D4B808E4786 High Voltage Battery

Service
Workshop Manual
Audi e-tron 2019 ➤
High-voltage battery
Engine ID
EAS EAS EAV
A B A
Edition 01.2021
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
93 - Electric drive systems
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2021 Audi AG, Ingolstadt D4B808E4786

High-voltage battery - Edition 01.2021
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the high-voltage system . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 2
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Additional repair instructions for work on electric drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Assessing high-voltage system risk level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Checking warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 High-voltage battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Exploded view - high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Exploded view - switching unit for high-voltage battery SX6 . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Determining mean cell voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Charging and discharging battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Checking high-voltage battery for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 Removing and installing high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.7 Lifting high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.8 Removing and installing underbody guard for high-voltage battery . . . . . . . . . . . . . . . . . . 66
3.9 Removing and installing battery regulation control unit J840 . . . . . . . . . . . . . . . . . . . . . . . . 72
3.10 Removing and installing switching unit for high-voltage battery SX6 . . . . . . . . . . . . . . . . . . 72
4 High-voltage battery components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Exploded view - high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2 Exploded view - high-voltage battery (level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3 Overview of fitting locations - battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.4 Overview of fitting locations - battery connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.5 Overview of fitting locations - battery modules control units . . . . . . . . . . . . . . . . . . . . . . . . 99
4.6 Inspecting and classifying high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.7 Marking battery modules, battery connectors and control units . . . . . . . . . . . . . . . . . . . . . . 103
4.8 Handling replacement bolts for cover for battery housing . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.9 Removing and installing cover for battery housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.10 Removing and installing battery housing (level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.11 Renewing battery housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.12 Removing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.13 Installing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.14 Removing and installing battery modules control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.15 Provisional energisation of high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Contents i
ii Contents
00 – Technical data
1 Safety precautions
(ARL007377; Edition 01.2021)
♦ Work that requires high-voltage system to be de-energised
⇒ Electric drive motor 0EF; Rep. gr. 00; Assessing high-volt‐
age system risk level
⇒ p1.1 recautions when working on the high-voltage system”,
page 1
⇒ p1.2 recautions when working in the vicinity of high-voltage
components”, page 2
1.1 Safety precautions when working on the high-voltage system

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock or
electric arcs.
– The high-voltage system must be de-energised before any
work is performed on the high-voltage system.
– For work that does not affect the high-voltage system direct‐
ly, the high-voltage system must also be de-energised in
some cases.
– Please note the work for which the high-voltage system must
be de-energised ⇒ Rep. gr. 00; Assessing high-voltage sys‐
tem risk level.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energise the high-voltage system.
Electric and magnetic fields can cause fatal injury.

The high-voltage system generates electric and magnetic fields.
Danger of severe or fatal injuries caused by malfunctioning of
active implants (e.g. pacemakers, insulin pumps).
– Persons with active implants must not perform work on the
high-voltage system.
Risk of damage to high-voltage wiring

Incorrect handling may result in damage to the insulation of
high-voltage wires or high-voltage connectors.
– Never use high-voltage wiring or high-voltage connectors as
a support.
– Never support tools or equipment on high-voltage wires and
high-voltage connectors.
– High-voltage cables must not be excessively bent or kinked.
– Pay attention to coding when connecting high-voltage con‐
nections.
1. Safety precautions 1
1.2 Safety precautions when working in the vicinity of high-voltage compo‐

nents
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock or
electric arcs 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 imple‐
ments in the vicinity of high-voltage components and high-
voltage wires.
– Never perform work using welding, brazing, thermal bonding
or hot air in the vicinity of high-voltage components or high-
voltage wires.
2 Rep. gr.00 - Technical data

2 Repair instructions
⇒ f2.1 or cleanliness”, page 3
⇒ p2.2 lates”, page 3
⇒ o2.3 f impact wrenches”, page 3
⇒ r2.4 epair instructions for work on electric drive”, page 4
2.1 Rules for cleanliness

Even small amounts of dirt can cause malfunctions in the high-
voltage battery. Therefore it is important to observe the follow‐
ing rules for cleanliness when working on the high-voltage bat‐
tery:
♦ No work may be performed at nearby work stations that
could cause dirt to enter the high-voltage battery.
♦ Any swarf produced when screwing in bolts must be vac‐
uumed off immediately.
♦ Place removed parts on a clean surface and cover them.
Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot
be carried out immediately.
♦ Only install clean components; replacement parts should on‐
ly be unpacked immediately prior to installation. Do not use
parts that have not been stored in the proper packaging (e.g.
in tool boxes etc.).
♦ Protect electrical connectors that have been unplugged and
bolted connections that have been separated against dirt
and moisture.
2.2 Identification plates

When renewing vehicle components, the identification plates on
the old parts that have a replacement part number (see ⇒ Elec‐
tronic parts catalogue) must be attached to the new parts due to
approval regulations.
2.3 Use of impact wrenches

In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are ob‐
served. In general, electric and compressed-air impact wrench‐
es should be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at
low speed.
• Use a suitable impact wrench with variable speed and ad‐
justable torque range.
• Use suitable bits when working in the vicinity of sensitive
surfaces, e.g. plastic-coated bits for aluminium rims.
2. Repair instructions 3
• When working in the vicinity of natural gas systems, observe

the information in the Workshop Manual “Natural gas en‐
gines - General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the
head of the bolt/nut makes contact and then continue tight‐
ening with a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.
2.4 Additional repair instructions for work

on electric drive
⇒ Electric drive motor 0EF; Rep. gr. 00; Repair instructions
4 Rep. gr.00 - Technical data

3 Assessing high-voltage system risk

level
⇒ Electric drive motor 0EF; Rep. gr. 00; Assessing high-voltage
system risk level
3. Assessing high-voltage system risk level 5

93 – Electric drive systems

1 Safety precautions
Observe safety precautions ⇒ p1 recautions”, page 1 .
6 Rep. gr.93 - Electric drive systems

2 Warning labels
⇒ w2.1 arning labels”, page 7
2.1 Checking warning labels

⇒ w2.1.1 arning labels - e-tron 50”, page 7
⇒ w2.1.2 arning labels - e-tron 55/e-tron S”, page 7
2.1.1 Checking warning labels - e-tron 50

Warning labels are affixed to all high-voltage components.
When performing maintenance work, it is important to ensure
that these warning labels do not get damaged or dirty, and that
they are present on all high-voltage components.
Renew if necessary.
There are warning labels on the following components:
♦ High-voltage battery 1 -AX2- - top
♦ High-voltage battery 1 -AX2- - front (with switching unit for

high-voltage battery -SX6-)
2.1.2 Checking warning labels - e-tron 55/e-

tron S
Warning labels are affixed to all high-voltage components.
2. Warning labels 7
When performing maintenance work, it is important to ensure

that these warning labels do not get damaged or dirty, and that
they are present on all high-voltage components.
Renew if necessary.
There are warning labels on the following components:
♦ High-voltage battery 1 -AX2- - top
♦ High-voltage battery 1 -AX2- - front (with switching unit for

high-voltage battery -SX6-)

3 High-voltage battery unit

⇒ v3.1 iew - high-voltage battery”, page 9
⇒ v3.2 iew - switching unit for high-voltage batterySX6”, page
15
⇒ m3.3 ean cell voltage”, page 17
⇒ a3.4 nd discharging battery modules”, page 19
⇒ h3.5 igh-voltage battery for leaks”, page 20
⇒ a3.6 nd installing high-voltage battery 1AX2”, page 37
⇒ h3.7 igh-voltage battery 1AX2”, page 62
⇒ a3.8 nd installing underbody guard for high-voltage battery”,
page 66
⇒ a3.9 nd installing battery regulation control unitJ840”, page
72
⇒ a3.10 nd installing switching unit for high-voltage batterySX6”,
page 72
3.1 Exploded view - high-voltage battery

⇒ v3.1.1 iew - high-voltage battery, e-tron 50”, page 9
⇒ v3.1.3 iew - high-voltage battery, e-tron S”, page 13
3.1.1 Exploded view - high-voltage battery, e-tron 50
3. High-voltage battery unit 9

1 - Underbody guard
❑ Removing and instal‐
ling ⇒ Running gear,
axles, steering; Rep.
gr. 40; Subframe; Ex‐
ploded view - subframe
2 - Bolts
❑ 2x
❑ 55 Nm
3 - Bolts
❑ 4x
❑ 24 Nm
4 - Bracket
❑ For high-voltage battery
1 -AX2-
5 - Bolts
❑ 2x
❑ 55 Nm
6 - Bolts
❑ 4x
❑ 24 Nm
7 - High-voltage battery 1 -
AX2-
ling ⇒ page 37
8 - Coolant pipe
❑ Right-side, inside
9 - Coolant pipe
❑ Right-side, outside
10 - Retainer
❑ For coolant pipes
11 - High-voltage wiring harness
❑ To electric drive motor for rear axle -V663-
12 - Retainer
❑ For high-voltage wiring harness
13 - Bolt
❑ 2x
❑ 24 Nm
14 - Bolt
❑ For high-voltage battery 1 -AX2-
❑ Beneath rear seat bench
❑ 55 Nm
15 - Bracket
16 - Bolt
❑ 2x
❑ 24 Nm

17 - Bracket
❑ 2x
18 - Coolant pipe (rear)
19 - Bolts
❑ 24 Nm
20 - Bracket
21 - Bolts
❑ 55 Nm
22 - Sealing plug
23 - Spacer sleeve
❑ 2x
24 - Securing plate
❑ 2x
25 - Bolt
❑ Long version
❑ 2x
❑ 55 Nm
26 - Bolt
❑ For subframe
❑ Tightening torque ⇒ Running gear, axles, steering; Rep. gr. 42; Subframe; Exploded view - subframe
27 - Bolt
❑ Short version
❑ 2x
❑ 30 Nm
28 - Coolant pipe
❑ Left-side
29 - Retainer
❑ For coolant pipe (left-side)
30 - Bolt
❑ 18x
❑ Renew after removing
❑ 50 Nm +180°
31 - Bolt
❑ For securing battery in centre
❑ 4x
❑ 55 Nm
32 - Bolt
❑ For underbody guard

1 - Underbody guard
2 - Bolts
❑ 2x
❑ 55 Nm
3 - Bolts
❑ 4x
❑ 24 Nm
4 - Bolts
❑ 2x
❑ 55 Nm
5 - Bolts
❑ 4x
❑ 24 Nm
6 - Bracket
1 -AX2-
AX2-
ling ⇒ page 37
8 - Coolant pipe
9 - Coolant pipe
10 - Retainer
11 - Dummy connector
❑ Depending on version
12 - Retainer
14 - Bolt
❑ 3x
❑ 55 Nm
15 - Coolant pipe (rear)
16 - Bolts
❑ 8x
❑ 24 Nm
17 - Bracket


18 - Bolts
❑ 4x
❑ 55 Nm
19 - Spacer sleeve
❑ 2x
20 - Securing plate
❑ 2x
21 - Bolt
❑ Long version
❑ 2x
❑ 55 Nm
22 - Bolt
❑ For subframe
23 - Bolt
❑ Short version
❑ 2x
❑ 30 Nm
24 - Coolant pipe
❑ Left-side
25 - Bolt
❑ 18x
❑ 50 Nm +180°
26 - Bracket
27 - Bolt
❑ 4x
❑ 55 Nm
28 - Bolt
3.1.3 Exploded view - high-voltage battery, e-tron S

1 - Underbody guard
2 - Bolts
❑ 2x
❑ 55 Nm
3 - Bolts
❑ 4x
❑ 24 Nm
4 - Bolts
❑ 2x
❑ 55 Nm
5 - Bolts
❑ 4x
❑ 24 Nm
6 - Bracket
1 -AX2-
AX2-
ling ⇒ page 37
8 - Coolant pipe
9 - Coolant pipe
10 - Retainer
❑ To electric drive motor 2 for rear axle -V648-
13 - Retainer
14 - Bolt
❑ 3x
❑ 55 Nm
15 - Bolts
❑ 8x
❑ 24 Nm
16 - Bracket

17 - Bolts
❑ 4x
❑ 55 Nm
18 - Spacer sleeve
❑ 2x
19 - Securing plate
❑ 2x
20 - Bolt
❑ Long version
❑ 2x
❑ 55 Nm
21 - Bolt
❑ For subframe
22 - Bolt
❑ Short version
❑ 2x
❑ 30 Nm
23 - Coolant pipe
❑ Left-side
24 - Bolt
❑ 18x
❑ 50 Nm +180°
25 - Bracket
26 - Bolt
❑ 4x
❑ 55 Nm
27 - Bolt
3.2 Exploded view - switching unit for high-voltage battery -SX6-

1 - Cap nut
❑ 9 Nm
AX2-
❑ Overview of fitting loca‐
tions ⇒ page 80
3 - Potential equalisation line
4 - Bolt
❑ 20 Nm
5 - Switching unit for high-
voltage battery -SX6-
ling ⇒ page 72
6 - Pressure equalisation
valve
❑ 4x
❑ Apply grease (⇒ Elec‐
tronic parts catalogue)
to contact surface
7 - Bolt
❑ Tightening torque and
sequence ⇒ page 16
8 - Seal
Switching unit for high-voltage battery -SX6- - tightening torque

and sequence

– Tighten bolts in stages:

Stage Bolts Tightening torque
1. In sequence -1 ... 4- 8 Nm
2. Remaining items: in any 8 Nm
sequence
3.3 Determining mean cell voltage

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
♦ High-voltage diagnostics box -VAS 5581- (if required)
♦ Adapter cable -VAS 5581/8- (if required)

Procedure
The mean cell voltage must be determined before a battery
module is renewed:
High-voltage battery removed:
– Connect high-voltage diagnostics box -VAS 5581- to vehicle
diagnostic tester with adapter cable -VAS 5581/8-.
• CAN bus terminal resistor of high-voltage diagnostics box
-VAS 5581- is pre-set to 120 Ω and must not be changed.
– Remove battery regulation control unit -J840- ⇒ page 72
and connect it to adapter cable -VAS 5581/8-.
– Connect adapter cable -VAS 5581/8- -item 1- to coolant tem‐
perature sender 1 for high-voltage battery -G898-.
– Connect short cable of adapter cable -VAS 5581/8- to

12 Volt connector on switching unit for high-voltage battery
-SX6-.

– e-tron 50: Connect long cable of adapter cable -VAS 5581/8-

to housing for 12 Volt connector.
– e-tron 55/e-tron S: Connect long cable of adapter cable

-VAS 5581/8- to 12 Volt connector on battery housing (level
2).
– Connect black earth terminal of adapter cable -VAS 5581/8-

to earth on battery housing.
High-voltage battery removed or installed:
– Select and start ODIS-Service mode on vehicle diagnostic
tester.
– Select Special functions tab.
– Select the following:
♦ High-voltage
♦ 008C - Determine mean cell voltage
– Start selected program and follow instructions on display of
vehicle diagnostic tester.

3.4 Charging and discharging battery mod‐

ules
♦ Module balancing device -VAS 6910-
♦ Autonomous software -VAS 6910/5-

♦ Connecting cable for HV positive with ring cable lug and
knurled screw -VAS 6910/12A-1-
♦ Connecting cable for HV negative with ring cable lug and
knurled screw -VAS 6910/12A-2-
Note:
Note colour coding of the following connecting cables.
e-tron 50:
♦ Connecting cable -VAS 6910/18-1- for battery modules with

standard layout of battery terminals
mirrored layout of battery terminals
e-tron 55/e-tron S, battery module manufactured by LG Chem:

e-tron 55/e-tron S, battery module manufactured by Samsung
SDI:

Procedure
A new battery module must be charged or discharged according
to the result of the mean cell voltage calculation ⇒ page 17 .
• Battery module removed ⇒ page 158
– Connect module balancing device -VAS 6910- ⇒ manual for
-VAS 6910-.
– Start program and follow instructions on display of module
balancing device.

– Install new battery module ⇒ page 172 after it has been

charged or discharged to the mean cell voltage level deter‐
mined previously.
3.5 Checking high-voltage battery for leaks

⇒ e3.5.1 quipment layout - checking high-voltage battery for
leaks, part 1, e-tron 50”, page 20
leaks, part 2, e-tron 50”, page 22
leaks, part 1, e-tron 55/e-tron S”, page 22
leaks, part 2, e-tron 55/e-tron S”, page 24
⇒ b3.5.5 attery housing for leaks - e-tron 50”, page 25
⇒ b3.5.6 attery housing (levels 1 and 2) for leaks - e-tron 55/e-
tron S”, page 28
⇒ b3.5.7 attery housing (level 2) for leaks - e-tron 55/e-tron S”,
page 34
3.5.1 Test equipment layout - checking high-voltage battery for leaks, part 1,
e-tron 50
• High-voltage battery 1 -AX2- removed ⇒ a3.6.1 nd installing
high-voltage battery 1AX2 - e-tron 50/e-tron 55”, page 37
• Additional measures for checking for leaks ⇒ page 21

1 - Rubber plug -VAS

6911/10-
❑ Remove pressure
equalisation valves and
fit rubber plugs:
♦ 4x on switching unit for
high-voltage battery -SX6-
♦ 4x on housing for 12 Volt
connector ⇒ page 21
❑ Fitted on high-voltage
battery 1 -AX2-
3 - Leak-tight connector -
T40417-
❑ 2x
T40418-
❑ 3x
5 - Adapter cable -VAS
5581/8-
❑ Connect short cable to
12 Volt connector on
switching unit for high-
voltage battery -SX6- ⇒
page 21
❑ Connect long cable to
12 Volt connector (rear
right) on high-voltage
battery 1 -AX2- ⇒ page
21
6 - Test plug -VAS 6911/3-1-
❑ Connector catch must
be at top (can be
moved if necessary)
7 - Leak-tight connector -VAS 6911/4-2-
Additional measures for checking for leaks
– Connect adapter cable -VAS 5581/8- to housing for 12 Volt

connector.
– Remove pressure equalisation valves and fit rubber plugs
-VAS 6911/10-.

e-tron 50
1 - Distributor -VAS 691

005/1-
2 - Pressure sensor -VAS 611
013-
3 - Connection cable -VAS
5051/66-
4 - Test instrument box -VAS
6356/1-
❑ Connect pressure sen‐
sor -VAS 611 013- to
green socket T/D-1 of
test instrument box -
VAS 6356/1- with con‐
nection cable -VAS
5051/66-
❑ On high-voltage battery
1 -AX2-
6 - Test plug -VAS 6911/3-1-
be at top (can be
moved if necessary)
7 - Cooling system tester -
V.A.G 1274 B-
e-tron 55/e-tron S
• High-voltage battery 1 -AX2- removed ⇒ a3.6 nd installing
high-voltage battery 1AX2”, page 37
• Additional measures for checking for leaks ⇒ page 23

1 - Rubber plug -VAS

6911/10-
❑ Remove pressure
equalisation valves and
fit rubber plugs:
♦ 4x on switching unit for
high-voltage battery -SX6-
♦ 4X on back of high-voltage
battery 1 -AX2- ⇒ page
23
❑ Fitted on high-voltage
battery 1 -AX2-
T40417-
❑ 2x
T40418-
❑ 3x
5 - Adapter cable -VAS
5581/8-
❑ Connect short cable to
switching unit for high-
❑ Connect long cable to
battery housing (level
2) ⇒ page 23
6 - Test plug -VAS 6911/3-1-
be at top (can be
moved if necessary)
7 - Leak-tight connector -VAS 6911/4-2-
❑ 2x
Additional measures for checking for leaks
– Connect adapter cable -VAS 5581/8- to 12 Volt connector on

battery housing (level 2).
• Not required if only level 1 is being checked.

– Remove pressure equalisation valves and fit rubber plugs

-VAS 6911/10- in back of high-voltage battery 1 -AX2-.
• Not required if only level 1 is being checked.
e-tron 55/e-tron S
1 - Distributor -VAS 691

005/1-
2 - Pressure sensor -VAS 611
013-
3 - Connection cable -VAS
5051/66-
4 - Test instrument box -VAS
6356/1-
❑ Connect pressure sen‐
sor -VAS 611 013- to
green socket T/D-1 of
test instrument box -
VAS 6356/1- with con‐
nection cable -VAS
5051/66-
❑ On high-voltage battery
1 -AX2-
6 - Test plug -VAS 6911/3-1-
be at top (can be
moved if necessary)
7 - Cooling system tester -
V.A.G 1274 B-

3.5.5 Checking battery housing for leaks -

e-tron 50
♦ High-voltage diagnostics box -VAS 5581-
Test requirements
• High-voltage battery 1 -AX2- must be acclimatised.
• The leak test and acclimatisation must be carried out at a
constant ambient temperature.
• Testing set -VAS 691 005- must have been cleaned.
Cleaning testing set -VAS 691 005-
Proceed as follows to ensure that no coolant residue remains in

testing set -VAS 691 005-:
– Fit -VAS 691 005/4- on outlet -B-.
– Fit cleaning nozzle -D- from testing set on outlet -A-.
– Close open outlet -C- with lever.
– Hold outlet -B- upwards and blow through with compressed
air; any coolant present will come out of cleaning nozzle -D-
when you do this.
NOTICE
The pressures during the self-test and the leak test are dif‐
ferent. The battery housing and testing equipment may be
damaged if the specified pressures are not adhered to.

Performing self-test of testing set -VAS 691 005- with turbo‐

charger tester -V.A.G 1397/A-
– Assemble the following parts:

♦ Y-connector -VAS 691 005/1-
♦ Test connector set -VAS 6911/3- assembled -2-
♦ Turbocharger tester -V.A.G 1397/A- -1-
♦ Hand pump -V.A.G 1274B- -3-
– Open cut-off valves “A” and “C” on Y-connector -VAS 691
005/1-.
– Switch on turbocharger tester -V.A.G 1397A- and select set‐
ting “II”.
– Using hand pump -V.A.G 1274B-, build up pressure until
turbocharger tester -V.A.G 1397/A- shows a value of 300 …
350 mbar.
– Close cut-off valve “C” on Y-connector -VAS 691 005/1-.
– Wait approx. one minute (settling time), then check drop in
pressure on turbocharger tester -V.A.G 1397A-.
• Maximum pressure loss after 30 seconds: less than 5 mbar
Performing self-test of testing set -VAS 691 005- with pressure
sensor -V.A.G 1397B-

♦ Pressure sensor -V.A.G 1397B- -2-
– Open cut-off valve “C” on Y-connector -VAS 691 005/1-.

– Switch on pressure sensor -V.A.G 1397B- and press menu

button until “P relative” appears.
– Press “OK” and then press reset button. The display should
show 0 mbar.
NOTICE
Excessive pressure will damage the pressure sensor -V.A.G
1397B.-.

pressure sensor -V.A.G 1397B- shows a value of 300 …
350 mbar.
pressure on pressure sensor -V.A.G 1397B-.
Procedure
• High-voltage battery 1 -AX2- removed ⇒ a3.6.1 nd installing
high-voltage battery 1AX2 - e-tron 50/e-tron 55”, page 37
• Cover for high-voltage battery 1 -AX2- installed ⇒ a4.9.1 nd
installing cover for battery housing - e-tron 50”, page 104
– Check that bracket for high-voltage battery 1 -AX2- is bolted
on -arrows-.
– Set up test equipment ⇒ e3.5.1 quipment layout - checking

high-voltage battery for leaks, part 1, e-tron 50”, page 20
and ⇒ e3.5.2 quipment layout - checking high-voltage bat‐
tery for leaks, part 2, e-tron 50”, page 22 .
– Connect test equipment box -VAS 6356/1- to vehicle diag‐
nostic tester.
– Connect battery regulation control unit -J840- at adapter ca‐
ble -VAS 5581/8-.


NOTICE
Risk of damage to pressure gauge due to pressure peaks
from pumping process.
– Do NOT use hand pump at connection to pressure gauge
when tap of connecting piece is open.
– Open tap and read off current pressure at regular intervals.
– Select and start Diagnosis mode on vehicle diagnostic

tester.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 008C - Hybrid battery management -J840
♦ 008C - Hybrid battery management - functions
♦ 008C - Commissioning
If leak has been identified:
– Build up test pressure again, locate leak using commercially
available leak detection spray and repair leak.
If no leak has been identified:
– Remove rubber plugs -VAS 6911/10- from switching unit
for high-voltage battery -SX6- and from housing for 12 Volt
connector.
– Apply grease (⇒ Electronic parts catalogue) to contact sur‐
face before fitting new pressure equalisation valves.
– Dismantle test equipment.
3.5.6 Checking battery housing (levels 1 and

2) for leaks - e-tron 55/e-tron S
• If the cover for battery housing (level 1) has been opened,
level 1 of the battery housing must be checked for leaks
before fitting level 2. Levels 1 and 2 must subsequently be
checked together.

♦ Adapter cable -VAS 5581/8-

♦ Seal -T40422-
♦ Washer -N 901 797 04- (2x)

Test requirements



when you do this.
NOTICE


005/1-.
ting “II”.
350 mbar.


show 0 mbar.
NOTICE
1397B.-.

350 mbar.
Checking battery housing (level 1) for leaks
• High-voltage battery 1 -AX2- removed ⇒ a3.6 nd installing

high-voltage battery 1AX2”, page 37
• Cover for high-voltage battery 1 -AX2- installed ⇒ a4.9.3 nd
installing cover for battery housing (level 1) - e-tron 55/e-
tron S”, page 117
– Bolt sealing pieces -T40422- onto battery housing cover,
level 1 (4 Nm).
– Place a washer -N 901 797 04- -item 1- at each of the
locations indicated in illustration.

– To check for leaks, screw in bolts -2- that were removed

from brackets ⇒ page 128 (24 Nm).
high-voltage battery for leaks, part 1, e-tron 55/e-tron S”,
page 22 and ⇒ e3.5.4 quipment layout - checking high-volt‐
age battery for leaks, part 2, e-tron 55/e-tron S”, page 24 .
nostic tester.
ble -VAS 5581/8-.

NOTICE

tester.


after the other:
If no leak is identified in level 1 of battery housing:
– After successfully performing leak test, remove bolts and
sealing pieces -T40422-
– Install battery housing (level 2) and cover for battery housing
(level 2) ⇒ page 125 .
– Levels 1 and 2 of battery housing must subsequently be
checked for leaks together.
Checking battery housing (levels 1 and 2) for leaks
• Adapter cable -VAS 5581/8- connected to 12 Volt connector
on battery housing (level 2) ⇒ page 23
NOTICE

tester.
after the other:
– Remove rubber plugs -VAS 6911/10- from switching unit for
high-voltage battery -SX6- and from back of high-voltage
battery 1 -AX2-.

3.5.7 Checking battery housing (level 2) for

leaks - e-tron 55/e-tron S
• If only cover for battery housing (level 2) has been opened,
levels 1 and 2 are checked together.
Test requirements

when you do this.
NOTICE



005/1-.
ting “II”.
350 mbar.



show 0 mbar.
NOTICE
1397B.-.

350 mbar.
Procedure
• High-voltage battery 1 -AX2- removed ⇒ page 37
high-voltage battery for leaks, part 1, e-tron 55/e-tron S”,
page 22 and ⇒ e3.5.4 quipment layout - checking high-volt‐
age battery for leaks, part 2, e-tron 55/e-tron S”, page 24 .
nostic tester.
ble -VAS 5581/8-.

NOTICE


tester.
after the other:
– Remove rubber plugs -VAS 6911/10- from switching unit for
high-voltage battery -SX6- and from back of high-voltage
battery 1 -AX2-.
3.6 Removing and installing high-voltage

battery 1 -AX2-
⇒ a3.6.1 nd installing high-voltage battery 1AX2 - e-tron 50/e-
tron 55”, page 37
⇒ a3.6.2 nd installing high-voltage battery 1AX2 - e-tron S”,
page 50
3.6.1 Removing and installing high-voltage

battery 1 -AX2- - e-tron 50/e-tron 55
♦ Hose clamps up to 25 mm -3094-

♦ Engine bung set -VAS 6122-
♦ Scissor-type assembly platform -VAS 6131B- or scissor-type

assembly platform -VAS 6131A-
♦ Coolant collecting system -VAS 5014- or drip tray for work‐

shop hoist -VAS 6208-
♦ Hose clip pliers -VAS 6340-
♦ Insulating mat -VAS 6762/44- from high-voltage tool set -

VAS 6762-
♦ Protective gloves
Use of impact wrenches ⇒ page 3

Removing
• If the high-voltage battery is opened after removal, a leak
test must be performed after assembly. Battery regulation
control unit -J840- is required in order to do so. Removing
battery regulation control unit -J840- ⇒ page 72
• The mean cell voltage of the high-voltage battery must be
determined if one or several battery modules need to be
renewed after removing the high-voltage battery ⇒ page 17 .
• New battery modules must be charged or discharged ac‐
cording to the result of the mean cell voltage calculation ⇒
page 19 .
DANGER
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have an Audi high-voltage technician (HVT) or an Audi
high-voltage expert (HVE) de-energise the high-voltage
system.
– De-energise high-voltage system ⇒ Motor; Rep. gr. 93; De-

energising high-voltage system.
– Perform classification of high-voltage battery 1 -AX2- ⇒ page
101 .
– Remove rear seat bench ⇒ General body repairs, seats;
Rep. gr. 72; Rear seats; Removing and installing rear seat
bench/individual seats.
e-tron 50:
– Fold floor covering towards front and remove bolt -arrow-.

e-tron 55:

– Fold floor covering towards front and remove bolts -arrows-.

All vehicles (continued):
– Raise vehicle on lifting platform.
– Remove all underbody trim panels ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody trim; Exploded view - un‐
derbody trim.
– Remove underbody guard ⇒ Running gear, axles, steering;
Rep. gr. 40; Subframe; Exploded view - subframe.
– Raise vehicle again on lifting platform.
• The arms of the lifting platform must not hinder the lowering
of the high-voltage battery later.
– Clamp off coolant hose (front left) to high-voltage battery
using hose clamp up to 25 mm -3094-.
– Place coolant collecting system -VAS 5014- or drip tray for

workshop hoist -VAS 6208- underneath.
– Release hose clip -arrow- and detach coolant hose from
coolant pipe.
– Release hose clip -arrow- and detach coolant hose (rear left)
from coolant pipe.
– Unclip all retainers -2- for coolant pipe (left-side) -1- from
high-voltage battery -arrow-.

– Detach coolant pipe.

– Clamp off coolant hose (front) to high-voltage battery using
hose clamp up to 25 mm -3094-.

– Release hose clip -arrow- and detach coolant hose.
– Unplug electrical connector -1- for coolant temperature
sender 1 for high-voltage battery -G898-.
– Clamp off coolant hoses (front right) with hose clamps up to
25 mm -3094-.
– Move coolant hose clear at retainer -1-.

– Release hose clips -arrows- and disconnect coolant hoses
from coolant pipes.
– Detach retaining clip -1- for electrical wiring at high-voltage
battery.

– Unplug electrical connector at coolant temperature sender 2

for high-voltage battery -G899- -item 2-.
– Release hose clips -arrows- and detach coolant hoses (rear
right) from coolant pipes.
– Unclip all retainers -2- for coolant pipes (right-side) -1- from
– Detach coolant pipes.

– Release hose clips -arrows- and detach coolant hoses (rear)

from high-voltage battery.
– Unclip coolant pipe (rear) from retainers -arrows- (shown
without electric drive motor for rear axle -V663-).

– Unplug electrical connectors at switching unit for high-volt‐

age battery -SX6-:
1- Unplug connector for electrical air conditioner compressor

-V470- and PTC heater element 2 -Z131-; procedure ⇒
page 43 .
2- Unplug dummy connector (or charging unit 3 for high-volt‐
age battery -AX6-); procedure ⇒ page 43 .
3- Unplug connector to voltage converter -A19-, PTC heater
element 1 -Z130- and charging unit 1 for high-voltage bat‐
tery -AX4-; procedure ⇒ page 43 .
4- Unplug connector to high-voltage battery charging socket
1 -UX4-; procedure ⇒ page 43 .
6- Diagnostic connector
7- Unplug connector to electric drive control unit for front axle
-J1234-; procedure ⇒ page 44
8- Unscrew earth cable.
NOTICE
Risk of irreparable damage to control unit due to electrostatic
discharge and insufficient attention to cleanliness.
– Discharge static electricity by touching ESD workplace.
– Keep inside of control unit clean and dry.
– Protect electrical connectors of wiring harness and sockets

from dirt.
Procedure for unplugging electrical connectors
Unplugging connector for:

♦ Electrical air conditioner compressor -V470- and PTC heater

element 2 -Z131-
♦ Dummy connector (or charging unit 3 for high-voltage bat‐
tery -AX6-)
♦ Voltage converter -A19- and PTC heater element 1 -Z130-
♦ High-voltage battery charging socket 1 -UX4-
– Press down fastener -arrow A- and pull connector locking
mechanism -1- out as far as stop -arrow B-.
– Press fastener in direction of -arrow C- and detach connec‐
tor.
– Move high-voltage wires clear.
Unplug electrical connector for electric drive control unit for front
axle -J1234-:
– Release securing clip -1- to side -arrow A- and swivel

catch -2- for electrical connector downwards in direction of
-arrow B-.

Continued
– Unbolt retainer -2-.

– Remove bolts -3-.
– Unplug electrical connector -1- for electric drive motor for
rear axle -V663-.
– Unscrew bolts -1, 2, 4- on left side of vehicle.
Note:
Remove spacer sleeve under bolt -1- after lowering high-volt‐
age battery.
– Detach bracket -3-.

– Provisionally tighten bolt -arrow- for subframe again
(130 Nm).
– Perform the same work steps on right side of vehicle.

– Remove bolts -arrows- at rear of high-voltage battery (shown
without subframe, rear).

– Remove bolts -arrows- at bottom of high-voltage battery.
– Remove bolts -arrows- at front of high-voltage battery.
– Pull out scissor-type assembly platform -VAS 6131B- com‐

pletely and position it underneath vehicle. (Shown without
lifting platform for illustration purposes)

• Drawbar of scissor-type assembly platform points to rear of

vehicle.
– Place two insulating mats -VAS 6762/44- on scissor-type
assembly platform.
– Carefully raise scissor-type assembly platform -VAS 6131B-
so it makes contact with high-voltage battery from below.
• There must not be any load on spirit level -arrow- of scissor-

type assembly platform from battery.
– Remove bolts -arrows-.

NOTICE
Danger of damage to wires and hoses if the high-voltage
battery is lowered.
– Check that all connections between high-voltage battery
and body have been detached.
– Carefully guide high-voltage battery out of body when low‐
ering.
– Initially, only lower high-voltage battery by approx. 50 mm.

– Unplug electrical connector -arrow- at rear right of high-volt‐
age battery.
• High-voltage battery still only lowered by approx. 50 mm

– Place coolant line -1- (with coolant hose connected) down

towards front between high-voltage battery and bracket -2-.
– Lower scissor-type assembly platform -VAS 6131B- further;
while doing so, carefully guide electrical wiring to elec‐
tric drive control unit for rear axle -J1235- over subframe
-arrow-.
Installing
Installation is carried out in reverse order; note the following:
• Renew bolts tightened with specified tightening angle.
• Use pure coolant additive as a lubricant to install coolant
hoses ⇒ Electronic parts catalogue.
• Do not reuse coolant.
A potential equalisation measurement must be performed on
the high-voltage components affected after installation of high-
voltage components or potential equalisation lines.
– Connect vehicle diagnostic tester.
– Select and start ODIS-Service mode.
♦ High-voltage
♦ Potential equalisation measurement on high-volt-
age components (BEV)
♦ 008C - Potential equalisation measurement - AX2 -
high-voltage battery 1
WARNING
tric arcs.
high-voltage expert (HVE) re-energise the high-voltage
system.
– Re-energise high-voltage system ⇒ Motor; Rep. gr. 93; Re-

– Fill up and bleed cooling system ⇒ Motor; Rep. gr. 19; Cool‐
ing system/coolant; Filling and bleeding cooling system.

– Install rear seat bench ⇒ General body repairs, seats; Rep.

gr. 72; Rear seats; Removing and installing rear seat bench/
individual seats.
Tightening torques
♦ ⇒ v3.1 iew - high-voltage battery”, page 9
♦ ⇒ Running gear, axles, steering; Rep. gr. 42; Subframe; Ex‐
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
trim; Exploded view - underbody trim
3.6.2 Removing and installing high-voltage

battery 1 -AX2- - e-tron S
♦ Hose clamps up to 25 mm -3094-
♦ Engine bung set -VAS 6122-


♦ Coolant collecting system -VAS 5014- or drip tray for work‐

shop hoist -VAS 6208-
♦ Hose clip pliers -VAS 6340-
♦ Insulating mat -VAS 6762/44- from high-voltage tool set -

VAS 6762-
Use of impact wrenches ⇒ page 3
Removing
• If the high-voltage battery is opened after removal, a leak
test must be performed after assembly. Battery regulation
control unit -J840- is required in order to do so. Removing
battery regulation control unit -J840- ⇒ page 72
• The mean cell voltage of the high-voltage battery must be
determined if one or several battery modules need to be
renewed after removing the high-voltage battery ⇒ page 17 .
• New battery modules must be charged or discharged ac‐
cording to the result of the mean cell voltage calculation ⇒
page 19 .
DANGER
tric arcs.
high-voltage expert (HVE) de-energise the high-voltage
system.
– De-energise high-voltage system ⇒ Motor; Rep. gr. 93; De-

– Perform classification of high-voltage battery 1 -AX2- ⇒ page
101 .

– Remove rear seat bench ⇒ General body repairs, seats;

Rep. gr. 72; Rear seats; Removing and installing rear seat
bench/individual seats.
– Fold floor covering towards front and remove bolts -arrows-.
– Raise vehicle on lifting platform.

– Remove all underbody trim panels ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody trim; Exploded view - un‐
derbody trim.
– Raise vehicle again on lifting platform.
• The arms of the lifting platform must not hinder the lowering
of the high-voltage battery later.
– Clamp off coolant hose (front left) to high-voltage battery
using hose clamp up to 25 mm -3094-.

– Release hose clip -arrow- and detach coolant hose from
coolant pipe.

– Release hose clip -arrow- and detach coolant hose (rear left)
from coolant pipe.
– Unclip all retainers -2- for coolant pipe (left-side) -1- from
– Detach coolant pipe.

– Clamp off coolant hose (front) to high-voltage battery using
hose clamp up to 25 mm -3094-.

– Release hose clip -arrow- and detach coolant hose.
– Unplug electrical connector -1- for coolant temperature
– Clamp off coolant hoses (front right) with hose clamps up to
25 mm -3094-.

– Move coolant hose clear at retainer -1-.

from coolant pipes.
– Detach retaining clip -1- for electrical wiring at high-voltage
battery.
– Unplug electrical connector at coolant temperature sender 2

for high-voltage battery -G899- -item 2-.
– Release hose clips -arrows- and detach coolant hoses (rear
right) from coolant pipes.
– Unclip all retainers -2- for coolant pipes (right-side) -1- from
– Detach coolant pipes.

– Unscrew bolt -3- and remove bracket -4-.


– Unplug electrical connector -2- (left-side) for electric drive
motor for rear axle -V663-.
– Unscrew bolt -2- and remove bracket -1-.

– Unplug electrical connector -4- (right-side) for electric drive
motor 2 for rear axle -V648-.

leading to electric drive motor for rear axle -V663- and elec‐
tric drive motor 2 for rear axle -V648-.
– Unplug electrical connectors at switching unit for high-volt‐
age battery -SX6-:

1- Unplug connector for electrical air conditioner compressor

-V470- and PTC heater element 2 -Z131-; procedure ⇒
page 56 .
2- Unplug dummy connector (or charging unit 3 for high-volt‐
age battery -AX6-); procedure ⇒ page 56 .
3- Unplug connector to voltage converter -A19-, PTC heater
element 1 -Z130- and charging unit 1 for high-voltage bat‐
tery -AX4-; procedure ⇒ page 56 .
6- Diagnostic connector
7- Unplug connector to electric drive control unit for front axle
-J1234-; procedure ⇒ page 57
8- Unscrew earth cable.
NOTICE
Risk of irreparable damage to control unit due to electrostatic
discharge and insufficient attention to cleanliness.
– Discharge static electricity by touching ESD workplace.
– Keep inside of control unit clean and dry.
– Protect electrical connectors of wiring harness and sockets

from dirt.
Procedure for unplugging electrical connectors
Unplugging connector for:

♦ Electrical air conditioner compressor -V470- and PTC heater

element 2 -Z131-
♦ Dummy connector (or charging unit 3 for high-voltage bat‐
tery -AX6-)
♦ Voltage converter -A19- and PTC heater element 1 -Z130-
♦ High-voltage battery charging socket 1 -UX4-
– Press down fastener -arrow A- and pull connector locking
mechanism -1- out as far as stop -arrow B-.
– Press fastener in direction of -arrow C- and detach connec‐
tor.
– Move high-voltage wires clear.
Unplug electrical connector for electric drive control unit for front
axle -J1234-:
– Release securing clip -1- to side -arrow A- and swivel

catch -2- for electrical connector downwards in direction of
-arrow B-.

Continued
– Unscrew bolts -1, 2, 4- on left side of vehicle.

Note:
Remove spacer sleeve under bolt -1- after lowering high-volt‐
age battery.
– Provisionally tighten bolt -arrow- for subframe again
(130 Nm).
– Perform the same work steps on right side of vehicle.

– Remove bolts -arrows- at rear of high-voltage battery (shown
without subframe, rear).
– Remove bolts -arrows- at bottom of high-voltage battery.

– Remove bolts -arrows- at front of high-voltage battery.
– Pull out scissor-type assembly platform -VAS 6131B- com‐

pletely and position it underneath vehicle. (Shown without
lifting platform for illustration purposes)
• Drawbar of scissor-type assembly platform points to rear of

vehicle.
– Place two insulating mats -VAS 6762/44- on scissor-type
assembly platform.
– Carefully raise scissor-type assembly platform -VAS 6131B-
so it makes contact with high-voltage battery from below.

• There must not be any load on spirit level -arrow- of scissor-

type assembly platform from battery.
NOTICE
Danger of damage to wires and hoses if the high-voltage
battery is lowered.
– Check that all connections between high-voltage battery
and body have been detached.
– Carefully guide high-voltage battery out of body when low‐
ering.
– Initially, only lower high-voltage battery by approx. 50 mm.

– Unplug electrical connector -arrow- at rear right of high-volt‐

age battery.
– Lower scissor-type assembly platform -VAS 6131B- further.
Installing
• Renew bolts tightened with specified tightening angle.
• Use pure coolant additive as a lubricant to install coolant
hoses ⇒ Electronic parts catalogue.
• Do not reuse coolant.
– Connect vehicle diagnostic tester.
– Select and start ODIS-Service mode.
♦ High-voltage
WARNING
tric arcs.
high-voltage expert (HVE) re-energise the high-voltage
system.
– Re-energise high-voltage system ⇒ Motor; Rep. gr. 93; Re-

– Fill up and bleed cooling system ⇒ Motor; Rep. gr. 19; Cool‐
ing system/coolant; Filling and bleeding cooling system.
– Install rear seat bench ⇒ General body repairs, seats; Rep.
gr. 72; Rear seats; Removing and installing rear seat bench/
individual seats.

Tightening torques
♦ ⇒ v3.1 iew - high-voltage battery”, page 9
♦ ⇒ Running gear, axles, steering; Rep. gr. 42; Subframe; Ex‐
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
trim; Exploded view - underbody trim
3.7 Lifting high-voltage battery 1 -AX2-

⇒ h3.7.1 igh-voltage battery 1AX2 - e-tron 50”, page 62
⇒ h3.7.2 igh-voltage battery 1AX2 - e-tron 55/e-tron S”, page
64
3.7.1 Lifting high-voltage battery 1 -AX2- -

e-tron 50
♦ Traverse -VAS 501 009- (not illustrated)
♦ Chain -VAS 501 011-, 4x (not illustrated)
♦ Support tool -T40416-
♦ Suitable forklift (note ⇒ operating instructions for -VAS 501

009-)
Procedure
• High-voltage battery 1 -AX2- removed and placed on scis‐
sor-type assembly platform -VAS 6131B- ⇒ page 37
– Bolt a mounting bracket -T40416- each onto four corners of
battery frame (40 Nm).
– Slide traverse -VAS 501 009- onto fork arms of forklift.

– Attach chains -VAS 501 011- to traverse -VAS 501 009-.

– Position traverse -VAS 501 009- on fork arms of forklift.
• Dimension -a- = 1000 mm

– Fix traverse to fork arms to prevent slipping; to do so, tighten
retaining bolts to 10 Nm and also secure with nut.
– Hook chains -VAS 501 011- into mounting brackets -
T40416-.
• The open sides of the hooks must face outwards.
WARNING
Risk of injury if unsuitable forklift is used
Danger of trapping or crushing parts of the body
– Note ⇒ operating instructions for -VAS 501 009-.
– Observe permissible load centre distance of forklift.
– Raise high-voltage battery with forklift.

Note:
Proceed in the same manner to lift high-voltage battery out of its
packaging; to do so, remove side panels of packaging.

3.7.2 Lifting high-voltage battery 1 -AX2- -

e-tron 55/e-tron S
♦ Traverse -VAS 501 009- (not illustrated)
♦ Chain -VAS 501 011-, 4x (not illustrated)
♦ Support tool -T40416-
♦ Suitable forklift (note ⇒ operating instructions for -VAS 501

009-)
Procedure
• High-voltage battery 1 -AX2- removed and placed on scis‐
sor-type assembly platform -VAS 6131B- ⇒ page 37
– Bolt a mounting bracket -T40416- each onto four corners of
battery frame (40 Nm).
– Slide traverse -VAS 501 009- onto fork arms of forklift.
– Attach chains -VAS 501 011- to traverse -VAS 501 009-.

– Shorten the two chains that are to be attached to high-volt‐

age battery at rear (as seen in direction of travel) with
mounting -arrow-.
• Eight free chain links must be visible.

– Position traverse -VAS 501 009- on fork arms of forklift.

– Fix traverse to fork arms to prevent slipping; to do so, tighten
retaining bolts to 10 Nm and also secure with nut.
– Hook chains -VAS 501 011- into mounting brackets -
T40416-.
• The open sides of the hooks must face outwards.
WARNING
Risk of injury if unsuitable forklift is used
– Note ⇒ operating instructions for -VAS 501 009-.
– Observe permissible load centre distance of forklift.
– Raise high-voltage battery with forklift.

Note:
Proceed in the same manner to lift high-voltage battery out of its
packaging; to do so, remove side panels of packaging.

3.8 Removing and installing underbody

guard for high-voltage battery
♦ Electric cutter -V.A.G 1561A-
♦ Scraper, 15 and 25 mm -V.A.G 1561/7+8-
♦ Blade, toothed, 19 -V.A.G 1561/28-
♦ Blade, toothed, 38 -V.A.G 1561/30-


♦ Adapter -VAS 6131/13-2- (4x) from supplementary kit, Audi

Q7 >2005 -VAS 6131/13-
♦ Guide pins -T40199-
♦ Butyl adhesive sealing cord ⇒ Electronic parts catalogue

♦ Polyurethane adhesive sealant -AKD 476 KD5 05-
Removing
– Remove side member trim (both sides) and underbody trim
(front and rear on both sides) ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Underbody trim; Exploded view - underbody
trim.
– Remove bolts -1- for underbody guard for high-voltage bat‐
tery 1 -AX2-.

– Remove inner bolts/nuts -arrow- for underbody guard for

high-voltage battery 1 -AX2-.
Note:
Bolts on outside edge of underbody guard remain screwed in at
this stage.
– Set up scissor-type assembly platform -VAS 6131B- as fol‐
lows:
Platform Parts from support set for Audi -VAS 6131/10-
coordinates and adapters -VAS 6131/13-2-
B3 /10-1 /10-4 /10-5 /13-2
G3 /10-1 /10-4 /10-5 /13-2
B13 /10-1 /10-4 /10-5 /13-2
C13 /10-1 /10-4 /10-5 /13-2
– Manoeuvre scissor-type assembly platform underneath un‐
derbody guard so it is in line with direction of travel. (Shown
without lifting platform and with wheels removed for illustra‐
tion purposes)
– Position support elements from -VAS 6131/10- and adapters

-VAS 6131/13-2- on both sides of underbody guard.
• Bolted connections must not be covered.
– Remove bolts -arrow- from outer edge of underbody guard.

• Scissor-type assembly platform remains in raised position.

To avoid damage to the coolant hoses located on the inside,
the following steps must be adhered to:
– Using electric cutter -V.A.G 1561A- -1- with blade, toothed,

19 -V.A.G 1561/28- -2-, cut through bond along outer edge
of underbody guard.
– Only use electric cutter -V.A.G 1561A- with blade, toothed,
38 -V.A.G 1561/30- at marked areas -arrows-.
Note:
♦ Opening joint with scrapers, e.g. from scraper set -VAS
6845- makes it easier to cut through bond.
♦ Select high speed for electric cutter.

– After cutting through bond, lower scissor-type assembly plat‐

form -VAS 6131B-.
– Detach underbody guard.
Installing
– If underbody guard for high-voltage battery 1 -AX2- is be‐

ing renewed, unclip plates on top of used underbody guard
-arrow-, and clip them onto new underbody guard.
– Trim adhesive bead using scraper, 25 mm -V.A.G 1561/8-;
do NOT remove it completely.
– Apply butyl adhesive sealing cord onto remaining adhesive
surrounding battery housing -arrow A-.
• The butyl adhesive sealing cord may become deformed dur‐

ing transport and storage. If this is the case, ensure butyl
adhesive sealing cord is positioned so that it is upright and it
is not twisted.
Note:
Trimmed sealing cord serves as template and provides orienta‐
tion.
– Apply a ring of polyurethane adhesive sealant -AKD 476
KD5 05- each at four holes for body bolts -arrows B-.
– Place underbody guard onto support elements on scissor-
type assembly platform -VAS 6131B-.
– Screw in guide pins -T40199- at four corners of high-voltage
battery and fit underbody guard.

– Carefully raise scissor-type assembly platform.

• Second mechanic required
– Fit underbody guard exactly on guide pins -T40199- on high-
voltage battery housing.
• Underbody guard must not be moved in transverse direction
after it has been positioned.
• If underbody guard has been moved in transverse direction,
butyl adhesive sealing cord must be removed and a new
butyl adhesive sealing cord must be applied.
– Screw in bolts -arrow- on outer edge of underbody guard
by hand and tighten them in stages: e-tron 50, item 31 in
exploded view ⇒ Item 31 (page 82) ; e-tron 55/e-tron S,
item 21 in exploded view ⇒ Item 21 (page 85) .
– Lower scissor-type assembly platform -VAS 6131B- and

move it out from underneath vehicle.
– Screw in bolts/nuts by hand and tighten.

Tightening torques
♦ -Item 1-: e-tron 50, item 31 in exploded view ⇒ Item 31
(page 11) ; e-tron 55, item 27 in exploded view ⇒ Item 27
(page 13) ; e-tron S: item 26 in exploded view ⇒ Item 26
(page 15)
♦ -Arrow-: e-tron 50, item 31 in exploded view ⇒ Item 31 (page
82) ; e-tron 55/e-tron S, item 21 in exploded view ⇒ Item 21
(page 85)
3.9 Removing and installing battery regula‐

tion control unit -J840-
Removing
– If renewing the control unit, select the “Replace control unit”
function for the appropriate control unit ⇒ Vehicle diagnostic
tester.
– Switch off the ignition and all electrical equipment and store
the ignition key outside the vehicle.
– Remove A-pillar trim (bottom) ⇒ General body repairs, inte‐
rior; Rep. gr. 70; Passenger compartment trim panels; Re‐
moving and installing A-pillar trim.
– Reach between glove box -4- and A-pillar -5- and unplug
electrical connector -1-.
– Carefully release fastener -arrow- and remove battery regu‐

lation control unit -2- from bracket -3-.
Installing
– Install A-pillar trim (bottom) ⇒ General body repairs, interior;
Rep. gr. 70; Passenger compartment trim panels; Removing
and installing A-pillar trim.
3.10 Removing and installing switching unit

for high-voltage battery -SX6-
• Required qualification for the following work: HVT, second
mechanic EIP



♦ Guide pin -T40199-
♦ Cover -T40420- (only required if a new switching unit for

high-voltage battery is not installed immediately after remov‐
al)
♦ Vacuum cleaner
♦ Cleaning solution -D 009 401 04-
♦ Grease ⇒ Electronic parts catalogue
Removing
DANGER
Danger of severe or fatal injury from electric shock or electric
arcs.
– The following work must only be performed by a qualified
Audi high-voltage technician (HVT).
– Remove high-voltage battery 1 -AX2- ⇒ page 37 .

• Battery regulation control unit -J840- is removed ⇒ page 72

Put on protective equipment before performing the following

work steps:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue
Further procedure:
CAUTION
It is possible to trigger pyrotechnic components unintentional‐
ly.
Risk of injury
– Never reach into housing for 12 Volt connector.
– Clean area around switching unit for high-voltage battery

-SX6- carefully with cleaning solution -D 009 401 04-, and
dry it.
• It is important that no dirt gets into opening of switching unit
for high-voltage battery -SX6-.
– Unbolt potential equalisation line at switching unit for high-
voltage battery -SX6- -arrow-.
– Unplug high-voltage wiring harness -2- at switching unit for

high-voltage battery -SX6-.
– e-tron S: Also unplug high-voltage wiring harness -1- at

switching unit for high-voltage battery -SX6-.
– To disconnect high-voltage wiring harness, release securing
clip -1- to side -arrow A- and swivel catch -2- for electrical
connector downwards in direction of -arrow B-.

– Remove bolts -1 ... 4-.
– Screw guide pins -T40199- into the four unused threaded

holes. (Illustration shows three of the guide pins.)
– Unscrew remaining bolts for switching unit for high-voltage

battery -SX6-.
– Remove swarf from threaded holes using a vacuum cleaner
-1-.

– With the help of a second mechanic, lift switching unit for

high-voltage battery -SX6- off high-voltage battery 1 -AX2-
-arrow-.
NOTICE
Risk of damage to electronic components due to improper
handling
– Never place switching unit for high-voltage battery down
with open side facing down.
– Without setting it down, turn switching unit for high-voltage

battery -SX6- over, and then set it down.

• Do not turn switching unit for high-voltage battery -SX6- over

above high-voltage battery to prevent short circuits if unit
falls.
• Open side -arrow- of switching unit faces upwards.
• Cover high-voltage connections with lint-free cloth.
DANGER
tric arcs.
– When renewing, install the new switching unit immediately
after removing the old one.
– Never leave the high-voltage battery unattended when the
switching unit is removed.
– Never insert tools into the openings in the high-voltage
battery when the switching unit is removed.
– Cover opening for switching unit for high-voltage battery -

SX6- in high-voltage battery 1 -AX2- immediately with cover
-T40420-.
Installing
• Renewing components ⇒ page 15
– Apply grease (⇒ Electronic parts catalogue) to area marked
in colour -arrow- outside seal -1-.

– Perform leak test for high-voltage battery ⇒ page 20 .

– Perform potential equalisation measurement on switching
unit for high-voltage battery -SX6-.
Procedure
• Use high-voltage diagnostics box -VAS 5581- with adapter
cable -VAS 5581/8-.
• To do so, connect battery regulation control unit -J840- to
adapter cable -VAS 5581/8-.
• Connect adapter cable -VAS 5581/8- at coolant temperature
sender 1 for high-voltage battery -G898- -1-.
• Connect short cable to 12 Volt connector on switching unit

for high-voltage battery -SX6-.
• Connect long cable to 12 Volt connector on battery housing
(level 2).

• Connect black earth terminal to earth on battery housing.

– Select Diagnosis mode and start this mode.
after the other:
♦ 0001 - Systems with diagnostic capability
♦ 008C - Hybrid battery management - J840
– Install high-voltage battery 1 -AX2- ⇒ page 37 .
Tightening torques
♦ ⇒ Fig. ““Switching unit for high-voltage battery -SX6- - tight‐
ening torque and sequence”“, page 16

4 High-voltage battery components

⇒ v4.1 iew - high-voltage battery”, page 80
⇒ v4.2 iew - high-voltage battery (level 2)”, page 90
⇒ o4.3 f fitting locations - battery modules”, page 92
⇒ o4.4 f fitting locations - battery connectors”, page 96
⇒ o4.5 f fitting locations - battery modules control units”, page
99
⇒ a4.6 nd classifying high-voltage battery 1AX2”, page 101
⇒ b4.7 attery modules, battery connectors and control units”,
page 103
⇒ r4.8 eplacement bolts for cover for battery housing”, page 103
⇒ a4.9 nd installing cover for battery housing”, page 104
⇒ a4.10 nd installing battery housing (level 2)”, page 125
⇒ b4.11 attery housing”, page 139
⇒ b4.12 attery module”, page 158
⇒ b4.13 attery module”, page 172
⇒ a4.14 nd installing battery modules control units”, page 181
⇒ e4.15 nergisation of high-voltage battery”, page 182
4.1 Exploded view - high-voltage battery

⇒ v4.1.2 iew - high-voltage battery, e-tron 55/e-tron S”, page
83
⇒ f4.1.3 or battery housing - applying sealant, e-tron 50/e-
tron 55/e-tron S”, page 85
⇒ f4.1.4 or battery housing - tightening torque and sequence,
e-tron 50”, page 87
⇒ f4.1.5 or battery housing (level 1) - tightening torque and
sequence, e-tron 55/e-tron S”, page 89

1 - O-ring
2 - Coolant connection
❑ With coolant tempera‐
ture sender 1 for high-
voltage battery -G898-
3 - Bolt
❑ 5 Nm
4 - Connection
❑ For ventilation between
battery housing and un‐
derbody guard
❑ 18 Nm
5 - Hose
❑ For ventilation between
battery housing and un‐
derbody guard
6 - Retainer
7 - Battery housing
8 - Sleeve
❑ 4x
❑ Press into battery hous‐
ing as far as stop
❑ Retaining elements/as‐
sembly aids for secur‐
ing bolts (centre) for
battery
9 - Connection
❑ For switching unit for
high-voltage battery -
SX6-
10 - Cover
❑ For battery housing
❑ Removing and installing ⇒ page 104
11 - Bolt
❑ Handling replacement bolts for cover for battery housing ⇒ page 103
❑ Tightening torque and sequence ⇒ page 87
12 - Bolt
13 - Bolt
14 - Bolt
15 - Bolt
16 - Damping element
4. High-voltage battery components 81

❑ 4x
17 - Bolt
❑ 2x
19 - Nut
❑ 3.5 Nm + 90°
20 - Nut
❑ 4x
❑ 8 Nm
❑ Apply sealing compound (⇒ Electronic parts catalogue) to nut and to gap between nut and housing for
12 Volt connection
21 - Housing
❑ For 12 Volt connection
22 - Gasket
23 - Bracket
24 - Bolt
❑ Tightening torque ⇒ Item 13 (page 10)
25 - Bolt
❑ 24 Nm
26 - Coolant pipe
27 - Bracket
❑ For coolant pipe
28 - O-ring
29 - Pressure equalisation valve
❑ 4x
❑ Apply grease (⇒ Electronic parts catalogue) to contact surface
30 - Underbody guard
31 - Securing bolts for underbody guard (outside)
❑ Working around circumference, tighten in stages
♦ Stage 1: 8 Nm
♦ Stage 2: 12 Nm
♦ Stage 3: 15 Nm
Securing nuts for underbody guard (inside)
❑ Tighten in stages
♦ Stage 1: 8 Nm
♦ Stage 2: 12 Nm

♦ Stage 3: 15 Nm
32 - Plates
❑ Clipped onto underbody guard
4.1.2 Exploded view - high-voltage battery, e-tron 55/e-tron S

1 - Connection
❑ For battery vent hole
2 - Battery vent hole
3 - Retainer
❑ For battery vent hole
4 - Battery housing (level 1)
5 - Sleeve
❑ 4x
❑ Press into battery hous‐
ing (level 1) as far as
stop
❑ Retaining elements/as‐
sembly aids for secur‐
ing bolts (centre) for
battery
6 - Connection
❑ For switching unit for
high-voltage battery -
SX6-
7 - Cover
(level 1)
ling ⇒ page 117
8 - Bolt
❑ Handling replacement
bolts for cover for bat‐
tery housing ⇒ page
103
❑ Tightening torque and
sequence ⇒ page 89
9 - Bolt
10 - Bolt
11 - Bolt
12 - Bolt
❑ 4x
14 - Bolt

❑ 2x
16 - O-ring
17 - Connecting line
❑ To level 2
18 - Nut
❑ 8 Nm
19 - Pressure equalisation valve
❑ 4x
❑ Apply grease (⇒ Electronic parts catalogue) to contact surface
20 - Underbody guard
21 - Securing bolts for underbody guard (outside)
❑ Working around circumference, tighten in stages
♦ Stage 1: 8 Nm
♦ Stage 2: 12 Nm
♦ Stage 3: 15 Nm
Securing nuts for underbody guard (inside)
❑ Tighten in stages
♦ Stage 1: 8 Nm
♦ Stage 2: 12 Nm
♦ Stage 3: 15 Nm
22 - Plates
❑ Clipped onto underbody guard
23 - Bolt
❑ 5 Nm
24 - O-ring
25 - Coolant connection
❑ With coolant temperature sender 1 for high-voltage battery -G898-
4.1.3 Cover for battery housing - applying sealant, e-tron 50/e-tron 55/e-tron S

1 - Butyl adhesive sealing

cord
❑ Can only be used once
❑ Routing ⇒ page 86
2 - Battery housing
3 - End of butyl adhesive
sealing cord
❑ Route so ends overlap
a - 5.8 mm
b - 10 mm
c - 11 mm
d - 9.2 mm
e - 28.6 mm
f - 13.3 mm
Routing butyl adhesive sealing cord
• Routing butyl adhesive sealing cord -arrows- at rear right:

• Routing butyl adhesive sealing cord -arrows- at rear left:

• Routing butyl adhesive sealing cord -arrows- at front right:
• Routing butyl adhesive sealing cord -arrows- at front left:
4.1.4 Cover for battery housing - tightening torque and sequence, e-tron 50

• Handling replacement bolts for cover for battery housing ⇒

r4.8 eplacement bolts for cover for battery housing”, page
103
Stage Bolts Tightening torque Note
1. -1- 1) 80 Nm Mask off area around bolts on cover for battery housing
to avoid paintwork being damaged by tools. Screw in
bolts by hand until they make contact.
2. -2- 1) 5.5 Nm + 90° Fit bolts by hand and screw in until they make contact.
3. -3- 24 Nm
4. -4- 5 Nm
5. -5- 8 Nm
6. -6- 8 Nm Remove cover -T40420-, screw in bolts and put cover
back on.
7. -7- 1) 5 Nm Fit bolts by hand and screw in until they make contact.
Torque of 5 Nm may be exceeded when screwing in bolts
until they make contact.


9. All outer cover 5 Nm Fit bolts by hand and screw in until they make contact.
bolts in clock‐ Torque of 5 Nm may be exceeded when screwing in bolts
wise sequence 1) until they make contact.
10. All outer cover 8 Nm
bolts in clock‐
wise sequence
1) Renew bolts after removing.
4.1.5 Cover for battery housing (level 1) - tightening torque and sequence,
e-tron 55/e-tron S
• Handling replacement bolts for cover for battery housing ⇒

page 103


1. -1- 1) 80 Nm Mask off area around bolts on cover for battery housing
to avoid paintwork being damaged by tools. Screw in
bolts by hand until they make contact.
2. -2- 1) 5.5 Nm + 90° Fit bolts by hand and screw in until they make contact.
3. -3- 5 Nm
4. -4- 8 Nm
7. All outer cover 5 Nm Fit bolts by hand and screw in until they make contact.
bolts in clockwise Torque of 5 Nm may be exceeded when screwing in bolts
sequence 1) until they make contact.
8. All outer cover 8 Nm
bolts in clockwise
sequence
1) Renew bolts after removing.
4.2 Exploded view - high-voltage battery (level 2)

The exploded view only applies to the e-tron 55 and the e-
tron S.

1 - Bolt
❑ 24 Nm
2 - Bracket
3 - Coolant hose
4 - Bolt
❑ 8 Nm
5 - Retainer
❑ For coolant hose
6 - Potential equalisation line
7 - Bolt
❑ 20 Nm
8 - Gasket
9 - Nut
❑ 8 Nm
10 - Battery housing
❑ Level 2
ling ⇒ page 125
11 - Bolt
❑ 5 Nm
12 - Cover
(level 2)
ling ⇒ page 113
13 - Stud
❑ 24 Nm
14 - Bolt
❑ 24 Nm
15 - Nut
❑ 8 Nm
16 - Gasket
17 - Coolant hose
18 - Bolt
❑ 8 Nm
19 - Retainer
❑ For coolant hose
20 - Nut
❑ 9 Nm

4.3 Overview of fitting locations - battery

modules
⇒ o4.3.1 f fitting locations - battery modules, e-tron 50”, page
92
⇒ o4.3.2 f fitting locations - battery modules, e-tron 55/e-tron S”,
page 94
4.3.1 Overview of fitting locations - battery modules, e-tron 50

• The battery modules must be re-installed in the same loca‐
tions.
• Some battery modules are fitted with standard layout of bat‐
tery terminals, some with mirrored layout ⇒ page 103 .
– Mark battery modules for re-installation with number and
arrow indicating direction of travel, as shown. Use a water‐
proof felt-tip pen for marking.

1 - Battery module 1 -J991-

10 - Battery module 10 -
J1000-
J1001-
J1002-
J1045-
J1046-
J1047-
J1048-
J1049-
J1077-
J1078-
Battery modules - tightening torque

• Renew bolts -arrows- after removing.

• Tighten bolts -arrows- in diagonal sequence to 9.5 Nm
+360°.
4.3.2 Overview of fitting locations - battery modules, e-tron 55/e-tron S

• The battery modules must be re-installed in the same loca‐
tions.
• Some battery modules are fitted with standard layout of bat‐
tery terminals, some with mirrored layout ⇒ page 103 .
– Mark battery modules for re-installation with number and ar‐
row indicating direction of travel (use waterproof felt-tip pen).


J1000-
J1001-
J1002-
J1045-
J1046-
J1047-
J1048-
J1049-
J1077-
J1078-


Battery modules - tightening torque
• Renew bolts -arrows- after removing.

• Tighten bolts -arrows- in diagonal sequence to 9.5 Nm
+360°.

connectors
⇒ o4.4.1 f fitting locations - battery connectors, e-tron 50”, page
96
⇒ o4.4.2 f fitting locations - battery connectors, e-tron 55/e-
tron S”, page 97
4.4.1 Overview of fitting locations - battery connectors, e-tron 50

• The battery connectors must be re-installed in the same lo‐
cations.
• The designation of the battery connector stems from the
numbering of the battery modules connected at this point.
• After removing battery connectors, bolts must be pressed
back until they engage.
• Do not touch bolts with your bare hands.
– Mark battery connectors for re-installation, as shown. Use a
waterproof felt-tip pen for marking.

A - Connection for switching

unit for high-voltage battery -
SX6-
❑ Tightening torque ⇒
Item 12 (page 81)
Battery connectors - tightening torque
– Tighten bolts -arrows- to 8 Nm.
4.4.2 Overview of fitting locations - battery connectors, e-tron 55/e-tron S

• The battery connectors must be re-installed in the same lo‐
cations.
• The designation of the battery connector stems from the
numbering of the battery modules connected at this point.

• After removing battery connectors, bolts must be pressed

back until they engage.
• Do not touch bolts with your bare hands.
– Mark battery connectors for re-installation, as shown (use
waterproof felt-tip pen).
A - Connection for switching

unit for high-voltage battery -
SX6-
Item 9 (page 84)
B - Connecting line to level 2
Item 18 (page 85)
Battery connectors - tightening torque
– Tighten bolts -arrows- to 8 Nm.


modules control units
⇒ o4.5.1 f fitting locations - battery modules control units, e-tron
50”, page 99
⇒ o4.5.2 f fitting locations - battery modules control units, e-
4.5.1 Overview of fitting locations - battery modules control units, e-tron 50

• The battery modules control units must be re-installed in the
same locations.
– Mark battery modules control units for re-installation, as
shown. Use a waterproof felt-tip pen for marking.
1 - Battery modules control

unit -J1208-
❑ For activating battery
modules 1, 2, 3
unit 2 -J1209-
modules 4, 5, 6
unit 3 -J1210-
modules 7, 8, 9
unit 4 -J1211-
modules 10, 11, 12
unit 5 -J1212-
modules 13, 14, 15
unit 6 -J1213-
modules 16, 17, 18
unit 7 -J1214-
modules 19, 20, 21
unit 8 -J1215-
modules 22, 23, 24
unit 9 -J1216-
❑ For activating battery modules 25, 26, 27

4.5.2 Overview of fitting locations - battery modules control units, e-tron 55/e-
tron S
same locations.
– Mark battery modules control units for re-installation, as
shown. Use a waterproof felt-tip pen for marking.

unit -J1208-
modules 1, 2, 3
unit 2 -J1209-
modules 4, 5, 6
unit 3 -J1210-
modules 7, 8, 9
unit 4 -J1211-
modules 10, 11, 12
unit 5 -J1212-
modules 13, 14, 15
unit 6 -J1213-
modules 16, 17, 18
unit 7 -J1214-
modules 19, 20, 21
unit 8 -J1215-
modules 22, 23, 24
unit 9 -J1216-
10 - Battery modules control unit 10 -J1217-

4.6 Inspecting and classifying high-voltage

battery 1 -AX2-

Procedure
CAUTION
Risk to health due to toxic vapours, dust and liquids.
– Never perform work on high-voltage batteries in which a
short circuit has occurred.
CAUTION
The high-voltage battery can become extremely hot. This can
cause injuries.
Take care not to burn your hands.
– Put on protective gloves.
High-voltage battery 1 -AX2- must be checked for:

♦ Cracks in housing or cover of high-voltage battery.
♦ Deformations in housing or cover of high-voltage battery.
♦ Temperature-induced discolourations and heat tinting on
housing
♦ Escaping electrolyte
♦ Damage to high-voltage contacts.
♦ Presence and legibility of information and warning labels
♦ Correct fitting of potential equalisation line.
♦ Corrosion damage
– After performing visual inspection, perform a classification of
high-voltage battery -AX2-.
High-voltage battery removed:

– Remove battery regulation control unit -J840- ⇒ page 72 and

connect it to adapter cable -VAS 5581/8-.

-SX6-.
– e-tron 50: Connect long cable of adapter cable -VAS 5581/8-

to housing for 12 Volt connector.
– e-tron 55/e-tron S: Connect long cable of adapter cable

-VAS 5581/8- to 12 Volt connector on battery housing (level
2).


High-voltage battery removed or installed:
tester.
♦ High-voltage
♦ 008C - Classification
4.7 Marking battery modules, battery con‐

nectors and control units
• A basic requirement for the high-voltage battery to function
properly is that the battery modules and control units are
refitted at the same location. To do this, mark the individual
battery modules and control units before removing them.
Identification
Various battery modules are fitted in level 1 of battery housing:
♦ Battery modules with standard layout of battery terminals
♦ Battery modules with mirrored layout of battery terminals
♦ Allocation of battery modules ⇒ Electronic parts catalogue
Marking the battery connectors makes assembly easier if sever‐
al or all battery modules are removed. Use a waterproof felt-tip
pen for marking.
♦ ⇒ o4.3 f fitting locations - battery modules”, page 92
♦ ⇒ o4.4 f fitting locations - battery connectors”, page 96
♦ ⇒ o4.5 f fitting locations - battery modules control units”,
page 99
4.8 Handling replacement bolts for cover

for battery housing
If a thread of the battery housing (level 1) is damaged, a re‐
placement bolt can be used; distinguishing features:
♦ Bolt used in series production: Torx head T25
♦ Replacement bolt: Torx head T30 5.4x20 ⇒ Electronic parts
catalogue

If a replacement bolt is identified when removing the cover for

battery housing (level 1), this bolt and its installation position
must be marked for re-installation.
• During installation, screw in marked replacement bolt in
marked threaded hole.
4.9 Removing and installing cover for bat‐

tery housing
⇒ a4.9.1 nd installing cover for battery housing - e-tron 50”,
page 104
⇒ a4.9.2 nd installing cover for battery housing (level 2) - e-
⇒ a4.9.3 nd installing cover for battery housing (level 1) - e-
4.9.1 Removing and installing cover for bat‐

tery housing - e-tron 50
• Required qualification for the following work: HVE, second
mechanic EIP
♦ High-voltage tool set -VAS 6762-
♦ Scraper no. 6 from scraper set -VAS 6845-

♦ Torque wrench -VAS 6883/1A-
♦ High-voltage tool set, Torx, 3/8 inch -VAS 691 003- (not
illustrated)
♦ Set of plastic wedges -VAS 852 015- (not illustrated)
♦ Vacuum cleaner
Removing
DANGER
arcs.
Audi high-voltage expert (HVE).
– Remove switching unit for high-voltage battery -SX6- ⇒ page

72 .

• Cover -T40420- fitted

Procedure:
– Carefully clean area surrounding battery housing using
cleaning solution -D 009 401 04- and dry it.
– Remove nut -3- and bolt -1-.
– Disconnect coolant hose -arrow-.

– Detach coolant pipe -4-.
– Remove bolt -arrow- on opposite side and detach bracket.
– Remove nuts -arrows- on housing for 12 Volt connection.
– Lift housing for 12 Volt connection and unplug electrical con‐

nector -arrow-.


work steps:
♦ Fabric gloves
♦ Safety goggles
• The second mechanic required to assist with installation
must put on the same protective equipment.
Further procedure:
– Pull off damping elements -arrows-.

– Mask off area around bolts -1- on cover for battery housing
to avoid paintwork being damaged by tools.

– Unscrew bolts -1- by hand.

– Unscrew bolts -2 ... 5- on cover for battery housing.
– Remove retaining bracket.
– Remove cover -T40420-, unscrew bolts -6- and put cover
back on.
– Unscrew all outer cover bolts -7, 8-.
– Pay attention to any replacement bolts ⇒ page 103 .
-1-.
CAUTION
Risk of damage to components of high-voltage battery due to
improper handling
Tools may damage the wiring harness at the location marked.
– Never apply tools at the location marked.
– Do not drive in wedges at the location marked -arrow-.

CAUTION
improper handling
– Only drive in wedges used to release cover for battery
housing up to maximum permissible penetration depth.
– Make a marking for penetration depth on each wedge from

set of plastic wedges -VAS 852 015-:
– Only drive in each wedge between battery housing and cov‐
er for battery housing up to marked penetration depth.
CAUTION
improper handling
– Do NOT drive in tools between housing wall and battery
frame.
– First lift cover for battery housing -1- at an easily accessible

point; to do so, apply wedge from set of plastic wedges
-VAS 852 015- between cover and housing wall -2-, keeping
wedge close to battery cover at all times.
• Wedge must not be applied between housing wall -2- and
battery frame -3-.

– Pull off outer butyl adhesive sealing cord -1- outwards

-arrow-.
– Lift cover for battery housing further (if necessary, use two
wedges from set of plastic wedges -VAS 852 015- to do so).
– If necessary, cut through adhesive using scraper no. 6 from
-VAS 6845-.
– Detach cover -T40420-.
– Detach cover for battery housing (level 1).
Installing
– Remove remaining sealant from battery housing and cover
for battery housing; to do so, press old butyl adhesive seal‐
ing cord together and use it to dab off remaining sealant.
– Clean sealing surfaces on battery housing and cover for
battery housing with cleaning solution -D 009 401 04- and
dry them off.
– Position butyl adhesive sealing cord on battery housing ⇒
page 85 .
is not twisted.
Routing butyl adhesive sealing cord -arrows- at rear right:
Routing butyl adhesive sealing cord -arrows- at rear left:

Routing butyl adhesive sealing cord -arrows- at front right:
Routing butyl adhesive sealing cord -arrows- at front left:
– Screw guide pins -T10341- into battery housing at locations

shown.

– Fit new O-rings -3-.

– With the help of a second mechanic, position cover -1- for
battery housing onto guide pins and onto housing -2- of
high-voltage battery.
– Make sure bolt holes align.
• Cover for battery housing must not be moved in transverse
direction after it has been positioned.
• If cover for battery housing has been moved in transverse
direction, butyl adhesive sealing cord must be removed and
a new butyl adhesive sealing cord must be applied.
Remaining installation steps are carried out in reverse se‐
quence; note the following:
– Tighten bolts for cover for battery housing ⇒ page 87 .
– Install switching unit for high-voltage battery -SX6- ⇒ page
72 .
– Apply sealing compound (⇒ Electronic parts catalogue) to
nuts -arrows- and to gaps between nuts and housing for 12
Volt connection.
– Check for leaks ⇒ b3.5.5 attery housing for leaks - e-tron

50”, page 25 .
Tightening torques
♦ ⇒ v3.1.1 iew - high-voltage battery, e-tron 50”, page 9
♦ ⇒ v4.1.1 iew - high-voltage battery, e-tron 50”, page 80


tery housing (level 2) - e-tron 55/e-
tron S
mechanic EIP

♦ Vacuum cleaner
Removing
work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
– Remove studs -arrows-.

– Move electrical wiring harness to electric drive motor for rear

axle -V663- clear.
– e-tron S: Move electrical wiring harness to electric drive mo‐
tor 2 for rear axle -V648- clear.
– Remove bolts on cover -arrow- for battery housing (level 2).

-1-.

CAUTION
improper handling
– Only drive in wedge used to release cover for battery
– Make a marking for penetration depth on wedge from set of

plastic wedges -VAS 852 015-:
– Only drive in wedge between battery housing and cover for
battery housing up to marked penetration depth.
– Raise cover for battery housing (level 2) with a wedge from
set of plastic wedges -VAS 852 015-.
– If necessary, cut through adhesive using scraper from -VAS

6845-.
Installing
dry them off.
– Position butyl adhesive sealing cord -1- in battery housing,
starting at wide part -arrow- of groove -2-.

– Position ends of butyl adhesive sealing cord at wide part of

groove so that they overlap.
is not twisted.

battery housing (level 2) onto housing of high-voltage bat‐
tery, making sure it fits correctly.
– Insert bolts -1, 2-.

– Tighten remaining bolted connections for cover for battery

housing in sequence indicated by -arrows 3 … 6-.
– Tighten studs -arrows-.
– Secure electrical wiring harness to electric drive motor for

rear axle -V663-.
– e-tron S: Secure electrical wiring harness to electric drive
motor 2 for rear axle -V648-.
– Check battery housing (levels 1 and 2) for leaks ⇒ page 28 .
Tightening torques
♦ ⇒ v4.2 iew - high-voltage battery (level 2)”, page 90

tery housing (level 1) - e-tron 55/e-
tron S
mechanic EIP

illustrated)
♦ Vacuum cleaner


Removing
DANGER
arcs.
– Remove switching unit for high-voltage battery -SX6- ⇒ page

72 .
• Cover -T40420- fitted

– Remove battery housing (level 2) ⇒ page 125 .
• Sealing pieces -T40422- fitted

work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
– Pull off damping elements -arrows-.

– Mask off area around bolts -1- on cover for battery housing
to avoid paintwork being damaged by tools.
– Unscrew bolts -1- by hand.

– Unscrew bolts -2 … 4- and all outer cover bolts -5, 6- on
cover for battery housing (level 1).
– Pay attention to any replacement bolts ⇒ page 103 .
-1-.

CAUTION
improper handling
Tools may damage the wiring harness at the location marked.
– Never apply tools at the location marked.
– Do not drive in wedges at the location marked -arrow-.

CAUTION
improper handling
– Only drive in wedges used to release cover for battery
– Make a marking for penetration depth on each wedge from

set of plastic wedges -VAS 852 015-:
– Only drive in each wedge between battery housing and cov‐
er for battery housing up to marked penetration depth.
CAUTION
improper handling
– Do NOT drive in tools between housing wall and battery
frame.
– First lift cover for battery housing -1- at an easily accessible

point; to do so, apply wedge from set of plastic wedges
-VAS 852 015- between cover and housing wall -2-, keeping
wedge close to battery cover at all times.
• Wedge must not be applied between housing wall -2- and
battery frame -3-.
– Pull off outer butyl adhesive sealing cord -1- outwards
-arrow-.

– Lift cover for battery housing further (if necessary, use two
wedges from set of plastic wedges -VAS 852 015- to do so).
– If necessary, cut through adhesive using scraper from -VAS
6845-.
– Detach cover -T40420-.
Installing
dry them off.
– Position butyl adhesive sealing cord on battery housing ⇒
page 85 .
is not twisted.
Routing butyl adhesive sealing cord -arrows- at rear right:
Routing butyl adhesive sealing cord -arrows- at rear left:

Routing butyl adhesive sealing cord -arrows- at front right:
Routing butyl adhesive sealing cord -arrows- at front left:
– Screw guide pins -T10341- into battery housing at locations

shown.

– Fit new O-rings -3-.

battery housing (level 1) onto guide pins and onto housing
-2- of high-voltage battery.
– Make sure bolt holes align.
– Tighten bolts for cover for battery housing (level 1) ⇒ page
89 .
– Install switching unit for high-voltage battery -SX6- ⇒ page
72 .
– Check battery housing (level 1) for leaks ⇒ page 28 .
– Install battery housing (level 2) ⇒ page 125 .
– Check battery housing (levels 1 and 2) for leaks ⇒ page 28 .
4.10 Removing and installing battery hous‐

ing (level 2)
The procedure only applies to the e-tron 55 and the e-tron S.


♦ Workshop hoist -VAS 6100-

illustrated)
♦ Shackle, 10 mm -VAS 691 009A- (4x), not illustrated

WARNING
Risk of injury if battery housing drops when it is lifted
– Use only specified special tools to lift battery housing.
♦ Suspension ring -VAS 501 013- (not illustrated)

♦ Swivel bolts -VAS 691 013- (2x, not illustrated)
♦ Swivel bolts -VAS 691 015- (2x, not illustrated)
♦ Retaining strap -T40155- (2x)
♦ Contact protection -T40421-
♦ Seal -T40422-
♦ Vacuum cleaner

Removing
DANGER
arcs.

– Move coolant hoses clear.

– Remove cover for battery housing (level 2) ⇒ page 113 .
properly is that the battery modules are refitted at the same
location. To do this, number the individual battery modules
according to the overview of fitting locations before removing
them ⇒ page 103 .
NOTICE
Risk of damage to corresponding battery modules control unit
due to voltage differences.
– It is essential to keep to the sequence of steps described.

DANGER
arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– Carry out visual inspection of personal protective equip‐
ment (PPE). The personal protective equipment must be
dry and undamaged.
– The following steps require a second suitably qualified per‐
son to be present to supervise.
– The second person may only assist the high-voltage ex‐
pert where required to the extent of his/her qualification.
– Persons without the appropriate qualification are not per‐
mitted to work actively on an open battery if sufficient con‐
tact protection is not in place.
– Always follow country-specific laws and regulations (e.g.
first aid training).

work steps:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 1 up to 158 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 550 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 550kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
Further procedure:
– Unplug 32-pin connector from battery modules control unit 6
-J1213- and battery modules control unit 7 -J1214- ⇒ page
100 .
– Mark ⇒ page 103 and remove battery connectors 15-16 and
20-21 -arrows-.
– Press back bolts for battery connectors.

– Remove swarf from threaded holes on battery connectors
using a vacuum cleaner -1-.

CAUTION
Danger from poor contact due to grease at contact surfaces
– Do NOT touch contact surfaces of battery connectors with
bare hands.
– Immediately clean battery connectors that have come into
contact with grease.
– Use cleaning solution -D 009 401 04- to clean battery con‐

nectors that have come into contact with grease.
– Immediately after removing battery connectors, fit contact
protection -T40421- at free contact surfaces of battery mod‐
ules.
– Make contact protection at contact surfaces of connecting

line using insulating tape -arrow-.

– Mark ⇒ page 103 and remove battery connector 17-18

-arrows-.

– Immediately after removing battery connectors, fit contact

protection -T40421- at free contact surfaces of battery mod‐
ules.

DANGER
arcs.
– Carry out visual inspection of high-voltage battery to en‐
sure there is sufficient contact protection.
– Check high-voltage battery has sufficient contact protection.

– Take off protective equipment worn up to now.
work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
– Remove nuts -arrows-.

– Disconnect diagnostic cable -1-.
– To do so, release connector locking mechanism -arrow A-,
press down fastener -1- and unplug connector -arrow B-.

– To avoid damage when lifting off battery housing (level 2),

tie electrical connector -1- up to connecting line with a cable
tie -arrow-.
– Unplug connector -1- to battery modules control units.
– Remove nuts -arrows-.

– Unbolt potential equalisation line -2-.

– Disconnect coolant hoses -1, 3-.

– Screw swivel bolts -VAS 691 013- into empty threaded holes
at rear of battery housing (level 2) and tighten to 10 Nm.
– Screw swivel bolts -VAS 691 015- into empty threaded holes
at front of battery housing (level 2) and tighten to 10 Nm.
– Hook suspension ring -VAS 501 013- into workshop hoist

-VAS 6100-.
– Guide retaining straps -T40155- through suspension ring.

WARNING
Risk of injury if battery housing drops when it is lifted
– Use only specified special tools to lift battery housing.
– Secure retaining straps to swivel bolts using shackles -VAS

691 009A-.
– Carefully lift off battery housing.
– Set battery housing down on a large flat surface.
• The surface must be large enough that battery housing (lev‐
el 2) can rest on the 4 »feet« with which it is bolted onto
battery housing (level 1).
– Immediately after setting battery housing (level 2) down, seal
off openings in level 1 with sealing pieces -T40422-.
Installing

– Detach sealing pieces -T40422-.
– Fit seals -1, 3- in bottom of battery housing (level 2) -item 2-.

– Carefully fit battery housing.

– Tighten bolts -arrows-.
– Connect coolant hoses -1, 3-.

– Tighten bolt -2- for potential equalisation line.
DANGER
arcs.
dry and undamaged.


work steps:
ing)
effect up to 500 V
Further procedure:
– Before fitting battery connectors, measure voltage between

battery terminals to be connected using voltage tester -VAS
6762/45-.
– When performing measurement before fitting last battery
connector, a voltage can be measured when switching unit
for high-voltage battery -SX6- is installed. In this case, a
load can be applied by pressing both buttons on voltage
tester -VAS 6762/45-. If voltage tester -VAS 6762/45- no
longer shows any voltage with load applied, work may be
continued.
DANGER
Danger of severe or fatal injury caused by short circuit with
electric arc.
– Do NOT continue procedure if voltage can be measured
between battery terminals. Determine and eliminate fault.
– Only continue procedure if system is de-energised.
– Fit and secure battery connector 17-18 -arrows-.

DANGER
Danger from possible electric arc
– To increase distance between hand and battery connector,
use pliers with protective insulation from high-voltage tool
set to apply battery connector.
– Apply battery connector “20-21” using pliers from high-volt‐

age tool set -VAS 6762- and secure.
– Plug in 32-pin connector on battery modules control unit 6
-J1213- and battery modules control unit 7 -J1214-.
– Perform provisional energisation ⇒ page 182 .
tester.
♦ High-voltage

Tightening torques
♦ ⇒ v4.2 iew - high-voltage battery (level 2)”, page 90
4.11 Renewing battery housing

⇒ b4.11.1 attery housing - e-tron 50”, page 139
⇒ b4.11.2 attery housing (level 1) - e-tron 55/e-tron S”, page
147
⇒ b4.11.3 attery housing (level 2) - e-tron 55/e-tron S”, page
156
4.11.1 Renewing battery housing - e-tron 50

♦ Voltage tester -VAS 6762/45-
♦ Vacuum cleaner
Procedure
To renew battery housing, all components in the old battery
housing must be transferred to the new housing. Use a water‐
– Remove cover for battery housing ⇒ page 104 .
Before transferring components:
• To make sure components can be installed at original posi‐
tions, make sketches or take pictures of installation positions
of individual components, especially of routing of electrical
wiring.
• Mark all battery modules ⇒ page 92 .
• Mark all battery connectors ⇒ page 96 .
• Mark all battery modules control units ⇒ page 99 .

– Remove battery modules control units ⇒ page 181 .

– Unclip brackets for battery modules control units.
DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V
Further procedure:

– To reduce total voltage of high-voltage battery, first remove

the following battery connectors:
♦ Battery connector 9-10
– Immediately fit contact protection -T40421- at battery mod‐

ule to be removed and at adjacent battery modules.
CAUTION
bare hands.

– Coat and protective hood approved for working with electric
arcs can now be taken off.
– To reduce total voltage of high-voltage battery to beneath 60
V, remove the following battery connectors:


– Fit contact protection -T40421- at free contact surfaces of

battery modules.

DANGER
arcs.

work steps:
♦ Fabric gloves
♦ Safety goggles
Installing
Due to the low individual voltage of battery modules, contact
protection does not have to be fitted at these contact surfaces.
– Remove battery connectors. Remove battery modules indi‐
vidually ⇒ page 158 and install in new battery housing at the
same locations ⇒ page 172 according to following method:
Se‐ Remove battery connec‐ Remove and install bat‐
quence tors tery modules
1. 1-2, 2-3 1, 2, 3
2. 4-5, 5-6 4, 5, 6
3. 7-8, 8-9 7, 8, 9
4. 10-11, 11-12 10, 11, 12
5. 13-14, 14-15 13, 14, 15
6. 16-17, 17-18 16, 17, 18
7. 19-20, 20-21 19, 20, 21
8. 22-23, 23-24 22, 23, 24
9. 25-26, 26-27 25, 26, 27

DANGER
arcs.
dry and undamaged.

work steps:
♦ Helmet with visor approved for working with electric arcs,
min. protective effect of 320 kJ
effect up to 500 V
Further procedure:

6762/45-.


continued.
DANGER
electric arc.
– Secure the following battery connectors:


DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V
Further procedure:


6762/45-.
continued.
DANGER
electric arc.
– Secure further battery connectors:

work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
– Clip on brackets for battery modules control units.
– Install battery modules control units ⇒ page 181 .
Tightening torques
♦ ⇒ Fig. ““Battery modules - tightening torque”“, page 93
♦ ⇒ Fig. ““Battery connectors - tightening torque”“, page 97
4.11.2 Renewing battery housing (level 1) -

e-tron 55/e-tron S

♦ Vacuum cleaner
Procedure
wiring.
DANGER
arcs.
dry and undamaged.


work steps:
ing)
effect up to 500 V
Further procedure:
– To reduce total voltage of high-voltage battery, first remove

the following battery connectors:

– Immediately fit contact protection -T40421- at battery mod‐

ule to be removed and at adjacent battery modules.
CAUTION
bare hands.

– Coat and protective hood approved for working with electric
arcs can now be taken off.
– Remove connection for switching unit for high-voltage bat‐
tery -SX6- -item A- and connecting line to level 2 -item B-.

– To reduce total voltage of high-voltage battery to beneath 60

V, remove the following battery connectors:
– Fit contact protection -T40421- at free contact surfaces of

battery modules.


work steps:
♦ Fabric gloves
♦ Safety goggles
Installing
– Remove battery connectors. Remove battery modules indi‐
vidually ⇒ page 165 and install in new battery housing at the
same locations ⇒ page 176 according to following method:
Se‐ Remove battery connec‐ Remove and install bat‐
quence tors tery modules
1. 1-2, 2-3 1, 2, 3
2. 4-5, 5-6 4, 5, 6
3. 7-8, 8-9 7, 8, 9
4. 10-11, 11-12 10, 11, 12
5. 13-14, 14-15 13, 14, 15
6. - 21 individually
7. 22-23, 23-24 22, 23, 24
8. 25-26, 26-27 25, 26, 27
9. 28-29, 29-30 28, 29, 30
10. 31-32, 32-33 31, 32, 33
11. 34-35, 35-36 34, 35, 36

DANGER
arcs.
dry and undamaged.

work steps:
♦ Helmet with visor approved for working with electric arcs,
min. protective effect of 320 kJ
effect up to 500 V
Further procedure:

6762/45-.


continued.
DANGER
electric arc.

– Install connection for switching unit for high-voltage battery
-SX6- -item A- and connecting line to level 2 -item B-.

DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V
Further procedure:


6762/45-.
continued.
DANGER
electric arc.
– Secure further battery connectors:

work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
Tightening torques
4.11.3 Renewing battery housing (level 2) -

e-tron 55/e-tron S
Procedure
work steps:
♦ Fabric gloves
♦ Safety goggles


wiring.
CAUTION
bare hands.

– Remove remaining battery connectors.
Installing
– Remove battery modules individually ⇒ page 165 and install
in new battery housing at the same locations ⇒ page 176 .


Tightening torques
4.12 Removing battery module

⇒ b4.12.1 attery module - e-tron 50”, page 158
⇒ b4.12.2 attery module - e-tron 55/e-tron S”, page 165
4.12.1 Removing battery module - e-tron 50


illustrated)
♦ Module release tool -T40424-
♦ Plastic scraper (commercially available)

♦ Vacuum cleaner
Removing
DANGER
arcs.
• If a battery module needs to be renewed, the mean cell

voltage of the high-voltage battery must be determined first
⇒ page 17 .

• A new battery module must be charged or discharged ac‐

cording to the result of the mean cell voltage calculation
before installing ⇒ page 19 .
– Remove cover for battery housing ⇒ page 104 .
them.
– Mark battery modules for re-installation ⇒ page 103 .
DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V

Further procedure:
NOTICE
– Unplug 32-pin connector from corresponding battery mod‐

ules control unit ⇒ page 100 .
– Unplug electrical connector from battery module to be re‐
moved. To do so, release connector locking mechanism
-arrow A-, press down fastener -arrow B- and unplug con‐
nector.
– Mark battery connectors for re-installation ⇒ page 103 .
– Remove battery connectors on both sides of battery module

to be removed -arrows-.

CAUTION
– Do NOT touch contact surfaces of battery connectors or
battery terminals of battery modules with bare hands.
– Immediately clean contact surfaces that have come into
– Use cleaning solution -D 009 401 04- to clean contact surfa‐

ces that have come into contact with grease.
– Fit contact protection -T40421- at battery module to be re‐
moved and at adjacent battery modules.
work steps:
♦ Fabric gloves
♦ Safety goggles

Further procedure:
– Unscrew bolts -arrows- for battery module.

– Fit hooks -T40424/1- on clamping piece from module re‐
lease tool -T40424- ⇒ Operating instructions for module re‐
lease tool -T40424-.
– Secure clamping piece from module release tool -T40424- to

battery module to be removed.
• Hooks -arrows- of clamping piece must engage in housing
ribs on front and rear of battery module.
– Clamp hooks hand-tight using knurled screw -1-.
– Connect support bridge from module release tool -T40424-
to clamping piece using pin -2-.

– If necessary, compensate for difference in height with plastic

feet -T40424/3- (supplied with release tool) ⇒ Operating in‐
structions for module release tool -T40424-.
WARNING
Risk of injury due to use of incorrect tools.
– Do NOT use a workshop hoist to release the battery mod‐
ule from the heat conductor paste.
– Slowly and carefully release battery module from heat con‐

ductor paste using spindle -1- with maximum of 7 Nm.
Note:
If the battery module cannot be released, check whether all
bolts have been removed from the battery module and repeat
the releasing procedure.
– After releasing, lower battery module again and detach sup‐
port bridge.
– Take hold of battery module by grip and lift it out of battery
housing.
Note:
Alternatively, the previously released battery module can be
lifted out using the workshop hoist -VAS 6100- by removing
the grip and fitting the swivel bolt -VAS 691 013- (tightening
torque: 10 Nm) ⇒ Operating instructions for module release tool
-T40424-.
– Detach battery module and set it down on clean, lint-free
surface.
Note
The heat conductor paste contains silicone; contact with bond‐

ing surfaces must therefore be avoided.
– Remove remnants of heat conductor paste on battery mod‐

ule with cleaning solution -D 009 401 04-.
– Remove remnants of heat conductor paste in mounting in
battery housing with plastic scraper (commercially available).

– Clean mounting in battery housing with cleaning solution -D

009 401 04-.
– Remove swarf from threaded holes for bolted connections
for modules using a vacuum cleaner -1-.
4.12.2 Removing battery module - e-tron

55/e-tron S

illustrated)
♦ Module release tool -T40424-
♦ Plastic scraper (commercially available)

♦ Vacuum cleaner
Removing
• If a battery module needs to be renewed, the mean cell
voltage of the high-voltage battery must be determined first
⇒ page 17 .
Removing battery module (level 2):

Removing battery module (level 1):

them.
– Mark battery modules for re-installation ⇒ page 103 .
DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V
Further procedure:
The procedure for removing a battery module from level 2 is
described here as an example.
NOTICE
– Unplug 32-pin connector from corresponding battery mod‐

ules control unit ⇒ page 100 .
– Unplug electrical connector from battery module to be re‐
moved. To do so, release connector locking mechanism

-arrow A-, press down fastener -1- and unplug connector

-arrow B-.
– Mark battery connectors for re-installation ⇒ page 103 .
– Remove battery connectors on both sides of battery module

to be removed -arrows-.

CAUTION
– Do NOT touch contact surfaces of battery connectors or
battery terminals of battery modules with bare hands.
– Immediately clean contact surfaces that have come into
– Use cleaning solution -D 009 401 04- to clean contact surfa‐

ces that have come into contact with grease.
– Fit contact protection -T40421- at battery module to be re‐
moved and at adjacent battery modules.
work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
– Unscrew bolts -arrows- for battery module.

– Fit hooks -T40424/1- on clamping piece from module re‐
lease tool -T40424- ⇒ Operating instructions for module re‐
lease tool -T40424-.

– Secure clamping piece from module release tool -T40424- to

battery module to be removed.
• Hooks -arrows- of clamping piece must engage in housing
ribs on front and rear of battery module.
– Clamp hooks hand-tight using knurled screw -1-.
– Connect support bridge from module release tool -T40424-
to clamping piece using pin -2-.
– If necessary, compensate for difference in height with plastic

feet -T40424/3- (supplied with release tool) ⇒ Operating in‐
structions for module release tool -T40424-.
WARNING
Risk of injury due to use of incorrect tools.
– Do NOT use a workshop hoist to release the battery mod‐
ule from the heat conductor paste.
– Slowly and carefully release battery module from heat con‐

ductor paste using spindle -1- with maximum of 7 Nm.

Note:
If the battery module cannot be released, check whether all
bolts have been removed from the battery module and repeat
the releasing procedure.
– After releasing, lower battery module again and detach sup‐
port bridge.
– Take hold of battery module by grip and lift it out of battery
housing.
Note:
Alternatively, the previously released battery module can be
lifted out using the workshop hoist -VAS 6100- by removing
the grip and fitting the swivel bolt -VAS 691 013- (tightening
torque: 10 Nm) ⇒ Operating instructions for module release tool
-T40424-.
– Detach battery module and set it down on clean, lint-free
surface.
Note

– Remove remnants of heat conductor paste on battery mod‐

ule with cleaning solution -D 009 401 04-.
– Remove remnants of heat conductor paste in mounting in
battery housing with plastic scraper (commercially available).
– Clean mounting in battery housing with cleaning solution -D

009 401 04-.
– Remove swarf from threaded holes for bolted connections
for modules using a vacuum cleaner -1-.

4.13 Installing battery module

⇒ b4.13.1 attery module - e-tron 50”, page 172
⇒ b4.13.2 attery module - e-tron 55/e-tron S”, page 176
4.13.1 Installing battery module - e-tron 50

♦ 2-component heat conductor paste ⇒ Electronic parts cata‐
logue
♦ Applicator -VAS 891 005-
Installing
DANGER
arcs.

work steps:
♦ Fabric gloves
♦ Safety goggles

Note

– Screw static mixer supplied onto 2-component heat conduc‐

tor paste and insert cartridges into applicator -VAS 891 005-.
– Apply the amount of 2-component heat conductor paste that
corresponds to the content of a static mixer onto a piece
of paper and dispose of it. This ensures that the two compo‐
nents of the 2-component heat conductor paste are properly
mixed.
– Apply the specified amount of 2-component heat conductor
paste to the battery housing in a double T shape using appli‐
cator -VAS 891 005-.
– Amount applied can be read off scale on applicator -VAS
891 005-.
♦ 180 ml of heat conductor paste
– Insert battery module in battery housing according to mark
made during removal within 60 minutes.
– Tighten bolts -arrows- for battery module in diagonal se‐
quence and in stages ⇒ page 93 .
– Before performing further assembly steps, check that battery

module is in correct installation position:

• The battery module is installed correctly if the battery con‐

nector can connect the positive and negative terminals of the
battery modules -arrows-.
DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V

Further procedure
NOTICE
– Detach contact protection -T40421- from installed battery

module and from adjacent battery modules.

6762/45-.

continued.

DANGER
electric arc.
– If voltage measurement is OK, fit battery connectors

-arrows- immediately.

work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
NOTICE
– Fit electrical connector on battery module and lock it.

– Plug 32-pin connector into corresponding battery modules
control unit ⇒ page 100 .
– Install cover for battery housing ⇒ page 104 .
Tightening torques
4.13.2 Installing battery module - e-tron 55/e-

tron S
♦ 2-component heat conductor paste ⇒ Electronic parts cata‐
logue

♦ Applicator -VAS 891 005-

Installing
DANGER
arcs.

work steps:
♦ Fabric gloves
♦ Safety goggles
The procedure for installing a battery module from level 2 is
described here as an example.
Note

– Screw static mixer supplied onto 2-component heat conduc‐

tor paste and insert cartridges into applicator -VAS 891 005-.
– Apply the amount of 2-component heat conductor paste that
corresponds to the content of a static mixer onto a piece
of paper and dispose of it. This ensures that the two compo‐
nents of the 2-component heat conductor paste are properly
mixed.
– Apply the specified amount of 2-component heat conductor
paste to the battery housing in a double T shape using appli‐
cator -VAS 891 005-.
– Amount applied can be read off scale on applicator -VAS
891 005-.
Battery module manufactured by LG Chem:
♦ Level 1: 160 ml of 2-component heat conductor paste


Battery module manufactured by Samsung SDI:
– Insert battery module in battery housing according to mark
made during removal within 60 minutes.
– Tighten bolts -arrows- for battery module in diagonal se‐
quence and in stages ⇒ page 96 .
– Before performing further assembly steps, check that battery

module is in correct installation position:
• The battery module is installed correctly if the battery con‐

nector can connect the positive and negative terminals of the
battery modules -arrows-.

DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V
Further procedure
NOTICE
– Detach contact protection -T40421- from installed battery

module and from adjacent battery modules.


6762/45-.

continued.
DANGER
electric arc.
– If voltage measurement is OK, fit battery connectors

-arrows- immediately.

work steps:
♦ Fabric gloves

♦ Safety goggles
Further procedure:
NOTICE

Battery module (level 2) installed:
– Install cover for battery housing (level 2) ⇒ page 113 .
Battery module (level 1) installed:
– Install cover for battery housing (level 1) ⇒ page 104 .
Tightening torques
4.14 Removing and installing battery mod‐

ules control units
Removing
– If renewing the control unit, select the “Replace control unit”
function for the appropriate control unit ⇒ Vehicle diagnostic
tester.
same locations.
– If several battery modules control units are to be removed,
mark them for re-installation ⇒ page 103 .
work steps:
♦ Fabric gloves
♦ Safety goggles
Further procedure:
Preparatory work depending on fitting location and number of
battery modules control units:
– Remove cover for battery housing:
♦ ⇒ a4.9.1 nd installing cover for battery housing - e-tron 50”,
page 104
♦ ⇒ a4.9.3 nd installing cover for battery housing (level 1) -
e-tron 55/e-tron S”, page 117
♦ ⇒ a4.9.2 nd installing cover for battery housing (level 2) -

– Release and unplug electrical connectors -1, 2-.
– Using a small screwdriver, release retaining catches

-arrows- and take battery modules control unit out of brack‐
et.
Installing
• If one or more battery modules control units are renewed,
they must be re-addressed before installing the cover for
battery housing as part of the provisional energisation.
4.15 Provisional energisation of high-volt‐

age battery
⇒ e4.15.1 nergisation of high-voltage battery - test equipment,
e-tron 50”, page 182
⇒ e4.15.2 nergisation of high-voltage battery - e-tron 50”, page
183
⇒ e4.15.3 nergisation of high-voltage battery - test equipment,
⇒ e4.15.4 nergisation of high-voltage battery - e-tron 55/e-
tron S”, page 187
4.15.1 Provisional energisation of high-voltage battery - test equipment, e-tron

50

1 - Coolant temperature send‐

er 1 for high-voltage battery
-G898-
• Adapter cable -VAS
5581/8- connected to cool‐
ant temperature sender 1
for high-voltage battery -
G898-
AX2-
• Cover for battery housing
removed
• Battery modules and bat‐
tery modules control units
connected
• Observe warnings and
procedure ⇒ page 183
• Set down upside-down
next to high-voltage bat‐
tery 1 -AX2- on stable sur‐
face on top of insulating
mat -VAS 6762/44-
• Short cable of adapter ca‐
ble -VAS 5581/8- connec‐
ted to 12 Volt connector on
switching unit for high-volt‐
age battery -SX6-
4 - Housing for 12 Volt con‐
nection
• Placed on top of high-volt‐
age battery 1 -AX2-
• Connected to 12 Volt con‐
nection of high-voltage battery 1 -AX2-
• Long cable of adapter cable -VAS 5581/8- connected to 12 Volt connector
4.15.2 Provisional energisation of high-volt‐

age battery - e-tron 50
• Provisional energisation of the high-voltage battery should
be performed before finally bonding on the battery cover in
order to check the electrical function of control units and
battery modules. The cover for battery housing remains re‐
moved during this procedure.


Procedure
ble -VAS 5581/8-.
– Set up test equipment ⇒ e4.15.1 nergisation of high-voltage
battery - test equipment, e-tron 50”, page 182 ; when doing
so, proceed as follows and observe warnings:
DANGER
arcs.

– Set down switching unit for high-voltage battery -SX6- up‐
side-down next to high-voltage battery 1 -AX2- on stable
surface on top of insulating mat -VAS 6762/44-.
• The open side of the switching unit must face upwards.

-SX6-.
– Connect adapter cable -VAS 5581/8- to coolant temperature

– Connect housing for 12 Volt connector to 12 Volt connection

of high-voltage battery 1 -AX2-.
– Connect long cable of adapter cable -VAS 5581/8- to hous‐

ing for 12 Volt connector.
tester.
after the other:
– Start selected program, select program point Generate
battery overview and follow instructions on display of ve‐
hicle diagnostic tester.
– If electrical function of battery is OK, select program point
Module addressing and follow instructions on display of
If electrical function is OK, assemble high-voltage battery com‐
pletely:
♦ Install cover for battery housing ⇒ page 104 .
♦ Check high-voltage battery for leaks ⇒ page 25 .
4.15.3 Provisional energisation of high-voltage battery - test equipment, e-

tron 55/e-tron S

1 - Coolant temperature send‐

er 1 for high-voltage battery
-G898-
• Adapter cable -VAS
5581/8- connected to cool‐
ant temperature sender 1
for high-voltage battery -
G898-
AX2- (level 1)
• Cover for battery housing
removed
• Battery modules and bat‐
tery modules control units
connected
• Observe warnings and
procedure ⇒ page 187
• Set down upside-down
next to high-voltage bat‐
tery 1 -AX2- on stable sur‐
face on top of insulating
mat -VAS 6762/44-
• Short cable of adapter ca‐
ted to 12 Volt connector on
switching unit for high-volt‐
age battery -SX6-
4 - 12 Volt connector
❑ On rear of battery
housing (level 2)
• Long cable of adapter ca‐
ted to 12 Volt connector on battery housing (level 2)
5 - Battery connector 17-18
• Inserted in level 2
Observe warnings and procedure ⇒ page 187
6 - Battery connectors 15-16 and 20-21
• Inserted in level 2
• Observe warnings and procedure ⇒ page 187
7 - Diagnostic cable
❑ Connection between levels 1 and 2
❑ Observe connection sequence ⇒ page 190
8 - High-voltage battery 1 -AX2- (level 2)
• Cover for battery housing (level 2) removed
• Battery modules and battery modules control units connected
• Secured with 2 bolts -arrows-
• Observe warnings and procedure ⇒ page 187

4.15.4 Provisional energisation of high-volt‐

age battery - e-tron 55/e-tron S
• Provisional energisation of the high-voltage battery should
be performed before finally bonding on the battery covers
in order to check the electrical function of control units and
battery modules. The covers for battery housing remain re‐
moved during this procedure.
• If only components from level 2 of high-voltage battery 1
-AX2- were removed and installed as part of the repair work
performed beforehand, contrary to the description provided
here, the cover for level 1 should remain closed and the
switching unit for high-voltage battery -SX6- should remain
installed.

Procedure
ble -VAS 5581/8-.
– Set up test equipment ⇒ page 185 ; when doing so, proceed
as follows and observe warnings:
DANGER
arcs.

work steps:
♦ Fabric gloves
♦ Safety goggles

Further procedure:
– Initially fit battery housing (level 2) without gaskets and se‐
cure it with 2 bolts.
– Connect diagnostic cable -arrow-.
DANGER
arcs.
dry and undamaged.

work steps:
ing)
effect up to 500 V

Further procedure

6762/45-.
continued.
DANGER
electric arc.

DANGER
Danger from possible electric arc
– To increase distance between hand and battery connector,
use pliers with protective insulation from high-voltage tool
set to apply battery connector.
– Apply battery connector “20-21” using pliers from high-volt‐

age tool set -VAS 6762- and secure.
NOTICE

– Set down switching unit for high-voltage battery -SX6- up‐
side-down next to high-voltage battery 1 -AX2- on stable
surface on top of insulating mat -VAS 6762/44-.
• The open side of the switching unit must face upwards.

-SX6-.
– Connect adapter cable -VAS 5581/8- to coolant temperature

– Connect long cable of adapter cable -VAS 5581/8- to 12 Volt

connector on battery housing (level 2).

tester.
after the other:
– Start selected program, select program point Generate
battery overview and follow instructions on display of ve‐
hicle diagnostic tester.
– If electrical function of battery is OK, select program point
Module addressing and follow instructions on display of
If electrical function is OK, assemble high-voltage battery com‐
pletely:
♦ Install cover for battery housing (level 1) ⇒ page 117 .
♦ Check battery housing (level 1) for leaks ⇒ page 28 .
♦ Install battery housing (level 2) ⇒ page 125 .
♦ Install cover for battery housing (level 2) ⇒ page 113 .
♦ Check battery housing (levels 1 and 2) for leaks ⇒ page 28 .

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93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1 Safety precautions when working on the high-voltage system

Electric and magnetic fields can cause fatal injury.

Risk of damage to high-voltage wiring

1.2 Safety precautions when working in the vicinity of high-voltage compo‐

2 Rep. gr.00 - Technical data

2.1 Rules for cleanliness

2.2 Identification plates

2.3 Use of impact wrenches

• When working in the vicinity of natural gas systems, observe

2.4 Additional repair instructions for work

4 Rep. gr.00 - Technical data

3 Assessing high-voltage system risk

3. Assessing high-voltage system risk level 5

93 – Electric drive systems

6 Rep. gr.93 - Electric drive systems

2.1 Checking warning labels

2.1.1 Checking warning labels - e-tron 50

♦ High-voltage battery 1 -AX2- - front (with switching unit for

2.1.2 Checking warning labels - e-tron 55/e-

When performing maintenance work, it is important to ensure

♦ High-voltage battery 1 -AX2- - front (with switching unit for

8 Rep. gr.93 - Electric drive systems

3 High-voltage battery unit

3.1 Exploded view - high-voltage battery

3.1.1 Exploded view - high-voltage battery, e-tron 50

3. High-voltage battery unit 9

10 Rep. gr.93 - Electric drive systems

3.1.2 Exploded view - high-voltage battery, e-tron 55

3. High-voltage battery unit 11

12 Rep. gr.93 - Electric drive systems

❑ For high-voltage battery 1 -AX2-

3.1.3 Exploded view - high-voltage battery, e-tron S

3. High-voltage battery unit 13

14 Rep. gr.93 - Electric drive systems

3.2 Exploded view - switching unit for high-voltage battery -SX6-

3. High-voltage battery unit 15

Switching unit for high-voltage battery -SX6- - tightening torque

16 Rep. gr.93 - Electric drive systems

– Tighten bolts in stages:

3.3 Determining mean cell voltage

♦ Adapter cable -VAS 5581/8- (if required)

– Connect short cable of adapter cable -VAS 5581/8- to

3. High-voltage battery unit 17

– e-tron 50: Connect long cable of adapter cable -VAS 5581/8-

– e-tron 55/e-tron S: Connect long cable of adapter cable

– Connect black earth terminal of adapter cable -VAS 5581/8-

18 Rep. gr.93 - Electric drive systems

3.4 Charging and discharging battery mod‐

♦ Autonomous software -VAS 6910/5-

♦ Connecting cable -VAS 6910/18-1- for battery modules with

♦ Connecting cable -VAS 6910/17-1- for battery modules with

♦ Connecting cable -VAS 6910/22-1- for battery modules with

3. High-voltage battery unit 19

– Install new battery module ⇒ page 172 after it has been

3.5 Checking high-voltage battery for leaks

20 Rep. gr.93 - Electric drive systems

1 - Rubber plug -VAS

Additional measures for checking for leaks

– Connect adapter cable -VAS 5581/8- to housing for 12 Volt