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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.

WARNING:

The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions.

  1. Verify that DTC P0AC1, P0B10, P0C44, P0C47, P0C4A or P1F18 is not set.
  2. Vehicle OFF, disable the high voltage at the A4 hybrid/EV battery pack. Refer to High Voltage Disabling .
  3. Remove the A4 hybrid/EV battery pack from the vehicle. Refer to Drive Motor Battery Replacement and Shipping Preparation (Volt)
  4. Remove the A4 hybrid/EV battery pack cover. Refer to Drive Motor Battery Cover Replacement
  5. Connect the battery tray ground straps with a jumper to chassis ground.
  6. Disconnect the harness connector at the B204B hybrid/EV battery pack coolant temperature sensor 2.
  7. Test for less than 10 Ω between the low reference circuit terminal 1 and ground.
    • If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the K16 hybrid/EV battery energy control module.
    8. NOTE:

    With the S15 manual service disconnect removed the 12 V battery connected and the Vehicle in Service Mode, may cause additional DTCs to set. Continue with diagnostics and clear any additional DTCs when repairs are complete.

  8. Connect the EL-50211  low voltage jumper harness extension.
  9. Connect the 12 V battery.
  10. Vehicle in Service Mode, verify the scan tool Hybrid/EV Battery Pack Coolant Temperature Sensor 2 is less than -35° C (-38.2° F).
    • If greater than the specified range, test the signal circuit terminal 2 for a short to ground. If the circuit tests normal, replace the K16 hybrid/EV battery energy control module.
  11. Install a 3 A fused jumper wire between the signal circuit terminal 2 and the low reference circuit terminal 1. Verify the scan tool Hybrid Battery Pack Coolant Temperature Sensor 2 is greater than 80° C (176° F).
    • If less than the specified range, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the K16 hybrid/EV battery energy control module.
  12. If all circuits test normal, replace the B204B hybrid/EV battery pack coolant temperature sensor 2.
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