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‌SPECIFICATIONS

ELECTRICAL

Hybrid/EV System Heating and Cooling - Volt

TEMPERATURE VERSUS RESISTANCE

B204 Hybrid/EV Battery Pack Coolant Temperature Sensor*

B32 Hybrid/EV Battery Temperature Sensor*

B202 Hybrid/EV Electronics Coolant Temperature Sensor*

FASTENER SPECIFICATIONS

Single Use Non-Threaded Fasteners/Components

Reusable Threaded Fastener Tightening Specifications

APPROXIMATE FLUID CAPACITIES

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

SCHEMATIC WIRING DIAGRAMS

HYBRID/EV COOLING WIRING SCHEMATICS

Hybrid/EV Battery Modules - Temperature Sensors 1 through 6

Fig. 1: Hybrid/EV Battery Modules - Temperature Sensors 1 through 6 Courtesy of GENERAL MOTORS COMPANY

Hybrid/EV Battery Pack Cooling

Fig. 2: Hybrid/EV Battery Pack Cooling Courtesy of GENERAL MOTORS COMPANY

Cooling Fans

Fig. 3: Cooling Fans

Courtesy of GENERAL MOTORS COMPANY

Hybrid/EV Electronics Cooling

Fig. 4: Hybrid/EV Electronics Cooling Courtesy of GENERAL MOTORS COMPANY

DIAGNOSTIC INFORMATION AND PROCEDURES

DTC P0480: COOLING FAN RELAY CONTROL CIRCUIT

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0480

Cooling Fan Relay Control Circuit

Circuit/System Description

The radiator cooling fans are controlled as a pair with a pulse width modulated (PWM) signal on the cooling fan relay control circuit from the hybrid/EV powertrain control module 2. Although the hybrid/EV powertrain control module 2 is directly connected to the cooling fans, the ECM is considered the master controller. The ECM sends a fan command PWM signal to the hybrid/EV powertrain control module 2 through the cooling fan signal hardwire circuit. The hybrid/EV powertrain control module 2 operates in a pass-through mode for any ECM-derived fan request. The higher the duty cycle the higher the cooling fan speed. The right side fan

operates at a maximum speed of 3200 RPM while the left side fan operates at a maximum speed of 2900 RPM.

When the ECM is awake and there are no faults, the hybrid/EV powertrain control module 2 sends its cooling fan requests to the ECM via serial data. The ECM uses this request and other vehicle inputs to decide if and what speed the cooling fans should operate. The ECM sends the cooling fan signal command to the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 sends the fan relay control signal to the cooling fans to operate and at what speed.

If the vehicle is in Charge Mode and the hybrid/EV powertrain control module 2 requests the cooling fans to operate and the ECM is not awake, the hybrid/EV powertrain control module 2 will directly control the cooling fans. If active cooling is needed, the ECM wakes up to operate the air conditioning control module and then the ECM is the master controller for the fans.

Conditions for Running the DTC

The 12 V battery voltage is greater than or equal to 10.2 V.

Conditions for Setting the DTC

The hybrid/EV powertrain control module 2 has detected an open, short to ground or short to voltage fault on the fan relay control circuit.

Action Taken When the DTC Sets DTC P0480 is a type B DTC. Conditions for Clearing the DTC DTC P0480 is a type B DTC. Reference Information Schematic Reference

Engine Heating/Cooling Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that both the cooling fans are operating at a high speed when commanding the Cooling Fan Motor Command to 90% with a scan tool.

If either or both cooling fans are not operating at a high speed

Refer to Circuit/System Testing.

If the cooling fans are operating as commanded

3. Verify that both the cooling fans are operating at a low speed when commanding the Cooling Fan Motor Command to 10% with a scan tool.

If either or both cooling fans are not operating at a low speed

Refer to Circuit/System Testing.

If the cooling fans are operating as commanded

4. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the harness connector at the appropriate G10 Cooling Fan Motor.

2. Test for less than 10 Ω between the ground circuit terminal 2 and ground.

If 10 Ω or greater

Repair the open/high resistance in the circuit.

If less than 10 Ω

3. Connect a test lamp between the B+ circuit terminal 1 and ground.

4. Verify a test lamp illuminates between the B+ circuit terminal 1 and ground.

If the test lamp does not illuminate and the circuit fuse is good

1. Vehicle OFF.

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 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. Vehicle OFF.

2. 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 G10 Cooling Fan Motor and the fuse.

If the test lamp illuminates

5. Connect a test lamp between the control circuit terminal 4 and the B+ circuit terminal 1.

6. Vehicle in service mode, verify the test lamp changes between dim (10%) and bright (90%) when

commanding the Cooling Fan Motor Command ON between 10% and 90% with a scan tool.

If the test lamp is always dim or does not illuminate

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2. Vehicle in Service Mode.

2. Test for less than 1 V between the control circuit and ground.

If 1 V or greater, repair the short to voltage on the circuit. If less than 1 V

3. Vehicle OFF.

4. Test for less than 2 Ω in 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 K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is always bright

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

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, replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp changes illumination between bright (90%) and dim (10%)

7. Replace the G10 cooling fan motor.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Engine Coolant Fan Shroud Replacement for G10 cooling fan motor replacement

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P0A7E: HYBRID/EV BATTERY PACK HIGH TEMPERATURE

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0A7E

Hybrid/EV Battery Pack High Temperature

Circuit/System Description

The hybrid/EV battery pack has 6 hybrid/EV battery module temperature sensors. The hybrid/EV powertrain control module 2 uses the battery temperature sensors to determine the hybrid/EV battery module temperature to control the energy storage cooling system operation.

The energy storage system cooling system uses a 12 V hybrid/EV battery pack coolant pump, a refrigerant/coolant heat exchanger (chiller) and the electric A/C compressor motor control module assembly to cool down the high voltage hybrid/EV battery.

Conditions for Running the DTC

The hybrid/EV powertrain control module 2 and hybrid/EV battery energy control module are awake and communicating.

None of the following DTCs are set: P0A9C, P0A9D, P0A9E, P0AC6, P0AC7, P0AC8, P0ACB, P0ACC, P0ACD, P0AE9, P0AEA, P0AEB, P0BC3, P0BC4, P0BC5, P0C34, P0C35, P0C36, or U179C.

Conditions for Setting the DTC

The maximum sensed temperature in the hybrid/EV battery is greater than 73.5°C (164.3°F).

Action Taken When the DTC Sets

DTC P0A7E is a type A DTC.

The hybrid/EV powertrain control module 2 opens the high voltage contactors.

Conditions for Clearing the DTC DTC P0A7E is a type A DTC. Reference Information Schematic Reference

Hybrid/EV Cooling Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that DTC P0480, P0534, P0C47, P148A-P148C, P1EC6, P1E8C or P1E8D is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle

If none of the DTCs are set

WARNING: Do NOT attempt to repair a Lithium Ion Hybrid/EV Battery Pack when an internal coolant leak is evident. The Hybrid/EV Battery Pack must always be replaced as an assembly. Failure to replace a coolant contaminated Hybrid/EV Battery Pack may result in fire, which can cause severe injury or death.

3. Test for proper coolant level and operation of the hybrid/EV battery coolant system, refrigerant system and coolant fan system. Refer to Hybrid/EV Battery Cooling Diagnostic.

DTC P0A9C-P0A9E, P0AC6-P0ACD, P0AE9-P0AEB, P0BC3-P0BC5, OR P0C34-P0C36: HYBRID/EV BATTERY TEMPERATURE SENSOR

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0A9C

Hybrid/EV Battery Temperature Sensor 1 Performance

DTC P0A9D

Hybrid/EV Battery Temperature Sensor 1 Circuit Low Voltage

DTC P0A9E

Hybrid/EV Battery Temperature Sensor 1 Circuit High Voltage

DTC P0AC6

Hybrid/EV Battery Temperature Sensor 2 Performance

DTC P0AC7

Hybrid/EV Battery Temperature Sensor 2 Circuit Low Voltage

DTC P0AC8

Hybrid/EV Battery Temperature Sensor 2 Circuit High Voltage

DTC P0ACB

Hybrid/EV Battery Temperature Sensor 3 Performance

DTC P0ACC

Hybrid/EV Battery Temperature Sensor 3 Circuit Low Voltage

DTC P0ACD

Hybrid/EV Battery Temperature Sensor 3 Circuit High Voltage

DTC P0AE9

Hybrid/EV Battery Temperature Sensor 4 Performance

DTC P0AEA

Hybrid/EV Battery Temperature Sensor 4 Circuit Low Voltage

DTC P0AEB

Hybrid/EV Battery Temperature Sensor 4 Circuit High Voltage

DTC P0BC3

Hybrid/EV Battery Temperature Sensor 5 Performance

DTC P0BC4

Hybrid/EV Battery Temperature Sensor 5 Circuit Low Voltage

DTC P0BC5

Hybrid/EV Battery Temperature Sensor 5 Circuit High Voltage

DTC P0C34

Hybrid/EV Battery Temperature Sensor 6 Performance

DTC P0C35

Hybrid/EV Battery Temperature Sensor 6 Circuit Low Voltage

DTC P0C36

Hybrid/EV Battery Temperature Sensor 6 Circuit High Voltage

Circuit/System Description

The hybrid/EV battery temperature sensor is a variable resistor that measures the temperature of the hybrid/EV battery cell groups. The hybrid/EV battery interface control module supplies 5 V to the signal circuit and a ground for the low reference circuit. The hybrid/EV battery temperature sensor resistance changes with battery temperature. The lower the temperature, the higher the resistance of the sensor. The higher the temperature, the lower the resistance of the sensor. The hybrid/EV powertrain control module 2 uses the battery temperature sensors to control the battery cooling system operation.

Conditions for Running the DTC

P0A9D, P0A9E, P0AC7, P0AC8, P0ACC, P0ACD, P0AEA, P0AEB, P0BC4, P0BC5, P0C35, P0C36 and P0C7E

The 12 V battery voltage is greater than 9 V.

Hybrid/EV powertrain control module 2 and hybrid/EV battery energy control module are awake and communicating

None of the following DTCs are set: P1E93, P1E99, P1E9F, P1EA5, P1E8E, P1E94, P1E9A, or P1EA0

P0A9C, P0AC6, P0ACB, P0AE9, P0BC3 and P0C34

None of the following DTCs are set: P0A9C, P0A9D, P0A9E, P0AC6, P0AC7, P0AC8, P0ACB, P0ACC, P0ACD, P0AE9, P0AEA, P0AEB, P0BC3, P0BC4, P0BC5, P0C34, P0C35, P0C36, P1E8E, P1E8F, P1E90, P1E91, P1E93, P1E94, P1E95, P1E96, P1E97, P1E99, P1E9A, P1E9B, P1E9C, P1E9D, P1E9F, P1EA0, P1EA1, P1EA2, P1EA3, P1EA5, P1EB1, P1EB2, P1EB3, P1EB4, P1EB5, U2401, U2603, U2604, U2605, U2606.

Conditions for Setting the DTC

P0A9C, P0AC6, P0ACB, P0AE9, P0BC3 and P0C34

The difference between a hybrid/EV battery temperature sensor and the average of all the other hybrid/EV battery temperature sensors is greater than 20°C (36°F).

P0A9D, P0AC7, P0ACC, P0AEA, P0BC4 and P0C35

The hybrid/EV battery temperature sensor is greater than 80°C (176°F).

P0A9E, P0AC8, P0ACD, P0AEB, P0BC5 and P0C36

The hybrid/EV battery temperature sensor is -40°C (-40°F).

Action Taken When the DTC Sets

DTCs P0A9C, P0A9D, P0A9E, P0AC6, P0AC7, P0AC8, P0ACB, P0ACC, P0ACD, P0AE9, P0AEA, P0AEB, P0BC3, P0BC4, P0BC5, P0C34, P0C35 and P0C36 are type B DTCs.

If all sensors fail, the vehicle will operate in a reduced power mode and the extended range mode.

Conditions for Clearing the DTC

DTCs P0A9C, P0A9D, P0A9E, P0AC6, P0AC7, P0AC8, P0ACB, P0ACC, P0ACD, P0AE9, P0AEA, P0AEB, P0BC3, P0BC4, P0BC5, P0C34, P0C35 and P0C36 are type B DTCs.

Diagnostic Aids

Low or no coolant or refrigerant in the system may set a DTC P0A9D, P0AC7, P0ACC, P0AEA, P0BC4 or P0C35.

Reference Information

Schematic Reference

Hybrid/EV Cooling Schematics

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

EL-50211 Low Voltage Harness

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that DTC P0C47, P1E8C or P1EC6 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If none of the DTCs are set

3. Observe the scan tool Hybrid Battery 1 - 6 temperature parameters. The sensor readings should be between -39 and +80°C (-38.2 and + 176°F) with less than a 20°C (36°F) difference between any of the temperature sensor readings. Refer to Temperature Versus Resistance

If not within the specified range

Refer to Circuit/System Testing.

If within the specified range

4. All OK.

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. Vehicle OFF, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling . Remove the A4 Hybrid/EV Battery Pack cover. Refer to High Voltage Battery Cover Replacement

2. Disconnect the harness connector at the appropriate B32 Hybrid/EV Battery Temperature Sensor.

3. Test for less than 10 Ω between the low reference circuit terminal 2 and ground.

If 10 Ω or greater

1. Disconnect the appropriate harness connector at the K16 Battery Energy Control Module.

2. Test for less than 2 Ω in the low reference circuit end to end.

If 2 Ω or greater, replace the Hybrid/EV Battery Pack internal wiring harness. If less than 2 Ω, replace the K16 Battery Energy Control Module.

If less than 10 Ω

NOTE: With the S15 manual service disconnect removed the 12 V battery connected and the Vehicle in Service Mode, may cause additional DTCs to set. Continue with diagnostics and clear any additional DTCs when repairs are complete.

4. Connect the EL-50211 Low Voltage Jumper Harness Extension. Connect the 12 V battery. Vehicle in Service Mode.

5. Verify with the scan tool the appropriate Hybrid/EV Battery Temperature Sensor is less than -35°C (-38.2°F).

If -35°C (-38.2°F) or greater

1. Vehicle OFF, disconnect the appropriate harness connector at the K16 Battery Energy Control Module.

2. Test for infinite resistance between the signal circuit and ground.

If less than infinite resistance, replace the Hybrid/EV Battery Pack internal wiring harness. If infinite resistance, replace the K16 Battery Energy Control Module.

If less than -35°C (-38.2°F)

6. Install a 3 A fused jumper wire between the signal circuit terminal 1 and the low reference circuit terminal 2. Verify with the scan tool the appropriate Hybrid/EV Battery Temperature Sensor is greater than 80°C (176°F).

If less than 80°C (176°F)

1. Vehicle OFF, disconnect the appropriate harness connector at the K16 Battery Energy Control Module. Vehicle in Service Mode.

2. Test for less than 1 V between the signal circuit terminal and ground.

If 1 V or greater, replace the Hybrid/EV Battery Pack internal wiring harness. If less than 1 V

3. Vehicle Off.

4. Test for less than 2 Ω in the signal circuit end to end.

If 2 Ω or greater, replace the Hybrid/EV Battery Pack internal wiring harness. If less than 2 Ω, replace the K16 Battery Energy Control Module.

If 80°C (176°F) or greater

7. Test or replace the appropriate B32 Hybrid/EV Battery Temperature Sensor.

Component Testing

1. Vehicle OFF, disconnect the harness connector at the appropriate B32 Hybrid/EV Battery Temperature Sensor.

2. Test for 9.9 - 13.4 k Ω at approximately 21.11°C (70°F) between the signal terminal and the low reference terminal. Refer to Temperature Versus Resistance for Hybrid/EV Battery Temperature Sensor.

If not within the specified range

Replace the appropriate B32 Hybrid/EV Battery Temperature Sensor.

If within the specified range

3. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Cell Battery High Voltage Sensor Replacement (Thermistor 6) Cell Battery High Voltage Sensor Replacement (Thermistor 4) Cell Battery High Voltage Sensor Replacement (Thermistor 1) Cell Battery High Voltage Sensor Replacement (Thermistor 5) Cell Battery High Voltage Sensor Replacement (Thermistor 3) Cell Battery High Voltage Sensor Replacement (Thermistor 2) for B32 Hybrid/EV Battery Temperature Sensor replacement.

Control Module References for K16 battery energy control module replacement, programming and setup.

DTC P0C43-P0C46: HYBRID/EV BATTERY PACK COOLANT TEMPERATURE SENSOR

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0C43

Hybrid/EV Battery Pack Coolant Temperature Sensor 1 Performance

DTC P0C44

Hybrid/EV Battery Pack Coolant Temperature Sensor 1 Circuit Low Voltage

DTC P0C45

Hybrid/EV Battery Pack Coolant Temperature Sensor 1 Circuit High Voltage

DTC P0C46

Hybrid/EV Battery Pack Coolant Temperature Sensor 1 Circuit Erratic

Circuit/System Description

The hybrid/EV battery pack coolant temperature sensor is located in the coolant inlet of the hybrid/EV battery. The temperature sensor is a variable resistor that measures the temperature of the hybrid/EV battery coolant.

The hybrid/EV battery pack coolant temperature sensor resistance changes with battery coolant temperature. The lower the temperature, the higher the resistance of the sensor. The higher the temperature, the lower the resistance of the sensor. The battery energy control module uses the hybrid/EV battery temperature sensor to determine the hybrid/EV battery pack temperature to control the battery cooling and heating operations.

Conditions for Running the DTC

P0C43

Vehicle ON after all high voltage contactor relays had been Open for 4 hours. The 12 V battery voltage is greater than 10.2 V.

None of the following DTCs are set: P0C44, P0C45, P0C46, P0C47, P0A9C, P0A9D, P0A9E, P1E8C, P1E8D, P19FD, P19FE, P19FF, or U0111.

P0C44

The 12 V battery voltage is greater than 10.2 V.

Battery energy control module is awake and communicating. DTC P1A07 is not set.

P0C45

The 12 V battery voltage is greater than 10.2 V.

Battery energy control module is awake and communicating. DTC P1A07 is not set.

P0C46

The 12 V battery voltage is greater than 10.2 V.

Battery energy control module is awake and communicating.

None of the following DTCs are set: DTC P0C44, P0C45 or U185A.

Conditions for Setting the DTC

P0C43

The hybrid/EV battery pack coolant temperature sensor reading is not within 22°C (40°F) of the outside air temperature AND is not within 23°C (41°F) of the Average Hybrid Battery Pack Temperature.

P0C44

The hybrid/EV battery pack coolant temperature sensor 1 is greater than 87.5°C (189.5°F).

P0C45

The hybrid/EV battery pack coolant temperature sensor 1 is less than or equal to -40°C (-40°F).

P0C46

The hybrid/EV battery pack coolant temperature sensor is intermittent or has changed by 64°C (115°F) or greater within 4 seconds.

Action Taken When the DTC Sets

DTC P0C43 - P0C46 are type B DTCs.

The active heating mode is disabled.

Conditions for Clearing the DTC

DTC P0C43 - P0C46 are type B DTCs.

Diagnostic Aids

Low or no coolant or refrigerant in the system may set a DTC P0C43.

DTC P0C43 - P0C46 will prevent battery heating and the vehicle will be unable to start in cold weather with battery temperatures below -25°C (-13°F).

Reference Information

Schematic Reference

Hybrid/EV Cooling Schematics

Hybrid/EV Energy Storage Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that DTC P0AC1 or P0B10 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If none of the DTCs are set

3. Verify the scan tool Hybrid/EV Battery Pack Coolant Temperature Sensor 1 parameter is between -39 and

+87.5°C (-38.2 and +189.5°F).

If not within the specified range

Refer to Circuit/System Testing.

If within the specified range

4. Verify the scan tool Hybrid/EV Battery Pack Coolant Temperature Sensor and Outside Air Temperature Sensor parameters are within 22°C (40°F) of each other after the vehicle has been OFF and not charging for 4 hours or greater.

If not within the specified range

Refer to Circuit/System Testing.

If within the specified range

5. All OK.

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, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling . Remove the A4 Hybrid/EV Battery Pack cover. Refer to High Voltage Battery Cover Replacement . Disconnect the harness connector at the B204A Hybrid/EV Battery Pack Coolant Temperature Sensor.

2. Test for less than 10 Ω between the low reference circuit terminal 2 and ground.

If 10 Ω or greater

1. Test for less than 2 Ω in the low reference circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit.

If less than 2 Ω, replace the K16 Battery Energy Control Module.

If less than 10 Ω

NOTE: With the S15 Manual Service Disconnect removed, the 12 V battery connected, and the Vehicle in Service Mode, may cause additional DTCs to set. Continue with diagnostics and clear any additional DTCs when repairs are complete.

3. Connect the EL-50211 Low Voltage Jumper Harness Extension. Connect the 12 V battery. Vehicle in Service Mode.

4. Verify the scan tool Hybrid/EV Battery Pack Coolant Temperature Sensor is less than -35°C (-38.2°F).

If greater than -35°C (-38.2°F)

1. Vehicle OFF, test for infinite resistance between the signal circuit terminal 1 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance, replace the K16 Battery Energy Control Module.

If less than -35°C (-38.2°F)

5. Install a 3 A fused jumper wire between the signal circuit terminal 1 and the low reference circuit terminal 2.

6. Verify the scan tool Hybrid/EV Battery Pack Coolant Temperature Sensor is greater than 87.5°C (189.5°F).

If less than 87.5°C (189.5°F)

1. Test for less than 1 V between the signal circuit and ground.

If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

2. Vehicle OFF, test for less than 2 Ω in 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 K16 Battery Energy Control Module.

If 87.5°C (189.5°F) or greater

7. Replace the B204A Hybrid/EV Battery Pack Coolant Temperature Sensor.

Component Testing

1. Vehicle OFF, disconnect the harness connector at the B204A Hybrid/EV Battery Pack Coolant Temperature Sensor.

2. Test for 2.2 - 3.0K Ω at approximately 21°C (70°F) between the signal terminal and the low reference terminal. Refer to Temperature Versus Resistance for Hybrid/EV Battery Pack Coolant Temperature Sensor.

If not within the specified range

Replace the B204A Hybrid/EV Battery Pack Coolant Temperature Sensor.

If within the specified range

3. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Engine Coolant Temperature Sensor Replacement for B204A Hybrid/EV battery pack coolant temperature sensor.

Control Module References for battery energy control module replacement, programming and setup.

DTC P0C47, P1E8C, OR P1E8D: HYBRID/EV BATTERY PACK COOLANT PUMP

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0C47

Hybrid/EV Battery Pack Coolant Pump Control Circuit

DTC P1E8C

Hybrid/EV Battery Pack Coolant Pump Enable Circuit Low Voltage

DTC P1E8D

Hybrid/EV Battery Pack Coolant Pump Enable Circuit High Voltage

Circuit/System Description

The hybrid/EV battery pack coolant pump circulates coolant through the hybrid/EV battery refrigerant/coolant heat exchanger and the hybrid/EV battery pack to control the temperature of the hybrid/EV battery pack.

The Enable, Control and Feedback circuits connect the hybrid/EV powertrain control module 2 to the hybrid/EV battery pack coolant pump.

When the Enable circuit is high, the pump is allowed to operate as specified by the Control circuit signal. The pulse-width modulated Control circuit signal from the hybrid/EV powertrain control module 2 determines the hybrid/EV battery pack coolant pump speed. The higher the duty cycle the higher the pump speed. The hybrid/EV battery pack coolant pump utilizes a pulse-width modulated signal on the Feedback circuit to the hybrid/EV powertrain control module 2. During normal operation, the feedback circuit provides pump speed information to the hybrid/EV powertrain control module 2. If the hybrid/EV battery pack coolant pump determines there is an internal fault it provides this information on the same feedback circuit instead of pump speed information.

Conditions for Running the DTC

P0C47

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is enabled.

The coolant pump is commanded between 5 - 95%.

P1E8C

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is enabled.

P1E8D

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is disabled.

Conditions for Setting the DTC

P0C47

The hybrid/EV powertrain control module 2 detects the Coolant Pump Control circuit is open, shorted to voltage or shorted to ground.

P1E8C

The hybrid/EV powertrain control module 2 detects the Coolant Pump Enable circuit is shorted to ground.

P1E8D

The hybrid/EV powertrain control module 2 detects the Coolant Pump Enable circuit is open or shorted to voltage.

Action Taken When the DTC Sets

DTCs P0C47, P1E8C and P1E8D are type B DTCs. Hybrid/EV battery pack active heating is disabled.

Conditions for Clearing the DTC

DTCs P0C47, P1E8C and P1E8D are type B DTCs.

Diagnostic Aids

Always verify coolant freeze point protection if a fault occurs in cold climate conditions. An improper coolant to water ratio may result in slushy or frozen coolant, resulting in DTCs or overheating. Measure coolant concentration using the J-26568 refractometer or equivalent to verify a 50/50 mix and freeze protection to -37°C (-34°F).

The Coolant Pump Feedback parameter on the scan tool indicates the status of the pump. When the pump self-diagnostics indicate normal operation, the parameter will indicate a PWM between 45 and 55%.

Different PWM values will identify when a pump self-diagnostic has failed:

Coolant Pump Feedback Parameter

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections

Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle On.

2. Verify that DTC P0C43, P0C44, P0C45, P0C46, P1FFB, P1FFC, P1FFD, P1FFE, U0111, U185B, or

U2602 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If none of the DTCs are set

3. Verify the hybrid/EV powertrain control module 2 parameters listed below when commanding the hybrid/EV battery pack coolant pump between 20% and 90% with a scan tool.

Hybrid/EV Battery Pack Coolant Pump Command to be 10% or greater. Hybrid/EV Battery Pack Coolant Pump Feedback to be 50% +/-5%.

Hybrid/EV Battery Pack Coolant Pump Speed is greater than 500 RPM.

The scan tool parameters listed are not within the specified ranges

Refer to Circuit/System Testing.

The scan tool parameters listed are within the specified ranges

4. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the harness connector at the G37 Hybrid/EV Battery Pack Coolant Pump.

2. Test for less than 5 Ω between the ground circuit terminal 4 and ground.

If 5 Ω or greater

Repair the open/high resistance on the ground circuit.

If less than 5 Ω

3. Vehicle On.

4. Test for B+ between the B+ circuit terminal 5 and the ground circuit terminal 4.

If less than B+

1. Vehicle OFF, test for infinite resistance between the B+ circuit terminal 5 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 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 and the fuse is blown, replace the G37 Hybrid/EV Battery Pack Coolant Pump.

If B+

5. Connect a test lamp between the enable circuit terminal 1 and the ground circuit terminal 4.

6. Vehicle OFF, charge cord removed. Verify the test lamp is OFF.

If the test lamp is ON

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the pump enable circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V, replace the K114B hybrid/EV powertrain control module 2.

If the test lamp is OFF

7. Vehicle On. Verify the test lamp illuminates. Command the Hybrid Battery Pack Coolant Pump ON (20 - 90%) with a scan tool if necessary.

If the test lamp is OFF

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the pump enable 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 pump enable 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 is ON

8. Connect a test lamp between the control circuit terminal 3 and the B+ circuit terminal 5.

9. Verify that a test lamp changes illumination between bright (20%) and dim (90%) when commanding the Hybrid Battery Pack Coolant Pump ON between 20% and 90% with a scan tool.

If the test lamp is always dim or does not illuminate

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the control circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in 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 K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is always bright

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

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, replace the K114B Hybrid/EV Powertrain Control Module 2.

The test lamp changes illumination between bright (20%) and dim (90%)

10. Remove the test lamp.

11. Verify the scan tool Hybrid Battery Pack Coolant Pump Feedback parameter is 0%.

If greater than 0%

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the feedback circuit terminal 2 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance, replace the K114B Hybrid/EV Powertrain Control Module 2.

If 0%

12. Install a 3 A fused jumper wire between the feedback circuit terminal 2 and the ground circuit terminal 4.

13. Verify the scan tool Hybrid Battery Pack Coolant Pump Feedback parameter is greater than 90%.

If 90% or less

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the feedback circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the feedback 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 greater than 90%

14. Replace the G37 Hybrid/EV Battery Pack Coolant Pump.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Drive Motor Battery Coolant Pump Replacement

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P0CE9, P1F44, OR P1F45: HYBRID/EV ELECTRONICS COOLANT PUMP

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0CE9

Hybrid/EV Electronics Coolant Pump Control Circuit

DTC P1F44

Hybrid/EV Electronics Coolant Pump Enable Circuit Low Voltage

DTC P1F45

Hybrid/EV Electronics Coolant Pump Enable Circuit High Voltage

Circuit/System Description

The hybrid/EV electronics coolant pump circulates coolant through the power electronics coolant radiator, drive motor generator power inverter module, the battery charger, and the 14 V accessory power module to control the temperature of these modules.

The Enable, Control and Feedback circuits connect the hybrid/EV powertrain control module 2 to the hybrid/EV electronics coolant pump.

When the Enable circuit is high, the pump is allowed to operate as specified by the Control circuit signal. The pulse-width modulated Control circuit signal from the hybrid/EV powertrain control module 2 determines the hybrid/EV electronics coolant pump speed. The higher the duty cycle the higher the pump speed. The hybrid/EV electronics coolant pump utilizes a pulse-width modulated signal on the Feedback circuit to the hybrid/EV powertrain control module 2. During normal operation, the feedback circuit provides pump speed information to the hybrid/EV powertrain control module 2. If the hybrid/EV electronics coolant pump determines there is an internal fault it provides this information on the same feedback circuit instead of pump speed information.

Conditions for Running the DTC

P0CE9

The 12 V battery voltage is greater than 10.2 V.

The hybrid/EV electronics coolant pump is enabled.

The hybrid/EV electronics coolant pump is commanded between 5% and 95%.

P1F44

The 12 V battery voltage is greater than 10.2 V.

The hybrid/EV electronics coolant pump is enabled.

P1F45

The 12 V battery voltage is greater than 10.2 V.

The Hybrid/EV electronics coolant pump is disabled.

Conditions for Setting the DTC

P0CE9

The Hybrid/EV Powertrain Control Module 2 detects the Coolant Pump Control circuit is open, shorted to voltage or shorted to ground.

P1F44

The Hybrid/EV Powertrain Control Module 2 detects the Coolant Pump Enable circuit is shorted to ground.

P1F45

The Hybrid/EV Powertrain Control Module 2 detects the Coolant Pump Enable circuit is open or shorted to voltage.

Action Taken When the DTC Sets

DTCs P0CE9, P1F44, and P1F45 are a Type B DTCs.

Conditions for Clearing the DTC

DTCs P0CE9, P1F44, and P1F45 are a Type B DTCs.

Diagnostic Aids

DTC P1F44, and P1F45 may cause DTC P0CE9 to set.

Always verify coolant freeze point protection if a fault occurs in cold climate conditions. An improper coolant to water ratio may result in slushy or frozen coolant, resulting in DTCs or overheating. Measure coolant concentration using the J-26568 refractometer or equivalent to verify a 50/50 mix and freeze protection to -37°C (-34°F).

The Coolant Pump Feedback parameter on the scan tool indicates the status of the pump. When the pump self-diagnostics indicate normal operation, the parameter will indicate a PWM between 45 and 55%.

Different PWM values will identify when a pump self-diagnostic has failed:

Coolant Pump Feedback Parameter

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle On.

2. Verify that DTC P0C43, P0C44, P0C45, P0C46, P0C47, or P1EC6 is not set.

If any of the DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If none of the DTCs are set

3. Verify the hybrid/EV powertrain control module 2 parameters listed below when commanding the hybrid/EV electronics coolant pump between 20% and 90% with a scan tool.

Hybrid/EV Electronics Coolant Pump Command to be 10% or greater Hybrid/EV Electronics Coolant Pump Feedback to be 50% +/-5%

Hybrid/EV Electronics Coolant Pump Speed is greater than 500 RPM.

The scan tool parameters listed are not within the specified ranges

Refer to Circuit/System Testing.

The scan tool parameters listed are within the specified range

4. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the harness connector at the G35 Hybrid/EV Electronics Coolant Pump.

2. Test for less than 5 Ω between the ground circuit terminal 4 and ground.

If 5 Ω or greater

Repair the open/high resistance on the ground circuit.

If less than 5 Ω

3. Vehicle On.

4. Test for B+ between the B+ circuit terminal 5 and the ground circuit terminal 4.

If less than B+

1. Vehicle OFF, test for infinite resistance between the B+ circuit terminal 5 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 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 and the fuse is blown

3. Replace the G35 Hybrid/EV Electronics Coolant Pump.

If B+

5. Connect a test lamp between the enable circuit terminal 1 and the ground circuit terminal 4.

6. Vehicle OFF, charge cord removed. Verify the test lamp is OFF.

If the test lamp is ON

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2. Vehicle On.

2. Test for less than 1 V between the pump enable circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is OFF

7. Vehicle On. Verify the test lamp illuminates. Command the Hybrid/EV electronics coolant pump ON (20

- 90%) with a scan tool if necessary.

If the test lamp is OFF

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the pump enable 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 pump enable circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is ON

8. Connect a test lamp between the control circuit terminal 3 and the B+ circuit terminal 5.

9. Verify the test lamp changes illumination between bright (20%) and dim (90%) when commanding the hybrid/EV electronics coolant pump ON between 20% and 90% with a scan tool.

If the test lamp is always dim or does not illuminate

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the control circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is always bright

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

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. Replace the K114B Hybrid/EV Powertrain Control Module 2.

The test lamp changes illumination between bright (20%) and dim (90%)

10. Remove the test lamp.

11. Verify the scan tool Hybrid/EV Electronics Coolant Pump Feedback parameter is 0%.

If greater than 0%

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the feedback circuit terminal 2 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance

3. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If 0%

12. Install a 3 A fused jumper wire between the feedback circuit terminal 2 and the ground circuit terminal 4.

13. Verify the scan tool, Hybrid/EV Electronics Coolant Pump Feedback parameter is greater than 90%.

If 90% or less

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the feedback circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the feedback circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If greater than 90%

14. Replace the G35 Hybrid/EV Electronics Coolant Pump.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Generator Control Module Coolant Pump Replacement for Hybrid/EV electronics coolant pump replacement

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P0CEF-P0CF2: HYBRID/EV ELECTRONICS COOLANT TEMPERATURE SENSOR

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC P0CEF

Hybrid/EV Electronics Coolant Temperature Sensor Performance

DTC P0CF0

Hybrid/EV Electronics Coolant Temperature Sensor Circuit Low Voltage

DTC P0CF1

Hybrid/EV Electronics Coolant Temperature Sensor Circuit High Voltage

DTC P0CF2

Hybrid/EV Electronics Coolant Temperature Sensor Circuit Erratic

Circuit/System Description

The hybrid/EV electronics coolant temperature sensor is located in the combined electronics coolant radiator/air conditioning condenser assembly. The temperature sensor is a variable resistor that measures the temperature of the hybrid/EV electronics coolant. The hybrid/EV electronics coolant temperature sensor resistance changes with coolant temperature. The lower the temperature, the higher the resistance of the sensor. The higher the temperature, the lower the resistance of the sensor. The hybrid/EV powertrain control module 2 uses the hybrid/EV electronics coolant temperature sensor to determine the hybrid/EV electronics temperature to control the hybrid/EV electronics cooling operation.

Conditions for Running the DTC

P0CEF

The 12 V battery voltage is greater than or equal to 10.2 V. Vehicle ON for less than 20 seconds.

Propulsion system inactive time is greater than 5 hours.

Hybrid/EV electronics coolant pump off soak time is greater than 1 hour. Air Conditioning compressor off soak time is greater than 1 hour.

On Board Charger module off soak time is greater than 1 hour.

None of the following DTCs are set; P0071-P0074, P0532, P0533, P0606, P0711-P0713, P0CF0, P0CF1, P0CE9, P0A2B, P0A2C, P0A2D, P1F44, or P1F45.

P0CF0, P0CF1 and P0CF2

Vehicle ON.

The 12 V battery voltage is greater than or equal to 10.2 V.

Conditions for Setting the DTC

P0CEF

The hybrid/EV electronics coolant temperature does not fall within 27°C (48.6°F) of the outside air temperature.

AND

The hybrid/EV electronics coolant temperature does not fall within 27°C (48.6°F) of the transmission fluid temperature.

AND

The hybrid/EV electronics coolant temperature does not fall within 28°C (50°F) of the air condition high side pressure, converted to temperature.

P0CF0

The hybrid/EV electronics coolant temperature is greater than 100°C (212°F) indicating a circuit voltage less than 0.20 V.

P0CF1

The hybrid/EV electronics coolant temperature is less than -40°C (-40°F) indicating a circuit voltage greater than 4.90 V.

P0CF2

The hybrid/EV electronics coolant temperature is intermittent or has changed greater than 90°C (162°F).

Condition exists for 4 seconds or more.

Actions Taken When the DTC Sets

P0CEF-P0CF2 are type B DTCs.

The Hybrid/EV Electronics Coolant Pump is commanded to a fixed speed.

Conditions for Clearing the DTC P0CEF-P0CF2 are type B DTCs. Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle in Service Mode, verify that DTC P0CE9 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If none of the DTCs are set

2. Verify the Hybrid Electronics Coolant Temperature is between -39 and +99°C (-38.2 and +210°F) with a scan tool.

If not within the specified range

Refer to Circuit/System Testing.

If within the specified range

3. All OK.

Circuit/System Testing

1. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Disconnect the harness connector at the B202 Hybrid/EV Electronics Coolant Temperature Sensor.

2. Test for less than 10 Ω between the low reference circuit terminal 2 and ground.

If 10 Ω or greater

1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 2 Ω in the low reference 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 less than 10 Ω

3. Vehicle in Service Mode.

4. Verify the scan tool Hybrid Electronics Coolant Temperature is less than -35°C (-38.2°F).

If -35°C (-38.2°F) or greater

1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the signal circuit and the circuits listed below: Low reference circuit

Chassis ground

If less than infinite resistance, repair the appropriate short to ground on the circuit. If infinite resistance, replace the K114B Hybrid/EV Powertrain Control Module 2.

If less than -35°C (-38.2°F)

5. Install a 3 A fused jumper wire between the signal circuit terminal 1 and the low reference circuit terminal 2.

6. Verify the scan tool Hybrid Electronics Coolant Temperature is greater than 99°C (210°F).

If less than 99°C (210°F)

1. Vehicle OFF, remove the jumper wire, disconnect the X1 harness connector at the K114B Hybrid/EV Powertrain Control Module 2, Vehicle ON.

2. Test for less than 1 V between the signal circuit and ground.

If 1 V or greater, repair the short to voltage on the circuit. If less than 1 V

3. Vehicle OFF, test for less than 2 Ω in 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 99°C (210°F) or greater

7. Replace the B202 Hybrid/EV Electronics Coolant Temperature Sensor.

Component Testing

1. Vehicle OFF, disconnect the harness connector at the B202 Hybrid/EV Electronics Coolant Temperature Sensor.

2. Test for 2 - 2.5k Ω at approximately 21.11°C (70°F) between the signal terminal and the low reference terminal. Refer to Temperature Versus Resistance for Hybrid/EV Electronics Coolant Temperature Sensor.

If not within the specified range

Replace the B202 Hybrid/EV Electronics Coolant Temperature Sensor.

If within the specified range

3. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Coolant Temperature Sensor Replacement

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P19FA-P19FC: HYBRID/EV ELECTRONICS COOLANT PUMP FEEDBACK

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P19FA

Hybrid/EV Electronics Coolant Pump Feedback Circuit High Frequency

DTC P19FB

Hybrid/EV Electronics Coolant Pump Feedback Circuit Low Frequency

DTC P19FC

Hybrid/EV Electronics Coolant Pump Feedback Circuit Performance

Circuit/System Description

The hybrid/EV electronics coolant pump circulates coolant through the power electronics coolant radiator, drive motor generator power inverter module, the battery charger, and the 14 V accessory power module to control the temperature of these modules.

The Enable, Control and Feedback circuits connect the hybrid/EV powertrain control module 2 to the hybrid/EV electronics coolant pump.

When the Enable circuit is high, the pump is allowed to operate as specified by the Control circuit signal. The pulse-width modulated Control circuit signal from the hybrid/EV powertrain control module 2 determines the hybrid/EV electronics coolant pump speed. The higher the duty cycle the higher the pump speed. The hybrid/EV electronics coolant pump utilizes a pulse-width modulated signal on the Feedback circuit to the hybrid/EV powertrain control module 2. During normal operation, the feedback circuit provides pump speed information to the hybrid/EV powertrain control module 2. If the hybrid/EV electronics coolant pump determines there is an internal fault it provides this information on the same feedback circuit instead of pump speed information.

Conditions for Running the DTC

P19FA and P19FB

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is enabled.

The coolant pump is commanded between 11 - 90%. All above conditions met for at least 3 seconds.

P19FC

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is disabled for at least 10 seconds.

DTC P19FC has not already failed when coolant pump was enabled.

OR

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is enabled.

The coolant pump is commanded between 11 - 90%.

Hybrid/EV electronics coolant temperature sensor is greater than -20°C (-4°F). All above conditions met for at least 5 seconds.

None of the following DTCs are set: P0CE9, P0CEF, P0CF0, P0CF1, P0CF2, P1F44, or P1F45.

Conditions for Setting the DTC

P19FA

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit frequency is greater than 750 Hz.

P19FB

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit frequency is less than

8.6 Hz.

P19FC

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit indicated pump speed is greater than 250 RPM when the pump is not enabled.

OR

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit indicated pump speed is more than 800 RPM different than the expected pump speed when the pump is commanded between 11 - 90% PWM.

Action Taken When the DTC Sets

DTCs P19FA, P19FB and P19FC are type B DTCs.

Conditions for Clearing the DTC

DTCs P19FA, P19FB and P19FC are type B DTCs.

Diagnostic Aids

Always verify coolant freeze point protection if a fault occurs in cold climate conditions. An improper coolant to water ratio may result in slushy or frozen coolant, resulting in DTCs or overheating. Measure coolant concentration using the J-26568 refractometer or equivalent to verify a 50/50 mix and freeze protection to -37°C (-34°F).

The Coolant Pump Feedback parameter on the scan tool indicates the status of the pump. When the pump self-diagnostics indicate normal operation, the parameter will indicate a PWM between 45 and 55%.

Different PWM values will identify when a pump self-diagnostic has failed:

Coolant Pump Feedback Parameter

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle On.

2. Verify that DTC P0C43, P0C44, P0C45, P0C46, or P0C47 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If none of the DTCs are set

3. Verify the hybrid/EV powertrain control module 2 parameters listed below when commanding the hybrid/EV electronics coolant pump between 20% and 90% with a scan tool.

Hybrid/EV Electronics Coolant Pump Command to be 10% or greater. Hybrid/EV Electronics Coolant Pump Feedback to be 50% +/-5%.

Hybrid/EV Electronics Coolant Pump Speed is greater than 500 RPM.

The scan tool parameters listed are not within the specified ranges

Refer to Circuit/System Testing.

The scan tool parameters listed are within the specified ranges

4. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the harness connector at the G35 Hybrid/EV Electronics Coolant Pump.

2. Test for less than 5 Ω between the ground circuit terminal 4 and ground.

If 5 Ω or greater

Repair the open/high resistance on the ground circuit.

If less than 5 Ω

3. Vehicle On.

4. Test for B+ between the B+ circuit terminal 5 and the ground circuit terminal 4.

If less than B+

1. Vehicle OFF, test for infinite resistance between the B+ circuit terminal 5 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 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 and the fuse is blown

3. Replace the G35 Hybrid/EV Electronics Coolant Pump.

If B+

5. Connect a test lamp between the enable circuit terminal 1 and the ground circuit terminal 4.

6. Vehicle OFF, charge cord removed. Verify the test lamp is OFF.

If the test lamp is ON

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the pump enable circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Replace the K114B hybrid/EV powertrain control module 2.

If the test lamp is OFF

7. Vehicle On. Verify the test lamp illuminates. Command the Hybrid/EV Electronics Coolant Pump ON (20

- 90%) with a scan tool if necessary.

If the test lamp is OFF

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the pump enable 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 pump enable circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is ON

8. Connect a test lamp between the control circuit terminal 3 and the B+ circuit terminal 5.

9. Verify that a test lamp changes illumination between bright (20%) and dim (90%) when commanding the Hybrid/EV Electronics Coolant Pump ON between 20% and 90% with a scan tool.

If the test lamp is always dim or does not illuminate

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the control circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is always bright

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

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. Replace the K114B Hybrid/EV Powertrain Control Module 2.

The test lamp changes illumination between bright (20%) and dim (90%)

10. Remove the test lamp.

11. Verify the scan tool Hybrid/EV Electronics Coolant Pump Feedback parameter is 0%.

If greater than 0%

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the feedback circuit terminal 2 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance

3. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If 0%

12. Install a 3 A fused jumper wire between the feedback circuit terminal 2 and the ground circuit terminal 4.

13. Verify the scan tool Hybrid/EV Electronics Coolant Pump Feedback parameter is greater than 90%.

If 90% or less

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the feedback circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If greater than 90%

14. Replace the G35 Hybrid/EV Electronics Coolant Pump.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Generator Control Module Coolant Pump Replacement for Hybrid/EV electronics coolant pump replacement.

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P19FD-P19FF: HYBRID/EV BATTERY PACK COOLANT PUMP FEEDBACK CIRCUIT

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P19FD

Hybrid/EV Battery Pack Coolant Pump Feedback Circuit High Frequency

DTC P19FE

Hybrid/EV Battery Pack Coolant Pump Feedback Circuit Low Frequency

DTC P19FF

Hybrid/EV Battery Pack Coolant Pump Feedback Circuit Performance

Circuit/System Description

The hybrid/EV battery pack coolant pump circulates coolant through the hybrid/EV battery refrigerant/coolant heat exchanger and the hybrid/EV battery pack to control the temperature of the hybrid/EV battery pack.

The Enable, Control and Feedback circuits connect the hybrid/EV powertrain control module 2 to the hybrid/EV battery pack coolant pump.

When the Enable circuit is high, the pump is allowed to operate as specified by the Control circuit signal. The pulse-width modulated Control circuit signal from the hybrid/EV powertrain control module 2 determines the hybrid/EV battery pack coolant pump speed. The higher the duty cycle the higher the pump speed. The hybrid/EV battery pack coolant pump utilizes a pulse-width modulated signal on the Feedback circuit to the hybrid/EV powertrain control module 2. During normal operation, the feedback circuit provides pump speed information to the hybrid/EV powertrain control module 2. If the hybrid/EV battery pack coolant pump determines there is an internal fault it provides this information on the same feedback circuit instead of pump speed information.

Conditions for Running the DTC

P19FD and P19FE

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is enabled.

The coolant pump is commanded between 11 - 90%. All above conditions met for at least 3 seconds.

P19FF

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is disabled for at least 10 seconds.

DTC P19FF has not already failed when coolant pump was enabled.

OR

The 12 V battery voltage is greater than or equal to 10.2 V. The coolant pump is enabled.

The coolant pump is commanded between 11 - 90%.

Hybrid/EV battery pack coolant inlet temperature sensor is greater than -20°C (-4°F). All above conditions met for at least 5 seconds.

None of the following DTCs are set: P0C43, P0C44, P0C45, P0C47, P1E8C, P1E8D, P19FD or P19FE.

Conditions for Setting the DTC

P19FD

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit frequency is greater than 750 Hz.

P19FE

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit frequency is less than

8.6 Hz.

P19FF

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit indicated pump speed is greater than 250 RPM when the pump is not enabled.

OR

The hybrid/EV powertrain control module 2 detects the Coolant Pump Feedback circuit indicated pump speed is more than 800 RPM different than the expected pump speed when the pump is commanded between 11 - 90% PWM.

Action Taken When the DTC Sets

DTCs P19FD, P19FE and P19FF are type B DTCs.

Hybrid/EV battery pack active heating and active cooling are disabled.

Conditions for Clearing the DTC

DTCs P19FD, P19FE and P19FF are type B DTCs.

Diagnostic Aids

Always verify coolant freeze point protection if a fault occurs in cold climate conditions. An improper coolant to water ratio may result in slushy or frozen coolant, resulting in DTCs or overheating. Measure coolant concentration using the J-26568 refractometer or equivalent to verify a 50/50 mix and freeze protection to -37°C (-34°F).

The Coolant Pump Feedback parameter on the scan tool indicates the status of the pump. When the pump self-diagnostics indicate normal operation, the parameter will indicate a PWM between 45 and 55%.

Different PWM values will identify when a pump self-diagnostic has failed:

Coolant Pump Feedback Parameter

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that DTC P0C43, P0C44, P0C45, P0C46, P1FFB, P1FFC, P1FFD, P1FFE, U0111, U185B, or

U2602 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If none of the DTCs are set

3. Verify the hybrid/EV powertrain control module 2 parameters listed below when commanding the hybrid/EV battery pack coolant pump between 20% and 90% with a scan tool.

Hybrid/EV Battery Pack Coolant Pump Command to be 10% or greater. Hybrid/EV Battery Pack Coolant Pump Feedback to be 50% +/-5%.

Hybrid/EV Battery Pack Coolant Pump Speed is greater than 500 RPM.

The scan tool parameters listed are not within the specified ranges

Refer to Circuit/System Testing.

The scan tool parameters listed are within the specified ranges

4. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the harness connector at the G37 Hybrid/EV Battery Pack Coolant Pump.

2. Test for less than 5 Ω between the ground circuit terminal 4 and ground.

If 5 Ω or greater

Repair the open/high resistance on the ground circuit.

If less than 5 Ω

3. Vehicle in Service Mode.

4. Test for B+ between the B+ circuit terminal 5 and the ground circuit terminal 4.

If less than B+

1. Vehicle OFF, test for infinite resistance between the B+ circuit terminal 5 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 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 and the fuse is blown

3. Replace the G37 Hybrid/EV Battery Pack Coolant Pump.

If B+

5. Connect a test lamp between the enable circuit terminal 1 and the ground circuit terminal 4.

6. Vehicle OFF, charge cord removed. Verify the test lamp is OFF.

If the test lamp is ON

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the pump enable circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Replace the K114B hybrid/EV powertrain control module 2.

If the test lamp is OFF

7. Vehicle ON. Verify the test lamp illuminates. Command the Hybrid Battery Pack Coolant Pump ON (20 - 90%) with a scan tool if necessary.

If the test lamp is OFF

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the pump enable 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 pump enable circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is ON

8. Connect a test lamp between the control circuit terminal 3 and the B+ circuit terminal 5.

9. Verify that a test lamp changes illumination between bright (20%) and dim (90%) when commanding the Hybrid Battery Pack Coolant Pump ON between 20% and 90% with a scan tool.

If the test lamp is always dim or does not illuminate

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the control circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is always bright

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

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. Replace the K114B Hybrid/EV Powertrain Control Module 2.

The test lamp changes illumination between bright (20%) and dim (90%)

10. Remove the test lamp.

11. Verify the scan tool Hybrid Battery Pack Coolant Pump Feedback parameter is 0%.

If greater than 0%

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the feedback circuit terminal 2 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance

3. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If 0%

12. Install a 3 A fused jumper wire between the feedback circuit terminal 2 and the ground circuit terminal 4.

13. Verify the scan tool Hybrid Battery Pack Coolant Pump Feedback parameter is greater than 90%.

If 90% or less

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the feedback circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If greater than 90%

14. Replace the G37 Hybrid/EV Battery Pack Coolant Pump.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Drive Motor Battery Coolant Pump Replacement

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P148A-P148C: COOLING FAN SIGNAL CIRCUIT

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P148A

Cooling Fan Signal Circuit Performance

DTC P148B

Cooling Fan Signal Circuit Low Voltage

DTC P148C

Cooling Fan Signal Circuit High Voltage

Diagnostic Fault Information

Circuit/System Description

The hybrid/EV powertrain control module 2 indirectly controls the radiator fans. When propulsion is active, the engine control module (ECM) processes all requests for the cooling fans to be turned ON regardless of which module originates the request. The ECM decides if and at what speed the cooling fans should operate. The ECM sends the cooling fan command to the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 sends the signal to the cooling fans to operate and at what speed. If the vehicle is in Charge Mode and the hybrid/EV powertrain control module 2 requests the cooling fans to operate and the ECM is not awake, the hybrid/EV powertrain control module 2 will control the cooling fans without ECM intervention.

The ECM communicates the fan command PWM signal to the hybrid/EV powertrain control module 2 through the cooling fan speed signal circuit/hardwire circuit and also sends a redundant serial data signal. Since the hardwire circuit is an output from the ECM but an input to the hybrid/EV powertrain control module 2, each module has unique DTCs to monitor the same circuit.

Conditions for Running the DTC

P148A

The 12 V battery voltage is greater than or equal to 10.2 V. The propulsion system is active for more than 43 seconds.

The cooling fan speed request has not changed by greater than 5% for at least 43 seconds. None of the following DTCs are set: P148B, P148C, or U0293.

OR

The 12 V battery voltage is greater than or equal to 10.2 V. The propulsion system is inactive.

The energy storage system thermal condition request is ActiveCool. The cooling fans are enabled for more than 43 seconds.

The cooling fan speed request has not changed by greater than 5% for at least 43 seconds. None of the following DTCs are set: P148B, P148C, or U0293.

P148B

The 12 V battery voltage is greater than or equal to 10.2 V.

P148C

The 12 V battery voltage is greater than or equal to 10.2 V. The propulsion system is active for more than 43 seconds.

OR

The 12 V battery voltage is greater than or equal to 10.2 V. The propulsion system is inactive.

The energy storage system thermal condition request is ActiveCool. The cooling fans are enabled for more than 43 seconds.

Conditions for Setting the DTC

P148A

The PWM cooling fan signal circuit duty cycle request from engine control module (Hardwire) is not within 30% of the redundant engine cooling fan speed sent to the hybrid/EV powertrain control module 2 via serial data.

P148B

The hybrid/EV powertrain control module 2 has detected a duty cycle of less than 3% from the engine control module.

P148C

The hybrid/EV powertrain control module 2 has detected a duty cycle of greater than 97% from the engine control module.

Action Taken When the DTC Sets

DTCs P148A, P148B and P148C are type B DTCs.

Conditions for Clearing the DTC

DTCs P148A, P148B and P148C are type B DTCs.

Reference Information

Schematic Reference

Engine Heating/Cooling Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle ON.

2. Verify DTC P1485, P1486, P1487, P148A, P148B, or P148C is not set.

If the DTC is set

Refer to Circuit/System Testing.

If the DTC is not set

3. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2, vehicle in Service Mode.

NOTE: The cooling fan circuit is pulled up to a voltage within the ECM. 3 - 4 V measured on this circuit with the hybrid/EV powertrain control module 2 disconnected is normal.

2. Test for 3 - 4 V between the cooling fan circuit terminal 9 and ground.

If less than 3 V

1. Vehicle OFF, disconnect the X1 harness connector at the K20 Engine Control Module.

2. Test for infinite resistance between the cooling fan 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 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 K20 Engine Control Module.

If 4V or greater

1. Vehicle OFF. Disconnect the X1 harness connector at the K20 Engine Control Module, vehicle in Service Mode.

2. Test for less than 1 V between the cooling fan circuit and ground. If greater than 1 V, repair the short to voltage on the circuit. If 1 V or less, replace the K20 Engine Control Module.

If 3 - 4 V

3. Vehicle OFF, disconnect the X1 harness connector at the K20 Engine Control Module.

4. Reconnect the K114B Hybrid/EV Powertrain Control Module 2 connector X2.

5. Vehicle in Service Mode. Test for greater than 10 V between the signal circuit and ground.

If 10 V or less

Replace the Hybrid/EV Powertrain Control Module 2.

If greater than 10 V

6. Replace the K20 Engine Control Module.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Control Module References for engine control module or hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P1EC6: HYBRID/EV BATTERY PACK HEATER PERFORMANCE

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptor

DTC P1EC6

Hybrid/EV Battery Pack Heater Performance

Circuit/System Description

The hybrid/EV battery pack coolant heater is mounted to the coolant inlet on the back side of the hybrid/EV battery contactor assembly. The hybrid/EV battery pack coolant heater uses the hybrid/EV battery high voltage as its power source. The hybrid/EV battery pack heater high voltage is controlled by a solid state relay/transistor. The hybrid/EV powertrain control module 2 supplies voltage to the control circuit for the high voltage solid state relay/transistor. The hybrid/EV battery pack coolant heater high voltage circuit is fuse protected.

When the Conditions for Running the DTC are met, the hybrid/EV battery pack coolant heater is commanded ON. The hybrid/EV powertrain control module 2 then monitors for a temperature change at the hybrid/EV battery pack coolant temperature sensor 1 to determine if the hybrid/EV battery pack coolant heater is functioning properly.

Conditions for Running the DTC

The 12 V battery voltage is greater than 10.2 V.

The hybrid/EV battery pack coolant temperature sensor is less than 20°C (68°F). Runs once per drive cycle, either in propulsion system active or in Charge Mode.

Hybrid/EV battery pack state of charge is greater than 5%. Hybrid/EV battery pack voltage is greater than 280 V.

None of the following DTCs are set; P0C43, P0C44, P0C45, P0C47, P19FD, P19FE, P19FF, P1EC3, P1E8C, P1E8D, P1FFB, P1FFC, P1FFD, or P1FFE.

Conditions for Setting the DTC

The hybrid/EV powertrain control module 2 commands the hybrid/EV battery pack coolant pump to 7% and the battery heater to 100% for 4 seconds, then varies battery heater output in relation to battery voltage for a maximum of 3 minutes.

The hybrid/EV powertrain control module 2 did not see the battery pack coolant temperature rise more than 3°C (5.4°F) within 60 seconds of commanding the battery heater OFF.

Action Taken When the DTC Sets

DTC P1EC6 is a type B DTC.

Hybrid/EV battery pack active heating is disabled.

Conditions for Clearing the DTC DTC P1EC6 is a type B DTC. Diagnostic Aids

P1EC6 will prevent battery heating and the vehicle will be unable to start in cold weather if battery temperature drops below -25°C (-13°F).

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information Special Tools

EL-48900 HEV Safety Kit

EL-50772 Insulation Multimeter

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify that DTC P0AA1, P0AA4, P0AD9, P0ADD, P0AE1, P0AE3, P0D0A, P0D09, P1EBD, P1EC0, or

P1EC3 is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If none of the DTCs are set

NOTE: Other DTCs will set.

3. Vehicle OFF. Remove the G37 Hybrid/EV Battery Pack Coolant Pump fuse. Set the vehicle Charge Mode to IMMEDIATE. Connect the charge cord set. With the vehicle in Charge Mode, Vehicle in Service Mode.

4. Verify the scan tool Hybrid/EV Battery Pack Coolant Temperature Sensor parameter increases 3° C (5.4° F) within 120 s when command the hybrid/EV battery pack coolant heater ON with a scan tool.

If the Hybrid/EV Battery Pack Coolant Temperature Sensor did not increase 3° C (5.4° F) within 120 s

Refer to Circuit/System Testing.

If the Hybrid/EV Battery Pack Coolant Temperature Sensor did increase 3° C (5.4° F) within 120 s

5. All OK.

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, disable the high voltage at the A4 Hybrid/EV Battery Pack. Refer to High Voltage Disabling .

2. Remove the Drive Motor Battery Cover. Refer to High Voltage Battery Cover Replacement . Disconnect the E54 Hybrid/EV Battery Pack Coolant Heater harness connector at the A28 Hybrid/EV Battery Contactor Assembly.

NOTE: The following continuity tests must be performed using the Ohm setting.

3. Test for 61 - 75 Ω between terminal 1 and terminal 2 at the E54 Hybrid/EV Battery Pack Coolant Heater.

If not within the specified range

Verify that the battery pack coolant heater fuse is not blown. Replace the fuse if it is blown and the E54 Hybrid/EV Battery Pack Coolant Heater.

If within the specified range

NOTE: The following continuity tests must be performed using an EL-50772 Insulation Multimeter.

4. Select the Isolation test setting, then select the 500 V range. Refer to Troubleshooting With an Insulation Multimeter . Test for greater than 550M Ω between the E54 Hybrid/EV Battery Pack Coolant Heater terminals listed below and battery tray ground with the EL-50772 , set on the Isolation test setting:

Terminal 1

Terminal 2

If less than 550M Ω

NOTE: Also verify that the battery pack coolant heater fuse is not blown.

Replace the E54 Hybrid/EV Battery Pack Coolant Heater.

If 550M Ω or greater

5. Replace the A28 Hybrid/EV Battery Contactor Assembly.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

High Voltage Battery Heater Replacement

High Voltage Battery Disconnect Relay Fuse Replacement (Front - BDU) High Voltage Battery Disconnect Relay Fuse Replacement (Rear - BDU) for Battery Heater Fuse Replacement

High Voltage Battery Disconnect Relay Replacement for A28 Hybrid/EV Battery Contactor Assembly replacement

DTC P1FFB-P1FFE: HYBRID/EV BATTERY PACK COOLANT LEVEL

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P1FFB

Hybrid/EV Battery Pack Coolant Level Sensor Circuit

DTC P1FFC

Hybrid/EV Battery Pack Coolant Level Sensor Circuit Low Voltage

DTC P1FFD

Hybrid/EV Battery Pack Coolant Level Sensor Circuit High Voltage

DTC P1FFE

Hybrid/EV Battery Pack Coolant Level Low

Circuit/System Description

The hybrid/EV battery pack coolant system has a level sensor. The hybrid/EV battery pack coolant level sensor is attached to the coolant surge tank. The level sensor is a 2 state bi-metallic reed switch which changes state when the switch reed is exposed to magnetism. The level of the hybrid/EV battery pack coolant in the surge tank causes a magnet-equipped float to move towards and away from the sensor as coolant level decreases or increases. The hybrid/EV powertrain control module 2 supplies 5 V to the signal circuit and a ground for the low reference circuit. The hybrid/EV battery pack coolant level sensor resistance decreases when the battery coolant level in the surge tank gets low. The hybrid/EV powertrain control module 2 uses the hybrid/EV battery pack coolant level sensor to determine if the hybrid/EV battery pack coolant system is low on coolant.

Conditions for Running the DTC

P1FFB, P1FFC, and P1FFD

The 12 V battery voltage is greater than 10.2 V.

P1FFE

The vehicle speed is zero for more than 30 seconds

The battery pack temperature is between 0°C (32°F) and 120°C (248°F)

None of the following DTCs are set: P0721, P077B, P215C, P2610, U0100 or U0101 Once set, the DTC will not run again until a scan tool clear code command is sent.

Conditions for Setting the DTC

P1FFB

The hybrid/EV battery pack coolant level sensor voltage is between 2.8 V - 3.1 V

P1FFC

The hybrid/EV battery pack coolant level sensor voltage is below 1.37 V

P1FFD

The hybrid/EV battery pack coolant level sensor voltage is above 4.0 V

P1FFE

The hybrid/EV battery pack coolant level sensor voltage is between 1.38 - 2.84 V for more than 2 consecutive key cycles

Action Taken When the DTC Sets

DTC P1FFB, P1FFC, P1FFD, and P1FFE are type A DTCs.

The driver information center (DIC) displays the SERVICE HIGH VOLTAGE CHARGING SYSTEM message.

Hybrid/EV battery pack charging is disabled.

Hybrid/EV battery pack active heating and active cooling are disabled. DTC P1FFF is set.

Conditions for Clearing the DTC

DTC P1FFB, P1FFC, and P1FFD are type A DTCs.

DTC P1FFE is a type A DTC but will only clear with a scan tool clear code command.

Diagnostic Aids

Parking the vehicle on a steep incline may set DTC P1FFE.

DTC P1FFE will not clear or go to history with ignition cycles once DTC is set. DTC P1FFE will only clear with a scan tool clear code command.

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Verify that the vehicle hybrid/EV battery cooling system is full.

If the hybrid/EV battery cooling system is low

WARNING: Do NOT attempt to repair a Lithium Ion Hybrid/EV Battery Pack when an internal coolant leak is evident. The Hybrid/EV Battery Pack must always be replaced as an assembly. Failure to replace a coolant contaminated Hybrid/EV Battery Pack may result in fire, which can

cause severe injury or death.

Refer to Hybrid Cooling System Loss of Coolant (Battery), Hybrid Cooling System Loss of Coolant (Power Electronics)Hybrid Cooling System Loss of Coolant (Battery)

If the hybrid/EV battery cooling system is full

2. Refer to Circuit/System Testing.

Circuit/System Testing

1. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Disconnect the harness connector at the B258 Hybrid/EV Battery Coolant Level Sensor.

2. Test for less than 10 Ω between the low reference circuit terminal B and ground.

If 10 Ω or greater

1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 2 Ω in the low reference 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 less than 10 Ω

3. Vehicle in Service Mode.

4. Test for 4.8 - 5.2 V between the 5 V signal circuit terminal A and ground.

If 4.8 V or less

1. Vehicle OFF, disconnect the X1 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 in 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 5.2 V or greater

1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid/EV Powertrain Control Module 2. Vehicle in Service Mode.

2. Test for less than 1 V between the signal circuit and ground.

If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.

If within the specified range

5. Vehicle OFF, remove the B258 Hybrid/EV Battery Coolant Level Sensor from the coolant surge tank.

NOTE: The coolant sensor must be removed from the coolant surge tank to ensure the coolant float magnet does not close the internal reed switch.

6. Test for 24 - 25.4k Ω between the signal terminal A and the low reference terminal B.

If not within the specified range

Replace the B258 Hybrid/EV Battery Coolant Level Sensor.

If within the specified range

NOTE: Moving the magnet slightly along the bottom of the sensor will assist closing the internal switch.

7. Using a magnet, place the magnet off center of the B258 Hybrid/EV Battery Coolant Level Sensor, opposite of the terminals on the epoxy side to close the internal reed switch.

8. Test for 7.1 - 7.54k Ω between the signal terminal A and the low reference terminal B.

If not within the specified range

Replace the B258 Hybrid/EV Battery Coolant Level Sensor.

If within the specified range

9. Replace the coolant surge tank.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Radiator Surge Tank Replacement (Drive Motor Battery Radiator Surge Tank)Radiator Surge Tank Replacement (Drive Motor Generator Power Inverter Module Surge Tank)

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

DTC P1FFF: SYSTEM ISOLATION/COOLANT LEVEL SENSOR FAULT - HYBRID/EV BATTERY CHARGING SYSTEM DISABLED

Diagnostic Instructions

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptor

DTC P1FFF

System Isolation/Coolant Level Sensor Fault - Hybrid/EV Battery Charging System Disabled

Circuit/System Description

This diagnostic is an indicator that hybrid/EV battery pack charging is disabled because the hybrid/EV powertrain control module 2 detected one of the following conditions:

WARNING: Do NOT attempt to repair a Lithium Ion Hybrid/EV Battery Pack when an internal coolant leak is evident. The Hybrid/EV Battery Pack must always be replaced as an assembly. Failure to replace a coolant contaminated Hybrid/EV Battery Pack may result in fire, which can cause severe injury or death.

A loss of isolation between the hybrid/EV battery pack high voltage circuits and vehicle chassis A low coolant condition of the hybrid/EV battery pack coolant system

A fault in the hybrid/EV battery pack coolant level sensor/circuit

Conditions for Running the DTC

The hybrid powertrain control module 2 and battery energy control module are awake and communicating.

Once set, the DTC will not run again until a scan tool clear code command is sent.

Conditions for Setting the DTC

NOTE: DTC P1FFF will never set alone.

When DTC P0AA6, P1AE6, P1FFB, P1FFC, P1FFD, or P1FFE is set, DTC P1FFF will also be set.

Action Taken When the DTC Sets

DTC P1FFF is a type A DTC.

The driver information center (DIC) displays the SERVICE HIGH VOLTAGE CHARGING SYSTEM message.

Hybrid/EV battery pack charging is disabled.

Hybrid/EV battery pack active cooling is disabled.

Conditions for Clearing the DTC

DTC P1FFF is a type A DTC but will only clear with a scan tool clear code command.

Diagnostic Aids

DTC P1FFF will not clear or go to history with ignition cycles once DTC is set. DTC P1FFF will only clear with a scan tool clear code command.

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Drive Motor Battery System Description

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections

Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Verify that DTC P0AA6, P1AE6, P1FFB, P1FFC, P1FFD, or P1FFE are not set.

If DTC P0AA6 or P1AE6 is set

Refer to DTC P0AA6 or P1AE6 .

If DTC P1FFB, P1FFC, P1FFD, or P1FFE is set

Refer to DTC P1FFB-P1FFE.

If none of the DTCs are set

NOTE: In order to clear P1FFF, the K114B Hybrid/EV Powertrain Control Module 2 may have to be programmed or replaced if the module contains the current calibration level.

2. Clear Codes. Verify DTC P0AA6, P1AE6, P1FFB, P1FFC, P1FFD, or P1FFE does not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If none of the DTCs are set

3. All OK.

HYBRID/EV ELECTRONICS COOLING DIAGNOSTIC

HYBRID/EV BATTERY COOLING DIAGNOSTIC

HYBRID/EV BATTERY PACK COOLANT PUMP MALFUNCTION

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

Circuit/System Description

The hybrid/EV battery pack coolant pump circulates coolant through the hybrid/EV battery refrigerant/coolant heat exchanger and the hybrid/EV battery pack to control the temperature of the hybrid/EV battery pack.

The Enable, Control and Feedback circuits connect the hybrid/EV powertrain control module 2 to the hybrid/EV battery pack coolant pump.

When the Enable circuit is high, the pump is allowed to operate as specified by the Control circuit signal. The pulse-width modulated Control circuit signal from the hybrid/EV powertrain control module 2 determines the hybrid/EV battery pack coolant pump speed. The higher the duty cycle the higher the pump speed. The hybrid/EV battery pack coolant pump utilizes a pulse-width modulated signal on the Feedback circuit to the hybrid/EV powertrain control module 2. During normal operation, the feedback circuit provides pump speed information to the hybrid/EV powertrain control module 2. If the hybrid/EV battery pack coolant pump determines there is an internal fault it provides this information on the same feedback circuit instead of pump speed information.

Diagnostic Aids

Always verify coolant freeze point protection if a fault occurs in cold climate conditions. An improper coolant to water ratio may result in slushy or frozen coolant, resulting in DTCs or overheating. Measure coolant concentration using the J-26568 refractometer or equivalent to verify a 50/50 mix and freeze protection to -37°C (-34°F).

The Coolant Pump Feedback parameter on the scan tool indicates the status of the pump. When the pump self-diagnostics indicate normal operation, the parameter will indicate a PWM between 45 and 55%.

Different PWM values will identify when a pump self-diagnostic has failed:

Coolant Pump Feedback Parameter

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle On.

2. Verify that DTC P0C47, P1E8C, P1E8D, P19FD, P19FE, or P19FF is not set.

If any DTC is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If none of the DTCs are set

3. Verify the hybrid/EV powertrain control module 2 parameters listed below when commanding the hybrid/EV battery pack coolant pump between 20% and 90% with a scan tool.

Hybrid/EV Battery Pack Coolant Pump Command to be 10% or greater. Hybrid/EV Battery Pack Coolant Pump Feedback to be 50% +/-5%.

Hybrid/EV Battery Pack Coolant Pump Speed is greater than 500 RPM.

The scan tool parameters listed are not within the specified ranges

Refer to Circuit/System Testing.

The scan tool parameters listed are within the specified ranges

4. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the harness connector at the G37 Hybrid/EV Battery Pack Coolant Pump.

2. Test for less than 5 Ω between the ground circuit terminal 4 and ground.

If 5 Ω or greater

Repair the open/high resistance on the ground circuit.

If less than 5 Ω

3. Vehicle On.

4. Test for B+ between the B+ circuit terminal 5 and the ground circuit terminal 4.

If less than B+

1. Vehicle OFF, test for infinite resistance between the B+ circuit terminal 5 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 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 and the fuse is blown

3. Replace the G37 Hybrid/EV Battery Pack Coolant Pump.

If B+

5. Connect a test lamp between the enable circuit terminal 1 and the ground circuit terminal 4.

6. Vehicle OFF, charge cord removed. Verify the test lamp is OFF.

If the test lamp is ON

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the pump enable circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Replace the K114B hybrid/EV powertrain control module 2.

If the test lamp is OFF

7. Vehicle On. Verify the test lamp illuminates. Command the Hybrid/EV Battery Pack Coolant Pump ON (20 - 90%) with a scan tool if necessary.

If the test lamp is OFF

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the pump enable 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 pump enable circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is ON

8. Connect a test lamp between the control circuit terminal 3 and the B+ circuit terminal 5.

9. Verify that a test lamp changes illumination between bright (20%) and dim (90%) when commanding the Hybrid/EV Battery Pack Coolant Pump ON between 20% and 90% with a scan tool.

If the test lamp is always dim or does not illuminate

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the control circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is always bright

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

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. Replace the K114B Hybrid/EV Powertrain Control Module 2.

The test lamp changes illumination between bright (20%) and dim (90%)

10. Remove the test lamp.

11. Verify the scan tool Hybrid/EV Battery Pack Coolant Pump Feedback parameter is 0%.

If greater than 0%

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the feedback circuit terminal 2 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance

3. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If 0%

12. Install a 3 A fused jumper wire between the feedback circuit terminal 2 and the ground circuit terminal 4.

13. Verify the scan tool Hybrid/EV Battery Pack Coolant Pump Feedback parameter is greater than 90%.

If 90% or less

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the feedback circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit.

If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If greater than 90%

14. Connect the G37 Hybrid/EV Battery Pack Coolant Pump.

15. Vehicle On.

16. Place your hand on the coolant pump and verify that pump operation is felt when commanding the Hybrid/EV Battery Pack Coolant Pump ON to 90% with a scan tool.

If pump operation cannot be felt at 90%

Replace the G37 Hybrid/EV Battery Pack Coolant Pump.

If pump operation is felt at 90%

17. All OK. Refer to Hybrid/EV Battery Cooling Diagnostic to verify for proper flow of the coolant pump and system.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Drive Motor Battery Coolant Pump Replacement

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

HYBRID/EV ELECTRONICS COOLANT PUMP MALFUNCTION

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

Circuit/System Description

The hybrid/EV electronics coolant pump circulates coolant through the power electronics coolant radiator, drive motor generator power inverter module, the battery charger, and the 14V accessory power module to control the temperature of these modules.

The Enable, Control and Feedback circuits connect the hybrid/EV powertrain control module 2 to the hybrid/EV electronics coolant pump.

When the Enable circuit is high, the pump is allowed to operate as specified by the Control circuit signal. The pulse-width modulated Control circuit signal from the hybrid/EV powertrain control module 2 determines the hybrid/EV electronics coolant pump speed. The higher the duty cycle the higher the pump speed. The hybrid/EV electronics coolant pump utilizes a pulse-width modulated signal on the Feedback circuit to the hybrid/EV powertrain control module 2. During normal operation, the feedback circuit provides pump speed information to the hybrid/EV powertrain control module 2. If the hybrid/EV electronics coolant pump determines there is an internal fault it provides this information on the same feedback circuit instead of pump speed information.

Diagnostic Aids

Always verify coolant freeze point protection if a fault occurs in cold climate conditions. An improper coolant to water ratio may result in slushy or frozen coolant, resulting in DTCs or overheating. Measure coolant concentration using the J-26568 refractometer or equivalent to verify a 50/50 mix and freeze protection to -37°C (-34°F).

The Coolant Pump Feedback parameter on the scan tool indicates the status of the pump. When the pump self-diagnostics indicate normal operation, the parameter will indicate a PWM between 45 and 55%.

Different PWM values will identify when a pump self-diagnostic has failed:

Coolant Pump Feedback Parameter

Reference Information

Schematic Reference Hybrid/EV Cooling Schematics Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hybrid/EV Cooling System Description and Operation

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Vehicle On.

2. Verify that DTC P0CE9, P1F44, P1F45, P19FA, P19FB, or P19FC is not set.

If any of the DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle If none of the DTCs are set

3. Verify the hybrid/EV powertrain control module 2 parameters listed below when commanding the hybrid/EV electronics coolant pump between 20% and 90% with a scan tool.

Hybrid/EV Electronics Coolant Pump Command to be 10% or greater. Hybrid/EV Electronics Coolant Pump Feedback to be 50% +/-5%.

Hybrid/EV Electronics Coolant Pump Speed is greater than 500 RPM.

The scan tool parameters listed are not within the specified ranges

Refer to Circuit/System Testing.

The scan tool parameters listed are within the specified ranges

4. All OK.

Circuit/System Testing

1. Vehicle OFF, disconnect the harness connector at the G35 Hybrid/EV Electronics Coolant Pump.

2. Test for less than 5 Ω between the ground circuit terminal 4 and ground.

If 5 Ω or greater

Repair the open/high resistance on the ground circuit.

If less than 5 Ω

3. Vehicle On.

4. Test for B+ between the B+ circuit terminal 5 and the ground circuit terminal 4.

If less than B+

1. Vehicle OFF, test for infinite resistance between the B+ circuit terminal 5 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 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 and the fuse is blown

3. Replace the G35 Hybrid/EV Electronics Coolant Pump.

If B+

5. Connect a test lamp between the enable circuit terminal 1 and the ground circuit terminal 4.

6. Vehicle OFF, charge cord removed. Verify the test lamp is OFF.

If the test lamp is ON

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the pump enable circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Replace the K114B hybrid/EV powertrain control module 2.

If the test lamp is OFF

7. Vehicle On. Verify the test lamp illuminates. Command the Hybrid/EV Electronics Coolant Pump ON (20

- 90%) with a scan tool if necessary.

If the test lamp is OFF

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the pump enable 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 pump enable circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is ON

8. Connect a test lamp between the control circuit terminal 3 and the B+ circuit terminal 5.

9. Verify that a test lamp changes illumination between bright (20%) and dim (90%) when commanding the Hybrid/EV Electronics Coolant Pump ON between 20% and 90% with a scan tool.

If the test lamp is always dim or does not illuminate

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the control circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the control circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If the test lamp is always bright

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

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. Replace the K114B Hybrid/EV Powertrain Control Module 2.

The test lamp changes illumination between bright (20%) and dim (90%)

10. Remove the test lamp.

11. Verify the scan tool Hybrid/EV Electronics Coolant Pump Feedback parameter is 0%.

If greater than 0%

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for infinite resistance between the feedback circuit terminal 2 and ground. If less than infinite resistance, repair the short to ground on the circuit.

If infinite resistance

3. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If 0%

12. Install a 3 A fused jumper wire between the feedback circuit terminal 2 and the ground circuit terminal 4.

13. Verify the scan tool Hybrid/EV Electronics Coolant Pump Feedback parameter is greater than 90%.

If 90% or less

1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.

2. Test for less than 1 V between the feedback circuit terminal and ground. If 1 V or greater, repair the short to voltage on the circuit.

If less than 1 V

3. Test for less than 2 Ω in the feedback circuit end to end.

If 2 Ω or greater, repair the open/high resistance in the circuit. If less than 2 Ω

4. Replace the K114B Hybrid/EV Powertrain Control Module 2.

If greater than 90%

14. Connect the G35 Hybrid/EV Electronics Coolant Pump.

15. Vehicle On.

16. Place your hand on the coolant pump and verify that pump operation is felt when commanding the Hybrid/EV Electronics Coolant Pump ON to 90% with a scan tool.

If pump operation cannot be felt at 90%

Replace the G35 Hybrid/EV Electronics Coolant Pump.

If pump operation is felt at 90%

17. Electronic control of the pump is OK. Verify for proper flow of the coolant pump and system.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

Generator Control Module Coolant Pump Replacement for Hybrid/EV electronics coolant pump replacement.

Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.

HYBRID COOLING SYSTEM LOSS OF COOLANT (POWER ELECTRONICS)

HYBRID COOLING SYSTEM LOSS OF COOLANT (BATTERY)

HYBRID COOLING SYSTEM PRESSURE CAP TESTING

Special Tools

GE-46143 Radiator Cap and Surge Tank Test Adapter

EN-24460-A Cooling System Pressure Tester For equivalent regional tools, Refer to Special Tools Pressure Cap Testing

WARNING: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

1. Remove the pressure cap.

2. Wash the pressure cap sealing surface with water.

Fig. 6: Identifying Pressure Cap Tester Courtesy of GENERAL MOTORS COMPANY

NOTE: Lubricate GE-46143 Radiator Cap and Surge Tank Test Adapter and pressure cap O-rings with coolant and press cap to seat O-ring on

GE-46143 Radiator Cap and Surge Tank Test Adapter before turning to engage threads.

3. Use the EN-24460-A Cooling System Pressure Tester (1) with GE-46143 Radiator Cap and Surge Tank Test Adapter (2) in order to test the pressure cap.

4. Test the pressure cap for the following conditions:

Pressure release when the EN-24460-A Cooling System Pressure Tester exceeds the pressure rating of the pressure cap.

Maintain the rated pressure for at least 10 seconds.

Note the rate of pressure loss.

5. Replace the pressure cap under the following conditions:

The pressure cap does not release pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

HYBRID COOLING SYSTEM LEAK TEST

Special Tools

EN-24460-A Cooling System Pressure Tester

GE-46143 Radiator Cap and Surge Tank Test Adapter For equivalent regional tools, Refer to Special Tools

WARNING: Under pressure, the temperature of the solution in the radiator can be considerably higher, without boiling. Removing the radiator cap while the engine is hot (pressure is high), will cause the solution to boil instantaneously, with explosive force. The solution will spew out over the engine, fenders, and the person removing the cap. Serious bodily injury may result. Flammable antifreeze, such as alcohol, is not recommended for use at any time. Flammable antifreeze could cause a serious fire.

WARNING: In order to help avoid being burned, do not remove the radiator cap while the engine and the radiator are hot. Scalding fluid and steam can be blown out under pressure if the cap is removed too soon.

1. Remove the pressure cap.

2. Test the operation of the pressure cap. Refer to Hybrid Cooling System Pressure Cap Testing.

3. Wash the pressure cap mating surface with water.

Fig. 7: Cooling System Pressure Tester Components Courtesy of GENERAL MOTORS COMPANY

4. Use the EN-24460-A Cooling System Pressure Tester with the GE-46143 Radiator Cap and Surge Tank Test Adapter in order to apply pressure to the cooling system.

Do not exceed the pressure cap rating.

5. The cooling system should hold the rated pressure for at least 2 minutes. Observe the gauge for any pressure loss.

NOTE: Do not use stop leak or any other chemicals. Only use premix Dexcool (50/50 mixture of Dexcool and deionized)

6. Repair any leaks as required.

REPAIR INSTRUCTIONS

DRIVE MOTOR BATTERY COOLING SYSTEM DRAINING AND FILLING

Special Tools

GE-26568 Coolant and Battery Tester

GE-46143 Cooling System Adapter

GE-47716 Vac-N-Fill Coolant Refill Tool GE-50385 Battery Pack Coolant Adapters EL-51753 Battery Leak Test Kit

EL-50812 Battery Leak Test Kit Equivalent regional tools:Special Tools.

WARNING: Before conducting any repair to this high voltage cooling system, it is necessary to determine/verify whether no high-voltage system faults exist. If high-voltage faults exist, follow published DTC diagnostics/repair procedures prior to performing any cooling system repairs. Failure to correct High Voltage Faults before working on the high voltage cooling system could result in personal injury or death.

WARNING: Do NOT attempt to repair a Lithium Ion Hybrid/EV Battery Pack when an internal coolant leak is evident. The Hybrid/EV Battery Pack must always be replaced as an assembly. Failure to replace a coolant contaminated Hybrid/EV Battery Pack may result in fire, which can cause severe injury or death.

WARNING: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

NOTE: If system is being drained to perform internal service or replacement of the high-voltage battery, it is necessary to purge the high-voltage battery of any residual coolant. Refer to the High-Voltage Battery Coolant Purge procedure at the end of this procedure.

Drain Points

Fig. 8: Battery Inlet And Outlet Branch Drain Point Courtesy of GENERAL MOTORS COMPANY

1. The graphic shows the 2 draining points:

1. Battery Inlet Branch Drain Point (1)

2. Battery Outlet Branch Drain Point (2)

Draining Procedure

NOTE: Draining of the cooling system or replacement of any drive motor battery cooling system parts requires the actuation of the Hybrid/EV Battery Pack Coolant Pump Bleed Procedure in the GDS tool.

To completely drain the high-voltage battery cooling system, coolant must be drained from three locations: The inlet branch quick connect, the outlet branch quick connect, and the inlet & outlet pipes at the high-voltage battery.

If draining the system for high-voltage battery internal service or replacement, it is necessary to purge all coolant from the battery using an additional procedure. Go to Purging & Remove of Coolant from Battery .

1. Turn the Vehicle Power Off, remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

2. Drain battery coolant inlet branch. Disconnect the battery coolant pump outlet hose at the chiller inlet pipe at the right frame rail. Drive Motor Battery Coolant Cooler Inlet Hose Replacement (Pump Outlet to Chiller Inlet)Drive Motor Battery Coolant Cooler Inlet Hose Replacement (Tube Assembly to Chiller) (Tube Assembly to Chiller).

3. Drain battery coolant outlet branch. Disconnect the high-voltage battery outlet pipe at the surge tank inlet hose quick connect near the left frame rail. Drive Motor Control Module Radiator Outlet Hose Replacement.

4. Drain the inlet and outlet branch at the battery. Disconnect high-voltage battery inlet pipe and outlet pipe. Refer to Drive Motor Control Module Radiator Inlet Hose Replacement (Drive Motor Battery to Tube).

Vac-N-Fill Procedure

1. Turn the Vehicle Power Off, remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

Fig. 9: Radiator Cap & Surge Tank Test Adapter Courtesy of GENERAL MOTORS COMPANY

NOTE: To prevent boiling of the coolant/water mixture in the vehicles cooling system, do not apply vacuum to a cooling system above 49°C (120°F). The tool will not operate properly when the coolant is boiling.

2. Install GE-46143 adapter.

3. Attach the Van-N-Fill cap (1) to GE-46143 adapter.

Fig. 10: Vacuum Gauge Assembly & Vac N Fill Cap Courtesy of GENERAL MOTORS COMPANY

4. Attach the vacuum gauge assembly (1) to the Vac-N-Fill cap (2).

Fig. 11: Vacuum Gauge Assembly & Fill Hose Courtesy of GENERAL MOTORS COMPANY

5. Attach the fill hose (1) to the barb fitting on the vacuum gauge assembly (2). Ensure that the valve is closed.

Fig. 12: Graduated Reservoir, Vacuum Tank & Cut-Out Area Courtesy of GENERAL MOTORS COMPANY

NOTE: Use a Pre-mixed DEXCOOL® (50/50 mixture of DEXCOOL® and deionized water). Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.

6. Pour the coolant mixture into the graduated reservoir (1).

7. Place the fill hose in the graduated reservoir (1).

NOTE: Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain valve located on the bottom of the tank is closed.

8. Install the vacuum tank (2) on the graduated reservoir with the fill hose routed through the cut-out area

(3) in the vacuum tank.

Fig. 13: Vacuum Tank & Venturi Assembly Courtesy of GENERAL MOTORS COMPANY

9. Attach the venturi assembly (1) to the vacuum tank (2).

Fig. 14: Venturi Assembly & Valve

Courtesy of GENERAL MOTORS COMPANY

10. Attach a shop air hose to the venturi assembly (1). Ensure the valve (2) on the venturi assembly is closed.

Fig. 15: Vacuum Hose, Gauge Assembly & Tank Courtesy of GENERAL MOTORS COMPANY

11. Attach the vacuum hose (1) to the vacuum gauge assembly (2) and the vacuum tank (3).

Fig. 16: Valve & Venturi Assembly

Courtesy of GENERAL MOTORS COMPANY

12. Open the valve (1) on the venturi assembly (2). The vacuum gauge will begin to rise and a hissing noise will be present.

Fig. 17: Vacuum Gauge Needle

Courtesy of GENERAL MOTORS COMPANY

13. Continue to draw vacuum until the needle stops rising (1). This should be 610 - 660 mm Hg (24 - 26 in Hg).

Cooling hoses may start to collapse. This is normal due to vacuum draw.

14. To aid in the fill process, position the graduated reservoir above the coolant fill port.

Fig. 18: Vacuum Gauge Assembly & Needle Courtesy of GENERAL MOTORS COMPANY

15. Slowly open the valve (1) on the vacuum gauge assembly (2). When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.

16. Close the valve on the venturi assembly.

17. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss.

If vacuum loss is observed, refer to Hybrid Cooling System Loss of Coolant (Power Electronics)Hybrid Cooling System Loss of Coolant (Battery).

18. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.

Fig. 19: Vacuum Gauge

Courtesy of GENERAL MOTORS COMPANY

19. Once the vacuum gauge (1) reaches zero, close the valve on the vacuum gauge assembly and repeat steps 12 - 18.

20. Place vehicle in Service Mode. With the GDS scan tool, activate the hybrid/EV battery pack coolant pump for 5 minutes while maintaining 381 mm (15 in Hg) vacuum throughout the process. The pump can be activated by navigating to the following location:

1. Module Diagnostics

2. Hybrid Powertrain Control Module 2

3. Control Functions

4. Hybrid/EV Battery Pack Coolant Pump

5. Command Pump to 80%

21. Detach the Vac-N-Fill cap from the GE-46143 adapter.

22. Remove GE-46143 adapter from the surge tank fill neck.

Fig. 20: Surge Tank

Courtesy of GENERAL MOTORS COMPANY

23. Upon completion of the hybrid/EV battery pack coolant pump activation, adjust the surge tank coolant level to the FULL COLD line on the side of the surge tank (1).

24. Inspect the concentration of the coolant mixture using GE-26568 tester.

REMOVING EXCESS COOLANT FROM SYSTEM

NOTE: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.

1. Detach the vacuum hose from the vacuum gauge assembly.

Fig. 21: Vacuum Hose & Extraction Hose Courtesy of GENERAL MOTORS COMPANY

2. Attach the extraction hose (1) to the vacuum hose (2).

Fig. 22: Venturi Assembly & Valve

Courtesy of GENERAL MOTORS COMPANY

3. Open the valve (1) on the venturi assembly (2) to start a vacuum draw.

Fig. 23: Extraction Hose And Surge Tank Courtesy of GENERAL MOTORS COMPANY

4. Assemble the extraction hose (1) and insert into the surge tank (2).

Fig. 24: Surge Tank

Courtesy of GENERAL MOTORS COMPANY

5. Adjust the surge tank coolant level to the FULL COLD line on the side of the surge tank (1).

6. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.

PURGING & REMOVAL OF COOLANT FROM BATTERY

NOTE: Prior to performing high-voltage battery internal service, it is necessary to purge any residual coolant inside the battery that is left over from the cooling system draining procedure. Similarly, coolant must be removed from the battery prior to return shipping. This procedure must also be used when purging complete system of contaminated coolant.

NOTE: This procedure can be performed in vehicle, or with battery removed from vehicle.

Fig. 25: Plugs From Battery Leak Test Kits Courtesy of GENERAL MOTORS COMPANY

1. Install necessary plugs from EL-50812 & EL-51753 Battery Leak Test Kits (1, 2).

2. Install GE-50385 Battery Pack Coolant Adapters to the battery coolant ports.

3. Connect the GE-47716 Vac N Fill vacuum hose to the GE-50385 adapter with thru-port.

Fig. 26: Connect Other End Of Vacuum Hose to Vac N Fill Vacuum Tank Courtesy of GENERAL MOTORS COMPANY

4. Connect other end of vacuum hose to the Vac N Fill vacuum tank.

5. Install the venturi assembly to the vacuum tank with valve closed.

6. Attached regulated shop air supply hose to venturi assembly.

7. Open valve on venturi assembly to apply vacuum to high-voltage battery internal coolant loop.

8. Build vacuum for at least one minute.

Fig. 27: GE-50385 Plug to Break Vacuum And Purge Battery Of Coolant Courtesy of GENERAL MOTORS COMPANY

9. Temporarily remove GE-50385 plug to break vacuum and purge battery of coolant.

10. Install plug to build vacuum again.

11. Repeat step 7-9 several times until no more coolant can be extracted.

DRIVE MOTOR GENERATOR POWER INVERTER MODULE COOLING SYSTEM DRAINING AND FILLING

Special Tools

GE-26568 Coolant and Battery Tester

GE-47716 Vac-N-Fill Coolant Refill Tool

BO-38185 Hose Clamp Pliers Equivalent regional tools: Special Tools

WARNING: Before conducting any repair to this high voltage cooling system, it is

necessary to determine/verify whether no high-voltage system faults exist. If high-voltage faults exist, follow published DTC diagnostics/repair procedures prior to performing any cooling system repairs. Failure to correct High Voltage Faults before working on the high voltage cooling system could result in personal injury or death.

WARNING: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

Draining Procedure

1. Turn Vehicle Power Off and remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

2. Raise and support the vehicle. Lifting and Jacking the Vehicle

3. Remove Front Wheelhouse Liner Replacement (Left Side) Front Wheelhouse Liner Replacement (Right Side)

Fig. 28: Clamp And Coolant Hose

Courtesy of GENERAL MOTORS COMPANY

4. Loosen Clamp (2) BO-38185 pliers

5. Remove Coolant Hose (1)

6. Lower the vehicle.

Vac-N-Fill Procedure

1. Turn Vehicle Power Off and remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

Fig. 29: Radiator Cap & Surge Tank Test Adapter Courtesy of GENERAL MOTORS COMPANY

NOTE: To prevent boiling of the coolant/water mixture in the vehicles cooling system, do not apply vacuum to a cooling system above 49°C (120°F). The tool will not operate properly when the coolant is boiling.

2. Install GE-46143 cooling system adapter

3. Attach the Vac-N-Fill cap (1) to GE-46143 cooling system adapter.

Fig. 30: Vacuum Gauge Assembly & Vac N Fill Cap Courtesy of GENERAL MOTORS COMPANY

4. Attach the vacuum gauge assembly (1) to the Vac-N-Fill cap (2).

Fig. 31: Vacuum Gauge Assembly & Fill Hose Courtesy of GENERAL MOTORS COMPANY

5. Attach the fill hose (1) to the barb fitting on the vacuum gauge assembly (2). Ensure that the valve is closed.

Fig. 32: Graduated Reservoir, Vacuum Tank & Cut-Out Area Courtesy of GENERAL MOTORS COMPANY

NOTE: Use a Pre-mixed DEXCOOL® (50/50 mixture of DEXCOOL® and deionized water). Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.

6. Pour the coolant mixture into the graduated reservoir (1).

7. Place the fill hose in the graduated reservoir (1).

NOTE: Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain valve located on the bottom of the tank is closed.

8. Install the vacuum tank (2) on the graduated reservoir with the fill hose routed through the cut-out area

(3) in the vacuum tank.

Fig. 33: Vacuum Tank & Venturi Assembly Courtesy of GENERAL MOTORS COMPANY

9. Attach the venturi assembly (1) to the vacuum tank (2).

Fig. 34: Venturi Assembly & Valve

Courtesy of GENERAL MOTORS COMPANY

10. Attach a shop air hose to the venturi assembly (1). Ensure the valve (2) on the venturi assembly is closed.

Fig. 35: Vacuum Hose, Gauge Assembly & Tank Courtesy of GENERAL MOTORS COMPANY

11. Attach the vacuum hose (1) to the vacuum gauge assembly (2) and the vacuum tank (3).

Fig. 36: Valve & Venturi Assembly

Courtesy of GENERAL MOTORS COMPANY

12. Open the valve (1) on the venturi assembly (2). The vacuum gauge will begin to rise and a hissing noise will be present.

Fig. 37: Vacuum Gauge Needle

Courtesy of GENERAL MOTORS COMPANY

13. Continue to draw vacuum until the needle stops rising (1). This should be 610 - 660 mm Hg (24 - 26 in Hg).

Cooling hoses may start to collapse. This is normal due to vacuum draw.

14. To aid in the fill process, position the graduated reservoir above the coolant fill port.

Fig. 38: Vacuum Gauge Assembly & Needle Courtesy of GENERAL MOTORS COMPANY

15. Slowly open the valve (1) on the vacuum gauge assembly (2). When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.

16. Close the valve on the venturi assembly.

17. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss.

If vacuum loss is observed, refer to Loss of Coolant .

18. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.

Fig. 39: Vacuum Gauge At Zero

Courtesy of GENERAL MOTORS COMPANY

19. Once the vacuum gauge reaches zero (1), close the valve on the vacuum gauge assembly and repeat steps 12 - 18.

20. Detach the Vac-N-Fill cap from the GE-46143 adapter.

21. Remove GE-46143 adapter from the surge tank fill neck.

22. Add coolant to the system as necessary.

23. Inspect the concentration of the coolant mixture using GE-26568 tester.

NOTE: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.

24. Detach the vacuum hose form the vacuum gauge assembly.

Fig. 40: Vacuum Hose & Extraction Hose Courtesy of GENERAL MOTORS COMPANY

25. Attach the extraction hose (1) to the vacuum hose (2).

Fig. 41: Venturi Assembly & Valve

Courtesy of GENERAL MOTORS COMPANY

26. Open the valve (1) on the venturi assembly (2) to start a vacuum draw.

Fig. 42: Coolant Extraction Hose

Courtesy of GENERAL MOTORS COMPANY

27. Use the extraction hose (1) to draw out coolant to the proper level.

28. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.

COOLANT TEMPERATURE SENSOR REPLACEMENT

Removal Procedure

WARNING: Before conducting any repair to this high voltage cooling system, it is necessary to determine/verify whether no high-voltage system faults exist. If high-voltage faults exist, follow published DTC diagnostics/repair procedures prior to performing any cooling system repairs. Failure to correct High Voltage Faults before working on the high voltage cooling system could result in personal injury or death.

1. Turn the Vehicle Power Off, remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

2. Drain the cooling system. Drive Motor Generator Power Inverter Module Cooling System Draining

and Filling

3. Remove Front Bumper Fascia Center Support Replacement

4. Remove Pedestrian Sound Alert Speaker Replacement

Fig. 43: Electrical Connector And Coolant Temperature Sensor Courtesy of GENERAL MOTORS COMPANY

5. Disconnect Electrical Connector (1).

6. Remove the coolant temperature sensor (2).

Installation Procedure

Fig. 44: Electrical Connector And Coolant Temperature Sensor Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Component Fastener Tightening Caution .

1. Install the coolant temperature sensor (2) and tighten to 33 N.m (24 lb ft).

2. Connect Electrical Connector (1)

3. Install Front Bumper Fascia Center Support Replacement

4. Install Pedestrian Sound Alert Speaker Replacement

5. Fill the cooling system. Drive Motor Generator Power Inverter Module Cooling System Draining and Filling

ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT

Removal Procedure

WARNING: Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

WARNING: Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 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 at all times when working with the high voltage battery assembly, whether the system is energized or not.

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

1. Remove High Voltage Battery Cover Replacement

2. Remove High Voltage Battery Disconnect Relay Replacement

Fig. 45: Electrical Connector And Engine Coolant Temperature Sensor Courtesy of GENERAL MOTORS COMPANY

3. Disconnect Electrical Connector(1).

4. Loosen Clamp(2).

5. Remove Engine Coolant Temperature Sensor(3).

Installation Procedure

Fig. 46: Electrical Connector And Engine Coolant Temperature Sensor Courtesy of GENERAL MOTORS COMPANY

1. Install Engine Coolant Temperature Sensor(3).

2. Install Clamp(2).

3. Connect Electrical Connector(1).

4. Install High Voltage Battery Disconnect Relay Replacement

5. Install High Voltage Battery Cover Replacement

DRIVE MOTOR CONTROL MODULE RADIATOR INLET HOSE REPLACEMENT

Removal Procedure

WARNING: Before conducting any repair to this high voltage cooling system, it is necessary to determine/verify whether no high-voltage system faults exist. If high-voltage faults exist, follow published DTC diagnostics/repair procedures prior to performing any cooling system repairs. Failure to correct High Voltage Faults before working on the high voltage cooling system could result in personal injury or death.

WARNING: Do not use a service jack in locations other than those specified to lift this vehicle. Lifting the vehicle with a jack in those other locations could cause the vehicle to slip off the jack and roll; this could cause injury or death.

1. Turn the Vehicle Power Off, remove all keyless entry transmitters from the vehicle and secure in a place outside the vehicle.

2. Drain the cooling system. Drive Motor Generator Power Inverter Module Cooling System Draining and Filling

3. Raise and support the vehicle. Lifting and Jacking the Vehicle

4. Remove Front Wheelhouse Liner Replacement (Left Side) Front Wheelhouse Liner Replacement

(Right Side)

5. Remove Headlamp Replacement

Fig. 47: Clamp And Coolant Hose

Courtesy of GENERAL MOTORS COMPANY

6. Disengage Clamp(1) Hose Clamp Replacement Guidelines - Spring Type

7. Remove Coolant Hose(2)

Fig. 48: Coolant Hose And Clip

Courtesy of GENERAL MOTORS COMPANY

8. Remove Coolant Hose(2).

9. Remove Clip(1).

Fig. 49: Generator Control Module Coolant Pump Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

NOTE: Note the position of the pump and the bracket.

10. Remove the 2 generator control module coolant pump bracket nuts (2).

11. Remove the generator control module coolant pump bracket (1).