Circuit/System Testing
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.
- Verify no battery-related DTCs are set.
- If any battery-related DTCs are set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle for hybrid battery diagnostics.
- If battery-related DTCs are not set
- If any battery-related DTCs are set
- Clear DTC, connect the drive motor battery charger cable to vehicle and known good household supply voltage.
- Verify DTC P1EF0 or P1EF1 is set.
- If none of the DTCs are set
Vehicle owner will have to attempt charge at home again. If the vehicle will not charge they will need electrical supply serviced.
- If any of the DTCs are set
- If none of the DTCs are set
- Vehicle OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack and the T18 Battery Charger. Refer to High Voltage Disabling .
- Disconnect the X4 connector at the T18 Battery Charger and at the X5 connector at the A4 Hybrid/EV Battery Pack.
- Test for infinite resistance between the 300 V circuit terminals listed below and ground:
- Terminal A X4
- Terminal B X4
- If less than the specified range
Test the 300 V circuit for a short to ground.
- If within specified range
- Test for less than 10 Ω between the 300 V circuit terminals listed below:
- T18 Battery Charger terminal A X4 and A4 Hybrid/EV Battery Pack A X5
- T18 Battery Charger terminal B X4 and A4 Hybrid/EV Battery Pack B X5
- If greater than the specified range
Test the 300 V circuit for an open/high resistance.
- If within specified range
- Test for infinite resistance between the 300 V circuit terminal A X4 and B X4.
- If less than the specified range
Test the 300 V circuits for a short between the circuits.
- If all circuits tests normal
- If less than the specified range
- Replace the T18 Battery Charger.