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SPECIFICATIONS
FASTENER SPECIFICATIONS
ELECTRICAL
Plug-In Charging - Volt
|
Application |
Specification |
|
|
Metric |
English (USA) |
|
|
Drive Motor Battery Charger Bolt |
22 N.m |
16 lb ft |
|
Drive Motor Battery Charger Fastener |
22 N.m |
16 lb ft |
|
Drive Motor Battery Charger Receptacle Fastener |
12 N.m |
106 lb in |
SCHEMATIC WIRING DIAGRAMS
PLUG-IN CHARGING WIRING SCHEMATICS
Battery State of Charge
Fig. 1: Battery State of Charge
Courtesy of GENERAL MOTORS COMPANY
Charging Port Door
Fig. 2: Charging Port Door
Courtesy of GENERAL MOTORS COMPANY
Battery Charger
Fig. 3: Battery Charger
Courtesy of GENERAL MOTORS COMPANY
DIAGNOSTIC INFORMATION AND PROCEDURES
DTC P0CF4-P0CF6: CONTROL PILOT CIRCUIT
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 P0CF4
Control Pilot Circuit Performance
DTC P0CF5
Control Pilot Circuit Low Voltage
DTC P0CF6
Control Pilot Circuit High Voltage
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
Control Pilot Signal |
P0CF4, P0CF5, P0CF6, P0CF9, P0D01, 1 |
P0CF4, P0CF5, P0CF6, 1 |
P0CF4, P0CF5, P0CF6, P0CF9, 1 |
P0CF4, P0CF5, P0CF6, 1 |
|
Proximity Signal |
P0D58, 1 |
P0D59, 1 |
P0D59, 1 |
- |
|
110/120 A/C Line 1 |
1 |
P0D3F, P1EE6 |
1 |
- |
|
110/120 A/C Line 2 |
1 |
P1EE6 |
1 |
- |
|
110/120 A/C Ground |
- |
P0D59, 1 |
1 |
- |
|
1. Plug In Charging Malfunction |
||||
Circuit/System Description
The hybrid/EV powertrain control module 2 monitors a pilot signal from the drive motor battery charger cable. The hybrid/EV powertrain control module 2 utilizes this signal to manage the charging process between the drive motor battery charger cable and the hybrid/EV powertrain control module 2.
Under normal charging conditions the control pilot signal is generated by the drive motor battery charger cable. This diagnostic runs with the drive motor battery charger cable disconnected to verify the vehicle side circuit integrity.
The diagnostic signal is generated internally by the hybrid/EV powertrain control module 2.
Conditions for Running the DTC
DTC P0CF4
The vehicle 12 V battery system voltage is 10.2 V or greater.
The drive motor battery charger cable is disconnected and the charge port door is closed.
The vehicle needs to be driven above 8 km/h (5 mph).
DTC P0CF5
The vehicle 12 V battery system voltage is 10.2 V or greater.
The drive motor battery charger cable is disconnected and the charge port door is closed.
DTC P0CF6
The vehicle 12 V battery system voltage is 10.2 V or greater.
The drive motor battery charger cable is disconnected and the charge port door is closed.
The vehicle needs to be driven above 8 km/h (5 mph).
Conditions for Setting the DTC
DTC P0CF4
The control pilot circuit is not meeting its internal range requirements for 5 seconds. This can only be set internal to the hybrid/EV powertrain control module 2. This is an internal circuit voltage in the hybrid/EV powertrain control module 2 and can not be measured.
DTC P0CF5
The control pilot circuit voltage divided by the system voltage is less than 0.03 V for 5 seconds. This is an internal circuit voltage in the hybrid/EV powertrain control module 2 and can not be measured.
DTC P0CF6
The control pilot circuit voltage divided by the system voltage is greater than 0.55 V for 5 seconds. This is an internal circuit voltage in the hybrid/EV powertrain control module 2 and can not be measured.
Actions Taken When the DTC Sets
DTC P0CF4-P0CF6 are type A DTCs.
Disables high voltage battery charging.
Conditions for Clearing the DTC
DTC P0CF4-P0CF6 are type A DTCs.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 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 T18 Battery Charger. Refer to High Voltage Disabling . Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
Fig. 4: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
NOTE: The following tests are performed at the X98 Hybrid/EV Battery Charger Receptacle and not at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
2. Test for infinite resistance between control pilot signal circuit terminal 2 of the X98 Hybrid/EV Battery Charger Receptacle and the terminals listed below:
Terminal 4
Terminal 1
Terminal 5
Terminal 3
If less than infinite resistance
1. Disconnect the harness connector from the X98 Hybrid/EV Battery Charger Receptacle.
NOTE: This test is performed on the vehicle side of the harness connector.
2. Test for infinite resistance between the harness connector control pilot signal circuit terminal 2 and the terminals listed below:
Terminal 4
Terminal 1
Terminal 5
Terminal 3
If less than infinite resistance, repair the short between the circuits.
If infinite resistance, replace the X98 Hybrid/EV Battery Charger Receptacle.
If infinite resistance
3. Replace the K114B Hybrid/EV Powertrain Control Module 2.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Drive Motor Battery Charger Receptacle Replacement
Control Module References
for hybrid/EV powertrain control module 2 replacement, programming and setup.
DTC P0CF9 OR P0D01: CONTROL PILOT CHARGING SWITCH PERFORMANCE
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 P0CF9
Control Pilot Charging Switch Performance
DTC P0D01
Control Pilot Charging Ventilation Switch Performance
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
Control Pilot Signal |
P0CF4, P0CF5, P0CF6, P0CF9, P0D01, 1 |
P0CF4, P0CF5, P0CF6, 1 |
P0CF4, P0CF5, P0CF6, P0CF9, 1 |
P0CF4, P0CF5, P0CF6, 1 |
|
Proximity Signal |
P0D58, 1 |
P0D59, 1 |
P0D59, 1 |
- |
|
110/120 A/C Line 1 |
1 |
P0D3F, P1EE6 |
1 |
- |
|
110/120 A/C Line 2 |
1 |
P1EE6 |
1 |
- |
|
110/120 A/C Ground |
- |
P0D59, 1 |
1 |
- |
|
1. Plug In Charging Malfunction |
||||
Circuit/System Description
The hybrid/EV powertrain control module 2 has two internal switches used to modify the control pilot signal. The first internal switch modifies the control pilot signal to indicate to the drive motor battery charger cable that the vehicle is either ready or not ready to accept energy. The second internal switch modifies the control pilot signal to indicate to some drive motor battery charger cables (currently not used) if indoor ventilation is required.
Conditions for Running the DTC
The 12 V battery voltage is greater than 10.2 V.
The drive motor battery charger cable is disconnected and the charge port door is closed.
The diagnostics for DTC P0CF4-P0CF6 must have passed before these will run.
Conditions for Setting the DTC
The hybrid/EV powertrain control module 2 measures a pilot signal voltage out of range for 5 seconds. This is an internal circuit voltage in the hybrid/EV powertrain control module 2 and can not be measured.
Actions Taken When the DTC Sets
DTC P0CF9 and P0D01 are type A DTCs
Disables the high voltage battery charging.
Conditions for Clearing the DTC
DTC P0CF9 and P0D01 are type A DTCs.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 ON.
2. Verify that DTC P0CF9 or P0D01 is not set.
If either of the DTCs are set
Replace the K114B Hybrid/EV Powertrain Control Module 2.
If none of the DTCs are set
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.
DTC P0D1F: CONTROL MODULE DATE/TIME SYNCHRONIZATION PERFORMANCE
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 P0D1F
Control Module Date/Time Synchronization Performance
Circuit/System Description
The hybrid/EV powertrain control module 2 monitors the date and time data it receives from the radio. This time information is used to ensure the module's internal clock is synchronized to the customer's local time. The Time of Day Charging feature utilizes this internal clock to keep track of time and alarms for delayed charging modes. If this radio time data is received during a drive cycle, the system is considered synchronized.
Conditions for Running the DTC
The vehicle needs to go from Vehicle OFF to Vehicle in Service Mode to start the diagnostic.
Conditions for Setting the DTC
The vehicle is driven for more than 5 consecutive drive cycles where trip distance exceeds 15 Km (9.3 mi), and the date and time were unavailable from the OnStar Module.
Actions Taken When the DTC Sets
DTC P0D1F is a type C DTC.
On the Navigation screen "Default Charge Mode: Immediately" is displayed.
The battery charger Time Of Day charging option is disabled, and charging mode is set to IMMEDIATE.
Conditions for Clearing the DTC DTC P0D1F is a type C DTCs. Reference Information Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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, verify no radio DTC's are set.
If any radio DTC's are set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle .
If no radio DTC's are set
2. Replace the K114B Hybrid/EV Powertrain Control Module 2.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Control Module References for hybrid/EV powertrain control module 2 replacement, programming and setup.
DTC P0D26: BATTERY CHARGER SYSTEM PRECHARGE TIME TOO LONG
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 P0D26
Battery Charger System Precharge Time Too Long
Circuit/System Description
In order to prevent large in-rush current, battery charger bus high voltage is routed through a pre-charge resistor whenever high voltage charging is commanded ON. The hybrid/EV powertrain control module 2 monitors the time it takes the battery charger bus voltage to attain the same level as the battery pack voltage. If it takes too long, a DTC is set.
Conditions for Running the DTC
Battery charger must go from disconnected to connected.
Drive motor battery charger cable must be connected and vehicle receiving power.
Conditions for Setting the DTC
The hybrid/EV powertrain control module 2 determines the battery charger does not reach its pre-charge voltage within 1 second.
Actions Taken When the DTC Sets
DTC P0D26 is a Type A DTC.
Disables the high voltage battery charging.
Disables 12V battery charging.
Conditions for Clearing the DTC DTC P0D26 is a Type A DTC. Reference Information Schematic Reference
Plug-In Charging Schematics
Hybrid/EV Energy Storage Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 DTC P0C78 is not set.
If the DTC is set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle .
If the DTC is not set
2. Verify DTC P0CF4, P0CF5, P0CF6, P0D4E, P0D4F, P0D58, or P0D59 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. Connect the drive motor battery charger cable. Verify DTC P0D26 is not set and the vehicle will charge.
If the DTC is set and the vehicle will not charge
Refer to Circuit/System Testing.
If the DTC is not set and the vehicle charges
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. Disable the high voltage for servicing at the A4 Battery Pack, K1 14V Power Module and the T18 Battery Charger. Refer to High Voltage Disabling .
2. Disconnect the X3 connector at the T18 Battery Charger, the X4 connector at the K1 14V Power Module and the X6 connector at the A4 Battery Pack.
3. Verify that all HV harness connector and mating module connector terminals are free from moisture, corrosion and arc flash damage.
If any terminals show signs of damage
Replace the HV wiring harness and effected modules as necessary.
If no arc flash damage, moisture, or corrosion is found
4. Test the following HV harness terminals for less than 2 Ω end to end:
X6-1 to X3-1
X6-1 to X4-B
X6-2 to X3-2
X6-2 to X4-A
If 2 Ω or greater
Replace the HV wiring harness.
If less than 2 Ω
5. Remove the T18 Battery Charger 15A fuse from the A4 Battery Pack. Refer to High Voltage Battery Disconnect Relay Fuse Replacement (Front - BDU) High Voltage Battery Disconnect Relay Fuse Replacement (Rear - BDU) for Front-BDU.
6. Test the battery charger 15A fuse for an open condition.
If the fuse is open
NOTE: The HV harness must remain disconnected from all modules.
1. Test the HV harness terminals X6-1 to X6-2 for infinite resistance.
If less than infinite resistance, replace the fuse and the HV wiring harness.
If infinite resistance
NOTE: This test is performed at the module terminals with the test measurement initially several Meg ohms and slowly decreasing to a minimal value.
2. Test the K1 14 V Power Module X4 terminals for greater than 10K Ω, X4-A to X4-B.
If 10K Ω or less, replace the K1 14V Power Module and the fuse.
If greater than 10 K Ω
NOTE: This test is performed at the module terminals with the test measurement initially several Meg ohms and slowly decreasing to a minimal value.
3. Test the T18 Battery Charger terminals for greater than 10K Ω, X3-1 to X3-2.
If 10K Ω or less, replace the T18 Battery Charger and the fuse.
If greater than 10 K Ω
4. Replace the T18 Battery Charger and the fuse, reassemble the vehicle, clear DTCs and repeat Circuit/System Verification.
If Circuit/System Verification is not OK, replace the A28 Hybrid/EV Battery Contactor Assembly.
If Circuit/System Verification is OK, all OK.
If the fuse is OK
7. Reinstall the fuse. Replace the T18 Battery Charger, reassemble the vehicle, clear DTCs and repeat Circuit/System Verification.
If Circuit/System Verification is not OK
Replace the A28 Hybrid/EV Battery Contactor Assembly.
If Circuit/System Verification is OK
8. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Battery 300-Volt Positive and Negative Cable Replacement - High Voltage Battery to Charger
Receptacle, Accessory DC Power Control Module, and Drive Motor Battery Charger
for HV wiring harness
Generator Battery Disconnector Relay Replacement
for A28 hybrid/EV battery contactor assembly
Control Module References
for T18 Battery Charger, often referred to as the Drive Motor Battery Charger, or K1 14V Power Module replacement, programming and setup
DTC P0D2B OR P0D2C: CONTROL PILOT/STATUS INDICATOR CONTROL CIRCUIT
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 P0D2B
Control Pilot Indicator Control Circuit
DTC P0D2C
Charge Status Indicator Control Circuit
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
Charge Pilot Indicator Control |
P0D2B |
P0D2B |
P0D2B |
- |
|
Charge Status Indicator Control |
P0D2C |
P0D2C, 1 |
P0D2C |
- |
|
Charge Complete Indicator Control |
1 |
1 |
1 |
- |
|
Low Reference |
- |
P0D2C, P0D2B |
- |
- |
|
1. Plug In Charging Indicator Malfunction |
||||
Circuit/System Description
The status of charging events (including delays) is communicated to the user through a charge status indicator and audio tones. The battery state of charge indicator, located on the top middle of the instrument panel, will be solid lit green when the vehicle is charging under automatic control. It will have a fast flash green if the charging is delayed and will begin later. It will have a slow flash green when charging is complete. A solid lit yellow indicator means the vehicle is not able to accept a charge. And if there is no indicator lit it means the electronic vehicle supply equipment is not working properly or connected.
Conditions for Running the DTC
Both conditions need to run for diagnostic to pass.
Condition 1
The 12 V battery voltage is greater than 10.2 V.
Vehicle in Service Mode.
The drive motor battery charger cable is disconnected (charge status indicator commanded OFF).
Condition 2
The 12 V battery voltage is greater than 10.2 V.
Vehicle in Service Mode.
The vehicle is connected to an AC supply and the battery charger is charging the vehicle (charge status indicator commanded ON).
Conditions for Setting the DTC
Charge status indicator Commanded OFF, The hybrid/EV powertrain control module 2 detects a short to battery for about 4 s.
Charge status indicator Commanded ON, The hybrid/EV powertrain control module 2 detects a short to ground or an open/high resistance for 4 s.
Actions Taken When the DTC Sets
DTC P0D2B and P0D2C are type C DTCs.
Conditions for Clearing the DTC
DTC P0D2B and P0D2C are type C DTCs.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 Testing
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure includes the following steps:
Identify how to disable high voltage.
Identify how to test for the presence of high voltage.
Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
Visually and functionally inspect the gloves before use.
Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures may result in serious injury or death.
1. Vehicle OFF, disconnect the X1 harness connector at the B305 Ambient Light/Sunload Sensor and Battery State of Charge Indicator.
2. Test for less than 10 Ω between the low reference terminal 1 and ground.
If 10 Ω or greater
Repair the open/high resistance in the circuit.
If less than 10 Ω
NOTE: If the drive motor battery charger cable is connected. The drive motor battery charger cable must be disconnected for more than 10 seconds before performing the next step.
3. Connect a test lamp between the control circuit terminal 4 and ground.
4. Verify the test lamp does not illuminate.
If the test lamp does illuminate
1. 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 and ground.
If 1 V or greater, repair the short to voltage in the circuit.
If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
If the test lamp does not illuminate
5. Connect the drive motor battery charger cable.
6. Verify that the test lamp illuminates within the first 5 seconds of connecting the drive motor battery charger cable.
If the test lamp does not illuminate
1. Disconnect the drive motor battery charger cable. 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. 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 does illuminate
7. Disconnect the drive motor battery charger cable for at least 10 seconds. Connect a test lamp between the control circuit terminal 3 and ground.
8. Verify the test lamp does not illuminate.
If the test lamp does illuminate
1. 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 and ground.
If 1 V or greater, repair the short to voltage in the circuit.
If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
If the test lamp does not illuminate
9. Connect the drive motor battery charger cable.
10. Verify that the test lamp illuminates within 25 seconds of connecting the drive motor battery charger cable.
If the test lamp does not illuminate
1. Disconnect the drive motor battery charger cable. 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. 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 does illuminate
11. Replace the B305 Ambient Light/Sunload Sensor and Battery State of Charge Indicator.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Sun Load Temperature and Headlamp Automatic Control Ambient Light Sensor Replacement
for B305 Ambient Light/Sunload Sensor and Battery State of Charge Indicator replacement.
Control Module References
for battery charger replacement, programming and setup.
DTC P0D3E-P0D40: BATTERY CHARGER INPUT VOLTAGE 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 P0D3E
Battery Charger Input Voltage Sensor Performance
DTC P0D3F
Battery Charger Input Voltage Sensor Circuit Low Voltage
DTC P0D40
Battery Charger Input Voltage Sensor Circuit High Voltage
Circuit/System Description
The hybrid/EV powertrain control module 2 monitors the AC voltage sensor inside the battery charger. The signal is pulse-width modulated and the duty cycle increases as the AC voltage increases. The duty cycle equals 10% when the AC voltage sensor reports less than 60 V. The duty cycle equals 90% when the AC voltage sensor reports more than 280 V. Therefore, during normal operation the duty cycle is between 10% and 90%.
Conditions for Running the DTC
P0D3E
The 12 V battery voltage is greater than 10.2 V.
The vehicle is driven above 6 km/h (4 mph).
P0D3F and P0D40
The 12 V battery voltage is greater than 10.2 V.
The vehicle is connected to an AC supply and the battery charger is charging the vehicle.
Conditions for Setting the DTC
DTC P0D3E
The battery charger AC input duty cycle is greater than 12% or less than 8%.
DTC P0D3F
The battery charger AC input duty cycle is between 1% and 8%. OR
The battery charger AC input duty cycle equals 100%.
DTC P0D40
The battery charger AC input duty cycle is between 92% and 99%. OR
The battery charger AC input duty cycle equals 0%.
Actions Taken When the DTC Sets
DTC P0D3E, P0D3F and P0D40 are type B DTCs.
Disables high voltage battery charging.
Conditions for Clearing the DTC
DTC P0D3E, P0D3F and P0D40 are type B DTCs.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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. Drive the vehicle above 6 km/h (4 mph).
2. Vehicle OFF. Connect the vehicle to an AC supply to begin charging.
3. Vehicle in Service Mode.
4. Verify that P0D3E, P0D3F, or P0D40 is not set.
If any of the DTCs are set
Refer to Circuit/System Testing.
If none of the DTCs are set
5. All OK.
Circuit/System Testing
1. Vehicle OFF, disconnect the X1 harness connector at the T18 Battery Charger. Vehicle in Service Mode.
2. Verify the scan tool High Voltage Battery Charger AC Input Duty Cycle parameter is less than 10%.
If 10% or greater
1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
2. Test for infinite resistance between the AC voltage sensor circuit terminal 10 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 less than 10%
3. Install a 3 A fused jumper wire between the AC voltage sensor circuit terminal 10 and the ground circuit terminal 2.
4. Verify the scan tool Battery Charger AC Input Status Duty Cycle 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. Vehicle in Service Mode.
2. Test for less than 1 V between the AC voltage sensor circuit terminal 10 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 AC voltage sensor 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%
5. Replace the T18 Battery Charger.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Control Module References for K114B Hybrid/EV Powertrain Control Module 2 or T18 Battery Charger replacement, programming and setup
DTC P0D4D-P0D4F: BATTERY CHARGER HYBRID/EV BATTERY OUTPUT VOLTAGE 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 P0D4D
Battery Charger Hybrid/EV Battery Output Voltage Sensor Performance
DTC P0D4E
Battery Charger Hybrid/EV Battery Output Voltage Sensor Circuit Low Voltage
DTC P0D4F
Battery Charger Hybrid/EV Battery Output Voltage Sensor Circuit High Voltage
Circuit/System Description
The hybrid/EV powertrain control module 2 monitors the DC voltage sensor inside the battery charger. The signal is pulse-width modulated and the duty cycle increases as the DC voltage increases. The duty cycle equals 10% when the DC voltage sensor reports less than 0 V. The duty cycle equals 90% when the DC voltage sensor reports more than 500 V. Therefore, during normal operation the duty cycle is between 10% and 90%.
Conditions for Running the DTC
The 12 V battery voltage is greater than 10.2 V.
The vehicle is connected to an AC supply and the battery charger is charging the vehicle.
Conditions for Setting the DTC
DTC P0D4D
The difference between the battery charger DC output voltage and hybrid/EV battery DC input voltage is greater than 30 V.
DTC P0D4E
The battery charger DC output duty cycle is between 1% and 8%. OR
The battery charger DC output duty cycle equals 100%.
DTC P0D4F
The battery charger DC output duty cycle is between 92% and 99%. OR
The battery charger DC output duty cycle equals 0%.
Actions Taken When the DTC Sets
DTC P0D4D, P0D4E and P0D4F are type B DTCs.
Disables high voltage battery charging.
Conditions for Clearing the DTC
DTC P0D4D, P0D4E and P0D4F are type B DTCs.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 DTC P0D4E or P0D4F is not set.
If any of the DTCs are set
Refer to Circuit/System Testing.
If none of the DTCs are set
2. Connect the vehicle to an AC supply to begin charging. Vehicle in Service Mode.
3. Verify that DTC P0D26 is not set.
If the DTC is set
Refer to DTC P0D26.
If the DTC is not set
4. Verify that DTC P0D4D is not set.
If the DTC is set
Refer to Circuit/System Testing.
If the DTC is not set
5. All OK.
Circuit/System Testing
NOTE: You must perform Circuit/System Verification first.
1. Vehicle OFF, disconnect the X1 harness connector at the T18 Battery Charger. Vehicle in Service Mode.
2. Verify the scan tool High Voltage Battery Charger Output Duty Cycle parameter is less than 10%.
If 10% or greater
1. Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
2. Test for infinite resistance between the DC voltage sensor circuit terminal 3 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 less than 10%
3. Install a 3 A fused jumper wire between the DC voltage sensor circuit terminal 3 and the ground circuit terminal 2.
4. Verify the scan tool Battery Charger DC Output Status Duty Cycle 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. Vehicle in Service Mode.
2. Test for less than 1 V between the DC voltage sensor circuit terminal 3 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 DC voltage sensor 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%
5. Replace the T18 Battery Charger.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Control Module References for K114B Hybrid/EV Powertrain Control Module 2 or T18 Battery Charger replacement, programming and setup.
DTC P0D58 OR P0D59: PROXIMITY DETECTION CIRCUIT LOW/HIGH VOLTAGE
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 P0D58
Proximity Detection Circuit Low Voltage
DTC P0D59
Proximity Detection Circuit High Voltage
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
AC Voltage Line 1 |
P1EE6 |
P1EE6 |
- |
- |
|
AC Voltage Line 2 |
P1EE6 |
P1EE6 |
- |
- |
|
AC Voltage Ground |
1 |
P0D59 |
1 |
- |
|
Control Pilot Signal |
1 |
1 |
1 |
- |
|
Proximity Signal |
P0D58 |
P0D59 |
P0D59 |
- |
|
1. Plug In Charging Indicator Malfunction |
||||
Circuit/System Description
The proximity detection circuit prevents movement of the vehicle while the drive motor battery charger cable is connected. This diagnostic runs with the drive motor battery charger cable disconnected to verify the vehicle side circuit integrity.
Conditions for Running the DTC
The 12 V battery voltage is greater than 10.2 V.
The vehicle speed is greater than 20 km/h (15 mph) for more than 5 seconds.
No vehicle speed DTCs are set.
Conditions for Setting the DTC
DTC P0D58
The hybrid/EV powertrain control module 2 measures a voltage less than 4.2 V for 5 seconds.
DTC P0D59
The hybrid/EV powertrain control module 2 measures a voltage greater than 4.8 V for 5 seconds.
Actions Taken When the DTC Sets
DTC P0D58 and P0D59 are type A DTCs.
Disable the high voltage battery charging.
Conditions for Clearing the DTC
DTC P0D58 and P0D59 are type A DTCs.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 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 T18 Battery Charger. Refer to High Voltage Disabling . Reconnect the X2 harness connector at the T18 Battery Charger.
Fig. 5: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
NOTE: The following tests are performed at the X98 Hybrid/EV Battery Charger Receptacle and not at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
2. Test for less than 10 Ω between the low reference circuit terminal 1 and ground.
If 10 Ω or greater
1. Disconnect the X2 harness connector at the T18 Battery Charger.
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 T18 Battery Charger.
If less than 10 Ω
3. Connect the 12 V battery. Vehicle in Service Mode.
Fig. 6: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
4. Test for 4.2 - 4.8 V between the signal circuit terminal 5 and ground.
If less than 4.2 V
1. Vehicle OFF, disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle. Vehicle in Service Mode.
NOTE: The following tests are performed at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
2. Test for 4.2 - 4.8 V between the signal circuit terminal 5 and ground.
If less than 4.2 V
3. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
4. Test for infinite resistance between the signal circuit terminal 5 and ground.
If less than infinite resistance, repair the short to ground in the circuit.
If infinite resistance
5. 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 greater than 4.8 V
1. Vehicle OFF, disconnect the X2 harness connector at the T18 Battery Charger. Disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle. Vehicle in Service Mode.
NOTE: The following tests are performed at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
2. Test for 4.2 - 4.8 V between the signal circuit terminal 5 and ground.
If greater than 4.8 V
3. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
4. Test for less than 1 V between the signal circuit terminal 5 and ground.
If 1 V or greater, repair the short to voltage in the circuit.
If less than 1 V
5. Test for 2.565 - 2.835K Ω between the signal circuit terminal 5 and the low reference circuit terminal 1.
If not within the specified range, replace the X98 Hybrid/EV Battery Charger Receptacle.
If within the specified range, replace the K114B Hybrid/EV Powertrain Control Module 2.
If within 4.2 - 4.8 V
5. Replace the K114B Hybrid/EV Powertrain Control Module 2.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Drive Motor Battery Charger Receptacle Replacement
Control Module References
for battery charger or hybrid/EV powertrain control module 2 replacement, programming and setup.
DTC P0D5A: PROXIMITY DETECTION CIRCUIT ERRATIC
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 P0D5A
Proximity Detection Circuit Erratic
Circuit/System Description
This diagnostic runs with the drive motor battery charger cable connected. The hybrid/EV powertrain control module 2 uses a 5 V regulated signal through a 2700 Ω resistor to a low reference circuit in the battery charger to detect if the drive motor battery charger cable is attached.
Conditions for Running the DTC
The drive motor battery charger cable is connected.
Conditions for Setting the DTC
The hybrid/EV powertrain control module 2 determines the proximity signal voltage is erratic for 40 seconds.
Actions Taken When the DTC Sets DTC P0D5A is a type C DTC. Conditions for Clearing the DTC DTC P0D5A is a type C DTC. Diagnostic Aids
The proximity status circuit is susceptible to moisture intrusion. If signs of moisture intrusion are observed in the hybrid/EV battery charger receptacle harness connector, the hybrid/EV battery charger receptacle should be replaced. If moisture is detected on one connector, always be sure to inspect the mating connector as well.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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. Connect the drive motor battery charger cable.
2. Verify DTC P0D5A is not set.
If the DTC is set
Replace the X98 Hybrid/EV Battery Charger Receptacle.
If the DTC is not set
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Drive Motor Battery Charger Receptacle Replacement
DTC P0D5C: BATTERY CHARGER HYBRID/EV BATTERY OUTPUT POWER PERFORMANCE
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 P0D5C
Battery Charger Hybrid/EV Battery Output Power Performance
Circuit/System Description
The hybrid/EV powertrain control module 2 monitors the hybrid/EV battery pack voltage and current sensors to determine battery charger output power efficiency.
Conditions for Running the DTC
The vehicle 12 V battery system voltage needs to be above 10 V.
There cannot be any high voltage or current sensor faults present.
Drive motor battery charger cable must be connected and vehicle receiving power.
Conditions for Setting the DTC
Battery charger output power efficiency is less than 67% of nominal value for 10 seconds.
Hybrid/EV electronics coolant temperature is between -12°C (10°F) and 65°C (149°F).
Actions Taken When the DTC Sets
DTC P0D5C is a type B DTC.
Disables the high voltage battery charging.
Conditions for Clearing the DTC DTC P0D5C is a type B DTC. Reference Information Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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. Connect the drive motor battery charger cable.
2. Verify DTC P0D5C is not set.
If the DTC is set
Replace the T18 Battery Charger.
If the DTC is not set
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Control Module References for T18 Battery Charger, often referred to as the Drive Motor Battery Charger, replacement, programming, and setup
DTC P0D5E: BATTERY CHARGER SYSTEM HIGH VOLTAGE PRESENT
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 P0D5E
Battery Charger System High Voltage Present
Circuit/System Description
The hybrid/EV battery contains 4 high voltage contactors and 1 transistor. The high voltage contactors allow the high voltage DC batteries to be connected to the vehicle or contain the high voltage DC within the hybrid/EV battery assembly. The 4 high voltage contactors are a main positive high voltage contactor, main negative high voltage contactor, charge positive high voltage contactor, and precharge high voltage contactor. The 1 transistor is the heater transistor. These contactors/transistors close and open in sequence and are controlled by the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 supplies voltage to the control circuit for the high voltage contactors/transistors. Ground is provided through the case ground.
Conditions for Running the DTC
All contactors are commanded open.
Runs once per charger contacts discharge event.
None of the following DTCs are set: P0D4D, P0D4E or P0D4F.
Conditions for Setting the DTC
High voltage bus does not discharge to below 60 V within 4 seconds of the charger contactors being commanded open.
Actions Taken When the DTC Sets
DTC P0D5E is a type A DTC.
The hybrid/EV powertrain control module 2 opens the high voltage contactors.
Conditions for Clearing the DTC
DTC P0D5E is a type A DTC.
The
Clear Secured High Voltage DTCs
reset function must be performed with a scan tool before clear codes.
Reference Information
Schematic Reference
Hybrid/EV Energy Storage Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
INLINE HARNESS 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
NOTE: The following setup steps must be performed exactly in order to exercise the contactors.
1. Ignition OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down.
2. OPEN the driver door using outside door handle. Leave driver door OPEN.
NOTE: The brake pedal must remain depressed throughout the remainder of the contactor steps.
3. PRESS and HOLD the brake pedal.
NOTE: DO NOT press the power button and enter Vehicle in Service Mode.
4. Command the Hybrid/EV Battery Contactors ALL OPEN with a scan tool.
5. Disconnect the S15 Manual Service Disconnect.
NOTE: DO NOT use the Release Control button to turn OFF any of the contactors.
Once the Release Control button is pushed the Circuit/System Verification will need to be restarted from the beginning.
6. Command the Battery Charging System Positive Contactor CLOSED and ALL OPEN with a scan tool while listening for the contactor to close and open. The KR116B Battery Charging System Positive Contactor should be heard closing and opening.
If the Battery Charging System Positive Contactor does not open and close
Refer to Circuit/System Testing.
If the Battery Charging System Positive Contactor does open and close
7. Replace the T18 Battery Charger.
Circuit/System Testing
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure includes the following steps:
Identify how to disable high voltage.
Identify how to test for the presence of high voltage.
Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
Visually and functionally inspect the gloves before use.
Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures may result in serious injury or death.
1. Vehicle OFF, disconnect the X358 harness connector at the A4 Hybrid/EV Battery Pack.
2. Test for less than 10 Ω between the ground circuit terminal 5 and ground.
If 10 Ω or greater
1. Vehicle OFF.
2. Test for less than 2 Ω in the ground circuit end to end.
If 2 Ω or greater, repair the open/high resistance in the circuit.
If less than 2 Ω, repair the open/high resistance in the ground connection.
If less than 10 Ω
3. Verify that a test lamp illuminates between the A4 Hybrid/EV Battery Pack harness B+ circuit terminal 1 X358 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 A28 Hybrid/EV Battery Contactor Assembly and K16 Battery Energy Control Module ensuring you reconnect the connectors in the sequence provided in Repair Instructions. Refer to
Battery Energy Control Module Replacement
.
If the test lamp illuminates
4. Vehicle OFF, disconnect the X357 harness connector at the A4 Hybrid/EV Battery Pack. Vehicle in Service Mode.
5. Verify that a test lamp does not illuminate between the A4 Hybrid/EV Battery Pack harness control circuit terminal 7 X357 and ground.
If the test lamp illuminates
1. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid 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, replace the K114B Hybrid Powertrain Control Module 2.
If the test lamp does not illuminate
6. Vehicle OFF, disconnect the X1 harness connector at the K114B Hybrid Powertrain Control Module 2.
7. Test for infinite resistance between the A4 Hybrid/EV Battery Pack harness control circuit terminal 7 X357 and ground.
If less than infinite resistance
Repair the short to ground on the circuit.
If infinite resistance
8. 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
9. Replace the K114B Hybrid Powertrain Control Module 2.
10. Verify that DTC P0D5E does not set while operating the vehicle within the Conditions for Running the DTC.
If DTC P0D5E is set
Replace the A28 Hybrid/EV Battery Contactor Assembly.
If DTC P0D5E is not set
11. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
High Voltage Battery Disconnect Relay Replacement
for A28 Hybrid/EV Battery Contactor Assembly.
Control Module References
for battery charger, battery energy control module or hybrid/EV powertrain control module 2 replacement, programming and setup.
DTC P0E61 OR P0E65: BATTERY CHARGER ENABLE CIRCUIT
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 P0E61
Battery Charger Enable Circuit
DTC P0E65
Battery Charger Control Circuit
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
Battery Charger Enable |
P0E61 |
P0E61 |
P0E61 |
- |
|
Battery Charger Control |
P0E65 |
P0E65 |
P0E65 |
- |
Circuit/System Description
The battery charger is controlled with a charger enable signal and a pulse width modulated (PWM) charger control circuit from the hybrid/EV powertrain control module 2. The charger enable signal is set to 12 V when the hybrid/EV powertrain control module 2 is awake. This allows the battery charger to operate while driving to allow DC voltage sensor operation.
Conditions for Running the DTC
DTC P0E61
The 12 V battery voltage is greater than 10.2 V.
DTC P0E65
The 12 V battery voltage is greater than 10.2 V.
Vehicle in Service Mode or the drive motor battery charger cable is connected.
Conditions for Setting the DTC
DTC P0E61
The hybrid/EV powertrain control module 2 detects an open, short to ground, or short to voltage on battery charger enable circuit for 1 second.
DTC P0E65
The hybrid/EV powertrain control module 2 detects an open, short to ground, or short to voltage on battery charger control circuit for 1 second.
Actions Taken When the DTC Sets
DTC P0E61 and P0E65 are type B DTCs.
Disables high voltage battery charging.
Conditions for Clearing the DTC
DTC P0E61 and P0E65 are type B DTCs.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 Testing
1. Vehicle OFF. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2. Disconnect the X1 harness connector at the T18 Battery Charger.
2. Test for infinite resistance between the terminals listed below at the T18 Battery Charger X1 harness connector:
Battery charger enable terminal 11 and B+ terminal 9
Battery charger enable terminal 11 and ground terminal 2
Battery charger control terminal 4 and B+ terminal 9
Battery charger control terminal 4 and ground terminal 2
If less than infinite resistance
Repair the short between the circuits.
If infinite resistance
3. Test for less than 2 Ω between the terminals listed below end to end:
T18 Battery Charger terminal 11 X1 and K114B Hybrid/EV Powertrain Control Module 2 terminal 44 X2
T18 Battery Charger terminal 4 X1 and K114B Hybrid/EV Powertrain Control Module 2 terminal 53 X2
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.
5. Verify P0E61 or P0E65 is not set.
If any of the DTCs are set
Replace the T18 Battery Charger.
If none of the DTCs are set
6. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Control Module References for battery charger or hybrid/EV powertrain control module 2 replacement, programming and setup.
DTC P1EE6: BATTERY CHARGER AC VOLTAGE NOT PRESENT
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 P1EE6
Battery Charger AC Voltage Not Present
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
AC Voltage Line 1 |
P1EE6 |
P1EE6 |
- |
- |
|
AC Voltage Line 2 |
P1EE6 |
P1EE6 |
- |
- |
|
AC Voltage Ground |
- |
P1EE6 |
1 |
- |
|
1. Plug In Charging Malfunction |
||||
Circuit/System Description
The hybrid battery charger receptacle is connected to the battery charger through two 110/220 V AC circuits and one ground circuit. When the battery charger has been enabled by the hybrid/EV powertrain control module 2, the battery charger will provide an AC voltage measurement to the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 allows charging to occur if proper AC voltage is present.
Conditions for Running the DTC
The 12 V battery voltage is greater than 10.2 V.
The drive motor battery charger cable is connected.
DTCs P0D3E, P0D3F, P0D40, or P0D5C is not set.
Conditions for Setting the DTC
The battery charger AC input voltage is below 5 V.
Actions Taken When the DTC Sets
DTC P1EE6 is a type C DTC.
Disables the vehicle high voltage battery charging.
Conditions for Clearing the DTC DTC P1EE6 is a type C DTC. Diagnostic Aids
The hybrid/EV battery charger receptacle contains internal fuses on Voltage AC Line 1 and Voltage AC Neutral Line 2 circuits. A battery charger internal failure may cause these fuses to blow. If an open circuit is found in the hybrid/EV battery charger receptacle, the battery charger may also need to be replaced.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 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. Clear DTC, connect a known good drive motor battery charger cable to vehicle and household supply voltage.
2. Verify DTC P1EE6 is set.
If DTC P1EE6 is not set
Replace customer's drive motor battery charger cable.
If DTC P1EE6 is set
3. Vehicle OFF, disable the high voltage at the T18 Battery Charger. Refer to High Voltage Disabling
4. Disconnect the X2 harness connector at the T18 Battery Charger.
5. Test into the harness for infinite resistance between the 110/220 V AC circuit terminals listed below and ground:
T18 Battery Charger terminal 1 X2
T18 Battery Charger terminal 4 X2
If less than infinite resistance
1. Disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
2. Test into the harness for infinite resistance between the appropriate 110/220 V AC circuit terminal and ground.
If less than infinite resistance, repair the short to ground in the circuit.
If infinite resistance, replace the X98 Hybrid/EV Battery Charger Receptacle.
If infinite resistance
6. Test into the harness for infinite resistance between all the 110/220 V AC circuit terminals listed below:
T18 Battery Charger terminal 1 X2
T18 Battery Charger terminal 3 X2
T18 Battery Charger terminal 4 X2
If less than infinite resistance
1. Disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
2. Test into the harness for infinite resistance between the three 110/220 V AC circuit terminals.
If less than infinite resistance, repair the short between the circuits.
If infinite resistance, replace the X98 Hybrid/EV Battery Charger Receptacle.
If infinite resistance
Fig. 7: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
7. Test for less than 10 Ω between the 110/220 V AC circuit terminals listed below:
T18 Battery Charger terminal 1 X2 and X98 Hybrid/EV Battery Charger Receptacle 3
T18 Battery Charger terminal 3 X2 and X98 Hybrid/EV Battery Charger Receptacle 1
T18 Battery Charger terminal 4 X2 and X98 Hybrid/EV Battery Charger Receptacle 4
If 10 Ω or greater
1. Disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
2. Test for less than 2 Ω in the 110/220 V AC circuit end to end.
If 2 Ω or greater, repair the open/high resistance in the circuit.
If less than 2 Ω
3. Replace the X98 Hybrid/EV Battery Charger Receptacle.
4. Verify the DTC does not set.
If the DTC sets, replace the T18 Battery Charger and X98 Hybrid/EV Battery Charger Receptacle.
If the DTC does not set
5. All OK.
If less than 10 Ω
8. Replace the T18 Battery Charger.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Drive Motor Battery Charger Receptacle Replacement
Control Module References
for battery charger replacement, programming and setup.
PLUG-IN CHARGING 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
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
Control Pilot Signal |
P0CF4, P0CF5, P0CF6, P0CF9, P0D01, 1 |
P0CF4, P0CF5, P0CF6, 1 |
P0CF4, P0CF5, P0CF6, P0CF9, 1 |
P0CF4, P0CF5, P0CF6, 1 |
|
Proximity Signal |
P0D58, 1 |
P0D59, 1 |
P0D59, 1 |
- |
|
110/120 A/C Line 1 |
1 |
P0D3F, P1EE6 |
1 |
- |
|
110/120 A/C Line 2 |
1 |
P1EE6 |
1 |
- |
|
110/120 A/C Ground |
- |
P0D59, 1 |
1 |
- |
|
1. Plug In Charging Malfunction |
||||
Circuit/System Description
The drive motor battery charger cable allows the vehicle to be charged using a common household power outlet. The drive motor battery charger cable contains LEDs that indicate the status of the drive motor battery charger cable. The drive motor battery charger cable automatically prohibits voltage transfer to the hybrid/EV battery charger receptacle and the Fault Indicator is illuminated red if it senses internal faults or inadequate household voltage. If the drive motor battery charger cable senses no faults the AC Present Indicator is illuminated solid green.
When the hybrid/EV powertrain control module 2 senses the drive motor battery charger cable is connected to the vehicle charge receptacle, it will communicate with the off-vehicle charge equipment to ensure compatibility and proper function. The hybrid/EV powertrain control module 2 will then indicate the status of charging events (including user-programmable delays) to the user via instrument panel mounted plug-in charging status indicator LEDs and audio tones.
Diagnostic Aids
If the drive motor battery charger cable Fault Indicator is illuminated solid red or flashing red before plugging into the vehicle, the charger cable will need to be diagnosed first.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 ON, verify no DTCs are set.
If DTCs are set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle .
If no DTCs are set
2. With the charge cord NOT connected to the vehicle battery charger receptacle, verify the vehicle plug-in charging status indicators are OFF.
If the vehicle plug-in charging status indicators are not OFF with the charge cord disconnected from the vehicle
Refer to Plug-In Charging Indicator Malfunction.
If the vehicle plug-in charging status indicators are OFF
3. Vehicle OFF and connect the charge cord to the vehicle battery charger receptacle.
4. Verify the vehicle charge status indicators are operating properly.
If the vehicle charge status indicator is solid yellow
Refer to Circuit/System Testing.
If the vehicle charge status indicator is not illuminated
1. Vehicle ON.
NOTE: Vehicle must be ON and not in Service Mode for message operation.
2. Verify the Charge Cord Connected message is displayed in the instrument panel/message center.
If the Charge Cord Connected message is displayed, refer to Plug-In Charging Indicator
Malfunction.
If the Charge Cord Connected message is NOT displayed, refer to Circuit/System Testing.
If the vehicle charge status indicator is operating properly
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. Connect the customer's drive motor battery charger cable to household power outlet, but not the vehicle battery charger receptacle.
2. After 25 seconds, verify drive motor battery charger cable AC Present Indicator illuminates solid green.
If drive motor battery charger cable AC Present Indicator does not illuminate solid green
1. Connect a known good drive motor battery charger cable to the same household power outlet.
If known good drive motor battery charger cable AC Present Indicator illuminates solid green, replace the customer's drive motor battery charger cable.
If known good drive motor battery charger cable AC Present Indicator does not illuminate solid green, have the service provider inspect the household power outlet for insufficient voltage, high frequency noise, or open/high resistance.
If drive motor battery charger cable AC Present Indicator does illuminate solid green
Fig. 8: Drive Motor Battery Charger Cable Terminals Courtesy of GENERAL MOTORS COMPANY
3. Test for greater than 1 V between the low voltage circuits listed below on drive motor battery charger cable.
Proximity status signal circuit terminal 5
Control pilot signal circuit terminal 2
If less than 1 V
Replace drive motor battery charger cable.
If greater than 1 V
Fig. 9: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
NOTE: The following tests are performed at the X98 Hybrid/EV Battery Charger Receptacle and not at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
NOTE: When measuring resistance observe proper meter polarity by connecting the common/ground meter probe to ground/vehicle chassis.
NOTE: You must measure with a high-impedance Digital Multimeter (DMM) such as the EL-39200 or equivalent.
4. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Test for 100k Ω - 4M Ω between the control pilot signal terminal 2 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
If 4M Ω or greater
1. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2
2. Test for 2 Ω in the control pilot 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 less than 100k Ω
1. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2
2. Test for infinite resistance between the control pilot signal circuit and ground.
If less than infinite resistance, repair the short to ground in the circuit.
If infinite resistance, replace the K114B Hybrid/EV Powertrain Control Module 2.
If within the specified range
Fig. 10: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
5. Test for less than 1 V between the control pilot signal terminal 2 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
If greater than 1 V
1. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2
2. Test for less than 1 V between the control pilot signal circuit and ground.
If greater than 1 V, repair the short to voltage in the circuit.
If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
If less than 1 V
6. Vehicle in Service Mode.
Fig. 11: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
7. Test for 4.2 - 4.8 V between the proximity status signal terminal 5 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
If less than 4.2 V
1. Vehicle OFF, test for infinite resistance between the proximity status signal circuit and ground.
If less than infinite resistance, repair the short to ground on the circuit.
If infinite resistance
2. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2.
3. Test for less than 2 Ω in the proximity status 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 greater than 4.8 V
1. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2
2. Test for 0 V between the proximity status signal circuit and ground.
If greater than 0 V, repair the short to voltage in the circuit.
If 0 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
If within the specified range
8. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Disconnect the X2 harness connector from T18 Battery Charger and the X2 harness connector from the K114B Hybrid/EV Powertrain Control Module 2.
Fig. 12: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
9. Test for infinite resistance between the terminals listed below at the X98 Hybrid/EV Battery Charger Receptacle:
110/220 V A/C Line 1 terminal 3 and 110/220 V A/C Neutral Line 2 terminal 4
110/220 V A/C Line 1 terminal 3 and 110/220 V A/C Ground terminal 1
110/220 V A/C Line 1 terminal 3 and Control pilot signal circuit terminal 2
110/220 V A/C Line 1 terminal 3 and Proximity status signal circuit terminal 5
110/220 V A/C Neutral Line 2 terminal 4 and 110/220 V A/C Ground terminal 1
110/220 V A/C Neutral Line 2 terminal 4 and Control pilot signal circuit terminal 2
110/220 V A/C Neutral Line 2 terminal 4 and Proximity status signal circuit terminal 5
110/220 V A/C Ground terminal 1 and Control pilot signal circuit terminal 2
Control pilot signal circuit terminal 2 and Proximity status signal circuit terminal 5
If less than infinite resistance
Repair the short between the circuits.
If infinite resistance
10. Disconnect the harness connector from the X98 Hybrid/EV Battery Charger Receptacle.
Fig. 13: Hybrid/Ev Battery Charger Receptacle And Terminals Courtesy of GENERAL MOTORS COMPANY
11. Test for 2.56 - 2.84k Ω between the 110/220 V A/C Ground terminal 1 and Proximity status signal circuit terminal 5 at the X98 Hybrid/EV Battery Charger Receptacle.
If not within the specified range
Replace the X98 Hybrid/EV Battery Charger Receptacle.
If within the specified range
NOTE: This test is performed on the vehicle side of the harness connector.
12. Test for infinite resistance between the 110/220 V A/C Ground terminal 1 and Proximity status signal circuit terminal 5 of the harness connector.
If less than infinite resistance
Repair the short between the circuits.
If infinite resistance
13. Replace and program the K114B Hybrid/EV Powertrain Control Module 2.
14. Repeat Circuit/System Verification and confirm vehicle is All OK.
If Circuit/System Verification was not All OK
Replace the T18 Battery Charger.
If Circuit/System Verification was All OK
15. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Drive Motor Battery Charger Receptacle Replacement
Control Module References
for T18 battery charger, or K114B hybrid/EV powertrain control module 2 replacement, programming and setup.
PLUG-IN CHARGING INDICATOR 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
Diagnostic Fault Information
|
Circuit |
Short to Ground |
Open/High Resistance |
Short to Voltage |
Signal Performance |
|
Charge Pilot Indicator Control |
P0D2B |
P0D2B |
P0D2B |
- |
|
Charge Status Indicator Control |
P0D2C |
P0D2C, 1 |
P0D2C |
- |
|
Charge Complete Indicator Control |
1 |
1 |
1 |
- |
|
Low Reference |
- |
P0D2C, P0D2B |
- |
- |
|
1. Plug In Charging Indicator Malfunction |
||||
Circuit/System Description
The status of charging events (including delays) is communicated to the user through a vehicle plug-in charge status indicator and audio tones. The vehicle plug-in charge status indicator, located on the top middle of the instrument panel, contains a green LED (charge status indicator) and yellow LED (charge pilot indicator) controlled by the Hybrid Powertrain Control Module 2 and a second green LED (charge complete indicator) controlled by the BCM. The indicator will have a short flash green when the vehicle is charging under automatic control. The flash rate increases from one to four as the battery charges. It will have a long flash green if the charging is delayed and will begin later. It will be illumined solid green when charging is complete. A solid lit yellow indicator means the vehicle is not able to accept a charge.
Reference Information
Schematic Reference
Plug-In Charging Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Plug-In Charging 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 U135B is not set.
If DTC U135B is set
Refer to DTC U1340-U135F .
If DTC U135B is not set
3. Verify no other hybrid/EV battery-related DTCs are set.
If any hybrid/EV battery-related DTCs are set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle
If no hybrid/EV battery-related DTCs are set
4. Vehicle OFF. Ensure the charge cord is not connected to the vehicle.
5. Verify the vehicle charge indicator is OFF.
If the vehicle charge indicator is not OFF
Refer to Circuit/System Testing.
If the vehicle charge indicator is OFF
6. Connect the charge cord.
7. Verify the vehicle charge indicator is operating properly.
If the vehicle charge indicator is solid yellow
Refer to Plug-In Charging Malfunction
If the vehicle charge indicator is OFF
1. Vehicle ON.
NOTE: Vehicle must be ON and not in Service Mode for message operation.
2. Verify the Charge Cord Connected message is displayed in the instrument panel/message center.
If the Charge Cord Connected message is displayed, refer to Circuit/System Testing.
If the Charge Cord Connected message is NOT displayed, refer to
Plug-In Charging
Malfunction
.
If the vehicle charge indicator is operating properly
8. 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, disconnect the X1 harness connector at the B305 Ambient Light/Sunload Sensor and Battery State of Charge Indicator.
2. Test for less than 10 Ω between the low reference terminal 1 and ground.
If 10 Ω or greater
Repair the open/high resistance in the circuit.
If less than 10 Ω
NOTE: If the drive motor battery charger cable is connected. The drive motor battery charger cable must be disconnected for more than 10 s before performing the next step.
3. Connect a test lamp between the yellow LED control circuit terminal 4 and ground.
4. Verify the test lamp does not illuminate.
If the test lamp illuminates
1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
2. Test for less than 1 V between the control circuit and ground.
If 1 V or greater, repair the short to voltage in the circuit.
If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
If the test lamp does not illuminate
5. Connect the drive motor battery charger cable.
6. Verify that the test lamp illuminates or flashes in the first 5 s of connecting the drive motor battery charger
cable.
If the test lamp does not illuminate
1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
2. Test for infinite resistance between the control circuit and ground
If less than infinite resistance, repair the short to ground on the circuit.
If infinite resistance
3. Test for less than 2 Ω in the control circuit end to end.
If 2 Ω or greater, repair the open/high resistance in the circuit.
If less than 2 Ω, replace the K114B Hybrid/EV Powertrain Control Module 2.
If the test lamp illuminates
7. Disconnect the drive motor battery charger cable for at least 10 s. Connect a test lamp between the green LED control circuit terminal 3 and ground.
8. Verify test lamp does not illuminate.
If the test lamp illuminates
1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
2. Test for less than 1 V between the control circuit and ground.
If 1 V or greater, repair the short to voltage in the circuit.
If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
If the test lamp does not illuminate
9. Connect the drive motor battery charger cable.
10. Verify that the test lamp illuminates or flashes within 25 s of connecting the drive motor battery charger cable.
If the test lamp does not illuminate
1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
2. Test for infinite resistance between the control circuit and ground.
If less than infinite resistance, repair the short to ground on the circuit.
If infinite resistance
3. Test for less than 2 Ω in the control circuit end to end.
If 2 Ω or greater, repair the open/high resistance in the circuit.
If less than 2 Ω, replace the K114B Hybrid/EV Powertrain Control Module 2.
If the test lamp illuminates
11. Replace the B305 Ambient Light/Sunload Sensor and Battery State of Charge Indicator.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Sun Load Temperature and Headlamp Automatic Control Ambient Light Sensor Replacement
for B305 Ambient Light/Sunload Sensor and Battery State of Charge Indicator replacement.
Control Module References
for T18 battery charger, or K114B hybrid/EV powertrain control module 2 replacement, programming and setup.
REPAIR INSTRUCTIONS
CHARGE PORT HOUSING BEZEL REPLACEMENT
Fig. 14: Charge Port Housing Bezel
Courtesy of GENERAL MOTORS COMPANY
|
Callout |
Component Name |
|
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:
|
|
|
Callout |
Component Name |
|
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
meters (50 feet) of the vehicle, either indoors or outdoors.
|
|
|
Callout |
Component Name |
|
voltage battery assembly, whether the system is energized or not. Failure to follow the procedures may result in serious injury or death.
Preliminary Procedures 1. Open the charge port door. 2. High Voltage Disabling |
|
|
1 |
Charge Port Housing Bezel Procedure 1. Insert a plastic wedge type-tool between the hinge assembly and housing bezel. 2. Gently apply pressure to the bezel outward and disengage the bezel from the charge port housing assembly. 3. Remove the charge port housing bezel. 4. High Voltage Enabling |
CHARGE PORT DOOR REPLACEMENT
Fig. 15: Charge Port Door
Courtesy of GENERAL MOTORS COMPANY
|
Callout |
Component Name |
|
Preliminary Procedures 1. Open the charge port door. 2. High Voltage Disabling |
|
|
1 |
Charge Port Door Procedure 1. Using a flat-bladed driver, lift slightly upward on the tab at the center of the hinge in order to release the door from the hinge assembly. 2. Slide the door outward, away from the hinge and remove. 3. High Voltage Enabling |
CHARGE PORT HOUSING REPLACEMENT
Fig. 16: Charge Port Housing
Courtesy of GENERAL MOTORS COMPANY
|
Callout |
Component Name |
|
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:
|
|
|
Callout |
Component Name |
|
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
meters (50 feet) of the vehicle, either indoors or outdoors.
|
|
|
Callout |
Component Name |
|
voltage battery assembly, whether the system is energized or not. Failure to follow the procedures may result in serious injury or death.
Preliminary Procedures 1. High Voltage Disabling 2. Front Wheelhouse Liner Replacement (Left Side) Front Wheelhouse Liner Replacement (Right Side) 3. Charge Port Door Replacement 4. Disconnect the electrical connector. |
|
|
1 |
Charge Port Housing
CAUTION: Refer to Exterior Trim Emblem Removal Caution .
Procedure 1. From inside the fender, release the lower tab to the charge port housing assembly. 2. Push outward on the assembly housing. 3. Using a plastic trim-type stick, gently pry outward while pulling outward on the rear edge of the housing. 4. High Voltage Enabling |
CHARGE PORT DOOR AJAR INDICATOR SWITCH REPLACEMENT
Fig. 17: Charge Port Door Ajar Indicator Switch Courtesy of GENERAL MOTORS COMPANY
|
Callout |
Component Name |
|
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:
|
|
|
Callout |
Component Name |
|
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
meters (50 feet) of the vehicle, either indoors or outdoors.
|
|
|
Callout |
Component Name |
|
voltage battery assembly, whether the system is energized or not. Failure to follow the procedures may result in serious injury or death.
Preliminary Procedures 1. High Voltage Disabling 2. Charge Port Housing Replacement |
|
|
1 |
Charge Port Door Ajar Switch Procedure 1. Release the charge port door ajar indicator switch and connector from the charge port housing cavity. 2. High Voltage Enabling |
DRIVE MOTOR BATTERY CHARGER REPLACEMENT
Fig. 18: Drive Motor Battery Charger Courtesy of GENERAL MOTORS COMPANY
|
Callout |
Component Name |
|
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:
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
|
|
|
Callout |
Component Name |
|
when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
Failure to follow the procedures may result in serious injury or death.
Preliminary Procedures 1. High Voltage Disabling 2. Drive Motor Generator Power Inverter Module Cooling System Draining and Filling 3. Disconnect all electrical connectors.
NOTE: |
|
|
Callout |
Component Name |
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Add a protective bag or enclosure to the harness side connector to prevent inadvertent liquid spills during rework. Corrosion will form if this procedure is not followed properly.
4. Generator Control Module Coolant Radiator Hose Replacement , and Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line) Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line to Traction Power Inverter Module Inlet) |
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1 |
Drive Motor Battery Charger Bolt
CAUTION: Refer to Fastener Caution .
Tighten 22 N.m (16 lb ft) |
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Drive Motor Battery Charger Fastener (Qty: 3) Tighten 22 N.m (16 lb ft) |
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Drive Motor Battery Charger Procedure 1. High Voltage Enabling 2. Battery Charger Programming and Setup |
DRIVE MOTOR BATTERY CHARGER RECEPTACLE REPLACEMENT
Fig. 19: Drive Motor Battery Charger Receptacle Courtesy of GENERAL MOTORS COMPANY
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Component Name |
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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:
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Component Name |
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Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
meters (50 feet) of the vehicle, either indoors or outdoors.
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Component Name |
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voltage battery assembly, whether the system is energized or not. Failure to follow the procedures may result in serious injury or death.
Preliminary Procedures 1. Remove the electric vehicle supply equipment (EVSE) charge cord plug handle from the charger receptacle. 2. High Voltage Disabling 3. Charge Port Housing Replacement |
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Drive Motor Battery Charger Receptacle Fastener (Qty: 4)
CAUTION: Refer to Fastener Caution .
Tighten 12 N.m (106 lb in) |
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Drive Motor Battery Charger Receptacle Retainer Procedure Using a trim type tool, release the retainer. |
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Drive Motor Battery Charger Receptacle Procedure 1. Open the hood. 2. Disconnect the electrical connector. 3. Unclip the charger receptacle harness retainer. 4. High Voltage Enabling |
DESCRIPTION AND OPERATION
PLUG-IN CHARGING SYSTEM DESCRIPTION AND OPERATION
Plug-In Charging System Components
The high voltage battery charging system consists of four main components:
1. The off-vehicle charging equipment:
Drive motor battery charger cable, often referred to as the travel cord set
Optional, permanent 230/240 V charge station
2. The hybrid/EV battery charger receptacle, often referred to as the drive motor battery charger receptacle.
3. The battery charger, often referred to as the drive motor battery charger.
4. The hybrid/EV battery pack.
A variety of mechanical, visual, and audio indicators/devices are used to communicate with the user of the charging equipment.
Drive Motor Battery Charger Cable/Charge Station
The drive motor battery charger cable provided with the vehicle features a standard household electrical plug on one end and a plug designed to interface with the vehicles hybrid/EV battery charger receptacle on the other end. The drive motor battery charger cable features a charge current interrupt device with AC power and fault indicators, and it is stored in the vehicle's cargo area. An optional charge station is available for customers who want to reduce the amount of time needed to recharge. The optional charge station, if available, is hard-wired to a 230/240 V power supply and must be permanently mounted at the customer's location. The optional charge station features the same plug on the vehicle end as the drive motor battery charger cable.
The Drive Motor Battery Charger Cable Indicators and the Vehicle Indicators
The drive motor battery charger cable has two indicators, the AC Present Indicator and the Fault Indicator, which display its status.
Solid green AC Present Indicator means AC voltage is present at the wall plug and there are no faults.
Flashing green AC Present Indicator and solid red Fault Indicator means the electrical outlet or plug is faulty or overheated.
Solid red Fault Indicator means the AC outlet does not have a proper ground and charging is not permitted for safety reasons.
Flashing red Fault Indicator means there is a vehicle fault and the charger cable ground-fault circuit interrupter (GFCI) has tripped.
Solid green AC Present Indicator and flashing red Fault Indicator means the charger cable has failed self- check.
The off-vehicle battery charging equipment is supervised and controlled by the hybrid/EV powertrain control module
2. The hybrid/EV powertrain control module 2 is the primary controller, and all diagnostic trouble codes will set in that module even though some of the diagnostics are actually run within the battery charger. Charging events can be delayed at customer request to take advantage of lower rates during non-peak hours. The status of charging events, including delays, is communicated to the user through visual indications, instrument panel mounted charge status indicator, and audio tones. The vehicle charge status indicator, located on the top middle of the instrument panel, will be short flashing green when the vehicle is charging under automatic control. The flash rate increases from one to four as the battery charges. It will be long flashing green if the charging is delayed and will begin later. It will be solid green when charging is complete. A solid yellow indicator means the vehicle is not able to accept a charge. If there is no indicator, the drive motor battery charger cable is not working properly or not connected.
Vehicle Receptacle
The vehicle receptacle, or hybrid/EV battery charger receptacle, is located behind the charging port door on the driver's side front fender. The receptacle is accessed by depressing and opening the receptacle door. The vehicle may be equipped with a secondary charge status indicator at the receptacle.
Battery Charger
The battery charger is a serviceable assembly containing several micro-processors and two separate high voltage chargers. One of the high voltage chargers is used while charging with a 120 V charge source, and both are used with a 230/240 V charge source. The battery charger is mounted beneath the vehicle cargo load floor. DEX-COOL® coolant is used to ensure that the charger does not exceed its maximum designed operating temperature. The battery charger, along with the 14 V power module and the drive motor generator power inverter module, are cooled by a power electronics cooling loop, which is separate from other cooling systems.
12 V Battery Maintenance Mode
Battery Maintenance Mode is an automatic function that prevents deep discharge of the 12 V battery in specific circumstances. It is enabled when the drive motor battery charger cable is plugged into the hybrid/EV battery charger receptacle and the hybrid/EV battery pack is not being charged. Operation differs depending on whether the power mode is Vehicle Off or Vehicle in Service Mode.
With Vehicle Off, the 12 V battery is monitored at periodic intervals up to a maximum of 30 days. With Vehicle in Service Mode, the 12 V battery is monitored at periodic intervals up to a maximum of 60 hours. If voltage is low, the 12 V battery is charged by the 14 V power module using external power for up to four hours. This function is only intended to prevent a dead 12 V battery and does not provide a full charge. This is more efficient than continuously trickle charging, thus minimizing the usage of external power.
Under normal circumstances, with a 12 V battery that is charged when the vehicle is parked, Battery Maintenance Mode will simply monitor the voltage level, and no charging will be necessary. With Vehicle Off, Battery Maintenance Mode will maintain the 12 V battery for up to 30 days. For longer periods, refer to Owner Manual for instructions.
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS
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Tool Number/Description |
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Tool Number/Description |
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EL-48900 HEV Safety Kit or equivalent Dealer Equipment |
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Tool Number/Description |
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EL-50774 Low/High Resistance Meter |
