Diagnostic Test

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.

CHECK HIGH VOLTAGE BATTERY AND HIGH VOLTAGE CABLE FROM BATTERY PACK TO HIGH VOLTAGE POWER DISTRIBUTION CENTER
NOTE:
NOTE: The Fluke 1587 isolation meter charges an internal capacitor that discharges when performing the High Voltage Isolation Check. If the meter leads are not connected correctly or the Fluke 1587 isolation meter internal fuse is bad, the Fluke 1587 isolation meter will always read 500 M ohms because the internal capacitor cannot discharge. Before performing any test with the Fluke 1587 isolation meter make sure the Fluke 1587 isolation meter is working properly.

Place the meter leads into the (+) and (-) Insulation Ports (located in the lower left corner on the Fluke 1587 isolation meter).

Rotate the mode selector to the "50V•••1000V Insulation Scale" position.

Make sure the Fluke 1587 isolation meter is on the 500V scale (this can be viewed on the bottom of the screen display, in the center). If the Fluke 1587 isolation meter is not on the 500V scale then press the "RANGE" button until the 500V scale is displayed.

Touch the meter Positive lead to the meter Negative lead, hold them together, and then press and hold the "Insulation TEST" button.

If a value of 550 M ohms is displayed, then the internal fuse is open or the meter leads are not connected properly. Make sure the meter leads are in the correct ports. If the meter leads are connected properly, then the Fluke 1587 isolation meter internal fuse must be replaced (the internal fuse is located next to the AA batteries in the back of the Fluke 1587 isolation meter).
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 .
  NOTE:
  If the high voltage Service Disconnect is removed from the vehicle while the ignition is on, DTC P1E25-00 will set. Make sure if any work was performed on the vehicle to reinstall the Service Disconnect and clear this DTC.
3. Disconnect the C1 harness connector at the High Voltage Battery.
4. Using the FLUKE 1587 multimeter, measure the resistance between the (H300) HVDC (+) circuit and the (H301) HVDC(-) circuit at the High Voltage Battery C1 connector harness side.
  NOTE:
  When the FLUKE 1587 multimeter is connected to the C1 connector, the resistance value will be erratic and fluctuate for several minutes. Please allow 3 minutes for the fluctuation to stop, then read the resistance value. This will occur for all resistance readings using the FLUKE 1587 multimeter.
  
  Is the resistance between 67K Ohms and 220K Ohms?
  
  Yes
  - Go To 6
  No
  - Go To 2
AIR ELECTRIC HEATER (AEH) AND HIGH VOLTAGE BATTERY CABLES
1. Disconnect the Air Electric Heater at the High Voltage Power Distribution Center C2 connector.
2. Using the FLUKE 1587 Multimeter, measure the resistance between the (H300) HVDC(+) circuit and the (H301) HVDC(-) circuit at the High Voltage Battery C1 connector, harness side.
  Is the resistance between 67K Ohms and 220K Ohms?
  
  Yes
  - Replace the Air Electric Heater and High Voltage Cable between the Air Electric Heater C3 connector and HV Power Distribution Center C2 connector in accordance with the service information. Refer to HEATER, AIR ELECTRIC (AEH), REMOVAL .
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
  No
  - Go To 3
CHECK THE ELECTRONIC AIR COMPRESSOR (EAC)
1. Disconnect the C3 connector at the Electronic Air Compressor (EAC).
2. Using the FLUKE 1587 multimeter, measure the resistance between the (H300) HVDC(+) circuit and the (H301) HVDC(-) circuit at the High Voltage Battery C1 connector, harness side.
  Is the resistance between 67K Ohms and 220K Ohms?
  
  Yes
  - Replace the Electronic Air Compressor (EAC) in accordance with the Service Information. Refer to COMPRESSOR, ELECTRIC AIR CONDITIONING (EAC), REMOVAL .
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
  No
  - Go To 4
CHECK THE e-MOTOR AND HV CABLE BETWEEN e-MOTOR AND HIGH VOLTAGE BATTERY
1. Disconnect the C3 connector at the e-Motor.
2. Using the FLUKE 1587 multimeter, measure the resistance between the (H300) HVDC(+) circuit and the (H301) HVDC(-) circuit at the High Voltage Battery C1 connector, harness side.
  Is the resistance between 67K Ohms and 220K Ohms?
  
  Yes
  - Replace the e-Motor and the HV Cable between the Power Inverter Module C4 connector and the e-Motor C3 connector in accordance with the service information.
    Refer to MOTOR, ELECTRIC, REMOVAL .
    
    ,
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
  No
  - Go To
    Refer to 5.
CHECK THE HIGH VOLTAGE DISTRIBUTION CENTER AND THE POWER INVERTER MODULE (PIM)
1. Disconnect the C3 connector at the Power Inverter Module (PIM).
2. Using the FLUKE 1587 multimeter, measure the resistance between the (H300) HVDC(+) circuit and the (H301) HVDC(-) circuit at the High Voltage Battery C1 connector, harness side.
  Is the resistance between 67K Ohms and 220K Ohms?
  
  Yes
  - Replace the High Voltage Power Distribution Center in accordance with the service information.
    Refer to CENTER, HIGH-VOLTAGE POWER DISTRIBUTION, REMOVAL .
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
  No
  - Replace the PIM and the HV Cable from the PIM C2 connector to the High Voltage Battery C1 connector in accordance to the service information.
    Refer to MODULE, POWER INVERTER (PIM), REMOVAL .
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
CHECK THE BATTERY PACK
1. Disconnect the C2 connector at the High Voltage Battery.
2. Using the FLUKE 1587 multimeter, measure resistance between the (H300) HVDC(+) circuit and the (H301) HVDC(-) circuit at the High Voltage Battery C2 connector, harness side.
  Is the resistance between 45K Ohms and 275K Ohms?
  
  Yes
  - Replace the High Voltage Battery in accordance with the service information. Refer to BATTERY, HIGH-VOLTAGE, REMOVAL .
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
  No
  - Go To
    Refer to 7.
CHECK THE BATTERY COOLANT HEATER AND ON BOARD CHARGING MODULE (OBCM)
1. Disconnect the C3 connector from the Battery Coolant Heater.
2. Using the FLUKE 1587 multimeter, measure the resistance between the (H300) HVDC(+) circuit and the (H301) HVDC(-) circuit at the High Voltage Battery C2 connector, harness side
  Is the resistance between 45K Ohms and 275K Ohms?
  
  Yes
  - Replace the Battery Coolant Heater and the HV cable between the OBCM C3 connector and the Battery Coolant Heater C3 connector in accordance with the service information. Refer to HEATER, BATTERY COOLANT (BCH), REMOVAL .
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
  No
  - Replace the OBCM and the HV Cable between the OBCM C4 connector and the High Voltage Battery C2 connector in accordance with the service information.
    Refer to MODULE, ONBOARD CHARGING (OBCM), REMOVAL .
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .