Service Procedure
Service ProcedureECM Programming Event
Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) with the calibration update. When using a MDI for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 10/24/11 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided.
For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal.
1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming.
2. Reprogram the engine control module (ECM). Refer to SI and Service Programming System (SPS) documentation for programming instructions.
1. Connect the MDI to the vehicle.
2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen.
3. Select ECM Engine Control Module - Programming from the Supported Controllers screen.
4. Follow the on-screen instructions.
3. After programming the ECM, return to the SPS Supported Controllers screen and select ECM Engine Control Module (Automatic Transmission) - Setup and follow the on-screen instructions.
4. Clear all diagnostic trouble codes (DTCs).
5. Start the vehicle and confirm that there are no messages on the driver information center display or any telltales illuminated.
Starter Generator Phase Lead to Terminal Weld Inspection
Note
Be sure to capture all DTC information using scan tool prior to disconnecting high voltage. Diagnostic information will be lost when the power is disconnected.
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.
1. Turn the ignition OFF and wait 5 minutes to allow the high voltage capacitors to discharge.
2. Remove all vehicle keys and secure in a location outside the vehicle. If the vehicle is equipped with push button start, the keys must remain at least 3 meters (10 feet) away from the vehicle.
3. Open hood and place protective covers on fenders and front grill areas.
4. Remove 12V battery cover (1).
5. Disconnect the 12V negative battery cable from battery (2). Make sure cable (3) is securely tucked away so as to not reconnect to battery terminal.
6. Verify no battery chargers are connected to vehicle.
7. Remove passenger side rear seatback.
8. Remove the three trim retainers and reposition the trunk liner to gain access to the A4 hybrid/EV battery pack.
9. Disengage the blue connector position assurance (1) from the high voltage interlock switch by pulling the CPA straight out. Do not fully remove the CPA from the switch or damage to the CPA will result.
10. Depress the white tab on the high voltage interlock switch and slide the interlock switch toward the left side of the vehicle (2).
11. Flip the S15 hybrid/EV battery pack high voltage manual disconnect lever, located on the A4 hybrid/EV battery pack, toward the right side of the vehicle and secure in the open position with a zip tie (3).
12. Loosen clamps (1) on air intake duct (2) remove air intake duct. Note small hose should remain on engine valve cover.
13. Remove coolant hose support connection (1) at the starter generator.
14.
Danger
Wear high voltage insulation gloves with leather protectors until it has been determined that a high voltage exposure risk is no longer present. Failure to follow the procedures exactly as written may result in serious injury or death.
Remove 3 phase cover nuts (1) from starter generator. Lift cover (2) straight up.
15. Check for Voltage
Test the DMM by measuring a 12V battery. The reading on the DMM should accurately reflect the battery voltage.
16. Verify that the voltage has been disabled at the energy storage system. Using the DMM on the DC voltage scale, test for less than 3V at the following points:
- High voltage 3-Phase terminal V to vehicle chassis ground
- High voltage 3-Phase terminal W to vehicle chassis ground
- High voltage 3-Phase terminal U to vehicle chassis ground
- High voltage 3-Phase terminal U to High voltage 3-Phase terminal V
- High voltage 3-Phase terminal V to High voltage 3-Phase terminal W
- High voltage 3-Phase terminal W to High voltage 3-Phase terminal U
If 3V or Greater
A contactor is stuck closed or a loss of isolation has occurred within the A4 hybrid/EV battery pack. Refer to Hybrid/EV Battery Voltage Present in SI.
If less than 3V
Test the DMM by measuring a 12V battery. The reading on the DMM should accurately reflect the battery voltage.
- If the DMM does not properly measure a 12V battery, repair or replace the DMM and perform Steps 15 and 16 again.
- If the DMM properly measures a 12V battery, the starter generator, high voltage 3-phase cables, or general vehicle can now be serviced if all of the test results were less than 3 V. Proceed to Step 17.
17. Remove 3-phase cable bolts (1), note bolts are not to be removed. Lift terminal block straight up.
18. Verify torque wrench is set to correct level for terminal test. The torque specification is 11 Nm (8 lb ft)..
19. Perform following procedure on starter generator 3-phase terminals:
Note
Fork fixture tool EL50953 should not rotate once it is seated correctly and torque is applied. If the tool rotates, then the terminal is damaged or the tool slipped. Install the tool by hand and make sure that it is locked in place and does not rotate before the torque wrench is used.
1. Put fork fixture tool EL50953 (5) on the phase pin (4) in the 3-phase insulator.
2. Turn the torque wrench in a counter clockwise direction. Do NOT apply a downward force onto the phase pin. Stop when the torque wrench produces an audible "click" or indicates the 11 Nm (8 lb-ft) threshold is achieved.
3. Repeat Steps 19.1 and 19.2 to test all three phase pins.
4. Using a plastic trim tool (or equivalent) determine if the terminal (1) is loose. Check all three terminals (1) with the tool.
Note
If the weld is broken, the terminal will be very loose once pressure is applied to it with the plastic tool. In portion "A" of the illustration, the terminal moved so much it covered half of the bolt hole (4). There may be normal "play/slop" between the external ring terminal (1) and the plastic encasement block (2) that the terminals sit in. Refer to portion "B" of the illustration. This normal play is a few thousandths of an inch. If the external ring terminal (1) and the flat blade terminal (3) that goes up into the starter generator move together when pushing with the plastic tool, the weld is good.
- If any of the terminals (1) are loose, replace the starter generator. Refer to Starter Generator Replacement in SI.
- If the terminals (1) are NOT loose, proceed to Step 19.5.
5. Visually inspect the terminals (1), housing (2), insulator and joints for damage that may have been caused by the EL-50953 tool during this test.
- If the terminals, housing, insulator and joints are NOT damaged, proceed to Step 20.
- If the terminals, housing, insulator and joints are damaged, replace the starter generator. Refer to Starter Generator Replacement in SI.
20. Install the 3-phase terminal block assembly to the starter generator assembly. Verify the Oring seals on the top and bottom of terminal block are in place. Tighten the bolts (1) to 9 Nm (80 lb-in).
21. Install the 3 phase terminal block cover (2) and 3 phase terminal block cover nut (1). Tighten to 9 Nm (80 lb-in). Take care that cover is installed square so as small interlock pins are inserted correctly.
22. Install coolant hose support at starter generator. Tighten to 9 Nm (80 lb-in).
23. Install the air intake (2) to throttle body, air box, and small valve cover hose connection. Tighten clamps (1) to 4 Nm (35 lb-in)..
24. Remove zip tie from EV battery pack high voltage manual disconnect lever (3).
25. Push in the red safety plunger and flip the S15 hybrid/EV battery pack high voltage manual disconnect lever (1) to the closed position.
26. Slide the white interconnect switch (2) to the closed position (toward the passenger side of vehicle).
27. Re-engage the blue connector position assurance (CPA) (3) of the high voltage interlock switch by pushing the CPA straight until a click is felt.
28. Reposition the trunk liner and install the retainers.
29. Install the rear seatback in its normal position.
30. Reconnect 12V battery negative cable. Torque to 4.5 Nm (44 lb-in).
31. Install 12V battery cover.
32. Close the hood.
33. Connect the MDI to ALDL connector and open the Diagnostic Tool Program.
34. Start the vehicle.
35. Open and close the driver and passenger windows as instructed by the DIC message.
36. Clear diagnostic trouble codes.
37. Turn on the rear defrost, set cabin blower on high, and set AC on MAX cool.
38. Run vehicle with high loads at 1500 rpm for 10 seconds.
39. Turn key to off position and open and close the driver door. Wait until the dome light turns off.
40. Restart vehicle.
41. Turn off the rear defrost, AC and cabin blower.
42. Check all controllers for DTCs. Code U0422 and/or C0561 may be set. If DTCs U0422 and/or C0561 are set, clear them. If other DTCs are present, refer to the appropriate diagnostic information in SI for those DTCs. If the DTCs will not clear, refer to the appropriate diagnostic information in SI.
43. Re-set the clock.
Belt Tensioner Stop Bolt Inspection
1. Check to see if tensioner is tight against stop.
- If the tensioner is tight against stop, proceed to Step 2.
- If the tensioner is NOT tight against stop, proceed to Step 4.
2. Loosen tensioner stop bolt.
3. Using a 15mm wrench, move mechanical tensioner (tensioner arm should move away from stop).
4. Ensure that the locator pin (2) in the tensioner stop is in the mating hole in the bracket.
5. Tighten the tensioner stop bolt (1) to 9 Nm (80 in lb).