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
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.
- Connect the customer's drive motor battery charger cable to household power outlet, but not the vehicle battery charger receptacle.
- After 25 seconds, verify drive motor battery charger cable AC Present Indicator illuminates solid green.
- If drive motor battery charger cable AC Present Indicator does not illuminate solid greenÂ
- Connect a known good drive motor battery charger cable to the same household power outlet.
- If known good drive motor battery charger cable AC Present Indicator illuminates solid green, replace the customer's drive motor battery charger cable.
- If known good drive motor battery charger cable AC Present Indicator does not illuminate solid green, have the service provider inspect the household power outlet for insufficient voltage, high frequency noise, or open/high resistance.
- Go to next step: If drive motor battery charger cable AC Present Indicator does illuminate solid greenÂ
Test for greater than 1 V between the low voltage circuits listed below on drive motor battery charger cable.
- Proximity status signal circuit terminal 5
- Control pilot signal circuit terminal 2
- If less than 1 VÂ
Replace drive motor battery charger cable.
- Go to next step: If greater than 1 VÂ
- NOTE:
The following tests are performed at the X98 Hybrid/EV Battery Charger Receptacle face and not at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.
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.
Rather have a pro handle this?
A certified mobile mechanic comes to your home or office. They bring the tools, you stay comfortable. No tow truck, no waiting room, no surprises.
No obligation. See pricing before you book.