Use Double Cartridge Adhesive
-VAS5237- to apply the heat paste.

Part Number

Part Description

D -G00-018-M3

Heat paste

Gun

•

Before applying the heat paste, release a
small amount through the applicator to ensure
the paste is mixing properly.

•

When filling Template -T10606-, ALL of the
heat paste must be used.

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 37 of 48

•

Pay close attention to the wiring harnesses
when installing the cell module.

•

Torque new bolts in a cross pattern to 16
Nm + 180°.

Part Number

Part Description

N -912-809-01

Bolt

•

Torque bolts for
connection to 8 Nm.

the

high-voltage

DANGER

STOP!
Incorrect installation of battery modules and
module connectors.
Short circuit electric arc can cause severe
bodily or fatal injuries.
Check the battery modules and module connectors
for correct installation.
Only continue with the procedure when there is no
voltage in between the battery terminals.
Pay very close attention to the Repair Manual steps
outlining the use of the -VAS6762/45-.

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 38 of 48

Reconnect high-voltage circuit:
•

Reconnection is
disconnecting.

the

reverse

order

of

•

Reference ELSA Repair Manual: Repair
Manual > Motor > Electric Drive Motor 0EH,
0EJ > 93 Electric drive > High-Voltage Battery
Unit > Circuit, Disconnecting, 82 kWh

Check for high-voltage battery faults:
•

Using -VAS671007- or -VAS5581A-, in
conjunction with the Diagnostic Tester, verify
there are no faults stored for any high-voltage
battery component before installing the highvoltage battery cover.

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 39 of 48

Install and seal high-voltage battery cover:
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
TIP
Ensure all shock protection is removed prior to
installing cover.
Pay attention to the cover position. The cover part
number stamping is positioned at the front of the
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 , Sealing, 82 kWh

Part Number

Part Description

1EA-804-841-AC

Cover (if necessary)

D -454-300-H2

Sealant

1EA-802-131-A

Connection element (qty. 2)
Position

1EA-802-132-A

Connection element (qty. 2)
Position

WHT-008-738-A

Middle bolts (qty. 22)
Position

WHT-009-218

Perimeter bolts (qty. 82)
Position

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 40 of 48

•

Torque the new fasteners in the following
order:

1. Connection element bolts to
100 Nm.
2. Middle bolts to 5.5 Nm + 90°.
TIP
Utilize a second technician to keep track of, or mark
each bolt once it has been torqued.

3. Bolts to 8 Nm.
4. Bolts to 8 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. 2024 Audi of America, Inc. and Audi Canada. All Rights Reserved.
91FN Page 41 of 48

Prepare high-voltage battery for installation:
NOTE
Replacing the spacers and stickers is only
necessary if the high-voltage battery cover is
replaced.
•

Install new spacers (qty. 8) onto the highvoltage battery cover. Reference the old cover
for installation position if needed.

•

Apply new sticker and warning sign .

•

Remove old separating film from around
the high-voltage battery mounting holes and
install new separating film.
o

Do not install separating film if there
was no existing film already in place.

Part Number

Part Description

1EA-804-973

Spacer (qty. 8)

1EA-998-103

Separating film

12E-010-006-AA

Sticker

1EA-010-505

Warning sign

•

Apply wax around the base of the connection
elements .

•

Completely cover all (22)
with wax.

middle

Part Number

Part Description

D -316-000-A1

Wax/Undercoat

bolts

COVERAGE DETAIL

Connection elements

Middle bolts

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 42 of 48

•

Install new pressure relief valve and
connection seals .

Part Number

Part Description

1HV-915-754-A

Valve

0Z1-915-433-A

Seal (qty. 2)

Re-install high-voltage battery:
•

Installation is the reverse order of removal.

•

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

•

Use new bolts.

Part Number

Part Description

N -912-832-01

Center bolts (qty. 4)

N -909-428-04

Perimeter bolts (qty. 24)

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 43 of 48

•

Torque the new bolts in the following
sequence:

1. Bolts to 50 Nm + 90°.
2. Bolts to 40 Nm + 180°.

Perform high-voltage battery leak test:
•

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.”

Restart 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 recommission the high-voltage system.
•

Follow the “High-voltage system, restart” test
plan steps.

•

Pay close attention to all of the test plan 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 44 of 48

Fill cooling system
•

Top off coolant.

•

See ELSA Repair Manual: Repair manual >
Motor > Electric Drive Motor 0EH, 0EJ > 19
Cooling System > Cooling System/Coolant >
Cooling System, Filling

•

Perform these steps in conjunction with
Guided Function test plan, “0001 – Filling
cooling circuit.”

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 45 of 48

Reinstall underbody covers and side covers:
•

Installation is the reverse order of removal.

•

Reference the ELSA Repair Manual as
needed.

•

Replace any damaged fasteners.

Clear repair related faults:
•

Exit GFF and send the diagnostic protocol to
GFF paperless.

Perform classification of removed cell module(s):
•

Select “Self Test” and populate the “008C –
Classification of a battery module” test plan.

•

Perform the test plan and follow all on-screen
prompts.

Proceed to Step 2 of the SVM instructions.

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 46 of 48

Section D – 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.

US DEALERS - Proceed to Section E
Item#: AUD4927ENG

-OR-

CANADIAN DEALERS - Proceed to Section F

Item # AUD4927FRE

Section E - Parts Return/Disposal – US DEALERS ONLY
High-Voltage Battery Module(s):
Refer to the latest instructions for high-voltage battery recycling, found in Elsa2Go: Elsa2Go-> Infomedia->Service
References->Electric Vehicle Category ->“HV Battery Recycling Program Guide”
All other parts:
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).

Section F - Parts Return/Disposal – CANADIAN DEALERS ONLY
High-Voltage Battery Module(s):
Refer to the latest version of TSB 2062871.
All other parts:
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 Part Destruction and Core Disposition Report
for Canada.

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 47 of 48

Appendix A – Bus Sleep Instructions
Carry out the following steps in the specified sequence to put the vehicle in a bus sleep.
•

Switch off the ignition.

•

Turn off the hazards.

•

Remove diagnosis interface from the vehicle diagnosis connection.

•

Remove battery charger from the 12V battery.

•

Close front and rear lid as well as all doors.

•

Lock vehicle.

•

Move vehicle key (remote control) at least 20 meters away from the vehicle.

•

Wait at least 5 minutes until the vehicle is in bus silence.

•

Then unlock vehicle again.

•

Connect and switch on battery charger.

•

Insert diagnosis interface on vehicle diagnosis connection.

•

Switch on the ignition.

•

Place a vehicle key (remote control) in the center console on the reader coil.

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 48 of 48