VIN

Licence Plate

1

Review the high-voltage safety information. Refer to High Voltage Safety .

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2

Vehicle OFF. Post red HIGH-VOLTAGE ENABLED sign clearly visible on the vehicle.

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3

Ensure the area around the vehicle is restricted and marked as such via warning cones, cordon tape or chain. Ensure all personnel not tasked with enabling the High-Voltage System have cleared the area.

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4

Disconnect and remove all 12 V battery chargers and the AC Charge Cable from the X98 Hybrid Battery Charger Receptacle.

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5

Remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

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6

Attempt to start the vehicle with the Ignition Mode Switch.

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7

Secure the vehicle from rolling, set transmission selector to park (P) position.

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8

Note: The 12 V battery must be disconnected to ensure proper test results.

Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection .

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9

Remove the S15 manual service disconnect (1). Place the manual service disconnect in a secure place outside the vehicle.

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10

Cover the exposed high-voltage opening with insulation tape rated at a minimum of 600 V or equivalent.

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11

Wait 5 minutes before continuing, to allow the high-voltage capacitors to discharge.

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12

Verify the EL-50554 voltage disable assurance test harness using the EL-50774, verify that the EL-50554-1 and EL-50554-2 cables measure less than 1 Ω at the following points:

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13

Using the EL-50774, verify that the EL-50554-1 and EL-50554-2 have infinite resistance between the High-voltage DC (+360 V) positive terminal A to High-voltage DC (-360 V) negative terminal B.

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14

Verify the EL-50554-1 and EL-50554-2 High-voltage DC (-360 V) negative terminal B and the High-voltage DC (+360 V) positive terminal A have the proper terminal tension. Refer to Testing for Proper Terminal Contact. Testing for Intermittent Conditions and Poor Connections

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15

Remove the T6 power inverter module cover. Refer to Drive Motor Generator Power Inverter Module Cover Replacement

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16

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

Disconnect the X3 harness connector at the T6 power inverter module.

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17

Note: The following tests must be performed using a EL-50774 set to the DC voltage setting. Performing the following tests with the EL-50774 not set on the DC voltage setting will result in inaccurate test results.

Note: A 9 V DC battery can be used to test the EL-50774.

Test the EL-50774 by measuring a 12 V battery.

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18

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.

Verify that the voltage has been disabled at the T6 power inverter module. Using the EL-50774, verify the voltage measures less than 3 V at the following points:

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19

Verify that the voltage has been disabled at the X3 harness connector at the T6 power inverter module. Using the EL-50774, verify the voltage measures less than 3 V at the following points:

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20

Remove the 3 catalytic converter nuts . Disconnect catalytic converter from the exhaust manifold. Move and secure the exhaust to one side. Refer to Catalytic Converter Replacement .

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21

Remove the front exhaust pipe heat shield. Refer to Exhaust Pipe Heat Shield Replacement : Rear  → Center  → Front .

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22

Disconnect the X1 and X2 harness connectors at the A28 hybrid battery contactor assembly.

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23

Disconnect the high-voltage interlock harness connector listed below at the A28 hybrid battery contactor assembly.

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24

Disconnect the X4 harness connector at the A28 hybrid battery contactor assembly.

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25

Connect the EL-50554-1 to the A28 hybrid battery contactor assembly. Using the EL-50774, verify the voltage measures less than 3 V at the following points:

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26

Verify that the voltage has been disabled at the X4 harness connector at the A28 hybrid battery contactor assembly. Using the EL-50774, verify the voltage measures less than 3 V at the following points:

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27

Disconnect the X5 harness connector at the A28 hybrid battery contactor assembly.

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28

Connect the EL-50554-2 to the A28 hybrid battery contactor assembly. Using the EL-50774, verify the voltage measures less than 3 V at the following points:

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29

Verify that the voltage has been disabled at the X5 harness connector at the A28 hybrid battery contactor assembly harness. Using the EL-50774, verify the voltage measures less than 3 V at the following points:

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30

Disconnect the X3 harness connector at the A28 hybrid battery contactor assembly.

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31

Verify that the voltage has been disabled at the A28 hybrid battery contactor assembly. Using the EL-50774, verify the voltage measures less than 3 V at the following points:

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32

Note: A 9 V DC battery can be used to test the EL-50774.

Test the EL-50774 by measuring a 12 V battery.

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33

If all the test results were less than 3 V, the A4 battery pack assembly, 360 V DC power inverter cables or general vehicle can now be serviced.

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34

Sign, date and time this protocol. Replace red HIGH VOLTAGE ENABLED with GREEN HIGH VOLTAGE DISABLED sign.

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Date:

Time:

Signature