Circular 91FN

Service Action
Code: 91FN
Subject
Software Update for High Voltage Battery Control Module - Version 3.2.1
Document History
Date
Summary
01/19/2024
Affected Vehicles
Original publication
Country
Beginning
Model
Year
Ending
Model
Year
Vehicle
Vehicle Count
USA
USA
CAN
CAN
2022
2022
2022
2022
2023
2023
2023
2023
Q4 E-TRON SPORTBACK
Q4 E-TRON SUV
Q4 E-TRON SPORTBACK
Q4 E-TRON SUV
914
4,321
133
892
Check Campaigns/Actions screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this
action. Elsa is the only valid campaign inquiry & verification source.
About This Service
Action

Campaign status must show “open.”

If Elsa shows other open action(s), inform your customer so that the work can also be completed at
the same time the vehicle is in the workshop for this campaign.
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.
Code Visibility
On or about January 19, 2024, the campaign code will be applied to affected vehicles.
Owner Notification
Owner notification will take place in January 2024. Owner letter examples are included in this
bulletin for your reference.
Campaign Expiration
Date
This campaign expires on January 31, 2029. Work must be performed on or before this date
to be eligible for payment. Keep this expiration date in mind when scheduling customers for this
action. If a customer wishes to have this work performed after the expiration date, your normal
costs associated with this work will apply.
Additional Information
Please alert everyone in your dealership about this action, including Sales, Service, Parts
and Accounting personnel. Contact Warranty if you have any questions.
Dealers must ensure that every affected inventory vehicle has this campaign completed before
delivery to consumers.
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 1 of 48
Parts Information (if required)
Criteria
Quantity
Part Number
P.O.C. Part Description
As needed
0Z1-915-599-J
CELL MOD.
Ordering Method
(see description
below)
IMPORTANT INFORMATION FOR PART NUMBER 0Z1-915-599-J (Cell module):
0Z1-915-599-J (Cell Module) will be return blocked. In the chance that a cell module
needs returning, this return will need to be scheduled with your Dealer Support
Specialist (DSS).
For batteries not actively part of the repair process, either new or spent, dealers should
ensure compliance with local fire code battery storage requirements. Dealers who have
the appropriate storage capabilities/facilities that meet local fire code requirements, are
encouraged to order/ stock parts to complete the 91FN Repair.
ALL
4 per cell module
N -912-809-01
SCREW
1 per cell module
D -G00-018-M3
PASTE
1 per cell module
0Z1-998-474
SEP. FILM
1
1HV-915-754-A
VALVE
2
0Z1-915-433-C
GASKET
24
N -909-428-04
BOLT
4
N -912-832-01
BOLT
82
WHT-009-218
BOLT
22
WHT-008-738-A
BOLT
1
D -316-000-A1
UNDER COAT
2
1EA-802-131-A
CONNECTION
2
1EA-802-132-A
CONNECTION
1
D -454-300-H2
SEALANT
1
1EA-998-103
SEP. FILM
4
N -102-252-02
BOLT
1
G -12E-100-1G CON
G12 EVO Coolant Concentrate
(US Dealers)
1
G -12E-100-2G CON
G12 EVO Coolant Concentrate
(Canadian Dealers)
Free Order
The following underbody trim clips are needed ONLY in the event of breakage. They
may not be required for every repair.
Up to 14
WHT-003-491
NUT
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 2 of 48
Parts Control Type:
Free Order
Parts will be managed by Free Order
Initial Allocation:
NO
There will be no parts allocation. Please reference the Repair Projection Tool (below)
to view your potential VIN population.
Repair Projection Tool:
(right click to open)
NOTE
Campaign parts should always be ordered as per the parts information in this circular. The ordering system will
supersede the part, if applicable.
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 3 of 48
Claim Entry Instructions
The labor times listed here may differ from the labor operations and labor times listed in ELSA.
After campaign has been completed, enter claim as soon as possible to help prevent work from being duplicated
elsewhere. Attach the Elsa screen print showing action open on the day of repair to the repair order.
If customer refused campaign work:
 U.S. dealers: Submit the request through Audi Warranty Online under the Campaigns/Update option.
 Canada dealers: Upload the repair order [signed by customer] to Audi WIN/Operations/Campaign Closure.
Service Number
91FN
Damage Code
0099
Parts Vendor Code
Claim Type
002
Sold vehicle: 7 10
Unsold vehicle: 7 90
Causal Indicator
Mark labor as causal if cell module(s) are not replaced
Mark CELL MOD* as causal part if a cell module(s) is replaced
Vehicle Wash
Vehicle Loaner
Do not claim wash under this action
See special claiming instructions for rental/loaner claiming.
NOTE: A 2nd claim must be entered for rental/loaner claiming
Vehicles have more than one criteria.
Complete and claim all applicable criteria on one claim.
Criteria I.D.
01, 02 and 03
Perform check cell equalization test plan and perform software update
LABOR
Labor Op
Time Units
Description
2706 89 50
SEE ELSA
Connect battery charger
0150 98 99
20
Perform cell equalization check via ODIS
0151 00 00
Time stated on
diagnostic protocol
Perform software update
0150 00 99
20
Bus sleep and adaptation test drive
0150 99 99
Time stated on
diagnostic protocol
Additional work if there is evidence that the
flash routine was interrupted
Continued on next page
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 4 of 48
NOTE: The software update and related GFF work is performed on more than one diagnostic
session. The multiple GFF logs can be added together.
Ensure the GFF logs are added together correctly. For example, two logs from the same
diagnostic session are not allowed.
Claims and GFF logs may be audited to ensure that the actual GFF log time is being claimed.
The technician is instructed to indicate which SVM code correlates with the specific GFF log to
aid in determining which GFF logs are used to calculate the total GFF time claimed.
EXAMPLE:
Continued on next page
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 5 of 48
AND (only if necessary)
Remove high-voltage battery and replace one or more cell modules.
LABOR
Labor Op
Time Units
Description
9301 19 50
SEE ELSA
Battery module remove+reinstall
9301 19 53
(up to 11)
SEE ELSA
Battery module remove+reinstall
(each additional module)
9302 19 82
SEE ELSA
Battery housing remove+reinstall
9303 19 60
SEE ELSA
High voltage battery remove+reinstall
1938 17 50
SEE ELSA
Coolant drain & fill
9303 01 50
SEE ELSA
High voltage battery check
9310 83 50
SEE ELSA
Disable HV system voltage deactivate and
activate
0150 00 00
Time stated on
diagnostic protocol
GFF Operations
9301 01 50
SEE ELSA
Battery module check
(classification)
9302 29 82
SEE ELSA
Battery housing clean
(if upper cover is reused)
9301 00 50
SEE ELSA
Package module
(only needed if removed module requires
special packaging based on classification
results)
9301 89 50
SEE ELSA
Battery module charge
9301 89 53
(up to 11)
SEE ELSA
Battery module charge
(each additional module)
9303 01 52
SEE ELSA
High voltage battery check
(classification)
PARTS
Quantity
Part Number
Description
As needed
(up to 12)
0Z1915599J
2.00
0Z1915433C
GASKET
1.00/cell module
0Z1998474
SEP. FILM
2.00
1EA802131A
CONNECTION
2.00
1EA802132A
CONNECTION
1.00
1EA998103
SEP. FILM
1.00
1HV915754A
VALVE
1.00
D 316000A1
WAX UNDERCOAT
1.00
D 454300H2
SEALANT
CELL MOD*
Continued on next page
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 6 of 48
PARTS (continued)
Quantity
Quantity
Quantity
1.00/cell module
D G00018M3
Paste
Up to 40.00
or
Up to 2.00
G 12E100S1
or
G 12E050S0
COOLANT (concentrate)
or
COOLANT (pre-mix)
USA
ONLY
Up to 40.00
or
Up to 80.00
G 12E100S1
or
G 12E050S0
COOLANT (concentrate)
or
COOLANT (pre-mix)
CANADA
ONLY
4.00
N 10225202
BOLT, HEX. HD. (COMBI.)
(only needed if HV battery is being removed for
the first time)
24.00
N 90942804
BOLT, HEX. HD. WITH SHOULDER
4.00/cell module
N 91280901
Screw
4.00
N 91283201
BOLT
22.00
WHT008738A
BOLT
82.00
WHT009218
BOLT
The following can be added if the HV battery cover required replacement
PARTS
Quantity
Part Number
Description
1.00
1EA804841AC
HOUSING
8.00
1EA804973
HOLDER
1.00
1EA010505
WARN. SIGN
1.00
12E010006AA
STICKER
The following can be added as needed in the event of breakage during the repair.
PARTS
Vehicle Loaner
(if required)
Quantity
Part Number
Description
As required
WHT003491
NUT
As required
WHT009733
BOLT
As required
N 0385494
RIVET
Enter vehicle loaner claim as a separate (2nd) claim
Claim Type
7 MO
Service Number
91FN
Damage Code
0010
Parts Vendor Code
002
Outside Labor Operation
LOAN1600
(letter O, not number 0)
Enter dollar amount on
rental/loaner invoice
($50 max per day)
(2 day maximum)
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 7 of 48
Customer Letter Example (USA)




This notice applies to your vehicle:   , 
Subject: Service Action 91FN - Software Update for High Voltage Battery Control Module - Version 3.2.1
Dear Audi Owner,
As part of Audi’s ongoing commitment to customer satisfaction, we are informing you of our decision to conduct a
service action on certain 2022-2023 model year Audi vehicles. Our records show that you are the owner of a vehicle
affected by this action.
About this Service Action: 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.
What will we do?
Your authorized Audi dealer will perform a software update and evaluate your vehicle
to determine if any battery cell module(s) needs replacement. This work will take about
three (3) hours to complete and will be performed for you free of charge.
If the evaluation shows a battery cell module(s) needs replacement, the work to do the
replacement will take at least one day to complete once your dealer has the necessary
parts and equipment on hand, and will be performed for you free of charge. Please
keep in mind that your dealer will need additional time for the preparation of the work,
as well as to accommodate their daily workshop schedule.
What should you do?
In order to limit any possible inconvenience, please contact your authorized Audi dealer
as soon as possible to schedule this work. For your convenience, you can also visit
www.audiusa.com and click on the “Find a Dealer” link to locate a dealer near you and
schedule this service.
This service action will be available for you free of charge only until January 31, 2029.
If you wish to have this service performed after that date, your dealer’s normal costs
associated with this repair will apply.
Lease vehicles and
address changes
If you are the lessor and registered owner of the vehicle identified in this action, please
forward this letter immediately via first-class mail to the lessee within ten (10) days of
receipt. If you have changed your address or sold the vehicle, please fill out the
enclosed prepaid Owner Reply card and mail it to us so we can update our records.
Can we assist you
further?
If your authorized Audi dealer fails or is unable to complete this work free of charge
within a reasonable time, please contact Audi Customer Experience at 1-800-253-2834
or via our “Contact Us” page at www.audiusa.com.
Checking your vehicle for To check your vehicle’s eligibility for repair under this or any other recall/service
open Recalls and Service campaign, please visit the Recall/Service Campaign Lookup tool at
www.audiusa.com and enter your Vehicle Identification Number (VIN).
Campaigns
We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your
vehicle continues to meet and exceed your expectations.
Sincerely,
Audi Customer Protection
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 8 of 48
Customer Letter Example (Canada)




This notice applies to your vehicle:   , 
Subject: Service Action 91FN - Software Update for High Voltage Battery Control Module - Version 3.2.1
Dear Audi Owner,
As part of Audi’s ongoing commitment to customer satisfaction, we are informing you of our decision to conduct a
service action on certain 2022-2023 model year Audi vehicles. Our records show that you are the owner of a vehicle
affected by this action.
About
Action:
this
Service 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.
What will we do?
Your authorized Audi dealer will perform a software update and evaluate your vehicle
to determine if any battery cell module(s) needs replacement. This work will take about
three (3) hours to complete and will be performed for you free of charge.
If the evaluation shows a battery cell module(s) needs replacement, the work to do the
replacement will take at least one day to complete once your dealer has the necessary
parts and equipment on hand, and will be performed for you free of charge. Please
keep in mind that your dealer will need additional time for the preparation of the work,
as well as to accommodate their daily workshop schedule.
What should you do?
In order to limit any possible inconvenience, please contact your authorized Audi dealer
as soon as possible to schedule this work. Please keep in mind that your dealer may
need additional time for the preparation of the work, as well as to accommodate their
daily workshop schedule.
This service action will be available for you free of charge only until January 31, 2029.
If you wish to have this service performed after that date, your dealer’s normal costs
associated with this repair will apply.
Lease vehicles and
address changes
If you are the lessor and registered owner of the vehicle identified in this action, please
forward this letter immediately via first-class mail to the lessee within ten (10) days of
receipt. If you have changed your address or sold the vehicle, please fill out the
enclosed prepaid Owner Reply card and mail it to us so we can update our records.
Can we assist you
further?
If your authorized Audi dealer fails or is unable to complete this work free of charge
within a reasonable time, please contact Audi Customer Relations Monday through
Friday from 8AM to 8PM EST at 1-800-822-2834 or via our “Contact Audi Canada”
page at www.audi.ca.
We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your
vehicle continues to meet and exceed your expectations.
Sincerely,
Audi Customer Protection
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 9 of 48
Safety Precautions When Working ON the High-voltage System
(additional information is also available in the ELSA Repair Manual)
DANGER
Extremely dangerous due to high voltage.
•
The high-voltage system is under heavy voltage. Severe bodily injury or death by electrocution or electric
arcs is possible.
•
When working on the high-voltage system the high-voltage system must be de-energized.
•
When performing procedures that do not directly affect the high-voltage system, in some cases it is still
necessary to de-energize the high-voltage system.
•
Pay attention when the high-voltage system must be de-energized. Refer to the Repair Manual
•
Have a High-Voltage Technician or a High-Voltage Expert de-energize the high-voltage system.
The electric and magnetic fields are extremely dangerous.
•
There are electric and magnetic fields on the high-voltage system. Death or serious injury are possible due
to malfunction of active implants (for example cardiac pacemakers, insulin pumps).
•
Persons with active implants may not perform procedures on the high-voltage system.
WARNING
Risk of injury - motor may start unexpectedly
It is difficult to determine whether the drive system of an electric vehicle or hybrid vehicle is active. Moving parts can
trap or draw in parts of the body.
CAUTION
Risk of damage to high-voltage wiring
•
Incorrect handling may result in damage to the insulation of high-voltage wires or high-voltage connectors.
•
Do not support yourself on high-voltage cables or connectors.
•
Never prop tools against high-voltage wiring or high-voltage connectors.
•
Never bend or kink high-voltage wiring.
•
Observe the coding of the high-voltage connectors when joining them up.
Safety Precautions When Working NEAR the High-voltage System
(additional information is also available in the ELSA Repair Manual)
DANGER
Extremely dangerous due to high voltage.
•
The voltage levels in the high-voltage system constitute a safety hazard. Danger of severe or fatal injuries
from electric shock if high-voltage components or high-voltage wiring are damaged.
•
Carry out a visual check of high-voltage components and high-voltage wiring.
•
Never use cutting/forming tools or other sharp-edged implements.
•
Never perform work using welding, brazing, thermal bonding or hot air in the area of high-voltage
components and high-voltage cables.
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 10 of 48
DANGER
High voltage increases the risk of fatal injury
Electrocution can cause severe bodily or fatal injury.
•
For the following procedures suitable personal protective equipment must be worn.
•
For the following steps two correspondingly qualified technicians must be present for the supervision.
•
If necessary, a second technician can help the high-voltage expert outside of the hazardous area within
their qualification.
•
The personal protective equipment (PPE) must be dry and undamaged.
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 11 of 48
Repair Overview
IMPORTANT
If the vehicle being worked on also has the 91EV campaign assigned, the 91EV flash must be completed before
attempting the 91FN.
If the 91EV is performed before the 91FN, a bus sleep MUST be performed after the 91EV was completed and
before the 91FN is started.
•
Check HV battery cell modules via a test
plan.
•
Update vehicle software using a multi-step
software update process.
•
Replace HV battery cell module(s) based on
test plan results, if necessary.
NOTE
•
These repair instructions may differ from the labor operations and labor times listed in ELSA.
•
Damages resulting from improper repair or failure to follow these work instructions are the dealer’s
responsibility and are not eligible for reimbursement under this action.
•
This procedure must be read in its entirety prior to performing the repair.
•
Due to variations in vehicle equipment and options, the steps/illustrations in this work procedure may not
identically match all affected vehicles.
•
Diagnosis and repair of pre-existing conditions in the vehicle are not covered under this action.
•
When working during extreme temperatures, it is recommended that the vehicle be allowed to acclimate
inside the shop to avoid temperature-related component damage/breakage.
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 12 of 48
Required Tools (for software flash)
Battery Tester/Charger
Diagnostics Interface
W-LAN
-VAS5908-
-VAS6154A(or newer equivalent)
Diagnostic Tester
-VAS6150D(or higher)
USB Module
-VAS6154/4A(included with -VAS6154A-)
(or newer equivalent)
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 13 of 48
Required Tools (if HV battery cell module requires replacement)
Engine Support Set
-10-222B-
Adapter
-10-222A/14Qty. = 2
Module Lifting Aid
Lifting Tackle
-T10619-
-3033-
Shock-Proof Protection
(30 Pcs)
Shock-Proof Protection
-T10608-
Qty. = 3
Removal Wedge Set
Engine Support - Bracket
w/Spindle and hook
-VAS895015-
Shop Crane
-VAS6100(or equivalent)
-T10628-
-10-222A/10-
Insulating Mat
-VAS6762/44-
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 14 of 48
Scissor Lift Table
Engine Bung Set
-VAS6131B-
-VAS6122-
(or equivalent)
(or equivalent)
Leak-tight Connector
Pressure and Vacuum
Pump
-T10607-
Digital Pressure Sensor
-VAG1397B-
Cooling System Tester Directional Valve
-VAS691005/1(component of
-VAS691005-)
High Voltage Tool Set Voltage Tester
-VAS671005-
High Voltage Tool Set –
Screwdriver
-VAS6762/34-
High Voltage Tool Set Torque Wrench
-VAS6883/1A-
Cooling System Tester Directional Valve
-VAS691005/5-
-VAS6762/45-
(component of
-VAS691005-)
Template
Cooling System Charge Kit
-T10606-
-VAS6096-
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 15 of 48
Cooling System Tester
Hose Clamps - Up To
25mm
-VAG1274B-
-3094(or equivalent)
Module Balancer
-VAS6910-
Padlock
-T40262/1-
MEB Modules Expansion
Set
-VAS6910/21-
Vehicle Diagnosis System Connection Lead
-VAS5051/66-
(from Service Disconnect
Lock -T40262-)
Pressure Sensor
-VAS611013-
(MRT)
Insulated Torx Wrench Set
- 3/8
-VAS691003A-
*Extension Cables for
High-Voltage Battery
*High Voltage Diagnostics
Box
-VAS671007-
-VAS5581A-
*NOTE: Either -VAS671007- or -VAS5581A- may be used for this repair.
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 16 of 48
Cooling System Service
Machine – TEXA
High Voltage Tool Set –
Reversible Ratchet 3/8"
-VAS531011KIT-
-VAS6762/29-
High Voltage Tool Set –
Extension 140mm
-VAS6762/31-
Diagnostic Tester
-VAS6150X/6160X(or equivalent)
Double Cartridge
Adhesive Gun
-VAS5237-
Shackle (Equivalent to
VAS691009A)
-VAS691009USQty. = 8
Battery Tester/Charger
capable of minimum 90
Amp continuous supply
Female adapter for the
-VAS5237(based on shops preferred
adapter style)
(locally sourced)
Pipe Brush
-VAS294029-
Test Adapter - Hybrid
Module
(or equivalent)
-VAS6558A-
Double Suction Lifter
Qty. = 2
High Voltage Tool Set –
Screwdriver Insert XZN
M10
-VAG1344-
-VAS6762/27-
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 17 of 48
Required Shop Materials (if necessary)
Cleaner D -009-401-04
(shop supply)
-OR91% Isopropyl Alcohol
Lint Free Towels
(locally sourced)
(locally sourced)
NOTE: Use only 91% Isopropyl alcohol as a cleaner
(9% water). Do not use Isopropyl with any
additional surfactants (cleaners) or additives
(scents).
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 18 of 48
Repair Instruction
Section A - Check for Previous Repair
•
Enter the VIN in Elsa and proceed to the
“Campaign/Action” screen.
TIP
On the date of repair, print this screen and keep a
copy with the repair order.
•
Confirm the Campaign/Action is open . If the status is closed, no further work is
required.
•
Note the Applicable Criteria ID  for use
in determining the correct work to be done and
corresponding parts associated.
CRITICAL REPAIR STEP
STOP!
If multiple software update Campaign/Actions are
open, they must be performed in order of the Start
date . The oldest should be performed
first.
•
All Safety Recalls must be completed prior to
completing this campaign.
•
Proceed to Section B.
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 19 of 48
Section B – SVM Instructions
NOTE
Prior to launching the VAS Diagnostic Tester and starting an update, ensure the following conditions are met;
The ODIS software is completely up to date.
•
Refer to the “Current ODIS Service Version” circular found in Elsa2Go Service References.
The battery charger is connected to the vehicle battery and remains connected for the duration of the
software update.
•
Battery voltage must remain above 12.5 volts for the duration of the software update. Failure to do
so may cause the update to fail, which could result in damage to the control module. Control modules
damaged by insufficient voltage will not be covered.
The screen saver and power saving settings are off.
•
Failure to do so may result in the tester entering power save mode during the software update, which
could result in damage to the control module.
The VAS Diagnostic Tester is plugged in using the supplied power adapters.
•
Under no circumstances should the tester be used on battery power alone during the software
update. Failure to do so may result in the tester powering off during the update, which could result
in damage to the control module.
The VAS Diagnostics Interface MUST ONLY be connected to the tester with a USB cable.
•
Performing a software update using a Bluetooth or WiFi connection increases the risk of losing
connection during the update, which could result in damage to the control module.
It also greatly increases the time required to perform the update. Requests for additional time or
parts will be denied if the GFF log shows the update was performed using Bluetooth or WiFi.
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 20 of 48
CRITICAL REPAIR STEP
STOP!
•
Check for pre-existing faults.
•
If any of the modules being updated are offline and cannot be identified, the communication issue must be
addressed prior to starting this procedure.
•
Any module with a “Faulty Control Module” fault that cannot be cleared, must be addressed prior to starting
the flash. The flash may fail for the affected control module.
•
Diagnosis and repair of pre-existing conditions are not covered under this action.
•
No additional/other work may be performed on the vehicle for the entire duration of the update.
•
The firewall settings which are listed in the latest release notes of the current ODIS version always apply.
•
It is essential to follow the correct sequence when performing the individual steps, otherwise the flash routine
will be interrupted.
CRITICAL REPAIR STEP
STOP!
Before starting programming, it is essential to perform the following actions
for the -VAS5908- battery charger.
The battery charger’s default setting will switch the charger off automatically after a
period of time. To prevent this, the following must be carried out.
Switch it OFF and then ON again each time the charger is connected.
The battery charger’s display must have switched off before it’s restarted.
The charging time can be changed in the charger’s settings menu (access code =
6161). Refer to the owner’s manual for further information. DO NOT change any
settings that will damage the charger or the vehicle.
CRITICAL REPAIR STEP
STOP!
•
The software update is performed in multiple steps, using a different SVM code for each step.
•
Pay very close attention to the instructions outlined in each repair step.
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 21 of 48
CRITICAL REPAIR STEP
STOP!
Perform the following before beginning the software update procedure:
•
Switch off all consumers, air conditioning, heater blower motor, lights, heated seats, etc.
•
Ensure the latest version of ODIS is downloaded.
•
Ensure diagnostic head is connected to ODIS tester via USB cable.
•
Move selector lever to P.
NOTE
Flashing times will vary. The time it takes to complete the software updates is dependent on several factors, including
the workshops internet download speed.
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 22 of 48
NOTE
In an effort to keep track of the time units from the multiple SVM codes, the SVM code can be entered in the RO
field in ODIS. This will then be populated in the RO field in GFF Paperless.
•
Instead of selecting “No RO” during the vehicle scan, select “Own order number” .
•
Then enter in the SVM code(s) (or step) that is being used during that session .
•
Once the log is sent to GFF Paperless, the Diagnosis ID from the specific SVM performed can then be easily
identified:
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 23 of 48
Step 1 - Perform “Check Cell Equalization” Test Plan
•
Use operating mode, DIAGNOSIS.
•
Select the Guided Functions test plan list for address 008C.
•
Perform test plan, “AX2 – High-Voltage Battery 1 – Check cell
equalization” and follow the on-screen prompts.
•
If the test plan results indicate the HV battery is OK:
o
•
Proceed to Step 2
If the test plan results indicate a cell module requires replacement:
o
The cell module(s) must be replaced before performing any
additional software updates.
o
Proceed to Section C.
o
After the cell module(s) have been replaced, proceed to Step 2
of the SVM instructions to begin the software update process.
Step 2 - Perform SVM via DIAGNOSIS + CAN
•
This SVM code will erase some historical data for the HV battery.
•
Use operating mode, DIAGNOSIS.
•
Select “SVM – Code Input”.
•
Enter SVM code ME321ZDC and follow the on screen prompts.
•
Select communication path CAN when prompted.
IMPORTANT
The vehicle can no longer be driven once the SVM code has been
run.
•
Exit Diagnosis completely and send log to GFF Paperless.
•
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
<1> on the frame of the high-voltage battery
<2>. Then pivot back the hoist arm with the
vehicle support plate <1>  so that the highvoltage battery <2> 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 <1>.
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
<16>.
Refer to → Body Exterior; Rep. Gr.66;
Underbody Trim Panel; Rear Center
Underbody Trim Panel, Removing and
Installing.
•
Remove the rear underbody trim panel <14>.
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 <1>
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 <1> had not yet
been secured, install new bolts  and
torque to 20 Nm.
Part Number
Part Description
N -102-252-02
Bolt
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 <4> 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 <4> 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.
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 <3> in a cross pattern to 16
Nm + 180°.
Part Number
Part Description
N -912-809-01
Bolt
•
Torque bolts <3> for
connection <4> 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 <1>
1EA-802-132-A
Connection element (qty. 2)
Position <2>
WHT-008-738-A
Middle bolts (qty. 22)
Position <3>
WHT-009-218
Perimeter bolts (qty. 82)
Position <4>
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 <1 through 4> to
100 Nm.
2. Middle bolts <5 through 26> 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 <1 through 82> 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 <1> (qty. 8) onto the highvoltage battery cover. Reference the old cover
for installation position if needed.
•
Apply new sticker <2> and warning sign <3>.
•
Remove old separating film <4> 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 <1 through 4>.
•
Completely cover all (22)
<5 through 26> with wax.
middle
Part Number
Part Description
D -316-000-A1
Wax/Undercoat
bolts
COVERAGE DETAIL
Connection elements
<1 through 4>
Middle bolts
<5 through 26>
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 <1> and
connection seals <2>.
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 <1 through 24> to 50 Nm + 90°.
2. Bolts <25 through 28> 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