Battery Energy Control Module Wiring Junction Block Replacement

Battery Energy Control Module Wiring Junction Block Replacement

Removal Procedure

Danger:
Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.


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 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.


1. Ignition OFF, disable the high voltage at the A4 hybrid battery pack. Refer to High Voltage Disabling High Voltage Disabling.




2. Remove the fasteners (3) retaining the high voltage battery cables to the batteries.

3. Disengage the cable retaining clip (1) and reposition the high voltage cables.

4. Remove the fasteners (2) retaining the junction block to the generator control module.




5. Remove the current sensor connector (3), the pre-charge contacts (4) and the contactor connector (5).




6. Remove the generator control module connector (1).




7. Remove the drive motor battery wire junction block relay fasteners (1) and remove the drive motor battery wire junction block relay (2).

Installation Procedure





Caution: Refer to Fastener Caution Fastener Caution.

1. Install the drive motor battery wire junction block relay (2) and tighten the fasteners (1) to 9 Nm (80 lb in).




2. Connect the following to the generator battery disconnect relay junction block :

* Current Sensor Connector (3).

* Pre-Charge Contacts (4).

* Contactor Connector (5).




3. Install the connector (1) to the generator control module.




4. Install the fasteners (2) retaining the junction block to the generator control module.

5. Position the high voltage cables through the cable retaining clip (1).

6. Install the high voltage cables to the batteries and tighten the fasteners (3) to 9 Nm (80 lb in).

7. Enable the hybrid battery. Refer to High Voltage Enabling High Voltage Enabling.