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Home >> Chevrolet >> 2020 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different car >> Section 95 (Hybrid/EV Energy Storage System) >> Repair Instructions >> Hybrid/EV Battery Low State of Charge Recovery >> Circuit/System Testing

Circuit/System Testing

WARNING: This page is about a different car, the 2019 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:

Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps:

  • Identify how to disable high voltage.
  • Identify how to test for the presence of high voltage.
  • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

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

  • Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
  • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
    • Visually and functionally inspect the gloves before use.
    • Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

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

WARNING:

High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures may result in serious injury or death.

WARNING:

This vehicle is equipped with a high voltage battery that is completely isolated from the chassis ground. Never utilize AC powered test equipment to probe the high voltage system. Serious injury, death and component damage could occur if the high voltage system is grounded through the electric utility.

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

WARNING:

Damage to a Lithium Ion hybrid/EV battery pack could result in fire, loss of electrical isolation or exposure to high voltage. Until the high voltage system inspection has been completed, store the vehicle with hybrid/EV battery pack installed outside in a secure area away from buildings and other vehicles and protected from rain, snow and other moisture. Remove the hybrid/EV battery pack high voltage manual disconnect lever and store it in a secure place outside the vehicle. Cover the exposed high voltage opening with UL® listed, or equivalent, insulation tape rated at a minimum of 600 V.

Failure to follow these precautions could result in personal injury, death and property damage.

Inspection Procedure

    NOTE:

    Before recovering a battery, make sure all of the external EL-50332  components and cables are in good condition and working order.

  1. Disable the high voltage system for servicing at the K1 14V Power Module. Refer to High Voltage Disabling .
  2. Connect the EL-50332-265  14V Accessory Power Module Harness Interface Cable to the EL-50332-105  Universal Fuse Box.
  3. Connect the EL-50332-120  High Voltage Interface Cable to the EL-50332-105  Universal Fuse Box.
  4. Connect the EL-50332-120  High Voltage Interface Cable to the EL - 50332  Hybrid/EV Battery Service Tool.
  5. Connect the EL-50332-210  Cable, X3 HPCM2 Low Voltage Adapter to the EL-50332-110  Vehicle Interface Module.
  6. Connect the EL-50332-125  Vehicle Interface Module Low Voltage 24-Pin Cable to the EL-50332-110  Vehicle Interface Module.
  7. Connect the EL-50332-125  Vehicle Interface Module Low Voltage 24-Pin Cable to the EL-50332  Hybrid/EV Battery Service Tool.
    8. NOTE:

    Refer to the Special Tools for the correct regional power cord.

  8. Connect the appropriate regional power cord to the EL-50332  Hybrid/EV Battery Service Tool.
  9. Connect the appropriate regional power cord into a known good power outlet.
  10. Turn ON the EL - 50332  Hybrid/EV Battery Service Tool using the power switch.
  11. At the MAIN MENU, select RECOVERY, press the SELECT soft key.
  12. At the MAKE menu, select CHEVROLET, press the NEXT soft key.
  13. At the MODEL menu, select MALIBU, press the NEXT soft key.
  14. GM4725469Courtesy of GENERAL MOTORS COMPANY

    Connect the EL-50332-265  (1) to the 14V accessory DC power control module high voltage connector removed during the high voltage disabling procedure.

  15. Press the NEXT soft key.
  16. GM4725477Courtesy of GENERAL MOTORS COMPANY

    Connect the EL-50332-210  Cable (1), X3 HPCM2 Low Voltage Adapter to the A4 Hybrid/EV Battery Pack.

  17. Press the NEXT soft key.
  18. Install the S15 Manual Service Disconnect.
    19. NOTE:

    Depending on the charge condition of the battery pack, recovery time may vary.

  19. Press the NEXT soft key.
    20. NOTE:

    The EL-50332  will now recover the high voltage battery by charging as appropriate. Target voltage is 280 V. Recovery will be in a constant current mode (max 5 amp). A warranty code and pack voltage current data will be displayed at the conclusion of the balancing event.

  20. An audible tone will sound at the end of balancing or in the event of a fault condition.
    • A fault condition was detected 

      Refer to the EL - 50332  Hybrid/EV Battery Service Tool Instruction Manual.

    • Go to next step: Recovery completed successfully 
  21. At the Completed menu, press the NEXT soft key. Record warranty code. Press the EXIT soft key.
  22. Remove the S15 Manual Service Disconnect.
  23. Disconnect the EL - 50332  Hybrid/EV Battery Service Tool from the Hybrid/EV Battery Pack.
  24. Connect the 14V accessory DC power control module high voltage connector to the 14V accessory DC power control module.
  25. Enable the high voltage system. Refer to High Voltage Enabling .
  26. All OK.
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