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Circuit/System Testing

WARNING:

High voltage enabling and disabling shall be only performed by High Voltage Qualified Technicians. The procedures for high voltage enabling/disabling can be found in the service instructions and must be strictly followed at all times. The usage of the Protocol High Voltage Disabling / Enabling is mandatory. The High Voltage Qualified Technician is responsible for the adherence to the manufacturer's service instructions as well as current national legal regulations.

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

Questions regarding training can be answered by your national training centre.

WARNING:

Any hybrid/EV battery pack replacement shall be performed by High Voltage Qualified Technicians only. The replacement procedure can be found in the service instruction and must be strictly followed at all times. The High Voltage Qualified Technician is responsible for adherence to the manufacturer's service instructions as well as current national legal regulations. If the hybrid/EV battery pack needs to be replaced contact the Technical Assistance Centre for further instructions prior removal of the battery pack.

Diagnostic A

  1. Vehicle OFF and all vehicle systems OFF, disconnect the KR73 Ignition Main Relay. It may take up to 2 min for all vehicle systems to power down.
  2. Test for less than 10 Ω between the ground circuit terminal 1 and ground.
    • If 10 Ω or greater 
    1. Vehicle 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 
  3. Vehicle in Service Mode.
  4. Verify a test lamp illuminates between the B+ circuit terminal 3 and ground.
    • If the test lamp does not illuminate 

      Replace the X50A Fuse Block - Underhood

    • If the test lamp illuminates 
  5. Connect a test lamp between the control circuit terminal 2 and the ground circuit terminal 1.
  6. Verify the test lamp turns ON and OFF when commanding the Run/Crank Relay On and Off with a scan tool.
    • If the test lamp is always OFF 
    1. Vehicle OFF, remove the test lamp, disconnect the harness connector at the K9 Body 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.
    3. 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 K9 Body Control Module.
    • If the test lamp is always ON 
    1. Vehicle OFF, remove the test lamp, disconnect the harness connector at the K9 Body Control Module, 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 K9 Body Control Module.
    • If the test lamp turns ON and OFF 
  7. Verify that a test lamp does not illuminate between the ignition circuit terminal 5 and ground.
    • If the test lamp illuminates 

      Repair the short to voltage on the ignition circuit.

    • If the test lamp does not illuminate 
  8. Vehicle in Service Mode, connect a 40 A fused jumper wire between the B+ circuit terminal 3 and the ignition circuits listed below.
    • Ignition circuit terminal 4
    • Ignition circuit terminal 5
  9. Verify the device is activated.
    • If the device does not activate 
    1. Vehicle OFF, disconnect the harness connector at the device.
    2. Test for infinite resistance between the ignition 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 Ω in the ignition circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the device.
    • If the device activates 
  10. Test or replace the KR73 Ignition Main Relay.

Diagnostic B

  1. Vehicle OFF and all vehicle systems OFF, disconnect the KR75 Engine Controls Ignition Relay, 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 

      Replace the X50A Fuse Block - Underhood

    • If the test lamp illuminates 
  3. Verify a test lamp illuminates between the B+ circuit terminal 3 and ground.
    • If the test lamp does not illuminate 

      Replace the X50A Fuse Block - Underhood

    • If the test lamp illuminates 
  4. Connect a test lamp between the B+ circuit terminal 1 and the control circuit terminal 2.
  5. Verify the test lamp turns ON and OFF when cycling the S83 vehicle ON/OFF switch between Vehicle in Service Mode and Vehicle OFF.
    • If the test lamp is always OFF 
    1. Vehicle OFF, remove the test lamp, disconnect the harness connector at the K20 engine control module, 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
    3. Vehicle 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 K20 engine control module.
    • If the test lamp is always ON 
    1. Vehicle OFF, remove the test lamp, disconnect the harness connector at the K20 engine 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 K20 engine control module.
    • If the test lamp turns ON and OFF 
  6. Verify that a test lamp does not illuminate between the ignition circuit terminal 5 and ground.
    • If the test lamp illuminates 

      Repair the short to voltage on the ignition circuit.

    • If the test lamp does not illuminate 
  7. Vehicle in Service Mode, connect a 40 A fused jumper wire between the B+ circuit terminal 3 and the ignition circuit terminal 5.
  8. Verify device is activated.
    • If the device does not activate 
    1. Vehicle OFF, disconnect the harness connector at the device.
    2. Test for infinite resistance between the ignition circuit terminal 87 and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. 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 less than 2 Ω, replace the device.
    • If the device activates 
  9. Test or replace the KR75 Engine Controls Ignition Relay.

Diagnostic C

  1. Vehicle OFF and all vehicle systems OFF, disconnect the KR76 Retained Accessory Power Relay. It may take up to 2 min for all vehicle systems to power down.
  2. Test for less than 10 Ω between the ground circuit terminal 85 and ground.
    • If 10 Ω or greater 
    1. Vehicle 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 
  3. Vehicle in Service Mode.
  4. Verify a test lamp illuminates between the B+ circuit terminal 30 and ground.
    • If the test lamp does not illuminate 

      Replace the X51A Fuse Block - Instrument Panel

    • 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 turns ON and OFF when cycling the between Vehicle in Service Mode and Vehicle OFF.
    • If the test lamp is always OFF 
    1. Vehicle OFF, remove the test lamp, disconnect the harness connector at the K84 Keyless Entry 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.
    3. 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 K84 Keyless Entry Control Module.
    • If the test lamp is always ON 
    1. Vehicle OFF, remove the test lamp, disconnect the harness connector at the K84 Keyless Entry Control Module, 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 K84 Keyless Entry Control Module.
    • If the test lamp turns ON and OFF 
  7. Verify that a test lamp does not illuminate between the ignition circuit terminal 87 and ground.
    • If the test lamp illuminates 

      Repair the short to voltage on the ignition circuit.

    • If the test lamp does not illuminate 
  8. Vehicle in Service Mode, connect a 40 A fused jumper wire between the B+ circuit terminal 30 and the ignition circuit terminal 87.
  9. Verify device is activated.
    • If the device does not activate 
    1. Vehicle OFF, disconnect the harness connector at the device.
    2. Test for infinite resistance between the ignition 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 Ω in the ignition circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the device.
    • If the device activates 
  10. Test or replace the KR76 Retained Accessory Power Relay.
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