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Diagnostic Test

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  1. CHECK FOR A SERVICE DISCONNECT INTERNAL FUSE OPEN CIRCUIT 
    NOTE:

    If the high voltage Service Disconnect is removed from the vehicle while the ignition is on, a DTC will set. Make sure if any work was performed on the vehicle to reinstall the Service Disconnect and clear the DTC.

    1. Turn the ignition off.
    2. Remove the high voltage Service Disconnect in accordance with the Service Information. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .
    3. Measure the resistance between the high voltage contacts in the service disconnect.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go To  2

      No 

      • Go To  3
  2. CHECK THE HIGH VOLTAGE BATTERY PACK FOR LOSS OF ISOLATION 
    NOTE:

    This procedure determines if the loss of isolation is located within the battery pack or outside of the battery pack in another module or the high voltage wiring.

    With the scan tool, navigate to Battery Pack, Miscellaneous Functions, and perform the HIGH VOLTAGE ISOLATION CHECK.

    Does the HIGH VOLTAGE ISOLATION CHECK indicate a loss of isolation within the Battery Pack?

    Yes 

    No 

    • Go To  3
  3. CHECK THE POSITIVE (+) AND NEGATIVE (-) HIGH VOLTAGE BUS FOR LOSS OF ISOLATION 
      Fig 1: Fluke 1587M Multi-Meter
      GC0158562Courtesy of CHRYSLER GROUP, LLC
    2. Using a Fluke 1587 M? multi-meter or equivalent, set the selector to the ? scale.
      Fig 2: Power Distribution Center (PDC) Positive Test Port
      GC0157662Courtesy of CHRYSLER GROUP, LLC
    3. Place the red positive lead (1) of the multi-meter into the red (+) test port of the high voltage Power Distribution Center (PDC).
      Fig 3: Multi-Meter Negative Lead Clipped To 12-Volt Battery Negative Terminal
      GC0157677Courtesy of CHRYSLER GROUP, LLC
    4. Clip the black negative lead (2) from the multi-meter onto the 12-volt battery negative terminal.
      NOTE:

      Measured resistance greater than 500k (500, 000) Ohms indicates no loss of isolation. Measured resistance less than 500k (500, 000) Ohms indicates a loss of isolation to chassis ground.

    5. Press and hold the isolation test button (3) and record the Positive (+) high voltage Bus resistance measurement observed on the multi-meter display.
      Fig 4: Positive Lead In Negative Test Port Of The PDC
      GC0157737Courtesy of CHRYSLER GROUP, LLC
    6. Place the red positive lead (1) of the multi-meter into the black (-) test port of the high voltage Power Distribution Center (PDC).
      Fig 5: Negative Lead On 12-Volt Battery Negative Terminal
      GC0157706Courtesy of CHRYSLER GROUP, LLC
    7. Clip the black negative lead (2) from the multi-meter onto the 12-volt battery negative terminal.
      NOTE:

      Measured resistance greater than 500k (500, 000) Ohms indicates no loss of isolation. Measured resistance less than 500k (500, 000) Ohms indicates a loss of isolation to chassis ground.

    8. Press and hold the isolation test button (3) and record the Negative (-) high voltage Bus resistance measurement observed on the multi-meter display.

      Is the resistance above 500k Ohms for both the Positive (+) and Negative (-) high voltage Bus?

      Yes 

      • Test Complete.

      No 

      • Go To  4
  4. CHECK THE HIGH VOLTAGE SOURCE FOR A LOSS OF ISOLATION 
    1. Disconnect the C1 high voltage harness connector at the High Voltage Battery Pack (HVBP).
    2. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  5

      No 

      • Go To  12
  5. CHECK THE AIR ELECTRIC HEATER (AEH) FOR A LOSS OF ISOLATION 
    1. Disconnect the C3 high voltage harness connector at the Air Electric Heater (AEH).
    2. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  6

      No 

  6. CHECK THE AIR ELECTRIC HEATER (AEH) HIGH VOLTAGE HARNESS FOR A LOSS OF ISOLATION 
    1. Disconnect the C2 high voltage harness connector for the Air Electric Heater (AEH) at the High Voltage Power Distribution Center (HVPDC).
    2. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is still there an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  7

      No 

  7. CHECK THE ELECTRIC AIR COMPRESSOR (EAC) FOR A LOSS OF ISOLATION 
    1. Reconnect the C2 high voltage harness connector at the High Voltage Power Distribution Center (HVPDC).
    2. Reconnect the C3 high voltage harness connector at the Air Electric Heater (AEH).
    3. Disconnect the C3 high voltage harness connector at the Electric Air Compressor (EAC).
    4. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  8

      No 

  8. CHECK THE E-MOTOR FOR A LOSS OF ISOLATION 
    1. Reconnect the C3 high voltage harness connector at the Electric Air Compressor (EAC).
    2. Disconnect the C3 3-Phase high voltage harness connector at the e-Motor.
    3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  9

      No 

  9. CHECK THE E-MOTOR HIGH VOLTAGE HARNESS FOR A LOSS OF ISOLATION 
    1. Disconnect the C4 3-Phase high voltage harness connector at the Power Inverter Module (PIM).
    2. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  10

      No 

      • Replace the e-Motor 3-Phase to PIM high voltage harness in accordance with the Service Information. Refer to MOTOR, ELECTRIC, REMOVAL .
      • Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  10. CHECK THE POWER INVERTER MODULE (PIM) TO HIGH VOLTAGE BATTERY PACK (HVBP) HIGH VOLTAGE HARNESS FOR A LOSS OF ISOLATION 
    1. Reconnect the C3 3-Phase high voltage harness connector at the e-Motor.
    2. Reconnect the C4 3-Phase high voltage harness connector at the Power Inverter Module (PIM).
    3. Disconnect the C2 PIM to HVBP high voltage harness connector at the Power Inverter Module (PIM).
    4. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  11

      No 

  11. CHECK THE POWER INVERTER MODULE (PIM) FOR A LOSS OF ISOLATION 
    1. Reconnect the C2 high voltage harness connector at the Power Inverter Module (PIM).
    2. Disconnect the C3 PIM to HVPDC high voltage harness connector at the Power Inverter Module (PIM).
    3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      No 

  12. CHECK ON BOARD CHARGING HIGH VOLTAGE CIRCUIT FOR A LOSS OF ISOLATION 
    1. Reconnect the C1 high voltage harness connector at the High Voltage Battery Pack (HVBP).
    2. Disconnect the C2 high voltage harness connector at the On Board Charging Module (OBCM).
    3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  13

      No 

      • Go To  14
  13. CHECK THE ON BOARD CHARGING MODULE (OBCM) FOR A LOSS OF ISOLATION 
    1. Reconnect the C2 high voltage harness connector at the On Board Charging Module (OBCM).
    2. Disconnect the C3 high voltage harness connector at the On Board Charging Module (OBCM).
    3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Go To  15

      No 

      • Go To  16
  14. CHECK THE BATTERY CHARGER FOR A LOSS OF ISOLATION 
    1. Reconnect the C2 high voltage harness connector at the On Board Charging Module (OBCM).
    2. Disconnect the Battery Charger from the Electric Vehicle Charging Port.
    3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      • Replace the Electric Vehicle Charging Port to OBCM high voltage harness in accordance with the Service Information.
      • Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .

      No 

      • Replace the Battery Charger.
      • Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  15. CHECK THE ON BOARD CHARGING MODULE (OBCM) HIGH VOLTAGE HARNESS FOR A LOSS OF ISOLATION 
    1. Reconnect the C3 high voltage harness connector at the On Board Charging Module (OBCM).
    2. Disconnect the C4 high voltage harness connector at the On Board Charging Module (OBCM).
    3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      No 

  16. CHECK THE BATTERY COOLANT HEATER (BCH) FOR A LOSS OF ISOLATION 
    1. Reconnect the C3 high voltage harness connector at the On Board Charging Module (OBCM).
    2. Disconnect the C3 high voltage harness connector at the Battery Coolant Heater (BCH).
    3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to  3 of this procedure).

      Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?

      Yes 

      No 

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