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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.

  1. Vehicle OFF, disable the high voltage at the T18 Battery Charger. Refer to High Voltage Disabling . Disconnect the X5 connector at the A4 Hybrid/EV Battery Pack.
    2. NOTE:

    The following continuity test must be performed using the Ohm test setting.

  2. Test for less than 10 Ω between the 300 V circuit terminals listed below end to end:
    • T18 Battery Charger terminal A X4 and A4 Hybrid/EV Battery Pack terminal A X5
    • T18 Battery Charger terminal B X4 and A4 Hybrid/EV Battery Pack terminal B X5
    • If 10 Ω or greater 

      Verify that the charger maxi-fuse is not blown. Replace the charger maxi-fuse, if it is blown, and the 300 V DC cables.

    • If less than 10 Ω 
  3. Reconnect the X4 connector at the T18 Battery Charger.
    4. NOTE:

    The following continuity tests must be performed using the EL-50772 Insulation Multimeter. Select the Isolation test setting, then select the 500 V range.

  4. Using the EL-50772 Insulation Multimeter test for greater than 1M Ω between the circuit terminals listed below and ground:
    • A4 Hybrid/EV Battery Pack terminal A +300 V X5
    • A4 Hybrid/EV Battery Pack terminal B -300 V X5
    • If less than 1M Ω 
    1. Disconnect the X4 connector at the T18 Battery Charger.
    2. Using the EL-50772 Insulation Multimeter test the circuit for greater than 1M Ω between the circuit terminal and ground.
      • If less than the specified range, Verify that the charger maxi-fuse is not blown. Replace the charger maxi-fuse, if it is blown, and the 300 V DC cables.
      • If within the specified range, replace the T18 Battery Charger.
    • If 1M Ω or greater 
  5. Test for greater than 1M Ω between the A4 Hybrid/EV Battery Pack terminal A and terminal B X5.
    • If less than 1M Ω 
    1. Disconnect the X4 connector at the T18 Battery Charger.
    2. Test for greater than 1M Ω between the A4 Hybrid/EV Battery Pack terminal A and terminal B X5.
      • If less than the specified range, Verify that the charger maxi-fuse is not blown. Replace the charger maxi-fuse, if it is blown, and the 300 V DC cables.
      • If within the specified range, Verify that the charger maxi-fuse is not blown. Replace the charger maxi-fuse, if it is blown, and the T18 Battery Charger.
    • If 1M Ω or greater 
  6. Remove the maxi-fuse cover. Refer to Battery Charger and 14 V Power Module Maxi Fuse Replacement
  7. Verify that the charger maxi-fuse is not blown.
    • The maxi-fuse is blown 
      NOTE:

      The maxi-fuse date code defined as U38 is the 38th week of 2011.

    1. Verify the maxi-fuse date code.
      • The maxi-fuse date code is before U38, refer to The Maxi-Fuse Date Code is Before U38.
      • The maxi-fuse date code is U38 or later, refer to The Maxi-Fuse Date Code is U38 or Later.
    • The maxi-fuse is not blown 
  8. Replace the T18 Battery Charger.
  9. Verify that DTC P0D21, P0D22, or P0D23 does not set while operating the vehicle within the Conditions for Running the DTC.
    • If any of the DTCs set 

      Replace the K114B Hybrid/EV Powertrain Control Module 2.

    • If none of the DTCs set 
  10. All OK.
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