Just sharing what worked for me with a similar issue.

I downloaded the file of the new Navigation data (11/2023) file off the VW website. Received the Error message on the Discover Pro HMI using a Samsung SD Card (not a VW genuine).

I previously used this SD card a few years back and just replaced the files and it didn't work. I played around multiple times trying to get this update to work.

I then stumbled across a PDF file from VW https://app-connect.volkswagen.com/m...ember_2020.pdf which mentioned that hidden files on the SD Card are an issue.

So I found this website Fixed: Diskpart Clean Not Working, Diskpart Fails to Clean Disk/USB/SD Card in 2024 which explains that you can wipe the SD Card clean and re-partition it using Command Prompt. I followed the steps. WARNING: make sure you know the SD Card storage capacity and select the right disk, you don't want to accidentally erase your computers drive(s).

I then reformatted the SD Card to exFAT / 32GB allocation size. Unzipped the navigation files with 7zip straight to this SD Card and Voilą - it worked!

Note, I did also use the Service Menu when uploading which means holding the Menu button down on the Discover Pro for 3-5sec and following the prompts to update, then pressed start.