High Voltage Enabling

Diagnostic Instructions

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


Object ID: 6039892
High Voltage Service Lockout:

    Note:

    • Disabling the High Voltage Service Lockout should be performed by or under the direction of, the person who performed the High Voltage Disabling procedure.

  1. When instructed to do so, disable the High Voltage Service Lockout by inserting the key, unlock HV padlock (2) and remove padlock from the HVSL (3).
  2. Move the HVSL (4) from the ‘OFF’ to ‘ON’ position as indicated on the HVSL and move red connector position assurance tab to secured position.

Component Location

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

Master Electrical Component List

Description and Operation

Drive Motor Battery System Description

Electrical Information ReferenceScan Tool Reference

Control Module References for scan tool information

Circuit/System Testing

Danger: Ensure all High Voltage safety procedures are followed. You must have the appropriate level of up-to-date high voltage training and certification combined with Personal Protection Equipment (PPE) to continue. Review the procedure steps to ensure you have the proper qualifications. You must stop if not properly qualified. Failure to follow the procedure exactly as written may result in serious injury or death.

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage componentor 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. Review the high voltage safety information prior to performing the High Voltage Enabling procedure. High Voltage Safety
  2. Ensure that the 12 V battery is disconnected. Battery Negative Cable Disconnection and Connection

    3. Note:

    • Always tighten the high voltage fasteners to the specified torque and recheck. 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 disengaging the high voltage service lockout, inspect for the following:
    • Verify that all tools or loose components have been removed.
    • Inspect any disconnected High Voltage 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 components are installed, and any ground cables are connected.
    • Install any components or connectors that have been removed or replaced during diagnosis.
  4. If the drive motor battery cooling system was drained, perform the Vac-N-Fill cooling system draining and filling procedure steps 1 through 29. This is to ensure at least partial cooling system fill prior to enabling the system. Drive Motor Battery Cooling System Draining and Filling The Vac-N-Fill procedure will be completed later in step 14.

    5. Object ID: 5911766
  5. Disengage the high voltage service lockout (HVSL) (1) by cutting off the tie-strap and/or removing the locking device. Depress the connector tab and slide the connector halves together until the indicator tab wording changes from ‘OFF’ to ‘ON’. Engage the HVSL red connector position assurance tab.

    6. Note: It may be necessary to relearn windows express function and power front compartment system, as applicable, after restoring 12V battery power connection.

  6. Connect the 12V battery. Battery Negative Cable Disconnection and Connection.
  7. Vehicle Power Mode State:Service Mode.
  8. 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 not been replaced
  9. Vehicle Power Mode State:Service Mode.
  10. Once the diagnosis and vehicle repairs have been made, Clear the Secured High Voltage DTCs/lockout state by performing a reset. Refer to Clear Secured High Voltage DTCs.
  11. Vehicle Power Mode State: OFF and all vehicle systems OFF. It may take up to 12 minutes for all vehicle systems to power down.
  12. Vehicle Power Mode State ON.
  13. Verify with a scan tool no DTCs are set.
    • If no DTCs are set
  14. Complete the Drive Motor Battery Cooling System Vac-N-Fill procedure. Drive Motor Battery Cooling System Draining and Filling
  15. Verify with the scan tool the K107A, K107B, and K107C (as applicable) Drive Motor Control Modules and K16 Battery Energy Control Module  DTC Information that the following high voltage DTCs have Ran Since Code Clear and have not set:
    • Motor position sensor learn DTC P0C17.
    • Discharge and Pre-charge DTCs P0C76, P0C78, and P3061.
    • High voltage loss of isolation DTCs P0AA6, U2BFF and U359E (as applicable).
    • Review and operate the vehicle according to the applicable DTC Conditions for Running and ensure the DTCs run and pass.
    • Verify with the scan tool the K107A, K107B, and K107C (as applicable) Drive Motor Control Modules and K16 Battery Energy Control Module DTC Information that the specified DTCs have Ran Since Code Clear and have not set:
      • If the DTCs have Ran and Passed
    • 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 additional DTCs are set.