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Loss of Isolation on the High-Voltage Main Bus

Danger: Ensure all High-Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

Danger: Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

   • Safety glasses with appropriate side shields when within 50 feet of the vehicle, either indoors or outdoors
   • Certified and up-to-date Class "0" Insulation gloves rated at 1,000 V with leather protectors
      -  Visually and functionally inspect the gloves before use.
      -  Wear the Insulation gloves at all times when working with the high- voltage battery assembly, whether the system is energised or not.
Failure to follow the procedure exactly as written may result in serious injury or death.

Danger: This vehicle is equipped with a high-voltage battery that is completely isolated from the chassis earth. Never utilise AC powered test equipment to probe the high voltage system. Serious injury, death and component damage could occur if the high-voltage system is earthed through the electric utility.

Failure to follow the procedure exactly as written may result in serious injury or death.

Danger: Any hybrid/EV battery pack replacement shall be performed by High-Voltage Qualified Technicians only. The replacement procedure can be found in the service instruction and must be strictly followed at all times. The High-Voltage Qualified Technician is responsible for adherence to the manufacturer's service instructions as well as current national legal regulations. If the hybrid/EV battery pack needs to be replaced contact the Technical Assistance Centre for further instructions prior to removal of the battery pack.

Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools .

Loss of Isolation on the High-Voltage Main Bus

    Note: Wear your High-Voltage Insulation gloves until you have determined that a high-voltage exposure risk is no longer present.

  1. Ignition OFF, disable the high voltage at the A4 hybrid battery pack. Refer to High Voltage Disabling .
  2. Connect the 12 V battery.
  3. Ignition ON, verify that DTC P0AA1, P0AD9, P0ADD, P0AE2, P0AE4, P0D0A, P0D11, P1EBC-P1EBF, P1EC0 or P1EC3-P1EC5 is not set.
    4. ⇒If any DTC is set, diagnose them first. Refer to DTC P0AA1, P0AD9, P0ADD, P0AE2, P0AE4, P0D0A, P0D11, P1EBC-P1EBF, P1EC0 or P1EC3-P1EC5 .
  4. Ignition OFF, disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection .

    5. Note: The following continuity tests must be performed using an Insulation Multimeter. Select the Isolation test setting, then select the 500 V range.

  5. Using the Insulation Multimeter, test for greater than 750k Ω between the circuit terminals listed below and ground.
    6. • A28 Hybrid battery contactor assembly harness connector terminal A +300 V X4.
    • A28 Hybrid battery contactor assembly harness connector terminal B -300 V X4.
    ⇒If the test result is less than the specified value, disconnect the X356A connector at the K1 14 V power module. Test for greater than 750k Ω. If the test result is greater than the specified value, replace the K1 14 V power module. If the test result is less than the specified value, replace the 300 V DC cables.
  6. Test for greater than 750k Ω between the circuit terminals listed below and earth.
    7. • T6 Power inverter module harness connector terminal A -300 V X3.
    • T6 Power inverter module harness connector terminal B +300 V X3.
    ⇒If the test result is less than the specified value, replace the 300 V DC cables.
  7. Disconnect the X4 harness connector at the T6 power inverter module.

    8. Note: The following continuity tests require both the air conditioning control module and cabin heater control module circuits to be isolated by performing the following test up to 3 times if a fault is detected.

  8. Test for greater than 750k Ω between the circuit terminals listed below and earth.
    9. • Terminal A +300 V X4.
    • Terminal B -300 V X4.
    ⇒If the test result is less than the specified value, disconnect the X2 connector at the G1 air conditioning control module. Test for greater than 750k Ω between the circuit terminal and earth. If the test result is greater than the specified value, replace the G1 air conditioning control module.
    ⇒If the test result is less than the specified value, with the X2 connector at the G1 air conditioning control module disconnected. Disconnect the X2 connector at the K10 cabin heater control module. Test for greater than 750k Ω between the circuit terminal and earth. If the test result is greater than the specified value, replace the K10 cabin heater control module. If the test result is less than the specified value, replace the 300 V DC cables.
  9. Disconnect the X5 harness connector at the at the T6 power inverter module

    10. Note: There may be up to a 5 second delay for proper test results to be displayed.

  10. Test for greater than 750k Ω between the 3-phase cable circuit terminals listed below and earth.
    11. • Terminal 1 300 V X5.
    • Terminal 2 300 V X5.
    • Terminal 3 300 V X5.
    ⇒If the test result is less than the specified value, disconnect the X2 connector at the M15A Drive Motor 1. Test for greater than 750k Ω between the circuit terminal X2 at the M15A Drive Motor 1 and earth. If the test result is greater than the specified value, replace the 3- phase cables. If the test result is less than the specified value, replace the M15A Drive Motor 1.
  11. Disconnect the X6 harness connector at the T6 power inverter module.
  12. Test for greater than 750k Ω between the 3-phase cable circuit terminals listed below and earth.
    13. • Terminal 1 300 V X6.
    • Terminal 2 300 V X6.
    • Terminal 3 300 V X6.
    ⇒If the test result is less than the specified value, disconnect the X2 connector at the M15A Drive Motor 1. Test for greater than 750k Ω between the circuit terminal X2 at the M15B Drive Motor 2 and earth. If the test result is greater than the specified value, replace the 3- phase cables. If the test result is less than the specified value, replace the M15B Drive Motor 2.
  13. Disconnect the X8 harness connector at the power inverter module.
  14. Test for greater than 1.0M Ω between the 3-phase cable circuit terminals listed below and earth.
    15. • Terminal 1 300 V X8.
    • Terminal 2 300 V X8.
    • Terminal 3 300 V X8.
    ⇒If the test result is less than the specified value, replace the G5 transmission fluid pump - auxiliary.
  15. Test for greater than 750k Ω between the T6 power inverter module circuit terminals listed below and earth.
    16. • Terminal A +300 V X3.
    • Terminal B -300 V X3.
    • Terminal A +300 V X4.
    • Terminal B -300 V X4.
    • Terminal 1 300 V X5.
    • Terminal 2 300 V X5.
    • Terminal 3 300 V X5.
    • Terminal 1 300 V X6.
    • Terminal 2 300 V X6.
    • Terminal 3 300 V X6.
    • Terminal 1 300 V X8.
    • Terminal 2 300 V X8.
    • Terminal 3 300 V X8.
    ⇒If the test result is less than the specified value, replace the T6 power inverter module.
  16. If all circuits test normal, replace the A4 hybrid battery pack.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

    •  Drive Motor Battery Replacement and Shipping Preparation
    • 300 Volt Battery Positive and Negative Cable Replacement Link to 207100
    •  Air Conditioning and Drive Motor Battery Cooling Compressor Replacement
    •  Heater Coolant Heater Replacement
    •  Accessory DC Power Control Module Replacement
    • Control Module References for the T6 power inverter module replacement, programming and set-up
   


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