Audi A6 2011 Instruction manual

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Workshop Manual
Audi A6 2011 ➤
Audi A6 Avant 2011 ➤
Electrical system, hybrid
Engine ID CHJA
Edition 03.2014
Service
Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt D3E80453E4F

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Routing and securing wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 General warning instructions for work on the high-voltage system . . . . . . . . . . . . . . . . . . 3
1.1 Warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 De-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Re-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 General description of high-voltage technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Overview of high-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Maintenance connector for high-voltage system TW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Components specific to high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Electric drive motor V141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Hybrid battery unit AX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Power and control electronics for electric drive JX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4 High-voltage wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.5 Electrical air conditioner compressor V470 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.6 Brake servo vacuum pump V469 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.7 Cooling system for high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
Contents i

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
ii Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
00 – Technical data
1 Safety precautions
(ARL003756; Edition 03.2014)
⇒ “1.1 Safety precautions when working on vehicles with start/
stop system”, page 1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
1.1 Safety precautions when working on ve‐
hicles with start/stop system
Note the following when working on vehicles with start/stop sys‐
tem:
WARNING
Risk of injury due to automatic engine start on vehicles with
start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
1.2 Safety precautions when using testers
and measuring instruments during a
road test
Please note the following points if testers and measuring instru‐
ments have to be used while test driving the vehicle:
WARNING
Risk of accident due to driver distraction and if test equipment
is not secured safely.
Risk of injury if front passenger's airbag is triggered in an ac‐
cident.
• Operating test equipment when driving causes a distrac‐
tion.
• High risk of injury if test equipment is not secured safely.
♦ Always secure test equipment to rear seat with a strap; it
must be operated from there by a second person.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
1. Safety precautions 1

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 Repair notes
⇒ “2.1 Contact corrosion”, page 2
⇒ “2.2 Routing and securing wiring”, page 2
2.1 Contact corrosion
Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating are
fitted.
Furthermore, rubber components or plastic components and ad‐
hesives are made of non-conductive material.
Always fit new components if you are not sure that the old com‐
ponents are suitable ⇒ Electronic parts catalogue .
Note:
♦ We recommend the use of genuine replacement parts only;
they have been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage resulting from contact corrosion is not covered by
warranty.
2.2 Routing and securing wiring
♦ To prevent mix-ups and to ensure that all components are re‐
installed in their original installation positions, mark for exam‐
ple fuel lines, hydraulic lines, vacuum lines, activated charcoal
filter system or electrical wiring before removing them. Where
necessary, make sketches or take photographs.
♦ Because of the limited space in the engine compartment, it is
important to ensure that there is adequate clearance to any
moving or hot components to avoid damage to lines and wir‐
ing.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
2 Rep. gr.00 - Technical data

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
93 – Electric drive systems
1 General warning instructions for work
on the high-voltage system
Note
In the event of queries or uncertainty regarding the terms “elec‐
trically instructed person”, “Audi high-voltage technician”, “Audi
specialist for work on high-voltage systems” or the high-voltage
system itself, the relevant importer must be contacted prior to the
start of all work.
The system must first be de-energised before any work is done
on the high-voltage system ⇒ page 9 .
For work that requires de-energising of the high-voltage system,
please note:
The high-voltage system must be de-energised according to the
“Guided Fault Finding” routine in the ⇒ Vehicle diagnostic tester,
and ONLY by this method.
DANGER!
High voltage can cause fatal injury
Danger of severe or fatal injuries from electric shock
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) con‐
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that the system cannot be re-
energised. The ignition key and the maintenance connec‐
tor for high-voltage system - TW - are then stored in a safe
place by the qualified person.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.
For re-energising the system:
The high-voltage system must be re-energised according to the
“Guided Fault Finding” routine in the ⇒ Vehicle diagnostic tester,
and ONLY by this method.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
1. General warning instructions for work on the high-voltage system 3

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
DANGER!
High voltage can cause fatal injury
Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be re-energised by a
suitably qualified person (Audi high-voltage technician).
♦ The system may only be re-energised using the vehicle
diagnostic tester via “Guided Fault Finding”.
♦ The vehicle is then made ready for operation again by the
qualified person (Audi high-voltage technician).
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.
For work in the vicinity of high-voltage components:
DANGER!
Risk of fatal injury if high-voltage components are damaged.
Observe the following when working in the vicinity of high-volt‐
age components or wiring:
♦ It is not permitted to use cutting or forming tools, other
sharp-edged tools or heat sources such as welding, braz‐
ing, soldering, hot air or thermal bonding equipment.
♦ Before starting work, visually inspect the high-voltage
components in the areas involved.
♦ Before working in engine compartment, visually inspect
power and control electronics for electric drive - JX1- ,
electric drive motor - V141- , air conditioner compressor -
V470- and high-voltage wiring.
♦ Before working on the vehicle underbody, visually inspect
the high-voltage wiring and covers.
♦ Before working on the rear section of the vehicle, visually
inspect the high-voltage wiring and the electro-box with
the maintenance connector for high-voltage system - TW
- .
♦ Visually inspect all potential equalisation lines.
Check the following when making the visual inspection:
♦ There must be no external damage on any component.
♦ The insulation of the high-voltage wiring and potential
equalisation lines must not be damaged.
♦ There must be no unusual deformation of the high-voltage
wiring.
♦ All high-voltage components must be identified by a red
warning sticker.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
4 Rep. gr.93 - Electric drive systems

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
For work that requires the ignition to be switched on, please note:
DANGER!
When working on a vehicle with the ignition switched on or
while the drive system is active, the engine can start unex‐
pectedly and exhaust fumes can cause a health hazard in
closed rooms. Moving parts can trap or draw in parts of the
body and/or clothing (safety hazard).
Before switching on the ignition, perform the following steps:
♦ Move selector lever to position P
♦ Activate parking brake
♦ Switch off ignition
♦ Open bonnet
♦ Connect battery charger (e.g. - VAS 5095A- ) to jump-start
connections of 12 V electrical system
♦ Switch on ignition
For general warnings and for work that requires the ignition not
to be switched on, please note:
WARNING
Safety hazard: the engine can start unexpectedly.
Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.
General notes:
WARNING
Working on vehicles with high-voltage wiring:
• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insula‐
tion.
• High-voltage wiring must not be excessively bent or
kinked --> this can damage the insulation.
• The round high-voltage connectors are colour-coded with
an external coloured ring and are provided with mechan‐
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec‐
tors, otherwise the connectors can be damaged.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
1. General warning instructions for work on the high-voltage system 5

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Identification/coding of high-voltage wiring ⇒ page 36 .
Note
♦ The contact surfaces of the potential equalisation lines must
be checked prior to installation.
♦ The contact surfaces must be clean and free from rust and
grease.
♦ Otherwise, repair the contact surfaces using the contact sur‐
face cleaning set - VAS 6410- ⇒ Electrical system; General
information; Rep. gr. 97 ; Cleaning contact surfaces with con‐
tact surface cleaning set - VAS 6410- .
Explanation of the relevant qualifications
See: Basic information on high-voltage vehicles ⇒ Basic infor‐
mation on high-voltage vehicles; Rep. gr. 00 ; Qualification of
internal/external personnel
Working with the system de-energised
Assembly group Repair
group Work Reason
Air conditioner 87 Air duct directly on hybrid bat‐
tery unit - AX1- Air duct can only be removed if hy‐ brid battery unit - AX1- is removed
Air conditioner 87 High-pressure refrigerant line
to inner heat exchanger (IWT) Accessibility because of routing be‐ hind power and control electronics
for electric drive - JX1- .
Air conditioner 87 Detach electrical air condition‐
er compressor - V470- High-voltage component
Air conditioner 87 Remove electrical air condi‐
tioner compressor - V470- High-voltage component
Engine 10 Remove and install engine Electrical air conditioner compressor
- V470- must be removed
Engine 13 Remove bracket for ancillaries Electrical air conditioner compressor
- V470- must be removed
Gearbox 37 Remove and install gearbox High-voltage component, high-volt‐
age connection on connection box
Brake 47 Remove and install brake ser‐
vo Refrigerant line and high-voltage component must be removed
Brake hydraulics 47 Remove and install vacuum
pump for brake servo Refrigerant line and high-voltage component must be removed
Brakes - ABS 45 Remove and install ESP con‐
trol unit and hydraulic unit High-voltage component must be re‐ moved
General body repairs, ex‐
terior 50 Work on plenum chamber par‐ tition panel (removal and instal‐
lation)
Contact with high-voltage compo‐
nents and wires
Welding work 50, 51, 53
Body repairs (with
straightening jig) 50, 51, 53
Power and control elec‐
tronics for electric drive -
JX1-
93 Work on component, removing
and installing High-voltage component
High-voltage wiring har‐
ness for drive motor -
PX2-
93 Work on component, removing
and installing High-voltage component
High-voltage wiring har‐
ness for hybrid battery -
PX1-
93 Work on component, removing
and installing High-voltage component
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
6 Rep. gr.93 - Electric drive systems

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Assembly group Repair
group Work Reason
Hybrid battery unit - AX1- 93 Work on component, removing
and installing High-voltage component
Electrical air conditioner
compressor - V470- 93 Work on component, removing and installing High-voltage component
High-voltage wire for
electrical air conditioner
compressor - P3-
93 Work on component, removing
and installing High-voltage component
Electric drive motor -
V141- 93 Work on component, removing and installing High-voltage component
1.1 Warning labels
A warning label is attached to all high-voltage components.
When performing maintenance work, ensure that these labels do
not become damaged or dirty and that they are attached to all
high-voltage components.
There are warning labels on:
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
1. General warning instructions for work on the high-voltage system 7

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Lock carrier (yellow warning label)
♦ Hybrid battery unit - AX1- (red warning label and battery warn‐
ing label)
♦ Electric drive motor - V141- (red warning label)
♦ Power and control electronics for electric drive - JX1- (red
warning label)
♦ Electrical air conditioner compressor - V470- (red warning la‐
bel)
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
8 Rep. gr.93 - Electric drive systems

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 De-energising high-voltage system
The high-voltage system must be de-energised according to the
“Guided Fault Finding” routine in the ⇒ Vehicle diagnostic tester,
and ONLY by this method.
DANGER!
High voltage can cause fatal injury
Danger of severe or fatal injuries from electric shock
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) con‐
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that the system cannot be re-
energised. The ignition key and the maintenance connec‐
tor for high-voltage system - TW - are then stored in a safe
place by the qualified person.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.
Note
♦ De-energising high-voltage system:
♦ Connect vehicle diagnostic tester
♦ Select Guided Fault Finding mode
♦ Using the Go to button, select the following menu options in
succession:
♦Function/component selection
♦Body
♦Electrical system
♦Self-diagnosis-compatible systems
♦8C - Hybrid battery management -J840
♦8C - Hybrid battery management, functions
♦51 - De-energise high-voltage system (Rep. gr. 93)
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
2. De-energising high-voltage system 9

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3 Re-energising high-voltage system
The high-voltage system must be re-energised according to the
“Guided Fault Finding” routine in the ⇒ Vehicle diagnostic tester,
and ONLY by this method.
DANGER!
High voltage can cause fatal injury
Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be re-energised by a
suitably qualified person (Audi high-voltage technician).
♦ The system may only be re-energised using the vehicle
diagnostic tester via “Guided Fault Finding”.
♦ The vehicle is then made ready for operation again by the
qualified person (Audi high-voltage technician).
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.
Note
♦ Re-energising high-voltage system:
♦ Connect vehicle diagnostic tester
♦ Select Guided Fault Finding mode
♦ Using the Go to button, select the following menu options in
succession:
♦Function/component selection
♦Body
♦Electrical system
♦Self-diagnosis-compatible systems
♦8C - Hybrid battery management -J840
♦8C - Hybrid battery management, functions
♦51 - Re-energise high-voltage system (Rep. gr. 93)
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
10 Rep. gr.93 - Electric drive systems

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4 Potential equalisation lines
Note
♦ The contact surfaces of the potential equalisation line must be
checked prior to installation.
♦ The contact surfaces must be clean and free from rust and
grease.
♦ Otherwise, repair the contact surfaces using the contact sur‐
face cleaning set - VAS 6410- ⇒ Electrical system; General
information; Rep. gr. 97 ; Cleaning contact surfaces with con‐
tact surface cleaning set - VAS 6410- .
Potential equalisation line on hybrid battery unit - AX1- -2-
Tightening torque for nut on base of battery -3-: 9 Nm
Tightening torque for nut on body -1-: 18 Nm
Potential equalisation line on power and control electronics for
electric drive - JX1- -2-
Tightening torque for nut on power and control electronics for
electric drive - JX1- -1-: 18 Nm
Tightening torque for bolt on body -3-: 9 Nm
Potential equalisation line -2- on electric drive motor - V141-
Tightening torque for bolt -1- on body: 20 Nm
Tightening torque for bolt -3-: 20 Nm
Potential equalisation line for electrical air conditioner compres‐
sor - V470- -3-
Tightening torque for nut on longitudinal member -1-: 20 Nm
Tightening torque for nut on engine support -2-: 20 Nm
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
4. Potential equalisation lines 11

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5 General description of high-voltage
technology
5.1 Overview of high-voltage components
General description
The most important components of the A6 high-voltage system
are the electric drive motor - V141- , the hybrid battery unit - AX1- ,
the high-voltage wiring and the power and control electronics for
electric drive - JX1- . The power and control electronics for electric
drive contain the electric drive control unit - J841- , the voltage
converter - A19- and the DC/AC converter for drive motor - A37- .
Further components include the electrical air conditioner com‐
pressor - V470- , the low-temperature cooling system, the cooling
module for the hybrid battery unit - AX1- and the disengagement
clutch in the electric drive motor - V141- .
1 - Combustion engine
❑ ⇒ 4-cylinder direct pet‐
rol injection engine (2.0
ltr. 4-valve turbo, hy‐
brid); Rep. gr.
2 - High-voltage wire for elec‐
trical air conditioner compres‐
sor - P3-
❑ Coding of high-voltage
connection - red col‐
oured ring
❑ Removing and installing
⇒ page 49
3 - Power and control electron‐
ics for electric drive - JX1-
❑ Electric drive control
unit - J841-
❑ Voltage converter - A19-
❑ DC/AC converter for
drive motor - A37-
❑ Red warning label
⇒ page 8
❑ Coding of high-voltage
connections
⇒ page 38
❑ Removing and installing
⇒ page 27
4 - Hybrid battery unit - AX1-
❑ Red warning label and
battery warning label
⇒ page 8
❑ Coding of high-voltage
connections
⇒ page 37
❑ Removing and installing ⇒ page 19
❑ Maintenance connector for high-voltage system - TW- ⇒ page 13
5 - Air supply duct for cooling hybrid battery unit - AX1-
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
12 Rep. gr.93 - Electric drive systems

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6 - Cooling module for hybrid battery unit - AX1-
❑ ⇒ Heating, air conditioning; Rep. gr. 87
7 - Wiring junction - TV1- for high-voltage system
❑ ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
8 - Air supply duct for cooling hybrid battery unit - AX1-
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87
9 - High-voltage wiring harness for hybrid battery - PX1-
❑ High-voltage wire for hybrid battery, positive terminal - P1- red coloured ring
❑ High-voltage wire for hybrid battery, negative terminal - P2- brown coloured ring
❑ Coding of high-voltage connections on hybrid battery unit - AX1- ⇒ page 37
❑ Coding of high-voltage connections on power and control electronics for electric drive - JX1-
⇒ page 38
❑ Removing and installing ⇒ page 38
10 - High-voltage wiring harness for drive motor - PX2-
❑ High-voltage wire 1 for drive motor - P4- (U) blue coloured ring/coding lug on right side
❑ High-voltage wire 2 for drive motor - P5- (V) green coloured ring/coding lug on left side
❑ High-voltage wire 3 for drive motor - P6- (W) violet coloured ring/two coding lugs
❑ Coding of high-voltage connections on power and control electronics for electric drive - JX1-
⇒ page 38
❑ Coding of high-voltage connections on electric drive motor - V141- ⇒ page 38
❑ Removing and installing ⇒ page 43
11 - Electric drive motor - V141-
❑ Red warning label ⇒ page 8
❑ Coding of high-voltage connections ⇒ page 38
❑ Removing and installing ⇒ page 14
12 - Electrical air conditioner compressor - V470-
❑ Red warning label ⇒ page 8
❑ Coding of high-voltage connection: red coloured ring
❑ Notes ⇒ page 53
5.2 Maintenance connector for high-voltage
system - TW-
The maintenance connector for high-voltage system - TW- -1- is
an electrical bridge between the two battery banks of the hybrid
battery unit - AX1- .
When the maintenance connector for high-voltage system - TW-
is unplugged, the link between the battery banks is disconnected
and the remaining voltage in the high-voltage system dissipates.
The system is de-energised at this point.
The maintenance connector for high-voltage system - TW- is al‐
ways unplugged if the high-voltage system needs to be de-ener‐
gised ⇒ page 9 .
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
5. General description of high-voltage technology 13

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6 Components specific to high-voltage
system
6.1 Electric drive motor - V141-
6.1.1 General description
The electric drive motor - V141- -1- is located between the com‐
bustion engine and the gearbox.
It acts directly on the gearbox input shaft and has the following
functions:
♦ A drive motor to propel the vehicle with electric power only
♦ A generator to supply the electrical system with power and
charge the hybrid battery unit - AX1- .
♦ A starter to start the combustion engine.
The disengagement clutch in the electric drive motor - V141- can‐
not be renewed separately; there is no provision for opening and
dismantling the electric drive motor - V141- .
Potential equalisation line on electric drive motor - V141-
⇒ page 11 .
6.1.2 Removing and installing electric drive
motor - V141-
WARNING
Working on vehicles with high-voltage wiring:
• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insula‐
tion.
• High-voltage wiring must not be excessively bent or
kinked --> this can damage the insulation.
• The round high-voltage connectors are colour-coded with
an external coloured ring and are provided with mechan‐
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec‐
tors, otherwise the connectors can be damaged.
Removing
The electric drive motor - V141- is a component of the gearbox,
so the gearbox first has to be removed.
– De-energise high-voltage system.
The high-voltage system must be de-energised according to the
“Guided Fault Finding” routine in the ⇒ Vehicle diagnostic tester,
and ONLY by this method.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
14 Rep. gr.93 - Electric drive systems

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
DANGER!
High voltage can cause fatal injury
Danger of severe or fatal injuries from electric shock
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) con‐
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that the system cannot be re-
energised. The ignition key and the maintenance connec‐
tor for high-voltage system - TW - are then stored in a safe
place by the qualified person.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.
Note
♦ De-energising high-voltage system:
♦ Connect vehicle diagnostic tester
♦ Select Guided Fault Finding mode
♦ Using the Go to button, select the following menu options in
succession:
♦Function/component selection
♦Body
♦Electrical system
♦Self-diagnosis-compatible systems
♦8C - Hybrid battery management -J840
♦8C - Hybrid battery management, functions
♦51 - De-energise high-voltage system (Rep. gr. 93)
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
6. Components specific to high-voltage system 15

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Take care not to damage the red warning label on the housing
cover of the high-voltage connections.
First remove high-voltage wires on electric drive motor - V141-
⇒ page 43 .
– Remove electric drive motor - V141- ⇒ 8-speed automatic
gearbox 0BW (hybrid, front-wheel drive); Rep. gr. 38 ; Electric
drive motor - V141- ; removing and installing electric drive mo‐
tor - V141- .
Installing
– Remove electric drive motor - V141- ⇒ 8-speed automatic
gearbox 0BW (hybrid, front-wheel drive); Rep. gr. 38 ; Electric
drive motor - V141- ; removing and installing electric drive mo‐
tor - V141- .
WARNING
Working on vehicles with high-voltage wiring:
• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insula‐
tion.
• High-voltage wiring must not be excessively bent or
kinked --> this can damage the insulation.
• The round high-voltage connectors are colour-coded with
an external coloured ring and are provided with mechan‐
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec‐
tors, otherwise the connectors can be damaged.
Audi A6 2011 ➤ , Audi A6 Avant 2011 ➤
Electrical system, hybrid - Edition 03.2014
16 Rep. gr.93 - Electric drive systems