

Torque exhaust mount bolts and to
20 Nm.



Install new gasket and torque new nuts
to 20 Nm.

Part Number

Part Description

1K0.253.115.M

Muffler gasket

N 022.146.9

Nut (x2)

Re-energize high-voltage system and perform
potential equalization test:


Use test plan “008C_Isolationswiderstand_
HV_Batterie_messen_93D2” under address
word 008C.

If high-voltage battery was replaced, perform J840
replacement test plan:


Select the Guided Functions test plan
“8C – Replace control module” under address
word 008C.

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 69 of 96

Fill coolant:
NOTE


Coolant (40%) and distilled water (60%) for
freeze protection down to -25 ºC (-13 °F)



Coolant (50%) and distilled water (50%) for
freeze protection down to -36 ºC (-32.8 °F)



Refer to ETKA for the correct coolant.



See ELSA Repair Manual: Repair manual >
Engine > 4-Cylinder Direct Injection 1.2L; 1.4L
4V TFSI Engine (EA211) > 19 Cooling System
> Coolant System/Coolant > Coolant, Draining
and Filling > Coolant, Filling, High-Voltage
System Cooling Components



Perform
ODIS
“Cooling
system
filling/bleeding” test plan as required.



Follow on screen prompts.

Install coolant expansion tank cap:


Install expansion tank cap .



Secure the cap with new seal .

Part Number

Part Description

5Q0.121.809.A

Seal



Ensure the cable of the seal is wrapped
around the return hose so that the cap
cannot be removed.



Ensure the warning tag is secured to the 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 70 of 96

Install underbody trim panels:


Installation is the reverse order of removal.



Torque bolts and for braces to 20 Nm.



Torque remaining fasteners to 2 Nm.

Final steps:


Clear all repair related faults using Guided
Fault Finding.



Exit GFF and send diagnostic protocol online
when prompted.

Proceed to Section G

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 71 of 96

Section G – Campaign Completion Stamp


Once the campaign has been completed,
the technician should stamp the repair
order.



Stamps are available for ordering through
the Compliance Label Ordering Portal.



Proceed to Section H.

Item#: AUD4927ENG

-OR-

Item # AUD4927FRE

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 72 of 96

Section H - Parts Return/Disposal
Properly store (retain), destroy or dispose of removed parts in accordance with all state/province and local
requirements, unless otherwise indicated and/or requested through the Warranty Parts Portal (WPP) for U.S. and
the Part Destruction and Core Disposition Report for Canada.
U.S. Dealers:
Cell modules with corrosion and battery assemblies replaced during the 93D2 Service Action must be properly
recycled, see Section E of the 93D2 Service Action Circular. Dealers must use Kinsbursky Brothers Intl. (KBI) to
facilitate the recycling of damaged/corroded cell modules and battery assemblies.
Dealers will work directly with KBI to coordinate the return of any cell modules with signs of corrosion and nondamaged module assemblies related to the 93D2 Service Action. KBI will supply dealers with the necessary
shipping labels and special packaging for the return of each damaged/corroded cell module. Non-damaged battery
module assemblies must be returned in the replacement battery packaging.
After completing the 93D2 Service Action dealers should refer to Appendix G (A3 Battery Service Action Portal
User Instructions) in the circular and do the following:





Registration (One time only)
 Visit the A3 e-tron website at https://a3.evbatteryreturns.com and register the dealership with KBI
Module and Battery Returns
 Complete the Battery Return Request Form through the A3 Battery Service Action Portal
 Return of Damaged/Corroded Cell Modules:
 Modules must be shipped in the Department of Transportation (DOT) Damaged,
Defective and Recalled (DDR) packaging provided by KBI.
 Pack the damaged/corroded cell modules in the KBI provided DDR packaging; one
module per package
 In extreme cases, if all four modules are corroded and require four DDR packages, the
original battery housing should be destroyed and is not required to be recycled
 Use the KBI provided Bill of Lading, hazardous material labels and markings
 You must retain a copy of the Bill of Lading for 2 years per the DOT and/or 3
years if you are Universal Waste Handler in California or a Large Quantity
Handler of Universal Waste in any other state
 Return of Non-damaged/corroded Cell modules:
 Retain the non-corroded cell modules in the original battery assembly housing.
 The cell module voltage must be reduced.
 Reinstall the non-corroded modules into the battery assembly housing using the
original fasteners.
 Reinstall the cover of the battery assembly housing using as many of the original
fasteners as possible.
 Pack the battery assembly in the packaging crate from the new battery
 Use the KBI provided Bill of Lading, hazardous material labels and markings
 You must retain a copy of the Bill of Lading for 2 years per the DOT and/or 3
years if you are Universal Waste Handler in California or a Large Quantity
Handler of Universal Waste in any other state
 The Damaged/Corroded modules packaged in the DDR kits AND the crate containing the original
battery housing with non-damaged/corroded modules will be picked up in a single recovery
shipment in which KBI will provide a singular Bill of Lading.
Tracking
 Use the A3 Battery Service Action Portal to track the module and battery shipments




Once the shipments are received download Certificate of Acceptance for each shipment and
retain with the repair order

Transportation and Recycling Cost Reconciliation


Refer to the Claim Entry Instructions section in the 93D2 Service Action Circular on how to submit
for reimbursement of the transportation and recycling costs accrued with the return and recycling
of the modules and 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 73 of 96

Appendix A – Cooling System Tester -VAS691005/1- Self-Test


This test ensures the -VAS691005/1-
does not leak.



Test can be done with either -VAS1397A- or
-VAS1397B-.



No other tools should be attached to the
-VAS691005/1- connection B .



-VAS1397A- shown.

Clean -VAS691005/1-:


No other tools should be attached to the
-VAS691005/1- .



Connect cleaning nozzle to connection A
.



Open cut-off valves A and C .



Clean -VAS691005/1- with compressed air.
NOTE

The -VAS691005/1- must be cleaned before and
after the cooling system leak test.

Performing -VAS691005/1- self test:


Using VAS1397A:
o



Attach connection A of
-VAS691005/1- to connection II on
turbocharger tester -VAG1397A-.

Using VAS1397B:
o

Attach connection A of
-VAS691005/1- to connection II on
turbocharger tester -VAG1397B-.

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 74 of 96



Connect connection C of -VAS691005/1- to
hand pump -VAG1274B-.



Open cut-off valves A and C on
-VAS691005/1-.



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.


Using hand pump -VAG1274B-, build up
pressure
until
turbocharger
tester
-VAG1397A/B- reads approximately 2.5 bar.

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 75 of 96

Stabilize

Pressure loss
< 0 mbar = OK



Close cut-off
-VAS691005/1-.



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 there is no pressure loss after one minute,
then the -VAS691005/1- is OK.

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.
May 2020

93D2 Page 76 of 96

Appendix B – High-Voltage Battery Cooling System Leak Test


This test ensures the cooling system is
properly sealed prior to sealing the highvoltage battery housing.



Test can be done with either -VAS1397A- or
-VAS1397B-.



Seal off coolant connection on highvoltage
battery
with
sealing
plug
-VAS691005/3-.



Connect cooling system test adapter
-VAS691005/4- to coolant connection on
high-voltage battery.



Connect connection B of -VAS691005/1to test adapter -VAS691005/4- .



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-.

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 77 of 96



Connect connection C of -VAS691005/1- to
hand pump -VAG1274B-.



Open cut-off valves A and C on
-VAS691005/1-.



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.


Using hand pump -VAG1274B-, build up
pressure
until
turbocharger
tester
-VAG1397A- reads 2.5 bar.

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 78 of 96

Stabilize

Pressure loss
< 0.020 bar =
OK



Close cut-off
-VAS691005/1-.



Allow pressure to stabilize for one minute.



After the pressure is stable, wait 10 minutes
and check pressure drop on turbocharger