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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 A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling
  2. Connect the 12 V battery, disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.
  3. Connect a test lamp between the serial data wake-up circuit terminal 3 and ground.
  4. Verify the test lamp turns ON and OFF when cycling the S39 Ignition Mode Switch between Vehicle in Service Mode and Vehicle OFF.
    • If the test lamp is always OFF 
    1. Vehicle OFF, disconnect the harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for less than 2 Ω in the serial data wake-up circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K114B Hybrid/EV Powertrain Control Module 2.
    • If the test lamp is always ON 
    1. Vehicle OFF, disconnect the harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for less than 1 V between the ignition circuit and ground.
      • If 1 V or greater, repair the short to voltage on the circuit.
      • If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
    • If the test lamp turns ON and OFF 
  5. Vehicle OFF, remove the A4 Hybrid/EV Battery Pack cover. Refer to High Voltage Battery Cover Replacement (Top Cover) , High Voltage Battery Cover Replacement (Front Cover) , High Voltage Battery Cover Replacement (Left Side) and/or High Voltage Battery Cover Replacement (Right Side)
  6. Connect the EL-50211  low voltage jumper harness extension.
  7. Disconnect the X8 harness connector at the K16 Battery Energy Control Module.
  8. Connect a test lamp between the serial data wake-up circuit terminal 3 and ground.
  9. Verify the test lamp turns ON and OFF when cycling the S39 Ignition Mode Switch between Vehicle in Service Mode and Vehicle OFF.
    • If the test lamp is always OFF 
    1. Vehicle OFF, disconnect the EL-50211  low voltage jumper harness extension.
    2. Test for less than 2 Ω in the serial data wake-up circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
    • If the test lamp is always ON 
    1. Vehicle OFF, disconnect the EL-50211  low voltage jumper harness extension.
    2. Test for less than 1 V between the ignition circuit and ground.
      • If 1 V or greater, repair the short to voltage on the circuit.
    • If the test lamp turns ON and OFF 
  10. Replace the K16 Battery Energy Control Module.
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