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Towing and

Road Service Guide

For The

CODA Sedan

Quality and Education Services

AAA Automotive

1000 AAA Drive

Heathrow, FL 32746

October 21, 2011

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INDEX

GENERAL VEHICLE INFORMATION Major Component Locations and General Information 3 Sounds and Vibrations Specific to the Battery Electric Vehicles 3 GENERAL TOWING INFORMATION Equipment Availability 4

Special Precautions 4 Shifting out of Park and into Neutral 4 Car Carrier Loading and Transporting 5 Car Carrier Tie Down Points 6 Wheel-Lift Towing Procedure 8

EMERGENCY ROAD SERVICE INFORMATION Jacking /Tire Service 9

Out of Charge 10 Electric Charge Port 10

Jump-Start Procedures 11 Vehicle Entry (Unlocking) 13

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GENERAL INFORMATION The CODA sedan is a battery electric vehicle which utilizes a high voltage storage battery connected to an electric motor to propel the vehicle. The high voltage storage battery is located under the passenger compartment floor and may be covered with a black plastic covering. The wiring connecting the high voltage battery to the electric motor and control systems are covered with an orange loom, making them easy to identify (figure 1). Avoid contact with any of the orange wiring harness during vehicle service.

Figure 1

The battery pack in the CODA sedan is made up of 728 individual Lithium Iron Phosphate (LiFePO4) cells which, when charged has approximately 333 volts with the ability of delivering 36 kWh of energy to the electric propulsion motor. Take care when handling these vehicles, as parts may become extremely hot when the electric drive system is operating. Obey the caution labels attached to the vehicle. SOUNDS AND VIBRATIONS SPECIFIC TO BATTERY ELECTRIC VEHICLES: There will be no engine sounds or vibration even though the vehicle is able to move. Always change the shift position to P when parked. The following sounds or vibrations may occur when the drive system is operating and are not a malfunction:

Sounds may be heard from the battery control system behind the rear seats when the vehicle starts or stops.

Motor sounds may be heard from the engine compartment from the control components as well as the heating and ventilation system.

Sounds from the battery control system may be heard when the trunk lid is open.

Sounds may be heard due to regenerative braking when the brake pedal is depressed and accelerator is loosened.

Other sounds, such as motors and mechanical noises, may be heard from the brake system when the brake pedal is depressed.

Cooling fan sounds may be heard from the air intake vent, the fan noise may be louder than when driving normally.

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GENERAL TOWING INFORMATION EQUIPMENT AVAILABILITY:

The towing and tie-down equipment discussed in this guide is available through AW Direct, a preferred AAA supplier. Contact your local AAA club representative for special offers available to AAA contractors.

SPECIAL PRECAUTIONS:

The Coda Sedan has a locking steering column so the key is required to steer the vehicle and get it out of park.

If the vehicle needs to be towed, do so with front wheels raised. If the wheels connected to the electric motor are on the ground when towing, the motor may continue to generate electricity. This may cause an electricity leakage leading to a fire.

Car carrier or wheel-lift equipment are authorized methods of towing this vehicle. A car carrier is the preferred method of transporting. THERE IS NO APPROVED PROCEDURE FOR THE USE OF SLING-TYPE EQUIPMENT ON THIS VEHICLE.

When loading or pulling the CODA sedan, follow only the approved loading procedures specified in the following pages and listed in the AAA Towing & Service manual.

In an emergency situation where the vehicle will not roll or must be moved for towing access, wheel-jacking equipment, such as Go-Jacks are recommended.

SHIFTING OUT OF PARK AND INTO NEUTRAL: The vehicle may be shifted out of Park into Neutral by turning the ignition-on and READY-on modes. To select Neutral, turn the gear selector to the Neutral position (Figure 2).

Figure 2

If the 12 Volt auxiliary battery is discharged, the vehicle will not start and shifting out of park is not possible. There is no manual override to shift out of Park, except to jump start the vehicle.

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CAR CARRIER LOADING AND TRANSPORTING: The use of car carrier equipment is the preferred method of transporting the CODA sedan. Note: The curb weight for the CODA sedan is 3,670 lbs/1,668 kg The CODA sedan has a moderate amount of ground clearance at front and rear. Loading onto a conventional car carrier may require additional ramping in some circumstances. However, clearance at the trailing end of the vehicle should always be monitored as it is loaded. The towing eye bolt should be used for front loading of the CODA sedan. The eye bolt is located in the trunk with the tire inflation kit (Figure 3).

Figure 3

NOTE: Use a plastic trim tool or a plastic card, such as an old credit card to avoid damaging the painted surface when removing the plug from the bumper to gain access to the eyebolt receiver (Figure 4). Screw the eye bolt into the front pull point and attach the winch line to the eyebolt with the open side of the hook facing upward.

Figure 4

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If the towing eyebolt is missing or otherwise inaccessible, the use of nylon axle straps around the lower control arms is the recommended attachment point (Figure 5).

Figure 5

Before loading, ensure that the transmission is in “Neutral” and the ignition switch is in position to unlock the steering. When loading, remember that the eye bolts are designed for a straight ahead pull within a 20 degree window, so stop the vehicle as the winch wire rope begins to pull downward. To prevent too much downward pull you will need to keep the leading edge of the CODA sedan about 3 feet or more from the winch drum.

Once loaded, set the parking brake and secure the vehicle onto the carrier. Wheel strap tie downs are the only means of securing the CODA sedan to a car carrier as there are not any “T” hook slots accessible in the unibody to attach to (Figure 6). The battery and battery cooling system cover up any factory supplied “T” hook slots.

Figure 6

After securing, return the bed to the transporting position, then slacken the winch wire rope slightly to prevent downward pull on the towing eye bolt (if used) as bumps are encountered during transport. Make sure that the ignition is in the OFF position and the key is located in the cab of the tow vehicle.

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If the vehicle needs to be loaded rear facing, the rear structure of the vehicle may not support the weight of the pull. To safely load this vehicle rear facing on to a car carrier, attach nylon axle straps to the front lower control arms. Attach your winch line to the axle straps and pull the vehicle on the car carrier paying close attention to all contact points on the vehicle along with maintaining proper ground clearance while loading. It may be necessary to use a piece of wood or other protective means between the winch line hook and the undercarriage of the vehicle to prevent the hook or winch line from contacting the high voltage battery pack case or shielding (Figure 7).

Figure 7

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WHEEL-LIFT TOWING PROCEDURE: If a wheel-lift is used, the procedures shown below must be used. Refer to the AAA/CAA Tow and Service Manual for detailed information regarding towing this vehicle. Follow all general towing precautions.

Front Tow:

To tow CODA sedan with a wheel-lift from the front of the vehicle, observe the following:

Secure the front wheels firmly to the wheel-lift

Use a steering wheel securing device.

Attach safety chains and tow lights to the vehicle.

Ensure that the ignition is turned OFF to prevent unnecessary battery drain. Rear Tow:

To tow CODA sedan with a wheel-lift and dolly, observe the following:

Secure the rear wheels firmly to the wheel-lift and the front set of wheels firmly to the dolly.

After loading the CODA sedan onto the dolly and wheel-lift, place the transmission in Park.

Use a steering wheel securing device.

Attach safety chains and tow lights to the vehicle.

Ensure that the ignition is turned OFF to prevent unnecessary battery drain.

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EMERGENCY ROAD SERVICE PROCEDURES

JACKING/TIRE SERVICE: The CODA sedan does not have a factory supplied spare tire, jack or tire tools. It is supplied with a tire inflation kit (Figure 8). Follow the instructions on the kit itself to ensure proper installation of the sealing compound.

Figure 8

If the vehicle needs to be lifted, the approved lifting locations are on the unibody structure. Do not use the pinch weld or rocker sills, located inboard of the wheels as ducting for the battery cooling system runs in this area and may be damaged (Figures 9 & 10).

Figure 9 Figure 10

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OUT OF CHARGE SERVICE: The CODA sedan uses an industry standard electrical connector (J1772) to charge the battery. The vehicle is equipped with a connector which will attach to the vehicle and to a standard 110 volt electrical wall socket. The vehicle charge cable is stored in the trunk of the vehicle. If you encounter a CODA sedan which has been run out of charge, it is best to tow it to the operator’s home or place of business as it will take about an hour of charging to give the CODA sedan 12 miles of driving range using the charge cord supplied with the vehicle. If a commercial or home charge station is used, this time is reduced in half as these chargers can deliver about a 50 mile range in 2 hours.

ELECTRIC CHARGE PORT: The electric charging port on a CODA sedan is located on the left rear quarter panel of the vehicle. It looks like a conventional fuel filler door but behind it is the electrical connector for the charging equipment (Figure 11).

Figure 11

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BATTERY & JUMP-STARTING: The CODA sedan has a conventional 12 volt battery located on the passenger’s side of the trunk (Figure 12). If the 12 volt battery becomes discharged, the vehicle will not operate as this battery is required to close circuitry to allow the high voltage battery to power the drive motor.

Figure 12

The trunk on the CODA sedan is released electronically through a switch on the dash. With a discharged battery, this release will not function. To access the trunk, you will need to fold the rear seat down. Access to do so is on the top of the rear seat (Figure 13).

Figure 13

Depress the round button to release the seat, fold it forward then reach in and pull the emergency trunk release lever to release the trunk latch (Figure 14).

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Figure 14

Connect cables to the designated locations and in the order below. Disconnect cables in reverse order:

Connect a positive jumper cable clamp to the positive terminal of the battery

Connect the clamp on the other end of the positive cable to the positive (+) battery terminal on the second vehicle

Connect a negative cable clamp to the negative (-) battery terminal on the second vehicle

Connect the clamp at the other end of the negative cable to a solid, stationary, unpainted metallic point away from the battery

Turn the ignition key to the run position and ensure the “READY” indicator is illuminated on the dash

Make sure the vehicle will move under electric power

Have the operator take the vehicle to a repair facility to have the battery charged and evaluated

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VEHICLE ENTRY (UNLOCKING):

The CODA sedan uses a rod linkage within the door cavity for connecting the interior lock button to the latch assembly in the door (Figure 15).

Figure 15

The linkage is shielded all the way back to the latch assembly so in the cavity door linkage tools are not recommended for unlocking the CODA sedan. To gain access to the vehicle two methods are recommended:

Use a pillow wedge to open a gap at the rear corner of the right front door just large enough to allow access for a long reach tool to enter the passenger compartment. Manipulate the long reach tool to contact the interior lock button and pull the button rearward to unlock the vehicle.

Use 2 wedges to open a gap at the window sill level at the forward part of the right front door. Enter an under-the-glass type tool into the door cavity at the forward part of the door, pay close attention to any wiring harness or window mechanisms that may interfere with the tool. With the tool in the door cavity, back off or remove the wedge then pull the tool foot up on the inside of the door glass. Manipulate the tool into position to move the interior door lock button rearward to unlock the door. Remove the tool in reverse of the entry procedure and location. Use caution with this method as temperature extremes can make this entry risky.