Hybrid/EV Energy Storage (Hybrid Powertrain Control Module 2)
DTC P0641-P0643 or P0651-P0653 (Hybrid Powertrain Control Module 2)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
* Review Strategy Based Diagnosis Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions Diagnostic Procedure Instructions provides an overview of each diagnostic category.
DTC Descriptors
DTC P0641
- 5 V Reference 1 Circuit - Main
DTC P0642
- 5 V Reference 1 Circuit Low Voltage
DTC P0643
- 5 V Reference 1 Circuit High Voltage
DTC P0651
- 5 V Reference 2 Circuit - Charger
DTC P0652
- 5 V Reference 2 Circuit Low Voltage
DTC P0653
- 5 V Reference 2 Circuit High Voltage
Circuit/System Description
The high voltage interlock circuit is utilized to verify high voltage component integrity. High voltage interlock circuit is a circuit loop that passes through certain high voltage components. High voltage interlock circuit is used to determine if access to high voltage components is being attempted. The opening of these high voltage components causes high voltage interlock circuit to open. The hybrid powertrain control module 2 monitors both the high voltage interlock 5 V reference circuit voltage and the high voltage interlock signal circuit voltage in order to detect circuit faults. When the hybrid powertrain control module 2 detects a loss of high voltage interlock circuit voltage, the high voltage contactors are commanded open.
Conditions for Running the DTC
* The 12 V battery voltage is greater than 9 V.
* The hybrid powertrain control module 2 is awake and communicating
Conditions for Setting the DTC
DTC P0641 and P0643
The hybrid powertrain control module 2 detects the main loop 5 V reference voltage is greater than 4.90 V.
DTC P0642
The hybrid powertrain control module 2 detects the main loop 5 V reference voltage is less than 2.63 V and the main loop signal is less than 1.08 V.
DTC P0651 and P0653
The hybrid powertrain control module 2 detects the charger loop 5 V reference voltage is greater than 4.90 V.
DTC P0652
The hybrid powertrain control module 2 detects the charger loop 5 V reference voltage is less than 2.63 V and the charger loop signal is less than 1.08 V.
Action Taken When the DTC Sets
DTCs P0641-P0643 and P0651-P0653 are type A DTCs.
Conditions for Clearing the DTC
DTCs P0641-P0643 and P0651-P0653 are type A DTCs.
Reference Information
Schematic Reference
Hybrid Energy Storage Schematics Hybrid Energy Storage Schematics
Connector End View Reference
Component Connector End Views Hybrid/EV Battery Pack X1
Description and Operation
Drive Motor Battery System Description Drive Motor Battery System Description
Electrical Information Reference
* Circuit Testing Circuit Testing
* Connector Repairs Connector Repairs
* Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections
* Wiring Repairs Wiring Repairs
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References Programming and Relearning for scan tool information
Special Tools
EL-48900 - HEV Safety Kit
For equivalent regional tools, refer to Special Tools Tools and Equipment.
Circuit/System Verification
1. Vehicle in Service Mode, observe the scan tool High Voltage System Interlock Circuit Status parameter. The reading should be PASS.
• If the reading is UNKNOWN or FAIL, refer to P0641, P0642, and P0643.
2. Observe the scan tool Battery Charging System High Voltage Interlock Circuit Status parameter. The reading should be PASS.
• If the reading is UNKNOWN or FAIL, refer to P0651, P0652, and P0653.
Circuit/System Testing
Danger: 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 will perform the following tasks:
* 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 exactly as written may result in serious injury or death.
Danger: The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.
P0641, P0642, and P0643
Note: The main high voltage interlock circuit is routed through several inline connectors and modules.
1. Vehicle OFF, disable high voltage at the A4 hybrid/EV battery pack. Refer to High Voltage Disabling High Voltage Disabling
2. Connect the 12 V battery.
3. Vehicle in Service Mode, test for 4.8-5.2 V between the 5 V reference circuit terminal A at the S15 hybrid battery pack high voltage manual disconnect housing and ground.
• If less than the specified range, test the 5 V reference circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
• If greater than the specified range, test the 5 V reference circuit for a short to voltage. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
4. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Test for 8-10k ohm between the signal circuit terminal B and ground.
• If less than the specified range, test the signal circuit for a short to ground. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
• If greater than the specified range, test the signal circuit for an open/high resistance. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
5. If all circuits test normal, test or replace the S15 hybrid battery pack high voltage manual disconnect.
Danger: 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 will perform the following tasks:
* 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 exactly as written may result in serious injury or death.
Danger: The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.
P0651, P0652, and P0653
Note: The charger high voltage interlock circuit is routed through several inline connectors.
1. Vehicle OFF, disable high voltage at the A4 hybrid/EV battery pack. Refer to High Voltage Disabling High Voltage Disabling.
2. Connect the 12 V battery.
3. Vehicle in Service Mode, test for 4.8-5.2 V between the 5 V reference circuit terminal C at the S15 hybrid battery pack high voltage manual disconnect housing and ground.
• If less than the specified range, test the 5 V reference circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
• If greater than the specified range, test the 5 V reference circuit for a short to voltage. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
4. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Test for 8-10k ohm between the signal circuit terminal D and ground.
• If less than the specified range, test the signal circuit for a short to ground. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
• If greater than the specified range, test the signal circuit for an open/high resistance. If the circuit tests normal, replace the K114B hybrid powertrain control module 2.
5. If all circuits test normal, test or replace the S15 hybrid battery pack high voltage manual disconnect.
Component Testing
Test for 35-45 ohm between the following terminals of the S15 hybrid battery pack high voltage manual disconnect:
* Terminal A and terminal B
* Terminal C and terminal D
If not within the specified range, replace the S15 hybrid battery pack high voltage manual disconnect.
Repair Instructions
Perform the Diagnostic Repair Verification Verification Tests after completing the diagnostic procedure.
Control Module References Programming and Relearning for hybrid powertrain control module 2, 14 V power module, power inverter module, air conditioning compressor control module, and coolant heater control module replacement, programming and setup