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, disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling .
- 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
- If any conditions are found, remove, repair or replace as necessary.
- Ignition OFF, disconnect the X3 connector at the drive motor generator battery control module.
- Test for 1k Ξ©-209k Ξ© between the terminals listed below. The resistance of each temperature sensor should be within the specified range, and within 500 Ξ© 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
- If not within the specified range, replace the drive motor battery sensor module wiring harness.
- If all circuits test normal, replace the drive motor generator battery control module.
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:
- β’ You smell fuel, burning insulation, or see smoke.
- β’ Brakes feel soft, pull hard to one side, or make grinding noises.
- β’ The engine overheats, stalls repeatedly, or misfires under load.
- β’ You are missing required tools, torque specs, or safe lifting equipment.
- β’ You are not confident in the next step or safety outcome.