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Circuit/System Testing

WARNING: This page is about a different variant/trim than selected.
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.

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 exactly as written may result in serious injury or death.

WARNING:

The eAssist battery pack assembly will utilize an exchange program. Please consult the most recent revision of bulletin/PI# PIC5520, available in Service Information (SI), for a list of approved eAssist battery pack assembly service procedures. Components that may be removed and serviced without exchanging the complete battery pack assembly are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.

    NOTE:

    In High Voltage Disabling 

  1. Ignition OFF, disable high voltage at the A4 hybrid battery pack. Refer to High Voltage Disabling 
  2. Disconnect the X1 and X2 harness connectors K16 battery energy control module.
  3. Connect the EL-48571-30  high voltage battery pin out box to the appropriate K16 battery energy control module harness connector.
  4. Insert the DMM probes into the EL-48571-30 test cavities.
    5. NOTE:
    • The DMM must be set to the DC voltage setting.
    • Not all 24 switch positions of the EL-48571-30 will be used.
  5. Measure and record the voltage of each of the cells by cycling the EL-48571-30 through each of the 16 switch positions.
  6. Verify that each cell voltage reading is 3.0-4.1 V and all cell voltage readings are within 0.1 V of each other.
    • If any parameter is not between 3.0-4.1 V or is not within 0.1 V of the others 
    1. Inspect the appropriate voltage signal circuit and low reference circuit for a short to ground or an open/high resistance.
      • If a short to ground or an open/high resistance is found, replace the appropriate battery energy control module high voltage measuring harness.
      • If a short to ground or an open/high resistance is not found
    2. Replace the C4A hybrid/EV battery section 1 and C4B hybrid/EV battery section 2.
    • If all parameter are between 3.0-4.1 V and are within 0.1 V of each other 
  7. Replace the K16 battery energy control module.
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