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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. Remove the Drive Motor Battery Cover. Refer to High Voltage Battery Cover Replacement . Disconnect the E54 Hybrid/EV Battery Pack Coolant Heater harness connector at the A28 Hybrid/EV Battery Contactor Assembly.
    3. NOTE:

    The following continuity tests must be performed using the Ohm setting.

  3. Test for 61 - 75 Ω between terminal 1 and terminal 2 at the E54 Hybrid/EV Battery Pack Coolant Heater.
    • If not within the specified range 

      Verify that the battery pack coolant heater fuse is not blown. Replace the fuse if it is blown and the E54 Hybrid/EV Battery Pack Coolant Heater.

    • Go to next step: If within the specified range 
    4. NOTE:

    The following continuity tests must be performed using an EL-50772  Insulation Multimeter.

  4. Select the Isolation test setting, then select the 500 V range. Refer to Troubleshooting With an Insulation Multimeter . Test for greater than 550M Ω between the E54 Hybrid/EV Battery Pack Coolant Heater terminals listed below and battery tray ground with the EL-50772  , set on the Isolation test setting:
    • Terminal 1
    • Terminal 2
    • If less than 550M Ω 
      NOTE:

      Also verify that the battery pack coolant heater fuse is not blown.

      Replace the E54 Hybrid/EV Battery Pack Coolant Heater.

    • Go to next step: If 550M Ω or greater 
  5. Replace the A28 Hybrid/EV Battery Contactor Assembly.
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