EL-48900 HEV Safety Kit
Circuit/System Verification
1. Verify that DTC P0A80, P0A81, P0A9C, P0A9D, P0A9E, P0AC6, P0AC7, P0AC8, P0ACB, P0ACC, P0ACD, P0AE9, P0AEA, P0AEB,
P0BC1, or P0BDD is not set.
锟斤拷If any of the DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle).
2. Ignition ON, observe the scan tool BECM hybrid battery temperature parameters. The readings should be between -39 and +95锟斤拷C (-38.2 and
+203锟斤拷F) with no greater than a 15锟斤拷C ( 59锟斤拷F) difference between any of the four temperature sensor readings. Refer to Temperature Versus
Resistance ().
3. Using a scan tool, command the hybrid battery pack fan speed to 60 percent and let it run for 2 minutes.
4. Observe the scan tool hybrid battery air inlet and outlet temperature parameters. The readings should be between -39 and +95锟斤拷C (-38.2 and
+203锟斤拷F) with no greater than a 10锟斤拷C ( 50锟斤拷F) difference. Refer to Temperature Versus Resistance ().
Circuit/System Testing
Danger: 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 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 procedures exactly as written may result in serious injury or death.
1. Ignition OFF, disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling ().
2. Verify that none of the following conditions exist:
* the inlet and outlet air vents do not have any obstructions or blockages
* the vent fan blades are not broken or damaged
* the internal foam seals are not missing or damaged
锟斤拷If any conditions are found, remove, repair or replace as necessary.
3. Ignition OFF, disconnect the X3 connector at the drive motor generator battery control module.
4. Test for 1k ohm-209k ohm between the terminals listed below. The resistance of each temperature sensor should be within the specified
range, and within 500 ohm of each other. Refer to Temperature Versus Resistance ().
* Air Temperature Sensor 1-5 V reference circuit terminal 9 and low reference circuit terminal 10
* Air Temperature Sensor 2-5 V reference circuit terminal 11 and low reference circuit terminal 12
* Battery Temperature Sensor 1-5 V reference circuit terminal 1 and low reference circuit terminal 2
* Battery Temperature Sensor 2-5 V reference circuit terminal 3 and low reference circuit terminal 4
* Battery Temperature Sensor 3-5 V reference circuit terminal 5 and low reference circuit terminal 6
* Battery Temperature Sensor 4-5 V reference circuit terminal 7 and low reference circuit terminal 8
锟斤拷If not within the specified range, replace the drive motor battery sensor module wiring harness.
5. If all circuits test normal, replace the drive motor generator battery control module.
