NHTSA ID Number: 10176055
Manufacturer Communication Number: Circular93D2REV3
TSB/Document Date: 2020-06-04
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. Updated claiming and work instructions in the event the coolant expansion tank is damaged.
-VAS6911/15-
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.
May 2020
93D2 Page 13 of 96
Leak Tester - Test
Connector Set
-VAS6911/3A-
High Voltage Tool Set
-VAS6762-
Suspension Device
-T10543-
High-Voltage Battery
Repair Tool Set - Cutter 27mm
-VAS6900/1-
High-Voltage Battery
Repair Tool Set - Levering
Tool
-VAS6900/6-
High Voltage Tool Set Torque Wrench
-VAS6883/1A-
Drip Tray
-Insulated Torx Wrench
Set - 3/8-
-VAS6208-
-VAS691003A-
(or equivalent)
High-voltage cordon
Guide Sleeves
-VAS6884-
-VAS691005/9-
Test Adapter - Hybrid
Module
Diagnostic Box
-VAS6558A-
-VAS5581-
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.
May 2020
93D2 Page 14 of 96
CAUTION
Replacing battery housing:
The work must be performed by a high-voltage expert (HVE) or high-voltage technician (HVT) who has received
additional training (Replacing A3 etron housing in accordance with campaign instructions).
If moisture is found in high-voltage battery:
Work must be performed by high-voltage expert (HVE).
Safety Precautions When Working ON the High-voltage System (additional information
is also available in the ELSA Repair Manual)
DANGER
High-voltage can cause fatal injury
The voltage levels in the high-voltage system constitute a safety hazard. Danger of severe or fatal injuries
from electric shock.
Persons with life-sustaining or other electronic medical devices in or on their body must not perform any
work on the high-voltage system. Such medical devices include internal analgesic pumps, implanted
defibrillators, pacemakers, insulin pumps and hearing aids.
The high-voltage system must be de-energized by a suitably qualified person.
DANGER
There Is a Risk of Explosion Caused by Cooling System Leaks in the High-Voltage Battery. This Can
Cause a Buildup of Explosive Gases in the Battery Housing.
Explosions May Cause Severe Bodily Injuries.
Loss of coolant indicates there could be a coolant leak internal to the high-voltage battery housing.
If the indicator lights for “coolant level” and “high-voltage battery error” turn on, move the vehicle into the
open air into the defined separate parking area.
Notify the high-voltage expert (HVE).
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.
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.
May 2020
93D2 Page 15 of 96
Safety Precautions When Working IN THE VICINITY of the High-voltage System
(additional information is also available in the ELSA Repair Manual)
DANGER
High-voltage can cause fatal injury
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.
Repair Instruction
Section A - Check for Previous Repair
Enter the VIN in Elsa and proceed to the
“Campaign/Action” screen.
TIP
On the date of repair, print this screen and keep a
copy with the repair order.
Confirm the Campaign/Action is open . If the status is closed, no further work is
required.
Note the Applicable Criteria ID for use
in determining the correct work to be done and
corresponding parts associated.
CRITICAL REPAIR STEP
STOP!
If multiple software update Campaign/Actions are
open, they must be performed in order of the Start
date . The oldest should be performed
first.
All Safety Recalls must be completed prior to
completing this campaign.
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.
May 2020
93D2 Page 16 of 96
Section B – High-voltage Battery Removal from Vehicle
DANGER
High-voltage can cause fatal injury
The voltage levels in the high-voltage system constitute a safety hazard. Danger of severe or fatal injuries
from electric shock.
Persons with life-sustaining or other electronic medical devices in or on their body must not perform any
work on the high-voltage system. Such medical devices include internal analgesic pumps, implanted
defibrillators, pacemakers, insulin pumps and hearing aids.
An Audi high-voltage technician (HVT) or an Audi high-voltage expert (HVE) must de-energize and
re-energize the high-voltage system.
CAUTION
Risk of damaging the high-voltage cables.
Incorrect handling can damage the insulation of the high-voltage cables or high-voltage connectors.
NOTE
Removing the high-voltage battery can be performed by a High-voltage Trained (HVT) technician.
The High-voltage Expert (HVE) must be informed if the system cannot be de-energized.
If the system cannot be de-energized, do not continue with work.
De-energize high-voltage system:
Connect 12V battery charger.
Start the ODIS program and perform a vehicle
scan using “Diagnosis” Operating mode.
Perform the following Guided Functions test
plans in the following order.
o
“8C – Classification Hybrid battery
unit”
o
“008C_Isolationswiderstand_HV_Batt
erie_messen_93D2”
o
Record the results of the insulation
test.
CAUTION
The high-voltage expert must be informed if the
system cannot be de-energized.
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.
May 2020
93D2 Page 17 of 96
NOTE
The “008C_Isolationswiderstand_HV_Batterie_
messen_93D2” test plan will guide the repair in its
entirety. Pay attention to the on-screen instructions.
The “Function descriptions” within the test plan also
provide useful information.
Follow the test plan on-screen prompts.
NOTE
STOP!
Test plan text: Does the electrical shock protection
remain on all high-voltage components after deenergizing the high-voltage system?
Pay close attention when the
008C_Isolationswiderstand_HV_Batterie_mess
en_93D2 de-energization test plan step asks
about shock protection.
This step refers to the shock protection installed on
the e-machine or the Electric Drive Control Module
-J841- prior to removing the battery. It does not refer
to disassembling the high-voltage battery.
Disassembling the high-voltage battery will be
performed while wearing PPE.
The electrical shock protection on the high-voltage
components remains if you are not working on the
e-machine or opening the cover of the Electric Drive
Control Module -J841-.
Open coolant reservoir filler cap:
CAUTION
Risk of scalding due to hot steam and hot
coolant.
The coolant system is under pressure when
the engine is warm.
Cover the coolant bottle cap with a cloth
and then open it slowly to release the
pressure.
Cut anti-tamper seal .
Open filler cap .
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.
May 2020
93D2 Page 18 of 96
NOTE
Some vehicles may have been produced with the
cap glued to the expansion tank. If this scenario is
encountered, the coolant expansion tank, cap and
tie wrap should be replaced according to the ELSA
Repair Manual.
When replacing the tank, the original warning tag
should be transferred to the new tank and secured
with a new tie wrap.
Part Number
Part Description
1S0.121.407.J
Tank
2Q0.121.321.A
Cap
N 105.088.01
Tie Wrap
Soak muffler nuts:
Spray nuts with a commercially
available penetrating oil.
NOTE
Extreme care must be taken when removing the
muffler nuts.
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.
May 2020
93D2 Page 19 of 96
Remove underbody trim panels and rear wheels:
Support and remove center underbody panels
.
o
The lower rear of the front fender
liners will also have to be loosened.
Support and remove rear underbody panels
.
Remove braces and .
Remove both rear wheels.
Remove exhaust system:
Remove nuts .
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.
May 2020
93D2 Page 20 of 96
NOTE
If the muffler studs break, the studs can be replaced
instead of replacing the entire muffler.
Use a center punch in the exact center of
the broken stud.
Drill out the stud using a 3.5 mm drill bit first,
then a 5.0 mm drill bit and finally a 6.8 mm
drill bit.
Then tap the hole using a M8 x 1.25 mm
tap.
Install stud(s) part number WHT.002.622
U.S. Dealers: Contact Audi Warranty for
claiming instructions.
Canadian Dealers: Create an Audi
Technical Assistance ticket and obtain
campaign authorization for consequential
damage.
Remove the left and right bolts .
Remove the bolt and remove the exhaust
system .
Remove heat shield from battery:
Remove bolts from high-voltage battery
.
Remove heat shield .
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.
May 2020
93D2 Page 21 of 96
Remove coolant hoses:
CAUTION
The high-voltage battery can become extremely hot.
This can cause injuries. Take care not to burn your
hands.
Lift retaining clips and .
Detach coolant hoses and let coolant drain
from the high-voltage battery.
Seal coolant hoses with -VAS691005/2-.
Extract coolant from high-voltage battery coolant
pipes:
Connect coolant system tester adapter
-VAS691005/4- to a coolant hose
connection on the high-voltage battery.
Connect cooling system tester -VAG1274B to adapter .
Pump out all coolant from the high-voltage
battery coolant pipes.
NOTE
Extracting all coolant from the coolant lines
at this step prevents the risk of coolant
leaking into the high-voltage battery
housing during this repair.
DO NOT use compressed air to force out
coolant. Damage to the coolant pipes could
occur.
Prepare high-voltage battery for removal:
Remove nut .
Remove bolt .
Remove potential equalization line .
Unplug electrical connector and move
clear.
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.
May 2020
93D2 Page 22 of 96
Prepare high-voltage battery for removal (cont.):
Place the Transportation Protection Cap for
DC Connector 12E.971.883 on the
connection for the high-voltage cable.
Prepare high-voltage battery for removal (cont.):
Unplug electrical connector .
Move brake lines clear.
o
Carefully pry out pin from clip
.
o
Remove clip from high-voltage
battery.
o
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TSB/Document ID: Circular93D2REV3
Replacement Service Bulletin Number:
MFR Communication Date: 2020-05-20
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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