NHTSA ID Number: 10172000
Manufacturer Communication Number: Circular 57H3
TSB/Document Date: 2020-03-06
Summary
Audi has developed new software and/or parts applicable to certain Audi e-tron vehicles in order to bring these vehicles up to the latest factory specifications.
4KE.121.809
Lead seal
5Q0.010.001.A
Label
•
Work for Criteria 04 is complete.
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 20 of 28
Criteria 05 – Replace Bowden Cable for Doors
•
Replace operating cable for exterior door
handle on all four doors.
•
Front doors - See ELSA Repair Manual:
Repair manual > Body > Body Exterior > 57
Front Doors, Central Locking System > Door
Components > Exterior Door Operating Cable,
Removing and Installing
•
Rear doors - See ELSA Repair Manual: Repair
manual > Body > Body Exterior > 58 Rear
Doors > Door Components > Exterior Door
Operating Cable, Removing and Installing
NOTE
•
It is possible to unclip the cable from the
door lock/latch without removing the door
lock/latch from the door. The door lock/latch
does not require removal from the door.
•
The procedure for all doors is similar.
Part Number
Part Description
4M8.837.099
Bowden cable (driver door)
4N0.837.099
Bowden cable (other doors) (x3)
•
Work for Criteria 05 is complete.
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 21 of 28
Criteria 06 – Replace Flap for DC Charging Connection
•
Open charging socket door.
•
Press down on the DC charging port flap and
then pull it out of the charging socket away
from the vehicle.
•
Install new flap in the opposite direction of
removal until the flap audibly engages.
Part Number
Part Description
4KE.971.904.A
DC charge port cover
•
Work for Criteria 06 is complete.
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 “do-it-yourselfers,” 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 Audi
dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 22 of 28
Criteria 07 – Service Manual Release Mechanism
•
Open cover for manual release mechanism.
•
Check the two manual release mechanisms
and unwind them if necessary.
NOTE
This photo shows the release mechanism properly
installed.
•
Work for Criteria 07 is complete.
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 23 of 28
Criteria 09 – Service High-voltage Cable
•
Remove rear underbody trim panel .
•
Visually inspect the high-voltage cable to the
rear electric drive.
o
•
•
•
The cable must not be in contact with
the subframe or rear electric drive
unit .
If the high-voltage cable is not making contact:
o
No further work is required.
o
Re-install underbody trim panel in the
reverse order of removal.
Torque M6 bolts to 8 Nm.
Torque other bolts to 2 Nm.
If the high-voltage cable is making contact with
either component and only the outer woven
aramid covering is damaged:
o
The high-voltage
aligning.
cable
requires
o
Proceed to repair step “Aligning
high-voltage cable”.
If the inner insulation is damaged:
o
The high-voltage cable must be
replaced.
o
See ELSA Repair Manual: Repair
manual > Motor > Electric Drive Motor
0EF > 93 Electric drive > High-Voltage
Cables > Drive Motor High-Voltage
Wiring Harness, Removing and
Installing > Rear Motor High-Voltage
Cable Set, Removing and Installing
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 24 of 28
Aligning high-voltage cable (if necessary):
•
Loosen bolt .
•
Press cable towards the front of the vehicle
.
•
While holding cable forward, torque bolt
to 9 Nm.
•
If the high-voltage cable is no longer making
contact:
o
No further work is required.
o
Re-install underbody trim panel in the
reverse order of removal.
Torque M6 bolts to 8 Nm.
Torque other bolts to 2 Nm.
•
If the high-voltage cable is still making contact:
•
De-energize the high-voltage system.
DANGER
High voltage increases the risk of fatal injury.
Severe bodily injury or death by electrocution or
electric arcs is possible.
Have an Audi high-voltage technician or an Audi
high-voltage expert de-energize the high-voltage
system.
o
See ELSA Repair Manual: Repair
manual > Motor > Electric Drive Motor
0EF > 93 Electric drive > High-Voltage
System, De-Energizing
•
Remove bolts .
•
Unplug connector.
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 25 of 28
•
Unscrew bolt at bracket.
•
Press wiring harness towards front of vehicle
as described above and bolt bracket back on
to final torque while maintaining the tension.
•
Plug connector back in and tighten bolts to
7 Nm.
•
Verify high-voltage cable is not making
contact.
•
Reinstall rear underbody trim panel in the
reverse order of removal.
•
o
Torque M6 bolts to 8 Nm.
o
Torque other bolts to 2 Nm.
Work for Criteria 09 is complete.
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 26 of 28
Section C – Campaign Completion Stamp
•
Once the campaign has been completed,
the technician should stamp the repair
order.
•
Stamps are available for ordering through
the Compliance Label Ordering Portal.
•
Proceed to Section D.
Item#: AUD4927ENG
-OR-
Item # AUD4927FRE
Section D - Parts Return/Disposal
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.
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 27 of 28
Appendix A – Warning and Safety Precautions (additional information is also available in
the ELSA Repair Manual)
Safety Precautions When Working ON the High-voltage System
DANGER
Extremely dangerous due to high voltage.
•
The high-voltage system is under heavy voltage. Severe bodily injury or death by electrocution or electric
arcs is possible.
•
When working on the high-voltage system the high-voltage system must be de-energized.
•
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.
•
Pay attention when the high-voltage system must be de-energized. Refer to the Repair Manual
•
Have an Audi high-voltage technician or an Audi high-voltage expert de-energize the high-voltage system.
The electric and magnetic fields are extremely dangerous.
•
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).
•
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
•
Incorrect handling may result in damage to the insulation of high-voltage wires or high-voltage connectors.
•
Do not support yourself on high-voltage cables or connectors.
•
Never prop tools against high-voltage wiring or high-voltage connectors.
•
Never bend or kink high-voltage wiring.
•
Observe the coding of the high-voltage connectors when joining them up.
Safety Precautions When Working NEAR the High-voltage System
DANGER
Extremely dangerous due to high voltage.
•
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.
•
Carry out a visual check of high-voltage components and high-voltage wiring.
•
Never use cutting/forming tools or other sharp-edged implements.
•
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 “do-it-yourselfers,” 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 Audi dealer. 2020 Audi of America, Inc. and Audi Canada. All Rights Reserved.
February 2020
57H3 Page 28 of 28
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TSB/Document ID: Circular 57H3
Replacement Service Bulletin Number:
MFR Communication Date: 2020-02-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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