Part 2
Note: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.
9. Disconnect the F117 harness connector at the K1 14 V accessory power module X1 harness connector.
10. Disconnect the X1 harness connector at the K1 14 V accessory power module.
Note: A 9 V battery can be used to test the DMM.
11. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
Note: 5 minutes must have elapsed since removing the manual service disconnect before continuing to allow the high voltage capacitors to discharge and ensure proper test results.
12. Verify that the voltage has been disabled at the K1 14 V accessory power module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
13. Verify that the voltage has been disabled at the X1 harness connector at the K1 14 V accessory power module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the A4 battery pack assembly. Refer to Hybrid\EV Battery Voltage Present Hybrid/EV Battery Voltage Present.
Note: A 9 V battery can be used to test the DMM.
14. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
15. If all the test results were less than 3 V, the K1 14 V accessory power module can now be serviced.
Servicing the T18 Battery Charger or X98 Hybrid/EV Battery Charger Receptacle
1. Review the high voltage safety information. Refer to High Voltage Safety High Voltage Safety
2. Disconnect and remove all 12 V battery chargers and the AC Charge Cable from the X98 Hybrid Battery Charger Receptacle.
3. Remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.
4. Attempt to start the vehicle with the Ignition Mode Switch.
• If the vehicle enters Propulsion System Active mode or the engine starts, locate and remove all keyless entry transmitters from within the vehicle and return to step 3.
Note: The 12 V battery must be disconnected to ensure proper test results.
5. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection
6. Remove the S15 manual service disconnect (1). Place the manual service disconnect in a secure place outside the vehicle.
7. Cover the exposed high voltage opening with UL(R) listed, or equivalent, insulation tape rated at a minimum of 600 V.
8. Wait 5 minutes before continuing, to allow the high voltage capacitors to discharge.
9. Remove the front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement
Note: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.
10. Disconnect the F120 harness connector at the T18 battery charger.
11. Disconnect the X4 harness connector at the T18 battery charger.
Note: A 9 V DC battery can be used to test the DMM.
12. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
Note: 5 minutes must have elapsed since removing the manual service disconnect before continuing to allow the high voltage capacitors to discharge and ensure proper test results.
13. Verify that no voltage is present at the T18 battery charger. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
14. Verify that the voltage has been disabled at the X4 harness connector at the T18 battery charger. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the A4 battery pack assembly. Refer to Hybrid\EV Battery Voltage Present Hybrid/EV Battery Voltage Present.
15. Disconnect the X3 harness connector at the T18 battery charger.
16. Verify that no voltage is present at the T18 battery charger. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage AC (-120/240 V) negative terminal B to vehicle chassis ground.
* High voltage AC (+120/240 V) positive terminal A to vehicle chassis ground.
* High voltage AC (+120/240 V) neutral terminal C to vehicle chassis ground.
* High voltage AC (+120/240 V) positive terminal A and high voltage AC (-120/240 V) negative terminal B.
* High voltage AC (+120/240 V) positive terminal A and high voltage AC neutral terminal C.
* High voltage AC (+120/240 V) positive terminal B and high voltage AC neutral terminal C.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
Note: A 9 V battery can be used to test the DMM.
17. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
18. If all the test results were less than 3 V, the T18 battery charger control module or X98 Hybrid Battery Charger Receptacle can now be serviced.
Servicing the G1 Air Conditioning Compressor
1. Review the high voltage safety information. Refer to High Voltage Safety High Voltage Safety
2. Disconnect and remove all 12 V battery chargers and the AC Charge Cable from the X98 Hybrid Battery Charger Receptacle.
3. Remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.
4. Attempt to start the vehicle with the Ignition Mode Switch.
• If the vehicle enters Propulsion System Active mode or the engine starts, locate and remove all keyless entry transmitters from within the vehicle and return to step 3.
Note: The 12 V battery must be disconnected to ensure proper test results.
5. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection
6. Remove the S15 manual service disconnect (1). Place the manual service disconnect in a secure place outside the vehicle.
7. Cover the exposed high voltage opening with UL(R) listed, or equivalent, insulation tape rated at a minimum of 600 V.
8. Wait 5 minutes before continuing, to allow the high voltage capacitors to discharge.
9. Remove the T6 power inverter module cover. Refer to Drive Motor Generator Power Inverter Module Cover Replacement Drive Motor Generator Power Inverter Module Cover Replacement.
Note: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.
10. Disconnect the X3 harness connector at the T6 power inverter module.
Note: A 9 V battery can be used to test the DMM.
11. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
Note: 5 minutes must have elapsed since removing the manual service disconnect before continuing to allow the high voltage capacitors to discharge and ensure proper test results.
12. Verify that the voltage has been disabled at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
13. Verify that the voltage has been disabled at the X3 harness connector at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the A4 battery pack assembly. Refer to Hybrid\EV Battery Voltage Present Hybrid/EV Battery Voltage Present.
14. Disconnect the X4 harness connector at the T6 power inverter module.
15. Verify that the voltage has been disabled at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
16. Verify that the voltage has been disabled at the X4 harness connector at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
17. Disconnect the F116 harness connector at the G1 air conditioning compressor X2 harness connector.
18. Disconnect the X2 harness connector at the G1 air conditioning compressor.
19. Verify that the voltage has been disabled at the G1 air conditioning compressor. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
Note: A 9 V battery can be used to test the DMM.
20. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
21. If all the test results were less than 3 V, the G1 air conditioning compressor can now be serviced.
Servicing the K10 Coolant Heater Control Module
1. Review the high voltage safety information. Refer to High Voltage Safety High Voltage Safety
2. Disconnect and remove all 12 V battery chargers and the AC Charge Cable from the X98 Hybrid Battery Charger Receptacle.
3. Remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.
4. Attempt to start the vehicle with the Ignition Mode Switch.
• If the vehicle enters Propulsion System Active mode or the engine starts, locate and remove all keyless entry transmitters from within the vehicle and return to step 3.
Note: The 12 V battery must be disconnected to ensure proper test results.
5. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection
6. Remove the S15 manual service disconnect (1). Place the manual service disconnect in a secure place outside the vehicle.
7. Cover the exposed high voltage opening with UL(R) listed, or equivalent, insulation tape rated at a minimum of 600 V.
8. Wait 5 minutes before continuing, to allow the high voltage capacitors to discharge.
9. Remove the traction power inverter module cover. Refer to Drive Motor Generator Power Inverter Module Cover Replacement Drive Motor Generator Power Inverter Module Cover Replacement.
Note: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.
10. Disconnect the X3 harness connector at the T6 power inverter module.
Note: A 9 V battery can be used to test the DMM.
11. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
Note: 5 minutes must have elapsed since removing the manual service disconnect before continuing to allow the high voltage capacitors to discharge and ensure proper test results.
12. Verify that the voltage has been disabled at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
13. Verify that the voltage has been disabled at the X3 harness connector at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the A4 battery pack assembly. Refer to Hybrid\EV Battery Voltage Present Hybrid/EV Battery Voltage Present.
14. Disconnect the X4 harness connector at the T6 power inverter module.
15. Verify that the voltage has been disabled at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
16. Verify that the voltage has been disabled at the X4 harness connector at the T6 power inverter module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
17. Disconnect the F119 harness connector at the K10 coolant heater control module X2 harness connector.
18. Disconnect the X2 harness connector at the K10 coolant heater control module.
19. Verify that the voltage has been disabled at the K10 coolant heater control module. Using the DMM, verify the voltage measures less than 3 V at the following points:
* High voltage DC (-360 V) negative terminal B to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A to vehicle chassis ground.
* High voltage DC (+360 V) positive terminal A and high voltage DC (-360 V) negative terminal B.
• If the test result was greater than 3 V, leave the DMM connected to the terminals until the voltage drops below 3 V to allow the high voltage capacitors to discharge. Continue to the next step once the voltage is below 3 V.
Note: A 9 V battery can be used to test the DMM.
20. Test the DMM by measuring a 12 V battery.
• If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.
21. If all the test results were less than 3 V, the K10 coolant heater control module can now be serviced.