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Circuit/System Testing

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 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.

WARNING:

The eAssist battery pack assembly will utilize an exchange program. Please consult the most recent revision of bulletin/PI# PIC5520, available in Service Information (SI), for a list of approved eAssist battery pack assembly service procedures. Components that may be removed and serviced without exchanging the complete battery pack assembly are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.

  1. Ignition OFF, disconnect the KR133 starter/generator coolant pump relay, ignition ON.
  2. 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. Ignition OFF.
    2. Test for less than 2 Ω in the B+ circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, 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. Ignition 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 G22 starter/generator control module coolant pump.
    4. Test for infinite resistance between the control circuit terminal 30 and ground.
      • If less infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance, test or replace the G22 starter/generator control module coolant pump.
    • If the test lamp illuminates 
  3. Verify a test lamp illuminates between the ignition circuit terminal 86 and ground.
    • If the test lamp does not illuminate 
    1. Ignition OFF.
    2. Test for less than 2 Ω in the ignition circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
    • If the test lamp illuminates 
  4. Connect a test lamp between the ignition circuit terminal 86 and the control circuit terminal 85.
  5. Verify the test lamp turns ON and OFF when commanding the Motor Coolant Pump Relay Enable ON and OFF with a scan tool.
    • If the test lamp is always OFF 
    1. Ignition OFF, disconnect the X2 harness connector at the K59 starter/generator control module, ignition ON.
    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
    3. Ignition OFF.
    4. Test for less than 2 Ω in the control circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K59 starter/generator control module.
    • If the test lamp is always ON 
    1. Ignition OFF, disconnect the X2 harness connector at the K59 starter/generator control module.
    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, replace the K59 starter/generator control module.
    • If the test lamp turns ON and OFF 
  6. Verify a test lamp does not illuminate between the control circuit terminal 30 and ground.
    • If the test lamp does not illuminate 

      Repair the short to voltage on the circuit.

    • If the test lamp does not illuminate 
  7. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the G22 starter/generator control module coolant pump. It may take up to 2 minutes for all vehicle systems to power down.
  8. Test for less than 10 Ω between the G22 starter/generator control module coolant pump ground circuit terminal 2 and ground.
    • If 10 Ω or greater 
    1. Ignition OFF.
    2. Test for less than 2 Ω in the ground circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 10 Ω 
  9. Connect the harness connector at the G22 starter/generator control module coolant pump.
  10. Ignition ON, connect a 10 A fused jumper wire between the B+ circuit terminal 87 and the control circuit terminal 30.
  11. Verify the G22 starter/generator control module coolant pump is activated. The G22 starter/generator control module coolant pump will make an audible noise during operation.
    • If the G22 starter/generator control module coolant pump does not activate 
    1. Ignition OFF.
    2. Test for less than 2 Ω in the control circuit terminal 30 end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, test or replace the G22 starter/generator control module coolant pump.
    • If the G22 starter/generator control module coolant pump activates 
  12. Test or replace the KR133 starter/generator coolant pump relay.
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