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Charger Door Release Malfunction




Charger Door Release Malfunction

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.

Diagnostic Fault Information






Circuit/System Description

The hybrid powertrain control module 2 monitors the voltage values of the charge port wake-up signal circuit and the charge port request signal circuit. When the charge port door release switch is pressed, the two switch contacts close and provides B+ voltage to the two signal circuits. This provides B+ to the Wake-up Circuit input of the hybrid powertrain control module 2 and lowers the voltage on the charge port door request signal circuit input to the hybrid powertrain control module 2, The hybrid powertrain control module 2 detects the voltage on the signal circuits and provides a 12V pulse to the charge port relay, the relay briefly becomes energized which then allows B+ voltage to the charge port door latch which activates and releases the charge port door.

Reference Information

Schematic Reference

Plug-In Charging Schematics Plug-In Charging Schematics

Connector End View Reference

Component Connector End Views Hybrid/EV Battery Pack X1

Description and Operation

Charge Port Door Description and Operation Charge Port Door Description and Operation

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

Scan Tool Reference

Control Module References Programming and Relearning for scan tool information

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify the charge port door actuator function when commanding the Charge Port Door Unlatch with a scan tool.

• If the charge port door actuator does not unlatch
Refer to Circuit/System Testing - Charge Port Door Actuator Malfunction

• If the charge port door actuator unlatches

3. Verify the charge port door actuator functions when pressing the charge port door open request switch.

• If the charge port door actuator does not unlatch
Refer to Circuit/System Testing - Charge Port Door Switch Inoperative When Module Is Awake

• If the charge port door actuator unlatches

4. Vehicle OFF, it may take up to 2 minutes for the hybrid powertrain control module 2 to enter the sleep mode.

5. Verify the charge port door actuator functions when pressing the charge port door open request switch.

• If the charge port door actuator does not unlatch
Refer to Circuit/System Testing - Charge Port Door Switch Inoperative When Module Is Asleep

• If the charge port door actuator unlatches

6. All OK.

Circuit/System Testing

Charge Port Door Actuator Malfunction

1. Vehicle OFF, disconnect the KR119 charge port door relay. It may take up to 2 minutes for all vehicle systems to power down.

2. Test for less than 10 ohms between the ground circuit terminal 85 and ground.

• If 10 ohms or greater

1. Vehicle OFF.

2. Test for less than 2 ohms in the ground circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, repair the open/high resistance in the ground connection.

• If less than 10 ohms

3. Vehicle in Service Mode.

4. Verify a test lamp illuminates between the B+ circuit terminal 87 and ground.

• If the test lamp does not illuminate and the circuit fuse is good

1. Vehicle OFF.

2. Test for less than 2 ohms in the B+ circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.

• If the test lamp does not illuminate and the circuit fuse is open

1. Vehicle OFF.

2. Test for infinite resistance between the B+ circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Disconnect the harness connector at the M80 charge port door actuator.

4. Test for infinite resistance between the control circuit terminal 30 and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance, replace the KR119 charge port door relay.

• If the test lamp illuminates

5. Connect a test lamp between the control circuit terminal 86 and the ground circuit terminal 85.

6. Verify the test lamp briefly illuminates when commanding the Charge Port Door Unlatch with a scan tool.

• If the test lamp is always OFF

1. Vehicle OFF, disconnect the harness connector at the K114B hybrid powertrain control module 2.

2. Test for infinite resistance between the control circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Test for less than 2 ohms in the control circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, replace the K114B hybrid powertrain control module 2.

• If the test lamp is always ON

1. Vehicle OFF, disconnect the harness connector at the K114B hybrid powertrain control module 2, Vehicle in Service Mode.

2. Test for less than 1 V between the control circuit and ground.

• If 1 V or greater, repair the short to voltage on the circuit.

• If less than 1 V, replace the K114B hybrid powertrain control module 2.

• If the test lamp turns ON and OFF

7. Verify that a test lamp does not illuminate between the control circuit terminal 30 and ground.

• If the test lamp illuminates
Repair the short to voltage on the control circuit

• If the test lamp does not illuminate

8. Vehicle OFF, disconnect the harness connector at the M80 charge port door actuator. It may take up to 2 minutes for all vehicle systems to power down.

9. Test for less than 10 ohms between the M80 charge port door actuator ground circuit terminal 1 and ground.

• If 10 ohms or greater

1. Vehicle OFF.

2. Test for less than 2 ohms in the ground circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, repair the open/high resistance in the ground connection.

• If less than 10 ohms

10. Connect the harness connector at the M80 charge port door actuator.

11. Vehicle in Service Mode, connect a 20 A fused jumper wire between the B+ circuit terminal 87 and the control circuit terminal 30.

12. Verify the M80 charge port door actuator is activated.

• If the M80 charge port door actuator does not activate

1. Vehicle OFF, disconnect the harness connector at the M80 charge port door actuator.

2. Test for less than 2 ohms in the control circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, replace the M80 charge port door actuator.

• If the M80 charge port door actuator activates

13. Test or replace the KR119 charge port door relay.

Charge Port Door Switch Inoperative When Module Is Awake

1. Vehicle OFF, disconnect the harness connector at the S113 charge port door open request switch. It may take up to 2 minutes for all vehicle systems to power down.

2. Test for less than 10 ohms between the low reference circuit terminal 6 and ground.

• If 10 ohms or greater

1. Disconnect the harness connector at the K114B hybrid powertrain control module 2

2. Test for less than 2 ohms in the low reference circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, replace the K114B hybrid powertrain control module 2.

• If less than 10 ohms

3. Vehicle in Service Mode, test for 4.8-5.2 V between the 5 V reference circuit terminal 3 and ground.

• If less than 4.8 V

1. Vehicle OFF, disconnect the harness connector at the K114B hybrid powertrain control module 2.

2. Test for infinite resistance between the 5 V reference circuit and ground

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Test for less than 2 ohms in the 5 V reference circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, replace the K114B hybrid powertrain control module 2.

• If greater than 5.2 V

1. Vehicle OFF, disconnect the harness connector at the K114B hybrid powertrain control module 2, Vehicle in Service Mode.

2. Test for less than 1 V between the 5 V reference circuit and ground.

• If 1 V or greater, repair the short to voltage on the circuit.

• If less than 1 V, replace the K114B hybrid powertrain control module 2.

• If between 4.8-5.2 V

4. Test or replace the S113 charge port door open request switch.

Charge Port Door Switch Inoperative When Module Is Asleep

1. Vehicle OFF, disconnect the harness connector at the S113 charge port door open request switch. Vehicle in Service Mode.

2. Verify a test lamp illuminates between the B+ circuit terminal 1 and ground.

• If the test lamp does not illuminate and the circuit fuse is good

1. Vehicle OFF.

2. Test for less than 2 ohms in the B+ circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.

• If the test lamp does not illuminate and the circuit fuse is open

1. Vehicle OFF.

2. Test for infinite resistance between the B+ circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Disconnect the X2 harness connector at the K114B hybrid powertrain control module 2.

4. Test for infinite resistance between the signal circuit terminal 2 and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance, replace the K114B hybrid powertrain control module 2.

• If the test lamp illuminates

3. Vehicle OFF, connect the harness connector at the S113 charge port door open request switch. Disconnect the X2 harness connector at the K114B hybrid powertrain control module 2.

4. Connect a test lamp between the signal circuit terminal 29 and ground.

5. Verify the test lamp turns ON and OFF by pressing the S113 charge port door open request switch.

• If the test lamp is always OFF

1. Vehicle OFF, disconnect the harness connector at the S113 charge port door open request switch.

2. Test for infinite resistance between the signal circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Test for less than 2 ohms in the control circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, test or replace the S113 charge port door open request switch.

• If the test lamp is always ON

1. Vehicle OFF, disconnect the harness connector at the S113 charge port door open request switch, Vehicle in Service Mode.

2. Test for less than 1 V between the control circuit and ground.

• If 1 V or greater, repair the short to voltage on the circuit.

• If less than 1 V, test or replace the S113 charge port door open request switch.

• If the test lamp turns ON and OFF

6. Replace the K114B hybrid powertrain control module 2.

Component Testing

Relay Test

1. Vehicle OFF, disconnect the KR119 charge port door relay.

2. Test for 60-200 ohms between terminals 85 and 86.

• If less than 60 ohms or greater than 200 ohms
Replace the KR119 charge port door relay.

• If between 60-200 ohms

3. Test for infinite resistance between the terminals listed below:

* 30 and 86

* 30 and 87

* 30 and 85

* 85 and 87

• If less than infinite resistance
Replace the KR119 charge port door relay.

• If infinite resistance

4. Install a 3 A fused jumper wire between relay terminal 85 and 12 V. Install a jumper wire between relay terminal 86 and ground.

5. Test for less than 2 ohms between terminals 30 and 87.

• If 2 ohms or greater
Replace the KR119 charge port door relay.

• If less than 2 ohms

6. All OK

Charge Port Door Open Request Switch

1. Vehicle OFF, disconnect the harness connector at the S113 charge port door open request switch.

2. Test for infinite resistance between the signal terminal 2 and the B+ terminal 1 with the switch in the open position.

• If less than infinite resistance
Replace the S113 charge port door open request switch.

• If infinite resistance

3. Test for less than 3 ohms between the signal terminal 2 and the B+ terminal 1 with the switch in the closed position.

• If 3 ohms or greater
Replace the S113 charge port door open request switch.

• If less than 3 ohms

4. All OK

Charge Port Door Actuator

1. Vehicle OFF, disconnect the harness connector at the M80 charge port door actuator.

2. Install a 20 A fused jumper wire between the control terminal 2 and 12 V. Install a jumper wire between the ground terminal 1 and ground.

3. Verify the M80 charge port door actuator activates.

• If the M80 charge port door actuator does not activate.
Replace the M80 charge port door actuator.

• If the M80 charge port door actuator activates.

4. All OK

Repair Instructions

Perform the Diagnostic Repair Verification Verification Tests after completing the diagnostic procedure.

* Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center)Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness)

* Charge Port Door Actuator Replacement Charge Port Door Actuator Replacement

* Charger Door Release Switch Replacement Removal and Replacement

* Control Module References Programming and Relearning for hybrid powertrain control module 2 replacement, programming and setup

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