Service

Workshop Manual
Q3 2019 ➤ , Q4 e-tron 2022 ➤ ,
Q5 2008 ➤ , A8 2018 ➤ ,
Q6 e-tron 2024 ➤ , A7 2018 ➤ ,
e-tron/ Q8 e-tron 2019 ➤ , A6 2019 ➤ ,
Q2 2019 ➤ , A3 2013 ➤ , Q7/ Q8 2016 ➤ ,
A8 2010 ➤ , e-tron GT 2022 ➤ ,
Q5 2017 ➤ , A6 2011 ➤ , A3 2021 ➤
General information - high-voltage
Edition 06.2024

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
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 © 2024 Audi AG, Ingolstadt D4D80B588B0

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Contents

93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety information and repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Working on high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Employee qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 De-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Re-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Workshop procedures for high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Quarantine arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 High-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Classifying high-voltage batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Packaging high-voltage batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Contents i
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ii Contents
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93 – Electric drive systems

1 Safety information and repair notes
10008NT9YJ43.002.1 - 06.2024

1.1 Safety information

Observe safety information ⇒ Safety information and repair
notes; Rep. gr. 00 ; Safety information .

1.2 Repair instructions

Observe repair instructions ⇒ Safety and repair instructions;
Rep. gr. 00 ; Repair instructions .

1. Safety information and repair notes 1

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2 Working on high-voltage vehicles

2.1 Employee qualification

2.1.1 Training profiles and focus of training

Training profile according to Scenario
DGUV-I 209-093
EIP (electrically instructed per‐ Induction training for non-elec‐
son) trical work (< 60 VDC)
HVT (high-voltage technician) Working on inherently safe HV
production vehicles
♦ Vehicles are de-energised
exclusively with certifica‐
tion.
♦ Complete contact protec‐
tion in place.

HVE (high-voltage expert) Working on live HV compo‐

nents
♦ Working on live parts with‐
out contact protection, for
fault finding, component re‐
placement, etc.

2.1.2 Qualifications and working for emer‐

gency service, authorised workshop
and importer
Work Emergency Authorised workshop Importer/H
service V battery
compe‐
tence cen‐
tre
Electrically Electrically High-volt‐ High-volt‐
instructed instructed age techni‐ age expert
person - person - cian - HVT - HVE
EIP EIP
Breakdown yes - - -
assistance
Service, - yes yes yes
standard
repairs (not
HV rele‐
vant), GFF
Deactiva‐ - - Diagnostic Diagnostic
tion of and man‐ and man‐
high-volt‐ ual power ual power
age system disconnec‐ disconnec‐
tion tion
Fault find‐ - - yes yes
ing and re‐
pairs on
high-volt‐
age system
(apart from
high-volt‐
age repair)

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Work Emergency Authorised workshop Importer/H

service V battery
compe‐
tence cen‐
tre
Repairs on - - - yes
high-volt‐
age battery

2.2 De-energising high-voltage system

Listed in the Workshop Manual ⇒ Rep. gr. 00 ; Hazard rating
of high-voltage system are all work measures for which the
system must be de-energised.
♦ De-energise the system via Guided Functions with the aid of
⇒ Vehicle diagnostic tester.
♦ Fill in the test protocols for de-energisation. In the course
of testing, the test protocols are printed out, filled in, signed
and attached to the work order.

2.3 Re-energising high-voltage system

♦ Re-energise the system via Guided Functions with the aid of
⇒ Vehicle diagnostic tester.
♦ Fill in the test protocols for re-energisation. In the course of
testing, the test protocols are printed out, filled in, signed
and attached to the work order.

2.4 Workshop procedures for high-voltage

vehicles
Important
• When a high-voltage vehicle is accepted at an authorised
workshop, adhere to the workshop procedures specified for
high-voltage vehicles.
• The workshop procedures for high-voltage vehicles are
available in the information medium of the manufacturer
(Dealer Portal/ServiceNet) or in the information medium of
the importer.

2.5 Quarantine arrangements

Working on accident high-voltage vehicles
Important
• If a defective or accident high-voltage vehicle is delivered,
inform high-voltage technician (HVT).
• Unload vehicles with high-voltage battery straight to a dedi‐
cated space.
• Authorised workshops should make immediate contact with
the nearest high-voltage service partner or importer.
• Post a warning sign on the high-voltage vehicle reading
“Warning! Hazardous voltage” - VAS 6649- or words to that
effect. In the event of a quarantine, further signs will be
necessary.
• Secure high-voltage vehicle to prevent unauthorised access.
• Protect severely accident-damaged vehicles and removed
high-voltage batteries against rain and damp.

2. Working on high-voltage vehicles 3

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Arrangements for setting up quarantine area

The use of a sealed floor plate is recommended.

1 - Warning sign "Danger from batteries" - VAS 6786-

2 - Warning sign “Warning! Hazardous voltage” - VAS 6649-
3 - Prohibition sign “No fire” - VAS 6882-
4 - Prohibition sign “Access prohibited” - VAS 6881-
5 - Isolated area inc. hazard warning signs
6 - Outer safety zone
7 - Suitable open area, e.g. parking space.
Procedure (continued)
Important
• Record complaints in DISS.
• Perform a visual inspection of the accident vehicle and ap‐
praise its hazard potential by means of the following assess‐
ment criteria.
Important
• Use temperature gauge - VAS 6886- to measure tempera‐
ture.
Assessment criteria Meaning
Signs of fire Important
Sparks, smoke or vapour • If at least one assessment
criterion applies: beware of
Unusual noises inside the hazard Follow measure a)
high-voltage battery, e.g.
crackling or hissing. • If none of the assessment
criteria apply, proceed with
Pungent smell b)
Fluid leak, suspected fluid in
high-voltage battery system.
Mechanical damage with
exposed, accessible con‐
tacts/conductors.
Accessibility of high-voltage
battery for temperature meas‐
urements, e.g. due to missing
or damaged body parts, sur‐
face temperature of high-volt‐
age battery higher than 80°C.

a) Observe the following measures in the event of “BEWARE!

HAZARD”:
Keep a safe distance.
Observe high-voltage vehicle/high-voltage battery for abnor‐
malities.
Have fire extinguishing equipment ready and at the first sign
of fire immediately notify the fire service and evacuate the
building.
Do not inhale smoke/gas. Wear mask.
If the high-voltage battery has suffered mechanical damage
with exposed, accessible contacts/conductors, do not touch
the vehicle or the high-voltage battery.
Quarantine high-voltage vehicle/high-voltage battery if possi‐
ble.

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a) Observe the following measures in the event of “BEWARE!

HAZARD”:
Cordon off a large area and inform responsible party as per
reporting procedure.
Use PPE.

b) If the accident-damaged high-voltage vehicle is deemed

to be non-hazardous based on the assessment criteria, the
following steps must be taken:
⇒ “3.1.2 Classification of high-voltage batteries with aid of
ODIS”, page 12 .
Perform the work steps outside the buildings or in a suitable
area if possible.
It may be necessary to repair the 12V onboard electrical system
for a diagnosis.

2. Working on high-voltage vehicles 5

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3 High-voltage battery

3.1 Classifying high-voltage batteries

3.1.1 Basics of classifying high-voltage bat‐

teries
The installed high-voltage batteries are highly complex compo‐
nents and systems that could be affected during their service
life by defects, failure and partial failure.
The high-voltage battery could be damaged in a road traffic
incident.
The substances contained in high-voltage batteries are hazard‐
ous materials.
The state of the high-voltage battery impacts the following serv‐
ice requirements and workshop procedures:
♦ Special qualification requirements of service employees EIP,
HVT and HVE.
♦ Repairability of high-voltage battery.
♦ Packaging and transportation of high-voltage batteries.
♦ Quarantine and reporting processes to be carried out.
Important
• To assess the hazard potential of the high-voltage battery,
classify the high-voltage battery.

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Three states can be assigned to the high-voltage battery:

1 - “NORMAL”, not critical: no measures need to be taken.

2 - “WARNING”, critical: failure to observe the recommended
measures may lead to fatal/serious injury.
3 - “DANGER”, dangerous: failure to observe the recommended
measures will lead to fatal/serious injury.
Carry out assessment based on classification matrix.
Classification matrix
Assessment criteria Classification
Visual, senso‐ Functional, Thermal
ry electrical
♦ No relevant ♦ High-volt‐ ♦ Tempera‐ ♦ NORMAL
mechanical age battery ture within
damage. can be di‐ tolerance. Not critical: No
agnosed. measures
♦ No fluid have to be
leaks. ♦ No relevant taken.
entries in
event
memory.

Fulfilment of ALL criteria results in classifica‐

tion “NORMAL”.
♦ Relevant ♦ High-volt‐ ♦ Tempera‐ ♦ WARNING
mechanical age battery ture out‐
damage, cannot be side toler‐ Critical: Fail‐
e.g. dent, diagnosed. ance. ure to observe
crack, the recom‐
opening, ♦ Relevant mended
defective entries in measures may
seal. event lead to fatal/
memory. serious injury.
♦ Corrosion
damage
♦ Pungent
smell.

Fulfilment of ONE criterion results in classifica‐

tion “WARNING”.

3. High-voltage battery 7
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Assessment criteria Classification

Visual, senso‐ Functional, Thermal
ry electrical
♦ Fluid leak, ♦ Tempera‐ ♦ DANGER
suspected ture ≥
fluid in 60 °C. Dangerous:
high-volt‐ Failure to ob‐
age battery serve the rec‐
system. ommended
measures will
♦ Sparks, lead to fatal/
smoke or serious injury.
vapour.
♦ Signs of
fire.
♦ Unusual
noises in‐
side the
high-volt‐
age bat‐
tery, e.g.
crackling or
hissing.
♦ Mechanical
damage
with ex‐
posed, ac‐
cessible
contacts/
conductors.
♦ Accessibili‐
ty of high-
voltage
battery for
tempera‐
ture meas‐
urements,
e.g. due to
missing or
damaged
vehicle
body parts,
surface
tempera‐
ture of
high-volt‐
age battery
higher than
80 °C.

Fulfilment of ONE criterion results in classifica‐

tion “DANGER”.
Matrix of measures
Classifica‐ Immediate Other measures and processes
tion measure Repair ac‐ Intermedi‐ Packaging
cording to ate stor‐ and trans‐
Workshop age/quar‐ port
Manual antine

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NORMAL ♦ Not ♦ Repair if ♦ Original ♦ Original

neces‐ neces‐ packag‐ packag‐
sary. sary. ing ing
♦ Not ♦ Original
stacked, packag‐
flat on ing with
ground. addi‐
tional
♦ Stored materi‐
inside als
or un‐
dercov‐
er out‐
side
and pro‐
tected
against
rain.

WARNING ♦ Quaran‐ ♦ Imple‐ ♦ Inform ♦ Special

tine ment respon‐ trans‐
disposal sible port
♦ Take meas‐ party in crate re‐
outside ures if accord‐ quired
or into repair ance (may
quaran‐ not pos‐ with re‐ need to
tine sible. porting be dis‐
area/ proce‐ man‐
quaran‐ ♦ Transfer dure. tled).
tine to non-
cabinet. critical ♦ Move ♦ May on‐
status high- ly be
♦ Use through voltage pack‐
PPE. repair if vehicle/ aged by
possi‐ high- trained
ble. voltage person‐
battery nel.
to suita‐
ble out‐
side
area/
space.
♦ Protect
re‐
moved
high-
voltage
battery
against
mois‐
ture.

Carry out additional actions as instructed by HVE.

3. High-voltage battery 9
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DANGER ♦ Keep a ♦ Not rel‐ ♦ Quaran‐ ♦ Do not

safe evant. tine ve‐ pack‐
dis‐ hicle/ age.
tance. battery
and call ♦ Do not
♦ Ob‐ fire trans‐
serve service port.
high- if nec‐
voltage essary.
vehicle/
high- ♦ Ob‐
voltage serve
battery. high-
voltage
♦ Have vehicle/
fire ex‐ high-
tin‐ voltage
guishing battery.
equip‐
ment
ready
and at
the first
sign of
fire im‐
medi‐
ately
notify
the fire
service
and
evacu‐
ate the
building.
♦ Do not
inhale
smoke/
gas.
Wear
mask.
♦ If the
high-
voltage
battery
has suf‐
fered
me‐
chanical
damage
with ex‐
posed,
accessi‐
ble con‐
tacts or
conduc‐
tors, do
not
touch
the ve‐
hicle or
the
high-
voltage
battery.
♦ Quaran‐
tine
high-
voltage

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vehicle/
high-
voltage
battery
if possi‐
ble.
♦ Cordon
off a
large
area
and in‐
form re‐
sponsi‐
ble par‐
ty as
per re‐
porting
proce‐
dure.
♦ Use
PPE.

Classification procedure
♦ The classification is software-based and carried out with the
aid of “Guided Functions” via ODIS.
♦ Measured values of cell voltages and temperature sensors
are collected, the event memory is read out, and communi‐
cation with the battery regulation control unit is checked.
♦ Classification can be carried out with the high-voltage bat‐
tery fitted in the vehicle or removed.
♦ Only an HVE may reclassify the battery based on an assess‐
ment specific to the case.
Procedure
Visual, sensory, functional, Criteria:
electrical and thermal assess‐ 1. Signs of fire?
ment.
2. Sparks, smoke or vapour
noticeable?
3. Noise from high-voltage bat‐
tery, e.g. crackling?
4. Pungent smell?
5. Fluid leak or suspected flu‐
id in high-voltage battery sys‐
tem?
6. Severe mechanical damage
to high-voltage battery?
7. Temperature and cell volt‐
age measurement?
8. Functional check of high-
voltage battery?
Classification NORMAL (not critical)
WARNING (critical)
DANGER (dangerous)

3. High-voltage battery 11
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3.1.2 Classification of high-voltage batteries

with aid of ODIS
Special tools and workshop equipment required
♦ diagnostics interface - VAS 6154A-
♦ high-voltage diagnostics box -CN- - VAS 5581A-

Assessing condition

With high-voltage battery installed:

– ⇒ Vehicle diagnostic tester Connect.
– Carry out classification with ⇒ Vehicle diagnostic tester.

Continued
With high-voltage battery removed:
– Connect high-voltage diagnostics box -CN- - VAS 5581A-
using vehicle-specific test adapters to communication con‐
nector of high-voltage battery.
– Switch on high-voltage diagnostics box -CN- - VAS 5581A- .
– Connect to ⇒ Vehicle diagnostic tester via diagnostics inter‐
face - VAS 6154A- or USB cable.
– Carry out classification with ⇒ Vehicle diagnostic tester.

3.2 Packaging high-voltage batteries

3.2.1 General notes on packaging high-volt‐

age batteries
The procedure described here is based on ADR regulations
(Agreement concerning the International Carriage of Dangerous
Goods by Road). Country-specific legislation must be observed.
According to ADR regulations, the listed high-voltage batteries
come under category UN 3480. For the latest packaging in‐
structions and special regulations, see the hazardous materials
table of the ADR.
The procedure is orientated around the classification status of
the high-voltage battery.
For transporting high-voltage batteries with the status “WARN‐
ING”, the currently applicable transport laws apply.
It is not permissible to transport high-voltage batteries with the
status “DANGER”.

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Initial sit‐ Clas‐ Classi‐ Assignment of packaging regula‐

uation sifica‐ fication tion
tion status
per‐
forme
d by
Batteries HVT ♦ Tech‐P 903 / LP 903 transport in
that are or nicallygenuine part crate (protect bat‐
new, in HVE OK tery against short circuit and slip‐
use or ping). If the battery is to be dis‐
used but ♦ Sta‐ posed of or recycled, SV 377:
functional, tus: P909 applies => e.g. genuine part
e.g. war‐ “NOR‐crate labelled accordingly: LITH‐
ranty case MAL” IUM BATTERIES FOR DISPOS‐
due to low AL or LITHIUM BATTERIES FOR
residual RECYCLING
capacity.
Batteries HVE ♦ Sta‐ SV 376: P 908 / LP 904 ap‐
that are tus: plies, pack according to packag‐
damaged/ “de‐ ing group, inner packaging (in‐
defective fec‐ dividually in inner packaging)
but safe tive, and outer packaging required
for trans‐ safe (>30 kg = only one battery
port, e.g. for per outer packaging), foil around
defective trans‐battery/electrolyte leakage must
cell con‐ port” be prevented, ventilation if nec‐
troller, essary, e.g. inner packaging re‐
triggered quired (incl. non-flammable, non-
pyrofuse conductive heat insulation). Pro‐
without tect battery against short circuit.
other de‐ Note on consignment label: DAM‐
fects. AGED/DEFECTIVE LITHIUM-ION
BATTERIES or DAMAGED/DE‐
FECTIVE LITHIUM METAL BAT‐
TERIES, reference in transport
documents: TRANSPORT AS
PER SPECIAL REGULATION
376
Batteries HVE, ♦ Techni‐P 911 / LP 906 special trans‐
heavily con‐ cally not
port crate required. Packaging
damaged sulta‐ OK approved by relevant authority.
and trans‐ tion The applicable transport laws ap‐
port criti‐ with ♦ Status:ply. Pack according to packag‐
cal SV im‐ “WARN‐ ing group I, note on consign‐
376 (e.g. porter ING” ment label: DAMAGED/DEFEC‐
leaking if TIVE LITHIUM-ION BATTERIES
electro‐ nec‐ or DAMAGED/DEFECTIVE LITH‐
lyte, rele‐ essa‐ IUM METAL BATTERIES, refer‐
vant cell ry ence in transport documents:
defects). TRANSPORT AS PER SPECIAL
REGULATION 376
Battery Main‐ ♦ Tech‐Do not consign
reactive tain nical‐
(heat de‐ dis‐ ly not
velop‐ tance OK
ment/fire/ , call
smoke, fire ♦ Sta‐
noise serv‐ tus:
etc.). ice if “DAN‐
nec‐ GER”
essa‐
ry.

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3.2.2 Packing high-voltage battery modules

with the status “defective, safe for
transport”

The description applies to defective high-voltage battery mod‐

ules that are defective but sufficiently stable to be transported.
– Classify high-voltage module ⇒ “3.1.2 Classification of high-
voltage batteries with aid of ODIS”, page 12 .

All vehicles (continued)

Preparing packaging

UN stickers must not be covered by other stickers.

– Remove cardboard insert from packaging.
– Turn packaging over.

– Use adhesive filament tape -2- to seal packaging -1- with

overlaps as shown in illustration.
Filament adhesive tape, refer to ⇒ Electronic parts catalogue
(ETKA)

Packing a module with the status “defective, safe for transport”

– Cover all contacts of battery modules with adhesive tape to
prevent short circuit.

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Packing with hollow glass granulate or vermiculite

– Use filament adhesive tape -2- to seal overlap -arrows- at
bottom of packaging.

WARNING
Risk to health due to dust from expanded glass granules.
Risk of irreversible dust deposits in lungs, which could lead to
respiratory problems.
– Wear a dust protection mask.

– Wear a dust protection mask.

– Fill packaging with an even layer (thickness of 2 cm) of
hollow glass granulate or vermiculite.
– Pull plastic bag over module.
Plastic bag, refer to ⇒ Electronic parts catalogue (ETKA)
– Place module in centre of packaging at an even distance
from outer walls.
– Fold plastic bag to side and seal it with adhesive tape so that
no liquid can escape.
– Pour in hollow glass granulate or vermiculite so that gaps
are filled and entire packaging is filled up to upper edge.

All vehicles (continued)

Packing with hollow glass granulate bag (if available on site)
– Place small hollow glass granulate bag in packaging and
distribute contents evenly.
– Pull plastic bag over module.
Plastic bag, refer to ⇒ Electronic parts catalogue (ETKA)
– Place module in centre of packaging at an even distance
from outer walls.
– Fold plastic bag to side and seal it with adhesive tape so that
no liquid can escape.
– Place large hollow glass granulate bag onto module.
– Distribute contents evenly so that a layer thickness of 2 cm
is ensured above module and so that gaps in packaging are
filled.

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All vehicles (continued)

– Put classification protocol in packaging.
– Use adhesive filament tape -2- to seal packaging -1- with
overlaps as shown in illustration.

– Attach warning notice for hazardous materials and informa‐

tion label to both sides of packaging.
♦ “Dangerous goods class 9”
♦ “UN number 3480”
♦ “Warning! Damaged lithium-ion battery”
♦ “This side up”

1 - “Protect against water”

2 - “Warning! Fragile”
3 - “This side up”
4 - “Maximum stacking load”
5 - “Dangerous goods label: Dangerous goods class 9 “Various
hazardous substances and items” packaging group 2”
6 - “Type label with UN number UN 3480 for lithium-ion batter‐
ies”

16 Rep. gr.93 - Electric drive systems