Volt

High-Voltage System Inspection

The Supplemental Inflatable Restraint (SIR) sensors are designed to identify the severity of a collision and from what direction a collision has occurred. The SIR sensors typically detect collision conditions for occupant impact-protection reasons. The hybrid powertrain control module 2 will open the high-voltage contactor relays and disable the vehicle whenever an SIR deployment occurs.

The supplemental inflatable restraint module transmits through serial data to the hybrid powertrain control module 2 whenever a sensor fault is detected or a collision event has been detected. The hybrid powertrain control module 2 will set a Crash Event Detected event and enter into a disable condition.

A complete inspection of the high-voltage system and components must be performed if the vehicle has been involved in a collision. The Crash Event Detected condition will remain active until cleared by the hybrid powertrain control module 2 Clear Secured High Voltage DTCs output control function of the scan tool.

Special Tools

For equivalent regional tools, refer to Special Tools .

Danger: High voltage enabling and disabling shall be only performed by High Voltage Qualified Technicians. The procedures for high-voltage enabling/disabling can be found in the service instructions and must be strictly followed at all times. The usage of the Protocol High Voltage Disabling/Enabling is mandatory. The High-Voltage Qualified Technician is responsible for the adherence to the manufacturer's service instructions as well as current national legal regulations.

Danger: High-voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures 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.

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.

1. The vehicle has been involved in a collision with body damage.

⇒	If vehicle damage does not allow for repair, remove the A4 hybrid/EV battery pack from the vehicle. Refer to Drive Motor Battery Replacement and Shipping Preparation . Refer to www.recyclemybattery.com for recycling information.

2. Have the air bags been deployed?

⇒	If the air bags have been deployed, refer to Air Bags Deployed Inspection.

3. Does the vehicle have right front end damage?

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If the vehicle has right front end damage, perform the high voltage disable procedure at the T18 battery charger. Refer to High Voltage Disabling . Perform a visual inspection of the T18 battery charger. Remove any covers or shields to gain access. Inspect the assembly for cracks, dents, pinched, cut or frayed high-voltage DC 300V cables, low-voltage cables or other physical damage.

4. Vehicle OFF, perform a visual inspection of the following high voltage components listed. Remove any covers or shields to gain access. Inspect the assembly for cracks, dents, pinched, cut or frayed high-voltage DC 300V cables, low-voltage cables or other physical damage.

•	A4 hybrid/EV battery pack (exterior only -- includes tray and A28 hybrid/EV battery contactor assembly)

•	T18 battery charger (if not done in previous step).

•	G1 air conditioning compressor.

•	K10 coolant heater control module.

•	K1 14 V accessory power module.

•	T6 power inverter module.

•	T12 automatic transmission assembly.

•	The high-voltage DC 300 V cable between the A4 hybrid/EV battery pack and the T18 battery charger.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the A4 hybrid/EV battery pack.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the G1 air conditioning compressor.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K10 coolant heater control module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K1 14 V accessory power module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K107A drive motor 1 control module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K107B drive motor 2 control module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K6 transmission fluid pump control module-auxiliary.

⇒	Perform the appropriate high-voltage disable procedure. Refer to High Voltage Disabling . Replace all components and cables identified as damaged. Continue to next step after repairs.

5. Vehicle in Service Mode, verify that no DTCs are set.

⇒	If any DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle .

6. With a scan tool clear the hybrid powertrain control module 2 Crash Event Detected disable condition only after all high-voltage components identified as damaged have been replaced. Refer to Clear Secured High-Voltage DTCs .
7. Perform the required body repairs as per the approved service procedures.

1. Perform the high-voltage disable procedure at the A4 hybrid/EV battery pack. Refer to High Voltage Disabling . If vehicle damage does not allow for access to the S15 hybrid/EV battery pack high-voltage manual disconnect lever, disconnect the 12V battery and remove the damaged portion of the vehicle until such time as the S15 hybrid/EV battery pack high-voltage manual disconnect lever can be removed and the High Voltage Disabling procedure can be completed. Remove the A4 hybrid/EV battery pack from the vehicle. Refer to Drive Motor Battery Replacement and Shipping Preparation .
2. Perform a visual inspection of the A4 hybrid/EV battery pack for cracks, dents or other physical external damage.

⇒	If physical damage is observed, replace all components identified as damaged. Continue to next step after repairs.

3. Perform a visual inspection of the following high-voltage components listed. Remove any covers or shields to gain access. Inspect the assembly for cracks, dents, pinched, cut or frayed high-voltage DC 300V cables, low-voltage cables or other physical damage.

•	T18 battery charger.

•	G1 air conditioning compressor.

•	K10 coolant heater control module.

•	K1 14 V accessory power module.

•	T6 power inverter module.

•	T12 automatic transmission assembly.

•	The high-voltage DC 300 V cable between the A4 hybrid/EV battery pack and the T18 battery charger.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the A4 hybrid/EV battery pack.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the G1 air conditioning compressor.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K10 coolant heater control module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K1 14 V accessory power module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K107A drive motor 1 control module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K107B drive motor 2 control module.

•	The high-voltage DC 300 V cable between the T6 power inverter module and the K6 transmission fluid pump control module-auxiliary.

⇒	Replace all components and cables identified as damaged. Continue to next step after repairs.

Note: Ignore DTCs P0A0C, P0A0D, P0D17 and P0D18. These will set with the S15 hybrid/EV battery pack high voltage manual disconnect lever removed, the 12 V battery connected and the Vehicle in Service Mode.

4. Install the EL-50211 low-voltage jumper harness extension.
5. Connect the 12 V battery.
6. Vehicle in Service Mode, verify that no DTCs are set.

⇒	If any DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle .

7. Perform the required body repairs as per the approved service procedures.