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
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 77 of 94
Appendix C – -VAS6911/3A- Adapter Self-Test
This test ensures the -VAS6911/3A- does
not leak.
Test can be done with either -VAS1397A- or
-VAS1397B-.
-VAS1397B- shown.
Using VAG1397A:
o
Attach connection A of
-VAS691005/1- to connection II on
turbocharger tester -VAG1397A-.
Using VAG1397B:
o
Attach connection A of
-VAS691005/1- to connection II on
turbocharger tester -VAG1397B-.
Connect connection C of -VAS691005/1- to
hand pump -VAG1274B-.
Open cut-off valves A and C on
-VAS691005/1-.
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 78 of 94
Using -VAG1397A-:
o
Turn
on
turbocharger
-VAG1397A-.
o
Select setting II .
tester
Using -VAG1397B-:
o
Turn
on
turbocharger
-VAG1397B-.
o
Press the menu button until the
relative pressure setting (P-rel) is
displayed .
o
Wait approximately 30 seconds for
tester to calibrate.
o
Display will then read 0.000.
tester
CAUTION
Risk of Tool Damage!
Do not exceed 2.99 bar or irreparable damage to
the tool will occur.
No other tools should be attached to the
-VAS691005/1-.
Using hand pump -VAG1274B-, build up
pressure
until
turbocharger
tester
-VAG1397A/B- reads between 0.300 and
0.350 bar (300 - 350 mbar).
Close cut-off
-VAS691005/1-.
valve
C
on
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 79 of 94
Stabilize
Pressure loss
< 5 mbar = OK
Allow pressure to stabilize for one minute.
After the pressure is stable, wait 30 seconds
and check pressure drop on turbocharger
tester -VAG1397A/B-.
If pressure drop does not exceed 5 mbar after
30 seconds, then the -VAS6911/3A- is OK.
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 80 of 94
Appendix D – High-Voltage Battery Acclimation Test
This test ensures the pressure inside the highvoltage battery housing has stabilized. This
will ensure an accurate reading during the
high-voltage battery pressure test.
Do not place any objects on the highvoltage battery.
Leave cut-off valve C open on -VAS691005/1when assembling the tools. Otherwise,
damage to the pressure gauge -VAS611013may occur.
This test must be performed under constant
temperature conditions.
Test block is
-VAS6911/3A- .
Seal pressure equalization openings on
battery housing (top section) with sealing
plugs -VAS6911/15- .
removed
from
the
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 81 of 94
Pressure
increase < 0.5
mbar = OK
Ensure cut-off valves A and C are open on
-VAS691005/1- when connecting tools.
Attach connection B of the -VAS691005/1- to
the -VAS6911/3A- .
Attach -VAS6911/3A- to the high-voltage
battery connection .
Close cut-off valve C on -VAS691005/1-.
Observe the pressure
-VAS611013- .
After five minutes, the pressure should not
increase by more than 0.5 mbar.
If pressure does increase by more than 0.5
mbar, wait another 5 minutes to allow the
pressure inside the battery housing to
acclimate.
reading
on
the
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 82 of 94
Appendix E – High-Voltage Battery Pressure Test
This test ensures the high-voltage battery
does not leak.
This test must be performed with pressure
gauge -VAS611013-.
Do not place any objects on the highvoltage battery.
Leave cut-off valve C open on -VAS691005/1when assembling the tools. Otherwise,
damage to the pressure gauge -VAS611013may occur.
This test must be performed under constant
temperature conditions.
Test block is
-VAS6911/3A- .
Ensure the pressure equalization openings on
battery housing (top section) are sealed with
sealing plugs -VAS6911/15- .
removed
from
the
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 83 of 94
Ensure cut-off valves A and C are open on
-VAS691005/1- when connecting tools.
Connect connection C of -VAS691005/1- to
hand pump -VAG1274B-.
Open cut-off valves A and C on
-VAS691005/1-.
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 84 of 94
Connection A of -VAS691005/1- is
attached to pressure gauge -VAS611013-.
The -VAS6911/3A- is attached to the highvoltage battery connection .
Connection B of the -VAS691005/1- is
attached to the -VAS6911/3A- .
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 85 of 94
CAUTION
Risk of Tool Damage!
Do not exceed 35
the tool will occur.
Stabilize
mbar or irreparable damage to
Turn on pressure tester -VAS611013-.
Using hand pump -VAG1274B-, build up
pressure until pressure gauge -VAS611013reads 30.1 or 30.2 mbar.
Close cut-off
-VAS691005/1-.
Allow pressure to stabilize for one minute.
valve
C
on
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 86 of 94
After the pressure is stable, wait 10 minutes
and check pressure drop on turbocharger
tester -VAS611013-.
If pressure drop does not exceed 9 mbar after
10 minutes:
o
Pressure loss
< 9 mbar = OK
The high-voltage battery is OK.
If pressure drop exceeds 9 mbar after 10
minutes:
o
Generate pressure as outlined in this
High-voltage battery pressure test.
o
Spray battery housing seams and
other areas with soapy water to find
the leak.
o
The sealing plugs for the pressure
equalization are also locations where
leaks can potentially occur.
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 87 of 94
Appendix F – Battery Housing Bolt Torque Sequence
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 88 of 94
Appendix G – A3 Battery Portal Instructions (U.S. Dealers Only)
Register New User Account
1. Navigate to the A3 Battery Recall Portal: https://a3.evbatteryreturns.com/
2. On the Sign In screen, click the New User tab.
3. Complete all required fields and click the Continue button.
4. Enter a unique password, confirm that password and click the Register User button.
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 89 of 94
5. After successful registration, you will be sent an email with a link to verify your account email address. NOTE:
You will not be able to log into the portal until after your account has been verified. If you do not receive the
account verification email, be sure to whitelist our domain (evbatteryreturns.com) to prevent emails from being
sent to your spam folder.
Existing User Sign In
1. Navigate to the A3 Battery Recall Portal: https://a3.evbatteryreturns.com/
2. On the Sign In screen, ensure the Existing User tab is selected:
3. Enter the Email and Password used when registering your account and click the Sign In button.
4a. [OPTIONAL] If you cannot remember your password, click the ‘Forgot Password?’ link.
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 90 of 94
4b. [OPTIONAL] Ensure your email is entered correctly and click the Reset Password button to send an email
with a link to reset your password. Once reset, you can immediately log in with your new password.
First Portal Login (i.e. Complete Dealership Setup)
1. At first login, you will be asked to finish the setup of your dealership. Click the Complete Setup button.
2. Enter your Dealer No. and Dealer Name into the dialog window. Click the Next button.
3. Enter the primary address from where batteries will be picked up. Click the Submit button.
NOTE: This will set the default pickup address, however, it can be changed at any time.
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 91 of 94
Schedule Battery Return Request
1. From the Battery Returns view, click the Schedule Return button.
2. A dialog will be displayed. Confirm the Pickup Address either by selecting an existing address or entering a
new address. Click the Next button.
3. Confirm Contact Information for person responsible for managing the battery return. NOTE: Your user
information will be added by default; but fields can be updated to a more appropriate contact person if necessary.
Click the Next button.
4. Enter the VIN associated with the battery being returned and select the number of defective battery modules
identified (between 1 – 4 modules). Review the list of potential hazards related to the battery and select any that
apply. NOTE: In most cases, no hazards will be selected; however, if you are unsure about this selection you
should contact our support team at [email protected].
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 92 of 94
5. Read the notification about Department of Transportation training requirements and certify whether the
employee responsible for packaging and offering battery for shipment is approved to ship hazardous materials.
Click the Get Estimate button. NOTE: If you select “No hazmat trained employee. Use an authorized third party
instead.”, all costs related to the use of that third party (approximately $700 – $1,400) will be passed through to
your dealership.
6. Review Cost Estimate charges. Select the checkbox to signify your agreement with the payment Terms and
Conditions. Click Submit Request.
7. A table of Battery Return Requests will now be displayed. You may click on the View icon to see more details
for the request. Further, you may click the Schedule New Return button to submit an additional request.
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 93 of 94
Update User Information
1. From any screen, click the User Profile option.
2. From this screen, you can update User, Dealer, or Dealer Locations information.
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 94 of 94
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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:
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