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Circuit/System Testing

WARNING:

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. Vehicle OFF, disconnect the harness connector at the P36 Battery State Of Charge Indicator.
  2. Test for less than 10 Ω between the low reference terminal C and ground.
    • If 10 Ω or greater 

      Repair the open/high resistance in the circuit.

    • If less than 10 Ω 
    3. NOTE:

    If the drive motor battery charger cable is connected. The drive motor battery charger cable must be disconnected for more than 10 s before performing the next step.

  3. Connect a test lamp between the signal terminal A and ground.
  4. Verify the test lamp does not illuminate.
    • If the test lamp illuminates 
    1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for less than 1 V between the signal circuit terminal and ground.
      • If 1 V or greater, repair the short to voltage in the circuit.
      • If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
    • If the test lamp does not illuminate 
  5. Connect the drive motor battery charger cable.
  6. Verify that the test lamp illuminates in the first 5 s of connecting the drive motor battery charger cable.
    • If the test lamp does not illuminate 
    1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for infinite resistance between the signal circuit and ground
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω the signal circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K114B Hybrid/EV Powertrain Control Module 2.
    • If the test lamp illuminates 
  7. Disconnect the drive motor battery charger cable for at least 10 s. Connect a test lamp between the signal terminal B and ground.
  8. Verify test lamp does not illuminate.
    • If the test lamp illuminates 
    1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for less than 1 V between the signal circuit terminal and ground.
      • If 1 V or greater, repair the short to voltage in the circuit.
      • If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
    • If the test lamp does not illuminate 
  9. Connect the drive motor battery charger cable.
  10. Verify that the test lamp illuminates within 25 s of connecting the drive motor battery charger cable.
    • If the test lamp does not illuminate 
    1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for infinite resistance between the signal circuit and ground
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω the signal circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K114B Hybrid/EV Powertrain Control Module 2.
    • If the test lamp illuminates 
  11. Connect a test lamp between the signal terminal D and ground.
  12. Command the BCM Charge Complete Indicator ON and OFF with a scan tool. Verify the test lamp turns ON and OFF when changing between the commanded states.
    • If the test lamp is always ON 
    1. Test for less than 1 V between the control circuit terminal and ground.
      • If 1 V or greater, repair the short to voltage in the circuit.
      • If less than 1 V, replace the K9 Body Control Module.
    • If the test lamp is always OFF 
    1. Test for infinite resistance between the control circuit and ground
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    2. Test for less than 2 Ω the control circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K9 Body Control Module.
    • The test lamp turns ON and OFF 
  13. Replace the P36 Battery State Of Charge Indicator.
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