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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.

Battery Charger Bus Diagnostics

  1. Vehicle OFF. Measure and record the C1 battery voltage at the C1 battery terminals. The C1 battery voltage should stabilize between 12.4 V and 12.8 V within a few minutes of turning the vehicle OFF.
  2. Vehicle ON, accessories OFF.
  3. Determine if the K1 14V Power Module is functioning.
    1. Measure and record the C1 battery voltage at the C1 battery terminals.
    2. The voltage should be at least 1 V greater than the voltage measured in step 1 but less than 15 V.
      • If not within the specified range, record the K1 14V Power Module is NOT functioning.
      • If within the specified range, record the K1 14V Power Module IS functioning.
    3. Continue diagnosis.
  4. Vehicle OFF, disable the high voltage at the T18 Battery Charger and the T24 Battery Charger-DC. Refer to High Voltage Disabling .
  5. Disconnect the T18 Battery Charger high voltage DC connector.
  6. Disconnect the K1 14 V Power Module high voltage connector.
  7. Disconnect the T24 Battery Charger-DC high voltage connectors X6 and X7.
  8. Disconnect the X4 harness connector at the A4 Hybrid/EV Battery Pack.
  9. Test for infinite resistance between the High voltage DC (+360 V) positive terminal A and the high voltage DC (-360 V) negative terminal B X4 harness connector.
    • If less than infinite resistance 

      Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If infinite resistance 
  10. Test for less than 10 Ω between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X7 harness connector at the T24 Battery Charger-DC and the high voltage DC (-360 V) negative terminal B X4 harness connector at the A4 Hybrid/EV Battery Pack.
    • High voltage DC (+360 V) positive terminal A X7 harness connector at the T24 Battery Charger-DC and the high voltage DC (+360 V) negative terminal A X4 harness connector at the A4 Hybrid/EV Battery Pack.
    • If 10 Ω or greater 

      Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If less than 10 Ω 
  11. Test for less than 10 Ω between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X6 harness connector at the T24 Battery Charger-DC and the high voltage DC (-360 V) negative terminal 2 X3 harness connector at the T18 Battery Charger.
    • High voltage DC (+360 V) positive terminal A X6 harness connector at the T24 Battery Charger-DC and the high voltage DC (+360 V) negative terminal 1 X3 harness connector at the T18 Battery Charger.
    • If 10 Ω or greater 

      Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If less than 10 Ω 
  12. Determine if the K1 14V Power Module was functioning when the DTC set.
    1. Refer to the K1 14V Power Module function record taken earlier in diagnosis.
        NOTE:

        The T18 battery charger Fuse is located within the A28 Hybrid/EV Battery Contactor Assembly.

      • If the K1 14V Power Module was NOT functioning, replace both the T18 Battery Charger and K1 14 V Power Module. Also test and replace the T18 Battery Charger fuse, if open.
      • If the K1 14V Power Module was functioning, replace ONLY the T18 Battery Charger.
    2. Continue diagnosis.
  13. Verify that DTC P0AF8 does not set while operating the vehicle within the Conditions for Running the DTC.
    • If DTC P0AF8 sets 

      Replace the T24 Battery Charger-DC.

    • Go to next step: If DTC P0AF8 does not set 
  14. Verify that DTC P0AF8 does not set while operating the vehicle within the Conditions for Running the DTC.
    • If DTC P0AF8 sets 

      Replace the A28 Hybrid/EV Battery Contactor Assembly.

    • Go to next step: If DTC P0AF8 does not set 
  15. All OK.

Battery Main Bus Diagnostics

  1. Vehicle OFF, disable the high voltage at the T6 Power Inverter Module, A4 Hybrid/EV Battery Pack and T24 Battery Charger-DC. Refer to High Voltage Disabling .
  2. Disconnect the X3 harness connector at the A4 Hybrid/EV Battery Pack.
  3. Disconnect the X2 high voltage connector at the T6 power inverter module.
  4. Disconnect the X1 and X3 connectors at the T24 Battery Charger-DC.
  5. Test for infinite resistance between the High voltage DC (+360 V) positive terminal A and the high voltage DC (-360 V) negative terminal B X3 connector at the A4 Hybrid/EV Battery Pack, harness side.
    • If less than infinite resistance 

      Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If infinite resistance 
  6. Test for infinite resistance between the High voltage DC (+360 V) positive terminal A and the high voltage DC (-360 V) negative terminal B X2 connector at the T6 Power Inverter Module, harness side.
    • If less than infinite resistance 

      Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If infinite resistance 
  7. Test for infinite resistance between the High voltage DC (+360 V) positive terminal A and the high voltage DC (-360 V) negative terminal B X1 connector at the T24 Battery Charger - DC, module side.
    • If less than infinite resistance 

      Replace the T24 Battery Charger-DC. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If infinite resistance 
  8. Test for less than 10 Ω between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X3 harness connector at the A4 Hybrid/EV Battery Pack and the high voltage DC (-360 V) negative terminal B X3 harness connector at the T24 Battery Charger-DC.
    • High voltage DC (+360 V) positive terminal A X3 harness connector at the A4 Hybrid/EV Battery Pack and the high voltage DC (+360 V) negative terminal A X3 harness connector at the T24 Battery Charger-DC.
    • If 10 Ω or greater 

      Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If less than 10 Ω 
  9. Test for less than 10 Ω between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X2 harness connector at the T6 Power Inverter Module and the high voltage DC (-360 V) negative terminal B X1 harness connector at the T24 Battery Charger-DC.
    • High voltage DC (+360 V) positive terminal A X2 harness connector at the T6 Power Inverter Module and the high voltage DC (+360 V) negative terminal A X1 harness connector at the T24 Battery Charger-DC.
    • If 10 Ω or greater 

      Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If less than 10 Ω 
  10. Test for less than 10 Ω between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X3 module connector at the T24 Battery Charger-DC and the high voltage DC (-360 V) negative terminal B X1 module connector at the T24 Battery Charger-DC.
    • High voltage DC (+360 V) positive terminal A X3 module connector at the T24 Battery Charger-DC and the high voltage DC (+360 V) negative terminal A X1 module connector at the T24 Battery Charger-DC.
    • If 10 Ω or greater 

      Replace the T24 Battery Charger-DC. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

    • Go to next step: If less than 10 Ω 
  11. Replace the T6 Power Inverter Module.
  12. Verify that DTC P0AF8 does not set while operating the vehicle within the Conditions for Running the DTC.
    • If DTC P0AF8 sets 

      Replace the A28 Hybrid/EV Battery Contactor Assembly.

    • Go to next step: If DTC P0AF8 does not set 
  13. All OK.
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