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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.

WARNING:

The eAssist battery pack assembly will utilize an exchange program. Please consult the most recent revision of bulletin/PI# PIC5520, available in Service Information (SI), for a list of approved eAssist battery pack assembly service procedures. Components that may be removed and serviced without exchanging the complete battery pack assembly are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.

NOTE:

Use the schematics and connector end views to identify the device serial data circuit terminals.

  1. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling .
  2. Reconnect the 12 V battery.
  3. Ignition/Vehicle OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 m (9.8 ft) away from vehicle. Disconnect the X2 harness connector at the K112A Hybrid/EV Battery Interface Control Module 1. It may take up to 2 min for all vehicle systems to power down.
  4. Ignition ON/Vehicle In Service Mode.
  5. Test for 1-5 V between each serial data circuit terminal and ground:
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 3 X2
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 4 X2
    • If 5 V or greater 

      Repair the short to voltage in the serial data circuit.

    • If less than 1 V 
    1. Ignition OFF, disconnect the X7 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for infinite resistance between the serial data 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 in the serial data 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 between 1-5 V 
  6. Ignition/Vehicle OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 m (9.8 ft) away from vehicle. Disconnect the X7 harness connector at the K114B Hybrid/EV Powertrain Control Module 2. It may take up to 2 min for all vehicle systems to power down.
  7. Ignition ON/Vehicle In Service Mode.
  8. Test for less than 5 V between each serial data circuit terminal and ground:
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 1 X2
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 2 X2
    • If 5 V or greater 

      Repair the short to voltage in the serial data circuit.

    • If less than 5 V 
  9. Ignition/Vehicle OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 m (9.8 ft) away from vehicle. It may take up to 2 min for all vehicle systems to power down.
  10. Test for infinite resistance between each serial data circuit terminal and ground:
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 1 X2
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 2 X2
    • If less than infinite resistance 

      Repair the short to ground in the serial data circuit.

    • If infinite resistance 
  11. Test for infinite resistance between K112A Hybrid/EV Battery Interface Control Module 1 terminals 1 X2 and 2 X2.
    • If less than infinite resistance 

      Repair the short together in the serial data circuits.

    • If infinite resistance 
  12. Test for less than 2 Ω in each serial data circuit end to end between the K112A Hybrid/EV Battery Interface Control Module 1 and the K114B Hybrid/EV Powertrain Control Module 2.
    • If 2 Ω or greater 

      Repair the open/high resistance in the serial data circuit.

    • If less than 2 Ω 
  13. Disconnect the X1 harness connector at the K112A Hybrid/EV Battery Interface Control Module 1 and the X2 harness connector at the K112B Hybrid/EV Battery Interface Control Module 2.
  14. Ignition ON/Vehicle In Service Mode.
  15. Test for less than 5 V between each serial data circuit terminal and ground:
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 1 X1
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 2 X1
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 3 X1
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 4 X1
    • If 5 V or greater 

      Repair the short to voltage in the serial data circuit.

    • If less than 5 V 
  16. Ignition/Vehicle OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 m (9.8 ft) away from vehicle. It may take up to 2 min for all vehicle systems to power down.
  17. Test for infinite resistance between each serial data circuit terminal and ground:
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 1 X1
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 2 X1
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 3 X1
    • K112A Hybrid/EV Battery Interface Control Module 1 terminal 4 X1
    • If less than infinite resistance 

      Repair the short to ground in the serial data circuit.

    • If infinite resistance 
  18. Test for infinite resistance between each pair of serial data circuit terminals:
    • K112A Hybrid/EV Battery Interface Control Module 1 terminals 1 X1 and 2 X1
    • K112A Hybrid/EV Battery Interface Control Module 1 terminals 3 X1 and 4 X1
    • If less than infinite resistance 

      Repair the short together in the serial data circuits.

    • If infinite resistance 
  19. Test for less than 2 Ω in each serial data circuit end to end between the K112A Hybrid/EV Battery Interface Control Module 1 and the K112B Hybrid/EV Battery Interface Control Module 2.
    • If 2 Ω or greater 

      Repair the open/high resistance in the serial data circuit.

    • If less than 2 Ω 
  20. Replace the K112A Hybrid/EV Battery Interface Control Module 1.
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