< Назад | Содержимое | Далее >

‌SPECIFICATIONS

FASTENER SPECIFICATIONS

ELECTRICAL

Hybrid/EV Energy Storage - Volt

Reusable Threaded Fastener Tightening Specifications

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

SCHEMATIC WIRING DIAGRAMS

HYBRID/EV ENERGY STORAGE WIRING SCHEMATICS

Battery Energy Control Module Power, Ground and Data Communication

Fig. 1: Battery Energy Control Module Power, Ground and Data Communication Courtesy of GENERAL MOTORS COMPANY

K114B Hybrid Powertrain Control Module 2 Power, Ground, and Internal Battery Communication

Fig. 2: K114B Hybrid Powertrain Control Module 2 Power, Ground, and Internal Battery Communication Courtesy of GENERAL MOTORS COMPANY

High Voltage Interlock Loop - Main

Fig. 3: High Voltage Interlock Loop - Main Courtesy of GENERAL MOTORS COMPANY

High Voltage Contactors - Control

Fig. 4: High Voltage Contactors - Control Courtesy of GENERAL MOTORS COMPANY

High Voltage Contactors

Fig. 5: High Voltage Contactors

Courtesy of GENERAL MOTORS COMPANY

Hybrid/EV Battery Section 1

Fig. 6: Hybrid/EV Battery Section 1

Courtesy of GENERAL MOTORS COMPANY

Hybrid/EV Battery Section 2

Fig. 7: Hybrid/EV Battery Section 2

Courtesy of GENERAL MOTORS COMPANY

Hybrid/EV Battery Section 3

Fig. 8: Hybrid/EV Battery Section 3

Courtesy of GENERAL MOTORS COMPANY

COMPONENT LOCATOR

DISASSEMBLED VIEWS

Battery Cover Assembly

Fig. 9: Battery Cover Assembly Components Courtesy of GENERAL MOTORS COMPANY

Battery Cable Assembly

Fig. 10: Battery Cable Assembly Components Courtesy of GENERAL MOTORS COMPANY

Battery Harness Module Assembly

Fig. 11: Battery Harness Module Assembly Components Courtesy of GENERAL MOTORS COMPANY

Battery Cell Assembly

Fig. 12: Battery Cell Assembly Components Courtesy of GENERAL MOTORS COMPANY

Battery Relay Mounting Assembly

Fig. 13: Battery Relay Mounting Assembly Components Courtesy of GENERAL MOTORS COMPANY

Battery Relay Assembly

Fig. 14: Battery Relay Assembly Components Courtesy of GENERAL MOTORS COMPANY

HIGH VOLTAGE BATTERY IDENTIFICATION

Battery Label with Smart Number

Fig. 15: Battery Label with Smart Number Courtesy of GENERAL MOTORS COMPANY

1. Smart Number

2. GM Assigned Part Number Identifier

3. Model Year

4. Technology Type: Energy, BAS, or HEV

5. Generation

6. Serial Number

7. VPPS Code

8. VPPS Identifier

9. VPPS: GM Compressed Vehicle Partitioning and Product Structure Code

10. Vehicle Mounting Location

11. DUNS Code

12. DUNS Identifier

13. Supplier Manufacturing/Assembly Site

14. Trace Code

15. Trace Code Identifier

16. Line/Machine

17. Shift

18. Manufactured/Assembled Year

19. Julian Day of Manufacture/Assembly

20. Daily Sequence

Battery Label with Part Number

Fig. 16: Battery Label with Part Number Courtesy of GENERAL MOTORS COMPANY

1. GM Part Number

2. GM Assigned Part Number Identifier

3. GM 8-Digit P/N

4. Revision Level

5. VPPS Code

6. VPPS Identifier

7. VPPS: GM Compressed Vehicle Partitioning and Product Structure Code

8. Vehicle Mounting Location

9. DUNS Code

10. DUNS Identifier

11. Supplier Manufacturing/Assembly Site

12. Trace Code

13. Trace Code Identifier

14. Line/Machine

15. Shift

16. Manufactured/Assembled Year

17. Julian Day of Manufacture/Assembly

18. Daily Sequence

DIAGNOSTIC INFORMATION AND PROCEDURES

HIGH VOLTAGE SAFETY

The High Voltage Safety procedure will perform the following tasks:

Identify precautions when performing service or inspections. Identify labels for components, wire harness, and connectors. Identify high voltage insulation glove inspection procedure.

When applicable, additional region-specific high voltage service requirements and/or Dangers will be located in the General Information, Safety Regulations service category and take precedence over the information presented here.

General High Voltage Dangers

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

NOTE: For European Region, a face shield is required in place of safety glasses.

WARNING: 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 may result in serious injury or death.

NOTE: For European Region, a special voltage tester such as the EL-52229 may be required. A multimeter that can measure current is prohibited.

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

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

Precautions when Performing Service or Inspections

Always verify that the high voltage has been disabled before working on or around high voltage components, wires, cables, or harnesses.

Remove all metal objects such as rings and watches.

The EL-48900 HEV safety kit contains safety cones. Place the safety cones around the vehicle to alert other technicians that you are working on the high voltage system.

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

Always wear certified and tested high voltage insulation gloves when inspecting or testing any high voltage wires and components.

Use the "One Hand" rule whenever possible: Work with only one hand.

Keep the other hand behind your back.

DO NOT carry any metal objects such as a mechanical pencil or a measuring tape that could fall and cause a short circuit.

After removing ring-terminal style high voltage wires, protect and insulate the terminal ends immediately with the EL-50209 high voltage terminal cover and UL® Listed or equivalent insulation tape rated at a minimum of 600 V.

Always tighten the high voltage terminal fasteners to the specified torque. Insufficient or excessive torque will cause malfunctions or damage.

After finishing work on the high voltage systems and before reinstalling the high voltage manual disconnect, inspect for the following:

Verify high voltage system integrity and that all connectors are installed. Verify that all tools or loose components have been removed.

Labels for Components, Wire Harness, and Connectors

The wire harnesses and cables for high voltage circuits are encased in an orange colored covering. In addition, high voltage components such as the Energy Storage System and high voltage cables are affixed with "High Voltage" red danger and orange warning labels.

High Voltage Insulation Glove Inspection Procedure

Fig. 17: Glove Inspection Procedure

Courtesy of GENERAL MOTORS COMPANY

The following procedure visually and functionally inspects the insulation gloves to be used while performing service on high voltage systems. This inspection procedure should be performed prior to any procedure that requires the use of class "0" insulation gloves rated at 1000 V.

1. Remove glove from leather protector.

2. Trap air in the glove and seal opening. Pinch or roll the opening closed tightly to prevent any air loss.

3. Press glove to increase pressure.

4. Inspect for the following conditions: Pin holes

Air leaks

Wear, tears, or abrasions Damp or wet material

Expired certification

If any of the above conditions are met

Do not use the gloves.

If none of the above conditions are met

5. All OK. Gloves are OK to use.

HIGH VOLTAGE DISABLING

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Refer to Diagnostic Procedure Instructions to provide an overview of each diagnostic category.

Circuit/System Description

The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure utilizes two possible methods to disable high voltage:

NOTE: The High Voltage Disable procedure, regardless of the method, only de- energizes the high voltage circuits and components outside of the Hybrid/EV battery pack, dangerous voltage levels always exist within the Hybrid/EV battery pack.

1. Scan Tool Method: The on-vehicle control module software, initiated by the GDS2 scan tool, disables and discharges high voltage outside of the Hybrid/EV battery pack.

2. DMM Method: If the GDS2 Scan Tool Method does not complete or cannot be implemented, A DMM-based physical measurement method is performed at certain high voltage connectors.

A successful GDS2 Scan Tool High Voltage Disable Procedure will:

1. Perform an analysis of the vehicle condition by verifying specific DTCs have run and passed.

2. Calculate the high voltage isolation resistance to the vehicle chassis.

3. Open the high voltage contactor relays and discharge the high voltage system by setting a crash event lockout. When this stage is reached the Clear Secured High Voltage DTCs procedure will have to be performed to enable the system again.

4. Latch a Service Lockout condition to prevent unintended enabling of the high voltage system.

5. Instruct you when to remove the manual service disconnect.

6. Indicate successful high voltage disabling by:

Displaying a PROCEDURE COMPLETE message on the scan tool

Displaying a CHECK VEHICLE'S HIGH VOLTAGE STATUS message on the scan tool which will require you to verify:

Vehicle is displaying an Instrument Cluster DIC message

Vehicle is sounding a continuous audible response from the vehicle Pedestrian Alert alarm

High Voltage Inverter Voltage parameter on scan tool indicates system high voltage has been lowered to a safe level

An Unsuccessful GDS2 Scan Tool High Voltage Disable Procedure:

If vehicle conditions DO NOT permit the GDS2 scan tool procedure to complete, you will have to verify high voltage disabling by measuring the applicable connectors for safe voltage level with a DMM.

Diagnostic Aids

Review the High Voltage Connectors information for connector identification and the approved procedures for disconnecting and connecting high voltage connectors.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

INLINE HARNESS CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Testing

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

WARNING: 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 1000V 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 energized or not.

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

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

NOTE: Ensure the 12V battery is fully charged and tested prior to continuing.

2. Disconnect and remove all 12 V Battery Chargers and the Charge Cable from the X98 Hybrid Battery Charger Receptacle.

NOTE: If vehicle conditions do not allow for GDS2 scan tool usage, proceed to GDS2 Scan Tool Procedure Unsuccessful below.

3. Access the GDS2 scan tool High Voltage Disable Procedure located under HPCM2 Control Functions.

4. Perform the actions as specified within the GDS2 scan tool procedure.

NOTE: If at any point the GDS2 scan tool displays a "PROCEDURE UNSUCCESSFUL" warning message or you lose communication, stop the GDS2 procedure and proceed to GDS2 Scan Tool Procedure Unsuccessful below.

5. WHEN INSTRUCTED by the GDS2 procedure, remove the S15 Manual Service Disconnect. Refer to Drive Motor Battery High Voltage Manual Disconnect Lever Replacement. Place the S15 Manual Service Disconnect in a secure place outside the vehicle. Cover the exposed high voltage opening with UL listed, or equivalent, insulation tape rated at a minimum of 600 V.

6. Verify the GDS2 scan tool procedure completed successfully by observing a GDS2 scan tool "PROCEDURE COMPLETE" message followed by a "CHECK VEHICLE'S HIGH VOLTAGE STATUS" message. Verify these messages are combined with ALL the following conditions:

Continuous Audible Vehicle Response of the Pedestrian Alert alarm DIC message

High Voltage Inverter Voltage parameter on scan tool indicates system high voltage is less than 10 volts

If the procedure was unsuccessful

Proceed to GDS2 Scan Tool Procedure Unsuccessful below.

If the procedure successfully completed

1. Turn the vehicle power mode to OFF.

2. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection . Note: Disconnecting the 12 V battery is the only method to deactivate the audible vehicle response. The audible response will not resume when the 12 V battery is reconnected.

NOTE: You will have to perform the Clear Secured High Voltage DTCs GDS2 scan tool procedure in order to re-enable the high voltage system upon completion of the required vehicle servicing.

3. The high voltage circuits and components OUTSIDE of the Hybrid/EV battery pack are now disabled/discharged.

NOTE: Print the High Voltage Disable Confirmation table if necessary. Circle Steps Completed to identify which components have been disabled.

High Voltage Disable Confirmation Table

GDS2 Scan Tool Procedure Unsuccessful

NOTE: If the GDS2 Scan Tool Procedure was unsuccessful, follow the steps below as applicable.

1. Turn the vehicle power mode to OFF. Remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

2. 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 the beginning of the GDS2 Scan Tool Procedure Unsuccessful procedure.

If the vehicle did not enter Propulsion System Active mode and the engine did not start

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

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

4. Remove the S15 Manual Service Disconnect. Refer to Drive Motor Battery High Voltage Manual Disconnect Lever Replacement. Place the S15 Manual Service Disconnect in a secure place outside the vehicle. Cover the exposed high voltage opening with UL® listed, or equivalent, insulation tape rated at a minimum of 600 V.

NOTE: 5 min must elapse before removing any high voltage connectors. Removal of non high voltage components is allowed during this wait time.

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

Fig. 18: T6 Power Inverter Module X1 56-Way Connector Cover, Nut And Bolts Courtesy of GENERAL MOTORS COMPANY

6. Remove the T6 Power Inverter Module X1 56-way connector cover nut (1) and bolts (2). Remove the cover (3).

7. Disconnect the T6 Power Inverter Module X1 56-way connector.

Fig. 19: T6 Power Inverter Module X2 HV Cable Cover And Remaining Bolt Courtesy of GENERAL MOTORS COMPANY

8. Remove the T6 Power Inverter Module X2 HV cable cover remaining bolt (1) and HV cable cover (2).

NOTE: A 9 V DC battery or the vehicles 12 V battery can be used to test the DMM.

9. Verify the test DMM by measuring a known good 9 to 12 V battery.

If the DMM does not properly measure the test battery

Repair or replace the DMM and repeat all voltage measurements.

If the DMM properly measures the test battery

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

Inspect the High Voltage DC connection seal for deformation or damage. Inspect the High Voltage DC connector for seal residue or debris. Always replace damaged seals and clean seal remnants from the connector with a non-marring tool.

10. Disconnect the T6 Power Inverter Module X2 high voltage harness connector which connects to the A4 Hybrid/EV Battery Pack.

Fig. 20: T6 Power Inverter Module X2 Connector Courtesy of GENERAL MOTORS COMPANY

NOTE: 5 min must have elapsed since removing the S15 Manual Service Disconnect before continuing to allow the high voltage capacitors to discharge and ensure proper test results.

11. Verify the voltage measures less than 3 V at the T6 Power Inverter Module X2 connector (1) 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 3 V or greater

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.

If less than 3 V

12. Verify the voltage measures less than 3 V at the HV DC harness connector (2) to the T6 Power Inverter Module X2 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 3 V or greater

There is a stuck closed contactor and a loss of isolation within the A4 Hybrid/EV Battery Pack. Refer to

Hybrid/EV Battery Voltage Present.

If less than 3 V

13. Verify the test DMM by measuring a known good 9 to 12 V battery.

If the DMM does not properly measure the test battery

Repair or replace the DMM and repeat all voltage measurements.

If the DMM properly measures the test battery

14. The T6 Power Inverter Module is now discharged. You may perform T6 Power Inverter Module, T12 Transmission or General vehicle service and exit the High Voltage Disabling procedure at this time but you MUST continue if additional high voltage component service is required.

If you do not need to perform additional high voltage component service

HV Disable for T6 power inverter module and/or T12 Transmission is complete.

If you need to perform additional high voltage component service

Fig. 21: A28 Hybrid/EV Battery Contactor Assembly Connectors Courtesy of GENERAL MOTORS COMPANY

15. Disconnect the low voltage harness connectors X357 and X358 at the A28 Hybrid/EV Battery Contactor Assembly.

16. Disconnect the T18 Battery Charger harness connector at the A28 Hybrid/EV Battery Contactor Assembly X6.

17. Verify the voltage measures less than 3 V at the A28 Hybrid/EV Battery Contactor Assembly connector X6 at the following points:

High voltage DC (-360 V) negative terminal 2 to vehicle chassis ground. High voltage DC (+360 V) positive terminal 1 to vehicle chassis ground.

High voltage DC (+360 V) positive terminal 1 and high voltage DC (-360 V) negative terminal 2.

If 3 V or greater

There is a stuck closed contactor and a loss of isolation within the A4 Hybrid/EV Battery Pack. Refer to

Hybrid/EV Battery Voltage Present.

If less than 3 V

18. Verify the voltage measures less than 3V at the A28 Hybrid/EV Battery Contactor Assembly connector X6 at the T18 Battery Charger harness side at the following points:

High voltage DC (-360 V) negative terminal 2 to vehicle chassis ground. High voltage DC (+360 V) positive terminal 1 to vehicle chassis ground.

High voltage DC (+360 V) positive terminal 1 and high voltage DC (-360 V) negative terminal 2.

If 3 V or greater

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.

If less than 3 V

19. Disconnect the G1 A/C Compressor harness connector at the A28 Hybrid/EV Battery Contactor Assembly X5.

20. Verify the voltage measures less than 3 V at the A28 Hybrid/EV Battery Contactor Assembly connector X5 at the following points:

High voltage DC (-360 V) negative terminal 2 to vehicle chassis ground. High voltage DC (+360 V) positive terminal 1 to vehicle chassis ground.

High voltage DC (+360 V) positive terminal 1 and high voltage DC (-360 V) negative terminal 2.

If 3 V or greater

There is a stuck closed contactor and a loss of isolation within the A4 Hybrid/EV Battery Pack. Refer to

Hybrid/EV Battery Voltage Present.

If less than 3 V

21. Verify the voltage measures less than 3V at the A28 Hybrid/EV Battery Contactor Assembly connector X5 at the G1 A/C Compressor harness side at the following points:

High voltage DC (-360 V) negative terminal 2 to vehicle chassis ground. High voltage DC (+360 V) positive terminal 1 to vehicle chassis ground.

High voltage DC (+360 V) positive terminal 1 and high voltage DC (-360 V) negative terminal 2.

If 3 V or greater

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.

If less than 3 V

22. Disconnect the K10 Cabin Heater Control Module harness connector at the A28 Hybrid/EV Battery Contactor Assembly connector X4.

23. Verify the voltage measures less than 3 V at the A28 Hybrid/EV Battery Contactor Assembly connector X4 at the following points:

High voltage DC (-360 V) negative terminal 2 to vehicle chassis ground. High voltage DC (+360 V) positive terminal 1 to vehicle chassis ground.

High voltage DC (+360 V) positive terminal 1 and high voltage DC (-360 V) negative terminal 2.

If 3 V or greater

There is a stuck closed contactor and a loss of isolation within the A4 Hybrid/EV Battery Pack. Refer to

Hybrid/EV Battery Voltage Present.

If less than 3 V

24. Verify the voltage measures less than 3 V at the A28 Hybrid/EV Battery Contactor Assembly connector X4 at the K10 Cabin Heater Control Module harness side 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 3 V or greater

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.

If less than 3 V

25. Disconnect the T6 Power Inverter Module harness connector at the A28 Hybrid/EV Battery Contactor Assembly X3.

26. Verify the voltage measures less than 3 V at the A28 Hybrid/EV Battery Contactor Assembly connector X3 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 3 V or greater

There is a stuck closed contactor and a loss of isolation within the A4 Hybrid/EV Battery Pack. Refer to

Hybrid/EV Battery Voltage Present. If less than 3 V

NOTE: Discard any 300 V Battery Positive and Negative cable connector seal that may be deformed or damaged. Replace any seal that is deformed, missing, or damaged.

NOTE: A 9 V DC battery or the vehicles 12 V battery can be used to test the DMM.

27. Verify the test DMM by measuring a known good 9 to 12 V battery.

If the DMM does not properly measure the test battery

Repair or replace the DMM and repeat all voltage measurements.

If the DMM properly measures the test battery

28. The high voltage connectors at the A4 Hybrid/EV battery pack are now discharged. You may perform A4 Hybrid/EV battery pack removal and exit the High Voltage Disabling procedure at this time but you MUST continue if additional high voltage component service is required.

If you do not need to perform additional high voltage component service

HV Disable for T6 power inverter module, T12 Transmission and A4 Hybrid battery pack is complete.

If you need to perform additional high voltage component service

29. Disconnect the high voltage connector(s) at the component(s) to be serviced.

30. Verify the voltage measures less than 3 V at the Module connector at the following points: High voltage DC (-360 V) negative terminal B or 2 to vehicle chassis ground.

High voltage DC (+360 V) positive terminal A or 1 to vehicle chassis ground.

High voltage DC (+360 V) positive terminal A or 1 and high voltage DC (-360 V) negative terminal B or 2.

If 3 V or greater

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.

If less than 3 V

31. Repeat the previous step at all high voltage module connectors for any additional high voltage components requiring service.

32. Verify the test DMM by measuring a known good 9 to 12 V battery.

If the DMM does not properly measure the test battery

Repair or replace the DMM and repeat all voltage measurements.

If the DMM properly measures the test battery

33. High voltage is disabled/discharged at all TESTED modules.

HIGH VOLTAGE ENABLING

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Refer to Diagnostic Procedure Instructions to provide an overview of each diagnostic category.

Circuit/System Description

The High Voltage Enabling procedure will perform the following tasks: Identify how to enable high voltage.

Verify high voltage system integrity and that all connectors are installed.

Diagnostic Aids

Review the High Voltage Connectors information for connector identification and the approved procedures for disconnecting and connecting high voltage connectors.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Testing

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

WARNING: 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 1000V 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 energized or not.

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

1. Review the high voltage safety information prior to performing the High Voltage Enabling procedure. Refer to

High Voltage Safety

2. Ensure that the 12 V battery is disconnected. Refer to Battery Negative Cable Disconnection and Connection

NOTE: Always tighten the high voltage fasteners to the specified torque.

Insufficient or excessive torque will cause malfunctions or damage.

The high voltage connectors that have been disconnected do not require a specific sequence when connecting.

3. After finishing work on the high voltage systems and before installing the S15 Manual Service Disconnect, inspect for the following:

Verify that all tools or loose components have been removed.

Inspect any disconnected 300 V Battery Positive and Negative cable seals for being deformed, missing, or damaged. Replace any seals that are deformed, missing, or damaged.

Verify high voltage system integrity and that all connectors are installed.

Verify that all high voltage interlock circuit connectors and covers are installed.

Install any components or connectors that have been removed or replaced during diagnosis.

4. Install the S15 Manual Service Disconnect (1). Refer to Drive Motor Battery High Voltage Manual Disconnect Lever Replacement

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

6. Vehicle in Service Mode.

7. Verify if the A4 Hybrid/EV Battery Pack or the K16 Battery Energy Control Module has been replaced.

If the A4 Hybrid/EV Battery Pack or the K16 Battery Energy Control Module has been replaced

Program the K16 Battery Energy Control Module. Refer to Battery Energy Control Module Programming and Setup . Continue to the next step once programming is complete.

If the A4 Hybrid/EV Battery Pack or the K16 Battery Energy Control Module has not been replaced

8. Verify if the High Voltage Disabling procedure performed prior to vehicle repair utilized the GDS2 scan tool method.

If the GDS2 scan tool high voltage disabling procedure was performed, the high voltage contactor relays are in a lockout state.

Perform the Clear Secured High Voltage DTCs procedure and return to the next step.

If the DMM Method high voltage disabling procedure was performed

9. Vehicle in Service Mode, perform the driver window express learn and clear all DTC Information with a scan tool. Refer to Window Motor Programming - Express Function .

10. Vehicle OFF and all vehicle systems OFF. It may take up to 5 min for all vehicle systems to power down.

11. Vehicle in Service Mode.

12. Verify with a scan tool no DTCs are set.

If any DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If no DTCs are set

13. Vehicle ON. Open the hood to start and idle the engine for 2 min.

14. Vehicle OFF and wait 5 min.

15. Vehicle in Service Mode. Verify with the scan tool the Hybrid/EV Powertrain Control Module and K114B Hybrid/EV Powertrain Control Module 2 DTC Information that the following DTCs have Ran Since Code Clear and have not set:

Motor position sensor learn DTCs P0C17 and P0C18.

Contactor DTCs P0AD9, P0ADD, P0D0A, and P1EBD.

Discharge and Pre-charge DTCs P0C76, P0C77, P0C78 and P0AFB.

High voltage loss of isolation DTCs P0AA6, P1AE6, P1AF0 and P1AF2.

If any DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If the DTCs have Not Ran Since Code Clear

1. Review and operate the vehicle according to the applicable DTC Conditions for Running and ensure the DTCs run and pass.

2. Verify with the scan tool the Hybrid/EV Powertrain Control Module and K114B Hybrid/EV Powertrain Control Module 2 DTC Information that the specified DTCs have Ran Since Code Clear and have not set:

If any DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle . If the DTCs have Ran and Passed

3. Test drive the vehicle and verify no DTCs are set.

If the DTCs have Ran and Passed

16. Test drive the vehicle and verify no DTCs are set.

EL-48571 HIGH VOLTAGE BATTERY PIN OUT BOX REFERENCE

Special Tools

EL-48571-55 Battery Pin Out Box Adapter

For regional equivalent tools, refer to Special Tools.

HIGH VOLTAGE CONNECTORS

Connector Type Identification

Fig. 22: Connector Type Identification Courtesy of GENERAL MOTORS COMPANY

WARNING: 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 1000V 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 energized or not.

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

WARNING: Ensure all High Voltage safety procedures are followed. Failure to follow the

procedure exactly as written may result in serious injury or death.

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

HV280 Connector Procedure

HV280 Disconnect Procedure

Fig. 23: Connector Position Assurance (CPA) Tab Courtesy of GENERAL MOTORS COMPANY

1. Pull the connector position assurance (CPA) (1) tab back from the locked position to the pre-stage position. There will be an audible click sound when the CPA tab is in the correct position.

Fig. 24: Female Connector And Female Connector Lock Courtesy of GENERAL MOTORS COMPANY

NOTE: Pull on the sides of the connectors only. The connector will stop in a partial- mate position when performing the next step.

2. Press firmly on the back of the female connector lock (1) and hold down, while pulling the female connector

(2) assembly halfway apart, until the connector is in the partial-mate position.

Fig. 25: Second Connector Lock And Female Connector Courtesy of GENERAL MOTORS COMPANY

NOTE: If the connector does not separate easily when pulled after the second connector lock is released, check that both sides of the second connector lock have been released.

3. Insert a suitable tool into the slot under the second connector lock (1). Using the tool as a lever, release the female connector by gently raising the second connector lock. An audible click or clicks will be heard on both sides of the connector as the second lock is released.

4. Remove the tool and pull the female connector (2) to fully disconnect.

HV280 Connect Procedure

Fig. 26: Connector Position Assurance (CPA) Tab, Index Guides And Connector Courtesy of GENERAL MOTORS COMPANY

NOTE: Ensure the CPA tab (1) is in the pre-stage position.

The connector will be fully mated when a series of 2 audible clicks is heard.

1. Align the connector with the index features (2) and install the connector by pushing on the sides of the connector (3).

Fig. 27: Connector Position Assurance (CPA) Tab Courtesy of GENERAL MOTORS COMPANY

NOTE: There will be an audible click sound when the CPA tab is placed in the locked position. The CPA tab and connector body touch when fully seated.

2. Push the CPA tab (1) forward from the pre-stage position to the locked position.

AMP+HVA280 Connector Procedure

AMP+HVA280 Disconnect Procedure

Fig. 28: Connector Position Assurance (CPA) Tab Courtesy of GENERAL MOTORS COMPANY

1. Pull the connector position assurance (CPA) (1) tab back from the locked position to the pre-stage position. There will be an audible click sound when the CPA tab is in the correct position.

Fig. 29: Female Connector Lock And Female Connector Courtesy of GENERAL MOTORS COMPANY

NOTE: Pull on the sides of the connectors only. The connector will stop in a partial- mate position when performing the next step.

2. Press firmly on the back of the female connector lock (1) and hold down, while pulling the female connector

(2) assembly halfway apart, until the connector is in the partial-mate position.

Fig. 30: Depressing Second Connector Lock To Disconnect Female Connector Courtesy of GENERAL MOTORS COMPANY

3. Insert a suitable tool into the slot (1) and depress the second connector lock. An audible click will be heard as the second lock is released.

4. Remove the tool and pull the female connector (2) to fully disconnect.

AMP+HVA280 Connect Procedure

Fig. 31: Connector Position Assurance (CPA) Tab, Index Guides And Connector Courtesy of GENERAL MOTORS COMPANY

NOTE: Ensure the CPA tab (1) is in the pre-stage position.

The connector will be fully mated when a series of two audible clicks is heard.

1. Align the connector with the index features (2) and install the connector by pushing on the sides of the connector (3).

Fig. 32: Connector Position Assurance (CPA) Tab Courtesy of GENERAL MOTORS COMPANY

NOTE: There will be an audible click sound when the CPA tab is placed in the locked position. The CPA tab and connector body touch when fully seated.

2. Push the CPA tab (1) forward from the pre-stage position to the locked position.

PP2000 Axial Connector Procedure

PP2000 Axial Disconnect Procedure

Fig. 33: Connector Position Assurance (CPA) Tab Courtesy of GENERAL MOTORS COMPANY

1. Pull the connector position assurance (CPA) tab (1) back from the locked position to the pre-stage position. There will be an audible click sound when the CPA tab is in the correct position.

Fig. 34: Primary Lock Feature

Courtesy of GENERAL MOTORS COMPANY

2. Depress the primary lock feature (1) to release the lever.

Fig. 35: Lift And Rotate Lever

Courtesy of GENERAL MOTORS COMPANY

NOTE: Only rotate the lever until the locks contact each other at the top of the connector (2).

3. Lift and rotate the lever (1) to place the connector in the partial-mate position.

Fig. 36: Connector Lock And Lever

Courtesy of GENERAL MOTORS COMPANY

4. Depress the connector lock (1). Keep the lock depressed and rotate the lever (2) forward to the pre-stage position. There will be an audible click sound when the connector lock disengages.

5. Pull back on the female connector to disconnect the connector completely.

PP2000 Axial Connect Procedure

Fig. 37: Lever, Connector Position Assurance (CPA) Tab And Index Guide Courtesy of GENERAL MOTORS COMPANY

CAUTION: Using the connector lever to draw the connectors together during the pre- stage position may damage the connector lever pivots. Initial mating of the connector halves MUST be performed without the use of the connector lever. Engage the harness connector to the header connector by hand and allow the connector lever to freely rotate from the pre-stage position. Use the lever to fully mate the connector halves only when lever has rotated beyond the pre- stage position.

NOTE: Ensure the lever (1) and CPA tab (2) are in the pre-stage position.

1. Align the connector with the index features (3) and install the connector to the pre-locking position. The lever will be released from its pre-stage position with a short movement.

Fig. 38: Lever And Connector Position Assurance (CPA) Tab Courtesy of GENERAL MOTORS COMPANY

2. Close the lever (1) to the full-stage position. There will be a very audible click sound.

3. Push the CPA tab (2) to lock the connector in the full-stage position. There will be a very audible click sound when the connector is secured.

PP2000 90 NFS Connector Procedure

PP2000 90 NFS Disconnect Procedure

Fig. 39: Using Tool Through Opening To Unlock Lever Courtesy of GENERAL MOTORS COMPANY

1. Place a suitable tool, such as a small flat-blade screwdriver, through the opening (1) at the front of the lever, and extend the tip down to near the base of the connector (2).

2. Rotate the tool slightly in either direction to unlock the lever.

Fig. 40: Lever And Female Connector Courtesy of GENERAL MOTORS COMPANY

3. Rotate the lever (1) to place the connector in a partial-mate position.

4. Remove the female connector (2) to complete the disconnection.

NOTE: Always clean seal remnants from the connector with a non-marring tool.

5. Inspect the High Voltage DC harness connector for seal residue or debris. Clean as necessary.

6. Inspect the High Voltage DC header connector seal for deformation or damage. Replace the DC connector header when seal damage is observed.

PP2000 90 NFS Connect Procedure

Fig. 41: Lever In Pre-Stage Assembly Position Courtesy of GENERAL MOTORS COMPANY

1. Ensure the lever is in the pre-stage assembly position (1).

Fig. 42: Female Connector And Lever Courtesy of GENERAL MOTORS COMPANY

2. Install the female connector (1) in the partial-mate position.

3. Rotate the lever (2) to place the connector in the full-mate position. There will be a very audible click sound when the lever locks in the full-stage position.

DTC P0A0C OR P0A0D: HIGH VOLTAGE SYSTEM INTERLOCK CIRCUIT VOLTAGE

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P0A0C

High Voltage System Interlock Circuit Low Voltage

DTC P0A0D

High Voltage System Interlock Circuit High Voltage

Circuit/System Description

The main high voltage interlock circuit loop is used to determine if access to high voltage components is being attempted. Attempting to gain access to these high voltage components causes the main high voltage interlock circuit to open. The hybrid/EV powertrain control module 2 sources 5 V on the main high voltage interlock circuit loop and monitors the return voltage. A resistor in the manual service disconnect allows the hybrid/EV powertrain control module 2 to detect improper main high voltage interlock circuit voltage, such as open or shorted circuits.

Conditions for Running the DTC

P0A0C

The 12 V battery voltage is greater than 10.2 V. The high voltage contactors are closed.

P0A0D

The 12 V battery voltage is greater than 10.2 V.

The hybrid/EV powertrain control module 2 is awake and communicating.

Conditions for Setting the DTC

P0A0C

The hybrid/EV powertrain control module 2 detects main high voltage interlock circuit loop voltage is less than 1.5 V.

P0A0D

The hybrid/EV powertrain control module 2 detects main high voltage interlock circuit loop voltage is greater than 1.2 V when the circuit is inactive.

OR

The hybrid/EV powertrain control module 2 detects main high voltage interlock circuit loop voltage is greater than 2.2 V when the circuit is active.

Actions Taken When the DTC Sets

DTCs P0A0C and P0A0D are Type A DTCs.

The hybrid/EV powertrain control module 2 opens the high voltage contactors.

Conditions for Clearing the DTC

DTCs P0A0C and P0A0D are Type A DTCs.

Diagnostic Aids

Test for a fully engaged hybrid battery pack high voltage manual disconnect whenever an open high voltage interlock circuit condition is observed. The hybrid battery pack high voltage manual disconnect must be pressed down fully in order to engage the high voltage interlock circuit terminals.

The main high voltage interlock circuit is also routed through several inline connectors.

The hybrid powertrain control module 2 scan tool parameter High Voltage Interlock Circuit Status will indicate Open Circuit whenever improper interlock circuit voltage is observed. Manipulating connections while monitoring the parameter for a change from Closed Circuit to Open Circuit may help locate intermittent connections.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

INLINE HARNESS CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Vehicle in Service Mode.

2. With a scan tool, observe the hybrid/EV powertrain control module 2 High Voltage Interlock Circuit Status parameter.

The parameter indicates an OPEN CIRCUIT condition.

Refer to Circuit/System Testing

The parameter indicates a CLOSED CIRCUIT condition.

3. All OK.

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

NOTE: The main high voltage interlock circuit is routed through several inline connectors and the S15 Manual Service Disconnect. The following steps assume the S15 manual service disconnect and the appropriate inline connectors are connected.

1. Vehicle OFF, disconnect the X357 harness connector at the A4 Hybrid/EV Battery Pack.

2. Vehicle in Service Mode. Test for 4.8V or greater between the 5 V reference circuit terminal 9 and ground.

If less than 4.8V

1. Vehicle OFF, disconnect the X1 connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the 5 V reference circuit terminal 47, X1 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance

3. Test for less than 2 Ω in the 5 V reference circuit terminal 47 end to end. If 2 Ω or greater, repair the open/high resistance on the circuit.

If less than 2 Ω replace the K114B Hybrid/EV Powertrain Control Module 2.

If 4.8V or greater

NOTE: Installing a 35 - 50 Ω resistor in place of a jumper should result in a constant Closed Circuit parameter indication.

3. With a scan tool, observe the hybrid/EV powertrain control module 2 High Voltage Interlock Circuit Status parameter while momentarily installing a jumper between the 5V reference circuit terminal 9 and the signal circuit terminal 11, X357. Verify the parameter momentarily indicates a Closed Circuit whenever the jumper is first connected.

If the parameter never indicates a Closed Circuit condition

1. Vehicle OFF, disconnect the X1 connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the signal circuit terminal 45 and ground. If less than infinite resistance, repair the short to ground on the circuit. If infinite resistance

3. Test for less than 2 Ω in the signal circuit terminal 45 end to end.

If 2 Ω or greater, repair the open/high resistance on the circuit.

If less than 2 Ω replace the K114B Hybrid/EV Powertrain Control Module 2.

If the parameter will indicate a Closed Circuit condition

4. Vehicle OFF. Test for 35 - 50 Ω between the 5 V reference circuit terminal 9 and the signal circuit terminal 11, X357 at the A4 Hybrid/EV battery pack.

If within the specified range

All OK.

If not within the specified range

5. Disable the high voltage for servicing at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling.

6. Disconnect the S15 Manual Service Disconnect.

7. Test for 35 - 45 Ω between the high voltage interlock circuit terminals of the S15 Manual Service Disconnect lever, terminal 1 and terminal 2.

If not within the specified range

Replace the S15 Manual Service Disconnect.

If within the specified range

8. Disconnect A4 Hybrid/EV battery pack connector X3.

9. Test for less than 2 Ω between the high voltage interlock circuit terminals of the 300V Battery Positive and Negative Cable.

If 2 Ω or greater

Replace the 300V Battery Positive and Negative Cable assembly.

If less than 2 Ω

10. Replace the A4 Hybrid/EV battery pack.

Component Testing

1. Disconnect the S15 Manual Service Disconnect.

2. Test for 35 - 45 Ω between the following terminals of the S15 Manual Service Disconnect, Terminal 1 and terminal 2.

If not within the specified range

Replace the S15 Manual Service Disconnect.

If within the specified range

3. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to Drive Motor Battery High Voltage Manual Disconnect Lever Replacement for S15 Manual Service Disconnect replacement.

Refer to Drive Motor Battery Replacement and Shipping Preparation for A4 Hybrid/EV battery pack replacement.

Refer to Battery 300-Volt Positive and Negative Cable Replacement - High Voltage Battery to Power Inverter Module and A/C Compressor

Refer to Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P0A7F: HYBRID/EV BATTERY PACK

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Refer to Diagnostic Procedure Instructions to provide an overview of each diagnostic category.

DTC Descriptor

DTC P0A7F

Hybrid/EV Battery Pack

Circuit/System Description

The hybrid/EV powertrain control module 2 calculates the high voltage battery pack capability and determines the high voltage battery pack end of life.

Conditions for Running the DTC

Vehicle ON.

The system voltage is at least 10.2 V.

Hybrid battery temperature is greater than 20° C (68° F). Hybrid battery temperature is less than 50° C (122° F).

Hybrid battery state of charge is between 15% and 100%.

When the hybrid/EV powertrain control module 2 calculates the actual battery power has exceeded the power limits multiplied by seconds of duration is greater than 80%.

None of the following DTCs are set: P0A9C, P0A9D, P0A9E, P0ABB, P0ABC, P0ABD, P0AC1, P0AC2, P0AC6, P0AC7, P0AC8, P0ACB, P0ACC, P0ACD, P0AE9, P0AEA, P0AEB, P0AF8, P0BC3, P0BC4, P0BC5, P0C34, P0C35, P0C36, P0C7D, P0C7E, P0C7F, P0C82, P0C83, P0C84, P0C89, P0C8A, P0C8B, P0C8E, P0C8F, P0C90, P0C93, P0C94, P0C95, P0C98, P0C99, P0C9A, P0CA9, P0CAA, P0CAB, P0CAE, P0CAF, P0CB0, P0CB3, P0CB4, P0CB5, P0CB8, P0CB9, P0CBA, P1A07, P1E8E, P1E8F, P1E90, P1E91, P1E93, P1E94, P1E95, P1E96, P1E97, P1E99, P1E9A, P1E9B, P1E9C, P1E9D, P1E9F, P1EA0, P1EA1, P1EA2, P1EA3, P1EA5, P1EB1, P1EB2, P1EB3, P1EB4, P1EB5, P1EBA, P1EBB, U0111, U185A, U2401, U2603, U2604, U2605, or U2606.

Conditions for Setting the DTC

Battery voltage and current is varying. Requires more than 10 minutes of city driving.

The hybrid/EV powertrain control module 2 calculates the power limits is less than the KW end of life power threshold.

Action Taken When the DTC Sets

DTC P0A7F is a type B DTC. Conditions for Clearing the DTC DTC P0A7F is a type B DTC. Diagnostic Aids

Removing the manual service disconnect before disconnecting the 12 V battery may cause a DTC P0A7F to set.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

NOTE: Removing the manual service disconnect before disconnecting the 12 V battery may cause a DTC P0A7F to set. Incorrectly performing the High Voltage Disabling procedure steps will cause false DTCs to set and result in misdiagnosis of vehicle components.

1. Record the freeze frame/failure records.

2. Verify that no other DTCs are set.

If any other DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle No other DTCs are set

3. Verify DTC P0A7F is set.

If DTC P0A7F is set

1. Vehicle OFF, disconnect the 12 V battery. Wait 30 seconds, reconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection .

2. Review and operate the vehicle according to the DTC Conditions for Running. Operate the vehicle for more than 10 minutes of city driving.

3. Verify that DTC P0A7F does not reset. If DTC P0A7F resets

1. Vehicle OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling.

2. Remove the A4 Hybrid/EV Battery Pack cover. Refer to High Voltage Battery Cover Replacement.

3. Inspect all internal high voltage busbar/cable terminals for arc-flash damage.

If high voltage terminal damage is present, replace the effected components.

If high voltage terminal damage is not present, replace the A4 hybrid/EV battery pack.

If DTC P0A7F does not reset

4. All OK.

If DTC P0A7F is not set

4. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to Drive Motor Battery Replacement and Shipping Preparation

Refer to Control Module References for battery energy control module and hybrid battery interface control modules replacement, programming and setup.

DTC P0AA1, P0AA4, P0AD9, P0ADD, P0AE3, P0AE4, P0D09, P0D0A, P1EBD, P1EC0, OR P1EC3: HYBRID/EV BATTERY & BATTERY CHARGING SYSTEM

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P0AA1

Hybrid/EV Battery Positive Contactor Circuit Stuck Closed

DTC P0AA4

Hybrid/EV Battery Negative Contactor Circuit Stuck Closed

DTC P0AD9

Hybrid/EV Battery Positive Contactor Control Circuit

DTC P0ADD

Hybrid/EV Battery Negative Contactor Control Circuit

DTC P0AE3

Hybrid/EV Battery Precharge Contactor Circuit Stuck Open

DTC P0AE4

Hybrid/EV Battery Precharge Contactor Control Circuit

DTC P0D0A

Battery Charging System Positive Contactor Control Circuit

DTC P0D09

Battery Charging System Positive Contactor Stuck Open

DTC P1EBD

Battery Charging System Contactor(s) Stuck Open

DTC P1EC0

Hybrid/EV Battery System Contactor(s) Stuck Open

DTC P1EC3

Hybrid/EV Battery Pack Heater Transistor Control Circuit

Circuit/System Description

The hybrid/EV battery contains 4 high voltage contactors and 1 solid state relay (transistor). The high voltage contactors and transistor allow the high voltage DC batteries to be connected to the vehicle or contain the high voltage DC within the hybrid/EV battery assembly. The 4 high voltage contactors consist of a main positive high voltage contactor, main negative high voltage contactor, charge positive high voltage contactor and a precharge negative high voltage contactor. The transistor controls the battery heater high voltage positive circuit. The contactors and transistor close and open in a specific sequence controlled by the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 supplies voltage to the control circuit for each high voltage contactor/transistor. Ground is provided through a vehicle ground external of the high voltage battery.

Conditions for Running the DTC

P0AA1

The 12 V battery voltage is greater than 10.2 V. The main negative contactor is open.

The main positive contactor has been open for more than 2 minutes.

The charger positive contactor has been open for more than 2 minutes.

None of the following DTCs are set; P0ABB, P0ABC, P0ABD, P0AF8, P1A07, P1AE8, P1AE9, or P1AEC.

P0AA4

The 12 V battery voltage is greater than 10.2 V. The main negative contactor is open.

The main positive contactor has been open for more than 2 minutes.

The charger positive contactor has been open for more than 2 minutes. Active battery heating is not enabled.

None of the following DTCs are set; P0ABB, P0ABC, P0ABD, P0AF8, P1A07, P1AE8, P1AE9, or P1AEC.

P0AD9, P0ADD, P0AE4, P0D0A, P1EC3 and P1EBD

The 12 V battery voltage is greater than 10.2 V.

P0AE3

During precharge mode.

The negative contactor is open. Battery heating is not enabled.

P0D09

During precharge mode.

The negative contactor is open. The charger contactor is closed.

Negative bus voltage is greater than 40 V.

P1EC0

The 12 V battery voltage is greater than 10.2 V.

The main positive and negative contactors have been closed for more than 1 second. The charger positive contactor is closed.

None of the following DTCs are set; P1AE8, P1AE9, or P1AEC.

Conditions for Setting the DTC

P0AA1

The positive bus voltage is greater than 30 V.

P0AA4

The negative bus voltage is greater than 30 V.

P0AD9, P0ADD and P0D0A

The hybrid/EV powertrain control module 2 has detected an open or short to voltage in the control circuit for the corresponding contactor.

P0AE3

The negative bus voltage is less than 5 V.

P0AE4

The hybrid/EV powertrain control module 2 has detected a short to voltage in the control circuit.

P0D09

The battery charger sensed voltage is less than 10 V.

P1EBD

The battery charger sensed voltage is less than 80% of hybrid/EV battery voltage.

P1EC0

The main bus voltage is less than 80% of hybrid/EV battery voltage.

P1EC3

The hybrid/EV powertrain control module 2 has detected an open, short to ground or short to voltage in the heater transistor control circuit.

Actions Taken When the DTC Sets

DTCs P0AE3, P0D09, P1EBD, or P1EC0 are type A DTCs.

DTCs P0AA1, P0AA4, P0AD9, P0ADD, P0AE4, P0D0A, or P1EC3 are type B DTCs.

Conditions for Clearing the DTC

DTCs P0AE3, P0D09, P1EBD, or P1EC0 are type A DTCs.

DTCs P0AA1, P0AA4, P0AD9, P0ADD, P0AE4, P0D0A, or P1EC3 are type B DTCs.

Diagnostic Aids

DTC P1EC3 will prevent battery heating and the vehicle will be unable to start in cold weather with battery temperatures below -25°C (-13°F).

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that DTC P0AD9, P0ADD, P0AE4, P0D0A, or P1EC3 is not set.

If any of the DTCs are set

Refer to Circuit/System Testing.

If none of the DTCs are set

3. Verify that DTC P0AA1 and/or P0AA4 is set without any of the above contactor Control Circuit DTCs.

If the DTC is set

Replace the A28 Hybrid/EV Battery Contactor Assembly.

If the DTC is not set

4. Connect the drive motor battery charger cable. Verify DTC P0D26 is not set and the vehicle will charge.

If the DTC is set and the vehicle will not charge

Refer to DTC P0D26 .

If the DTC is not set and the vehicle charges

5. Verify that DTC P0C78 is not set.

If the DTC is set

Refer to DTC P0C78 or P3061. If the DTC is not set

NOTE: The following setup steps must be performed exactly in order to exercise the contactors.

6. Ignition OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down.

7. OPEN the driver door using outside door handle. Leave driver door OPEN.

NOTE: The brake pedal must remain depressed throughout the remainder of the contactor steps.

8. PRESS and HOLD the brake pedal.

NOTE: DO NOT press the power button and enter Vehicle in Service Mode.

9. Command the Hybrid/EV Battery Contactors ALL OPEN with a scan tool.

10. Disconnect the S15 Manual Service Disconnect.

NOTE: DO NOT use the Release Control button to turn OFF any of the contactors.

Once the Release Control button is pushed the Circuit/System Verification will need to be restarted from the beginning.

11. Command the Hybrid/EV Battery Negative Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

12. Verify the Hybrid/EV Battery Negative Contactor should be heard closing and opening.

If the Hybrid/EV Battery Negative Contactor does not open and close

Refer to Circuit/System Testing.

If the Hybrid/EV Battery Negative Contactor does open and close

13. Command the Hybrid/EV Battery Positive Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

14. Verify the Hybrid/EV Battery Positive Contactor should be heard closing and opening.

If the Hybrid/EV Battery Positive Contactor does not open and close

Refer to Circuit/System Testing.

If the Hybrid/EV Battery Positive Contactor does open and close

15. Command the Hybrid/EV Battery Precharge Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

16. Verify the Hybrid/EV Battery Precharge Contactor should be heard opening and closing.

If the Hybrid/EV Battery Precharge Contactor does not open and close

Refer to Circuit/System Testing.

If the Hybrid/EV Battery Precharge Contactor does open and close

17. Command the Hybrid/EV Battery Charger Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

18. Verify the Hybrid/EV Battery Charger Contactor should be heard opening and closing.

If the Hybrid/EV Battery Charger Contactor does not open and close

Refer to Circuit/System Testing.

If the Hybrid/EV Battery Charger Contactor does open and close

19. All OK.

Circuit/System Testing

NOTE: You must perform Circuit/System Verification before proceeding.

DTC P0AD9, P0ADD, P0AE4, or P0D0A Contactor Diagnosis

1. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down.

2. Disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.

3. Test for less than 10 Ω between the ground circuit terminal 5 and ground.

If more than 10 Ω

1. Vehicle OFF.

2. Test for less than 2 Ω in the ground circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit.

If less than 2 Ω, repair the open/high resistance in the ground connection.

If less than 10 Ω

4. Verify that a test lamp illuminates between the B+ circuit terminal 1 and ground.

If the test lamp does not illuminate and the circuit fuse is good

1. Vehicle OFF.

2. Test for less than 2 Ω in the B+ circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit.

If less than 2 Ω, verify the fuse is not open and there is voltage at the fuse.

If the test lamp does not illuminate and the circuit fuse is open

1. Vehicle OFF.

2. Test for infinite resistance between the B+ circuit and ground.

If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance, replace the K16 Battery Energy Control Module and A28 Hybrid/EV Battery Contactor Assembly.

If the test lamp illuminates

5. Vehicle OFF, disconnect the X357 harness connector at the A4 Hybrid/EV Battery Pack. Vehicle in Service Mode.

6. Verify that a test lamp does not illuminate between each A4 Hybrid/EV Battery Pack harness connector control

circuit terminals listed below and ground: Terminal 2 X357

Terminal 4 X357

Terminal 6 X357

Terminal 7 X357

If the test lamp illuminates on any circuit

1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.

2. Test for less than 1 V between the control circuit and ground.

If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V, replace the K114B Hybrid Powertrain Control Module 2.

If the test lamp does not illuminate on all circuits

7. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2.

8. Test for infinite resistance between each A4 Hybrid/EV Battery Pack harness connector control circuit terminals listed below and ground:

Terminal 2 X357

Terminal 4 X357

Terminal 6 X357

Terminal 7 X357

If less than infinite resistance on either circuit

Repair the short to ground on the circuit.

If infinite resistance on both circuits

9. Test for less than 2 Ω between the harness connector terminals listed below:

Terminal 2 X357 at the A4 Hybrid/EV Battery Pack and terminal 9 X1 at the K114B Hybrid Powertrain Control Module 2

Terminal 4 X357 at the A4 Hybrid/EV Battery Pack and terminal 6 X1 at the K114B Hybrid Powertrain Control Module 2

Terminal 6 X357 at the A4 Hybrid/EV Battery Pack and terminal 8 X1 at the K114B Hybrid Powertrain Control Module 2

Terminal 7 X357 at the A4 Hybrid/EV Battery Pack and terminal 3 X1 at the K114B Hybrid Powertrain Control Module 2

If 2 Ω or greater on any circuit

Repair the open/high resistance in the circuit.

If less than 2 Ω on all circuits

10. Replace the A28 Hybrid/EV Battery Contactor Assembly.

11. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets

Replace the K114B Hybrid Powertrain Control Module 2.

If DTC P0C78 or P3061 does not set

12. All OK.

DTC P1EC3 - Hybrid/EV Battery Pack Heater Transistor Diagnosis

1. Vehicle in Service Mode.

2. Verify that DTC P0AA1, P0AA4, P0AD9, P0ADD, P0AE3, P0AE4, P0D0A, P0D09, P1EBD, or P1EC0, is

not set.

If any contactor DTC is set

Refer to the appropriate contactor Circuit/System Testing.

If no contactor DTC is set

3. Vehicle OFF, disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.

4. Vehicle in Service Mode.

5. Verify that a test lamp does not illuminate between the A4 Hybrid/EV Battery Pack harness control circuit terminal 2 and ground.

If the test lamp illuminates

1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.

2. Test for less than 1 V between the control circuit and ground.

If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V, replace the K114B Hybrid Powertrain Control Module 2.

If the test lamp does not illuminate

6. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2.

7. Test for infinite resistance between the A4 Hybrid/EV Battery Pack harness control circuit terminal 2 and ground.

If less than infinite resistance

Repair the short to ground on the circuit.

If infinite resistance

Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater

Repair the open/high resistance in the circuit.

If less than 2 Ω

8. Perform the High Voltage Disabling procedure and replace the A28 Hybrid/EV Battery Contactor Assembly.

9. Verify that DTC P1EC3 does not set while operating the vehicle within the Conditions for Running the DTC.

If the DTC is set

Replace the K114B Hybrid Powertrain Control Module 2.

If the DTC is not set

10. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to High Voltage Battery Disconnect Relay Replacement for A28 Hybrid/EV Battery Contactor

Assembly replacement.

Refer to Control Module References for battery energy control module and hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P0AA6 OR P1AE6: HYBRID/EV BATTERY VOLTAGE SYSTEM ISOLATION LOST & BATTERY ENERGY CONTROL MODULE HYBRID/EV BATTERY VOLTAGE ISOLATION SENSOR CIRCUIT

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P0AA6

Hybrid/EV Battery Voltage System Isolation Lost

DTC P1AE6

Battery Energy Control Module Hybrid/EV Battery Voltage Isolation Sensor Circuit

Circuit/System Description

The vehicle is equipped with a high voltage isolation monitor feature. The purpose of the battery energy control module high voltage isolation monitor circuit is to test the resistance between the high voltage positive and negative direct current (DC) bus and chassis ground. The battery energy control module isolation monitoring method is sometimes referred to as the active isolation monitor. The hybrid powertrain control module 2 requests the battery energy control module to perform this test. Measurement values are reported to the hybrid powertrain control module 2, which makes the determination of an isolation fault.

The isolation check for P0AA6 Hybrid Battery Voltage System Isolation Lost runs when all the contactors are open. This check monitors isolation in the battery system. This check runs only once during the time that the hybrid powertrain control module 2 is awake and runs after the contactors have been open for 35 seconds. This monitor typically runs when the vehicle is turned off after a drive. It could also run when the vehicle is first started, if there is a long enough period between the hybrid powertrain control module 2 waking up and the main contactors closing.

The battery energy control module runs an internal self check of this sensor circuit. When this test fails, DTC P1AE6 will be set.

Conditions for Running the DTC

P0AA6

The hybrid powertrain control module 2 and battery energy control module are awake and communicating All the contactors have been open for 35 seconds.

P1AE6

The 12 V battery voltage is greater than 11 V.

The hybrid powertrain control module 2 and battery energy control module are awake and communicating.

The hybrid powertrain control module 2 has requested the battery energy control module to run the isolation test.

The main contactors are open. DTC U185B is not set.

Conditions for Setting the DTC

P0AA6

The battery energy control module has detected active isolation resistance is less than 300K Ω if P0AA6 has not failed, or less than 350K Ω if P0AA6 has failed at least once.

5 out of 10 tests have failed.

P1AE6

The battery energy control module has detected a fault with the active isolation sensing circuits.

Actions Taken When the DTC Sets P0AA6 and P1AE6 are Type A DTCs. Conditions for Clearing the DTC

P0AA6 and P1AE6 are Type A DTCs.

P0AA6 requires one passing test at greater than 350K Ω resistance.

Diagnostic Aids

A single high voltage contactor stuck closed may set this DTC.

Condensation or water intrusion into the hybrid/EV battery pack may cause P0AA6 or P1AE6 to set.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

INLINE HARNESS CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

EL-50772 Insulation Multimeter

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Verify that DTC P0A7E, P0AA1, P0AA4, P0AD9, P0ADD, P0AE3, P0AE4, P0C32, P0D0A, P0D09, P1EBD,

P1EC0 or P1EC3 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If none of the DTCs are set

2. Verify that DTC P1AE6 is set and P0AA6 is not set.

If DTC P1AE6 is set without DTC P0AA6

Replace the K16 Battery Energy Control Module.

If both DTCs are set, or only DTC P0AA6 is set

3. Verify with a scan tool the hybrid powertrain control module 2, Isolation Test Resistance parameter is greater than 350k Ω.

If the parameter is 350k Ω or less

Refer to Circuit/System Testing.

If the parameter is greater than 350k Ω

4. All OK.

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

1. Vehicle OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling.

2. Remove the Drive Motor Battery Cover. Refer to High Voltage Battery Cover Replacement.

3. Disconnect the harness connector at the E54 Hybrid/EV Battery Pack Coolant Heater.

4. Test for 61 - 75 Ω between terminal A and terminal B at the E54 Hybrid/EV Battery Pack Coolant Heater.

If not within the specified range

Verify that the heater fuse is not blown. Replace the heater fuse if it is blown and the E54 Hybrid/EV Battery Pack Coolant Heater.

If within the specified range

NOTE: Only perform the following continuity tests with the EL-50772 Insulation Multimeter or equivalent.

5. Ensure only the EL-50772 insulation multimeter or equivalent is used with this procedure. Select the Isolation Test setting, then select the 500 V range. Refer to Troubleshooting With an Insulation Multimeter for important usage instructions.

6. Test for 550M Ω between the E54 Hybrid/EV Battery Pack Coolant Heater terminals listed below and battery tray ground:

Terminal A Terminal B

If less than 550M Ω

Verify that the heater fuse is not blown. Replace the heater fuse if it is blown and the E54 Hybrid/EV Battery Pack Coolant Heater.

If 550M Ω or greater

7. Replace the A4 Hybrid/EV Battery Pack.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to High Voltage Battery Heater Replacement

Refer to High Voltage Battery Disconnect Relay Replacement for A28 Hybrid Battery Contactor Assembly replacement

Refer to Drive Motor Battery Replacement and Shipping Preparation

Refer to Control Module References for K16 battery energy control module replacement, programming and setup.

DTC P0ABB, P0ABC, OR P0ABD: HYBRID/EV BATTERY VOLTAGE SENSOR

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P0ABB

Hybrid/EV Battery Voltage Sensor Performance

DTC P0ABC

Hybrid/EV Battery Voltage Sensor Circuit Low Voltage

DTC P0ABD

Hybrid/EV Battery Voltage Sensor Circuit High Voltage

Circuit/System Description

The hybrid/EV powertrain control module 2 monitors individual cell voltage readings from the battery energy control module. The battery energy control module monitors the voltage of the 96 battery cell groups. Voltage sense lines are attached to each individual cell group, and these sense lines terminate at a connector located on the top surface of the battery section. A voltage sense harness joins this connector to the battery energy control module.

Conditions for Running the DTC

P0ABB

The hybrid/EV powertrain control module 2 and battery energy control module are awake and communicating. DTC U0111 or U185A is not set.

P0ABC and P0ABD

The hybrid/EV powertrain control module 2 and battery energy control module are awake and communicating. The 12 V battery voltage is greater than 10.2 V.

DTC P1A07 is not set.

Conditions for Setting the DTC

P0ABB

The hybrid/EV powertrain control module 2 detects difference of 12 V between the average cell group voltage multiplied by 96 and the voltage measured at battery side of the main contactors.

P0ABC

The battery energy control module detects the terminal voltage is less than 24 V on the battery side of the main contactors.

P0ABD

The battery energy control module detects the terminal voltage is greater than 479 V on the battery side of the main

contactors.

Actions Taken When the DTC Sets

DTCs P0ABB, P0ABC, and P0ABD are Type A DTCs.

The vehicle will operate in a reduced power mode and the extended range mode.

Conditions for Clearing the DTC

DTCs P0ABB, P0ABC, and P0ABD are Type A DTCs.

Diagnostic Aids

The hybrid/EV battery pack high voltage manual service disconnect is out, not installed correctly, or a blown manual service disconnect fuse may cause P0ABB and/or P0ABC to set.

The hybrid/EV battery pack high voltage manual service disconnect was removed, out of sequence, or was out during a service procedure with the 12 V battery connected may cause P0ABB and/or P0ABC to set.

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

The Hybrid/EV Battery Section schematics in Energy Storage identify the battery section and voltage sense circuit terminal locations appropriate to each cell group.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48571 High Voltage Battery Pin Out Box

EL-48571-55 Battery Pin Out Box Adapter

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that no other DTCs are set.

If any DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If no other DTCs are set

3. Verify and record with a scan tool, the battery energy control module Hybrid Battery Pack Terminal 1 Voltage parameter and the hybrid/EV powertrain control module 2 Hybrid Battery Pack Voltage parameters are between 205 - 419 V and within 12 V of each other.

If not within the specified range and not within 12 V of each other

Refer to Circuit/System Testing.

If within the specified range and within 12 V of each other

4. All OK.

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

1. Vehicle OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling

2. Remove the S15 Manual Service Disconnect.

3. Test for less than 10 Ω across the S15 Manual Service Disconnect fuse terminals.

If 10 Ω or greater

Replace the S15 Manual Service Disconnect.

If less than 10 Ω

4. Remove the A4 hybrid/EV battery pack cover. Refer to High Voltage Battery Cover Replacement.

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

5. Disconnect all K16 battery energy control module connectors in the sequence provided in Repair Instructions. Refer to Battery Energy Control Module Replacement.

6. Inspect the harness connectors and the 16 battery energy control module connectors for corrosion.

If corrosion is present

Replace the Hybrid/EV Battery Pack Internal Harness and the K16 Battery Energy Control Module as applicable.

If corrosion is not present

NOTE: The Hybrid/EV Battery Section schematics in Energy Storage identify the battery section and voltage sense circuit terminal locations appropriate to each cell group.

7. Disconnect the harness connectors at the C5A Hybrid/EV Battery Module 1 and the C5G Hybrid/EV Battery Module 7.

8. Inspect the harness connector and the appropriate C5 Hybrid/EV Battery Module connector for corrosion.

If corrosion is present

Replace the A4 Hybrid/EV Battery Pack Internal Harness and the C4 Hybrid/EV Battery Section as

applicable.

If corrosion is not present

9. Connect the EL-48571 High Voltage Battery Pin Out Box with the EL-48571-55 Battery Pin Out Box Adapter to the appropriate battery module.

10. Insert the DMM probes into the EL-48571 High Voltage Battery Pin Out Box test cavities.

11. Measure and record the voltage of each of the cell groups by cycling the EL-48571 High Voltage Battery Pin Out Box through each of the switch positions. Refer to EL-48571 High Voltage Battery Pin Out Box Reference.

12. Verify each cell group voltage reading is between 3.45-4.05 V.

If not within the specified range

Replace the appropriate C4 Hybrid/EV Battery Section.

If within the specified range

13. Verify each cell group voltage reading is within 0.03 V of each other.

If greater than 0.03 V

Replace the appropriate C4 Hybrid/EV Battery Section.

If 0.03 V or less

NOTE: If DTC P0ABC or P0ABD are set, only voltage sense circuits 1 or 96 require testing. Perform the following testing at the hybrid/EV battery pack internal wiring harness connector.

14. Test for infinite resistance between each appropriate voltage sense circuit terminals and ground.

If less than infinite resistance

Replace the Hybrid/EV Battery Pack Internal Harness.

If infinite resistance

NOTE: If DTC P0ABC or P0ABD are set, only voltage sense circuits 1 or 96 require testing.

15. Test for less than 2Ω in each appropriate voltage sense circuits end to end.

If 2Ω or greater

Replace the Hybrid/EV Battery Pack Internal Harness.

If less than 2Ω

16. Replace the K16 Battery Energy Control Module.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to Drive Motor Battery High Voltage Manual Disconnect Lever Replacement for S15 manual service disconnect replacement.

Refer to High Voltage Section Battery Replacement (Battery Section 1)High Voltage Section Battery Replacement (Battery Section 2)High Voltage Section Battery Replacement (Battery Section 3)

Refer to Drive Motor Battery Replacement and Shipping Preparation

Refer to Auxiliary Battery Wiring Harness Replacement

Refer to Control Module References for K16 battery energy control module replacement, programming and setup.

DTC P0AC1, P0AC2, P0B10, P0B11, P0B13, P1EBA, OR P1EBB: HYBRID/EV BATTERY LOW RESOLUTION CURRENT SENSOR & HYBRID/EV BATTERY HIGH RESOLUTION CURRENT SENSOR

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Refer to Diagnostic Procedure Instructions to provide an overview of each diagnostic category.

DTC Descriptor

DTC P0AC1

Hybrid/EV Battery Low Resolution Current Sensor Circuit Low Voltage

DTC P0AC2

Hybrid/EV Battery Low Resolution Current Sensor Circuit High Voltage

DTC P0B10

Hybrid/EV Battery High Resolution Current Sensor Circuit Low Voltage

DTC P0B11

Hybrid/EV Battery High Resolution Current Sensor Circuit High Voltage

DTC P0B13

Hybrid/EV Battery Low Resolution Current Sensor - High Resolution Current Sensor Not Plausible

DTC P1EBA

Hybrid/EV Battery Low Resolution Current Sensor Exceeded Learning Limit

DTC P1EBB

Hybrid/EV Battery High Resolution Current Sensor Exceeded Learning Limit

Circuit/System Description

The hybrid/EV battery current sensor is mounted inside the hybrid/EV battery pack. The positive high voltage cable that goes to the positive contactor relay passes through the hybrid/EV battery pack current sensor. The hybrid/EV battery pack current sensor detects the amperage that flows in and out of the hybrid/EV batteries. The battery energy control module supplies and monitors a 5 V reference signal to the hybrid/EV battery pack current sensor. The hybrid/EV battery pack current sensor returns a signal between 0 and 5 V to the battery energy control module. The hybrid/EV battery pack current sensor signal is in proportion to the amperage going in and out of the hybrid/EV battery pack. The hybrid/EV battery pack current sensor has 2 measurement ranges in order to maintain accuracy.

The ranges are low resolution and high resolution. The measurement ranges of the hybrid/EV battery pack current

sensor have some overlap with each other. A signal voltage of the high resolution hybrid/EV battery pack current sensor greater than 2.5 V indicates that the hybrid/EV battery is being charged, and a signal voltage less than 2.5 V indicates discharging. A signal voltage of the low resolution hybrid/EV battery pack current sensor greater than 3.24 V indicates that the hybrid/EV battery is being charged and a signal voltage less than 3.24 V indicates discharging. The high resolution measures from -20 to +20 A. The low resolution measures from -500 to +230 A.

Conditions for Running the DTC

P0AC1, P0AC2, P0B10, and P0B11

The 12 V battery voltage is greater than 10.2 V.

The battery energy control module is awake and communicating.

P0B13

The hybrid/EV battery low resolution current sensor or the hybrid/EV battery high resolution current sensor value is between -20 and +20 A.

None of the following DTCs are set: P0AC1, P0AC2, P1EBA, P1A07, P0B10, P0B11, P0B13, P1EBB, U0111, U185A.

P1EBA and P1EBB

Runs during battery energy control module initialization. The 12 V battery voltage is greater than 10.2 V.

The high voltage main and charger contactors are open (during wake-up). DTC P1A07 is not set.

Conditions for Setting the DTC

P0AC1

The battery energy control module detects that the hybrid/EV battery pack current sensor low resolution is less than

-555 A.

P0AC2

The battery energy control module detects that the hybrid/EV battery pack current sensor low resolution is greater than +285 A.

P0B10

The battery energy control module detects that the hybrid/EV battery pack current sensor high resolution is less than

-23 A.

P0B11

The battery energy control module detects that the hybrid/EV battery pack current sensor high resolution is greater than +23 A.

P0B13

The difference between the Hybrid/EV Battery's low resolution current sensor value and its high resolution current sensor value is greater than 10 A.

P1EBA

The battery energy control module detects that the Pack Current Low Resolution Offset is greater than the calibration Low Resolution Offset of 8 A.

P1EBB

The battery energy control module detects that the Pack Current High Resolution Offset is greater than the calibration High Resolution Offset of 2.5 A.

Action Taken When the DTC Sets

DTC P0AC1, P0AC2, P0B10, P0B11, P1EBA and P1EBB are type A DTCs.

The vehicle will operate in a reduced power mode and the extended range mode.

Conditions for Clearing the DTC

DTC P0AC1, P0AC2, P0B10, P0B11, P1EBA and P1EBB are type A DTCs.

Diagnostic Aids

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Vehicle in Service Mode, all accessories OFF.

NOTE: Typical current in a parked vehicle with the Vehicle in Service Mode and all accessories OFF is between 1 A and 10 A.

2. Verify the scan tool battery energy control module Hybrid/EV Battery Pack Low Resolution Current Sensor parameter is between -555 A and +285 A and changes with the amount of current draw on the hybrid/EV battery pack.

If not within the specified range

Refer to Circuit/System Testing.

If within the specified range

NOTE: Typical current in a parked vehicle with the Vehicle in Service Mode and all accessories OFF is between 1 A and 10 A.

3. Verify the scan tool Hybrid/EV Battery Pack High Resolution Current Sensor parameter is between -23 A and

+23 A, and changes with the amount of current draw on the hybrid/EV battery pack.

If not within the specified range

Refer to Circuit/System Testing.

If within the specified range

4. All OK.

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal

Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

1. Vehicle OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling

2. Remove the A4 Hybrid/EV Battery Pack cover. Refer to High Voltage Battery Cover Replacement

3. Disconnect the X7 harness connector at the K16 Battery Energy Control Module.

NOTE: 2016 model year and early model year vehicles have an inline 4-wire harness connector, late model and newer vehicles have a 20-wire connector.

4. Disconnect the A28 Hybrid/EV Battery Contactor Assembly inline connector that contains the B30 Hybrid/EV Battery Pack Current Sensor circuits.

5. Test for less than 2 Ω in the low reference circuit end to end.

If 2 Ω or greater

Replace the Auxiliary Battery Wiring Harness.

If less than 2 Ω

6. Test for less than 2 Ω in the 5V reference circuit end to end.

If 2 Ω or greater

Replace the Auxiliary Battery Wiring Harness.

If less than 2 Ω

7. Test for less than 2 Ω in the low resolution signal circuit end to end.

If 2 Ω or greater

Replace the Auxiliary Battery Wiring Harness.

If less than 2 Ω

8. Test for less than 2 Ω in the high resolution signal circuit end to end.

If 2 Ω or greater

Replace the Auxiliary Battery Wiring Harness.

If less than 2 Ω

9. Test for infinite resistance between the 5 V reference circuit terminal and ground.

If less than infinite resistance

Replace the Auxiliary Battery Wiring Harness.

If infinite resistance

10. Test for infinite resistance between the low resolution signal circuit terminal and ground.

If less than infinite resistance

Replace the Auxiliary Battery Wiring Harness.

If infinite resistance

11. Test for infinite resistance between the high resolution signal circuit terminal and ground.

If less than infinite resistance

Replace the Auxiliary Battery Wiring Harness.

If infinite resistance

NOTE: The B30 Hybrid/EV Battery Pack Current Sensor is not serviced separately.

12. Replace the A28 Hybrid/EV Battery Contactor Assembly.

13. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.

14. Verify the DTC does not set.

If the DTC sets

Replace the K16 battery energy control module.

If the DTC does not set

15. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to Generator Battery Disconnector Relay Replacement for A28 Hybrid/EV Battery Contactor Assembly replacement

Refer to Auxiliary Battery Wiring Harness Replacement

Refer to Control Module References for K16 battery energy control module replacement, programming, and setup.

DTC P0AF8: HYBRID SYSTEM VOLTAGE

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Refer to Diagnostic Procedure Instructions to provide an overview of each diagnostic category.

DTC Descriptor

DTC P0AF8

Hybrid System Voltage

Circuit/System Description

The hybrid battery contains 192 individual cells. Two cells are welded together in parallel and called a cell group. There are a total of 96 cell groups in the hybrid battery assembly. These cell groups are electrically connected in series. Each individual cell group is rated at 3.7 V, for a nominal system voltage of 355 V direct current. The battery cell groups are joined to form 3 distinct sections. The first 24 battery cell groups make up battery section 1. This section is adjacent to the cowl and contains battery cell groups 73 through 96. The next 28 battery cell groups make up battery section 2. This section is located behind section 1 and contains battery cell groups 45 through 72. The transverse battery section is section number 3 and it contains the remaining 44 battery cell groups 1 through 44. The battery sections also contain two temperature sensors, with one sensor located at each end of the section.

The battery energy control module monitors the voltage of the 96 battery cell groups. The voltage sense lines are attached to each individual cell group, and these sense lines terminate at a connector located on the top surface of the battery section. A voltage sense harness joins this connector to the battery energy control module.

The battery energy control module will determine when a fault condition is present. Diagnostics and system status are communicated from the battery energy control module to the hybrid powertrain control module 2 through serial data. The hybrid powertrain control module 2 is the host controller for diagnostic trouble code information.

Conditions for Running the DTC

The hybrid/EV battery main contactors are closed.

None of the following DTCs are set; P0ABB, P0ABC, P0ABD, P1A07, P1AE8, P1AE9, P1AEA, P1AEB, P1AEC, P1AED, P1E20, P1E21, P1E28, or U1817.

OR

Battery charging is active.

None of the following DTCs are set; P0ABB, P0ABC, P0ABD, P0D4E, P0D4F, P0D5C, P16C5, P1A07, P1EEB, P1EEC, P1ECE, or U1838.

Conditions for Setting the DTC

The difference between the Hybrid/EV Battery pack voltage and the hybrid/EV powertrain control module 1 bus voltage is greater than 16 V.

OR

The difference between the Hybrid/EV Battery pack voltage and the charger module's bus voltage is greater than 16 V.

Action Taken When the DTC Sets

DTC P0AF8 is a type A DTC.

The vehicle will operate in a reduced power mode and the extended range mode.

Conditions for Clearing the DTC DTC P0AF8 is a type A DTC. Diagnostic Aids

An open charger fuse may cause DTC P0AF8 to set.

DTC P1EC0 may set a DTC P0AF8 if the vehicle is ON or vehicle in service mode while the contactors are stuck OPEN

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Verify that no other DTCs are set.

If any DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If no DTCs are set

2. Ensure the battery charge cord is not connected.

3. Vehicle ON.

NOTE: The contactors must be closed.

4. Verify with a scan tool, the hybrid/EV powertrain control module 1 High Voltage Circuit and the battery energy control module Hybrid Battery Pack Terminal 1 Voltage are within 16 V of each other and DTC P0AF8 did not reset.

If the parameters are not within 16 V of each other or DTC P0AF8 is set

Refer to Circuit/System Testing, Battery Main Bus Diagnostics.

If the parameters are within 16 V of each other and DTC P0AF8 is not set

5. Connect the battery charge cord.

6. Verify with a scan tool, the hybrid/EV powertrain control module 2 Battery Charger High Output and the battery energy control module Hybrid Battery Pack Terminal 1 Voltage are within 16 V of each other and DTC P0AF8 did not reset.

If the parameters are not within 16 V of each other or DTC P0AF8 is set

Refer to Circuit/System Testing, Battery Charger Bus Diagnostics.

If the parameters are within 16 V of each other and DTC P0AF8 is not set

7. All OK

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

Battery Charger Bus Diagnostics

1. Vehicle OFF, disable the high voltage at the T18 Battery Charger. Refer to High Voltage Disabling.

2. Disconnect the T18 Battery Charger high voltage DC connector.

3. Disconnect the K1 14V Power Module high voltage connector.

Fig. 43: A4 Hybrid/EV Battery Pack Connector Identification Courtesy of GENERAL MOTORS COMPANY

4. Disconnect the X6 harness connector at the A4 Hybrid/EV Battery Pack.

5. Test for infinite resistance between the High voltage DC (+360 V) positive terminal A and the high voltage DC (-360 V) negative terminal B X6 harness connector.

If less than infinite resistance

Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

If infinite resistance

6. Test for less than 10 Ω between the terminals listed below:

High voltage DC (-360 V) negative terminal B harness connector at the T18 Battery Charger and the high voltage DC (-360 V) negative terminal B X6 harness connector at the A4 Hybrid/EV Battery Pack.

High voltage DC (+360 V) positive terminal A harness connector at the T18 Battery Charger and the high voltage DC (+360 V) negative terminal A X6 harness connector at the A4 Hybrid/EV Battery Pack.

If 10 Ω or greater

Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

If less than 10 Ω

7. Replace the T18 Battery Charger and the fuse, if open.

8. Verify that DTC P0AF8 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0AF8 sets

Replace the K1 14V Power Module and the fuse, if open.

If DTC P0AF8 does not set

9. Verify that DTC P0AF8 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0AF8 sets

Replace the high voltage battery disconnect relay assembly.

If DTC P0AF8 does not set

10. All OK.

Battery Main Bus Diagnostics

1. Vehicle OFF, disable the high voltage at the T6 Power Inverter Module. Refer to High Voltage Disabling.

2. Disconnect the X3 harness connector at the A4 Hybrid/EV Battery Pack.

3. Disconnect the high voltage connector at the T6 power inverter module.

4. Test for infinite resistance between the High voltage DC (+360 V) positive terminal A and the high voltage DC (-360 V) negative terminal B X3 harness connector.

If less than infinite resistance

Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

If infinite resistance

5. Test for less than 10 Ω between the terminals listed below:

High voltage DC (-360 V) negative terminal B X3 harness connector at the A4 Hybrid/EV Battery Pack and the high voltage DC (-360 V) negative terminal B harness connector at the T6 Power Inverter Module.

High voltage DC (+360 V) positive terminal A X3 harness connector at the A4 Hybrid/EV Battery Pack and the high voltage DC (+360 V) negative terminal A harness connector at the T6 Power Inverter Module.

If 10 Ω or greater

Replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

If less than 10 Ω

6. Replace the T6 Power Inverter Module.

7. Verify that DTC P0AF8 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0AF8 sets

Replace the high voltage battery disconnect relay assembly.

If DTC P0AF8 does not set

8. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to Battery 300-Volt Positive and Negative Cable Replacement - High Voltage Battery to Power Inverter Module and A/C Compressor

Refer to Battery 300-Volt Positive and Negative Cable Replacement - High Voltage Battery to Charger Receptacle, Accessory DC Power Control Module, and Drive Motor Battery Charger

Refer to Drive Motor Battery Charger Replacement for T18 Battery Charger replacement.

Refer to Accessory DC Power Control Module Replacement for K1 14V Power Module replacement.

Refer to High Voltage Battery Disconnect Relay Fuse Replacement (Front - BDU)High Voltage Battery Disconnect Relay Fuse Replacement (Rear - BDU)

Refer to High Voltage Battery Disconnect Relay Replacement for high voltage battery disconnect relay

assembly.

Refer to Control Module References for battery charger, power inverter module replacement, programming and setup.

DTC P0AFA OR P0AFB: HYBRID/EV BATTERY SYSTEM VOLTAGE

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Refer to Diagnostic Procedure Instructions to provide an overview of each diagnostic category.

DTC Descriptor

DTC P0AFA

Hybrid/EV Battery System Voltage Low Voltage

DTC P0AFB

Hybrid/EV Battery System Voltage High Voltage

Circuit/System Description

The battery energy control module will diagnose its own systems and determine when a fault condition is present. Diagnostics and system status is communicated from the battery energy control module to the hybrid/EV powertrain control module 2 through serial data. The hybrid/EV powertrain control module 2 is the host controller for diagnostic trouble code (DTC) information. The battery energy control module monitors the hybrid/EV battery voltage at the battery side of the high voltage main contactors.

Conditions for Running the DTC

The battery energy control module is awake and communicating.

None of the following DTCs are set; P0ABC, P0ABD, P1A07, P0AF8, P0ABB, U0111, U185A.

Conditions for Setting the DTC

P0AFA

The Hybrid Battery Pack Voltage initially is less than 148.9 V and does not exceed 164.9 V. OR

The Minimum Hybrid Battery Cell Group Voltage in the hybrid battery initially is less than 1.55 V and does not exceed 1.72 V.

P0AFB

The Hybrid Battery Pack Voltage is greater than 438 V. OR

The Maximum Hybrid Battery Cell Group Voltage in the hybrid battery is greater than 4.56 V.

Action Taken When the DTC Sets

DTCs P0AFA and P0AFB are type A DTCs.

The vehicle will operate in a reduced power mode and the extended range mode.

Once the vehicle has been turned OFF, the hybrid/EV powertrain control module 2 will not CLOSE the high voltage contactors until the DTC has been cleared.

Conditions for Clearing the DTC

DTCs P0AFA and P0AFB are type A DTCs.

The Clear Secured High Voltage DTCs reset function must be performed with a scan tool before clear codes.

Diagnostic Aids

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

The hybrid/EV battery pack high voltage manual service disconnect is not installed correctly, or a blown manual service disconnect fuse will cause P0AFA to set.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48571 High Voltage Battery Pin Out Box

EL-48571-55 Battery Pinout Box Adapter

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Record the freeze frame/failure records.

NOTE: An intermittent condition is more likely to be present with a low state of charge. DO NOT plug in the vehicle to charge the hybrid/EV battery pack.

2. Vehicle in Service Mode.

3. Verify that DTC P0AA1, P0AD9, P0ADD, P0AE2, P0AE4, P0B3B, P0B3C, P0B3D, P0B3E, P0B40, P0B41, P0B42, P0B43, P0B45, P0B46, P0B47, P0B48, P0B4A, P0B4B, P0B4D, P0B4C, P0B4F, P0B50, P0B51, P0B52, P0B54, P0B55, P0B56, P0B57, P0B59, P0B5A, P0B5B, P0B5C, P0B5E, P0B60, P0B5F, P0B61, P0B63, P0B64, P0B65, P0B66, P0B69, P0B68, P0B6A, P0B6D, P0B6B, P0B6E, P0B70, P0B6F, P0B72, P0B74, P0B73, P0B75, P0B77, P0B78, P0B79, P0B7A, P0B7D, P0B7C, P0B7E, P0B7F, P0B81, P0B82, P0B83, P0B84, P0B86, P0B87, P0B88, P0B89, P0B8B, P0B8C, P0B8D, P0B8E, P0B90, P0B91, P0B92, P0B93, P0B95, P0B96, P0B97, P0B98, P0B9A, P0B9B, P0B9C, P0B9D, P0B9F, P0BA1, P0BA0, P0BA2, P0BA4, P0BA5, P0BA6, P0BA7, P0BA9, P0BAA, P0BAB, P0BAC, P0BAE, P0BAF, P0BB0, P0BB1, P0BB3, P0BB4, P0BB5, P0BB6, P0BB8, P0BB9, P0BBA, P0BBB, P0D0A, P0D11, P1B16, P1B17, P1B18, P1B19, P1B1A, P1B1B, P1B1C, P1B1D, P1B1E, P1B1F, P1B20, P1B21, P1B22, P1B23, P1B24, P1B25, P1B26, P1B27, P1B28, P1B29, P1B2B, P1B2A, P1B2C, P1B2D, P1B45, P1B46, P1B47, P1B48, P1B49, P1B4A, P1B4B, P1B4C, P1B4D, P1B4E, P1B4F, P1B50, P1B51, P1B52, P1B53, P1B54, P1B55, P1B56, P1B57, P1B58, P1B59, P1B5A, P1B5B, P1B5C, P1B5D, P1B5E, P1B5F, P1B60, P1B61, P1B62, P1B63, P1B64, P1B65, P1B66, P1B67, P1B68, P1B69, P1B6A, P1B6B, P1B6C, P1B6D, P1B6E, P1B6F, P1B70, P1B71, P1B72, P1B73, P1B74, P1B75, P1B76, P1B77, P1B78, P1B79, P1B7A, P1B7B, P1B7C, P1B7D, P1B7F, P1B7E, P1B80, P1B81, P1B82, P1B83, P1B84, P1B85, P1B86, P1B87, P1B88, P1B89, P1B8A, P1B8B, P1B8C, P1B8D, P1B8E, P1B8F, P1B90, P1B91, P1B92, P1B93, P1B94, P1B95, P1B97, P1B96, P1B98, P1B99, P1B9A, P1B9B, P1B9C, P1B9D, P1B9E, P1B9F, P1BA0, P1BA1, P1BA2, P1BA3, P1BA4, P1BA5, P1BA6, P1BA7, P1BA8, P1BA9, P1BAB, P1BAA, P1BAC, P1BAD, P1BAE, P1BAF, P1BB0, P1BB1, P1BB2, P1BB3, P1BB4, P1BB5, P1BB6, P1BB7, P1BB8, P1BB9, P1BBA, P1BBB, P1BBC, P1BBD, P1BBE, P1BBF, P1BC0, P1BC1, P1BC2, P1BC3, P1BC4, P1BC5, P1BC6, P1BC7, P1BC8, P1BC9, P1BCA, P1BCB, P1BCC, P1BCE, P1BCD, P1BCF, P1BD0, P1BD2, P1BD1, P1BD3, P1BD4, P1BD5, P1BD6, P1BD7, P1BD8, P1BD9, P1BDA, P1BDB, P1BDD, P1BDC, P1BDE, P1BDF, P1BE1, P1BE0, P1BE3, P1BE2, P1BE4, P1BE5, P1BE6, P1BE7, P1BE8, P1BE9, P1BEA, P1BEB, P1BEC, P1BED, P1BEE, P1BF0, P1BEF, P1BF1, P1BF2, P1BF4, P1BF3, P1BF5, P1BF4, P1BF7, P1BF8, P1BF9, P1BFA, P1BFB, P1BFC, P1BFD, P1BFE, P1E01, P1E02, P1E03, P1E04, P1E05, P1E06, P1E4C, P1E4D, P1E4E, P1E4F, P1E50, P1E51, P1E52, P1E53, P1E54, P1E55, P1E56, P1E57, P1E58, P1E59, P1E5A, P1E5B, P1E5C, P1E5D, P1E5E, P1E5F, P1E60, P1E62, P1E61, P1E63, P1E64, P1E65, P1E66, P1E67, P1E68, P1E69, P1E6A, P1E6B, P1E6D, P1E6C, P1E6E, P1E6F, P1E70, P1E71, P1E72, P1E73, P1E74, P1E76, P1E75, P1E77, P1E78, P1E79, P1E7A, P1E7B, P1E7C, P1E7D, P1E7E, P1E7F, P1E80, P1E81, P1E82, P1E83, P1E84, P1E85, P1E86, P1E87, P1E88, P1E89, P1E8A, P1EBC, P1EBF, P1EC0, P1EC3, P1EC4, P1EC5, U2603, U2604, U2605, U2606, or U2401 is not set.

If any of the DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle

If none of the DTCs are set

4. Verify the scan tool Hybrid/EV Battery Pack Terminal 1 Voltage is between 164.9 - 438 V.

If not within the specified range

Refer to Circuit/System Testing, Hybrid Battery Pack Voltage Diagnosis.

If within the specified range

5. Verify the scan tool Hybrid/EV Battery 1 - 96 voltages are between 3.45-4.56 V and all readings are within

0.03 V of each other.

If not between 3.45-4.56 V or not within 0.03 V of each other

Refer to Circuit/System Testing, Hybrid Battery 1 - 96 Cell Group Diagnosis.

If between 3.45-4.56 V and within 0.03 V of each other

NOTE: If the freeze frame/failure records were not initially stored, operate the vehicle under high hybrid/EV battery load conditions, such as hard acceleration, and attempt to set the DTC.

6. Review the freeze frame/failure records. Verify the stored Hybrid/EV Battery 1 - 96 voltages were all between

3.45 - 4.56 V and all readings were within 0.03 V of each other at the time the DTC set.

If not between 3.45 - 4.56 V or not within 0.03 V of each other

Replace the appropriate C4 Hybrid/EV Battery Section.

If between 3.45 - 4.56 V and within 0.03 V of each other

7. All OK.

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

Hybrid Battery Pack Voltage Diagnosis

1. Vehicle OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling

2. Remove the S15 manual service disconnect.

3. Test for less than 10 Ω across the S15 manual service disconnect fuse terminals.

If 10 Ω or greater

Replace the S15 manual service disconnect and repeat Circuit/System Verification.

If less than 10 Ω

4. Remove the A4 hybrid/EV battery pack cover. Refer to High Voltage Battery Cover Replacement

5. Install a known good S15 manual service disconnect.

WARNING: 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 may result in serious injury or death.

NOTE: You are testing high voltage.

6. Test for 164.9 - 438 V between the negative (300 V) C5A and positive (300 V) C5G at the A28 Hybrid/EV Battery Contactor Assembly.

If not within the specified range

Replace the A4 Hybrid/EV Battery Pack. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

If within the specified range

7. Replace the K16 Battery Energy Control Module. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

Hybrid Battery 1 - 96 Cell Group Diagnosis

1. Vehicle OFF, disable the high voltage at the A4 hybrid/EV battery pack. Refer to High Voltage Disabling.

2. Remove the A4 hybrid/EV battery pack cover. Refer to High Voltage Battery Cover Replacement

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

3. Disconnect all K16 battery energy control module connectors in the sequence provided in Repair Instructions. Refer to Battery Energy Control Module Replacement.

NOTE: The Hybrid/EV Battery Section schematics in Energy Storage identify the battery section and voltage sense circuit terminal locations appropriate to each cell group and corresponding DTC.

4. Disconnect the harness connector at the appropriate C4 Hybrid/EV Battery Section connector.

5. Connect the EL-48571 High Voltage Battery Pin Out Box with the EL-48571-55 Battery Pinout Box Adapter to the appropriate battery section.

6. Insert the DMM probes into the EL-48571 test cavities.

7. Measure and record the voltage of each of the cell groups by cycling the EL-48571 through each of the switch positions. Refer to EL-48571 High Voltage Battery Pin Out Box Reference

8. Verify each cell group voltage reading is between 3.45-4.05 V.

If not within the specified range

Replace the appropriate C4 Hybrid/EV Battery Section.

If within the specified range

9. Verify each cell group voltage reading is within 0.03 V of each other.

If greater than 0.03 V

Replace the appropriate C4 hybrid/EV battery section.

If 0.03 V or less

10. Test for infinite resistance between each appropriate voltage sense circuit terminals and ground.

If less than infinite resistance

Replace the Hybrid/EV Battery Pack Internal Harness.

If infinite resistance

11. Test for less than 2 Ω in each appropriate voltage sense circuits end to end.

If 2 Ω or greater

Replace the Hybrid/EV Battery Pack Internal Harness.

If less than 2 Ω

12. Replace the K16 Battery Energy Control Module. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs reset function must be performed.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to Drive Motor Battery High Voltage Manual Disconnect Lever Replacement for S15 manual service disconnect replacement.

Refer to High Voltage Section Battery Replacement (Battery Section 1)High Voltage Section Battery Replacement (Battery Section 2)High Voltage Section Battery Replacement (Battery Section 3)

Refer to Auxiliary Battery Wiring Harness Replacement for Hybrid/EV Battery Pack Internal Harness replacement

Refer to Drive Motor Battery Replacement and Shipping Preparation

Refer to Control Module References for K16 battery energy control module replacement, programming and setup.

DTC P0B3B-P0BBB, P1B16-P1B2D, P1B45-P1BFE, P1E01-P1E06, OR P1E4C-P1E8B: HYBRID/EV BATTERY CIRCUITS

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Refer to Diagnostic Procedure Instructions to provide an overview of each diagnostic category.

DTC Descriptor

DTC P0B3B

Hybrid/EV Battery 1 Circuit

DTC P0B3C

Hybrid/EV Battery 1 Circuit Performance

DTC P0B3D

Hybrid/EV Battery 1 Circuit Low Voltage

DTC P0B3E

Hybrid/EV Battery 1 Circuit High Voltage

DTC P0B40

Hybrid/EV Battery 2 Circuit

DTC P0B41

Hybrid/EV Battery 2 Circuit Performance

DTC P0B42

Hybrid/EV Battery 2 Circuit Low Voltage

DTC P0B43

Hybrid/EV Battery 2 Circuit High Voltage

DTC P0B45

Hybrid/EV Battery 3 Circuit

DTC P0B46

Hybrid/EV Battery 3 Circuit Performance

DTC P0B47

Hybrid/EV Battery 3 Circuit Low Voltage

DTC P0B48

Hybrid/EV Battery 3 Circuit High Voltage

DTC P0B4A

Hybrid/EV Battery 4 Circuit

DTC P0B4B

Hybrid/EV Battery 4 Circuit Performance

DTC P0B4C

Hybrid/EV Battery 4 Circuit Low Voltage

DTC P0B4D

Hybrid/EV Battery 4 Circuit High Voltage

DTC P0B4F

Hybrid/EV Battery 5 Circuit

DTC P0B50

Hybrid/EV Battery 5 Circuit Performance

DTC P0B51

Hybrid/EV Battery 5 Circuit Low Voltage

DTC P0B52

Hybrid/EV Battery 5 Circuit High Voltage

DTC P0B54

Hybrid/EV Battery 6 Circuit

DTC P0B55

Hybrid/EV Battery 6 Circuit Performance

DTC P0B56

Hybrid/EV Battery 6 Circuit Low Voltage

DTC P0B57

Hybrid/EV Battery 6 Circuit High Voltage

DTC P0B59

Hybrid/EV Battery 7 Circuit

DTC P0B5A

Hybrid/EV Battery 7 Circuit Performance

DTC P0B5B

Hybrid/EV Battery 7 Circuit Low Voltage

DTC P0B5C

Hybrid/EV Battery 7 Circuit High Voltage

DTC P0B5E

Hybrid/EV Battery 8 Circuit

DTC P0B5F

Hybrid/EV Battery 8 Circuit Performance

DTC P0B60

Hybrid/EV Battery 8 Circuit Low Voltage

DTC P0B61

Hybrid/EV Battery 8 Circuit High Voltage

DTC P0B63

Hybrid/EV Battery 9 Circuit

DTC P0B64

Hybrid/EV Battery 9 Circuit Performance

DTC P0B65

Hybrid/EV Battery 9 Circuit Low Voltage

DTC P0B66

Hybrid/EV Battery 9 Circuit High Voltage

DTC P0B68

Hybrid/EV Battery 10 Circuit

DTC P0B69

Hybrid/EV Battery 10 Circuit Performance

DTC P0B6A

Hybrid/EV Battery 10 Circuit Low Voltage

DTC P0B6B

Hybrid/EV Battery 10 Circuit High Voltage

DTC P0B6D

Hybrid/EV Battery 11 Circuit

DTC P0B6E

Hybrid/EV Battery 11 Circuit Performance

DTC P0B6F

Hybrid/EV Battery 11 Circuit Low Voltage

DTC P0B70

Hybrid/EV Battery 11 Circuit High Voltage

DTC P0B72

Hybrid/EV Battery 12 Circuit

DTC P0B73

Hybrid/EV Battery 12 Circuit Performance

DTC P0B74

Hybrid/EV Battery 12 Circuit Low Voltage

DTC P0B75

Hybrid/EV Battery 12 Circuit High Voltage

DTC P0B77

Hybrid/EV Battery 13 Circuit

DTC P0B78

Hybrid/EV Battery 13 Circuit Performance

DTC P0B79

Hybrid/EV Battery 13 Circuit Low Voltage

DTC P0B7A

Hybrid/EV Battery 13 Circuit High Voltage

DTC P0B7C

Hybrid/EV Battery 14 Circuit

DTC P0B7D

Hybrid/EV Battery 14 Circuit Performance

DTC P0B7E

Hybrid/EV Battery 14 Circuit Low Voltage

DTC P0B7F

Hybrid/EV Battery 14 Circuit High Voltage

DTC P0B81

Hybrid/EV Battery 15 Circuit

DTC P0B82

Hybrid/EV Battery 15 Circuit Performance

DTC P0B83

Hybrid/EV Battery 15 Circuit Low Voltage

DTC P0B84

Hybrid/EV Battery 15 Circuit High Voltage

DTC P0B86

Hybrid/EV Battery 16 Circuit

DTC P0B87

Hybrid/EV Battery 16 Circuit Performance

DTC P0B88

Hybrid/EV Battery 16 Circuit Low Voltage

DTC P0B89

Hybrid/EV Battery 16 Circuit High Voltage

DTC P0B8B

Hybrid/EV Battery 17 Circuit

DTC P0B8C

Hybrid/EV Battery 17 Circuit Performance

DTC P0B8D

Hybrid/EV Battery 17 Circuit Low Voltage

DTC P0B8E

Hybrid/EV Battery 17 Circuit High Voltage

DTC P0B90

Hybrid/EV Battery 18 Circuit

DTC P0B91

Hybrid/EV Battery 18 Circuit Performance

DTC P0B92

Hybrid/EV Battery 18 Circuit Low Voltage

DTC P0B93

Hybrid/EV Battery 18 Circuit High Voltage

DTC P0B95

Hybrid/EV Battery 19 Circuit

DTC P0B96

Hybrid/EV Battery 19 Circuit Performance

DTC P0B97

Hybrid/EV Battery 19 Circuit Low Voltage

DTC P0B98

Hybrid/EV Battery 19 Circuit High Voltage

DTC P0B9A

Hybrid/EV Battery 20 Circuit

DTC P0B9B

Hybrid/EV Battery 20 Circuit Performance

DTC P0B9C

Hybrid/EV Battery 20 Circuit Low Voltage

DTC P0B9D

Hybrid/EV Battery 20 Circuit High Voltage

DTC P0B9F

Hybrid/EV Battery 21 Circuit

DTC P0BA0

Hybrid/EV Battery 21 Circuit Performance

DTC P0BA1

Hybrid/EV Battery 21 Circuit Low Voltage

DTC P0BA2

Hybrid/EV Battery 21 Circuit High Voltage

DTC P0BA4

Hybrid/EV Battery 22 Circuit

DTC P0BA5

Hybrid/EV Battery 22 Circuit Performance

DTC P0BA6

Hybrid/EV Battery 22 Circuit Low Voltage

DTC P0BA7

Hybrid/EV Battery 22 Circuit High Voltage

DTC P0BA9

Hybrid/EV Battery 23 Circuit

DTC P0BAA

Hybrid/EV Battery 23 Circuit Performance

DTC P0BAB

Hybrid/EV Battery 23 Circuit Low Voltage

DTC P0BAC

Hybrid/EV Battery 23 Circuit High Voltage

DTC P0BAE

Hybrid/EV Battery 24 Circuit

DTC P0BAF

Hybrid/EV Battery 24 Circuit Performance

DTC P0BB0

Hybrid/EV Battery 24 Circuit Low Voltage

DTC P0BB1

Hybrid/EV Battery 24 Circuit High Voltage

DTC P0BB3

Hybrid/EV Battery 25 Circuit

DTC P0BB4

Hybrid/EV Battery 25 Circuit Performance

DTC P0BB5

Hybrid/EV Battery 25 Circuit Low Voltage

DTC P0BB6

Hybrid/EV Battery 25 Circuit High Voltage

DTC P0BB8

Hybrid/EV Battery 26 Circuit

DTC P0BB9

Hybrid/EV Battery 26 Circuit Performance

DTC P0BBA

Hybrid/EV Battery 26 Circuit Low Voltage

DTC P0BBB

Hybrid/EV Battery 26 Circuit High Voltage

DTC P1B16

Hybrid/EV Battery 27 Circuit Performance

DTC P1B17

Hybrid/EV Battery 27 Circuit Low Voltage

DTC P1B18

Hybrid/EV Battery 27 Circuit High Voltage

DTC P1B19

Hybrid/EV Battery 28 Circuit Performance

DTC P1B1A

Hybrid/EV Battery 28 Circuit Low Voltage

DTC P1B1B

Hybrid/EV Battery 28 Circuit High Voltage

DTC P1B1C

Hybrid/EV Battery 29 Circuit Performance

DTC P1B1D

Hybrid/EV Battery 29 Circuit Low Voltage

DTC P1B1E

Hybrid/EV Battery 29 Circuit High Voltage

DTC P1B1F

Hybrid/EV Battery 30 Circuit Performance

DTC P1B20

Hybrid/EV Battery 30 Circuit Low Voltage

DTC P1B21

Hybrid/EV Battery 30 Circuit High Voltage

DTC P1B22

Hybrid/EV Battery 31 Circuit Performance

DTC P1B23

Hybrid/EV Battery 31 Circuit Low Voltage

DTC P1B24

Hybrid/EV Battery 31 Circuit High Voltage

DTC P1B25

Hybrid/EV Battery 32 Circuit Performance

DTC P1B26

Hybrid/EV Battery 32 Circuit Low Voltage

DTC P1B27

Hybrid/EV Battery 32 Circuit High Voltage

DTC P1B28

Hybrid/EV Battery 27 Circuit

DTC P1B29

Hybrid/EV Battery 28 Circuit

DTC P1B2A

Hybrid/EV Battery 29 Circuit

DTC P1B2B

Hybrid/EV Battery 30 Circuit

DTC P1B2C

Hybrid/EV Battery 31 Circuit

DTC P1B2D

Hybrid/EV Battery 32 Circuit

DTC P1B45

Hybrid/EV Battery 33 Circuit Performance

DTC P1B46

Hybrid/EV Battery 33 Circuit Low Voltage

DTC P1B47

Hybrid/EV Battery 33 Circuit High Voltage

DTC P1B48

Hybrid/EV Battery 34 Circuit Performance

DTC P1B49

Hybrid/EV Battery 34 Circuit Low Voltage

DTC P1B4A

Hybrid/EV Battery 34 Circuit High Voltage

DTC P1B4B

Hybrid/EV Battery 35 Circuit Performance

DTC P1B4C

Hybrid/EV Battery 35 Circuit Low Voltage

DTC P1B4D

Hybrid/EV Battery 35 Circuit High Voltage

DTC P1B4E

Hybrid/EV Battery 36 Circuit Performance

DTC P1B4F

Hybrid/EV Battery 36 Circuit Low Voltage

DTC P1B50

Hybrid/EV Battery 36 Circuit High Voltage

DTC P1B51

Hybrid/EV Battery 37 Circuit Performance

DTC P1B52

Hybrid/EV Battery 37 Circuit Low Voltage

DTC P1B53

Hybrid/EV Battery 37 Circuit High Voltage

DTC P1B54

Hybrid/EV Battery 38 Circuit Performance

DTC P1B55

Hybrid/EV Battery 38 Circuit Low Voltage

DTC P1B56

Hybrid/EV Battery 38 Circuit High Voltage

DTC P1B57

Hybrid/EV Battery 39 Circuit Performance

DTC P1B58

Hybrid/EV Battery 39 Circuit Low Voltage

DTC P1B59

Hybrid/EV Battery 39 Circuit High Voltage

DTC P1B5A

Hybrid/EV Battery 40 Circuit Performance

DTC P1B5B

Hybrid/EV Battery 40 Circuit Low Voltage

DTC P1B5C

Hybrid/EV Battery 40 Circuit High Voltage

DTC P1B5D

Hybrid/EV Battery 41 Circuit Performance

DTC P1B5E

Hybrid/EV Battery 41 Circuit Low Voltage

DTC P1B5F

Hybrid/EV Battery 41 Circuit High Voltage

DTC P1B60

Hybrid/EV Battery 42 Circuit Performance

DTC P1B61

Hybrid/EV Battery 42 Circuit Low Voltage

DTC P1B62

Hybrid/EV Battery 42 Circuit High Voltage

DTC P1B63

Hybrid/EV Battery 43 Circuit Performance

DTC P1B64

Hybrid/EV Battery 43 Circuit Low Voltage

DTC P1B65

Hybrid/EV Battery 43 Circuit High Voltage

DTC P1B66

Hybrid/EV Battery 44 Circuit Performance

DTC P1B67

Hybrid/EV Battery 44 Circuit Low Voltage

DTC P1B68

Hybrid/EV Battery 44 Circuit High Voltage

DTC P1B69

Hybrid/EV Battery 45 Circuit Performance

DTC P1B6A

Hybrid/EV Battery 45 Circuit Low Voltage

DTC P1B6B

Hybrid/EV Battery 45 Circuit High Voltage

DTC P1B6C

Hybrid/EV Battery 46 Circuit Performance

DTC P1B6D

Hybrid/EV Battery 46 Circuit Low Voltage

DTC P1B6E

Hybrid/EV Battery 46 Circuit High Voltage

DTC P1B6F

Hybrid/EV Battery 47 Circuit Performance

DTC P1B70

Hybrid/EV Battery 47 Circuit Low Voltage

DTC P1B71

Hybrid/EV Battery 47 Circuit High Voltage

DTC P1B72

Hybrid/EV Battery 48 Circuit Performance

DTC P1B73

Hybrid/EV Battery 48 Circuit Low Voltage

DTC P1B74

Hybrid/EV Battery 48 Circuit High Voltage

DTC P1B75

Hybrid/EV Battery 49 Circuit Performance

DTC P1B76

Hybrid/EV Battery 49 Circuit Low Voltage

DTC P1B77

Hybrid/EV Battery 49 Circuit High Voltage

DTC P1B78

Hybrid/EV Battery 50 Circuit Performance

DTC P1B79

Hybrid/EV Battery 50 Circuit Low Voltage

DTC P1B7A

Hybrid/EV Battery 50 Circuit High Voltage

DTC P1B7B

Hybrid/EV Battery 51 Circuit Performance

DTC P1B7C

Hybrid/EV Battery 51 Circuit Low Voltage

DTC P1B7D

Hybrid/EV Battery 51 Circuit High Voltage

DTC P1B7E

Hybrid/EV Battery 52 Circuit Performance

DTC P1B7F

Hybrid/EV Battery 52 Circuit Low Voltage

DTC P1B80

Hybrid/EV Battery 52 Circuit High Voltage

DTC P1B81

Hybrid/EV Battery 53 Circuit Performance

DTC P1B82

Hybrid/EV Battery 53 Circuit Low Voltage

DTC P1B83

Hybrid/EV Battery 53 Circuit High Voltage

DTC P1B84

Hybrid/EV Battery 54 Circuit Performance

DTC P1B85

Hybrid/EV Battery 54 Circuit Low Voltage

DTC P1B86

Hybrid/EV Battery 54 Circuit High Voltage

DTC P1B87

Hybrid/EV Battery 55 Circuit Performance

DTC P1B88

Hybrid/EV Battery 55 Circuit Low Voltage

DTC P1B89

Hybrid/EV Battery 55 Circuit High Voltage

DTC P1B8A

Hybrid/EV Battery 56 Circuit Performance

DTC P1B8B

Hybrid/EV Battery 56 Circuit Low Voltage

DTC P1B8C

Hybrid/EV Battery 56 Circuit High Voltage

DTC P1B8D

Hybrid/EV Battery 57 Circuit Performance

DTC P1B8E

Hybrid/EV Battery 57 Circuit Low Voltage

DTC P1B8F

Hybrid/EV Battery 57 Circuit High Voltage

DTC P1B90

Hybrid/EV Battery 58 Circuit Performance

DTC P1B91

Hybrid/EV Battery 58 Circuit Low Voltage

DTC P1B92

Hybrid/EV Battery 58 Circuit High Voltage

DTC P1B93

Hybrid/EV Battery 59 Circuit Performance

DTC P1B94

Hybrid/EV Battery 59 Circuit Low Voltage

DTC P1B95

Hybrid/EV Battery 59 Circuit High Voltage

DTC P1B96

Hybrid/EV Battery 60 Circuit Performance

DTC P1B97

Hybrid/EV Battery 60 Circuit Low Voltage

DTC P1B98

Hybrid/EV Battery 60 Circuit High Voltage

DTC P1B99

Hybrid/EV Battery 61 Circuit Performance

DTC P1B9A

Hybrid/EV Battery 61 Circuit Low Voltage

DTC P1B9B

Hybrid/EV Battery 61 Circuit High Voltage

DTC P1B9C

Hybrid/EV Battery 62 Circuit Performance

DTC P1B9D

Hybrid/EV Battery 62 Circuit Low Voltage

DTC P1B9E

Hybrid/EV Battery 62 Circuit High Voltage

DTC P1B9F

Hybrid/EV Battery 63 Circuit Performance

DTC P1BA0

Hybrid/EV Battery 63 Circuit Low Voltage

DTC P1BA1

Hybrid/EV Battery 63 Circuit High Voltage

DTC P1BA2

Hybrid/EV Battery 64 Circuit Performance

DTC P1BA3

Hybrid/EV Battery 64 Circuit Low Voltage

DTC P1BA4

Hybrid/EV Battery 64 Circuit High Voltage

DTC P1BA5

Hybrid/EV Battery 65 Circuit Performance

DTC P1BA6

Hybrid/EV Battery 65 Circuit Low Voltage

DTC P1BA7

Hybrid/EV Battery 65 Circuit High Voltage

DTC P1BA8

Hybrid/EV Battery 66 Circuit Performance

DTC P1BA9

Hybrid/EV Battery 66 Circuit Low Voltage

DTC P1BAA

Hybrid/EV Battery 66 Circuit High Voltage

DTC P1BAB

Hybrid/EV Battery 67 Circuit Performance

DTC P1BAC

Hybrid/EV Battery 67 Circuit Low Voltage

DTC P1BAD

Hybrid/EV Battery 67 Circuit High Voltage

DTC P1BAE

Hybrid/EV Battery 68 Circuit Performance

DTC P1BAF

Hybrid/EV Battery 68 Circuit Low Voltage

DTC P1BB0

Hybrid/EV Battery 68 Circuit High Voltage

DTC P1BB1

Hybrid/EV Battery 69 Circuit Performance

DTC P1BB2

Hybrid/EV Battery 69 Circuit Low Voltage

DTC P1BB3

Hybrid/EV Battery 69 Circuit High Voltage

DTC P1BB4

Hybrid/EV Battery 70 Circuit Performance

DTC P1BB5

Hybrid/EV Battery 70 Circuit Low Voltage

DTC P1BB6

Hybrid/EV Battery 70 Circuit High Voltage

DTC P1BB7

Hybrid/EV Battery 71 Circuit Performance

DTC P1BB8

Hybrid/EV Battery 71 Circuit Low Voltage

DTC P1BB9

Hybrid/EV Battery 71 Circuit High Voltage

DTC P1BBA

Hybrid/EV Battery 72 Circuit Performance

DTC P1BBB

Hybrid/EV Battery 72 Circuit Low Voltage

DTC P1BBC

Hybrid/EV Battery 72 Circuit High Voltage

DTC P1BBD

Hybrid/EV Battery 73 Circuit Performance

DTC P1BBE

Hybrid/EV Battery 73 Circuit Low Voltage

DTC P1BBF

Hybrid/EV Battery 73 Circuit High Voltage

DTC P1BC0

Hybrid/EV Battery 74 Circuit Performance

DTC P1BC1

Hybrid/EV Battery 74 Circuit Low Voltage

DTC P1BC2

Hybrid/EV Battery 74 Circuit High Voltage

DTC P1BC3

Hybrid/EV Battery 75 Circuit Performance

DTC P1BC4

Hybrid/EV Battery 75 Circuit Low Voltage

DTC P1BC5

Hybrid/EV Battery 75 Circuit High Voltage

DTC P1BC6

Hybrid/EV Battery 76 Circuit Performance

DTC P1BC7

Hybrid/EV Battery 76 Circuit Low Voltage

DTC P1BC8

Hybrid/EV Battery 76 Circuit High Voltage

DTC P1BC9

Hybrid/EV Battery 77 Circuit Performance

DTC P1BCA

Hybrid/EV Battery 77 Circuit Low Voltage

DTC P1BCB

Hybrid/EV Battery 77 Circuit High Voltage

DTC P1BCC

Hybrid/EV Battery 78 Circuit Performance

DTC P1BCD

Hybrid/EV Battery 78 Circuit Low Voltage

DTC P1BCE

Hybrid/EV Battery 78 Circuit High Voltage

DTC P1BCF

Hybrid/EV Battery 79 Circuit Performance

DTC P1BD0

Hybrid/EV Battery 79 Circuit Low Voltage

DTC P1BD1

Hybrid/EV Battery 79 Circuit High Voltage

DTC P1BD2

Hybrid/EV Battery 80 Circuit Performance

DTC P1BD3

Hybrid/EV Battery 80 Circuit Low Voltage

DTC P1BD4

Hybrid/EV Battery 80 Circuit High Voltage

DTC P1BD5

Hybrid/EV Battery 81 Circuit Performance

DTC P1BD6

Hybrid/EV Battery 81 Circuit Low Voltage

DTC P1BD7

Hybrid/EV Battery 81 Circuit High Voltage

DTC P1BD8

Hybrid/EV Battery 82 Circuit Performance

DTC P1BD9

Hybrid/EV Battery 82 Circuit Low Voltage

DTC P1BDA

Hybrid/EV Battery 82 Circuit High Voltage

DTC P1BDB

Hybrid/EV Battery 83 Circuit Performance

DTC P1BDC

Hybrid/EV Battery 83 Circuit Low Voltage

DTC P1BDD

Hybrid/EV Battery 83 Circuit High Voltage

DTC P1BDE

Hybrid/EV Battery 84 Circuit Performance

DTC P1BDF

Hybrid/EV Battery 84 Circuit Low Voltage

DTC P1BE0

Hybrid/EV Battery 84 Circuit High Voltage

DTC P1BE1

Hybrid/EV Battery 85 Circuit Performance

DTC P1BE2

Hybrid/EV Battery 85 Circuit Low Voltage

DTC P1BE3

Hybrid/EV Battery 85 Circuit High Voltage

DTC P1BE4

Hybrid/EV Battery 86 Circuit Performance

DTC P1BE5

Hybrid/EV Battery 86 Circuit Low Voltage

DTC P1BE6

Hybrid/EV Battery 86 Circuit High Voltage

DTC P1BE7

Hybrid/EV Battery 87 Circuit Performance

DTC P1BE8

Hybrid/EV Battery 87 Circuit Low Voltage

DTC P1BE9

Hybrid/EV Battery 87 Circuit High Voltage

DTC P1BEA

Hybrid/EV Battery 88 Circuit Performance

DTC P1BEB

Hybrid/EV Battery 88 Circuit Low Voltage

DTC P1BEC

Hybrid/EV Battery 88 Circuit High Voltage

DTC P1BED

Hybrid/EV Battery 89 Circuit Performance

DTC P1BEE

Hybrid/EV Battery 89 Circuit Low Voltage

DTC P1BEF

Hybrid/EV Battery 89 Circuit High Voltage

DTC P1BF0

Hybrid/EV Battery 90 Circuit Performance

DTC P1BF1

Hybrid/EV Battery 90 Circuit Low Voltage

DTC P1BF2

Hybrid/EV Battery 90 Circuit High Voltage

DTC P1BF3

Hybrid/EV Battery 91 Circuit Performance

DTC P1BF4

Hybrid/EV Battery 91 Circuit Low Voltage

DTC P1BF5

Hybrid/EV Battery 91 Circuit High Voltage

DTC P1BF6

Hybrid/EV Battery 92 Circuit Performance

DTC P1BF7

Hybrid/EV Battery 92 Circuit Low Voltage

DTC P1BF8

Hybrid/EV Battery 92 Circuit High Voltage

DTC P1BF9

Hybrid/EV Battery 93 Circuit Performance

DTC P1BFA

Hybrid/EV Battery 93 Circuit Low Voltage

DTC P1BFB

Hybrid/EV Battery 93 Circuit High Voltage

DTC P1BFC

Hybrid/EV Battery 94 Circuit Performance

DTC P1BFD

Hybrid/EV Battery 94 Circuit Low Voltage

DTC P1BFE

Hybrid/EV Battery 94 Circuit High Voltage

DTC P1E01

Hybrid/EV Battery 95 Circuit Performance

DTC P1E02

Hybrid/EV Battery 95 Circuit Low Voltage

DTC P1E03

Hybrid/EV Battery 95 Circuit High Voltage

DTC P1E04

Hybrid/EV Battery 96 Circuit Performance

DTC P1E05

Hybrid/EV Battery 96 Circuit Low Voltage

DTC P1E06

Hybrid/EV Battery 96 Circuit High Voltage

DTC P1E4C

Hybrid/EV Battery 33 Circuit

DTC P1E4D

Hybrid/EV Battery 34 Circuit

DTC P1E4E

Hybrid/EV Battery 35 Circuit

DTC P1E4F

Hybrid/EV Battery 36 Circuit

DTC P1E50

Hybrid/EV Battery 37 Circuit

DTC P1E51

Hybrid/EV Battery 38 Circuit

DTC P1E52

Hybrid/EV Battery 39 Circuit

DTC P1E53

Hybrid/EV Battery 40 Circuit

DTC P1E54

Hybrid/EV Battery 41 Circuit

DTC P1E55

Hybrid/EV Battery 42 Circuit

DTC P1E56

Hybrid/EV Battery 43 Circuit

DTC P1E57

Hybrid/EV Battery 44 Circuit

DTC P1E58

Hybrid/EV Battery 45 Circuit

DTC P1E59

Hybrid/EV Battery 46 Circuit

DTC P1E5A

Hybrid/EV Battery 47 Circuit

DTC P1E5B

Hybrid/EV Battery 48 Circuit

DTC P1E5C

Hybrid/EV Battery 49 Circuit

DTC P1E5D

Hybrid/EV Battery 50 Circuit

DTC P1E5E

Hybrid/EV Battery 51 Circuit

DTC P1E5F

Hybrid/EV Battery 52 Circuit

DTC P1E60

Hybrid/EV Battery 53 Circuit

DTC P1E61

Hybrid/EV Battery 54 Circuit

DTC P1E62

Hybrid/EV Battery 55 Circuit

DTC P1E63

Hybrid/EV Battery 56 Circuit

DTC P1E64

Hybrid/EV Battery 57 Circuit

DTC P1E65

Hybrid/EV Battery 58 Circuit

DTC P1E66

Hybrid/EV Battery 59 Circuit

DTC P1E67

Hybrid/EV Battery 60 Circuit

DTC P1E68

Hybrid/EV Battery 61 Circuit

DTC P1E69

Hybrid/EV Battery 62 Circuit

DTC P1E6A

Hybrid/EV Battery 63 Circuit

DTC P1E6B

Hybrid/EV Battery 64 Circuit

DTC P1E6C

Hybrid/EV Battery 65 Circuit

DTC P1E6D

Hybrid/EV Battery 66 Circuit

DTC P1E6E

Hybrid/EV Battery 67 Circuit

DTC P1E6F

Hybrid/EV Battery 68 Circuit

DTC P1E70

Hybrid/EV Battery 69 Circuit

DTC P1E71

Hybrid/EV Battery 70 Circuit

DTC P1E72

Hybrid/EV Battery 71 Circuit

DTC P1E73

Hybrid/EV Battery 72 Circuit

DTC P1E74

Hybrid/EV Battery 73 Circuit

DTC P1E75

Hybrid/EV Battery 74 Circuit

DTC P1E76

Hybrid/EV Battery 75 Circuit

DTC P1E77

Hybrid/EV Battery 76 Circuit

DTC P1E78

Hybrid/EV Battery 77 Circuit

DTC P1E79

Hybrid/EV Battery 78 Circuit

DTC P1E7A

Hybrid/EV Battery 79 Circuit

DTC P1E7B

Hybrid/EV Battery 80 Circuit

DTC P1E7C

Hybrid/EV Battery 81 Circuit

DTC P1E7D

Hybrid/EV Battery 82 Circuit

DTC P1E7E

Hybrid/EV Battery 83 Circuit

DTC P1E7F

Hybrid/EV Battery 84 Circuit

DTC P1E80

Hybrid/EV Battery 85 Circuit

DTC P1E81

Hybrid/EV Battery 86 Circuit

DTC P1E82

Hybrid/EV Battery 87 Circuit

DTC P1E83

Hybrid/EV Battery 88 Circuit

DTC P1E84

Hybrid/EV Battery 89 Circuit

DTC P1E85

Hybrid/EV Battery 90 Circuit

DTC P1E86

Hybrid/EV Battery 91 Circuit

DTC P1E87

Hybrid/EV Battery 92 Circuit

DTC P1E88

Hybrid/EV Battery 93 Circuit

DTC P1E89

Hybrid/EV Battery 94 Circuit

DTC P1E8A

Hybrid/EV Battery 95 Circuit

DTC P1E8B

Hybrid/EV Battery 96 Circuit

Circuit/System Description

The hybrid battery contains 192 individual cells. Two cells are welded together in parallel and called a cell group. There are a total of 96 cell groups in the hybrid battery assembly. These cell groups are electrically connected in series. Each individual cell group is rated at 3.7 V, for a nominal system voltage of 355 V direct current. The battery cell groups are joined to form 3 distinct sections. The first 24 battery cell groups make up battery section 1. This section is adjacent to the cowl and contains battery cell groups 73 through 96. The next 28 battery cell groups make up battery section 2. This section is located behind section 1 and contains battery cell groups 45 through 72. The transverse battery section is section number 3 and it contains the remaining 44 battery cell groups 1 through 44. The battery sections also contain two temperature sensors, with one sensor located at each end of the section.

The battery energy control module monitors the voltage of the 96 battery cell groups. The voltage sense lines are attached to each individual cell group, and these sense lines terminate at a connector located on the top surface of the battery section. A voltage sense harness joins this connector to the battery energy control module.

The battery energy control module will determine when a fault condition is present. Diagnostics and system status are communicated from the battery energy control module to the hybrid powertrain control module 2 through serial data. The hybrid powertrain control module 2 is the host controller for diagnostic trouble code information.

Conditions for Running the DTC

DTC P0B3B, P0B3D, P0B3E, P0B40, P0B42, P0B43, P0B45, P0B47, P0B48, P0B4A, P0B4C, P0B4D, P0B4F, P0B51, P0B54, P0B52, P0B56, P0B57, P0B59, P0B5B, P0B5C, P0B5E, P0B60, P0B61, P0B63, P0B65, P0B66, P0B68, P0B6A, P0B6B, P0B6D, P0B6F, P0B70, P0B72, P0B74, P0B75, P0B77, P0B79, P0B7A, P0B7C, P0B7E, P0B7F, P0B81, P0B83, P0B84, P0B86, P0B88, P0B89, P0B8B, P0B8D, P0B8E, P0B90, P0B92, P0B93, P0B95, P0B97, P0B98, P0B9A, P0B9C, P0B9D, P0B9F, P0BA1, P0BA2, P0BA4, P0BA6, P0BA7, P0BA9, P0BAB, P0BAC, P0BAE, P0BB0, P0BB1, P0BB3, P0BB5, P0BB6, P0BB8, P0BBA, P0BBB, P1B17, P1B18, P1B1A, P1B1B, P1B1D, P1B1E, P1B20, P1B21, P1B23, P1B24, P1B26, P1B27, P1B28, P1B29, P1B2A, P1B2B, P1B2C, P1B2D, P1B46, P1B47, P1B4A, P1B4C, P1B4D, P1B4F, P1B50, P1B52, P1B53, P1B55, P1B56, P1B58, P1B59, P1B5B, P1B5C, P1B5E, P1B5F, P1B61, P1B64, P1B62, P1B65, P1B67, P1B68, P1B6A, P1B6B, P1B6D, P1B6E, P1B70, P1B71, P1B73, P1B74, P1B76, P1B77, P1B79, P1B7A, P1B7C, P1B7D, P1B7F, P1B80, P1B82, P1B83, P1B85, P1B86, P1B88, P1B89, P1B8B, P1B8C, P1B8E, P1B8F, P1B91, P1B92, P1B94, P1B95, P1B97, P1B98, P1B9A, P1B9B, P1B9D, P1B9E, P1BA0, P1BA1, P1BA3, P1BA4, P1BA6, P1BA7, P1BA9, P1BAA, P1BAC, P1BAD, P1BAF, P1BB0, P1BB2, P1BB3, P1BB5, P1BB6, P1BB8, P1BB9, P1BBB, P1BBC, P1BBE, P1BBF, P1BC1, P1BC2, P1BC4, P1BC5, P1BC7, P1BC8, P1BCA, P1BCB, P1BCD, P1BCE, P1BD0, P1BD1, P1BD3, P1BD4, P1BD6, P1BD7, P1BD9, P1BDA, P1BDC, P1BDD, P1BDF, P1BE0, P1BE2, P1BE3, P1BE5, P1BE6, P1BE8, P1BE9, P1BEB, P1BEC, P1BEE, P1BEF, P1BF1, P1BF2, P1BF4, P1BF5, P1BF7, P1BF8, P1BFA, P1BFB, P1BFD, P1BFE, P1E02, P1E03, P1E05, P1E06, P1E4C, P1E4D, P1E4E, P1E4F, P1E50, P1E51, P1E52, P1E53, P1E54, P1E55, P1E56, P1E57, P1E58, P1E59, P1E5A, P1E5B, P1E5C, P1E5D, P1E5E, P1E5F, P1E60, P1E61, P1E62, P1E63, P1E64, P1E65, P1E66, P1E67, P1E68, P1E69, P1E6A, P1E6B, P1E6C, P1E6D, P1E6E, P1E6F, P1E70, P1E71, P1E72, P1E73, P1E74, P1E75, P1E76, P1E77, P1E78, P1E79, P1E7A, P1E7B, P1E7C, P1E7D, P1E7E, P1E7F, P1E80, P1E81, P1E82, P1E83, P1E84, P1E85, P1E86, P1E87, P1E88, P1E89, P1E8A, P1E8B

All of the following conditions exist:

Vehicle in Service Mode, Vehicle ON or Engine Running.

The hybrid/EV battery energy control module is awake and communicating.

None of the following DTCs are set; P1A07, P1E8E, P1E8F, P1E90, P1E91, P1E92, P1E93, P1E94, P1E95, P1E96, P1E97, P1E98, P1E99, P1E9A, P1E9B, P1E9C, P1E9D, P1E9E, P1E9F, P1EA0, P1EA1, P1EA2, P1EA3, P1EA4, P1EA5, P1EB1, P1EB2, P1EB3, P1EB4, P1EB5, U2402, U2603, U2604, U2605, U2606, U2617, U2618, U2619, U2620, U2621, U2622, U2623, U2624.

DTC P0B3C, P0B41, P0B46, P0B4B, P0B50, P0B55, P0B5A, P0B5F, P0B64, P0B69, P0B6E, P0B73, P0B78, P0B7D, P0B82, P0B87, P0B8C, P0B91, P0B96, P0B9B, P0BA0, P0BA5, P0BAA, P0BAF, P0BB4, P0BB9, P1B19, P1B1F, P1B25, P1B45, P1B48, P1B4B, P1B4E, P1B51, P1B54, P1B57, P1B5A, P1B5D, P1B60, P1B63, P1B66, P1B69, P1B6C, P1B6F, P1B72, P1B75, P1B78, P1B7B, P1B7E, P1B81, P1B84, P1B87, P1B8A, P1B8D, P1B90, P1B93, P1B96, P1B99, P1B9C, P1B9F, P1BA2, P1BA5, P1BA8, P1BAB, P1BAE, P1BB1, P1BB4, P1BB7, P1BBA, P1BBD, P1BC0, P1BC3, P1BC6, P1BC9, P1BCC, P1BCF, P1BD2, P1BD5, P1BD8, P1BDB, P1BDE, P1BE1, P1BE4, P1BE7, P1BEA, P1BED, P1BF0, P1BF3, P1BF6, P1BF9, P1BFC, P1E01, P1E04

All of the following conditions exist: Vehicle ON.

Vehicle speed is greater than 0.

There is a change in the Voltage and Current readings. DTC U185A is not set.

Conditions for Setting the DTC

Battery Circuit

P0B3B, P0B40, P0B45, P0B4A, P0B4F, P0B54, P0B59, P0B5E, P0B63, P0B68, P0B6D, P0B72, P0B77, P0B7C, P0B81, P0B86, P0B8B, P0B90, P0B95, P0B9A, P0B9F, P0BA4, P0BA9, P0BAE, P0BB3, P0BB8, P1B28, P1B29, P1B2A, P1B2B, P1B2C, P1B2D, P1E4C, P1E4D, P1E4E, P1E4F, P1E50, P1E51, P1E52, P1E53, P1E54, P1E55, P1E56, P1E57, P1E58, P1E59, P1E5A, P1E5B, P1E5C, P1E5D, P1E5E, P1E5F, P1E60, P1E61, P1E62, P1E63, P1E64, P1E65, P1E66, P1E67, P1E68, P1E69, P1E6A, P1E6B, P1E6C, P1E6D, P1E6E, P1E6F, P1E70, P1E71, P1E72, P1E73, P1E74, P1E75, P1E76, P1E77, P1E78, P1E79, P1E7A, P1E7B, P1E7C, P1E7D, P1E7E, P1E7F, P1E80, P1E81, P1E82, P1E83, P1E84, P1E85, P1E86, P1E87, P1E88, P1E89, P1E8A, P1E8B are Type A DTCs.

The hybrid/EV battery energy control module detects high resistance on the circuit.

Circuit Performance

P0B3C, P0B41, P0B46, P0B4B, P0B50, P0B55, P0B5A, P0B5F, P0B64, P0B69, P0B6E, P0B73, P0B78, P0B7D, P0B82, P0B87, P0B8C, P0B91, P0B96, P0B9B, P0BA0, P0BA5, P0BAA, P0BAF, P0BB4, P0BB9, P1B19, P1B1F, P1B25, P1B45, P1B48, P1B4B, P1B4E, P1B51, P1B54, P1B57, P1B5A, P1B5D, P1B60, P1B63, P1B66, P1B69, P1B6C, P1B6F, P1B72, P1B75, P1B78, P1B7B, P1B7E, P1B81, P1B84, P1B87, P1B8A, P1B8D, P1B90, P1B93, P1B96, P1B99, P1B9C, P1B9F, P1BA2, P1BA5, P1BA8, P1BAB, P1BAE, P1BB1, P1BB4, P1BB7, P1BBA, P1BBD, P1BC0, P1BC3, P1BC6, P1BC9, P1BCC, P1BCF, P1BD2, P1BD5, P1BD8, P1BDB, P1BDE, P1BE1, P1BE4, P1BE7, P1BEA, P1BED, P1BF0, P1BF3, P1BF6, P1BF9, P1BFC, P1E01, P1E04 are Type A DTCs.

The faulted cell group does not change voltage.

Low Voltage

P0B3D, P0B42, P0B47, P0B4C, P0B51, P0B56, P0B5B, P0B60, P0B65, P0B6A, P0B6F, P0B74, P0B79, P0B7E, P0B83, P0B88, P0B8D, P0B92, P0B97, P0B9C, P0BA1, P0BA6, P0BAB, P0BB0, P0BB5, P0BBA, P1B17, P1B1A, P1B1D, P1B20, P1B23, P1B26, P1B46, P1B4C, P1B4F, P1B52, P1B55, P1B58, P1B5B, P1B5E, P1B61, P1B64, P1B67, P1B6A, P1B6D, P1B70, P1B73, P1B76, P1B79, P1B7C, P1B7F, P1B82, P1B85, P1B88, P1B8B, P1B8E, P1B91, P1B94, P1B97, P1B9A, P1B9D, P1BA0, P1BA3, P1BA6, P1BA9, P1BAC, P1BAF, P1BB2, P1BB5, P1BB8, P1BBB, P1BBE, P1BC1, P1BC4, P1BC7, P1BCA, P1BCD, P1BD0, P1BD3, P1BD6, P1BD9, P1BDC, P1BDF, P1BE2, P1BE5, P1BE8, P1BEB, P1BEE, P1BF1, P1BF4, P1BF7, P1BFA, P1BFD, P1E02, P1E05 are Type A DTCs.

Any hybrid/EV battery voltage signal is less than 0.2 V.

High Voltage

P0B3E, P0B43, P0B48, P0B4D, P0B52, P0B57, P0B5C, P0B61, P0B66, P0B6B, P0B70, P0B75, P0B7A, P0B7F, P0B84, P0B89, P0B8E, P0B93, P0B98, P0B9D, P0BA2, P0BA7, P0BAC, P0BB1, P0BB6, P0BBB, P1B18, P1B1B, P1B1E, P1B21, P1B24, P1B27, P1B47, P1B4A, P1B4D, P1B50, P1B53, P1B56, P1B59, P1B5C, P1B5F, P1B62, P1B65, P1B68, P1B6B, P1B6E, P1B71, P1B74, P1B77, P1B7A, P1B7D, P1B80, P1B83, P1B86, P1B89, P1B8C, P1B8F, P1B92, P1B95, P1B98, P1B9B, P1B9E, P1BA1, P1BA4, P1BA7, P1BAA, P1BAD, P1BB0, P1BB3, P1BB6, P1BB9, P1BBC, P1BBF, P1BC2, P1BC5, P1BC8, P1BCB, P1BCE, P1BD1, P1BD4, P1BD7, P1BDA, P1BDD, P1BE0, P1BE3, P1BE6, P1BE6, P1BE9, P1BEC, P1BEF, P1BF2, P1BF5, P1BF8, P1BFB, P1BFE, P1E03, P1E06 are Type A DTCs.

Any hybrid/EV battery voltage signal is greater than 4.8 V.

Action Taken When the DTC Sets

DTC P0B3B-P0BBB, P1B16-P1B2D, P1B45-P1BFE, P1E01-P1E06 or P1E4C-P1E8B are type A DTCs.

If any of these DTCs are set, the vehicle will operate in a reduced power mode and the extended range mode.

Battery Circuit, Low Voltage or High Voltage DTCs set: Once the vehicle has been turned OFF, the hybrid/EV powertrain control module 2 will not CLOSE the high voltage contactors until the DTC has been cleared.

Conditions for Clearing the DTC

DTC P0B3B-P0BBB, P1B16-P1B2D, P1B45-P1BFE, P1E01-P1E06 or P1E4C-P1E8B are type A DTCs.

Vehicle must be cycled from ON to OFF.

Diagnostic Aids

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

The Hybrid/EV Battery Section schematics in Energy Storage identify the battery section and voltage sense circuit terminal locations appropriate to each cell group and corresponding DTC.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Special Tools

EL-48571 High Voltage Battery Pin Out Box

EL-48571-55 Battery Pinout Box Adapter

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Record the freeze frame/failure records.

2. Vehicle in Service Mode.

3. Verify the scan tool Hybrid/EV Battery 1 - 96 voltages are between 3.45-4.05 V and all readings are within

0.03 V of each other.

If not between 3.45-4.05 V or not within 0.03 V of each other

Refer to Circuit/System Testing.

If between 3.45-4.05 V and within 0.03 V of each other

4. Clear the DTC and perform the Clear Secured High Voltage DTCs procedure.

5. Review and operate the vehicle according to the DTC Conditions for Running. Operate the vehicle for more than 10 minutes of city driving.

6. Verify the DTC does not reset.

If the DTC resets

Refer to Circuit/System Testing.

If the DTC does not reset

7. Plug-in the vehicle and charge the A4 Hybrid/EV Battery Pack.

8. Verify the DTC does not reset.

If the DTC resets

Refer to Circuit/System Testing.

If the DTC does not reset

9. All OK.

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal

Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

1. Vehicle OFF, disable high voltage at the A4 hybrid/EV battery pack. Refer to High Voltage Disabling

2. Remove the A4 hybrid/EV battery pack cover. Refer to High Voltage Battery Cover Replacement

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

3. Disconnect all K16 battery energy control module connectors in the sequence provided in Repair Instructions. Refer to Battery Energy Control Module Replacement.

4. Inspect the harness connectors and the K16 battery energy control module connectors for corrosion.

If corrosion is present

Replace the Hybrid/EV Battery Pack Internal Harness and the K16 Battery Energy Control Module as applicable.

If corrosion is not present

NOTE: The Hybrid/EV Battery Section schematics in Energy Storage identify the battery section and voltage sense circuit terminal locations appropriate to each cell group and corresponding DTC.

5. Disconnect the harness connector at the appropriate C4 Hybrid/EV Battery Section harness connector as indicated by the voltages or DTCs observed during Circuit/System Verification.

6. Inspect the harness connector and the appropriate C4 Hybrid/EV Battery Section connector for corrosion.

If corrosion is present

Replace the Hybrid/EV Battery Pack Internal Harness and the C4 Hybrid/EV Battery Section, as applicable.

If corrosion is not present

7. Connect the EL-48571 High Voltage Battery Pin Out Box with the EL-48571-55 Battery Pinout Box Adapter to the appropriate battery section.

8. Insert the DMM probes into the EL-48571 test cavities.

9. Measure and record the voltage of each of the cell groups by cycling the EL-48571 through each of the switch positions. Refer to EL-48571 High Voltage Battery Pin Out Box Reference

10. Verify each cell group voltage reading is between 3.45-4.05 V.

If not within the specified range

Replace the appropriate C4 Hybrid/EV Battery Section.

If within the specified range

11. Verify each cell group voltage reading is within 0.03 V of each other.

If greater than 0.03 V

Replace the appropriate C4 hybrid/EV battery section.

If 0.03 V or less

NOTE: Perform the following testing at the hybrid/EV battery pack internal wiring harness connector.

12. Test for infinite resistance between each appropriate voltage sense circuit terminals and ground.

If less than infinite resistance

Replace the Hybrid/EV Battery Pack Internal Harness.

If infinite resistance

13. Test for less than 2 Ω in each appropriate voltage sense circuits end to end.

If 2 Ω or greater

Replace the Hybrid/EV Battery Pack Internal Harness.

If less than 2 Ω

14. Replace the appropriate C4 hybrid/EV battery section. Operate the vehicle and verify the DTC does not reset.

If the DTC resets

Replace the K16 Battery Energy Control Module.

If the DTC does not reset

15. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to High Voltage Section Battery Replacement (Battery Section 1)High Voltage Section Battery Replacement (Battery Section 2)High Voltage Section Battery Replacement (Battery Section 3)

Refer to Drive Motor Battery Replacement and Shipping Preparation

Refer to Auxiliary Battery Wiring Harness Replacement

Refer to Control Module References for hybrid/EV battery energy control module replacement, programming and setup.

DTC P0C78 OR P3061: HYBRID/EV BATTERY SYSTEM PRECHARGE TIME TOO LONG & HYBRID/EV BATTERY PRECHARGE HIGH CURRENT

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P0C78

Hybrid/EV Battery System Precharge Time Too Long

DTC P3061

Hybrid/EV Battery Precharge High Current

Circuit/System Description

The hybrid/EV battery contains 4 high voltage contactors and 1 solid state relay (transistor). The high voltage contactors and transistor allow the high voltage DC batteries to be connected to the vehicle or contain the high voltage DC within the hybrid/EV battery assembly. The 4 high voltage contactors consist of a main positive high voltage contactor, main negative high voltage contactor, charge positive high voltage contactor and a precharge negative high voltage contactor. The transistor controls the battery heater high voltage positive circuit. The contactors and transistor close and open in a specific sequence controlled by the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 supplies voltage to the control circuit for the high voltage contactors/transistors. Ground is provided through the case ground.

In order to prevent large in-rush current, system bus high voltage is routed through a pre-charge resistor whenever high voltage is commanded ON. The hybrid/EV powertrain control module 2 monitors the time and current it takes the system bus voltage to attain the same level as the battery pack voltage. If it takes too long, or too much current flows, a DTC is set.

Conditions for Running the DTC

P0C78

Battery voltage sensor has not failed. Bus voltage sensor has not failed.

P3061

Battery voltage sensor has not failed. Battery current sensor has not failed. Precharge is active.

Conditions for Setting the DTC

P0C78

The bus voltage has not reached 95% of battery voltage within 700 ms of the contactors closing.

P3061

The bus current is greater than 3 amps for 88 ms during precharge.

Actions Taken When the DTC Sets

DTC P0C78 and P3061 are type A DTCs.

The hybrid/EV powertrain control module 2 opens the high voltage contactors.

Conditions for Clearing the DTC

DTC P0C78 and P3061 are type A DTCs.

Reference Information

Schematic Reference

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

INLINE HARNESS CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Record the freeze frame/failure records.

2. Vehicle in Service Mode.

3. Verify that DTC P0AA1, P0AA4, P0AD9, P0ADD, P0AE4, P0D0A, or P1EC3 is not set.

If any of the DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If none of the DTCs are set

NOTE: The following setup steps must be performed exactly in order to exercise the contactors.

4. Ignition OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down.

5. OPEN the driver door using outside door handle. Leave driver door OPEN.

NOTE: The brake pedal must remain depressed throughout the remainder of the contactor steps.

6. PRESS and HOLD the brake pedal.

NOTE: DO NOT press the power button and enter Vehicle in Service Mode.

7. Command the Hybrid/EV Battery Contactors ALL OPEN with a scan tool.

8. Disconnect the S15 Manual Service Disconnect.

NOTE: DO NOT use the Release Control button to turn OFF any of the contactors.

Once the Release Control button is pushed the Circuit/System Verification will need to be restarted from the beginning.

9. Command the Hybrid/EV Battery Negative Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

NOTE: It is normal for the contactor to make noise only when opening.

10. Verify the Hybrid/EV Battery Negative Contactor should be heard closing and opening.

If the Hybrid/EV Battery Negative Contactor does not open and close

Refer to Circuit/System Testing, Contactor Function Diagnosis.

If the Hybrid/EV Battery Negative Contactor does open and close

11. Command the Hybrid/EV Battery Positive Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

NOTE: It is normal for the contactor to make noise only when opening.

12. Verify the Hybrid/EV Battery Positive Contactor should be heard closing and opening.

If the Hybrid/EV Battery Positive Contactor does not open and close

Refer to Circuit/System Testing, Contactor Function Diagnosis.

If the Hybrid/EV Battery Positive Contactor does open and close

13. Command the Hybrid/EV Battery Precharge Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

NOTE: It is normal for the contactor to make noise only when opening.

14. Verify the Hybrid/EV Battery Precharge Contactor should be heard opening and closing.

If the Hybrid/EV Battery Precharge Contactor does not open and close

Refer to Circuit/System Testing, Contactor Function Diagnosis.

If the Hybrid/EV Battery Precharge Contactor does open and close

15. Command the Hybrid/EV Battery Charger Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open.

NOTE: It is normal for the contactor to make noise only when opening.

16. Verify the Hybrid/EV Battery Charger Contactor should be heard opening and closing.

If the Hybrid/EV Battery Charger Contactor does not open and close

Refer to Circuit/System Testing, Contactor Function Diagnosis.

If the Hybrid/EV Battery Charger Contactor does open and close

17. Test for less than 10 Ω across the S15 manual service disconnect fuse terminals.

If 10 Ω or greater

Obtain a new S15 manual service disconnect and Refer to Circuit/System Testing, High Voltage System Bus Diagnosis without DTC P0D26.

If less than 10 Ω

18. Vehicle OFF.

19. Install the S15 Manual Service Disconnect.

20. Clear the DTC Information. Vehicle OFF and wait 5 minutes. Vehicle ON, verify DTC P0C78 or P3061 do not set.

If any of the DTCs are set

NOTE: The vehicle must remain OFF to prevent DTC P0C78 and P3061 from running.

1. Vehicle OFF.

2. Wait 5 minutes.

3. Connect the drive motor battery charger cable.

4. Verify DTC P0D26 is not set and the vehicle will charge.

If the DTC is set and the vehicle will not charge, refer to Circuit/System Testing, High Voltage System Bus Diagnosis with DTC P0D26.

If the DTC is not set and the vehicle charges, refer to Circuit/System Testing, High Voltage System Bus Diagnosis without DTC P0D26.

If none of the DTCs are set

21. All OK.

Circuit/System Testing

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal

protection equipment (PPE) and proper procedures must be followed.

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

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

Contactor Function Diagnosis

1. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down.

2. Disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.

3. Test for less than 10 Ω between the ground circuit terminal 5 and ground.

If more than 10 Ω

1. Vehicle OFF.

2. Test for less than 2 Ω in the ground circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit.

If less than 2 Ω, repair the open/high resistance in the ground connection.

If less than 10 Ω

4. Verify that a test lamp illuminates between the B+ circuit terminal 1 and ground.

If the test lamp does not illuminate and the circuit fuse is good

1. Vehicle OFF.

2. Test for less than 2 Ω in the B+ circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit.

If less than 2 Ω, verify the fuse is not open and there is voltage at the fuse.

If the test lamp does not illuminate and the circuit fuse is open

1. Vehicle OFF.

2. Test for infinite resistance between the B+ circuit and ground.

If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance, replace the K16 Battery Energy Control Module and A28 Hybrid/EV Battery Contactor Assembly.

If the test lamp illuminates

5. Vehicle OFF, disconnect the X357 harness connector at the A4 Hybrid/EV Battery Pack. Vehicle in Service Mode.

6. Verify that a test lamp does not illuminate between each A4 Hybrid/EV Battery Pack harness connector control circuit terminals listed below and ground:

Terminal 2 X357

Terminal 4 X357

Terminal 6 X357

Terminal 7 X357

If the test lamp illuminates on any circuit

1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode.

2. Test for less than 1 V between the control circuit and ground.

If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V, replace the K114B Hybrid Powertrain Control Module 2.

If the test lamp does not illuminate on all circuits

7. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2.

8. Test for infinite resistance between each A4 Hybrid/EV Battery Pack harness connector control circuit terminals listed below and ground:

Terminal 2 X357

Terminal 4 X357

Terminal 6 X357

Terminal 7 X357

If less than infinite resistance on either circuit

Repair the short to ground on the circuit.

If infinite resistance on both circuits

9. Test for less than 2 Ω between the harness connector terminals listed below:

Terminal 2 X357 at the A4 Hybrid/EV Battery Pack and terminal 9 X1 at the K114B Hybrid Powertrain Control Module 2

Terminal 4 X357 at the A4 Hybrid/EV Battery Pack and terminal 6 X1 at the K114B Hybrid Powertrain Control Module 2

Terminal 6 X357 at the A4 Hybrid/EV Battery Pack and terminal 8 X1 at the K114B Hybrid Powertrain Control Module 2

Terminal 7 X357 at the A4 Hybrid/EV Battery Pack and terminal 3 X1 at the K114B Hybrid Powertrain Control Module 2

If 2 Ω or greater on any circuit

Repair the open/high resistance in the circuit.

If less than 2 Ω on all circuits

10. Replace the A28 Hybrid/EV Battery Contactor Assembly.

11. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets

Replace the K114B Hybrid Powertrain Control Module 2.

If DTC P0C78 or P3061 does not set

12. All OK.

High Voltage System Bus Diagnosis with P0D26

1. Disable the high voltage for servicing at the A4 Battery Pack, K1 14V Power Module and the T18 Battery

Charger. Refer to High Voltage Disabling.

2. Disconnect the X3 connector at the T18 Battery Charger and the X4 connector at the K1 14V Power Module.

3. Verify that all HV harness connector and mating module connector terminals are free from moisture, corrosion and arc flash damage.

If any terminals show signs of damage

Replace the HV wiring harness and effected modules as necessary.

If no arc flash damage, moisture, or corrosion is found

NOTE: This test is performed at the module terminals with the test measurement initially several Meg ohms and slowly decreasing to a minimal value. You must measure with a high-impedance Digital Multimeter (DMM). DO NOT use the

EL-50772 to measure insulation resistance.

4. Test the K1 14 V Power Module X4 terminals for greater than 10K Ω, X4-A to X4-B.

If 10K Ω or less

1. Replace the K1 14V Power Module.

2. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets, replace the A28 Hybrid/EV Battery Contactor Assembly. If DTC P0C78 or P3061 does not set

3. All OK.

If greater than 10K Ω

NOTE: This test is performed at the module terminals with the test measurement initially several Meg ohms and slowly decreasing to a minimal value. You must measure with a high-impedance Digital Multimeter (DMM). DO NOT use the

EL-50772 to measure insulation resistance.

5. Test the T18 Battery Charger terminals for greater than 10K Ω, X3-1 to X3-2.

If 10K Ω or less

1. Replace the T18 Battery Charger.

2. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets, replace the A28 Hybrid/EV Battery Contactor Assembly. If DTC P0C78 or P3061 does not set

3. All OK.

If greater than 10K Ω

6. Remove and open the A4 Battery Pack. Refer to High Voltage Battery Cover Replacement.

7. Inspect the High Voltage bus bars for loose/damaged terminal fasteners.

If a terminal concern is found

Replace all affected components.

If no internal concerns are observed

8. Replace the A28 Hybrid/EV Battery Contactor Assembly.

9. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running

the DTC.

If DTC P0C78 or P3061 sets

Replace the K114B Hybrid Powertrain Control Module 2.

If DTC P0C78 or P3061 does not set

10. All OK.

High Voltage System Bus Diagnosis without P0D26

1. Disable the high voltage for servicing at the A4 Battery Pack, G1 A/C Compressor, T6 Power Inverter Module and the K10 Coolant Heater. Refer to High Voltage Disabling.

2. Disconnect the X2 connector at the T6 Power Inverter Module, the X3, X4 and X5 connectors at the A4 Battery Pack, the X2 connector at the K10 Coolant Heater and the X2 connector at the G1 A/C Compressor.

3. Verify that all HV harness connector and mating module connector terminals are free from moisture, corrosion and arc flash damage.

If any terminals show signs of damage

Replace the HV wiring harness and effected modules as necessary.

If no arc flash damage, moisture, or corrosion is found

NOTE: This test is performed at the module terminals with the test measurement initially several Meg ohms and slowly decreasing to a minimal value. You must measure with a high-impedance Digital Multimeter (DMM). DO NOT use the

EL-50772 to measure insulation resistance.

4. Test the T6 Power Inverter Module X2 terminals for greater than 10K Ω, X2-A to X2-B.

If 10K Ω or less

1. Replace the T6 Power Inverter Module.

2. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets, replace the A28 Hybrid/EV Battery Contactor Assembly. If DTC P0C78 or P3061 does not set

3. All OK.

If greater than 10K Ω

NOTE: This test is performed at the module terminals with the test measurement initially several Meg ohms and slowly decreasing to a minimal value. You must measure with a high-impedance Digital Multimeter (DMM). DO NOT use the

EL-50772 to measure insulation resistance.

5. Test the K10 Coolant Heater X2 terminals for greater than 10K Ω, X2-1 to X2-2.

If 10K Ω or less

1. Replace the K10 Coolant Heater Control Module.

2. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets, replace the A28 Hybrid/EV Battery Contactor Assembly. If DTC P0C78 or P3061 does not set

3. All OK.

If greater than 10K Ω

NOTE: This test is performed at the module terminals with the test measurement initially several Meg ohms and slowly decreasing to a minimal value. You must measure with a high-impedance Digital Multimeter (DMM). DO NOT use the

EL-50772 to measure insulation resistance.

6. Test the G1 A/C Compressor X2 terminals for greater than 10K Ω, X2-A to X2-B.

If 10K Ω or less

1. Replace the G1 A/C Compressor.

2. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets, replace the A28 Hybrid/EV Battery Contactor Assembly. If DTC P0C78 or P3061 does not set

3. All OK.

If greater than 10K Ω

7. Remove and open the A4 Battery Pack. Refer to High Voltage Battery Cover Replacement.

8. Inspect the High Voltage bus bars for loose/damaged terminal fasteners.

If a terminal concern is found

Replace all affected components.

If no internal concerns are observed

9. Replace the A28 Hybrid/EV Battery Contactor Assembly and the K16 Battery Energy Control Module.

10. Verify that DTC P0C78 or P3061 does not set while operating the vehicle within the Conditions for Running the DTC.

If DTC P0C78 or P3061 sets

Replace the K114B Hybrid Powertrain Control Module 2.

If DTC P0C78 or P3061 does not set

11. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to High Voltage Battery Disconnect Relay Replacement for A28 Hybrid/EV Battery Contactor Assembly

Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement for G1 A/C compressor

Refer to Heater Coolant Heater Replacement for K10 Coolant Heater

Refer to Control Module References for T6 power inverter module, K1 14V Power Module, T18 battery charger, battery energy control module, or hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P1A07, P1E93, P1E99, P1E9F, P1EA5, P1FC3-P1FC8, P3035, OR P3040: BATTERY ENERGY CONTROL MODULE 5 V REFERENCE CIRCUIT & HYBRID/EV BATTERY INTERFACE CONTROL MODULE 1-12 5 V REFERENCE CIRCUIT(S)

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P1A07

Battery Energy Control Module 5 V Reference Circuit

DTC P1E93

Hybrid/EV Battery Interface Control Module 1 5 V Reference Circuit

DTC P1E99

Hybrid/EV Battery Interface Control Module 2 5 V Reference Circuit

DTC P1E9F

Hybrid/EV Battery Interface Control Module 3 5 V Reference Circuit

DTC P1EA5

Hybrid/EV Battery Interface Control Module 4 5 V Reference Circuit

DTC P1FC3

Hybrid/EV Battery Interface Control Module 5 5 V Reference Circuit

DTC P1FC4

Hybrid/EV Battery Interface Control Module 6 5 V Reference Circuit

DTC P1FC5

Hybrid/EV Battery Interface Control Module 7 5 V Reference Circuit

DTC P1FC6

Hybrid/EV Battery Interface Control Module 8 5 V Reference Circuit

DTC P1FC7

Hybrid/EV Battery Interface Control Module 9 5 V Reference Circuit

DTC P1FC8

Hybrid/EV Battery Interface Control Module 10 5 V Reference Circuit

DTC P3035

Hybrid/EV Battery Interface Control Module 11 5 V Reference Circuit

DTC P3040

Hybrid/EV Battery Interface Control Module 12 5 V Reference Circuit

Circuit/System Description

The hybrid battery contains 192 individual cells. Two cells are welded together in parallel and called a cell group. There are a total of 96 cell groups in the hybrid battery assembly. These cell groups are electrically connected in series. Each individual cell group is rated at 3.7 V, for a nominal system voltage of 355 V direct current. The battery cell groups are joined to form 3 distinct sections. The first 24 battery cell groups make up battery section 1. This section is adjacent to the cowl and contains battery cell groups 73 through 96. The next 28 battery cell groups make up battery section 2. This section is located behind section 1 and contains battery cell groups 45 through 72. The transverse battery section is section number 3 and it contains the remaining 44 battery cell groups 1 through 44. The battery sections also contain two temperature sensors, with one sensor located at each end of the section.

The battery energy control module monitors the voltage of the 96 battery cell groups. The voltage sense lines are attached to each individual cell group, and these sense lines terminate at a connector located on the top surface of the battery section. A voltage sense harness joins this connector to the battery energy control module.

The battery energy control module contains internal interface control modules that monitor specific cell groups.

The battery energy control module will determine when a fault condition is present. Diagnostics and system status are communicated from the battery energy control module to the hybrid powertrain control module 2 through serial data. The hybrid powertrain control module 2 is the host controller for diagnostic trouble code information.

Conditions for Running the DTC

P1A07

The battery energy control module is awake and communicating. The 12 V battery voltage greater than or equal to 9 V.

P1E93, P1E99, P1E9F, P1EA5, P1FC3, P1FC4, P1FC5, P1FC6, P1FC7, P1FC8, P3035, and P3040

The battery energy control module is awake and communicating.

None of the following DTCs are set; U2603, U2604, U2605, U2606, U2617, U2618, U2619, U2620, U2621, U2622, U2623, U2624

Conditions for Setting the DTC

P1A07, P1E93, P1E99, P1E9F, P1EA5, P1FC3, P1FC4, P1FC5, P1FC6, P1FC7, P1FC8, P3035, and P3040

The battery energy control module has detected an internal 5V reference circuit voltage is less than 2.8 V or greater than 3.2 V.

Actions Taken When the DTC Sets

DTCs P1A07 P1E93, P1E99, P1E9F, P1EA5, P1FC3, P1FC4, P1FC5, P1FC6, P1FC7, P1FC8, P3035, and

P3040 are Type A DTCs.

The vehicle will operate in a reduced power mode and the extended range mode.

Conditions for Clearing the DTC

DTCs P1A07 P1E93, P1E99, P1E9F, P1EA5, P1FC3, P1FC4, P1FC5, P1FC6, P1FC7, P1FC8, P3035, and P3040 are

Type A DTCs.

Reference Information

Description and Operation

Drive Motor Battery System Description

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

1. Verify that DTC P1A07, P1E93, P1E99, P1E9F, P1EA5, P1FC3, P1FC4, P1FC5, P1FC6, P1FC7, P1FC8,

P3035, or P3040 is not set.

If DTC P1A07, P1E93, P1E99, P1E9F, P1EA5, P1FC3, P1FC4, P1FC5, P1FC6, P1FC7, P1FC8,

P3035, or P3040 is set

1. Disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling.

2. Replace the K16 Battery Energy Control Module ensuring you reconnect the connectors in the sequence provided in Repair Instructions. Refer to Battery Energy Control Module Replacement.

If none of the DTCs are set

2. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Refer to Control Module References for battery energy control module programming and setup.

DTC P1E92, P1E98, P1E9E, P1EA4, P1FC9, P1FCA-P1FCE, P3036, OR P3041: HYBRID/EV BATTERY INTERFACE CONTROL MODULE 1-12 CELL BALANCING CIRCUIT(S)

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P1E92

Hybrid/EV Battery Interface Control Module 1 Cell Balancing Circuit

DTC P1E98

Hybrid/EV Battery Interface Control Module 2 Cell Balancing Circuit

DTC P1E9E

Hybrid/EV Battery Interface Control Module 3 Cell Balancing Circuit

DTC P1EA4

Hybrid/EV Battery Interface Control Module 4 Cell Balancing Circuit

DTC P1FC9

Hybrid/EV Battery Interface Control Module 5 Cell Balancing Circuit

DTC P1FCA

Hybrid/EV Battery Interface Control Module 6 Cell Balancing Circuit

DTC P1FCB

Hybrid/EV Battery Interface Control Module 7 Cell Balancing Circuit

DTC P1FCC

Hybrid/EV Battery Interface Control Module 8 Cell Balancing Circuit

DTC P1FCD

Hybrid/EV Battery Interface Control Module 9 Cell Balancing Circuit

DTC P1FCE

Hybrid/EV Battery Interface Control Module 10 Cell Balancing Circuit

DTC P3036

Hybrid/EV Battery Interface Control Module 11 Cell Balancing Circuit

DTC P3041

Hybrid/EV Battery Interface Control Module 12 Cell Balancing Circuit

Circuit/System Description

To maintain a similar state of charge on the cell groups, the hybrid/EV powertrain control module 2 looks at the cell group voltages and determines which cell groups need energy removed in order to maintain the battery groups at a similar state of charge. This is known as cell balancing. There is a transistor switched resistor wired in parallel with the cell group internal to the hybrid/EV battery interface control module portion of the battery energy control module. The hybrid/EV powertrain control module 2 sends a command to the hybrid/EV battery energy control module to begin cell balancing.

Conditions for Running the DTC

The hybrid/EV battery energy control module is awake and communicating. The high voltage fault circuit diagnostic is not running.

The cell balancing circuit is greater than 3.0 V.

None of the following DTCs are set, P1E8E, P1E94, P1E9A, P1EA0, P1FBD, P1FBE, P1FBF, P1FC0, P1FC1, P1FC2, P3037, P3042, U2603, U2604, U2605, U2606, U2617, U2618, U2619, U2620, U2621, U2622, U2623, or U2624.

Conditions for Setting the DTC