Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Diagnostic Test
- CHECK FOR AN ACTIVE DTC
- With the scan tool, read Battery Pack Control Module (BPCM) DTCs and record on the repair order.
- Record the Freeze Frame Data (If available), Event Data (If available), and Environmental Data.
- With the scan tool, erase DTCs.
- Using the recorded data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
- With the scan tool, read BPCM DTCs.
Did the DTC return?
Yes
- Go To 2
No
- Perform the TESTING FOR AN INTERMITTENT CONDITION procedure. Refer to INTERMITTENT CONDITION .
- CHECK RELATED HARNESS CONNECTIONS
- Disconnect all BPCM harness connectors.
- Disconnect all related in-line harness connections (if equipped).
- Disconnect the related component harness connectors.
- Inspect harness connectors, component connectors, and follow Quick Reference Guide to inspect related eTorque component connections:
- Proper connector installation.
- Damaged connector locks.
- Corrosion.
- Other signs of water intrusion.
- Weather seal damage (if equipped).
- Bent terminals.
- Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
- Terminals that have been pushed back into the connector cavity.
- Perform a terminal drag test on each connector terminal to verify proper terminal tension.
NOTE:CHECKING TORQUE ON ELECTRICAL CONNECTIONS
•Use a calibrated hand torque wrench of the proper range.
•Always check torque in the tightening direction with a steady pull.
•Correct torque is the reading obtained when the nut or bolt begins to turn.
Occasionally, the checking procedure will result in a high snap or creak torque due to overcoming static friction, followed by a lower torque reading after initial movement of the torqueable component. The more accurate torque check is the reading obtained just after the high breakaway and as the torqueable component begins to rotate. This is referred to as "stick slip".
•Record the measured torque value on the checklist
Repair any conditions that are found.
- Reconnect all BPCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
- Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
- Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
- With the scan tool, erase DTCs.
- Using the recorded Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
- With the scan tool, read BPCM DTCs.
Did the DTC return?
Yes
- Replace the Power Pack Unit in accordance with the Service Information. Refer to UNIT, POWER PACK PPU, REMOVAL AND INSTALLATION, 3.6L or UNIT, POWER PACK PPU, REMOVAL AND INSTALLATION, 5.7L .
- Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
No
- Perform the BATTERY PACK CONTROL MODULE (BPCM) VERIFICATION TEST. Refer to BPCM VERIFICATION TEST .
- Test complete.
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.