Diagnostic Test

Read the HIGH-VOLTAGE SAFETY PROCEDURES. Refer to  HIGH VOLTAGE SAFETY PROCEDURES  . 

When the HIGH-VOLTAGE POWER-DOWN PROCEDURE is necessary. Refer to  VEHICLE HIGH VOLTAGE POWER DOWN  . 

1. With the scan tool, read DTCs in all Electronic Control Units (ECUs) and record on the repair order.
2. For future reference, with the scan tool, run and save a vehicle Scan Report and all related recorded data.
3. With the scan tool, erase all DTCs.
4. Turn the ignition off for a minimum of 10.0 seconds.
5. Turn the ignition on.
6. Using the When Monitored and Set Conditions above and recorded data, operate the vehicle in the conditions that set the DTC.
7. With the scan tool, read DTCs.

   Did the DTC return?

   Yes 

   • Go To  2

   No 

   • Perform the appropriate INTERMITTENT CONDITION diagnostic procedure. Refer to TESTING FOR AN INTERMITTENT CONDITION .

1. Refer to the recorded DTCs.

   Are any other EVCU DTCs set such as P0532 or P0533?

   Yes 

   • Repair other EVCU DTCs. Refer to DIAGNOSTIC CODE INDEX .

   No 

   • Go To  3

1. Turn the ignition off.
2. Disconnect the A/C Pressure sensor harness connector.
3. Turn the ignition on.
4. Measure the voltage on the (F896) 5 Volt Supply circuit at the A/C Pressure Sensor harness connector.

   Is the voltage above 4.9 volts?

   Yes 

   • Go To  4

   No 

   • Go To  9

1. Turn the ignition off.
2. Connect a jumper wire between the (F896) 5 Volt Supply circuit and the (C18) A/C Pressure Sensor Signal circuit at the A/C Pressure Sensor harness connector.
3. Turn the ignition on.
4. With the scan tool, read the A/C Refrigerant Pressure.

   Does the A/C Refrigerant Pressure read about 543.0 PSI?

   Yes 

   • Go To  5

   No 

   • Go To  7

1. Turn the ignition off.
2. Remove the jumper wire from the A/C Pressure Sensor harness connector.
3. Connect a jumper wire between the (C918) Return circuit and the (C18) A/C Pressure Sensor Signal circuit at the A/C Pressure Sensor harness connector.
4. Turn the ignition on.
5. With the scan tool, read the A/C Refrigerant Pressure.

   Does the A/C Refrigerant Pressure read about 0 PSI?

   Yes 

   • Replace the A/C Pressure Sensor in accordance with the Service Information.
   • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .

   No 

   • Go To  6

1. Turn the ignition off.
2. Disconnect the PIM harness connector.
3. Measure the resistance of the (C918) Return circuit between the EVCU harness connector and the A/C Pressure Sensor harness connector.

   Is the resistance below 3.0 Ohms?

   Yes 

   • Go To  11

   No 

   • Repair the (C918) Return circuit for an open or high resistance.
   • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .

1. Measure the resistance of the (C18) A/C Pressure Sensor Signal circuit between the EVCU harness connector and the A/C Pressure Sensor harness connector.

   Is the resistance below 3.0 Ohms?

   Yes 

   • Go To  8

   No 

   • Repair the (C18) A/C Pressure Sensor Signal circuit for an open or high resistance.
   • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .

1. Check for continuity between the (C18) A/C Pressure Sensor Signal circuit and all other circuits at the EVCU harness connector.

   Is there continuity between the (C18) A/C Pressure Sensor Signal circuit and any other circuit?

   Yes 

   • Repair the (C18) A/C Pressure Sensor Signal circuit for a short to another circuit.
   • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .

   No 

   • Go To  11

1. Measure the resistance of the (F896) 5 Volt Supply circuit between the A/C Pressure Sensor harness connector and the EVCU harness connector.

   Is the resistance below 3.0 Ohms?

   Yes 

   • Go To  10

   No 

   • Repair the (F896) 5 Volt Supply circuit for an open or high resistance.
   • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .

1. Check for continuity between ground and the (F896) 5 Volt Supply circuit at the EVCU harness connector.

   Is there continuity between ground and the (F896) 5 Volt Supply circuit?

   Yes 

   • Repair the (F896) 5 Volt Supply circuit for a short to ground.
   • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .

   No 

   • Go To  11

1. Disconnect all EVCU harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
   • 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.

   Repair any conditions that are found.

5. Reconnect all EVCU harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PIM DTCs.

    Did the DTC return?

    Yes 

    • Replace the EVCU in accordance with the Service information. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) .
    • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .

    No 

    • Perform the Electric Vehicle Control Unit (EVCU) VERIFICATION TEST. Refer to ELECTRIC VEHICLE CONTROL UNIT (EVCU) VERIFICATION TEST .
    • Test complete.