Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Circuit/System Testing
- 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.
- 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.
- Ignition OFF, disconnect the X1 harness connector at the drive motor generator power inverter module assembly.
- Ignition ON, verify that the scan tool Contactor System Request Circuit Command parameter is 100 percent.
- If not the specified value, test the control circuit terminal 4 for a short to ground. If the circuit tests normal, replace the Battery Energy Control Module and Bracket Replacement .
- Install a 3 A fused jumper wire between the control circuit terminal 4 and ground. Verify that the scan tool Contactor System Request Circuit Command parameter is 0 percent.
- If not the specified value, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the drive motor generator battery control module.
- If all circuits test normal, replace the drive motor generator power inverter module assembly.
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:
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
Failure to follow the procedures may result in serious injury or death.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.