

Use applicator to apply primer for battery
housing (top section) evenly and in one
direction around adhesive bead and approx. 5
mm over edge of flange on battery housing
(top section); make sure there are no air
bubbles.



Allow primer to flash off for 30 minutes until it
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.
May 2020

93D2 Page 58 of 96

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.
May 2020

93D2 Page 59 of 96

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.
May 2020

93D2 Page 60 of 96



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.
May 2020

93D2 Page 61 of 96

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.
May 2020

93D2 Page 62 of 96



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.
May 2020

93D2 Page 63 of 96

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.
May 2020

93D2 Page 64 of 96

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(s), 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 housing with undamaged battery modules, 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.


Reduce the voltage by removing the high
voltage cables from all battery modules.



Caps -T10544- must be installed
where the high-voltage cables used to be
secured on any undamaged battery module.



Retain the entire battery module group in the
original battery housing and according to local
guidelines until the return packaging arrives.

TIP
When ordering a new Battery, provide the number
of corroded modules to your Parts Department so
they can order the correct number of recycling kits
for damaged/corroded modules.


The damaged/corroded cell module(s) must
be removed from the battery module assembly
once the return packaging arrives.



The remaining undamaged cell modules must
be secured to the battery housing (lower
section) using the original hardware.



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) using the original
hardware.

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 65 of 96



The old battery housing with undamaged
battery modules will be recycled (see
“STORAGE
AND
DISPOSITION
OF
BATTERIES” above).



See Appendix H for additional information.
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

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.
May 2020

93D2 Page 66 of 96

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.
May 2020

93D2 Page 67 of 96

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.
May 2020

93D2 Page 68 of 96

Install exhaust:


Installation is the reverse of removal.