Diagnostic Test
- CHECK FOR SYSTEM VOLTAGE DTCS IN ALL MODULES WARNING:
On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury.
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 .
Repair any Low or High Voltage DTCs in HCP, BPCM, PCM, or IDCM before proceeding and recheck operation. Refer to HYBRID CONTROL PROCESSOR MODULE (HCP), DIAGNOSTIC CODE INDEX , BATTERY PACK CONTROL MODULE (BPCM), DIAGNOSTIC CODE INDEX , 2.0L, DIAGNOSTIC CODE INDEX , INTEGRATED DUAL CHARGE MODULE (IDCM), DIAGNOSTIC CODE INDEX .
- With the scan tool, read DTCs in all Electronic Control Units (ECUs) and record on the repair order.
- For future reference, with the scan tool, run and save a Vehicle Scan Report and all related recorded data.
Are there any system voltage high or low DTCs present in any modules?
Yes
- Diagnose and repair the low voltage system or battery issue. Erase DTCs and retest.
- Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to HV VERIFICATION TEST .
No
- Go To Next Step.
- CHECK FOR CAN BUS COMMUNICATION RELATED DTCS
- Refer to the recorded DTCs and scan report.
Are there any CAN BUS DTCs active?
Yes
- Perform the appropriate diagnostic test.
- Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to HV VERIFICATION TEST .
No
- Go To Next Step.
- Refer to the recorded DTCs and scan report.
- CHECK RELATED HARNESS CONNECTIONS
- Disconnect all BPCM harness connectors.
- Disconnect all BPCM low voltage bridge harness connectors.
- Disconnect all HV bridge harness connectors.
- Disconnect all related in-line harness connections (if equipped).
- Disconnect the related component harness connectors.
- 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.
- Short in LV harness to the BPCM.
Repair any conditions that are found.
- Reconnect all BPCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
- Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
- Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
- With the scan tool, erase DTCs.
- Using the recorded Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
- With the scan tool, read BPCM DTCs.
Did the DTC return?
Yes
- Replace the Primary and Secondary High Voltage Battery Packs in accordance with the Service Information. Refer to HIGH VOLTAGE BATTERY, REMOVAL AND INSTALLATION .
- Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to HV VERIFICATION TEST .
No
- Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to HV VERIFICATION TEST .
- Test complete.