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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 high voltage at the A4 hybrid/EV battery pack. High Voltage Disabling 
  2. Remove the A4 hybrid/EV battery pack cover. Battery Upper Cover Replacement
    3. CAUTION:

    The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

    1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.
    2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.
    3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.
  3. Disconnect all K16 battery energy control module connectors in the sequence provided in Repair Instructions. Battery Energy Control Module Replacement
  4. Inspect the harness connectors and the K16 battery energy control module connectors for corrosion.
    • If corrosion is present 

      Replace the Hybrid/EV Battery Pack Internal Harness and the K16 Battery Energy Control Module as applicable.

    • Go to next step: If corrosion is not present 
    5. NOTE:

    The Hybrid/EV Battery Section schematics in Energy Storage identify the C5 Hybrid/EV Battery Modules appropriate to each cell battery module row.

  5. Disconnect the harness connectors at the appropriate C5 Hybrid/EV Battery Modules as indicated by the failed cell battery module row number observed during Circuit/System Verification.
  6. Inspect the harness connectors and the C5 Hybrid/EV Battery Module connectors for corrosion.
    • If corrosion is present 

      Replace the Hybrid/EV Battery Pack Internal Harness and the C4 Hybrid/EV Battery Section, as applicable.

    • Go to next step: If corrosion is not present 
  7. Replace the appropriate C4 Hybrid/EV Battery Section.
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