Diagnostic Test

WARNING: This page is about a different variant/trim than selected.

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.

NOTE:
Before performing any test with the Fluke 1587 M or equivalent multi-meter, test on a known good source (12V battery), to verify proper multi-meter functionality.

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 .
3. Measure the resistance between the high voltage contacts in the Service Disconnect.
  Is the resistance below 5.0 Ohms?
  
  Yes
  
  NOTE:
  The Service Disconnect internal fuse tests good at this time. Continue with the diagnosis.
  - Go To 2
  No
  
  NOTE:
  The Service Disconnect internal fuse is open. It is possible for the internal fuse to be damaged if the Service Disconnect is accidentally dropped.
  - If the Service Disconnect was dropped, replace the Service Disconnect in accordance with the Service Information and perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  - If the Service Disconnect was not dropped, it may have opened as a result of the loss of isolation. Continue with the diagnosis and replace the Service Disconnect following repair.
  - Go To 2
CHECK THE POSITIVE (+) AND NEGATIVE (-) HIGH VOLTAGE BUS FOR LOSS OF ISOLATION
1. Use a Fluke 1587 M multi-meter or equivalent to measure isolation resistance.
  
  Fig 1: Multi-Meter
  Courtesy of CHRYSLER GROUP, LLC
2. Set the multi-meter selector to the INSULATION scale and place the test leads in the + and - INSULATION ports as shown in illustration.
  
  Fig 2: Power Distribution Center (PDC) Positive Test Port
  Courtesy 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
  Courtesy 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
  Courtesy 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
  Courtesy 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 3
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 Step 2 of this procedure).
  Is there an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Go To 4
  No
  - Go To 11
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 Step 2 of this procedure).
  Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Go To 5
  No
  - Replace the Air Electric Heater (AEH) in accordance with the Service Information. Refer to HEATER, AIR ELECTRIC (AEH), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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 Step 2 of this procedure).
  Is still there an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Go To 6
  No
  - Replace the AEH to HVPDC high voltage harness in accordance with the Service Information. Refer to HEATER, AIR ELECTRIC (AEH), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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 Step 2 of this procedure).
  Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Go To 7
  No
  - Replace the Electric Air Compressor (EAC) in accordance with the Service Information. Refer to COMPRESSOR, ELECTRIC AIR CONDITIONING (EAC), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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 Step 2 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
  - Replace the e-Motor in accordance with the Service Information. Refer to MOTOR, ELECTRIC, REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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). HIGH-VOLTAGE ELECTRICAL CONNECTORS DISCONNECT, CONNECT.
2. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to Step 2 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
  - Replace the e-Motor 3-Phase to PIM high voltage harness in accordance with the Service Information. Refer to MOTOR, ELECTRIC, REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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 Step 2 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 PIM to HVBP high voltage harness in accordance with the Service Information. Refer to MODULE, POWER INVERTER (PIM), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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 Step 2 of this procedure).
  Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Replace the High Voltage Power Distribution Center (HVPDC) in accordance with the Service Information. Refer to CENTER, HIGH-VOLTAGE POWER DISTRIBUTION, REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  No
  - Replace the Power Inverter Module (PIM) in accordance with the Service Information. Refer to MODULE, POWER INVERTER (PIM), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
CHECK THE HIGH VOLTAGE BATTERY PACK (HVBP) 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 High Voltage Battery Pack (HVBP).
3. At the High Voltage Power Distribution Center (HVPDC) measure the Positive (+) and Negative (-) high voltage Bus for loss of isolation. (Refer to Step 2 of this procedure).
  Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Replace the High Voltage Battery Pack (HVPBP) in accordance with the Service Information. Refer to BATTERY, HIGH-VOLTAGE, REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  No
  - Go To 12
CHECK ON BOARD CHARGING HIGH VOLTAGE CIRCUIT FOR A LOSS OF ISOLATION
1. Reconnect the C2 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 Step 2 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
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 Step 2 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
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 Step 2 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.
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  No
  - Replace the Battery Charger.
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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 Step 2 of this procedure).
  Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Replace the OBCM to HVBP high voltage harness in accordance with the Service Information. Refer to MODULE, ONBOARD CHARGING (OBCM), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  No
  - Replace the On Board Charging Module (OBCM) in accordance with the Service Information. Refer to MODULE, ONBOARD CHARGING (OBCM), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
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 Step 2 of this procedure).
  Is there still an indicated loss of isolation detected in either the Positive (+) and/or Negative (-) Bus?
  
  Yes
  - Replace the BCH to OBCM high voltage harness in accordance with the Service Information. Refer to HEATER, BATTERY COOLANT (BCH), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
  No
  - Replace the Battery Coolant Heater (BCH) in accordance with the Service Information. Refer to HEATER, BATTERY COOLANT (BCH), REMOVAL .
  - Replace the high voltage Service Disconnect, if required, in accordance with the Service Information.
  - Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to STANDARD PROCEDURE .