Circuit/System Testing

WARNING: This page is about a different car, the 2019 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.

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.

NOTE:

An S15 Manual Service Disconnect that is not fully engaged may result in an intermittent DTC P0A0C.

Disable high voltage at the A4 hybrid/EV battery pack. Refer to High Voltage Disabling procedure.
Verify that terminal 1 and terminal 2 of the S15 Manual Service Disconnect X1 are not bent or broken and are OK.
- If not OK
  Replace the S15 Manual Service Disconnect.
- Go to next step: If OK
Test for 35 - 45 Ω between terminal 1 and terminal 2, X1 of the S15 Manual Service Disconnect.
- If not within the specified range
  Replace the S15 Manual Service Disconnect.
- Go to next step: If within the specified range
Remove the A4 hybrid/EV battery pack cover. Refer to High Voltage Battery Cover Replacement . Disconnect the X5 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
With the S15 Manual Service Disconnect removed, test for infinite resistance between each of the terminals listed below and ground;
- Terminal 1
- Terminal 11
- If less than infinite resistance
  Repair the short to ground on the appropriate circuit.
- Go to next step: If infinite resistance
Test for less than 10 Ω between the low reference circuit terminal 11 at the K114B Hybrid/EV Powertrain Control Module 2 and terminal 2 at the X21 Manual Service Disconnect Receptacle.
- If 10 Ω or greater
  Repair the open/high resistance in the circuit.
- Go to next step: If less than 10 Ω
Test for less than 10 Ω between the 5 V signal circuit terminal 1 at the K114B Hybrid/EV Powertrain Control Module 2 and terminal 1 at the X21 Manual Service Disconnect Receptacle.
- If 10 Ω or greater
  Repair the open/high resistance in the circuit.
- Go to next step: If less than 10 Ω
Replace the K114B Hybrid/EV Powertrain Control Module 2.