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.
Brake lines remain in clip .
Move electrical wiring harness 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 23 of 96
Prepare high-voltage battery for removal (cont.):
Free up fuel lines .
o
Unlock securing tabs and remove
fuel line clips from high-voltage
battery.
o
Remove fuel lines from clips .
Ignore item .
Prepare scissor lift table:
Equip the -VAS6131B- with -VAS6131/10- and
-VAS6131/13- as follows:
Table
Coordinates
Supports from -VAS6131/10- and
-VAS6131/13-
B5
/10-1
/10-2
/10-5
/10-9
F6
/10-1
/10-2
/10-5
/13-2
B12
/10-1
/10-2
/10-5
/10-9
F11
/10-1
/10-2
/10-5
/13-2
Secure the mounting elements to the scissor
lift table by hand.
Position the scissor lift table horizontally and
verify it is level using the bubble gauge.
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 24 of 96
Position the scissor lift table sideways under the vehicle (at a right angle to direction of travel).
Make sure the threaded spindles are completely screwed in.
Move the -VAS6131B- far enough upward until the mounting elements are positioned just under the highvoltage battery.
Rotate all of the mounting element spindles upward until all the mounting pins come in contact with the
mounting points.
Tighten the mounting element base plates to scissor lift table to 20 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.
May 2020
93D2 Page 25 of 96
Remove high-voltage battery from the vehicle:
Remove the bolts .
The bolts have a fastener so that they
cannot fall out.
CAUTION
There Is a Risk of Damaging Lines and Hoses
by Lowering the High-Voltage Battery.
Make sure all connections between the
high-voltage battery and the body have
been disconnected.
Carefully guide the high-voltage battery out
of the body when lowering.
Lower the high-voltage battery using the
scissor lift table.
TIP
The high-voltage battery can be removed from the
-VAS6131B- with the -VAS6100- without having to
change the position of the scissor lift table.
Move the scissor lift table with high-voltage
battery to the cordoned off work area.
TIP
Mark the position of the scissor lift table wheels with
tape or chalk to make installation of the battery
easier.
Proceed to Section C.
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 26 of 96
Section C – High-voltage Battery Inspection Overview and Documentation
DANGER
High-voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock.
Wear clothing approved for working with electric arcs.
Wear an insulated helmet with a protective mask.
Wear protective gloves.
Wear safety shoes.
The high-voltage system must be de-energized by a suitably qualified person.
NOTE
The high-voltage battery inspection must be done before AND after the high-voltage battery module group
is removed from the battery housing.
Removal of the battery housing (top section) and battery module group is outlined in Section D.
Examples of evidence of moisture, corrosion and green
discoloration in the 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.
May 2020
93D2 Page 27 of 96
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 28 of 96
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 29 of 96
Examples of oxidation that may be considered normal:
NOTE
Read the following carefully. Some of these examples may be considered normal oxidation. However, if a
combination of these scenarios is present, the high-voltage battery may require replacement.
Contact Audi Technical Assistance if there are any questions regarding the amount of corrosion/oxidation.
If this level of corrosion (fig. 1) is found only on
the top, the high-voltage battery does not
require replacement.
If this level of corrosion (fig. 1) is found only on
the bottom, the high-voltage battery does not
require replacement.
If this level of corrosion (fig. 1) is found on
both the top AND bottom, follow the
Documentation Requirements and contact
Audi Technical Assistance.
If this level of corrosion (fig. 2) is found only on
the top OR bottom, the high-voltage battery
does not require replacement.
If this level of corrosion (fig. 2) is found on both
the top AND bottom, the high voltage battery
does not require replacement.
If the top of the module has the level of
corrosion shown in (fig. 1) AND the bottom of
the module has the level of corrosion shown in
(fig. 2), the high-voltage battery does not
require replacement.
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 30 of 96
Documentation Requirements
NOTE
If there are no signs of water, moisture or corrosion, photos must still be uploaded to “doc-it” for documentation
purposed. If the technician does not have access to “doc-it”, they must supply the photos to their warranty
administrator to upload.
High-voltage battery leak test results:
Document results on repair order.
Take clear photos of all six sides of the battery module group and the bottom
section of the lower battery housing and upload photos to “doc-it”.
NO:
Take a clear photo of the low voltage connection inside the battery housing
(bottom section) and upload photo to “doc-it”.
Take a clear photo of the entire battery housing (lower section) and upload
photo to “doc-it”.
High-voltage battery housing requires replacement (outlined in Section D).
Are there signs of
water, moisture or
corrosion inside the
battery?
Audi Technical Assistance WEB contact must be created.
Take clear photos of the component and a close up photo of the corrosion and
attach to the TAC case.
YES:
Take clear photos of all six sides of the high-voltage battery module group and
the battery housing and attach to the TAC case.
If moisture can only be felt, e.g. black mat in the bottom section of the battery
housing is wet/moist, state: “moisture can only be felt, picture not capturing
condition” in TAC case.
Document leak test results in TAC case.
Document insulation test results in TAC case.
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 31 of 96
Photograph Requirements
NOTE
The follow are examples of how the required photographs should appear.
Photos for EVERY case:
Top and bottom
of battery
module group.
All four sides of
the battery
module group.
Battery housing
(lower section).
Low voltage
connector.
Additional photos if corrosion or moisture is found:
Wide shot of the
component.
Close up of the
condition
(moisture or
corrosion).
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 32 of 96
Section D – Opening High-voltage Battery Housing
DANGER
High-voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock.
Wear clothing approved for working with electric arcs (PPE).
Wear an insulated helmet with a protective mask.
Wear protective gloves.
Wear safety shoes.
The high-voltage system must be de-energized by a suitably qualified person.
WARNING
The work must be performed by a high-voltage expert (HVE) who has received additional training.
CAUTION
Risk to health due to toxic dust and liquids.
Never perform work on high-voltage batteries in which a short circuit has occurred.
The high-voltage battery can become extremely hot. This can cause injuries. Take care not to burn your
hands. Wear protective gloves.
CAUTION
Separating battery housing:
Work must be performed by high-voltage expert (HVE).
A second qualified person is required for all work on a high-voltage battery that has been opened.
The second person must not actively work on the high-voltage battery, he/she is present as a safeguard in
the event of an accident.
This section is made up of five sub-sections:
1. Performing High-voltage Battery Leak
Test
2. Removing
High-voltage
Module Group.
3. Preparing New Battery Housing.
4. Reinstalling Battery Module Group
into Battery Housing.
5. Sealing 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.
May 2020
93D2 Page 33 of 96
Moving high-voltage battery off the scissor lift
supports:
Move the high-voltage battery off the scissor
lift supports onto a work bench equipped with
wheels or onto the scissor lift platform.
The high-voltage battery must be placed onto
insulating mat -VAS6762/44-.
Install -T10542/1- and -T10542/4- on the highvoltage battery as shown, align the shackle to
the center of the battery and tighten the
original bolts to 40 Nm.
Secure one -T40155- to both of the left
-T10542/4- and one -T40155- to both right
-T10542/4- as shown.
Bind both -T40155- together over the highvoltage
battery
using
shackle
-VAS691009-.
If corrosion is found (as outlined in Section B) on
the high-voltage battery at any time during
removal:
Refer to the “Documentation Requirements”
above in Section C.
Proceed to Section 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.
May 2020
93D2 Page 34 of 96
Subsection 1 – Performing High-voltage Battery Leak Test
Perform HV battery leak test:
Perform tests in the following order:
1. Perform self-test
-VAS6911/3A-1-.
on
Leak
Tester
a. See Appendix C.
2. Perform
high-voltage
battery
acclimatization (pressure equalization)
test.
a. See Appendix D.
3. Perform high-voltage battery pressure
test.
a. See Appendix E.
If the pressure test fails, record the results of
the pressure test.
Subsection 2 – Removing High-voltage Battery Module Group
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 removed with tools
from the High Voltage Tool Set -VAS6762- and
-VAS691003-.
Remove high-voltage battery housing bolts:
Remove bolts on battery
housing (top 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.
May 2020
93D2 Page 35 of 96
CAUTION
When cutting between bolts and , it
is possible that the cutting tool can go in to
far and make contact with the SX6 ground
wire .
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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:
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