealer without delay to make arrangements to have the vehicle diagnosed/repaired. Lease vehicles and address changes If you are the lessor and registered owner of the vehicle identified in this letter, you shall forward this letter (and any subsequent notice, if applicable) to the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle identified in this letter, please fill out the enclosed prepaid Owner Reply Card and mail it to us so we can update our records. Can we assist you further? If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable time, please contact Customer Relations, Monday through Friday from 8AM to 8PM EST by phone at 1-800-822-8987 or via our โContact Usโ page at www.vw.ca. We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your safety and continued satisfaction with your vehicle. Sincerely, Volkswagen Customer Protection The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 9 of 45 Safety Precautions When Working ON the High-voltage System (additional information is also available in the ELSA Repair Manual) DANGER Extremely dangerous due to high voltage. ๏ท The high-voltage system is under heavy voltage. Severe bodily injury or death by electrocution or electric arcs is possible. ๏ท When working on the high-voltage system the high-voltage system must be de-energized. ๏ท When performing procedures that do not directly affect the high-voltage system, in some cases it is still necessary to de-energize the high-voltage system. ๏ท Pay attention when the high-voltage system must be de-energized. Refer to the Repair Manual ๏ท Have a High-Voltage Technician or a High-Voltage Expert de-energize the high-voltage system. The electric and magnetic fields are extremely dangerous. ๏ท There are electric and magnetic fields on the high-voltage system. Death or serious injury are possible due to malfunction of active implants (for example cardiac pacemakers, insulin pumps). ๏ท Persons with active implants may not perform procedures on the high-voltage system. WARNING Risk of injury – motor may start unexpectedly It is difficult to determine whether the drive system of an electric vehicle or hybrid vehicle is active. Moving parts can trap or draw in parts of the body. CAUTION Risk of damage to high-voltage wiring ๏ท Incorrect handling may result in damage to the insulation of high-voltage wires or high-voltage connectors. ๏ท Do not support yourself on high-voltage cables or connectors. ๏ท Never prop tools against high-voltage wiring or high-voltage connectors. ๏ท Never bend or kink high-voltage wiring. ๏ท Observe the coding of the high-voltage connectors when joining them up. Safety Precautions When Working NEAR the High-voltage System (additional information is also available in the ELSA Repair Manual) DANGER Extremely dangerous due to high voltage. ๏ท The voltage levels in the high-voltage system constitute a safety hazard. Danger of severe or fatal injuries from electric shock if high-voltage components or high-voltage wiring are damaged. ๏ท Carry out a visual check of high-voltage components and high-voltage wiring. ๏ท Never use cutting/forming tools or other sharp-edged implements. ๏ท Never perform work using welding, brazing, thermal bonding or hot air in the area of high-voltage components and high-voltage cables. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 10 of 45 DANGER High voltage increases the risk of fatal injury Electrocution can cause severe bodily or fatal injury. ๏ท For the following procedures suitable personal protective equipment must be worn. ๏ท For the following steps two correspondingly qualified technicians must be present for the supervision. ๏ท If necessary, a second technician can help the high-voltage expert outside of the hazardous area within their qualification. ๏ท The personal protective equipment (PPE) must be dry and undamaged. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 11 of 45 Repair Overview ๏ท All vehicles โ perform a test plan to check for cell modules with an increased self-discharge. If a module is identified by the test plan as needing replacement, it will be replaced while the HV battery is open. ๏ท Criteria 04 vehicles – replace one, preidentified, cell module inside the high voltage battery. ๏ท Criteria 05 vehicles – replace two, preidentified, cell modules inside the high voltage battery. NOTE There are three Criteria 04 VINs that have additional pre-identified cell modules. These VINs are included in a future campaign. All of the preidentified cell modules should be replaced under this action. NOTE ๏ท These repair instructions may differ from the labor operations and labor times listed in ELSA. ๏ท Damages resulting from improper repair or failure to follow these work instructions are the dealerโs responsibility and are not eligible for reimbursement under this action. ๏ท This procedure must be read in its entirety prior to performing the repair. ๏ท Due to variations in vehicle equipment and options, the steps/illustrations in this work procedure may not identically match all affected vehicles. ๏ท Diagnosis and repair of pre-existing conditions in the vehicle are not covered under this action. ๏ท When working during extreme temperatures, it is recommended that the vehicle be allowed to acclimate inside the shop to avoid temperature-related component damage/breakage. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 12 of 45 Required Tools Engine Support Set -10-222B- (MRT) Adapter -10-222A/14- (MRT) Module Lifting Aid -T10619- (MRT) Lifting Tackle -3033- (MRT) Shock-Proof Protection (30 Pcs) -T10608- (MRT) Shock-Proof Protection -T10628- (MRT) Removal Wedge Set -VAS895015- (MRT) Engine Support – Bracket w/Spindle and hook -10-222A/10- (MRT) Shop Crane -VAS6100- (or equivalent) Insulating Mat -VAS6762/44- (MRT) The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 13 of 45 Scissor Lift Table -VAS6131B- (or equivalent) Engine Bung Set -VAS6122- (or equivalent) Leak-tight Connector -T10607- (MRT) Pressure and Vacuum Pump -VAS671005- (MRT) Digital Pressure Sensor -VAG1397B- (MRT) High Voltage Tool Set โ Screwdriver -VAS6762/34- Cooling System Tester – Directional Valve -VAS691005/1- (component of MRT -VAS691005-) High Voltage Tool Set – Torque Wrench -VAS6883/1A- (MRT) High Voltage Tool Set – Voltage Tester -VAS6762/45- (MRT) Cooling System Tester – Directional Valve -VAS691005/5- (component of MRT -VAS691005-) Template -T10606- Cooling System Charge Kit -VAS6096- (MRT) The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 14 of 45 Cooling System Tester -VAG1274B- (MRT) Hose Clamps – Up To 25mm -3094- (or equivalent) Module Balancer -VAS6910- (MRT) Insulating Mat -VAS6910/21-3- (MRT) Protective Cover -VAS6910/21-1- (component of MRT -VAS6910/21-) Vehicle Diagnosis System – Connection Lead -VAS5051/66- (MRT) Pressure Sensor -VAS611013- (MRT) Insulated Torx Wrench Set – 3/8 -VAS691003A- (MRT) *Extension Cables for High-Voltage Battery -VAS671007- (MRT) *High Voltage Diagnostics Box -VAS5581A- (MRT) *NOTE: Either -VAS671007- or -VAS5581A- may be used for this repair. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 15 of 45 High Voltage Test Adapter (without AFeS) -VAS6558A/35- (MRT) High Voltage Tool Set โ Reversible Ratchet 3/8″ -VAS6762/29- (MRT) High Voltage Tool Set โ Extension 140mm -VAS6762/31- (MRT) Shackle (Equivalent to VAS691009A) -VAS691009USQty. = 8 (MRT) Diagnostic Tester -VAS6150X/6160X- (or equivalent) Battery Tester/Charger capable of minimum 70 Amp continuous supply Double Cartridge Adhesive Gun -VAS5237- High Voltage Tool Set โ Screwdriver Insert XZN M10 -VAS6762/27- The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 16 of 45 Required Shop Materials Cleaner D -009-401-04 (shop supply) -OR- 91% Isopropyl Alcohol (locally sourced) Lint Free Towels (locally sourced) NOTE: Use only 91% Isopropyl alcohol as a cleaner (9% water). Do not use Isopropyl with any additional surfactants (cleaners) or additives (scents). The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 17 of 45 Repair Instruction Section A – Check for Previous Repair TIP If Campaign Completion label is present, no further work is required. ๏ท Enter the VIN in Elsa and proceed to the โCampaign/Actionโ screen. TIP On the date of repair, print this screen and keep a copy with the repair order. ๏ท Confirm the Campaign/Action is open <arrow 1>. If the status is closed, no further work is required. ๏ท Note the Applicable Criteria ID <arrow 2> for use in determining the correct work to be done and corresponding parts associated. ๏ท Proceed to Section B. NOTE If the 93O2 is open in ELSA and ELSA service history shows a previous cell module replacement, please create a TAC WEB ticket and wait for further instructions before proceeding with this repair. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 18 of 45 Section B โ Replacing High-Voltage Battery Cell Module(s) NOTE Vehicles affected by the 93O2 have a cell module with faulty soldering connection to a measuring cable. The serial numbers of these modules have been identified and must be replaced. Additionally, there is a possibility there are modules in the high-voltage battery that exhibit an increased selfdischarge. These modules can be identified with a test plan, and must also be replaced. Identify cell module which requires replacement: ๏ท Use the chart found in one of the 93O2 attachment tabs in ELSA or in ServiceNet to determine the serial number of the module that requires replacement for the VIN youโre working on. NOTE There are three Criteria 04 VINs that have additional pre-identified cell modules. These VINs are included in a future campaign. All of the preidentified cell modules should be replaced under this action. Check cell balancing and determine if additional modules require replacement: ๏ท Perform a diagnostic scan of the vehicle. ๏ท Select the 008C Guided Functions test plan: o 008C โ Check cell equalization ๏ท Follow the test plan steps. The test plan will identify which (if any) additional cell module(s) will require replacement due to increased selfdischarge. ๏ท If additional cell modules require replacements, place the order for the additional parts and continue with this procedure once all parts have arrived. NOTE If a module is replaced due to increased selfdischarge, the balancing time counters must also be reset after the repair is complete. This is outlined in Section C. If no additional cell modules require replacement, the balancing time counters DO NOT have to be reset. ๏ท If no additional cell modules require replacement and all parts are available to complete this repair, continue with the next steps. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 19 of 45 NOTE It is possible that a cell module that requires replacement under the 93O2 (the serial # has already been identified), is the same module that failed the cell balancing test. Perform cell balancing on new cell module: ๏ท Check Measured Value Block (MVB) โmaximum voltage for battery cells, IDE08217. ๏ท The voltage reading listed will be entered in the DSS Manager program when balancing the new cell module. ๏ท Follow the VAS6910 operating instructions in conjunction with the DSS Manager program to perform the cell balancing on the new cell module. TIP Operating instructions for the VAS6910 and DSS Manager program can be found on the VW Special Tools and Equipment website. Populate Guided Functions test plans: ๏ท Perform a diagnostic scan of the vehicle. ๏ท Select โSelf Testโ and populate the following Guided Function test plans: o High-voltage system, de-energize o 008C โ High-voltage battery leak test o HV measurement module VAS6558/6558A The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 20 of 45 De-energize the high-voltage system: DANGER High voltage increases the risk of fatal injury Electrocution can cause severe bodily or fatal injury Have a high-voltage technician or a high-voltage expert de-energize the high-voltage system. ๏ท Follow the Guided Functions test plan steps. ๏ท Pay close attention to all of the test plan steps. Raise the vehicle: TIP Removal of the high-voltage battery is not possible on all hoists. Make sure that there is enough clearance. Pay attention that the high-voltage battery has enough clearance <a> during the lifting process so that the Scissor Lift Table -VAS6131Bcan be set down. ๏ท Pivot in the hoist with the vehicle support plate <1> on the frame of the high-voltage battery <2>. Then pivot back the hoist arm with the vehicle support plate <1> <a> so that the highvoltage battery <2> can be lowered in the next steps. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 21 of 45 Remove lower covers: ๏ท Reference ELSA Repair Manual. ๏ท Remove the front underbody trim panel <1>. Refer to โ Body Exterior; Rep. Gr.66; Underbody Trim Panel; Front Underbody Trim Panel, Removing and Installing. ๏ท Front wheel housing liner, loosening in the area of the high-voltage battery threaded connection. Refer to โ Body Exterior; Rep. Gr.66; Wheel Housing Liner; Front Wheel Housing Liner, Removing and Installing. ๏ท Remove the side underbody trim panels. Refer to โ Body Exterior; Rep. Gr.66; Underbody Trim Panel; Side Underbody Trim Panel, Removing and Installing. ๏ท Remove the rear center underbody trim panel <16>. Refer to โ Body Exterior; Rep. Gr.66; Underbody Trim Panel; Rear Center Underbody Trim Panel, Removing and Installing. ๏ท Remove the rear underbody trim panel <14>. Refer to โ Body Exterior; Rep. Gr.66; Underbody Trim Panel; Rear Underbody Trim Panel, Removing and Installing Perform high-voltage battery leak test: ๏ท Before disconnecting the high-voltage battery connectors, remove the protective covers <1> from both of the connectors first. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 22 of 45 ๏ท See ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > High-Voltage Battery 1 AX2 Leak Test ๏ท Perform these steps in conjunction with Guided Function test plan, โ008C โ Highvoltage battery leak test.โ Remove high-voltage battery: ๏ท See ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > High-Voltage Battery 1 AX2 , Removing and Installing, 82 kWh ๏ท Note the following when removing the highvoltage battery: o Mark the position of the scissor lift table on the floor to aid in repositioning the table during reinstallation. o Pay close attention to all wiring harnesses when lowering the battery. o Pay close attention to coolant hoses when lowering the battery. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 23 of 45 Secure media duct/channel (if necessary): ๏ท If the media duct/channel <1> had not yet been secured, install new bolts <circles> and torque to 20 Nm. Part Number Part Description N -102-252-02 Bolt NOTE If the media channel is already secured with bolts, the bolts do not have to be replaced again. Clean high-voltage battery cover: ๏ท Vacuum all loose dirt and debris from highvoltage battery. ๏ท It is also recommended to clean the connection element threads using a wire brush as shown. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 24 of 45 Remove high-voltage battery cover: ๏ท See ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > High-Voltage Battery 1 AX2 , Opening DANGER High voltage increases the risk of fatal injury Electrocution can cause severe bodily or fatal injury Pay close attention to which Repair Manual steps require Personal Protective Equipment. NOTE The upper part of battery housing can be reused under certain circumstances and does not have to be replaced. To determine if the cover can be reused, refer to the ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > Battery Housing Upper Section, Checking for Re-Use The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 25 of 45 Identify cell module which requires replacement: ๏ท Use the chart found in one of the 93O2 attachment tabs in ELSA or in ServiceNet to determine the serial number of the module that requires replacement for the VIN youโre working on. ๏ท Identify the module that requires replacement and clearly mark its location. NOTE If the serial number cannot be found on any of the cell modules, it is possible the module was replaced on a previous service visit. If the serial number cannot be found on any of the cell modules, create a VTA WEB ticket and wait for further instructions. Include photos of the serial numbers for each of the 12 cell modules and the high-voltage battery identification/part number label. Example of high-voltage battery identification, located on one end of the high-voltage battery case: The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 26 of 45 Perform insulation measurement: ๏ท Perform insulation measurement according to ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > Voltage and Insulation Measurement, 82 kWh ๏ท Perform the measurement in conjunction with ODIS test plan, โHV measurement module VAS6558/VAS6558A.โ Clean high-voltage battery sealant off of lower housing: ๏ท Clean old sealant using a lint free cloth and Cleaner D -009-401-04 or isopropyl alcohol. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 27 of 45 Disconnect the high-voltage circuit: ๏ท See ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > Circuit, Disconnecting, 82 kWh Remove the cell module: ๏ท See ELSA Repair manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Components > Battery Module, Removing ๏ท Ensure the shock protection is installed on ALL open high-voltage connections. TIP Pay close attention to the wiring harnesses, so they are not damaged or pinched during removal. The cell module can be freed from the adhesive bond from either end of the cell module. Clean the mounting area for the new cell module: ๏ท When cleaning the cell module mounting area, use extreme care so the sealant for the highvoltage battery splines and lower housing is not damaged and that no cleaners come into contact with the sealant. ๏ท Vacuum any loose debris from the mounting area of the cell module. ๏ท Clean cell module mounting area with Cleaner D -009-401-04 or isopropyl alcohol and allow it to completely dry. ๏ท Do not allow the cleaner to come in contact with any of the lower housing frame sealant. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 28 of 45 Installing new cell module(s): ๏ท Reference ELSA Repair manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Components > Battery Module, installing ๏ท Note the following when installing the new cell module(s): ๏ท Peel off the protective backing and apply the separating foil <arrow> as needed along the outer frame edges, in the area where the cell module is mounted. Part Number Part Description 0Z1-998-474 Separating foil/film ๏ท If the cell module being replaced is in the corner of the high-voltage battery, the separating foil must be applied to both outer frame edges as shown in area <A>. TIP Having a second technician pre-fold the separating film before installing will aid in applying the film. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 29 of 45 ๏ท Clean the bottom of the cell module using Cleaner D -009-401-04 or isopropyl alcohol and allow it to dry completely. ๏ท Double check the expiration date of the paste before applying. ๏ท Use Double Cartridge Adhesive Gun -VAS5237- to apply the heat paste. Part Number Part Description D -G00-018-M2 Heat paste ๏ท Before applying the heat paste, release a small amount through the applicator to ensure the paste is mixing properly. ๏ท When filling Template -T10606-, ALL of the heat paste must be used. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 30 of 45 ๏ท Pay close attention to the wiring harnesses when installing the cell module. ๏ท Torque new bolts <3> in a cross pattern to 16 Nm + 180ยฐ. Part Number Part Description N -912-809-01 Bolt ๏ท Torque bolts <3> for the high-voltage connection <4> to 8 Nm. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 31 of 45 DANGER STOP! Incorrect installation of battery modules and module connectors. Short circuit electric arc can cause severe bodily or fatal injuries. Check the battery modules and module connectors for correct installation. Only continue with the procedure when there is no voltage in between the battery terminals. Pay very close attention to the Repair Manual steps outlining the use of the -VAS6762/45-. Reconnect high-voltage circuit: ๏ท Reconnection is the reverse order of disconnecting. ๏ท Reference ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > Circuit, Disconnecting, 82 kWh Check for high-voltage battery faults: ๏ท Using -VAS671007- or -VAS5581A-, in conjunction with the Diagnostic Tester, verify there are no faults stored for any high-voltage battery component before installing the highvoltage battery cover. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 32 of 45 Install and seal high-voltage battery cover: NOTE The upper part of battery housing can be reused under certain circumstances and does not have to be replaced. To determine if the cover can be reused, refer to the ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > Battery Housing Upper Section, Checking for Re-Use TIP Ensure all shock protection is removed prior to installing cover. Pay attention to the cover position. The cover part number stamping is positioned at the front of the high-voltage battery. ๏ท SEE ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > High-Voltage Battery 1 AX2 , Sealing, 82 kWh Part Number Part Description 1EA-804-841-AC Cover (if necessary) D -454-300-H2 Sealant 1EA-802-131-A Connection element (qty. 2) Position <1> 1EA-802-132-A Connection element (qty. 2) Position <2> WHT-008-738-A Middle bolts (qty. 22) Position <3> WHT-009-218 Perimeter bolts (qty. 82) Position <4> The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 33 of 45 ๏ท Torque the new fasteners in the following order: 1. Connection element bolts <1 through 4> to 100 Nm. 2. Middle bolts <5 through 26> to 5.5 Nm + 90ยฐ. TIP Utilize a second technician to keep track of or mark each bolt once it has been torqued. 3. Bolts <A, B, C and D> to 8 Nm. 4. Bolts <1 through 82> to 8 Nm. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 34 of 45 Perform high-voltage battery leak test: ๏ท See ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > High-Voltage Battery 1 AX2 Leak Test ๏ท Perform these steps in conjunction with Guided Function test plan, โ008C โ Highvoltage battery leak test.โ Prepare high-voltage battery for installation: NOTE Replacing the spacers and stickers is only necessary if the high-voltage battery cover is replaced. ๏ท Install new spacers <1> (qty. 8) onto the highvoltage battery cover. Reference the old cover for installation position if needed. ๏ท Apply new sticker <2> and warning sign <3>. ๏ท Remove old separating film <4> from around the high-voltage battery mounting holes and install new separating film. o Do not install separating film if there was no existing film already in place. Part Number Part Description 1EA-804-973 Spacer (qty. 8) 1EA-998-103 Separating film 12E-010-006-AA Sticker 1EA-010-505 Warning sign The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 35 of 45 ๏ท Apply wax around the base of the connection elements <1 through 4>. ๏ท Completely cover all (22) middle bolts <5 through 26> with wax. Part Number Part Description D -316-000-A1 Wax/Undercoat COVERAGE DETAIL Connection elements <1 through 4> Middle bolts <5 through 26> ๏ท Install new pressure relief valve <1> and connection seals <2>. Part Number Part Description 1HV-915-754-A Valve 0Z1-915-433-A Seal (qty. 2) The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 36 of 45 Re-install high-voltage battery: ๏ท Installation is the reverse order of removal. ๏ท See ELSA Repair Manual: Repair Manual > Motor > Electric Drive Rear Wheel Drive EIP220 and All Wheel Drive EIA200, EIP220 > 93 Electric drive > High-Voltage Battery Unit > High-Voltage Battery 1 AX2 , Removing and Installing, 82 kWh ๏ท Use new bolts. Part Number Part Description N -912-832-01 Center bolts (qty. 4) N -909-428-04 Perimeter bolts (qty. 24) ๏ท Torque the new bolts in the following sequence: 1. Bolts <1 through 24> to 50 Nm + 90ยฐ. 2. Bolts <25 through 28> to 40 Nm + 180ยฐ. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 37 of 45 Recommission the high-voltage system: DANGER High voltage increases the risk of fatal injury Electrocution can cause severe bodily or fatal injury Have a high-voltage technician or a high-voltage expert recommission the high-voltage system. ๏ท Follow the Guided Functions test plan steps. ๏ท Pay close attention to all of the test plan steps. Fill cooling system: ๏ท Top off coolant. ๏ท Select โSelf Testโ and populate test plan, โ0001 โ Fill/bleed cooling system.โ ๏ท Connect the Cooling System Tester -VAG1274B- and create a pressure of 1.0 bar using the hand pump. ๏ท Run the test plan โ0001 โ Fill/bleed cooling systemโ and follow the on-screen prompts. ๏ท Once the test is successfully completed, repeat the test plan a second time. ๏ท Top off coolant. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 38 of 45 Reinstall underbody covers and side covers: ๏ท Installation is the reverse order of removal. ๏ท Reference the ELSA Repair Manual as needed. ๏ท Replace any damaged fasteners. Vehicles that had module(s) replaced ONLY because they were on the affected serial number list: ๏ท The balancing time counters do not have to be reset. ๏ท Proceed to Section D Vehicles that had additional module(s) replaced due to increased self-discharge: ๏ท The balancing time counters must be reset via SVM and additional test plans. ๏ท Proceed to Section C The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 39 of 45 Section C โ Reset Balancing Time Counters via SVM CRITICAL REPAIR STEP STOP! This additional SVM and additional test plan steps are only required if a cell module was replaced according to the direction from the โCheck cell equalizationโ test plan. If the cell module(s) were replaced only because they were identified by the serial number list, this additional step does not have to be completed. NOTE Prior to launching the VAS Diagnostic Tester and starting an update, ensure the following conditions are met; The ODIS software is completely up to date. ๏ง Refer to the โAlertsโ section on ServiceNet home page for the current ODIS version. The battery charger is connected to the vehicle battery and remains connected for the duration of the software update. ๏ท Battery voltage must remain above 12.5 volts for the duration of the software update. Failure to do so may cause the update to fail, which could result in damage to the control module. Control modules damaged by insufficient voltage will not be covered. The screen saver and power saving settings are off. ๏ท Failure to do so may result in the tester entering power save mode during the software update, which could result in damage to the control module. The VAS Diagnostic Tester is plugged in using the supplied power adapters. ๏ท Under no circumstances should the tester be used on battery power alone during the software update. Failure to do so may result in the tester powering off during the update, which could result in damage to the control module. The VAS Diagnostics Interface MUST ONLY be connected to the tester with a USB cable. ๏ท Performing a software update using a Bluetooth or WiFi connection increases the risk of losing connection during the update, which could result in damage to the control module. It also greatly increases the time required to perform the update. Requests for additional time or parts will be denied if the GFF log shows the update was performed using Bluetooth or WiFi. WARNING Radiator Fan(s) may cycle ON high speed during the Update Process! There is a serious risk that personal injury may result if contact is made with spinning fan blades. Keep hands and all objects away from Radiator Fan(s) during Update Process! The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 40 of 45 TIP To Update-Programming using SVM, review and follow instructions in Technical Bulletin 2014603: Software Version Management (SVM) Operating Instructions. The SVM Process must be completed in its entirety so the database receives the update confirmation response. A warranty claim may not be reimbursed if there is no confirmation response to support the claim. NOTE ๏ท Damages resulting from improper repair or failure to follow these work instructions are the dealerโs responsibility and are not eligible for reimbursement under this action. ๏ท Diagnosis and repair of pre-existing conditions in the vehicle are not covered under this action. CRITICAL REPAIR STEP STOP! Before starting programming, it is essential to perform the following actions for the -VAS5908- battery charger. The battery chargerโs default setting will switch the charger off automatically after a period of time. To prevent this, the following must be carried out. Switch it OFF and then ON again each time the charger is connected. The battery chargerโs display must have switched off before itโs restarted. ๏ท Connect battery charger -VAS5908-. ๏ท When connecting the charger to the battery, connect the positive cable to the positive charging terminal for the battery and connect the negative cable to the grounding lug on the chassis. DO NOT connect the ground cable directly to negative terminal of the battery. NOTE ๏ท All campaign software updates should be completed during a single, standalone ODIS Diagnostic Session. You must fully complete this campaign and send all logs before beginning any other campaigns or operations. ๏ท If there are any ODIS โHot-Fixโ patches installed, they must be removed from the scan tool before beginning this operation. ODIS โHot-Fixโ patches may affect the update process. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 41 of 45 ๏ท Place the vehicle key over the reader coil in the center console cupholder. ๏ท Any additional keys must be a minimum of 20 meters away from the vehicle. ๏ท Confirm that scan tool is communicating with the diagnostic head by USB <Green Arrow>. o If the Bluetooth symbol is shown <Red Arrow> then disconnect the diagnostic head from the vehicle and reconnect the USB cable to the diagnostic head and then reattach to the vehicle. ๏ท Upon ODIS startup, verify the โDiagnosisโ operating mode is selected <as shown>. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 42 of 45 ๏ท Once the GFF scan is complete, select โSpecial functionsโ <arrow 1>, then โAdapting softwareโ <arrow 2>, then select โPerform testโ <arrow 3>. ๏ท Select the correct option to โUpdate software via action codeโ. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 43 of 45 NOTE Using Bluetooth or WiFi for this action is PROHIBITED! Damage caused to electronic components during the SVM flash process is not covered. ๏ท Enter the corrective action code (SVM code) as listed below based on the current software version of diagnostic address 008C. TIP The GFF test plan for checking cell equalization should also direct which SVM code to use. 008C Software Version SVM code 1030 8CHVHDM1030 0930 8CHVHDM0930 ๏ท Select โAcceptโ <arrow> and follow the on screen prompts. NOTE Do not unplug the sound generator. ๏ท Do not end the diagnositc session. Perform bus sleep: ๏ท Carry out the following steps in the specified sequence to put the vehicle in a bus sleep. ๏ท Switch off the ignition. ๏ท Turn the hazards off. ๏ท Remove diagnosis interface from the vehicle diagnosis connection. ๏ท Remove battery charger from the 12V battery. ๏ท Close front and rear lid as well as all doors. ๏ท Lock vehicle. ๏ท Move vehicle key (remote control) at least 20 meters away from the vehicle. ๏ท Wait at least 15 minutes until the vehicle is in bus silence. ๏ท Then unlock vehicle again. The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 44 of 45 ๏ท Connect and switch on battery charger. ๏ท Insert diagnosis interface on vehicle diagnosis connection. ๏ท Switch on the ignition. ๏ท Place a vehicle key (remote control) in the center console on the reader coil. Perform software configuration: ๏ท From the special function tab, select โCtrl. module software configuration. ๏ท When prompted, select the option to perform the โSWK via diagnostic addressโ. ๏ท Enter diagnostic address 008C. ๏ท Follow the on-screen prompts. ๏ท Pay close attention to all steps outlined in the test plan and follow them exactly as described. ๏ท Do not end the diagnostic session. Perform โVKMS Adaptationโ test plan: ๏ท Turn ignition OFF. ๏ท Turn ignition ON and briefly make vehicle Drive ready. ๏ท Turn ignition OFF and back ON. ๏ท Start the VKMS Adaptation test plan. ๏ท Follow the on-screen prompts. ๏ท Pay close attention to all steps outlined in the test plan and follow them exactly as described. ๏ท Once all test plans are complete, exit Diagnosis and send the diagnostic protocol online. Proceed to Section D The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures are not intended to be attempted by โdo-it-yourselfers,โ and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Volkswagen dealer. ๏ฃ2022 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved. December 2022 93O2 Page 45 of 45 Section D โ Campaign Completion Label Install Campaign Completion Label ๏ท Fill out and affix Campaign Completion Label, part number CAMP 010 000, next to the vehicle emission control information label. TIP Ensure Campaign Completion Label does not cover any existing label(s). Proceed to Section E Section E – Parts Return/Disposal High-Voltage Cell Modules: US Dealers: Refer to the HV Battery Recycling Program information found in ServiceNet: ServiceNet > Electric/PHEV Vehicles Canadian Dealers: Refer to the latest version of TSB 2060231 All other parts: Properly store (retain), destroy or dispose of removed parts in accordance with all state/province and local requirements, unless otherwise indicated and/or requested through the Warranty Parts Portal (WPP) for U.S. and the Part Destruction and Core Disposition Report for Canada.
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Form No. F_3.4_AHQ-GQO-CP-C_060 Rev.3.0 93O2 USA IMPORTANT SAFETY RECALL Volkswagen of America, Inc. 3800 Hamlin Road Auburn Hills, MI 48326 <MONTH YEAR> <CUSTOMER NAME> <CUSTOMER ADDRESS> <CUSTOMER CITY STATE ZIPCODE> This notice applies to your vehicle: <MODEL YEAR> <BRAND> <CARLINE>, <VIN> NHTSA: 22V162 Subject: Safety Recall 93O2 – Flexible Printed Circuit Solder โ HV Battery Dear Volkswagen Owner, This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2021 model year Volkswagen ID.4 vehicles. Our records show that you are the owner of a vehicle affected by this action. What is the issue? Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. What will we do? To correct this defect, your authorized Volkswagen dealer will replace the affected battery cell modules. This work will take at least one day to complete and will be performed for you free of charge. Please keep in mind that your dealer may need additional time for the preparation of the repair, as well as to accommodate their daily workshop schedule. What should you do? Please contact your authorized Volkswagen dealer without delay to schedule this recall work. To set up an appointment online, please visit www.vw.com/finda- dealer. Precautions you should take If the recall issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, customers are advised to contact an authorized Volkswagen dealer without delay to make arrangements to have the vehicle diagnosed/repaired. Lease vehicles and address changes If you are the lessor and registered owner of the vehicle identified in this action, the law requires you to forward this letter immediately via first-class mail to the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle, please fill out the enclosed prepaid Owner Reply card and mail it to us so we can update our records. Can we assist you further? If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable time, or if you should have any questions about this communication, please reach out to us using your preferred method of communication at www.vw.com/contact or by calling us at 800-893-5298. Form No. F_3.4_AHQ-GQO-CP-C_060 Rev.3.0 93O2 USA IMPORTANT SAFETY RECALL Checking your vehicle for open Recalls and Service Campaigns To check your vehicleโs eligibility for repair under this or any other recall/service campaign, please visit www.vw.com/owners/recalls and enter your Vehicle Identification Number (VIN) into the Recall/Service Campaign Lookup tool. If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your safety and continued satisfaction with your vehicle. Sincerely, Volkswagen Customer Protection Formulario N.ยบ F_3.4_AHQ-GQO-CP-C_060 Rev. 3.0 93O2 EE. UU. CAMPAรA DE LLAMADA A REVISIรN IMPORTANTE POR MOTIVOS DE SEGURIDAD Volkswagen of America, Inc. 3800 Hamlin Road Auburn Hills, MI 48326 <MONTH YEAR> <CUSTOMER NAME> <CUSTOMER ADDRESS> <CUSTOMER CITY STATE ZIPCODE> El presente aviso corresponde a su vehรญculo: <MODEL YEAR> <BRAND> <CARLINE>, <VIN> NHTSA: 22V162 Asunto: Campaรฑa de llamada a revisiรณn 93O2 – Soldadura de circuitos impresos flexibles para baterรญa de alta tensiรณn (HV) Estimado propietario de un vehรญculo Volkswagen, El presente aviso se le envรญa de acuerdo con la Ley Nacional de Trรกfico y Seguridad de Vehรญculos Motorizados de EE. UU. Volkswagen ha determinado que existe un defecto relacionado con la seguridad vehicular en ciertos vehรญculos Volkswagen ID.4 modelo 2021. Nuestros registros indican que usted es propietario de uno de los vehรญculos afectados por esta campaรฑa. ยฟCuรกl es el problema? Es posible que puntos especรญficos de soldadura del circuito impreso flexible montado (FPCA) dentro de la baterรญa de alta tensiรณn (HV) no establezcan una conexiรณn fiable debido a problemas de fabricaciรณn. Las conexiones poco fiables dentro de la baterรญa de alta tensiรณn pueden causar averรญas o paradas mientras conduce. Esto podrรญa provocar un choque sin advertencia alguna. ยฟQuรฉ haremos? Para poder corregir este defecto, su concesionario Volkswagen autorizado reemplazarรก los mรณdulos de celdas de baterรญas afectados. Este servicio durarรก por lo menos un dรญa y se le ofrecerรก de forma gratuita. No obstante, considere la posibilidad de que su concesionario necesite tiempo adicional para la preparaciรณn del servicio y la organizaciรณn del horario del taller. ยฟQuรฉ debe hacer? Comunรญquese con su concesionario Volkswagen autorizado de inmediato para programar este servicio de reparaciรณn. Para concertar una cita en lรญnea, visite www.vw.com/find-a-dealer. ยฟQuรฉ precauciones debe tomar? Si el problema de la llamada a revisiรณn estรก presente en el vehรญculo, se alertarรก al conductor mediante un mensaje que aparecerรก en el panel de instrumentos que advierte sobre un problema en el sistema de alta tensiรณn. Si esto sucede, se recomienda a los clientes que se comuniquen con un concesionario Volkswagen autorizado de inmediato a fin de concertar una cita para diagnosticar o reparar el vehรญculo. Vehรญculos rentados y cambios de direcciรณn Si usted es el arrendador y propietario registrado del vehรญculo identificado en esta campaรฑa, la ley exige que reenvรญe esta carta de inmediato al arrendatario por correo de primera clase en el plazo de los diez (10) dรญas posteriores a la recepciรณn. Si cambiรณ de direcciรณn o vendiรณ el vehรญculo, complete la tarjeta prepagada de respuesta del propietario adjunta y envรญenosla para que podamos actualizar nuestros registros. Formulario N.ยบ F_3.4_AHQ-GQO-CP-C_060 Rev. 3.0 93O2 EE. UU. CAMPAรA DE LLAMADA A REVISIรN IMPORTANTE POR MOTIVOS DE SEGURIDAD ยฟDe quรฉ otra forma podemos ayudarlo? Si su concesionario Volkswagen autorizado no le brinda este servicio de forma gratuita dentro de un plazo razonable o no estรก en condiciones de hacerlo, o si usted tiene alguna pregunta sobre este aviso, pรณngase en contacto con nosotros mediante el medio de comunicaciรณn que prefiera a travรฉs de www.vw.com/contact o por telรฉfono al 800-893-5298. Verificaciรณn de su vehรญculo para campaรฑas de llamada a revisiรณn o de servicio vigentes Si desea comprobar la elegibilidad de su vehรญculo para una reparaciรณn en el marco de esta o de cualquier otra campaรฑa de llamada a revisiรณn o de servicio, visite www.vw.com/owners/recalls e ingrese el nรบmero de identificaciรณn del vehรญculo (VIN) en la herramienta Recall/Service Campaign Lookup (Bรบsqueda de campaรฑas de llamada a revisiรณn o de servicio). Si aรบn no estรก satisfecho, puede presentar una queja a la siguiente direcciรณn: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590. Tambiรฉn puede llamar a la lรญnea directa y gratuita de seguridad de vehรญculos al 1-888-327-4236 (TTY: 1-800-424- 9153) o ingresar a http://www.safercar.gov. Le pedimos disculpas por cualquier inconveniente que esto pueda haberle ocasionado; sin embargo, hemos tomado esta medida para garantizar su seguridad y su continua satisfacciรณn con el vehรญculo. Atentamente, Defensa del Consumidor de Volkswagen
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VOLKSWAGEN DEALER COMMUNICATION Ensure all dealership personnel are aware of this notice so they are able to address customer questions. Contact Warranty if you require additional assistance. Direct press inquiries to Volkswagen Public Relations. Volkswagen Customer Protection 93O2_DLR_LAUNCH Repair Available โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery This notice is for: ๏ผ Dealer Principal ๏ผ General Manager ๏ผ Sales Managers ๏ผ Service Manager ๏ผ Parts Manager ๏ผ Service Consultant ๏ผ Warranty Administrator ๏ผ Technicians Date: December 05, 2022 Issue: Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Precautions: If the recall issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, customers are advised to contact an authorized Volkswagen dealer without delay to make arrangements to have the vehicle diagnosed/repaired. Repair: ๏ท REPAIR AVAILABLE โ December 06, 2022 / Replace the affected battery cell modules. ๏ท See ELSA/ServiceNet for complete repair & claiming instructions ๏ท Check both the daily Campaign Open Inventory report and OMD for affected vehicles in inventory. Verify OPEN status in ELSA on the day of repair. ๏ท Repair every affected inventory vehicle before delivery to consumers. Parts Department: There will be no parts allocation. Please reference the Repair Projection Tool to view your potential VIN population. Parts will be managed by free oirder. Affected Vehicles Country Beginning Model Year Ending Model Year Vehicle Vehicle Count USA 2021 2021 ID4 356 CAN 2021 2022 ID4 6 *Counts reflect overall population; some vehicles may have already been repaired. Check Campaigns/Actions screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this action. Elsa is the only valid campaign inquiry & verification source. Notes: ๏ท Schedule owner repairs immediately ๏ท Owner mailing โ December 2022 U.S.A.: Loaner/rental coverage cannot be claimed under this action. However, loaner/rental may be covered under the Alternate Transportation Program. Please refer to the Volkswagen Warranty Policy and Procedures Manual for loaner claims information and reimbursement details. Canada: Loaner/rental coverage cannot be claimed under this action. Please refer to the Volkswagen Service Loaner Program to determine loaner eligibility. IMPORTANT REMINDER: VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS New Vehicles in Dealer Inventory: It is a violation of federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety. Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their inventory which are involved in a safety or compliance recall until the defect has been remedied. -END OF MESSAGE
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VOLKSWAGEN DEALER COMMUNICATION Ensure all dealership personnel are aware of this notice so they are able to address customer questions. Contact Warranty if you require additional assistance. Direct press inquiries to Volkswagen Public Relations. Volkswagen Customer Protection 93O2_DLR_REV_20221222 REVISION โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery This notice is for: ๏ผ Dealer Principal ๏ผ General Manager ๏ผ Sales Managers ๏ผ Service Manager ๏ผ Parts Manager ๏ผ Service Consultant ๏ผ Warranty Administrator ๏ผ Technicians Date: December 22, 2022 Revision Summary: An updated SVM code has been added to the work instructions for Safety Recall 93O2. A revised circular will be published to ELSA and ServiceNet on December 23, 2022. Please note: With this revision, the 97FY Service Action no longer needs to be performed prior to the 93O2 Safety Recall. Please ensure everyone in your dealership with recall/campaign-related responsibilities is made aware of this important revision. Discard any paper copies you may have printed and ensure they are replaced with the most current version. IMPORTANT REMINDER: VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS New Vehicles in Dealer Inventory: It is a violation of federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety. Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their inventory which are involved in a safety or compliance recall until the defect has been remedied. -END OF MESSAGE
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VOLKSWAGEN DEALER COMMUNICATION Ensure all dealership personnel are aware of this notice so they are able to address customer questions. Contact Warranty if you require additional assistance. Direct press inquiries to Volkswagen Public Relations. Volkswagen Customer Protection 93O2_DLR_ADV CORRECTED – Advance Notice โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery This notice is for: ๏ผ Dealer Principal ๏ผ General Manager ๏ผ Sales Managers ๏ผ Service Manager ๏ผ Parts Manager ๏ผ Service Consultant ๏ผ Warranty Administrator ๏ผ Technicians Date: April 08, 2022 Issue: Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Precautions: If this issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, owners are advised to make an appointment with their authorized Volkswagen dealer without delay to have the vehicle diagnosed/repaired. Repair: ๏ท REPAIR NOT YET AVAILABLE ๏ท Check daily campaign open inventory report or OMD for affected vehicles in inventory. Affected Vehicles Country Beginning Model Year Ending Model Year Vehicle Vehicle Count USA 2021 2021 ID4 351 *Counts reflect overall population; some vehicles may have already been repaired. Check Campaigns/Actions screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this action. Elsa is the only valid campaign inquiry & verification source. Notes: IMPORTANT REMINDER: VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS New Vehicles in Dealer Inventory: It is a violation of federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety. Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their inventory which are involved in a safety or compliance recall until the defect has been remedied. -END OF MESSAGE
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VOLKSWAGEN DEALER COMMUNICATION Volkswagen Customer Protection 93O2_DLR_ADV_INFO IMPORTANT โ Safety Recall 93O2 Repair Preparations This notice is for: ๏ผ Dealer Principal ๏ผ General Manager ๏ผ Sales Managers ๏ผ Service Manager ๏ผ Parts Manager ๏ผ Service Consultant ๏ผ Warranty Administrator ๏ผ Technicians Date: April 22, 2022 Important Information: The 93O2 repair will require the High Voltage battery to be opened. In an effort to allow dealers time to prepare for this repair, please take note of the following: ๏ท Repairs can only be performed at a certified Battery Repair Dealer ๏ท Dealer must have a fully trained / certified HVE ๏ท Dealer must have all related HVE and PPE equipment available Information regarding the special tools required will be provided in the future. -END OF MESSAGE
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VOLKSWAGEN DEALER COMMUNICATION Ensure all dealership personnel are aware of this notice so they are able to address customer questions. Contact Warranty if you require additional assistance. Direct press inquiries to Volkswagen Public Relations. Volkswagen Customer Protection 93O2_DLR_ADV Advance Notice โ Safety Recall 93O2 / Flexible Printed Circuit Solder โ HV Battery This notice is for: ๏ผ Dealer Principal ๏ผ General Manager ๏ผ Sales Managers ๏ผ Service Manager ๏ผ Parts Manager ๏ผ Service Consultant ๏ผ Warranty Administrator ๏ผ Technicians Date: April 08, 2022 Issue: Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Precautions: If this issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage system. Should this occur, owners are advised to make an appointment with their authorized Volkswagen dealer without delay to have the vehicle diagnosed/repaired. Repair: ๏ท REPAIR NOT YET AVAILABLE ๏ท Check daily campaign open inventory report or OMD for affected vehicles in inventory. Affected Vehicles Country Beginning Model Year Ending Model Year Vehicle Vehicle Count USA 2021 2021 ID4 351 CAN 2021 2021 ID4 5 *Counts reflect overall population; some vehicles may have already been repaired. Check Campaigns/Actions screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this action. Elsa is the only valid campaign inquiry & verification source. Notes: IMPORTANT REMINDER: VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS New Vehicles in Dealer Inventory: It is a violation of federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety. Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their inventory which are involved in a safety or compliance recall until the defect has been remedied. -END OF MESSAGE
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-162 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Volkswagen Group of America, Inc. Submission Date : MAY 26, 2022 NHTSA Recall No. : 22V-162 Manufacturer Recall No. : 93O2 Manufacturer Information : Manufacturer Name : Volkswagen Group of America, Inc. Address : 3800 Hamlin Road Auburn Hills MI 48326 Company phone : 1-800-893-5298 Population : Number of potentially involved : 351 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2021 Volkswagen ID4 Vehicle Type : Body Style : Power Train : NR Descriptive Information : Vehicles included in this recall determined by production records, according to identification of affected parts by the supplier. Vehicles not included in the recall were determined not to contain the affected parts that were identified by the supplier. ID4 351 Production Dates : DEC 16, 2020 – DEC 08, 2021 VIN Range 1 : Begin : WVGDMPE22MP007176 End : WVGUNPE20MP064439 โ Not sequential Description of Defect : Description of the Defect : Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Description of the Cause : Amount of solder contact points of FPCA is not sufficient and thickness of soldering layer out of tolerance parameters. Identification of Any Warning If this issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage Part 573 Safety Recall Report 22V-162 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 that can Occur : system. Involved Components : Component Name 1 : HV Module MEB Battery Component Description : HV Module MEB Battery Component Part Number : 0Z1.915.592.H /0Z1.915.599.H Supplier Identification : Component Manufacturer Name : LG ENERGY SOLUTION WROCLAW SP Address : ul. LG 1A Biskupice Podgรณrne Foreign States 55-040 Country : Poland Chronology : January 16, 2021: The first known field case occurred outside of the U.S. The claim was related to the vehicle not starting at the beginning of a trip. Analysis into the non-starting condition began. May 12, 2021: Supplier identified the root cause of the non-starting condition. Given that the claims did not relate to vehicles while driving, the topic was addressed as a quality topic. May 2021 โ December 2021: Quality and safety departments monitored the field and continued analyzing the nature and frequency of the non-starting condition. December 16, 2021: The topic was presented to the Volkswagen pre-Product Safety Committee panel, which requested additional details on affected population. January 13, 2022: A field claim alleging a stall while driving condition was reported in a non-Volkswagen vehicle outside of the U.S. Analysis into the stall while driving condition began. January 14, 2022: The Volkswagen Product Safety Committee recommended continued field monitoring and requested a follow-up presentation. At this time, the analysis had just begun following the first stall while driving field complaint. January 14, 2022 โ March 1, 2022: Further analysis of field claims and related diagnosis protocols to identify whether stall while driving issue might also affect Volkswagen vehicles. March 02, 2022: During a Multi-Brand Clearing committee meeting, impacted brands shared information on analysis of the potential stall while driving cases. Further update to differentiate between vehicles affected by the non-starting condition vs. the stall while driving condition was requested. March 09, 2022: The Multi-Brand Clearing committee decided to conduct a recall of Volkswagen vehicles in the Part 573 Safety Recall Report 22V-162 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 U.S. that contain the affected parts. Description of Remedy : Description of Remedy Program : At no cost to owners, the affected battery cell module(s) will be replaced. Volkswagen will not offer a reimbursement plan under this recall. How Remedy Component Differs from Recalled Component : Remedy parts were not assembled with the manufacturing deviation regarding the soldering issue in the battery modules. Identify How/When Recall Condition was Corrected in Production : On the 19.7.21 the issue was corrected at the supplier. Improvement of manufacturing at the supplier: (at supplier) CW29/21: Optimization of amount of soldering flux material. (corrective measure) <(at supplier) CW32/21: Optimization of automated optical inspection. (additional preventive measure)> Recall Schedule : Description of Recall Schedule : Dealers/Owners: On or before 05/13/2022 Planned Dealer Notification Date : MAY 13, 2022 – MAY 13, 2022 Planned Owner Notification Date : MAY 13, 2022 – MAY 13, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-162 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Volkswagen Group of America, Inc. Submission Date : SEP 14, 2022 NHTSA Recall No. : 22V-162 Manufacturer Recall No. : 93O2 Manufacturer Information : Manufacturer Name : Volkswagen Group of America, Inc. Address : 3800 Hamlin Road Auburn Hills MI 48326 Company phone : 1-800-893-5298 Population : Number of potentially involved : 356 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2021 Volkswagen ID4 Vehicle Type : Body Style : Power Train : NR Descriptive Information : Vehicles included in this recall determined by production records, according to identification of affected parts by the supplier. Vehicles not included in the recall were determined not to contain the affected parts that were identified by the supplier. ID4 356 Production Dates : DEC 16, 2020 – DEC 08, 2021 VIN Range 1 : Begin : WVGDMPE22MP007176 End : WVGUNPE20MP064439 โ Not sequential Description of Defect : Description of the Defect : Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Description of the Cause : Amount of solder contact points of FPCA is not sufficient and thickness of soldering layer out of tolerance parameters. Identification of Any Warning If this issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage Part 573 Safety Recall Report 22V-162 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 that can Occur : system. Involved Components : Component Name 1 : HV Module MEB Battery Component Description : HV Module MEB Battery Component Part Number : 0Z1.915.592.H /0Z1.915.599.H Supplier Identification : Component Manufacturer Name : LG ENERGY SOLUTION WROCLAW SP Address : ul. LG 1A Biskupice Podgรณrne Foreign States 55-040 Country : Poland Chronology : Please refer to the attached, updated chronology to support September 14, 2022 amendment. Description of Remedy : Description of Remedy Program : At no cost to owners, the affected battery cell module(s) will be replaced. Volkswagen will not offer a reimbursement plan under this recall. How Remedy Component Differs from Recalled Component : Remedy parts were not assembled with the manufacturing deviation regarding the soldering issue in the battery modules. Identify How/When Recall Condition was Corrected in Production : On the 19.7.21 the issue was corrected at the supplier. Improvement of manufacturing at the supplier: (at supplier) CW29/21: Optimization of amount of soldering flux material. (corrective measure) <(at supplier) CW32/21: Optimization of automated optical inspection. (additional preventive measure)> Part 573 Safety Recall Report 22V-162 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Recall Schedule : Description of Recall Schedule : Dealers/Owners: On or before 05/13/2022 Planned Dealer Notification Date : MAY 13, 2022 – MAY 13, 2022 Planned Owner Notification Date : MAY 13, 2022 – MAY 13, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-162 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Volkswagen Group of America, Inc. Submission Date : MAR 16, 2022 NHTSA Recall No. : 22V-162 Manufacturer Recall No. : 93O2 Manufacturer Information : Manufacturer Name : Volkswagen Group of America, Inc. Address : 3800 Hamlin Road Auburn Hills MI 48326 Company phone : 1-800-893-5298 Population : Number of potentially involved : 351 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2021 Volkswagen ID4 Vehicle Type : Body Style : Power Train : NR Descriptive Information : Vehicles included in this recall determined by production records, according to identification of affected parts by the supplier. Vehicles not included in the recall were determined not to contain the affected parts that were identified by the supplier. ID4 351 Production Dates : DEC 16, 2020 – DEC 08, 2021 VIN Range 1 : Begin : WVGDMPE22MP007176 End : WVGUNPE20MP064439 โ Not sequential Description of Defect : Description of the Defect : Specific soldering points on the flexible printed circuit assembled (FPCA) inside the HV battery may not establish a reliable connection due to manufacturing issues. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Unreliable connections inside the HV battery may lead to breakdowns or stalling while driving in the field. This can lead to a crash without warning. Description of the Cause : Amount of solder contact points of FPCA is not sufficient and thickness of soldering layer out of tolerance parameters. Identification of Any Warning If this issue is present in the vehicle, the driver would be alerted by a message appearing in the instrument panel warning about an issue in the high voltage Part 573 Safety Recall Report 22V-162 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 that can Occur : system. Involved Components : Component Name 1 : HV Module MEB Battery Component Description : HV Module MEB Battery Component Part Number : 0Z1.915.592.H /0Z1.915.599.H Supplier Identification : Component Manufacturer Name : LG ENERGY SOLUTION WROCLAW SP Address : ul. LG 1A Biskupice Podgรณrne Foreign States 55-040 Country : Poland Chronology : January 16, 2021: The first known field case occurred outside of the U.S. The claim was related to the vehicle not starting at the beginning of a trip. Analysis into the non-starting condition began. May 12, 2021: Supplier identified the root cause of the non-starting condition. Given that the claims did not relate to vehicles while driving, the topic was addressed as a quality topic. May 2021 โ December 2021: Quality and safety departments monitored the field and continued analyzing the nature and frequency of the non-starting condition. December 16, 2021: The topic was presented to the Volkswagen pre-Product Safety Committee panel, which requested additional details on affected population. January 13, 2022: A field claim alleging a stall while driving condition was reported in a non-Volkswagen vehicle outside of the U.S. Analysis into the stall while driving condition began. January 14, 2022: The Volkswagen Product Safety Committee recommended continued field monitoring and requested a follow-up presentation. At this time, the analysis had just begun following the first stall while driving field complaint. January 14, 2022 โ March 1, 2022: Further analysis of field claims and related diagnosis protocols to identify whether stall while driving issue might also affect Volkswagen vehicles. March 02, 2022: During a Multi-Brand Clearing committee meeting, impacted brands shared information on analysis of the potential stall while driving cases. Further update to differentiate between vehicles affected by the non-starting condition vs. the stall while driving condition was requested. March 09, 2022: The Multi-Brand Clearing committee decided to conduct a recall of Volkswagen vehicles in the Part 573 Safety Recall Report 22V-162 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 U.S. that contain the affected parts. Description of Remedy : Description of Remedy Program : REMEDY TBD Volkswagen will not offer a reimbursement plan under this recall. How Remedy Component Differs from Recalled Component : Remedy parts were not assembled with the manufacturing deviation regarding the soldering issue in the battery modules. Identify How/When Recall Condition was Corrected in Production : On the 19.7.21 the issue was corrected at the supplier. Improvement of manufacturing at the supplier: (at supplier) CW29/21: Optimization of amount of soldering flux material. (corrective measure) <(at supplier) CW32/21: Optimization of automated optical inspection. (additional preventive measure)> Recall Schedule : Description of Recall Schedule : Dealers/Owners: On or before 05/13/2022 Planned Dealer Notification Date : MAY 13, 2022 – MAY 13, 2022 Planned Owner Notification Date : MAY 13, 2022 – MAY 13, 2022 * NR – Not Reported
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