NHTSA ID Number: 10249236
Manufacturer Communication Number: Circular 91FN
TSB/Document Date: 2024-02-06
Summary
Affected vehicles will receive the latest software version via a software update. This software contains an optimized self-diagnosis function for the high-voltage battery. In addition to the software update, the high-voltage battery cells may experience an increased self-discharge. The high-voltage battery will be evaluated, and any affected high-voltage cell modules will be replaced.
Proceed to Step 3 once the SVM is complete.
Step 3 - Perform SVM via FLASH + CAN
•
Use operating mode, FLASH.
•
Select “SVM – Code Input”.
•
Enter SVM code ME321CAN and follow the on screen prompts.
•
Select communication path CAN when prompted.
•
Proceed to Step 4 once the SVM is complete.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 24 of 48
Step 4 – Perform Bus Sleep
•
Perform a five minute bus sleep.
•
See Appendix A for specific bus sleep instructions.
•
Proceed to Step 5 once the five minute bus sleep is complete.
Step 5 – Road Test + Clear Fault Memory + Perform Calibration Drive
•
Perform a road test/calibration drive at a speed above 25 mph (40
km/h).
•
Erase the entire event memory.
•
Send the diagnostic log to GFF Paperless.
•
Perform a calibration drive at a speed above 25 mph (40 km/h).
•
Proceed to Section D once the road test is complete.
CAUTION
When performing this road test, the vehicle will momentarily lose
acceleration when the three-phase drive -VX54- calibrates. Ensure the
road test is performed in a safe manner.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 25 of 48
Section C – Cell Module Replacement (if necessary)
NOTE
If a module requires replacement due to increased self-discharge, the “Check cell equalization” test plan may
prompt some additional steps that need to be performed. Ensure that the additional steps and test plans are
performed before closing the HV battery
since data from both the new and old cell modules is required.
Example:
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 26 of 48
CRITICAL REPAIR STEP
STOP!
Before balancing the new cell module, be sure that the vehicle is ready for the repair to be performed.
If possible, the high voltage battery should be de-energized right after recording the voltage reading to avoid possible
voltage variations.
Charging the vehicle, driving the vehicle, leaving the ignition on, or running the HVAC can change the high voltage
battery voltage.
After reading out the maximum cell module voltage from the MVBs, avoid moving the vehicle if possible. The vehicle
must not be charged or have any electrical consumers used. If this step is not followed, there is a risk that the new
cell module will not be balanced correctly resulting in possible faults and having to remove and re-balance the cell
module again.
Perform cell balancing on new cell module:
•
Check Measured Value Block (MVB)
“maximum voltage for battery cells, IDE08217.
•
The voltage reading listed will be entered in
the DSS Manager program when balancing
the new cell module.
•
Follow the VAS6910 operating instructions in
conjunction with the DSS Manager program to
perform the cell balancing on the new cell
module.
TIP
Operating instructions for the VAS6910 and DSS
Manager program can be found on the Audi Special
Tools and Equipment website.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 27 of 48
Populate Guided Functions test plans:
•
Perform a diagnostic scan of the vehicle.
•
Select “Self Test” and populate the following
Guided Function test plans:
o
008C - Classification of high-voltage
battery
o
High-voltage system, de-energize
o
008C - Initiation
o
VAS 6558 Hybrid test module
De-energize the high-voltage system:
DANGER
High voltage increases the risk of fatal injury
Electrocution can cause severe bodily or fatal
injury
Have a high-voltage technician or a high-voltage
expert de-energize the high-voltage system.
•
Follow the Guided Functions test plan steps.
•
Pay close attention to all of the test plan steps.
Raise the vehicle:
TIP
Removal of the high-voltage battery is not possible
on all hoists. Make sure that there is enough
clearance. Pay attention that the high-voltage
battery has enough clearance during the lifting
process so that the Scissor Lift Table -VAS6131Bcan be set down.
•
Pivot in the hoist with the vehicle support plate
on the frame of the high-voltage battery
. Then pivot back the hoist arm with the
vehicle support plate so that the highvoltage battery can be lowered in the next
steps.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 28 of 48
Remove lower covers:
•
Reference ELSA Repair Manual.
•
Remove the front underbody trim panel .
Refer to → Body Exterior; Rep. Gr.66;
Underbody Trim Panel; Front Underbody Trim
Panel, Removing and Installing.
•
Front wheel housing liner, loosening in the
area of the high-voltage battery threaded
connection.
Refer to → Body Exterior; Rep. Gr.66; Wheel
Housing Liner; Front Wheel Housing Liner,
Removing and Installing.
•
Remove the side underbody trim panels.
Refer to → Body Exterior; Rep. Gr.66;
Underbody Trim Panel; Side Underbody Trim
Panel, Removing and Installing.
•
Remove the rear center underbody trim panel
.
Refer to → Body Exterior; Rep. Gr.66;
Underbody Trim Panel; Rear Center
Underbody Trim Panel, Removing and
Installing.
•
Remove the rear underbody trim panel .
Refer to → Body Exterior; Rep. Gr.66;
Underbody Trim Panel; Rear Underbody Trim
Panel, Removing and Installing
Perform high-voltage battery leak test:
•
Before disconnecting the high-voltage battery
connectors, remove the protective covers
from both of the connectors first.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 29 of 48
•
See ELSA Repair Manual: Repair Manual >
Motor > Electric Drive Motor 0EH, 0EJ > 93
Electric drive > High-Voltage Battery Unit >
High-Voltage Battery Leak Test, 1 AX2
•
Perform these steps in conjunction with
Guided Function test plan, “008C – Initiation >
select option: Leak test of battery housing.”
Remove high-voltage battery:
•
See ELSA Repair Manual: Repair Manual >
Motor > Electric Drive Motor 0EH, 0EJ > 93
Electric drive > High-Voltage Battery Unit >
High-Voltage Battery 1 AX2, Removing and
Installing, 82 kWh
•
Note the following when removing the highvoltage battery:
o
Mark the position of the scissor lift
table on the floor to aid in repositioning
the
table
during
reinstallation.
o
Pay close attention to all wiring
harnesses when lowering the battery.
o
Pay close attention to coolant hoses
when lowering the battery.
Secure media duct/channel (if necessary):
•
If the media duct/channel had not yet
been secured, install new bolts and
torque to 20 Nm.
Part Number
Part Description
N -102-252-02
NOTE
If the media channel is already secured with bolts,
the bolts do not have to be replaced again.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 30 of 48
Clean high-voltage battery cover:
•
Vacuum all loose dirt and debris from highvoltage battery.
•
Clean the connection element threads using
pipe brush -VAS294029- (or equivalent) as
shown.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 31 of 48
Remove high-voltage battery cover:
CRITICAL REPAIR STEP
STOP!
RISK OF SEVERE CONSEQUENTIAL DAMAGE!
USE HAND TOOLS ONLY!
Do not use power tools to remove any of the hollow
bolts or any of the perimeter bolts.
Using power tools to remove the bolts can damage
the threads in the lower housing. Damaged threads
for the hollow bolts cannot be repaired and will
require replacement of the lower housing.
Claims for lower housing replacements due to
improper bolt removal will be denied.
•
See ELSA Repair Manual: Repair Manual >
Motor > Electric Drive Motor 0EH, 0EJ > 93
Electric drive > High-Voltage Battery Unit >
High-Voltage Battery 1 AX2 , Opening
DANGER
High voltage increases the risk of fatal injury
Electrocution can cause severe bodily or fatal
injury
Pay close attention to which Repair Manual steps
require Personal Protective Equipment.
NOTE
The upper part of battery housing can be reused
under certain circumstances and does not have to
be replaced.
To determine if the cover can be reused, refer to the
ELSA Repair Manual: Repair Manual > Motor >
Electric Drive Motor 0EH, 0EJ > 93 Electric drive >
High-Voltage Battery Unit > Battery Housing Upper
Section, Checking for Re-Use
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 32 of 48
Identify cell module which requires replacement:
•
Identify the module that requires replacement
and clearly mark its location.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 33 of 48
Perform insulation measurement:
•
Perform insulation measurement according to
ELSA Repair Manual: Repair Manual > Motor
> Electric Drive Motor 0EH, 0EJ > 93 Electric
drive > High-Voltage Battery Unit > Voltage
and Insulation Measurement, 82 kWh
•
Perform the measurement in conjunction with
ODIS test plan, “VAS 6558 Hybrid test
module.”
Clean high-voltage battery sealant off of lower
housing:
•
Clean old sealant using a lint free cloth and
Cleaner D -009-401-04 or isopropyl alcohol.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 34 of 48
Disconnect the high-voltage circuit:
•
See ELSA Repair Manual: Repair Manual >
Motor > Electric Drive Motor 0EH, 0EJ > 93
Electric drive > High-Voltage Battery Unit >
Circuit, Disconnecting, 82 kWh
Remove the cell module:
•
See ELSA Repair manual: Repair Manual >
Motor > Electric Drive Motor 0EH, 0EJ > 93
Electric drive > High-Voltage Battery
Components > Battery Module, Removing
•
Ensure the shock protection is installed on ALL
open high-voltage connections.
TIP
Pay close attention to the wiring harnesses, so they
are not damaged or pinched during removal.
The cell module can be freed from the adhesive
bond from either end of the cell module.
Clean the mounting area for the new cell module:
•
When cleaning the cell module mounting area,
use extreme care so the sealant for the highvoltage battery splines and lower housing is
not damaged and that no cleaners come into
contact with the sealant.
•
Vacuum any loose debris from the mounting
area of the cell module.
•
Clean cell module mounting area with Cleaner
D -009-401-04 or isopropyl alcohol and allow
it to completely dry.
•
Do not allow the cleaner to come in contact
with any of the lower housing frame sealant.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 35 of 48
Installing new cell module(s):
•
Reference ELSA Repair manual: Repair
Manual > Motor > Electric Drive Motor 0EH,
0EJ > 93 Electric drive > High-Voltage Battery
Components > Battery Module, installing
•
Note the following when installing the new cell
module(s):
•
Peel off the protective backing and apply the
separating foil as needed along the
outer frame edges, in the area where the cell
module is mounted.
Part Number
Part Description
0Z1-998-474
Separating foil/film
•
If the cell module being replaced is in the
corner of the high-voltage battery, the
separating foil must be applied to both outer
frame edges as shown in area .
TIP
Having a second technician pre-fold the separating
film before installing will aid in applying the film.
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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 36 of 48
•
Clean the bottom of the cell module using
Cleaner D -009-401-04 or isopropyl alcohol
and allow it to dry completely.
•
Double check the expiration date of the paste
before applying.
•
Use Double Cartridge Adhesive
-VAS5237- to apply the heat paste.
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TSB/Document ID: Circular 91FN
Replacement Service Bulletin Number:
MFR Communication Date: 2024-01-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: BACK OVER PREVENTION:SOFTWARE
MFR Component System:
MFR Component Subsystem:
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