Diagnostic Test

Read the HIGH-VOLTAGE SAFETY PROCEDURES. Refer to  HIGH VOLTAGE SAFETY PROCEDURES  . 

When the HIGH-VOLTAGE POWER-DOWN PROCEDURE is necessary. Refer to  HIGH VOLTAGE POWER DOWN  . 

1. With the scan tool, read DTCs in all Electronic Control Units (ECUs) and record on the repair order.
   NOTE:

   Repair any LIN BUS DTCs and A/C system DTCs, retest before proceeding.

2. For future reference, with the scan tool, run and save a vehicle Scan Report and all related recorded data.
3. With the scan tool, erase all DTCs.
4. Turn the ignition off for a minimum of 10.0 seconds.
5. Turn the ignition on.
6. Using the When Monitored and Set Conditions above and recorded data, operate the vehicle in the conditions that set the DTC.
7. With the scan tool, read DTCs.

   Did the DTC return?

   Yes 

   • Go To Next Step.

   No 

   • Perform the appropriate INTERMITTENT CONDITION diagnostic procedure. Refer to TESTING FOR AN INTERMITTENT CONDITION .

1. The ignition must be off when checking the continuity of a circuit.
2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and the component harness connector containing the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
3. Before measuring the resistance of any circuit, first measure the resistance between the two leads of the DVOM. Note:  The meter leads can add resistance to the measurement value.
4. Connect one lead of the DVOM to the circuit being tested at the component harness connector.
5. Connect the other lead to the circuit being tested at the ECU harness connector and measure the resistance of the circuit.
   NOTE:

   When probing a circuit at an Electronic Control Unit (ECU) harness connector, always use an appropriate back probing tool to prevent any possible damage to the ECU terminals.

   Is the resistance below 3.0 Ohms?

   Yes 

   • Go To Next Step.

   No 

   • Repair the circuit for an open or high resistance.
   • Perform the Hybrid Control Processor (HCP) VERIFICATION TEST. Refer to STANDARD PROCEDURE .

Read the CIRCUIT LOAD TESTING PROCEDURE for information on building a simple load test tool, additional load testing information and alternative methods of load testing or voltage drop testing a circuit. Refer to CIRCUIT LOAD TESTING PROCEDURES .

1. Disconnect the component harness connector to isolate the 12.0 volt supply circuit.
2. Connect the positive lead of the load test tool to the 12.0 volt supply circuit at the component harness connector (A) and the negative lead to a battery ground or chassis ground.

   Courtesy of CHRYSLER GROUP, LLC

3. Ensure that the circuit being tested is being powered on. If the 12.0 volt circuit being tested is an ignition feed for example, the ignition must be on. If testing an output from a relay, verify that the relay is energized and on.
4. If there is no resistance in the circuit the bulb on the load test tool should be illuminated and bright. Compare the brightness of the bulb in the load test tool to that of a direct connection to battery.
   NOTE:

   To verify with certainty there is not any resistance in the circuit being tested, perform a simple voltage drop test across the 3156 bulb of the load test tool.

   NOTE:

   A 12-volt test light can be substituted for the load test tool, but

   only 

   if the test light draws enough current to effectively load test the circuit. Many high impedance test lights draw very little amperage (less than 0.1 amps) and are not reliable to load test a circuit. To perform a proper load test of a circuit, the tool being used should draw more than approximately 0.75 amps.

   Is the load test bulb illuminated and bright?

   Yes 

   • Go To Next Step.

   No 

   • Repair the 12.0 volt circuit for an open or high resistance.
   • Perform the Hybrid Control Processor (HCP) VERIFICATION TEST. Refer to STANDARD PROCEDURE .

1. Disconnect the component harness connector to isolate the ground circuit.
2. Connect the positive lead of the load test tool to the positive side of the Battery and connect the negative lead of the load test tool to the ground circuit at the component harness connector (A).

   Courtesy of CHRYSLER GROUP, LLC

3. Connect the negative lead of the load test tool to the ground circuit at the component harness connector (A).
4. If there is no resistance in the circuit the bulb on the load test tool should be illuminated and bright. Compare the brightness of the bulb in the load test tool to that of a direct connection to battery.
   NOTE:

   To verify with certainty there is not any resistance in the circuit being tested, perform a simple voltage drop test across the 3156 bulb of the load test tool.

   NOTE:

   A 12-volt test light can be substituted for the load test tool, but

   only 

   if the test light draws enough current to effectively load test the circuit. Many high impedance test lights draw very little amperage (less than 0.1 amps) and are not reliable to load test a circuit. To perform a proper load test of a circuit, the tool being used should draw more than approximately 0.75 amps.

   Is the load test bulb illuminated and bright?

   Yes 

   • Go To Next Step.

   No 

   • Repair the ground circuit for an open or high resistance.
   • Perform the Hybrid Control Processor (HCP) VERIFICATION TEST. Refer to STANDARD PROCEDURE .

1. Replace the component in accordance with the Service Information. Refer to CHILLER, REMOVAL AND INSTALLATION .
2. Connect the component and Electronic Control Unit (ECU) harness connectors.
3. Turn the ignition on.
4. With the scan tool, erase DTCs.
5. Using the Environmental Data or When Monitored Conditions above, operate the vehicle within the conditions that set the DTC.
6. With the scan tool, read DTCs.

   Did the DTC return?

   Yes 

   • Go To Next Step.

   No 

   • Replacing the faulty component repaired the fault.
   • Perform the Hybrid Control Processor (HCP) VERIFICATION TEST. Refer to STANDARD PROCEDURE .

1. Disconnect all PIM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
   • Proper connector installation.
   • Damaged connector locks.
   • Corrosion.
   • Other signs of water intrusion.
   • Weather seal damage (if equipped).
   • Bent terminals.
   • Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
   • Terminals that have been pushed back into the connector cavity.
   • Perform a terminal drag test on each connector terminal to verify proper terminal tension.

   Repair any conditions that are found.

5. Reconnect all PIM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read HCP DTCs.

    Did the DTC return?

    Yes 

    • Replace the Power Inverter Module (PIM) in accordance with the Service information. Refer to POWER INVERTER MODULE (PIM) .
    • Perform the Hybrid Control Processor (HCP) VERIFICATION TEST. Refer to STANDARD PROCEDURE .

    No 

    • Perform the Hybrid Control Processor (HCP) VERIFICATION TEST. Refer to STANDARD PROCEDURE .
    • Test complete.