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.
Use extreme care when cutting between
bolts and so the wire is not
damaged.
CAUTION
Once the high-voltage battery is opened, it must be
covered with insulating mat -VAS6242/44whenever no work is being performed on the highvoltage battery.
Separate battery
-VAG1561A:
housing
sections
using
Fit blade (27 mm) -VAS6900/1- to electric
cutter -VAG1561A-.
Adjust speed on electric cutter -VAG1561A- to
4.
Cut open bonded seam between battery
housing (top section) and battery housing
(bottom section) in direction of .
Cut open bonded seam in direction of
arrow .
Cut open bonded seam in direction of
arrow .
Cut open bonded seam in direction of
arrow .
Detach battery housing (top section) from
battery housing (bottom section) .
If necessary, use lever -VAS6900/6- to
carefully pry battery housing (top section)
off battery housing (bottom section) and
apply removal wedge -3409-.
NOTE
Hold electric cutter -VAG1561A- at bottom
and with both hands.
Guide electric cutter -VAG1561A- along
edge of 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.
May 2020
93D2 Page 36 of 96
Perform insulation measurement:
Use test plan “008C_Isolationswiderstand_
HV_Batterie_messen_93D2”.
Record insulation measurement results.
Disconnect cables to SX6:
NOTE
It can be helpful to make sketches or take
photographs of the electrical wiring and the
installation position of electrical connectors and
cable ties. This helps to ensure that components are
re-installed in their original positions.
Release cover and detach.
Disconnect connecting cable 9 for battery
module -P34- in direction of
from connection on switching unit for highvoltage battery -SX6- and fit end caps
-VAS6762/48- on removed cable.
CAUTION
Use extreme care when removing covers . The
locking tabs can be easily damaged during removal.
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 37 of 96
CAUTION
Use extreme care when removing covers . The
locking tabs can be easily damaged during removal.
Release cover and detach.
Disconnect connecting cable 1 for battery
module -P26- in direction of
from connection on switching unit for highvoltage battery -SX6- and fit end caps
-VAS6762/48- on removed cable.
End caps -VAS6762/48- must be
fitted over the cable ends before continuing.
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 38 of 96
Disconnect connectors for SX6:
Release and unplug electrical connector .
Remove bolt .
Cut tie wraps .
Remove SX6:
Remove bolts .
Leave high-voltage cables connected to
-SX6- .
Support -SX6- so the high-voltage cables
are not under stress.
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 39 of 96
Disconnect connectors and pilot wire:
Release and unplug electrical connector .
Release and unplug electrical connector
for pilot wire.
Unclip wiring harnesses from battery housing
(lower section).
Loosen all seven bolts for 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.
May 2020
93D2 Page 40 of 96
Remove high-voltage battery bolts:
Loosen coolant pipes from connections on
battery housing (bottom section).
Remove bolts .
After removing bolts , remove any metal
shavings using a wet/dry vacuum cleaner with
plastic nozzle.
Remove excess adhesive away from
mounting areas for high-voltage battery.
Attach support tool -T10543-:
Remove adhesive residue from mountings for
lifting device.
Secure support tool -T10543- to shop crane
-VAS6100- using shackle -VAS691009- and
retaining straps -T40155-.
Position support tool -T10543- with shop crane
-VAS6100- centrally above battery module
assembly so that battery module
assembly remains level when it is lifted
out of battery housing (bottom section).
Secure support tool -T10543- to mounting
points on battery module assembly
.
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 41 of 96
Free up wire for Battery Regulation Control Module
-J840-:
Lift battery module assembly via lifting
device by approx. 5 cm using shop crane
-VAS6100-.
Disconnect connector .
Unhook the wire on the bracket for the
-J840-.
Ensure the bolt is removed.
Carefully pry the coolant pipe out of the
coolant connection on the battery housing
(lower 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 42 of 96
Lift battery out of battery housing:
Carefully lift the battery module group out
of the battery housing lower section using the
Shop Crane -VAS6100-.
Place the battery module group on the
insulation mat from the High-Voltage Tool Set
-VAS6762-.
Carry out a visual check of high-voltage
components and high-voltage wiring.
Perform visual check of bolted connections for
modules.
Document routing of wiring from battery
regulation control unit -J840-.
Guide electrical wire out of guide for battery
regulation control unit -J840-.
Lever coolant pipes out of coolant connection
on battery housing (bottom section).
Battery housing (bottom section) can be
moved out of cordoned-off area.
NOTE
The requirement to take clear photos of
all six sides of the high-voltage battery is
best done at this point.
DANGER
High-voltage battery module group must be remain
in the cordoned off area.
NOTE
Photo shows work being done on a bench. Work is
similar when battery housing (lower section) is
attached on the scissor lift table.
Inspect high-voltage battery for corrosion:
Refer to the “Documentation Requirements”
above in Section C.
If there is no evidence of moisture or corrosion:
o
High-voltage battery housing requires
replacement.
o
Proceed to Subsection 3.
If evidence of moisture or corrosion is found:
o
High-voltage
replacement.
o
Proceed to Section E.
requires
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 43 of 96
Subsection 3 – Preparing New Battery Housing
This work can be done outside the cordoned
off area.
PPE is not required.
Standard hand tools can be used.
Remove SX6 from old battery housing bottom
section:
Open cover on housing .
Note the wire installation positions.
Remove bolts and remove high-voltage
wires and .
Remove J840 from old battery housing bottom
section:
Remove bolts from bracket for battery
regulation control unit -J840- .
Remove bracket for battery regulation control
unit -J840- from 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.
May 2020
93D2 Page 44 of 96
Remove bolts .
Unplug electrical connector .
Remove battery regulation control unit -J840.
Remove seal from battery regulation control
unit -J840-.
Mask off all warning signs and labels in area
of adhesive bead with painters tape on the
new battery housing (bottom section).
Mask off holes for brake lines and fuel lines in
area of adhesive bead with painters tape on
the new battery housing (bottom section).
Mask off fluid connection in 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.
May 2020
93D2 Page 45 of 96
Apply “scratch coat” to new battery housing
(bottom section):
Use a non-woven scuff pad (3M “Scotch Brite
07447, for example) to manually remove any
residue from battery housing (bottom section).
Do not use power tools or materials that will
sand or grind away the housing material.
Temporarily fit top section to bottom section with
a few bolts:
Fix the two halves of the battery housing
together with some bolts tightened by hand.
Mark outlines of battery housing (top section)
on battery housing (bottom section) using a
pick or scriber.
Separate the two halves of the battery
housing.
Vacuum debris:
Vacuum all dust and debris out of the 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.
May 2020
93D2 Page 46 of 96
Install J840:
Clean sealing flanges for J840.
Install new gasket for J840.
Part Number
Part Description
5Q0.915.433
Gasket
(from
housing repair kit)
Plug in electrical connector with battery
regulation control unit -J840-.
Fit battery regulation control unit -J840- in
battery housing (bottom section).
Install new bolts and torque to 8 Nm
in diagonal sequence.
Part Number
Part Description
N 106.321.02
M6x25 bolt (from battery
housing repair kit)
Install bracket for battery regulation control
unit -J840- in battery housing (bottom
section).
Tighten bolts for bracket for battery
regulation control unit -J840- to 10 Nm.
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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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