Seal coolant connections using sealing plugs
-VAS691005/3-.
NOTE

Since the guide pins -VAS691005/9- are installed,
the sealing plugs -VAS691005/3- will not lock into
place.

Install high-voltage cables:


Place high-voltage wires and in
housing guide .



Install new bolts and torque to 8 Nm.

Part Number

Part Description

5Q0.998.215.A

M6x16 bolts - silver (from
battery housing repair kit)

TIP
The bolts secure the high-voltage cables to the
terminals, which move independently of the cable
housing guide.


Close cover on housing .



Proceed to Subsection 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 “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.
March 2020

93D2 Page 46 of 94

Subsection 4 – Reinstalling Battery Module Group Into Battery Housing


The work must be performed within the
cordoned off area.



The work requires a second technician AND
BOTH technicians MUST be wearing their
Personal Protective Equipment.



The second technician must not actively work
on the high-voltage battery. They are present
as a safeguard in the event of an accident.



The fasteners must be installed with tools from
the High Voltage Tool Set -VAS6762- and
-VAS691003-.

Vacuum debris out of high-voltage battery:


Use a wet/dry vacuum with a plastic nozzle
and vacuum all debris and sealant residue
from high-voltage 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 “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.
March 2020

93D2 Page 47 of 94

Position HV battery:


Move new battery housing (bottom section)
back to scissor lift table.



Position battery module assembly above
battery housing (bottom section) using
workshop hoist -VAS6100- and support tool
-T10543-.

Lower HV battery module assembly into battery
housing lower section:


Guide battery module assembly carefully into
battery housing (bottom section), paying
attention to electrical wiring and coolant pipes.

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.
March 2020

93D2 Page 48 of 94



Approx. 5 cm before battery module assembly
reaches its final position in battery housing
(bottom section):
o

Connect coolant pipes of battery
module assembly to connections in
battery housing (bottom section).

o

Guide cable into bracket for J840-.

o

Install connector .

o

Lower battery module assembly to
end position.

Install cable ties:


Pre-install new cable ties .

Part Number

Part Description

N 907.726.01

Cable tie



When installing cable ties, the high-voltage
battery support will need to be pried up
slightly with using the -3409- in order for the
new locking tabs to fully engage.

Remove guides:


Remove guides -VAS691005/9- from
coolant connections on battery housing
(bottom section).

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.
March 2020

93D2 Page 49 of 94

Disconnect support tool -T10543-:


Loosen support tool -T10543- at mounting
points on battery module assembly
.



Detach support tool -T10543- with the shackle
-VAS691009-.



Put support tool -T10543- down safely.

Carry out a visual check of high-voltage
components and high-voltage wiring:


Check high-voltage components and highvoltage wiring for external damage.



Check insulation for high-voltage wires and
potential equalization lines for damage.

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.
March 2020

93D2 Page 50 of 94

Secure HV battery:
NOTE





The new battery housing (bottom section) is
supplied without pre-cut threads in the area
of the bolted connection for the battery
module assembly and the cross member
.



DO NOT pre-thread holes .
Install new bolts
-VAS691003/19-

and

using

Part Number

Part Description

WHT.008.861

M8x30 Bolt (from battery
housing repair kit)



Observe the
sequence:

following

bolt

installation

o

Torque bolts to 20 Nm.

o

Torque bolts to 22 Nm.

o

Loosen bolts and by half a
turn.

o

Torque bolts to 20 Nm.

o

Torque bolts to 22 Nm.

Secure coolant pipes:


Connect coolant pipes to connections on
battery housing (bottom section).



Install bolts and torque 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 “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.
March 2020

93D2 Page 51 of 94

Connect electrical connectors:


Secure electrical connector .



Plug in electrical connector for pilot wire.

Install SX6:


Clean threads.



Install bolts with commercially
available locking fluid (medium strength) and
torque 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 “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.
March 2020

93D2 Page 52 of 94

Install cable ties and connect electrical connector:


Secure cable ties around high-voltage
cables.



Connect and attach connector .



Clean threads for bolt .



Install bolt with commercially available
locking fluid (medium strength) and torque to 8
Nm.

Connect HV cables:


Remove end cap -VAS6762/48- from
connecting cable 1 for battery module -P26-.



Connect connecting cable 1 for battery module
-P26- at switching unit for high-voltage
battery -SX6-.



Lock 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 “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.
March 2020

93D2 Page 53 of 94



Remove end cap -VAS6762/48- from
connecting cable 9 -P34-.



Connect connecting cable 9 for battery module
-P34- at switching unit for high-voltage
battery -SX6- in opposite direction of .



Lock cover .

Perform insulation measurement:


Use test plan “008C_Isolationswiderstand_
HV_Batterie_messen_93D2”.

Perform cooling system leak test:


Perform cooling system tester self-test (see
Appendix A).



Perform high-voltage battery cooling system
leak test (see Appendix B).



Proceed to Subsection 5.

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.
March 2020

93D2 Page 54 of 94

Subsection 5 – Sealing Battery Housing


The work must be performed within the
cordoned off area.



The work requires a second technician AND
BOTH technicians MUST be wearing their
Personal Protective Equipment.



The second technician must not actively work
on the high-voltage battery. They are present
as a safeguard in the event of an accident.



The fasteners must be installed with tools from
the High Voltage Tool Set -VAS6762- and
-VAS691003-.

Bonding battery housing:


Perform bonding procedure in one step.



Do not interrupt the bonding procedure.



Avoid taking breaks
procedure is complete.



Bonding surfaces are sensitive to dust and
grease. The adhesive will not be effective if
there is any dust or grease.



Bonding surface must be free of dirt and
grease.

until

the

bonding

Apply bonding agent to battery housing (bottom
section):


Clean battery housing (bottom section) with
isopropyl alcohol and lint-free cloth thoroughly
in area of adhesive bead.



Allow cleaning solution to completely dry.



Apply bonding agent along entire flange of
battery housing (bottom section) and approx.
2 cm below edge of flange.



Allow bonding agent to flash off until it is dry.

Part Number

Part Description

D 355.205.A2

Bonding agent

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.
March 2020

93D2 Page 55 of 94

Apply primer to battery housing (bottom section):


Use applicator to apply primer for battery
housing (bottom section) evenly and in one
direction to flange on battery housing (bottom
section) and approx. 2 cm over edge of flange;
make sure there are no air bubbles.



Allow primer to flash off for 30 minutes until it
is dry.

Part Number

Part Description

D 181.220.A1

Primer

Clean and prepare top section:


Ensure that heat insulation mat is securely
seated in battery housing (top section) .



The sealing/bonding surface must not be
covered by the heat insulation mat.



Holes must have sufficient clearance to
heat insulation mat .



Rework heat insulation mat with workshop
equipment if necessary.



Clean battery housing (top section) with
isopropyl alcohol and lint-free cloth thoroughly
in area of adhesive bead.



Allow cleaner to completely dry.



Use applicator to apply primer for battery
housing (top section) evenly and in one
direction around adhesive bead and approx. 5
mm over edge of flange on battery housing
(top section); make sure there are no air
bubbles.



Allow primer to flash off for 30 minutes until it