Audi Q5 Hybrid Quattro 2012
Audi Q5 Hybrid Quattro 2012
Audi Q5 Hybrid Quattro 2012
U
V
W
Connection Number Ring and Point Color Title
High Voltage Wires
The electrical lines of the high voltage system
differ considerably from the other lines in the
12 volt vehicle electrical system. Due to higher
voltage and current levels, high voltage electrical
lines have a signicantly larger cross section and
are connected by special plug-in contacts.
To draw attention to the danger of high voltage,
all wires of the high voltage system are color
coded orange.
To avoid incorrect assembly, the high voltage
connectors are mechanically coded and
identied by a colored ring under the bayonet
ring.
High voltage wires are also mechanically coded
at the round contacts. In a high voltage system,
all shock-proofed plug-in connections and high
voltage wires are protected against chang
by a thick layer of insulation and additional
corrugated tube sheathing.
The high voltage system has the following line
sections:
Two high voltage wires from the high voltage
battery to the power electronics (P1, P2)
Three high voltage wires from the power
electronics to the e-machine (P4, P5, P6)
Two-wire high voltage wire from the power
electronics to the A/C compressor (P3)
36
Safety Design
Insulation Monitoring
Every 30 seconds, an insulation measurement
is made in the high voltage system. This is
accomplished by applying system voltage,
which will detect insulation faults throughout
the high voltage circuit: in the high voltage
battery, traction current lines, power electronics,
three-phase lines connected to the electric drive
motor, in the line to the A/C compressor, and the
A/C compressor itself.
Electrical Safety Line
The safety line is a safety device designed to
monitor and actuate the open or closed state of
the high voltage system. It has an electrical and
mechanical component.
Electrically, it is a line that runs through all high
voltage components. If high voltage wires are
disconnected, the safety line is interrupted and
the high voltage system deactivated. It is like
a series electrical circuit which is closed by its
safety connectors. If this circuit is opened by
removing the safety connector, the high voltage
system is de-energized.
Pilot Line Contact 1 TV44 is the mechanical
component of the safety line. To remove this
line, a bayonet ring of the connector must rst
be lifted. This is combined with a locking bracket
which prevents high voltage wires from being
disconnected when voltage is present.
The safety connectors must be removed
before disconnecting high voltage wires from
high voltage components. This ensures that
the system is not powered when lines are
disconnected.
Safety Line Closed
All component parts of the high voltage system
are interconnected as a ring circuit by a separate
low voltage wire. The component connection to
the safety line is congured as a normally closed
(NC) contact system.
If all components are ready for operation, the
contacts are closed. If a voltage is applied to the
safety line, current can ow because the line is
closed.
A measurable current indicates that all
components of the safety line are ready for
operation.
Safety Line Open
If a normally closed (NC) contact is opened
because a component is not ready for operation,
or because the safety connector has been
removed, the safety line is now open. No current
can ow when a voltage is applied. This is a sign
that the high voltage system is not ready for
operation.
A check is made by Battery Regulation Control
Module J840 in the Hybrid Battery Unit to
determine if the safety line is closed or open. If
the control module determines the line is open,
it does not activate the high voltage contact,
thus breaking the connection between the high
voltage battery and the high voltage system.
489_037
Safety connector
connection
High voltage wire
connections P1 and P2
Locking
bracket
Note
Other commonly used terms or names
for the safety line are: pilot line and HV
Interlock.
!
37
High voltage
contact
Safety line contact
High voltage
contact
Bayonet ring
High voltage
connector P3
Safety line contact
489_092
High Voltage Connector Contacts
High voltage line P3 for the A/C compressor
system differs from other high voltage lines. It
has two wires, two double round contacts, and
two contacts for the electrical safety lines.
After connecting the terminal, the bayonet ring
must be pushed down until it audibly engages.
The connection is then closed.
Coding Ring
If the bayonet ring is pulled up and thus
unlocked, the color of the coding ring is visible.
Mechanical Coding
In addition to color ring codings, the
high voltage connector and terminals are
mechanically coded. The position of the coding
is indicated by a yellow mark.
High voltage connector
P1, P2, P3, P4, P5, P6
High voltage
contact
Bayonet ring
489_091
Coding ring
Unlocked
bayonet ring
High voltage
connector
489_095 489_093
High voltage
connector
Locked
bayonet ring
489_095
Coding ring
Unlocked
bayonet ring
High voltage
connector
Mechanical
coding
High voltage connector of terminal P4
38
The plug-in contacts of the high voltage wire can
only be removed if the locking bracket has been
swivelled back. Because the safety line is open,
voltage is no longer present at the high voltage
wire contacts and there is no danger of electric
shock when disconnecting the high voltage wire.
Conversely, the high voltage wire to JX1 can
only be connected to the Hybrid Battery Unit if
the locking bracket has been swivelled over the
two plug-in contacts. Only then can the safety
connector be inserted.
The high voltage system is not energized until
the safety connector has been inserted.
Note
Only qualied high voltage technicians are allowed to disconnect this safety connector to
de-energize the vehicle.
!
489_041
Connection P2 Connection P1
489_038
Pilot Line Connector TV44 489_039
Locking bracket
489_040
The high voltage wire can only be disconnected
from the Hybrid Battery Unit if Pilot Line
Connector 1 TV44 has already been removed. To
remove the line, the bayonet ring must be pulled
up. The safety line is now open and Battery
Management Control Module J840 has isolated
the high voltage battery via the high voltage
contacts.
Pilot Line Connector 1 TV44
Mechanical Locking of
the Safety Line Connector
Before working on the system, be sure that the
maintenance connector has been removed
(page 29).
39
Connection P1, P2
489_036
Terminals of Electric Drive Power
and Control Electronics JX1
P1, P2 From the High Voltage Battery to JX1
Hybrid Battery High Voltage Wiring Harness PX1
The high voltage battery and JX1 are electrically
connected by two orange colored high voltage
wires. The lines are of shielded, single pole
design.
P3 From JX1 to the A/C Compressor
Through to the A/C compressor, the air
conditioning system is an integral part of the
Audi Q5 hybrid quattro high voltage system. This
new system of activating the compressor means
that the vehicle interior can be air conditioned
even when the internal combustion engine is at
a standstill.
Depending on battery charge level, the air
conditioning system remains active. If the
charge level of the high voltage battery drops,
the system starts the internal combustion
engine automatically to charge the high voltage
battery.
The A/C compressor is connected to JX1 by a
two-wire line. To ensure a proper connection,
these high voltage wires are colored orange and
feature yellow mechanical markings, making
them difcult to interchange.
This two-wire line is of a shielded, two pole
design. If either of the two connectors of this
line are disconnected, it is the equivalent of
removing a safety connector, deactivating the
entire high voltage system.
P4, P5, P6 From JX1 to the e-machine
Drive Motor High Voltage Wiring Harness PX2
In JX1, the 266 volt DC voltage from the high
voltage battery is converted to three-phase AC
by a DC/AC voltage converter for operating the
e-machine.
The e-machine is connected to JX1 via three
high voltage cables. These lines are of shielded,
single pole design and, like the other high
voltage lines, are marked, color coded, and
mechanically coded so that they cannot be
interchanged.
Refer to current technical literature for more
details on line designations.
489_034
Connection P4, P5, P6
Connection P3
489_035
40
12 Volt Auxiliary Starter
The auxiliary starter is used only for starting
the internal combustion engine under certain
operating conditions. When this occurs,
68Ah Battery A is disconnected from the 12V
electrical system by Engine Control Module
J623 via Starter Battery Switch-Over Relay J580.
This makes the full capacitance of the battery
available to the starter motor.
The onboard power supply is then supplied via
Auxiliary Battery A1 and the DC/DC converter.
The temperature of the Auxiliary Battery must
be at least 32F (0C) before the 12 volt auxiliary
starter is enabled. It the high voltage system is
not ready for operation, 12 volt starting is not
possible.
Note
Both 12 volt batteries must be disconnected before servicing the 12 volt onboard power supply.
!
489_080
Auxiliary
Battery A1
Battery Monitoring
Control Module 2 J934
Battery Monitoring
Control Module J367
High voltage distribution junction
TV1 with Battery Cut-off Relay J7 and
Starter Battery Switch-Over Relay J540
Battery A
12 Volt Onboard Power Supply
The following hybrid quattro modications have
been incorporated into the standard Audi Q5
design:
12 Volt Onboard Power Supply
Alternator C has been eliminated. This
function is now performed by Electro-Drive
Drive Motor V141 (e-machine)
12 volt onboard power supply does not have
brake energy recuperation
12 volt onboard power supply is supplied by
the DC/DC converter of Electric Drive Power
and Control Electronics JX1
In addition, a second 12Ah battery (Auxiliary
Battery A1) is installed in the side section
at the rear left. Battery Monitoring Control
Module 2 J934 is connected to Data Bus On
Board Diagnostic Interface J533 via the LIN
bus
Auxiliary Battery A1 is activated by Battery Cut
Out Relay J7 when terminal 15 is switched
ON
Voltage Stabilizer J532 has been eliminated.
Its function is now performed by the Auxiliary
Battery. No electrical current is drawn from
the Auxiliary Battery when terminal 15 has
been switched OFF
41
Electronic Ignition Lock
The ignition lock uses the information ignition
key is inserted to instruct the high voltage
system to make the vehicle ready for operation.
For Battery Management Control Module J840,
the information ignition key is inserted is a
condition which must be met so that the control
module activates the high voltage contacts for
coupling the high voltage battery to the high
voltage system.
If the ignition key is removed, the control
module disconnects the high voltage battery
automatically from the high voltage system.
terminal 15 OFF
Hybrid manager (ECM) in sleep mode
No operating current
The terminals have the following status:
Ignition ON With Brake Not Depressed:
terminal 15 ON
Ignition ON With Brake Depressed:
terminal 15 ON
terminal 50 ON
Hybrid Ready
The vehicle can now be driven electrically, with
the internal combustion engine starting at a low
high voltage battery charge.
Airbag Control Module J234
To ensure that occupants and emergency
responders are not endangered by the high
voltage system in the event of a crash, the crash
detection signal from Airbag Control Module
J234 is also evaluated by Battery Regulation
Control Module J840. If a crash is detected, J840
isolates the high voltage battery from the high
voltage system via the high voltage contacts.
In the rst crash phase, only the belt tensioners
deploy and the high voltage contacts are
opened. If the airbags do not deploy, J840 can
be reset by switching the ignition OFF and
back ON again. This will allow the high voltage
contacts to be closed again, and the vehicle to
be restarted.
If the belt tensioners and airbags have deployed
in the second crash phase, the high voltage
contacts cannot be reset by cycling the ignition
OFF and back ON. Battery Regulation Control
Module J840 can only be reset using the VAS
Scan Tool.
The deployed airbags serve the emergency
responders as an indicator that the high voltage
contacts have been opened in a crash and the
high voltage system has been disconnected
from the high voltage battery.
489_083
42
Network Topology
Power Sunroof
Control Module
J245
Memory Seat/
Steering Column
Adjustment Control
Module J136
Anti-Theft Alarm
System Sensor
G578
Roof Shade
Control Module
J394
Air Quality
Sensor G238
Fresh Air Blower
Control Module
J126
Right Front Seat
Ventilation Control
Module J799
Rearview Camera
System Control
Module J772
Left Front Seat
Ventilation
Control Module
J800
Towing
Recognition
Control Module
J345
Multifunction
Steering Wheel
Control Module
J453
Steering Column
Electronics
Control Module
J527
A/C Pressure/
Temperature
Sensor G395
Garage Door
Opener Control
Module J530
Vehicle Electrical
System Control
Module J519
Light Switch E1
Wiper Motor
Control Module
J400
Rain/Light
Recognition
Sensor G397
Electronic
Steering Column
Lock Control
Module J764
Access/Start
Authorization
Switch E415
Garage Door
Opener Control
Head E284
Comfort System
Central Control
Module J393
Alarm Horn H12
Climatronic Control
Module J255
Flap Control
servomotors
Humidity Sensor
G355
Auxiliary Air
Heater Control
Module J604
Right Headlamp
Power Output
Stage J668
Left Headlamp
Power Output
Stage J667
Hybrid Battery
Recirculation Door
Positioning Motor
2 V480
Hybrid Battery
Recirculation Door
Positioning Motor
1 V479
Battery Fan
1 V457
Rear Lid Control
Module J605
Rear Lid Control
Module 2 J756
Front Passenger
Door Control
Module J387
Right Rear Door
Control Module
J389
Driver Door
Control Module
J386
Left Rear Door
Control Module
J388
43
489_001
Instrument
Cluster Control
Module J285
Parallel Parking
Assistance
Control Module
J791
ABS/ESP Control
Module J104
Active Steering
Control Module
J792
ESP Sensor
Unit G419
ESP Sensor
Unit 2 G536
All Wheel Drive
Control Module
J492
Steering Angle
Sensor G85
Electromechanical
Parking Brake
Control Module
J540
Power Steering
Control Module
J500
Front Information
Display Control
Head J685
Information
Electronics
Control Module
1 J794
Media Player in
Position 1 R118
On Board Data Bus
Diagnostic Interface J533
Digital Sound
System Control
Module J525
Engine Control
Module J623
Transmission
Control Module
J217
Electrical Drive
Control Module
J841
Battery
Regulation
Control Module
J840
Electronic
Damping Control
Module J250
Airbag Control
Module J234
Lane Change
Assistance
Control Module
2 J770
Radio R
A/C Compressor
Control Module
J842
Distance
Regulation
Control Module
J428
Battery
Monitoring
Control Module
J367
Directional
Stabilization
Assistance Control
Module J759
Automatic High
Beam Assist
Control Module
J844
Battery
Monitoring
Control Module
2 J934
Alternator C
Lane Change
Assistance Control
Module J769
Data Link
Connector
Powertrain CAN bus
Convenience CAN bus
Extended CAN bus
DPI/running gear CAN bus
Diagnostic CAN bus
Hybrid CAN bus
MOST bus
LIN bus
Sub-bus systems
Differing control modules
found only on the Audi
Q5 hybrid quattro
Color key:
System Management
44
V479
V457
V480
SX1 with J840
AX1 with A38
This schematic shows the components required
by the e-machine. Additional input and output
signals are interchanged between all vehicle
systems: for example, for the operation of the
heating and air conditioning systems, power
steering, and brake system.
The data exchange between the vehicle
systems is extremely important, given the back
and forth changeovers from electric drive to
internal combustion operation when driving.
The changes in drive torque must be virtually
transparent to preserve optimum driving
comfort.
The engine management system, transmission
system, and hybrid control system must be
coordinated. In the Audi Q5 hybrid quattro, the
ECM is the higher level (master) control module
for the internal combustion engine and electric
operation.
Key and Accompanying Messages:
AX1 Hybrid Battery Unit
PX1 Hybrid Battery High Voltage Wiring Harness
SX1 Connection and Junction Box 1
High voltage wire monitoring
A38 Hybrid Battery Unit
J104 ABS/ESP Control Module
Brake system hydraulic pressure, brake
pressure
Wheel speed measurement
J217 Transmission Control Module
Transmission speed
Gear recognition
Transmission hydraulics temperature
Electrical hydraulic pump, transmission
hydraulic pressure, gear shifting
Clutch control mechanism for internal
combustion engine, electric drive motor
J234 Airbag Control Module
Crash signal
J255 Climatronic Control Module
A/C compressor activation
J285 Instrument Cluster Control Module
Textual messages and vehicle operating
state descriptions on the instrument
cluster display
J533 On Board Data Bus Diagnostic Interface
Data transfer between the various bus
systems
J540 Electromechanical Parking Brake Control
Module
Driver exit detection
Powertrain CAN bus
DPI/running gear CAN bus
Hybrid CAN bus
Convenience CAN bus
MOST bus
LIN bus
High voltage wire
Color key:
45
489_043
J841
V470 with J842
PX1
Connection
on V141
J285
J794
J685 J533
J255
J540
J104
J623 J217 J234
J623 Engine Control Module
EV mode ON/OFF
Brake application signal
Drive-by-wire signal
Engine speed
Engine temperature
Driver absence detection
Electric drive motor coolant
temperature
Drive-by-wire signal
Engine speed
J685 Front Information Display Control Head
Animated vehicle operating state
descriptions
J794 Information Electronics Control Module 1
Display information transfer
J840 Battery Regulation Control Module
Battery temperature
Control of high voltage contacts
J841 Electrical Drive Control Module
Electric drive motor speed
Electric drive motor temperature
JX1 temperature
Voltage monitoring
J842 A/C Compressor Control Module
Compressor speed
V141 Electro-Drive Drive Motor
V457 Battery Fan 1
V470 Electrical A/C Compressor
V479 Hybrid Battery Recirculation Door
Positioning Motor 1
V480 Hybrid Battery Recirculation Door
Positioning Motor 2
46
EV
D
S and tip gates
Extended electrical
drive operation
Fuel-optimized
conguration with
moderate e-boost
function
Enhanced e-boost
function of the
electric drive
Driving under electric power down to a
high voltage battery charge level of 30%
All electric driving up to 62 mph (100 km/h)
Coasting
Start-stop
No e-boost function
Brake energy recuperation
Driving under electric power down to a
high voltage battery charge level of 30%
Coasting
Start-stop
Moderate e-boost function
Brake energy recuperation
Start-stop
Intensive e-boost function
Brake energy recuperation
No electrically powered driving
Gear Selector Position Program Possible Effects
Reference
For more detailed information about the design and function of the electromechanical parking brake,
refer to Self-Study Program 999703, The 2008 Audi A5 Running Gear.
Drive Programs
The Audi Q5 hybrid quattro has three customer
selectable drive programs:
Driver Detection
The status of the drivers door and brake
signal are monitored. A driver is recognized as
detected if:
Drivers door is closed
Vehicle is ready for operation (hybrid ready) or
the internal combustion engine is running
Vehicle is currently traveling at less than 4.3
mph (7 km/h)
D, R, S, or tip is selected
Brake pedal is not depressed
If the drivers door is now opened, a driver exit
is detected and the electromechanical parking
brake is automatically engaged.
To reactivate the driver exit detection function,
the vehicle must again exceed a speed of 4.3
mph (7 km/h).
In gear selector positions N (vehicle in car
wash) or P (mechanical lock in automatic
transmission), the parking brake is not engaged
automatically.
Driver Absence Detection
A driver presence is recognized if the following
conditions have been met:
Hybrid Ready
Drivers presence has been detected (drivers
door is closed and safety belt fastened)
OR
Drivers door is closed and a selector lever
position has been selected
If the drivers door is opened or if the safety belt
is unfastened with the gear selector in position
P, a driver absence is detected:
If this happens while the internal combustion
engine is running, the engine continues to
run without interruption
If this happens while the internal combustion
engine is at a standstill, the hybrid manager
(ECM) enters standby mode. No electric
current ows from the high voltage battery
and the internal combustion engine can no
longer start. Without a 12 volt charger, the
12 volt batteries now become discharged
47
Display and Operating Elements
for Driving in Hybrid Mode
For operation and display of the electric drive,
the Audi Q5 hybrid quattro has the following
features:
Power meter instead of tachometer
Special display in the instrument cluster
Animated display on MMI screen
High voltage battery charge indicator instead
of coolant temperature display
Extended Electric Driving Mode Button E709
Display in Power Meter
The power meter displays various vehicle
operating states and the power output or
charging capacity of the hybrid system during
the trip.
1 Vehicle ready Hybrid Ready, terminal 15
ON and terminal 50 ON
2 Electrically powered driving (engine starting
is possible) or hybrid driving
3 Limit for engine starting in EV mode
4 Economical driving (partial throttle range)
5 Full throttle range
6 Internal combustion engine 100%
7 e-machine provides assistance in addition to
maximum engine torque (e-boost)
8 terminal 15 OFF or terminal 15 ON and
terminal 50 OFF
9 Hydraulic braking in addition to energy
recovery by recuperation
10 Energy recovery by recuperation (under
braking and during acceleration)
11 Charge level of high voltage battery
489_079
3
4
11
1
5
10
6
7
2
8
9
48
Instrument Cluster
Display Fault Message
If a fault occurs in the high voltage system, it is
indicated by a yellow or red warning lamp on
the instrument cluster. Depending on the type of
fault, the applicable color and message text are
displayed.
Display Charging the High Voltage
Battery
If a charging current is detected, a green
charging connector appears on the instrument
cluster.
Hybrid drive:
system malfunction. Please
take vehicle in for servicing.
Hybrid drive: malfunction:
Possible failure of power
steering and brake booster.
The vehicle can still be driven.
You can continue driving in
internal combustion mode.
The vehicle cannot be driven.
Display Textual Message Denition
489_102
The detected charging current appears
on the display in the instrument cluster
mi
72.5F
mi
72.5F
Preparing to start
vehicle.
Please wait
49
Display Instrument Cluster
Electric drive mode (e-drive) is indicated on
the display of the instrument cluster. The high
voltage battery symbol and the arrows pointing
away from the wheels indicate that drive is
currently being provided by the high voltage
battery and electric drive motor.
The display also indicates all other driving
states, and are adapted to current driving status.
Display Hybrid Ready
The hybrid system is ready for operation.
Display Drive by Electric Motor Only
(e-machine)
The high voltage battery symbol and the green
arrows pointing away from the wheels indicate
that drive is currently being provided by the high
voltage battery and the electric drive motor.
Display Drive by Internal Combustion
Engine Only
The symbols for the internal combustion engine,
high voltage battery, and the yellow arrows
pointing away from the wheels indicate that
drive is currently being provided by the internal
combustion engine.
mi
72.5F
489_058
mi
72.5F
489_059
mi
72.5F
489_060
50
Display Drive by e-machine and
Internal Combustion Engine (e-boost)
The symbols for the internal combustion
engine, high voltage battery, and the yellow
green arrows pointing away from the wheels
indicate that drive is currently being provided
by the internal combustion engine, high voltage
battery, and electric drive motor.
Display Recuperation in Overrun
Phase; Speed Less than 99.4 mph
(160 km/h)
The high voltage battery symbol and the green
arrows pointing towards the wheels indicate
that brake energy recuperation is currently in
progress and the high voltage battery is being
charged.
Display Status and Internal
Combustion Engine
The symbols for the internal combustion engine
and the high voltage battery indicate that the
internal combustion engine is currently running
and the high voltage battery is being charged.
489_064
mi
72.5F
mi
72.5F
489_062
mi
72.5F
489_061
51
Display Hybrid Ready
The hybrid system is ready for operation.
Display Drive by Electric Motor Only
(e-machine)
The high voltage battery symbol and the green
arrows pointing away from the wheels indicate
that drive is currently being provided by the high
voltage battery and the electric drive motor.
Display Drive by Internal Combustion
Only
The symbols for the internal combustion engine,
high voltage battery, and the yellow arrows
pointing away from the wheels indicate that
drive is currently being provided by the internal
combustion engine.
MMI Screen
The Audi Q5 hybrid quattro comes with the MMI
Navigation plus system. Information on current
internal combustion engine operation, electric
drive motor operation, and high voltage battery
charge level can be displayed on the MMI
screen.
489_067
489_065
489_066
52
Display Drive by e-machine and
Internal Combustion Engine (e-boost)
The symbols for the internal combustion
engine, high voltage battery, and the yellow
green arrows pointing away from the wheels
indicate that drive is currently being provided
by the internal combustion engine, high voltage
battery, and e-machine.
Display Recuperation in Overrun Phase
Speed Less than 99.4 mph (160 km/h)
The high voltage battery symbol and the green
arrows pointing towards the wheels indicate that
brake energy recuperation is currently in progress
and that the high voltage battery is being charged.
Display Status and Internal
Combustion Engine
The symbols for the internal combustion engine
and the high voltage battery indicate that the
internal combustion engine is currently running
and the high voltage battery is being charged.
489_071
489_068
489_069
53
Display Consumption Statistics
Consumption statistics, fuel economy, and
energy recuperation are updated and displayed
every ve minutes. This data shows the previous
60 minutes in the form of a bar chart. The lled-
in bars are those of the current trip and not the
previous trip.
Operating Elements
By pressing the Extended Electric Driving Mode
Button E709 (EV mode), the driver can extend
the limits of all-electric driving, using the overall
power of the e-machine.
Requirements for driving in EV mode:
Speed less than 62 mph (100 km/h)
Charge level of the high voltage battery > 30%
Temperature of the high voltage battery
greater than 50F (10C)
Coolant temperature of the internal
combustion engine between 41F (5C) and
122F (50C)
Ambient temperature equal to or greater
than 50F (10C)
No DTCs in 12 volt starter system
Altitude less than 13123 ft (4000 m)
Not in tiptronic mode
System capability electrically equal to or
greater than 15 kW
Stop enabling signals are present
(from Start/Stop System)
When EV mode is activated, it is indicated by a
green symbol in the instrument cluster and by a
green bar below the EV mode button.
Effect of Failure
Failure of EV mode has no effect on hybrid
operation, though extended electrically powered
driving is not possible.
489_006 E709
Display of activated EV mode in the
display of the instrument cluster
489_008
489_096
gal/100 mi
Service
54
Special Tools
Lock for Service Disconnect T40262
To safeguard the high voltage system against
unintentional reactivation during service
work, the plastic cover is locked using the
maintenance connector padlock.
Adapter T40259
This tool set consists of three eyelets and
matching clevises for installing and removing
the high voltage battery.
Release Tool T40258
The release tool is used for removing the high
voltage connector.
489_047
489_045
489_046
55
Other Service Tools
Test Adapter VAS 6606/10
Electric Drive Power and Control Electronics
JX1 can be tested using the isolating box test
adapter VAS 6606.
Hybrid Warning Sign VAS 6649
Before beginning service work, warning signs
which read Caution: Hazardous Voltage must
be visibly displayed within the vehicle. Further
guidelines can be found in Guided Fault Finding.
Hybrid Warning Sign VAS 6650
Before beginning service work, warning signs
which read Do not activate switch. Work in
progress. must be visibly displayed within
the vehicle. Further guidelines can be found in
Guided Fault Finding.
12 Volt Charger
If the high voltage battery does not have enough
charge to start the vehicle (as indicated by the
instrument cluster display), it can be charged
with a 12 volt charger with a minimum rating of
30A.
Note
To ensure the proper and safe use of high voltage special tools, the guidelines in current technical
literature must be strictly followed.
!
Note
All work on the high voltage system must be performed by a qualied high voltage technician. Only
qualied high voltage technicians are allowed to disconnect the safety connector to de-energize the
vehicle.
!
489_101
489_049
489_100
56
Hybrid Measurement Module VAS 6558
This measurement module is used for generating
a measurement voltage of 500V (up to a
maximum of 1000V) with a minimum of current.
Voltage is supplied via a USB 2.0 port.
Voltage-OFF measurements can be made using
the tester and a measuring adapter. The test
box can also be used to measure insulation
resistance.
This tester is compatible with Scan Tools VAS
5051B, VAS 5052A and VAS 6150.
Hybrid Test Adapter VAS 6558/1A
Adapters are a part of set VAS 6558/1A and are
used both for voltage-OFF measurement and by
insulating resistors in the high voltage system in
conjunction with VAS 6558.
All high voltage wires in the measuring adapters
are coded mechanically and visually. They are
designed to t only a specic socket type.
Carefully disconnect and connect the high
voltage terminals of the measuring adapter,
otherwise the sockets could be damaged,
resulting in a loss of shock protection.
Voltage-OFF Measurement Adapter
VAS 6558/1-1
The voltage-OFF measurement adapter is
connected directly to voltage sources, high
voltage battery, and power electronics. High
ohmic resistors are integrated in the measuring
adapter. They ensure that only a low current is
present in the measuring sockets in the event of
a fault.
489_050
489_051
High voltage
measuring socket ()
Socket
shielding
High voltage
measuring socket (+)
Per 2 high voltage connecting lines
Note
The measuring adapter must be checked
prior to every voltage-OFF measurement.
!
Note
All work on the high voltage system must be performed by a qualied high voltage technician. Only
qualied high voltage technicians are allowed to disconnect the safety connector to de-energize the
vehicle.
!
57
Adapter for Insulation Resistance
Measurement in High Voltage System
VAS 6558/1-2
The two high voltage connecting lines of the
measuring adapter t the terminals of the hybrid
battery unit and the power electronics. The high
voltage connecting socket of the measuring
adapter ts the high voltage wires of the hybrid
battery unit and the power electronics.
This measuring adapter can be used to measure
the insulation resistance in the high voltage
system.
Adapter for Measuring Insulation
Resistance in the A/C Compressor and
Safety Line VAS 6558/1-3A
A high voltage connecting line of the measuring
adapter ts only the socket of the A/C
compressor in the power electronics and of the
A/C compressor itself.
The insulation resistance in the high voltage
wire to the A/C compressor can be measured via
the high voltage connecting socket. Due to the
safety line being integrated into the high voltage
connection of the A/C compressor, the safety
line can also be checked using this measuring
adapter.
Note
Adapters VAS 6558/1-2 and VAS 6558/1 3A may only be used if the absence of high voltage has been
established. To ensure the proper and safe use of high voltage special tools, the guidelines in current
technical literature must be strictly followed.
!
High voltage
measuring socket ()
489_052
High voltage
measuring socket (+)
Socket
shielding
Per 2 high voltage
connecting lines
High voltage connecting socket for
the high voltage line to be measured
(resistance measurement)
489_053
High voltage connecting socket for the
A/C compressor line to be measured
(resistance measurement)
High voltage
measuring socket ()
Safety line
socket (+)
Per 2 high voltage
connecting lines
High voltage
measuring socket (+)
Safety line
socket ()
Socket
shielding
Frequently Asked Questions (FAQs)
58
Extreme care should be taken when working on hybrid vehicles. You must always follow relevant
regulations and guidelines. This information will help you recognize hazards, enabling you to respond
promptly and correctly in the event of an accident.
Q: What service work can be done by the
customer?
A: All non-high voltage system service work
can be done by the customer, as with any
other Audi vehicle. However, work on the
high voltage system should only be done
by a trained high voltage technician at an
authorized service center in accordance with
Audi guidelines.
Q: What additional tasks should be performed as
part of PDI?
A: No additional preparations are needed for
high voltage components during the PDI
of the Audi Q5 hybrid quattro. In transport
mode, the electric motor is used solely as a
generator, which means that electric driving,
boost, start-stop, and recuperation are not
possible. In this mode, the high voltage
battery is continually charged as long as the
combustion engine is running.
Q: What needs to be kept in mind when the Audi
Q5 hybrid quattro is parked or stored?
A: Please refer to the standard checklist for
vehicles in stock and in storage. This list
describes what activities need to be carried
out and when.
Q: What should be done in the event of an
accident?
A: First, either someone in the car or a rescue
worker should switch OFF the ignition. This
process is the same as in any Audi vehicle.
The high voltage system in the Audi Q5 hybrid
quattro is automatically shut down when
the belt tensioners or airbags are activated.
There is no need for emergency responders
to isolate it. Details are provided in a separate
manual for emergency services.
Q: What type of voltage and current are there in
the high voltage system of the Audi Q5 hybrid
quattro?
A: When the high voltage system is active, direct
current (DC) voltage ows through the electric
A/C compressor, high voltage battery, and
power electronics. The electric motor operates
with alternating current (AC) voltage. An extra
capacitor is tted in the power electronics
to serve as a power reserve. This capacitor is
discharged when the ignition is switched OFF.
Q: Can the Audi Q5 hybrid quattro be washed in
an automatic car wash?
A: Yes, the Audi Q5 hybrid quattro can be washed
in an automatic car wash without any special
restrictions.
Q: Can you perform an engine wash on the Audi
Q5 hybrid quattro?
A: You can perform an engine wash on the Audi
Q5 hybrid quattro as long as you observe
accepted environmental rules. If using a high
pressure sprayer, do not aim it directly at high
voltage components.
Q: What should I do if the vehicle needs to be
towed?
A: The vehicle should be transported by at bed
towing. If this is not possible, it must be at
towed (front or rear axles must not be raised)
and a towing speed of 31 mph (50 km/h) must
not be exceeded.
Q: Can the Audi Q5 hybrid quattro be driven
without a high voltage battery?
A: Any malfunction in the high voltage battery
will trigger dened error mechanisms in the
system. In the event of a more serious defect,
the high voltage system will usually shut
down. If this happens, the vehicle can only be
driven until the 12V battery is discharged.
Q: What do I need to know about raising the
vehicle on a car lift, wheel alignment platform,
or brake test platform?
A: There are no special instructions for the
Audi Q5 hybrid quattro that differ from the
standard Audi Q5. Important: if the ignition
is switched ON, the combustion engine may
start.
Q: Does the customer require special training for
the Audi Q5 hybrid quattro?
A: The customer does not need any special
training. However, the information in the
owners manual specic to hybrid technology
should be noted.
59
Q: What levels of voltage and currents are
dangerous?
A: Alternating voltage of 25V or above and
direct voltage of 60V or above are dangerous.
Maximum contact voltage must not exceed
50V for alternating current (AC) voltage
or 120V for direct current (DC) voltage. A
current of approximately 5mA or more can be
recognized by the human body, with a current
of approximately 10mA or more representing
a serious safety hazard.
Q: What are the effects of alternating current
(AC) and direct current (DC) if a person comes
in direct bodily contact with these currents?
A: Alternating current (AC):
Direct contact with this current will add a
harmful disruptive electrical current to the
human body that can trigger involuntary
vibrations in the muscles and heart. The
lower the frequency, the more dangerous
the voltage. Ventricular brillation (heartbeat
alteration and/or heart stoppage) can result.
Without prompt rst aid, this can prove fatal.
Direct current (DC):
Direct contact with this current can break
down (liquify) body tissues through
electrolytic dissolution, resulting in tissue
poisoning. This damage will only be
noticeable several days after the DC direct
contact, and if left untreated, can be fatal.
Q: What are the effects and after effects of
electrical accidents?
A: Shock effect: Risk of injury from uncontrolled
movements and loss of balance.
Thermal effect: Burns and carbonizations at
the entry and exit points of the current, as
well as internal burns. Resulting stress to the
kidneys may be fatal.
Chemical effect: Blood and cell uids are
broken down by electrolysis. The result is
serious poisoning that becomes noticeable
after several days.
Effect on muscles: Muscle contractions and
impairment of controlling brain functions.
Consequences may include loss of movement,
contraction of the lung muscles (breathing
stops), and arrhythmia (ventricular brillation,
heart stops pumping).
Q: What should I do if a person is touching and/
or is in direct contact with electrical voltage?
A: It is important to follow these instructions:
1. Consider your own safety rst.
2. Do not touch someone who is in direct
contact with electrical voltage.
3. If possible, de-energize the electrical
system. Immediately switch OFF the
vehicles ignition or unplug the service
connector for the high voltage system.
4. Separate the person or electrical
conductor from the power source with a
non-conductive object (for example, a
wooden plank or broom handle).
Q: What rst aid should be given following an
electrical accident?
A: If the person is verbally unresponsive:
1. Check pulse and breathing.
2. Call 911 or arrange for someone else to
make the call without delay.
3. Perform articial respiration and CPR until
EMS arrives.
4. If it appears that the person has stopped
breathing or their heart is in distress, use
an automated external debrillator (AED)
to quickly diagnose and treat them. AEDs
are simple to use, with their proper use
taught in rst aid and CPR classes.
The AED will only supply a shock to the
patient if it detects an abnormal or no
heartbeat, and can return the patient to
a normal heartbeat. Even when the AED is
successful, the patient should still be
treated by a rst responder team.
If the person is verbally responsive:
1. Cool any burns and cover with a sterile lint-
free dressing.
2. The person must be examined by a doctor
to help prevent after effects.
Q: What should I do in the event of an accident
involving batteries or battery contents?
A: It is important to follow these instructions:
1. If skin contact occurs, rinse well with water.
2. In the case of gas inhalation, move the
person to fresh air.
3. If eye contact occurs, rinse with plenty of
water (for at least 10 minutes).
4. If battery contents are swallowed, the
person should drink plenty of water, but not
so much that vomiting is induced.
5. Seek medical treatment.
Self-Study Programs for the Audi Q5 hybrid quattro
60
SSP 994803 The 2009 Audi Q5
Vehicle Introduction
Body
Occupant Protection
Running Gear
Electrical System
Infotainment
Service
SSP 922903 The 2.0L 4V TFSI
Engine with AVS
Secondary Air System
SSP 990303 The 2012 Audi A7
Running Gear
Electromechanical Steering
Notes
62
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9
0
1
2
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Technical specications subject
to change without notice.
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2200 Ferdinand Porsche Drive
Herndon, VA 20171