Audi A6 Typ 4G: General, Technical data

Safety Precautions

High Voltage Vehicles Safety Precautions

  DANGER!

Danger to life through high voltage.

• The high voltage system operates through high voltage. Electrocution can cause death or very serious personal injury.
• Persons with internal electronic/medical life support devices or such devices carried on the body may not work on the high voltage system. Life support devices are, for example, internal analgesic pumps, implanted defibrillators, cardiac pacemakers, insulin pumps and hearing aids.
• The high voltage system must be de-energized by a suitably qualified person. Refer to → Electrical System Hybrid; Rep. Gr.93; High Voltage System, De-Energizing.

  DANGER!

Danger of unintended engine ignition

• It is difficult to determine whether the ready to drive mode is activated in electric and hybrid vehicles. Risk of parts of the body getting pinched or pulled.
• Turn off the ignition.
• Set the ignition key outside of the vehicle interior.

  DANGER!

Working with high voltage cables

• Never support objects on the high voltage cables and high voltage connectors; Risk of damaging the insulation.
• Never support tools on the high voltage cables and high voltage connectors; Risk of damaging the insulation.
• Never sharply bend or kink the high voltage cables; Risk of damaging the insulation.
• The round high voltage connectors are color-coded by an exterior color ring and are mechanically coded by the guide and code tabs. Always pay attention to the coding when connecting the round high voltage connectors to prevent mechanical damage to the high voltage connector.

Safety Precautions, Working Near High Voltage Components

  DANGER!

Damaged high voltage components may produce dangerously high voltage.

• The high voltage system operates through high voltage. Death or severe bodily injury caused by electrocution from damaged high voltage components and high voltage cables.
• Never use tools used for cutting, that are deformed or sharp-edged.
• Never use heat generating sources such as welding, soldering, hot air or thermal adhesive.
• Inspect the high voltage components in the area where the work will be performed before starting the procedure.
• Perform a visual inspection of the Electric Drive Power and Control Electronics, the Electro-Drive Drive Motor, Electrical A/C Compressor and the high voltage cables when working in the engine compartment.
• Perform a visual inspection of the high voltage cables and the covers when working on the floor panel.
• Perform a visual inspection of the high voltage cables when working in the rear of the vehicle.
• Perform a visual inspection of the High Voltage System Maintenance Connector.
• Perform a visual inspection of all of the potential equalization cables.

Note the following when performing the visual inspection:

• None of the components may display any exterior damage.
• The high voltage cable insulation and the potential equalization cables may not be damaged.
• The high voltage cables may not be deformed in any way.
• Each high voltage component muss be labeled with a red warning label.

Start/Stop System Safety Precautions

When Working on Vehicles with the Start/Stop System, Observe the Following:

  WARNING

Danger of personal injury when the engine starts automatically.

• When the Start/Stop System is activated (the indicator lamp in the instrument cluster is on), the engine can start up automatically.
• Always make sure the Start/Stop System is deactivated whenever working on the vehicle. Switch off the ignition.

Road Test with Testing Equipment Safety Precautions

If Measuring Equipment Are Required during a Test Drive, Observe the Following:

  WARNING

Distraction and inadequately secured measuring equipment poses an accident risk.

There is a risk due to deployment of the front passenger airbag in an accident.

• Operating measuring equipment while driving creates a distraction.
• There is an increased risk of injury if measuring equipment is not secured.

Always secure measuring equipment with a strap on the rear seat and have a second person in the rear seat operate it.

HID Headlamp Usage and Safety Precautions

Never Replace Bulbs If You Are Not Familiar with the Procedures, Safety Precautions and Tools.

  WARNING

Danger to life due to high voltage.

• For work on the yellow high voltage symbol marked areas HID headlamp must be de-energized.
• Turn off the ignition and all electrical consumers and remove the ignition key.
• Do not press the flasher.
• The gas discharge lamp control module should not be operated without the gas-discharge lamp.
• Due to the high voltage (over 28000 V when igniting the lamp), the gas-discharge lamp should only be operated inside the headlamp housing.

  WARNING

Risk of injury due to burning, UV rays, blinding and explosion.

• Due the high temperatures, absorption of UV rays, and the risk of blinding, the gas discharge lamp should only be operated inside the headlamp housing.
• Do not look into the beam of light. It may interfere with the ability to see for a significant period of time.
• Gas-discharge lamps are under pressure and can crack when bulbs are replaced.
• When removing and installing HID bulbs, always wear safety glasses and gloves.

  WARNING

Pollution risk.

• Gas-discharge bulbs require special disposal. They contain metallic mercury (Hg) and traces of thallium.
• Do not destroy gas-discharge lamps. Avoid contact with burst glass bulbs.
• Follow disposal requirements, only dispose of gas-discharge lamps in suitable containers at an authorized collection site.

  Caution

• Do not touch gas-discharge bulbs with bare hands. The remaining fingerprint would evaporate due to the heat of the operated bulb and condense on the reflector which would impair headlamp luminosity. Use clean cloth gloves to insert the gas-discharge lamp.
• Only replace faulty HID lamps with the same type of lamp. Bulb identification can be found on bulb socket or glass cone.
• Connectors must engage correctly when installed and must be checked for proper connection.

Repair Information

Clean Working Conditions

Even Very Small Particles of Dirt Can Cause a Fault. Follow the Rules of Cleanliness When Working:

• Thoroughly clean the connection locations/maintenance openings and the area around them prior to loosening/opening.
• Seal off any open lines and connections immediately with plugs, for example, take from Engine Bung Set -VAS6122-.
• Place removed parts on a clean surface and cover them with lint-free cloths.
• Cover or seal any open components carefully if the repair is not going to be performed immediately.
• Only install clean parts: Remove replacement parts from the packaging just before installing. Do not use any parts that have been removed from their packaging and left out (for example, in tool boxes).
• Do not use compressed air when the system is open.
• Protect any disconnected connectors from dirt and moisture and connect them only when they are completely dry.

General Information

• For the applicable wiring diagram. Refer to → Wiring diagrams, Troubleshooting & Component locations.

Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only fasteners with a special surface coating are used.

In addition, rubber or plastic parts and adhesive consist of non-conductive materials.

If there are doubts as to whether parts are suitable or not, use new parts. Refer to the Parts Catalog.

Note:

• We only recommend original replacement parts, they have been tested and are compatible with aluminum.
• We recommend using Audi accessories.
• Damage resulting from contact corrosion is not covered by warranty.

Electrostatic Discharge Work Surface

  Caution

Danger of causing damage to the vehicle electronics.

• Requirement: Make sure nothing, especially metal or other light weight particles, can get into the headlamp housing.
• Make sure also no oil, grease, silicone or other such materials can get into an open headlamp, otherwise they can turn into steam and fog up the headlamp.
• Touching electronic circuits with bare hands can lead to migration.
• ESD (electrostatic discharge) protection: Always follow standard DIN EN 613-40-5-1 when handling.
• Do not use any components or electronics that have fallen down.
• ESD Work Surface -VAS6613-. Refer to → Electrical System General Information; Rep. Gr.97; ESD Work Surface VAS6613.

Wire Routing and Securing

• Mark for example the fuel, hydraulic, vacuum, EVAP system lines or electrical wires before removing to prevent confusing them and to guarantee the installation position. Make sketches or take photos if necessary.
• Due to the restricted space in the engine compartment, make sure to allow for sufficient clearance to all moving or hot components to avoid damaging the wires.

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