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Circuit/System Testing: Notes

WARNING:

Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps:

  • Identify how to disable high voltage.
  • Identify how to test for the presence of high voltage.
  • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

  • Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
  • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
    • Visually and functionally inspect the gloves before use.
    • Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

NOTE:

Each device may need to be disconnected to isolate a circuit fault. Use the schematics and connector end views to identify the following:

  • Devices connected to the BECM dedicated serial data circuits
  • BECM dedicated serial data circuit terminating resistors
  • Device locations on the BECM dedicated serial data circuits
  • Each device 5 V reference, low reference and BECM dedicated serial data circuit terminals
  1. Perform the High Voltage Disabling procedure before proceeding with this diagnostic. Refer to High Voltage Disabling .
  2. Reconnect the 12 V battery.
  3. Vehicle OFF, all access doors closed, all vehicle systems OFF and all keys at least 3 m (9.8 ft) away from vehicle. Disconnect the harness connectors with the BECM dedicated serial data circuits at an easily accessible device that is not communicating. It may take up to 2 min for all vehicle systems to power down.
  4. Vehicle in Service Mode.
  5. Test for less than 4.5 V between each BECM dedicated serial data circuit at the device connector that was just disconnected and ground.
    • If less than 4.5 V 
  6. Vehicle OFF, all access doors closed, all vehicle systems OFF and all keys at least 3 m (9.8 ft) away from vehicle. It may take up to 2 min for all vehicle systems to power down.
  7. Test for greater than 100 Ω between each BECM dedicated serial data circuit at the device connector that was just disconnected and ground.
    • If greater than 100 Ω 
  8. Test for 110-130 Ω between the BECM dedicated serial data circuits at the device connector that was just disconnected.
    • If between 110-130 Ω 
  9. Refer to Testing the Device Circuits .
NOTE: Some Hybrid/EV Battery Interface Control Modules have a loop in the harness that connects its 5 V reference circuit back to another control circuit of the same device. When wired this way, test these loop circuits for the appropriate failure mode short to voltage, short to ground or open/high resistance prior to replacing the device for each of the following tests.
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