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Home >> Chevrolet >> 2017 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Hybrid/EV System Heating And Cooling) >> Diagnostic Information and Procedures >> DTC P0A85, P0BC8-P0BCA or P0D64-P0D66: Hybrid/EV Battery Pack Cooling Fan >> Circuit/System Testing

Circuit/System Testing

WARNING: This page is about a different variant/trim than selected.
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 and all vehicle systems OFF, disconnect the harness connector at the G14 Hybrid/EV Battery Pack Cooling Fan. It may take up to 2 min for all vehicle systems to power down.
  2. Test for less than 10 Ω between the ground circuit terminal 1 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. Vehicle ON.
  4. Verify a test lamp illuminates between the B+ circuit terminal 5 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 G14 Hybrid/EV Battery Pack Cooling Fan.
    • If the test lamp illuminates 
  5. Connect a test lamp between the control circuit terminal 4 and ground.
  6. Verify the test lamp turns ON when commanding the Hybrid/EV Battery Pack Cooling Fan with a scan tool and OFF when releasing the control.
    • If the test lamp is always OFF 
    1. Vehicle OFF, disconnect the X2 harness connector at the 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 Hybrid/EV Powertrain Control Module 2.
    • If the test lamp is always ON 
    1. Vehicle OFF, disconnect the X2 harness connector at the Hybrid/EV Powertrain Control Module 2.
    2. Test for less than 1V between the control circuit and ground.
      • If 1V or greater, test the control circuit for a short to voltage.
      • If less than 1V, replace the Hybrid/EV Powertrain Control Module 2.
    • If the test lamp turns ON and OFF 
  7. Test for 10V or greater between the signal circuit terminal 2 and ground.
    • If less than 10V 
    1. Vehicle OFF, disconnect the X1 harness connector at the Hybrid/EV Powertrain Control Module 2.
    2. Test for infinite resistance between the signal circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the signal circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the Hybrid/EV Powertrain Control Module 2.
    • If 10V or greater 
  8. Connect a 3 A fused jumper wire to the signal circuit terminal 2.
  9. Verify the scan tool Hybrid/EV Powertrain Control Module 2 parameter Hybrid//EV Battery Pack Cooling Fan Speed is greater than 0 RPM while rapidly tapping the jumper wire to ground.
    • If 0 RPM 
    1. Vehicle OFF, disconnect the X1 harness connector at the Hybrid/EV Powertrain Control Module 2.
    2. Test for less than 1V between the signal circuit and ground.
      • If 1V or greater, repair the signal circuit for a short to voltage.
      • If less than 1V, replace the Hybrid/EV Powertrain Control Module 2.
    • If greater than 0 RPM 
  10. Connect a test lamp between the control circuit terminal 3 and B+.
  11. Verify the test lamp becomes progressively dimmer as the fan speed is increased and progressively brighter as the fan speed is decreased when commanding the Hybrid/EV Battery Pack Cooling Fan with a scan tool.
    • If the test lamp does not illuminate 
    1. Vehicle OFF, disconnect the X2 harness connector at the Hybrid/EV Powertrain Control Module 2.
    2. Test for less than 1V between the control circuit and ground.
      • If 1V or greater, test the control circuit for a short to voltage.
      • If less than 1V
    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 Hybrid/EV Powertrain Control Module 2.
    • If the test lamp illuminates, but does not change in brightness 
    1. Vehicle OFF, disconnect the X2 harness connector at the Hybrid/EV Powertrain Control Module 2.
    2. Test for infinite resistance between the control circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance, replace the Hybrid/EV Powertrain Control Module 2.
    • If the test lamp brightness changes as commanded 
  12. Replace the G14 Hybrid/EV Battery Pack Cooling Fan.
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