NHTSA ID Number: 10172542
Manufacturer Communication Number: Circular93D2REV1
TSB/Document Date: 2020-04-02
Summary
It is possible that the high-voltage battery
housing bonded seam was made in a non-optimal position. If this condition is present, moisture can enter the high-voltage battery housing. The driver may be alerted to this condition by the illumination of a high-voltage system warning indicator on the instrument cluster display. Optimized work steps for repair efficiency. Clarified installation step for pressure release plugs
is dry.
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 56 of 94
Install seals:
Install new seals .
Part Number
Part Description
N/A
Seals (from battery housing
repair kit)
Prepare pneumatic gun -VAS6648-:
Pneumatic gun -VAS6648- requires Hi-Flo
Milton air coupler V-Style S-764 for 1/4"
hoses OR V-Style S-766 for 3/8" hoses.
(MCQ764).
DO NOT change the fitting on pneumatic gun
-VAS6648-.
Install adhesive cartridge into pneumatic gun
-VAS6648-.
Part Number
Part Description
D 190.000.M2
Adhesive
Cut the nozzle provided down to the marked
position 3.
Set desired pressure on pneumatic gun,
-VAS6648-.
o
Apply a short test bead on cardboard
to determine the desired operating
pressure.
NOTE
The battery housing (top section) must be fitted
within 20 minutes, otherwise the battery housing
sections will not bond properly.
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 57 of 94
Apply first bead:
NOTE
When applying the first adhesive bead, use
the outline of the battery housing (top
section) on the battery housing (bottom
section) for orientation.
The adhesive bead can pass over bolt
holes.
Two cartridges of adhesive contain enough
material for two parallel beads.
The pneumatic gun -VAS6648- must remain
perpendicular to the battery housing (bottom
section) flange when applying the adhesive
bead.
Start applying adhesive bead on long side of
battery housing (bottom section).
Apply adhesive
bead
around entire
circumference at a right angle to battery
housing (bottom section) so that ridge is
vertical.
Apply adhesive bead so that start and end of
bead overlap.
Apply second bead:
Apply a second adhesive bead parallel to the
first adhesive bead.
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 58 of 94
Ensure seals are installed.
Fit top section:
NOTE
Adhesive bead must emerge all around after battery
housing (top section) has been bolted on.
Install new M6x12 bolts (from repair kit) by
hand.
Part Number
Part Description
N/A
M6x12 Bolt
Tighten bolts to 8 Nm in the sequence
.
TIP
Appendix G is a full page photo of the tightening
sequence that can be printed so the tightening
sequence can be followed easier.
Spread adhesive:
Use a suitable paintbrush to spread any
adhesive that comes out and fill gaps between
top and bottom sections of battery housing.
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 59 of 94
Allow adhesive to cure:
The minimum drying time for the adhesive is
four hours.
During the minimum drying time (i.e. the time
between the bonding procedure and
performing further work), high-voltage battery
must be on the scissor-type assembly platform
at room temperature (at least 15 °C/59 °F).
TIP
Performing the bonding procedure at the end of the
work day and allowing the adhesive to dry overnight
is the best practice.
Apply wax to bolts:
Apply cavity wax D 329.215.M1 (shop supply)
over bolts .
Seal J840 bolts and connections:
Seal bolts and for battery regulation
control unit -J840- and connector housing
with butyl adhesive.
Part Number
Part Description
D 469.101.A3
Butyl adhesive
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 60 of 94
Seal around battery regulation control unit J840- and connector housing with
butyl adhesive.
Apply butyl adhesive around connector
housing so that the electrical connectors
can still be plugged in and released correctly.
Part Number
Part Description
D 469.101.A3
Butyl adhesive
Perform HV battery leak test:
Test can only be performed after the minimum
drying time has elapsed.
Perform tests in the following order:
4. Perform self-test
-VAS6911/3A-1-.
on
Leak
Tester
a. See Appendix C.
5. Perform
high-voltage
battery
acclimatization (pressure equalization)
test.
a. See Appendix D.
6. Perform high-voltage battery pressure
test.
a. See Appendix E.
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 61 of 94
Attach warning labels:
Ensure area is clean and free of debris or
residue.
Apply warning labels.
Part Number
Part Description
12E.010.006
Warning label (English)
12E.010.006.A
Warning label (French)
Install pressure release plugs:
Install pressure release plugs into the
battery housing (top section).
Part Number
Part Description
5Q0.998.841.B
Pressure release plug (from
battery housing repair kit)
Ensure the plugs are fully seated.
Proceed to Section F
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 62 of 94
Section E – High-Voltage Battery Replacement
WARNING
Work must be performed by high-voltage expert (HVE).
After the voltage has been reduced, the affected high-voltage batteries can be sent with “normal” status
(non-critical).
After exchanging the high-voltage battery, the new battery must be sealed with butyl at the low-voltage
connector and at the -J840- cover in accordance with the instructions, provided that these locations are not
sealed on the new component.
STORAGE AND DISPOSITION OF BATTERIES
U.S. Dealers:
To arrange for recycling of the damaged/corroded cell, and to obtain appropriate packaging and markings, visit
https://a3.evbatteryreturns.com and fill out a battery request form. While stored on-site at the dealership, the
damaged/corroded cell module must be managed in accordance with universal waste requirements located at 40
CFR Part 273 and relevant state law.
To arrange for recycling of the battery pack, and to obtain appropriate markings, visit
https://a3.evbatteryreturns.com and fill out a battery request form. The battery pack must be shipped in original
packaging supplied by Audi of America. While stored on-site at the dealership, the battery pack must be managed
in accordance with universal waste requirements located at 40 CFR Part 273 and relevant state law.
The damaged/corroded cell module must be
removed from the battery module assembly.
The remaining cell modules must be secured
to the battery housing (lower section).
The voltage must be reduced on the remaining
cell modules by removing high-voltage cables
and installing caps -T10544- where
the cables used to be secured.
Once the modules are secured in the battery
housing (lower section) and the voltage is
reduced, install and secure the original battery
housing (top section).
The old battery housing with battery pack will
be
recycled
(see
“STORAGE
AND
DISPOSITION OF BATTERIES” above).
NOTE
Dealers were auto-shipped an initial quantity of five
of the -T10544-.
Additional caps are orderable in quantities of 30
from the Audi Special Tools and Equipment
program: audi.snapon.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 “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 63 of 94
Apply additional seal to the new high voltage
battery (if necessary):
If necessary, seal around battery regulation
control unit -J840- and connector housing
with butyl adhesive.
If necessary, apply butyl adhesive around
connector housing so that the electrical
connectors can still be plugged in and
released correctly.
Part Number
Part Description
D 469.101.A3
Butyl adhesive
Attach warning labels (if necessary):
Ensure area is clean and free of debris or
residue.
Apply warning labels.
Part Number
Part Description
12E.010.006
Warning label (English)
12E.010.006.A
Warning label (French)
Proceed to Section F
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 64 of 94
Section F – Reinstalling High-Voltage Battery Into Vehicle
Install high-voltage battery:
Raise battery to the vehicle using the scissor
lift table.
Start all bolts by hand.
Torque bolts to 50 Nm + 270°.
TIP
The new battery housing (bottom section) and a
new high-voltage battery will come with bolts
and retainers .
Install fuel lines:
Install fuel lines into new clips .
Part Number
Part Description
5Q0.201.449.AE
Fuel line retaining clip (x2)
Ignore item .
Ensure locking tab is fully engaged.
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 65 of 94
Install brake lines and electrical connectors.
Install brake lines into retainers.
Plug in electrical connectors.
Install potential equalization line and electrical
connector :
Remove transportation cap.
Connect electrical connector .
Remove potential equalization line and
torque bolts to 9 Nm.
Install coolant hoses:
Install coolant hoses and secure retaining clips
and .
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 66 of 94
Install exhaust:
Installation is the reverse of removal.
Torque exhaust mount bolts and to
20 Nm.
Install new gasket and torque new nuts
to 20 Nm.
Part Number
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium lead positive grid, maximizes conductivity and...
- Robust envelope separator with puncture resistant back...
- Vent cap design that resists acid leakage
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium Lead positive grid, maximizes conductivity and...
- Robust Envelope Separator with puncture-resistant back...
- Vent cap design that resists acid leakage
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: Circular93D2REV1
Replacement Service Bulletin Number:
MFR Communication Date: 2020-03-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU c0ding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Pr0gramming): Allows for Ford, for Lincoln, and for Mazda ECU pr0gramming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- 39+ Services/Resets/Adaptations/Relearns/Calibrations: XTOOL D7S full system car scanner diagnostic tool tackles 99% of common car issues through its 36+ special functions, including Oil Reset, EPB, SAS, BMS, Throttle Reset, Injector C0ding, ABS Bleed, TPMS Reset, Power Balance, etc and also covers specific-vehicle functions like Crank Sensor Relearn, ABS Initialization, Cylinder Power Balance, Fuel Trim Reset, Idle Relearn etc. This car diagnostic scanner enhances efficiency, making repairs and maintenance hassle-free. Tip: DO NOT for All vehicles, please check compatibility first
- Cost-effective ECU C0ding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase
- OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.