Circuit/System Testing
WARNING:
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure includes the following steps:
- Identify how to disable high voltage.
- Identify how to test for the presence of high voltage.
- Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
- Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
- Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
- Visually and functionally inspect the gloves before use.
- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures may result in serious injury or death.
- Vehicle OFF, disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.
- Test for less than 10 Ω between the ground circuit terminal 5 and ground.
- If 10 Ω or greater
- Vehicle OFF.
- Test for less than 2 Ω in the ground circuit end to end.
- If 2 Ω or greater, repair the open/high resistance in the circuit.
- If less than 2 Ω, repair the open/high resistance in the ground connection.
- Go to next step: If less than 10 Ω
- Verify that a test lamp illuminates between the A4 Hybrid/EV Battery Pack harness B+ circuit terminal 1 X358 and ground.
- If the test lamp does not illuminate and the circuit fuse is good
- Vehicle OFF.
- Test for less than 2 Ω in the B+ circuit end to end.
- If 2 Ω or greater, repair the open/high resistance in the circuit.
- If less than 2 Ω, verify the fuse is not open and there is voltage at the fuse.
- If the test lamp does not illuminate and the circuit fuse is open
- Vehicle OFF.
- Test for infinite resistance between the B+ circuit and ground.
- If less than infinite resistance, repair the short to ground on the circuit.
- If infinite resistance, replace the A28 Hybrid/EV Battery Contactor Assembly and K16 Battery Energy Control Module ensuring you reconnect the connectors in the sequence provided in Repair Instructions. Refer to Battery Energy Control Module Replacement .
- Go to next step: If the test lamp illuminates
- Vehicle OFF, disconnect the X357 harness connector at the A4 Hybrid/EV Battery Pack. Vehicle in Service Mode.
- Verify that a test lamp does not illuminate between the A4 Hybrid/EV Battery Pack harness control circuit terminal 7 X357 and ground.
- If the test lamp illuminates
- Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.
- Test for less than 1 V between the control circuit and ground.
- If 1 V or greater, repair the short to voltage on the circuit.
- If less than 1 V, replace the K114B Hybrid Powertrain Control Module 2.
- Go to next step: If the test lamp does not illuminate
- Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2.
- Test for infinite resistance between the A4 Hybrid/EV Battery Pack harness control circuit terminal 7 X357 and ground.
- If less than infinite resistance
Repair the short to ground on the circuit.
- Go to next step: If infinite resistance
- If less than infinite resistance
- Test for less than 2 Ω in the control circuit end to end.
- If 2 Ω or greater
Repair the open/high resistance in the circuit.
- Go to next step: If less than 2 Ω
- If 2 Ω or greater
- Replace the K114B Hybrid Powertrain Control Module 2.
- Verify that DTC P0D5E does not set while operating the vehicle within the Conditions for Running the DTC.
- If DTC P0D5E is set
Replace the A28 Hybrid/EV Battery Contactor Assembly.
- Go to next step: If DTC P0D5E is not set
- If DTC P0D5E is set
- All OK.