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.
The eAssist battery pack assembly will utilize an exchange program. Please consult the most recent revision of bulletin/PI# PIC5520, available in Service Information (SI), for a list of approved eAssist battery pack assembly service procedures. Components that may be removed and serviced without exchanging the complete battery pack assembly are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.
- Ignition OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling .
- Connect the X1, X2, and X3 harness connectors at the K59 Starter/Generator Control Module.
- Determine which battery temperature sensor is not between -39° and 60°C (-38.2 and 140°F) by observing the scan tool Battery Energy Control Module Battery Temperature parameters.
- Disconnect the X2 and X3 harness connectors at the K16 Battery Energy Control Module.
- Test for 8-13k Ω at 19-24°C (66.2-75.2°F) between the appropriate temperature sensor signal circuit terminal and the low reference circuit terminal listed below:
- Temperature sensor 1 - Signal circuit terminal 2 X2 and low reference circuit terminal 7 X2
- Temperature sensor 2 - Signal circuit terminal 1 X2 and low reference circuit terminal 6 X2
- Temperature sensor 3 - Signal circuit terminal 4 X2 and low reference circuit terminal 9 X2
- Temperature sensor 4 - Signal circuit terminal 2 X3 and low reference circuit terminal 7 X3
- Temperature sensor 5 - Signal circuit terminal 1 X3 and low reference circuit terminal 6 X3
- Temperature sensor 6 - Signal circuit terminal 4 X3 and low reference circuit terminal 9 X3
- If not between 8-13k Ω
Replace the C4A Hybrid/EV Battery Section 1 and C4B Hybrid/EV Battery Section 2.
- If between 8-13k Ω
- Replace the K16 Battery Energy Control Module.
In High Voltage Disabling , perform the disabling procedure for servicing components within the A4 Hybrid/EV Battery Pack. The C4A Hybrid/EV Battery Section 1 and C4B Hybrid/EV Battery Section 2 will be disconnected as part of the disabling procedure.