Pinpoint Test Al : The Direct Current/Direct Current (Dc/Dc) Converter Control Module Does Not Respond To The Diagnostic Scan Tool

WARNING: This page is about a different variant/trim than selected.

WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

AL1 CHECK DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER CONTROL MODULE VOLTAGE POWER SUPPLY CIRCUIT

Disconnect Direct Current/Direct Current (DC/DC) Converter Control Module C4453D .

Measure:

Positive Lead	Measurement / Action	Negative Lead
C4453D-1	Courtesy of FORD MOTOR COMPANY	Ground

Is the voltage greater than 11 volts?

Yes

GO to AL2

No	VERIFY high current BJB MEGA fuse 8 (175A). If OK, REPAIR the circuit in question. If not OK, REFER to the OEM WIRING DIAGRAMS to identify the possible causes of the circuit short.

AL2 CHECK BECM (BATTERY ENERGY CONTROL MODULE) NETWORK COMMUNICATION
- Using a diagnostic scan tool, perform a network test.
Does the BECM pass the network test?

Yes GO to AL3

No GO to Pinpoint Test AJ

AL3 CHECK THE HS-CAN1 (HIGH SPEED-CONTROLLER AREA NETWORK 1) CIRCUITS BETWEEN THE DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER CONTROL MODULE AND THE BECM (BATTERY ENERGY CONTROL MODULE) FOR AN OPEN

WARNING: Never install the service disconnect plug when a high-voltage service cover is removed. Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.

Ignition OFF.

Depower the high voltage battery. REFER to: High Voltage Battery Disconnect and Connect - Hybrid Electric Vehicle (HEV) .

Remove the high voltage battery electronics cover. REFER to: Battery Energy Control Module (BECM) - Hybrid Electric Vehicle (HEV) .

Disconnect: Direct Current/Direct Current (DC/DC) Converter Control Module C4453A .

Disconnect: BECM C4237B .

Measure:

Positive Lead	Measurement / Action	Negative Lead
C4453A-3	Courtesy of FORD MOTOR COMPANY	C4237B-4
C4453A-4	Courtesy of FORD MOTOR COMPANY	C4237B-12

Are the resistances less than 3 ohms?

Yes

GO to AL4

No	REPAIR the circuit in question.

AL4 CHECK THE DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER CONTROL MODULE VOLTAGE SUPPLY CIRCUIT

Ignition ON.

Measure:

Positive Lead	Measurement / Action	Negative Lead
C4453A-1	Courtesy of FORD MOTOR COMPANY	Ground

Is the voltage greater than 11 volts?

Yes

GO to AL8

GO to AL5

AL5 CHECK THE DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER CONTROL MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN

Ignition ON.

Measure:

Positive Lead	Measurement / Action	Negative Lead
C4453A-1	Courtesy of FORD MOTOR COMPANY	C4237B-11

Is the resistance less than 3 ohms?

Yes

GO to AL6

No	REPAIR the circuit.

AL6 CHECK THE DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER CONTROL MODULE VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO GROUND

Measure:

Positive Lead	Measurement / Action	Negative Lead
C4453A-1	Courtesy of FORD MOTOR COMPANY	Ground

Is the resistance greater than 10, 000 ohms?

Yes

GO to AL7

GO to AL9

AL7 CHECK THE BECM (BATTERY ENERGY CONTROL MODULE) VOLTAGE SUPPLY CIRCUIT FOR AN OPEN

Ignition OFF.

Disconnect: BECM C4237A .

Ignition ON.

Measure:

Positive Lead	Measurement / Action	Negative Lead
C4237A-1	Courtesy of FORD MOTOR COMPANY	Ground
C4237A-10	Courtesy of FORD MOTOR COMPANY	Ground
C4237A-11	Courtesy of FORD MOTOR COMPANY	Ground

Is the voltage greater than 11 volts?

Yes	INSTALL a new BECM. REFER to: Battery Energy Control Module (BECM) - Hybrid Electric Vehicle (HEV) .

No	VERIFY BJB fuse 52 (15A) or BCM fuse 14 (10A) is OK. If OK, REPAIR the circuit. If not OK, If not OK, REFER to the OEM WIRING DIAGRAMS to identify the possible causes of the circuit short.

AL8 CHECK THE DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER CONTROL MODULE GROUND
- Ignition OFF.
- Measure the resistance between the Direct Current/Direct Current (DC/DC) Converter Control module case and a good chassis ground.
Is the resistance less than 3 ohms?

Yes GO to AL9

No REPAIR the Direct Current/Direct Current (DC/DC) Converter Control module ground as necessary.

AL9 CHECK FOR CORRECT DIRECT CURRENT/DIRECT CURRENT (DC/DC) CONVERTER CONTROL MODULE OPERATION

Disconnect and inspect all the Direct Current/Direct Current (DC/DC) Converter Control Module connectors.

Repair:
- corrosion (install new connector or terminals - clean module pins)
- damaged or bent pins - install new terminals/pins
- pushed-out pins - install new pins as necessary

Reconnect the Direct Current/Direct Current (DC/DC) Converter Control Module connectors. Make sure they seat and latch correctly.

Install the high voltage battery electronics cover. REFER to: Battery Energy Control Module (BECM) - Hybrid Electric Vehicle (HEV) .

Repower the high voltage battery. REFER to: High Voltage Battery Disconnect and Connect - Hybrid Electric Vehicle (HEV) .

Operate the system and determine if the concern is still present.

Is the concern still present?

Yes

CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new Direct Current/Direct Current (DC/DC) Converter Control Module. REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module - Hybrid Electric Vehicle (HEV) .

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.