Volt

Hybrid\EV Battery Voltage Present

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: 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.

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Review the high-voltage safety information prior to performing the High-Voltage Disabling procedure. Refer to High Voltage Safety .
2. The Servicing the A4 Battery Pack Assembly or 360 V DC Cables procedure has been performed.

⇒	The procedure has not been performed. Refer to High Voltage Disabling before continuing to the next step.

3. Disconnect the X1 and X2 harness connectors at the A28 hybrid battery contactor assembly.
4. Vehicle in Service Mode, using the DMM, verify that the voltage measures less than 1 V at the following points and earth:

•	Terminal 2 X1.

•	Terminal 4 X1.

•	Terminal 6 X1.

•	Terminal 7 X1.

•	Terminal 9 X1.

•	Terminal 11 X1.

⇒	If greater than the specified range, test the appropriate control circuit for a short-circuit to voltage. If the circuit tests normal, replace the K114B hybrid/EV powertrain control module 2.

5. Vehicle OFF, test for infinite resistance between control circuit terminal 2 X2 harness connector at the A28 hybrid/EV battery contactor assembly and earth.

⇒	If less than the specified value, test the control circuit for a short to ground. If the circuit tests normal, replace the K114B hybrid/EV powertrain control module 2.

Note: 

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

•	A 9 V battery can be used to test the DMM.

6. 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.

7. Using the DMM, verify the voltage measures less than 1 V at the following points and earth:

⇒	If the DMM does not properly measure a 12 V battery, repair or replace the DMM and repeat all voltage measurements.

8. Disconnect the high-voltage interlock harness connector listed below at the A28 hybrid/EV battery contactor assembly if not already disconnected.

•	F118 hybrid/EV battery pack connector jumper connector.

•	X6 14 V power module jumper connector.

•	X7 battery charger jumper connector.

9. Disconnect the X4 harness connector at the A28 hybrid/EV battery contactor assembly.
10. Verify that the voltage has been disabled at the X4 harness connector at the A28 hybrid/EV battery contactor assembly. Using the DMM, verify that the voltage measures less than 3 V at the following points:

•	High-voltage DC (-360 V) negative terminal B to vehicle chassis earth.

•	High-voltage DC (+360 V) positive terminal A to vehicle chassis earth.

•	High-voltage DC (+360 V) positive terminal A and high- voltage DC (-360 V) negative terminal B

⇒	If greater than the specified range, 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.

11. Disconnect the X5 harness connector at the A28 hybrid/EV battery contactor assembly.
12. Verify that the voltage has been disabled at the X5 harness connector at the A28 hybrid/EV battery contactor assembly. Using the DMM, verify that the voltage measures less than 3 V at the following points:

•	High-voltage DC (-360 V) negative terminal B to vehicle chassis earth.

•	High-voltage DC (+360 V) positive terminal A to vehicle chassis earth.

•	High-voltage DC (+360 V) positive terminal A and high- voltage DC (-360 V) negative terminal B

⇒	If greater than the specified range, 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: Wear your High-Voltage Insulation gloves until you have determined that a high-voltage exposure risk is no longer present.

Danger: The Hybrid/EV battery has exposed high-voltage and the installation of EL-5029 is required to completely isolate the voltage during the Hybrid/EV battery removal. Failure to follow the procedure exactly as written may result in serious injury or death.

13. Disconnect the X1 harness connector at the A28 hybrid/EV battery contactor assembly.

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

Note: Lowering the battery slightly will assist with the installation of the EL-50209.

14. Install the EL-50209.
15. Lower the battery from the vehicle with the EL-50209 installed. Refer to Drive Motor Battery Replacement and Shipping Preparation
16. There is a stuck-closed contactor and a loss of isolation within the A4 hybrid/EV battery pack assembly. Replace the A4 hybrid/EV pack assembly.

Perform the Diagnostic Repair Verification after completing the repair.

Drive Motor Battery Replacement and Shipping Preparation