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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 Charging System Negative Contactor

  1. Vehicle OFF, remove the Underbody Front Air Deflector Replacement Center. Refer to Underbody Front Air Deflector Replacement (Center) . Disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.
    NOTE: The Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP5112, available in Service Information (SI), for a list of approved Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions.
  2. Test for less than 10 Ω between the ground circuit terminal 5 and ground.
    • If 10 Ω or greater 
    1. Vehicle OFF.
    2. Test for less than 2 Ω in the ground circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 10 Ω 
  3. Vehicle in Service Mode.
  4. Test for less than 1 V between the control circuit 11 and ground.
    • If 1 V or greater 
    1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.
    2. Test for less than 1 V between the control 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 Powertrain Control Module 2.
    • If less than 1 V 
  5. Vehicle OFF, install the EL-51099  Low Voltage Jumper Harness Extension
  6. Vehicle OFF, turn ON the park lamps.
    NOTE: The following setup steps MUST BE PERFORMED EXACTLY in order to exercise the contactor.
  7. Command the Hybrid/EV Battery Contactors ALL OPEN with a scan tool.
    NOTE:
    • DO NOT  press the power button and enter Vehicle in Service Mode.
    • Ignore P0ABC after pulling the S15 Manual Service Disconnect.
  8. Disconnect the S15 Manual Service Disconnect. Disconnect the EL-51099  Low Voltage Jumper Harness Extension from the X358 harness connector at the A4 Hybrid/EV Battery Pack. Connect a test lamp between the control circuit terminal 11 and ground.
  9. Command the Hybrid/EV Battery Charger Negative Contactor CLOSED and ALL OPEN with a scan tool. Verify that the test lamp turns ON and OFF.
    NOTE: DO NOT  use the Release Control button to turn OFF any of the contactors. Once the Release Control button is pushed the setup steps will need to be restarted from the beginning.
    • If the test lamp does not turn ON and OFF 
    1. Vehicle OFF, remove the test lamp. Disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.
    2. Test for infinite resistance between control circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the control 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 Powertrain Control Module 2.
    • If the test lamp does turn ON and OFF 
  10. Remove the test lamp, Vehicle in Service Mode.
    NOTE: The EL-51099 Low Voltage Jumper Harness Extension X357 Black connector should still be connected between the vehicle and the A4 Hybrid/EV Battery Pack.
  11. Test for less than 1 V between the control circuit 11 and ground at the A4 Hybrid/EV Battery Pack.
    • If 1 V or greater 

      Replace the A4 Hybrid/EV Battery Pack.

    • If less than 1 V 
  12. Vehicle OFF, remove the Drive Motor Battery Cover. Refer to Drive Motor Battery Cover Replacement
  13. Disconnect the X359 harness connector at the A28 Hybrid/EV Battery Contactor Assembly.
  14. Test for infinite resistance between control circuit 11 X358 and ground circuit terminal 5.
    • If less than infinite resistance 

      Replace the A4 Hybrid/EV Battery Pack.

    • If infinite resistance 
  15. Test for less than 2 Ω in the control circuit end to end.
    • If 2 Ω or greater 

      Replace the A4 Hybrid/EV Battery Pack.

    • If less than 2 Ω 
  16. Replace the A28 Hybrid/EV Battery Contactor Assembly.

Battery Charging System Positive Contactor

  1. Vehicle OFF, remove the Underbody Front Air Deflector Replacement Center. Refer to Underbody Front Air Deflector Replacement (Center) . Disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.
    NOTE: The Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP5112, available in Service Information (SI), for a list of approved Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions.
  2. Test for less than 10 Ω between the ground circuit terminal 5 and ground.
    • If 10 Ω or greater 
    1. Vehicle OFF.
    2. Test for less than 2 Ω in the ground circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 10 Ω 
  3. Vehicle in Service Mode.
  4. Test for less than 1 V between the control circuit 12 and ground.
    • If 1 V or greater 
    1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.
    2. Test for less than 1 V between the control 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 Powertrain Control Module 2.
    • If less than 1 V 
  5. Vehicle OFF, install the EL-51099  Low Voltage Jumper Harness Extension
  6. Vehicle OFF, turn ON the park lamps.
    NOTE: The following setup steps MUST BE PERFORMED EXACTLY in order to exercise the contactor.
  7. Command the Hybrid/EV Battery Contactors ALL OPEN with a scan tool.
    NOTE:
    • DO NOT  press the power button and enter Vehicle in Service Mode.
    • Ignore P0ABC after pulling the S15 Manual Service Disconnect.
  8. Disconnect the S15 Manual Service Disconnect. Disconnect the EL-51099  Low Voltage Jumper Harness Extension from the X358 harness connector at the A4 Hybrid/EV Battery Pack. Connect a test lamp between the control circuit terminal 12 and ground.
  9. Command the Hybrid/EV Battery Charger Positive Contactor CLOSED and ALL OPEN with a scan tool. Verify that the test lamp turns ON and OFF.
    NOTE: DO NOT  use the Release Control button to turn OFF any of the contactors. Once the Release Control button is pushed the setup steps will need to be restarted from the beginning.
    • If the test lamp does not turn ON and OFF 
    1. Vehicle OFF, remove the test lamp. Disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.
    2. Test for infinite resistance between control circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the control 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 Powertrain Control Module 2.
    • If the test lamp does turn ON and OFF 
  10. Remove the test lamp, Vehicle in Service Mode.
    NOTE: The EL-51099 Low Voltage Jumper Harness Extension X357 Black connector should still be connected between the vehicle and the A4 Hybrid/EV Battery Pack.
  11. Test for less than 1 V between the control circuit 12 and ground at the A4 Hybrid/EV Battery Pack.
    • If 1 V or greater 

      Replace the A4 Hybrid/EV Battery Pack.

    • If less than 1 V 
  12. Vehicle OFF, remove the Drive Motor Battery Cover. Refer to Drive Motor Battery Cover Replacement
  13. Disconnect the X359 harness connector at the A28 Hybrid/EV Battery Contactor Assembly.
  14. Test for infinite resistance between control circuit 12 X358 and ground circuit terminal 5.
    • If less than infinite resistance 

      Replace the A4 Hybrid/EV Battery Pack.

    • If infinite resistance 
  15. Test for less than 2 Ω in the control circuit end to end.
    • If 2 Ω or greater 

      Replace the A4 Hybrid/EV Battery Pack.

    • If less than 2 Ω 
  16. Replace the A28 Hybrid/EV Battery Contactor Assembly.

Battery Charging System Multifunction Contactor

  1. Vehicle OFF, remove the Underbody Front Air Deflector Replacement Center. Refer to Underbody Front Air Deflector Replacement (Center) . Disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.
    NOTE: The Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP5112, available in Service Information (SI), for a list of approved Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions.
  2. Test for less than 10 Ω between the ground circuit terminal 5 and ground.
    • If 10 Ω or greater 
    1. Vehicle OFF.
    2. Test for less than 2 Ω in the ground circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 10 Ω 
  3. Vehicle in Service Mode.
  4. Test for less than 1 V between the control circuit 8 and ground.
    • If 1 V or greater 
    1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.
    2. Test for less than 1 V between the control 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 Powertrain Control Module 2.
    • If less than 1 V 
  5. Vehicle OFF, install the EL-51099  Low Voltage Jumper Harness Extension
  6. Vehicle OFF, turn ON the park lamps.
    NOTE: The following setup steps MUST BE PERFORMED EXACTLY in order to exercise the contactor.
  7. Command the Hybrid/EV Battery Contactors ALL OPEN with a scan tool.
    NOTE:
    • DO NOT  press the power button and enter Vehicle in Service Mode.
    • Ignore P0ABC after pulling the S15 Manual Service Disconnect.
  8. Disconnect the S15 Manual Service Disconnect. Disconnect the EL-51099  Low Voltage Jumper Harness Extension from the X358 harness connector at the A4 Hybrid/EV Battery Pack. Connect a test lamp between the control circuit terminal 8 and ground.
  9. Command the Hybrid/EV Battery Multifunction Contactor CLOSED and ALL OPEN with a scan tool. Verify that the test lamp turns ON and OFF.
    NOTE: DO NOT  use the Release Control button to turn OFF any of the contactors. Once the Release Control button is pushed the setup steps will need to be restarted from the beginning.
    • If the test lamp does not turn ON and OFF 
    1. Vehicle OFF, remove the test lamp. Disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.
    2. Test for infinite resistance between control circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the control 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 Powertrain Control Module 2.
    • If the test lamp does turn ON and OFF 
  10. Remove the test lamp, Vehicle in Service Mode.
    NOTE: The EL-51099 Low Voltage Jumper Harness Extension X357 Black connector should still be connected between the vehicle and the A4 Hybrid/EV Battery Pack.
  11. Test for less than 1 V between the control circuit 8 and ground at the A4 Hybrid/EV Battery Pack.
    • If 1 V or greater 

      Replace the A4 Hybrid/EV Battery Pack.

    • If less than 1 V 
  12. Vehicle OFF, remove the Drive Motor Battery Cover. Refer to Drive Motor Battery Cover Replacement
  13. Disconnect the X359 harness connector at the A28 Hybrid/EV Battery Contactor Assembly.
  14. Test for infinite resistance between control circuit 8 X358 and ground circuit terminal 5.
    • If less than infinite resistance 

      Replace the A4 Hybrid/EV Battery Pack.

    • If infinite resistance 
  15. Test for less than 2 Ω in the control circuit end to end.
    • If 2 Ω or greater 

      Replace the A4 Hybrid/EV Battery Pack.

    • If less than 2 Ω 
  16. Replace the A28 Hybrid/EV Battery Contactor Assembly.
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