Plug-In Charging Malfunction
Plug-In Charging 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 drive motor battery charger cable allows the vehicle to be charged using a common household power outlet. The drive motor battery charger cable contains LEDs that indicate the status of the drive motor battery charger cable. The drive motor battery charger cable automatically prohibits voltage transfer to the hybrid/EV battery charger receptacle and illuminates the indicator LEDs red if it senses internal faults or inadequate household voltage. If the drive motor battery charger cable senses no faults, voltage transfer to the hybrid/EV battery charger receptacle occurs and the indicator LEDs are illuminated green. Charging continues until Hybrid/EV Battery Pack State of Charge reaches 86% at which point the green indicator will flash slowly, indicating charging is complete.
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
Plug-In Charging System Description and Operation 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
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 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 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.
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 if you have any questions.
1. Verify no Powertrain DTCs are set.
• If any Powertrain DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Trouble Code (DTC) List - Vehicle.
2. Connect drive motor battery charger cable to household power outlet, but not the battery charger receptacle.
3. After 25 seconds, verify drive motor battery charger cable LEDs illuminate solid green.
• If drive motor battery charger cable LEDs do not illuminate solid green, connect a known good drive motor battery charger cable to the same household power outlet.
• If known good drive motor battery charger cable LEDs illuminate solid green, replace drive motor battery charger cable.
• If known good drive motor battery charger cable LEDs do not illuminate solid green, inspect household power outlet for insufficient voltage or open/high resistance.
4. Connect a test lamp between the low voltage circuits listed below on drive motor battery charger cable. Verify the test lamp illuminates.
* Proximity status signal circuit terminal D
* Control pilot signal circuit terminal B
• If the test lamp does not illuminate, replace drive motor battery charger cable.
5. Vehicle OFF, disconnect the harness connector from K114B hybrid/EV powertrain control module 2 X2 and the harness connector X98 hybrid/EV battery charger receptacle. Test for less than 2 ohms between the terminals listed below:
* Proximity status signal circuit terminal D at the X98 hybrid/EV battery charger receptacle and terminal 15 X2
* Control pilot signal circuit terminal B at the X98 hybrid /EV battery charger receptacle and terminal 8 X2
• If 2 ohms or greater, repair the open/high resistance in the circuit.
6. Test for infinite resistance between the terminals listed below and ground:
* Proximity status signal circuit terminal 15 X2
* Control pilot signal circuit terminal 8 X2
• If less than infinite resistance, repair the short to ground on the circuit.
7. Test for infinite resistance between proximity status signal circuit terminal 15 X2 and the control pilot signal circuit terminal 8 X2.
• If less than infinite resistance, repair the short between the circuit.
8. Vehicle in Service Mode, test for less than 1 V between the terminals listed below and ground:
* Proximity status signal circuit terminal 15 X2
* Control pilot signal circuit terminal 8 X2
• If 1 V or greater, repair the short to voltage on the circuit.
9. If all circuits test normal, replace the Hybrid Powertrain Control Module 2.
Repair Instructions
Perform the Diagnostic Repair Verification Verification Tests after completing the diagnostic procedure.
* Battery Charge Indicator Replacement Service and Repair
* Control Module References Programming and Relearning for battery charger control module replacement, programming and setup