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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 will perform the following tasks:

    • 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.

    Failure to follow the procedures exactly as written may result in serious injury or death.

  1. Verify a test lamp illuminates between the 14V Power Module B+ circuit ring terminal and ground.
    • If the test lamp does not illuminate and the circuit fuse is good 
    1. Remove the test lamp and disconnect the B+ cable at the 14V power module.
    2. Test for less than 2 Ω in the B+ circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, verify the mega fuse is not open and there is voltage at the fuse.
    • If the test lamp does not illuminate and the circuit fuse is open 
    1. Remove the test lamp and disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
    2. Disconnect the 14V power module B+ cable.
    3. Test for infinite resistance between the B+ circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance replace the K1 14V Power Module and the mega fuse.
    • If the test lamp illuminates 
  2. Disconnect the X2 harness connector at the 14V power module, vehicle ON.
  3. Test for 3.0-5.5 V between the control circuit terminal X2-01 and ground.
    • If less than 3.0 V 
    1. Vehicle OFF, disconnect the harness connectors at the K20 ECM.
    2. 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
    3. Test for less than 2 Ω in the control circuit end to end.
      • If greater the 2 Ω, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K20 ECM.
    • If greater than 5.5 V 
    1. Vehicle OFF, disconnect the harness connectors at the K20 ECM, Vehicle ON.
    2. Test for less than 1 V between the control circuit and ground.
      • If greater than 1 V, repair the short to voltage on the circuit.
      • If less than 1 V, replace the K20 ECM.
    • If between 3.0-5.5 V 
  4. Vehicle OFF, disconnect the harness connectors at the K20 ECM.
  5. Test for infinite resistance between the 14V power module status circuit terminal X2-03 and ground.
    • If less than infinite resistance 

      Repair the short to ground on the circuit.

    • If infinite resistance 
  6. Test for less than 2 Ω in the status circuit end to end.
    • If greater the 2 Ω 

      Repair the open/high resistance in the circuit.

    • If less than 2 Ω 
  7. Disable the high voltage. Refer to High Voltage Disabling .
    8. NOTE:

    T24 Battery Charger - DC high voltage connector X1 is disconnected during the High Voltage Disable procedure.

  8. Disconnect the T24 Battery Charger - DC high voltage connector X3 for the 14V Power Module.
  9. Verify that the 14V Power Module non-serviceable high voltage fuse within the T24 Battery Charger - DC is good. Test for less than 2 Ω between the following T24 Battery Charger-DC high voltage connector terminals:
    • High voltage negative terminal X1 B to high voltage negative terminal B X3
    • High voltage positive terminal X1 A to high voltage positive terminal A X3
    • If greater than 2 Ω 

      Replace the T24 Battery Charger - DC and the 14V Power Module.

    • If less than 2 Ω 
  10. Replace the K1 14V Power Module.
  11. Verify the DTC does not set.
    • If the DTC sets 

      Replace the K20 ECM.

    • If the DTC does not set 
  12. All OK.
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