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Lincoln Aviator 2020-2024 Service Manual / Electrical / Battery and Charging System / Voltage Converter/Inverter / Diagnosis and Testing - Direct Current/Direct Current (DC/DC) Converter Control Module

Lincoln Aviator: Voltage Converter/Inverter / Diagnosis and Testing - Direct Current/Direct Current (DC/DC) Converter Control Module

Diagnostic Trouble Code (DTC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Diagnostic Trouble Code Chart


Module   DTC Description Action
  DCDC P0A94:4B DC/DC Converter "A" Performance: Over Temperature   GO to Pinpoint Test C
  DCDC P0D32:00 DC/DC Converter Over Temperature: No Sub Type Information   GO to Pinpoint Test C
  DCDC P0E56:00 DC/DC Converter Input Voltage Too Low: No Sub Type Information   GO to Pinpoint Test D
  DCDC P0E56:13 DC/DC Converter Input Voltage Too Low: Circuit Open   GO to Pinpoint Test D
  DCDC P0E57:00 DC/DC Converter Input Voltage Too High: No Sub Type Information   GO to Pinpoint Test E
  DCDC U0100:00 Lost Communication With ECM/PCM "A": No Sub Type Information   GO to Pinpoint Test I
  DCDC U0111:00 Lost Communication With Battery Energy Control Module "A": No Sub Type Information   GO to Pinpoint Test J
  DCDC U0412:00 Invalid Data Received From Battery Energy Control Module "A": No Sub Type Information   GO to Pinpoint Test K
  DCDC U3000:04 Control Module: System Internal Failures   GO to Pinpoint Test L
  DCDC U3000:41 Control Module: General Checksum Failure   GO to Pinpoint Test M
  DCDC U3000:42 Control Module: General Memory Failure   GO to Pinpoint Test M
  DCDC U3000:45 Control Module: Program Memory Failure   GO to Pinpoint Test M
  DCDC U3000:49 Control Module: Internal Electronic Failure   GO to Pinpoint Test M
  DCDC U3000:96 Control Module: Component Internal Failure   GO to Pinpoint Test N
  DCDC U3003:16 Battery Voltage: Circuit Voltage Below Threshold   GO to Pinpoint Test F
  DCDC U3003:17 Battery Voltage: Circuit Voltage Above Threshold   GO to Pinpoint Test G
  DCDC U3003:62 Battery Voltage: Signal Compare Failure   GO to Pinpoint Test H

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Global Customer Symptom Code Chart


Customer Symptom Action
Driver Aid & Information > Warning Indicators/Messages/Chimes > Charging System > Stays On   GO to Pinpoint Test A
Driver Aid & Information > Warning Indicators/Messages/Chimes > Charging System > Stays On   GO to Pinpoint Test B

Pinpoint Test(s)


PINPOINT TEST A : THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) DOES NOT RESPOND TO THE SCAN TOOL

Normal Operation and Fault Conditions

REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module - System Operation and Component Description (414-05 Voltage Converter/Inverter, Description and Operation).

Possible Sources

  • Fuse(s)
  • 12-volt battery
  • DCDC
  • SOBDMC
  • Wiring, terminals or connectors
A1 CARRY OUT A NETWORK TEST
  • Ignition ON.
  • Carry out the network test.

Is the DCDC the only module to fail?
Yes GO to Pinpoint Test F
No DIAGNOSE the network concern.
REFER to: Communications Network - System Operation and Component Description (418-00 Module Communications Network, Description and Operation).

PINPOINT TEST B : CHECK CHARGING SYSTEM DISPLAYED IN THE MESSAGE CENTER

Normal Operation and Fault Conditions

REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module - System Operation and Component Description (414-05 Voltage Converter/Inverter, Description and Operation).

Possible Sources

  • Fuse(s)
  • 12-volt battery
  • High Voltage Battery cooling system
  • DCDC
  • Wiring, terminals or connectors
B1 CARRY OUT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF TEST
  • Ignition ON.

  • Access the  DCDC  and monitor the  DCDC_ENABLE  PID

    . If the PID does not read Enable verify the high voltage battery service disconnect is installed.
  • Carry out the DCDC self-test.

Are any DCDC DTCs present?
Yes DIAGNOSE any DCDC DTCs, REFER to the DTC chart in this section.
No GO to B2

B2 CARRY OUT THE BECM (BATTERY ENERGY CONTROL MODULE) SELF TEST
  • Carry out the BECM self-test.

Are any BECM DTCs present?
Yes DIAGNOSE any BECM DTCs,
REFER to: High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Diagnosis and Testing).
No GO to Pinpoint Test F

PINPOINT TEST C : P0A94:4B, P0D32:00

Normal Operation and Fault Conditions

The DCDC is liquid cooled by the motor electronics cooling system that consists of a radiator, coolant hoses, and a coolant pump. The DCDC monitors its temperature internally. The DCDC requests a coolant flow speed and monitors the coolant pump status from the BECM via HS-CAN.

If the internal temperature increases higher than 81°C (178°F), P0A94:4B sets and the output current is limited until the over-temperature condition clears.

If the internal temperature becomes excessive, DTC P0D32:00 sets and the DCDC goes to standby mode ( DCDC disabled) until the over-temperature condition clears. Presence of this DTC results in CHECK CHARGING SYSTEM being displayed in the message center and the 12-volt battery discharged.

Reduced or no functionality of 12-volt systems (such as the headlamps, and HVAC blower motor) may also be noticed.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC P0A94:4B DC/DC Converter "A" Performance: Over Temperature Sets in the DCDC when the internal thermistor reaches a temperature greater than 81°C (178°F).
DCDC P0D32:00 DC/DC Converter Over Temperature: No Sub Type Information Sets in the DCDC when one or all of the internal thermistor(s) reach a temperature above 110°C (230°F), or the base plate thermistor reaches a temperature above 86°C (187°F).

Possible Sources

  • Low coolant level
  • Airlock in system
  • Coolant flow restriction
  • Electric motor electronics coolant pump
  • Electric motor electronics radiator
  • Restricted airflow through motor electronics radiator
  • BECM
  • High ambient temperatures

Visual Inspection and Pre-checks

  • Verify no front end damage is present.
  • Verify the coolant level is not low.
  • Inspect coolant pipes and hoses for kinks, leaks or other damage.
  • Inspect for air flow restrictions.
C1 CHECK THE ELECTRIC POWERTRAIN COOLING SYSTEM COOLANT LEVEL
  • Ignition OFF.
  • Visually inspect the coolant level in the electric powertrain cooling system degas bottle.

Was the coolant level at specification?
Yes GO to C2
No Adjust the coolant level as needed and pressure test the cooling system and check for leaks.

C2 CHECK BECM (BATTERY ENERGY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
  • Ignition ON.
  • Using a diagnostic scan tool, clear the BECM DTCs.
  • Using a diagnostic scan tool, perform the BECM self-test.

Are DTCs P0A06:00, P0A07:00, P0C73:00, P2D00:00, P2D01:00, P2D02:00, P2D03:00, and/or P2D04:00 present?
Yes DIAGNOSE the BECM DTCs.
REFER to: High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Diagnosis and Testing).
No GO to C3

C3 ACTIVE COMMAND THE ELECTRIC MOTOR ELECTRONICS COOLANT PUMP ON AND REPEAT THE BECM (BATTERY ENERGY CONTROL MODULE) SELF TEST
  • Ignition ON.

  • Access the  BECM  and control the  COOL_PMP_B_CMD (%)  PID

  • Using the scan tool, active command the coolant pump to 100% for 5 minutes. Confirm if the affected coolant pump is running by feeling the pump for vibration.
  • Using a diagnostic scan tool, perform BECM self-test.

Is DTC P0A06:00, P0A07:00, P0C73:00, P2D00:00, P2D01:00, P2D02:00, P2D03:00, and/or P2D04:00 present OR is the affected coolant pump inoperative?
Yes
REFER to: High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Diagnosis and Testing).
No GO to C4

C4 CHECK FOR AN AIR FLOW RESTRICTION

NOTE: Verify no vehicle front end damage is present.

  • Check the electric powertrain radiators for external obstruction such as leaves or cardboard and verify all air deflectors are present.

Is an air flow restriction present?
Yes REPAIR as necessary.
No GO to C5

C5 CHECK THE ELECTRIC COOLING FAN OPERATION
  • Ignition ON.
  • Connect the diagnostic tool.

  • Access the  PCM  and control the  FAN_DSD (%)  PID

  • Active command the electric cooling fan to 100%.

Did the electric cooling fan operate?
Yes GO to C6
No DIAGNOSE the electric cooling fan operation. Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. Section 3 Symptom Charts.

C6 CHECK FOR A COOLANT FLOW RESTRICTION
  • Ignition OFF.
  • Verify there are no obvious coolant flow restrictions in the coolant hoses for the high voltage battery.
  • Inspect the coolant hoses and pipes for:
    • damage
    • kinks

Are the cooling system hoses and components free any kinks or damage?
Yes GO to C7
No REPAIR or INSTALL new components as necessary.

C7 CLEAR THE DIAGNOSTIC TROUBLE CODES (DTCS) AND REPEAT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF-TEST

NOTE: Let vehicle sit with the key off for minimum for 1 hour to allow the Direct Current/Direct Current Converter Control Module (DC/DC) to cool prior to performing next steps.

  • Using a diagnostic scan tool, clear the DCDC DTCs.
  • Using a diagnostic scan tool, perform the DCDC self-test.

Are any DCDC DTCs present?
Yes For U3000:49 GO to Pinpoint Test M
For P0D32:00 only, GO to C8
For all other DTCs, DIAGNOSE any remaining DTCs in this section, REFER to the DTC chart in this section.
No The system is operating correctly at this time. The DTCs may have set due to high environmental temperatures, high network traffic or an intermittent fault condition.

C8 CLEAR THE DIAGNOSTIC TROUBLE CODES (DTCS) AND REPEAT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF-TEST
  • Using a diagnostic scan tool, clear the DCDC DTCs.
  • Using a diagnostic scan tool, perform the DCDC self-test.

Is DTC P0D32:00 the only DTC present?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, INSTALL a new DCDC.
No The system is operating correctly at this time. The DTCs may have set due to high environmental temperatures, high network traffic or an intermittent fault condition.

PINPOINT TEST D : P0E56:00, P0E56:13

Normal Operation and Fault Conditions

The DCDC monitors the high-voltage available from the high-voltage battery. If the DCDC senses high voltage of less than 152 volts, it sets P0E56:00. The DCDC also compares that high-voltage reading with the high-voltage available to the SOBDMC, which is communicated via a HS-CAN message. When the DCDC compares its available high-voltage to that available to the SOBDMC and determines the difference to be 120 volts or more, it sets DTC P0E56:13. Both DTCs result in a request the CHECK CHARGING SYSTEM message be displayed in the message center. The DCDC attempts to maintain operation. An open high-voltage, low-current fuse (located in the high voltage battery junction box) may cause the DCDC to be non-functional, resulting in the 12-volt battery eventually becoming drained. Reduced or no functionality of 12-volt systems (such as the headlamps, HVAC blower motor) may also be noticed.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC P0E56:00 DC/DC Converter Input Voltage Too Low: No Sub Type Information Sets in the DCDC when the high voltage measured by the DCDC is less than 152 volts.
DCDC P0E56:13 DC/DC Converter Input Voltage Too Low: Circuit Open Sets in the DCDC when the difference in high voltage between the SOBDMC and DCDC is greater than 120 volts.

Possible Sources

  • High voltage low current fuse
  • High voltage cables
  • Wiring, terminals or connectors
  • DCDC
D1 COMPARE HIGH VOLTAGE BUS VOLTAGE PID (PARAMETER IDENTIFICATION) VALUES AT THE SOBDMC (SECONDARY ON-BOARD DIAGNOSTIC CONTROL MODULE C) AND DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE)

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Ignition ON.

  • Access the  DCDC  and monitor the  DCDC_ENABLE  PID

    . If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).

  • Access the  SOBDMC  and monitor the  HVBAT_V (V)  PID

  • Record the SOBDMC HVBAT_V PID.

  • Access the  DCDC  and monitor the  HEV_HI_VOL (V)  PID

  • Record the DCDC HEV_HI_VOL PID.

Is the difference between the SOBDMC PID and the DCDC PID 120V or greater?
Yes GO to D2
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.

D2 CHECK THE HIGH VOLTAGE CONNECTIONS AT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) AND HIGH VOLTAGE BATTERY
  • Ignition OFF.
  • Depower the high voltage battery.
  • Disconnect DCDC C1457A .
  • Disconnect High voltage battery C4236D HEV or C494 PHEV .
  • Inspect DCDC C1457A and high voltage battery C4236D HEV or C494 PHEV for:
    • corrosion
    • damaged or bent pins
    • pushed-out pins

Are any concerns present?
Yes INSTALL a new (14B322) wiring harness.
No GO to D3

D3 CHECK THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) S
  • Connect DCDC C1457A .
  • Connect High voltage battery C4236D HEV or C494 PHEV .
  • Verify the high voltage DCDC C1457A and high voltage battery C4236D HEV or C494 PHEV are fully seated.
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform DCDC self-test.

Are DTCs P0E56:00 or P0E56:13 present?
Yes GO to D4
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.

D4 CHECK THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) HIGH VOLTAGE CIRCUITS
  • Ignition OFF.
  • Disconnect DCDC C1457A .
  • Disconnect High voltage battery C4236D HEV or C494 PHEV .
  • For HEV measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1457A-2   C4236D-1
      C1457A-3   C4236D-2
  • For PHEV measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1457A-2   C494-4
      C1457A-3   C494-1

Are the resistances less than 3 ohms?
Yes GO to D5
No INSTALL a new (14B322) wiring harness.

D5 CHECK THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) HIGH VOLTAGE LOW CURRENT FUSE

  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.

  • Remove the high voltage low current fuse. HEV
    REFER to: High Voltage Low Current Fuse - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Removal and Installation).
    For PHEV
    REFER to: High Voltage Low Current Fuse - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Removal and Installation).
  • Measure the resistance of the high voltage low current fuse.

Is the resistance less than 3 ohms?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, INSTALL a new DCDC.
No For HEV INSTALL a new (50A) high voltage low current fuse.
REFER to: High Voltage Low Current Fuse - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Removal and Installation).
INSPECT the high voltage cable between the high voltage battery and DCDC for signs of an obvious short condition. INSTALL a new (14B322) wiring harness if a short exists. If an obvious short condition is not identified, INSTALL a new DCDC.
For PHEV INSTALL a new (40A) high voltage low current fuse.
REFER to: High Voltage Low Current Fuse - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Removal and Installation).
INSPECT the high voltage cable between the high voltage battery and DCDC for signs of an obvious short condition. INSTALL a new (14B322) wiring harness if a short exists. If an obvious short condition is not identified, INSTALL a new DCDC.

PINPOINT TEST E : P0E57:00

Normal Operation and Fault Conditions

The DCDC monitors the high voltage available from the high voltage battery. If the DCDC senses high voltage of greater than 327 volts for HEV or 413 volts for PHEV, it sets DTC P0E57:00 and requests the CHECK CHARGING SYSTEM message be displayed in the message center. The DCDC goes to standby mode ( DCDC disabled) until the high voltage condition clears, resulting in the 12-volt battery eventually becoming discharged. Reduced or no functionality of 12-volt systems (such as the headlamps and HVAC blower motor) may also be noticed.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC P0E57:00 DC/DC Converter Input Voltage Too High: No Sub Type Information Sets in the DCDC when the high voltage battery voltage is greater than 327 volts for HEV or 413 volts for PHEV.

Possible Sources

  • High voltage battery system fault
  • High voltage cables
  • DCDC
E1 CHECK THE SOBDMC (SECONDARY ON-BOARD DIAGNOSTIC CONTROL MODULE C) FOR HIGH VOLTAGE DIAGNOSTIC TROUBLE CODES (DTCS)
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Ignition OFF.
  • Ignition ON.
  • Using a diagnostic scan tool, perform the SOBDMC self-test and record the results.

Is SOBDMC DTC P1A07:00 reported?
Yes
REFER to: Electric Powertrain Control (303-14B Electric Powertrain Control - 3.0L EcoBoost – Hybrid (BQ), Diagnosis and Testing).
No GO to E2

E2 CHECK THE HIGH VOLTAGE PID (PARAMETER IDENTIFICATION) TO THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE)

  • Access the  DCDC  and monitor the  HEV_HI_VOL (V)  PID

    .

Does the PID read less than 327 volts for HEV or 413 volts for PHEV?
Yes The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.
No Perform the BECM self-test. If BECM DTCs are present, DIAGNOSE the BECM DTCs first.
If there are no BECM DTCs present, GO to E3

E3 CHECK THE HIGH VOLTAGE CONNECTIONS AT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) AND HIGH VOLTAGE BATTERY
  • Ignition OFF.
  • Depower the high voltage battery.
  • Disconnect DCDC C1457A .
  • Disconnect High voltage battery C4236D HEV or C494 PHEV .
  • Inspect DCDC C1457A and high voltage battery C4236D HEV or C494 PHEV for:
    • corrosion
    • damaged or bent pins
    • pushed-out pins

Is a concern present?
Yes Install a new (14B322) wiring harness.
No GO to E4

E4 CLEAR THE DIAGNOSTIC TROUBLE CODES (DTCS) AND REPEAT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF-TEST

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Connect DCDC C1457A .
  • Connect High voltage battery C4236D HEV or C494 PHEV .
  • Connect the high voltage battery.
  • Ignition ON.
  • Using the scan tool, clear the DCDC DTCs.
  • Using a diagnostic scan tool, view DCDC PIDs.

  • Access the  DCDC  and monitor the  DCDC_ENABLE  PID

    . If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other DTC's have been addressed.
  • Using a diagnostic scan tool, perform DCDC self-test.

Is DTC P0E57:00 present?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, INSTALL a new DCDC.
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.

PINPOINT TEST F : U3003:16

Normal Operation and Fault Conditions

The DCDC monitors the 12-volt battery system voltage internally at the B+ terminal of the DCDC. If the voltage drops below 10.3 volts at the B+ terminal (output of DC/DC) while the ignition is ON, the DCDC sets DTC U3003:16. The DCDC will continue to produce output current until the B+ terminal voltage is less than 8V. At that point the DCDC goes to standby mode ( DCDC disabled) and the 12-volt battery can eventually be discharged. Reduced or no functionality of 12-volt systems (such as the headlamps and HVAC blower motor) may also be noticed.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U3003:16 Battery Voltage: Circuit Voltage Below Threshold Sets if the DCDC detects an output of less than 10.3 volts. This DTC can also be set due to an improper jump start (reverse polarity jump starting), a loose B+ connection from the 12V battery to the DCDC or due to an internal fault.

Possible Sources

  • Reverse polarity jump
  • Open B+ circuit
  • Loose B+ connection
  • 12-volt battery
  • 12-volt battery cables
  • Wiring, terminals or connectors
  • Fuse(s)
  • DCDC
  • PCM
F1 CHECK THE HIGH CURRENT FUSE

NOTE: DTC U3003:16 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Verify the high current fuse box fuse 201 (275A) is OK.
  • CHECK all B+ cable connections between the 12V battery and the DCDC.

Are all of the B+ cable connections between the 12V battery and the DCDC secure?
Yes GO to F2
No SECURE any loose B+ cable connections between the 12V battery and the DCDC.

F2 CHECK FOR CONTINUITY BETWEEN THE 12V BATTERY B+ AND THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) B+

NOTE: DTC U3003:16 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Ignition OFF.
  • REFER to the wiring diagram for locations of all the B+ cable connections.
  • CHECK for continuity between the 12V battery B+ and C1475C (12V DCDC B+)
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) 12V BATTERY B+

Is the resistance less than 5 ohms?
Yes GO to F3
No VERIFY the high current fuse box fuse 201 (275A) is OK. If not OK, If not OK, INSTALL a new high current fuse box fuse 201 (275A). U3003:16 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the wiring diagram to identify the possible causes of the open circuit. INSTALL new B+ cables if necessary.

F3 TEST 12V BATTERY CONDITION

NOTE: All testing should be completed at the main engine compartment 12v battery.

  • Ignition OFF.
  • Perform the battery condition test.
    REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).

Did the battery pass the condition test?
Yes GO to F4
No INSTALL a new 12V battery.
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

F4 CHECK FOR DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) S P0E56:00 OR P0E56:13

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Ignition ON.

  • Access the  DCDC  and monitor the  DCDC_ENABLE  PID

    . If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform the DCDC self-test.

Are DTCs P0E56:00 or P0E56:13 present?
Yes GO to Pinpoint Test D
No GO to F5

F5 REMOVE AND INSPECT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) AUX BATTERY FUSE
  • Ignition OFF.
  • Remove and inspect BJB fuse 159 (15A) for being open.

Is the fuse open?
Yes REFER to the Wiring Diagrams manual to identify the possible cause of the circuit short. If no short is identified install a new fuse and test for normal operation.
No GO to F6

F6 PERFORM THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) AND PCM (POWERTRAIN CONTROL MODULE) SELF-TESTS

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Inspect the DCDC C1457B, make sure it is seated and latched correctly.
  • Ignition ON.
  • Using a diagnostic scan tool, view the DCDC PIDs.

  • Access the  DCDC  and monitor the  DCDC_ENABLE  PID

    . If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using the scan tool, clear the DCDC DTCs.
  • Using a diagnostic scan tool, perform the DCDC self-test and record any DTCs.
  • Using the scan tool, clear the PCM DTCs.
  • Using a diagnostic scan tool, perform the PCM self-test and record any DTCs.

Did both the DCDC and PCM perform a self-test?
Yes GO to F7
No DIAGNOSE the scan tool communication with the DCDC and/or PCM.
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

F7 COMPARE VOLTAGE AT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) TO THE BATTERY VOLTAGE
  • Start the vehicle (Ready indicator light ON).
  • Turn the headlamps on and the blower on high.
  • Measure:
    Positive Lead Measurement / Action Negative Lead
  • Ignition OFF.
  • Disconnect the 12V battery.
    REFER to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  • Inspect the DCDC 12V B+ terminal to verify there are at least 3 threads above the nut. If not, disassemble and inspect the terminal and stud, clean or replace one or both.
  • Start the vehicle (Ready indicator light ON).
  • Turn the headlamps on and the blower on high.
  • Measure:
    Click to display connectors

    NOTE: Place the positive lead on the DC/DC Converter B+ stud.


    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) G117

Is the measured voltage within 0.5V of 12V battery?
Yes For PCM DTC P0562:00 without DCDC DTC U3003:16, GO to F8
For DCDC DTC U3003:16 with or without PCM DTC P0562:00 OR if there are NO DTC's, GO to F11
No GO to F11

F8 REMOVE AND INSPECT THE PCM (POWERTRAIN CONTROL MODULE) VPWR FUSE
  • Ignition OFF.
  • Remove and inspect BJB fuse 6 (20A) for being open.

Is the fuse open?
Yes REFER to the Wiring Diagrams manual to identify the possible cause of the circuit short. If no short is identified install a new fuse and test for normal operation.
No GO to F9

F9 CHECK THE PCM (POWERTRAIN CONTROL MODULE) VPWR CIRCUITS
  • Ignition OFF.
  • Disconnect PCM HEV C175B or PHEV C1551B .
  • For HEV, connect a 5A fused jumper between:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C175B-60   Ground
  • For PHEV, connect a 5A fused jumper between:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1551B-60   Ground
  • Ignition ON.
  • For HEV, measure and record:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C175B-1   Ground
      C175B-2   Ground
      C175B-16   Ground
  • For PHEV, measure and record:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1551B-1   Ground
      C1551B-2   Ground
      C1551B-16   Ground

Is the measured voltage within 0.5V of 12V battery?
Yes GO to F10
No REPAIR the affected circuit.

F10 CHECK THE PCM (POWERTRAIN CONTROL MODULE) GROUND CIRCUITS
  • Ignition OFF.
  • Disconnect the fused jumper.
  • For HEV, measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C175B-46 12V BATTERY B+
      C175B-47 12V BATTERY B+
      C175B-61 12V BATTERY B+
      C175B-62 12V BATTERY B+
      C175B-76 12V BATTERY B+
      C175B-77 12V BATTERY B+
  • For PHEV, measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1551B-46 12V BATTERY B+
      C1551B-47 12V BATTERY B+
      C1551B-61 12V BATTERY B+
      C1551B-62 12V BATTERY B+
      C1551B-76 12V BATTERY B+
      C1551B-77 12V BATTERY B+

Does the test lamp illuminate on all pins?
Yes GO to F14
No REPAIR the affected circuit or chassis ground.

F11 MEASURE VOLTAGE DROP OF DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) B+ CABLE
  • Measure:
    Click to display connectors

    NOTE: Place the positive lead on the DC/DC Converter B+ stud.


    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) 12V BATTERY B+

Is the voltage drop less than 0.5 volt?
Yes Verify G117 and G119 body connections are OK. If not OK, REPAIR the connection. If OK, REPAIR 12V Battery B- circuit or INSTALL a new 12V battery negative cable if necessary.GO to F12 If there are NO DTC's, GO to F15.
No VERIFY the high current fuse box fuse 201 (275A) is OK. If not OK, If not OK, INSTALL a new high current fuse box fuse 201 (275A). U3003:16 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the wiring diagram to identify the possible causes of the open circuit. INSTALL new B+ cables if necessary.

F12 VERIFY THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) CASE GROUND
  • Reconnect the PCM connectors.
  • Start the vehicle (Ready indicator light ON).
  • Turn the headlamps on and the blower on high.
  • Measure:

    NOTE: Place the positive lead on the DC/DC Converter Case.


    Positive Lead Measurement / Action Negative Lead
    DC/DC Case

Is the voltage drop less than 0.5V?
Yes GO to F13
No INSPECT and REPAIR the DCDC case ground issue or the battery ground for corrosion.

F13 CLEAR THE DIAGNOSTIC TROUBLE CODES (DTCS) AND REPEAT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF-TEST

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Using the scan tool, clear the DCDC DTCs.
  • Using a diagnostic scan tool, view DCDC PIDs.
  • Monitor the EnableStat PID. If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other DTC's have been addressed.
  • Using a diagnostic scan tool, perform DCDC self-test.

Is DTC U3003:16 present?
Yes GO to F15
No The system is operating correctly at this time. The concern may have been caused by a discharged battery.

F14 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Ignition OFF.
  • Disconnect and inspect all PCM 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 PCM connectors. Make sure they seat and latch correctly.
  • Operate the system and determine if the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern,
   Click here to access Guided Routine (PCM). Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
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.

F15 CHECK FOR CORRECT DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) CONVERTER OPERATION
  • Ignition OFF.
  • Ignition ON.
  • Using a diagnostic scan tool, view DCDC PIDs.
  • Monitor the EnableStat PID. If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other DTC's have been addressed.

  • Access the  DCDC  and monitor the  DCDC_LOW_V_SET (V)  PID

    , record the voltage.
  • Measure:
    Click to display connectors

    NOTE: Place the positive lead on the DC/DC Converter B+ stud.


    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) G117

Is the voltage within .5V of the recorded PID value?
Yes Make sure the 12V battery voltage is within 0.5V, if not GO to F11 If the voltage is within 0.5V the system is operating correctly at this time. The concern may have been caused by module connections. Address the root cause of any connection issues.
No CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, INSTALL a new DCDC.

PINPOINT TEST G : U3003:17

Normal Operation and Fault Conditions

The DCDC monitors the 12-volt battery system voltage internally at the B+ terminal of the DCDC. If the voltage is greater than 16 volts, the DCDC sets DTC U3003:17. The DCDC goes to standby mode ( DCDC disabled) and the 12-volt battery can eventually be discharged. Reduced or no functionality of 12-volt systems (such as the headlamps and HVAC blower motor) may also be noticed.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U3003:17 Battery Voltage: Circuit Voltage Above Threshold Sets in the DCDC if the 12-volt battery system voltage is greater than 16.5 volts.

Possible Sources

  • External 12V battery charger
  • Aftermarket accessories
  • Wiring, terminals or connectors
  • Fuse(s)
  • DCDC
  • PCM
G1 CHECK THE HIGH CURRENT FUSE

NOTE: DTC U3003:17 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Verify the high current fuse box fuse 201 (275A) is OK.
  • CHECK all B+ cable connections between the 12V battery and the DCDC.

Are all of the B+ cable connections between the 12V battery and the DCDC secure?
Yes GO to G2
No SECURE any loose B+ cable connections between the 12V battery and the DCDC.

G2 PERFORM THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) AND PCM (POWERTRAIN CONTROL MODULE) SELF-TESTS

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Ignition ON.
  • Using a diagnostic scan tool, view the DCDC PIDs.

  • Access the  DCDC  and monitor the  DCDC_ENABLE  PID

    . If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using a diagnostic scan tool, clear all DCDC Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform the DCDC self-test and record Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, clear all PCM Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform the PCM self-test.

If DTC U3003:17 is reported in the DCDC and/or DTC P0563:00 reported in the PCM?
Yes If DTC U3003:17 is reported in the DCDC with other Diagnostic Trouble Codes (DTCs) REPAIR all other DCDC Diagnostic Trouble Codes (DTCs) before repairing U3003:17. GO to the DCDC DTC chart in this section. If U3003:17 is the only DTC reported in the DCDC and/or if DTC P0563:00 is reported in the PCM GO to G3
No The vehicle concern is not present at this time.

G3 CHECK VOLTAGE OF THE 12V BATTERY
  • Start the vehicle (Ready indicator light ON).
  • Turn off the headlamps, blower and any other accessories.
  • Measure:
    Positive Lead Measurement / Action Negative Lead

Is the voltage less than 16 volts?
Yes GO to G5
No GO to G4

G4 INSPECT VEHICLE ACCESSORIES
  • Ignition OFF.
  • Inspect the vehicle and disable any customer installed accessories.
  • Start the vehicle (Ready indicator light ON).
  • Measure:
    Positive Lead Measurement / Action Negative Lead

Is the voltage less than 16 volts?
Yes COMMUNICATE the accessory concern to the customer.
No GO to G5

G5 REMOVE AND INSPECT THE PCM (POWERTRAIN CONTROL MODULE) VPWR FUSE
  • Ignition OFF.
  • Remove and inspect BJB fuse 6 (20A) for being open.

Is the fuse open?
Yes REFER to the Wiring Diagrams manual to identify the possible cause of the circuit short. If no short is identified install a new fuse and test for normal operation.
No GO to G6

G6 CHECK THE PCM (POWERTRAIN CONTROL MODULE) VPWR CIRCUITS
  • Ignition OFF.
  • Disconnect PCM HEV C175B or PHEV C1551B .
  • For HEV, connect a 5A fused jumper between:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C175B-60   Ground
  • For PHEV, connect a 5A fused jumper between:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1551B-60   Ground
  • Ignition ON.
  • For HEV, measure and record:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C175B-1   Ground
      C175B-2   Ground
      C175B-16   Ground
  • For PHEV, measure and record:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1551B-1   Ground
      C1551B-2   Ground
      C1551B-16   Ground

Is the measured voltage within 0.5V of 12V battery?
Yes GO to G7
No REPAIR the affected circuit.

G7 CHECK THE PCM (POWERTRAIN CONTROL MODULE) GROUND CIRCUITS
  • Ignition OFF.
  • Disconnect the fused jumper.
  • For HEV, measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C175B-46 12V BATTERY B+
      C175B-47 12V BATTERY B+
      C175B-61 12V BATTERY B+
      C175B-62 12V BATTERY B+
      C175B-76 12V BATTERY B+
      C175B-77 12V BATTERY B+
  • For PHEV, measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1551B-46 12V BATTERY B+
      C1551B-47 12V BATTERY B+
      C1551B-61 12V BATTERY B+
      C1551B-62 12V BATTERY B+
      C1551B-76 12V BATTERY B+
      C1551B-77 12V BATTERY B+

Does the test lamp illuminate on all pins?
Yes GO to G8
No REPAIR the affected circuit or chassis ground.

G8 MEASURE VOLTAGE DROP OF DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) B+ CABLE
  • Measure:
    Click to display connectors

    NOTE: Place the positive lead on the DC/DC Converter B+ stud.


    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) 12V BATTERY B+

Is the voltage drop less than 0.5 volt?
Yes Verify G117 and G119 body connections are OK. If not OK, REPAIR the connection. If OK, REPAIR 12V Battery B- circuit or INSTALL a new 12V battery negative cable if necessary.GO to G9 If there are NO DTC's, GO to G10.
No VERIFY the high current fuse box fuse 201 (275A) is OK. If not OK, If not OK, INSTALL a new high current fuse box fuse 201 (275A). U3003:17 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the wiring diagram to identify the possible causes of the open circuit. INSTALL new B+ cables if necessary.

G9 VERIFY THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) CASE GROUND
  • Reconnect the PCM connectors.
  • Start the vehicle (Ready indicator light ON).
  • Turn the headlamps on and the blower on high.
  • Measure:

    NOTE: Place the positive lead on the DC/DC Converter Case.


    Positive Lead Measurement / Action Negative Lead
    DC/DC Case

Is the voltage drop less than 0.5V?
Yes For PCM DTC P0563:00 without DCDC DTC U3003:17 GO to G11
For DCDC DTC U3003:17 with or without PCM DTC P0563:00 GO to G10
No INSPECT and REPAIR the DCDC case ground issue or the battery ground for corrosion.

G10 CLEAR DIAGNOSTIC TROUBLE CODES (DTCS) AND REPEAT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF-TEST

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Using the scan tool, clear the DCDC Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, view the DCDC PIDs.
  • Monitor the EnableStat PID. If the PID does not read Enable verify the High Voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using a diagnostic scan tool, perform the DCDC self-test.

Is DTC U3003:17 reported in the DCDC or is DTC P0563:00 reported in the PCM?
Yes INSTALL a new DCDC.
No Concern is not present at this time. DTC U3003:17 or P0563:00 was most likely set due to the 12-volt battery being recently jump started or incorrectly charged using a battery charger.

G11 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Ignition OFF.
  • Disconnect and inspect all PCM 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 PCM connectors. Make sure they seat and latch correctly.
  • Operate the system and determine if the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern,
   Click here to access Guided Routine (PCM). Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
No Concern is not present at this time. DTC P0563:00 was most likely set due to the 12-volt battery being recently jump started, incorrectly charged using a battery charger, or by module connections.

PINPOINT TEST H : U3003:62

Normal Operation and Fault Conditions

The DCDC monitors the 12-volt battery system voltage internally at the B+ terminal and at the low voltage connector in the DCDC and compares the voltage. If the voltage difference is greater than 4.3 volts, the DCDC sets DTC U3003:62. The DCDC goes to standby mode ( DCDC disabled) and the 12-volt battery can eventually be discharged. Reduced or no functionality of 12-volt systems (such as the headlamps and HVAC blower motor) may also be noticed.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U3003:62 Battery Voltage: Signal Compare Failure Sets in the DCDC when the 12-volt battery system voltage measured at the DCDC B+ stud terminal and the DCDC low voltage connector voltage difference is greater than 4.3 volts. This DTC can also be set due to an improper jump start (reverse polarity jump starting), a loose B+ connection from the 12V battery to the DCDC or due to an internal fault.

Possible Sources

  • Reverse polarity jump
  • Open B+ circuit
  • Loose B+ connection
  • External 12V battery charger
  • Aftermarket accessories
  • Fuse(s)
  • Wiring, terminals or connectors
  • DCDC
H1 CHECK THE HIGH CURRENT FUSE

NOTE: DTC U3003:62 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Verify the high current fuse box fuse 201 (275A) is OK.
  • CHECK all B+ cable connections between the 12V battery and the DCDC.

Are all of the B+ cable connections between the 12V battery and the DCDC secure?
Yes GO to H2
No SECURE any loose B+ cable connections between the 12V battery and the DCDC.

H2 CHECK FOR CONTINUITY BETWEEN THE 12V BATTERY B+ AND THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) B+

NOTE: DTC U3003:62 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Ignition OFF.
  • REFER to the wiring diagram for locations of all the B+ cable connections.
  • CHECK for continuity between the 12V battery B+ and C1475C (12V DCDC B+)
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) 12V BATTERY B+

Is the resistance less than 5 ohms?
Yes GO to H3
No VERIFY the high current fuse box fuse 201 (275A) is OK. If not OK, If not OK, INSTALL a new high current fuse box fuse 201 (275A). U3003:62 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the wiring diagram to identify the possible causes of the open circuit. INSTALL new B+ cables if necessary.

H3 PERFORM THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF-TEST

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Ignition ON.
  • Using a diagnostic scan tool, view the DCDC PIDs.

  • Access the  DCDC  and monitor the  DCDC_ENABLE  PID

    . If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using the scan tool, clear the DCDC Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform the DCDC self-test and record Diagnostic Trouble Codes (DTCs).

Is DTC U3003:62 present?
Yes REPAIR all other DCDC Diagnostic Trouble Codes (DTCs) before repairing U3003:62. GO to the DCDC DTC chart in this section. If U3003:62 is the only DTC reported in the DCDC. GO to H4
No The vehicle concern is not present at this time.

H4 CHECK VOLTAGE OF THE 12V BATTERY
  • Start the vehicle (Ready indicator light ON).
  • Turn off the headlamps, blower and any other accessories.
  • Measure and record:
    Positive Lead Measurement / Action Negative Lead

Is the voltage less than 16 volts?
Yes GO to H5
No GO to H6

H5 INSPECT VEHICLE ACCESSORIES
  • Ignition OFF.
  • Inspect the vehicle and disable any customer installed accessories.
  • Start the vehicle (Ready indicator light ON).
  • Measure:
    Positive Lead Measurement / Action Negative Lead

Is the voltage less than 16 volts?
Yes GO to H7
No COMMUNICATE the accessory concern to the customer.

H6 COMPARE THE BATTERY VOLTAGE
  • Disconnect DCDC C1457C .
  • Disconnect DCDC C1457B .
  • Start the vehicle (Ready indicator light ON).
  • Turn off the headlamps, blower and any other accessories.
  • Measure and record :
    Positive Lead Measurement / Action Negative Lead
      C1457B-1
  • Measure and record:
    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+)

Is the difference in voltage between the measurements greater than 4.3 volts?
Yes If the voltage at the C1457C connector is less than 16 volts. GO to H7
If the voltage at the C1457B connector pin 1 is less than 12 volts. VERIFY the BJB fuse 159 (15A) is OK. If OK, REPAIR circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.
No GO to H10

H7 MEASURE VOLTAGE DROP OF DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) B+ CABLE
  • Measure:
    Click to display connectors

    NOTE: Place the positive lead on the DC/DC Converter B+ stud.


    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) 12V BATTERY B+

Is the voltage drop less than 0.5 volt?
Yes Verify G117 and G119 body connections are OK. If not OK, REPAIR the connection. If OK, REPAIR 12V Battery B- circuit or INSTALL a new 12V battery negative cable if necessary. GO to H8
No VERIFY the high current fuse box fuse 201 (275A) is OK. If not OK, If not OK, INSTALL a new high current fuse box fuse 201 (275A). U3003:62 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the wiring diagram to identify the possible causes of the open circuit. INSTALL new B+ cables if necessary.

H8 VERIFY THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) CASE GROUND
  • Reconnect the PCM connectors.
  • Start the vehicle (Ready indicator light ON).
  • Turn the headlamps on and the blower on high.
  • Measure:

    NOTE: Place the positive lead on the DC/DC Converter Case.


    Positive Lead Measurement / Action Negative Lead
    DC/DC Case

Is the voltage drop less than 0.5V?
Yes GO to H9
No INSPECT and REPAIR the DCDC case ground issue or the battery ground for corrosion.

H9 INSPECT ALL THE LOW VOLTAGE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) CONNECTORS
  • Ignition OFF.
  • Disconnect and inspect all DCDC 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 DCDC connectors. Make sure they seat and latch correctly.
  • Operate the system and determine if the concern is still present.

Is the concern still present?
Yes GO to H10
No Concern is not present at this time. DTC U3003:62 was most likely set due to module connections.

H10 CLEAR DIAGNOSTIC TROUBLE CODES (DTCS) AND REPEAT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF-TEST

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Using the scan tool, clear the DCDC Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, view the DCDC PIDs.
  • Monitor the EnableStat PID. If the PID does not read Enable verify the High Voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using a diagnostic scan tool, perform the DCDC self-test.

Is DTC U3003:62 present?
Yes INSTALL a new DCDC.
No The concern is not present at this time.

PINPOINT TEST I : U0100:00

Normal Operation and Fault Conditions

The DCDC communicates with the PCM over a HS-CAN to send and receive important vehicle data. When powered on, the DCDC continually monitors the HS-CAN. If communication with a module is lost, a fault is detected and the DCDC sets the appropriate DTC.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U0100:00 Lost Communication With ECM/PCM "A": No Sub Type Information This DTC sets if the DCDC does not receive an expected message from the PCM.

Possible Sources

  • Network traffic
  • Wiring, terminals or connectors
  • DCDC
  • PCM
I1 CHECK THE COMMUNICATION NETWORK
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform a network test.

Does the PCM pass the network test?
Yes GO to I2
No DIAGNOSE the scan tool communication with the PCM concern.
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

I2 CHECK THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODES (CMDTCS)

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Using a diagnostic scan tool, view DCDC PIDs.
  • Monitor the EnableStat PID. If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using a diagnostic scan tool, clear the DCDC Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform the DCDC self-test.

Is DTC U0100:00 retrieved?
Yes GO to I3
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.

I3 REVIEW THE DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE)
  • Review the Diagnostic Trouble Codes (DTCs) recorded during the DCDC self-test.

Is DTC U3003:16 or U3003:17 recorded?
Yes DIAGNOSE the battery voltage DTC stored in the DCDC. REFER to the DCDC DTC chart.
No GO to I4

I4 RETRIEVE THE DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE PCM (POWERTRAIN CONTROL MODULE)
  • Using a diagnostic scan tool, perform the PCM self-test.

Is DTC P0562:00 or P0563:00 recorded?
Yes DIAGNOSE the PCM DTC. Refer to the PCM DTC chart in this section.
No GO to I5

I5 INSPECT ALL THE PCM (POWERTRAIN CONTROL MODULE) CONNECTORS
  • Ignition OFF.
  • Disconnect and inspect all PCM 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 PCM connectors. Make sure they seat and latch correctly.
  • Operate the system and determine if the concern is still present.

Is the concern still present?
Yes GO to I6
No Concern is not present at this time. DTC U0100:00 was most likely set due to module connections.

I6 CHECK FOR A LOST COMMUNICATION WITH THE PCM (POWERTRAIN CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) IN OTHER MODULES
  • Using a diagnostic scan tool, retrieve Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.

Is DTC U0100:00 set in multiple modules?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, it is necessary to seek additional help. REFER to the Service Repair And Technical Assistance Process. A vehicle data recorder (VDR) or similar recorder may also be useful.
No CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, INSTALL a new DCDC.

PINPOINT TEST J : U0111:00

Normal Operation and Fault Conditions

The DCDC communicates with the BECM over a HS-CAN to send and receive important vehicle data. When powered on, the DCDC continually monitors the HS-CAN. If communication with a module is lost, a fault is detected and the DCDC sets the appropriate DTC.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U0111:00 Lost Communication With Battery Energy Control Module "A": No Sub Type Information This DTC sets if the DCDC does not receive an expected message from the BECM.

Possible Sources

  • Network traffic
  • Wiring, terminals or connectors
  • DCDC
  • BECM
J1 CHECK THE COMMUNICATION NETWORK
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform a network test.

Does the BECM pass the network test?
Yes GO to J2
No DIAGNOSE the scan tool communication with the BECM concern.
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

J2 CHECK THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODES (CMDTCS)

NOTE: The Direct Current/Direct Current Converter Control Module (DC/DC) will not self test if it is not Enabled.

  • Using a diagnostic scan tool, view DCDC PIDs.
  • Monitor the EnableStat PID. If the PID does not read Enable verify the high voltage battery service disconnect is installed and all other Diagnostic Trouble Codes (DTCs) have been addressed.
  • Using a diagnostic scan tool, clear the DCDC Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, perform the DCDC self-test.

Is DTC U0111:00 retrieved?
Yes GO to J3
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.

J3 REVIEW THE DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE)
  • Review the Diagnostic Trouble Codes (DTCs) recorded during the DCDC self-test.

Is DTC U3003:16 or U3003:17 recorded?
Yes DIAGNOSE the battery voltage DTC stored in the DCDC. REFER to the DCDC DTC chart.
No GO to J4

J4 RETRIEVE THE DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE BECM (BATTERY ENERGY CONTROL MODULE)
  • Using a diagnostic scan tool, perform the BECM self-test.

Is DTC U3003:16 or U3003:17 recorded?
Yes DIAGNOSE the BECM DTC.
REFER to: High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Diagnosis and Testing).
No GO to J5

J5 INSPECT ALL THE BECM (BATTERY ENERGY CONTROL MODULE) CONNECTORS
  • Ignition OFF.
  • Disconnect and inspect all BECM 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 BECM connectors. Make sure they seat and latch correctly.
  • Operate the system and determine if the concern is still present.

Is the concern still present?
Yes GO to J6
No Concern is not present at this time. DTC U0111:00 was most likely set due to module connections.

J6 CHECK FOR A LOST COMMUNICATION WITH THE BECM (BATTERY ENERGY CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) IN OTHER MODULES
  • Using a diagnostic scan tool, retrieve Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.

Is DTC U0111:00 set in multiple modules?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, it is necessary to seek additional help. REFER to the Service Repair And Technical Assistance Process. A vehicle data recorder (VDR) or similar recorder may also be useful.
No CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, INSTALL a new DCDC.

PINPOINT TEST K : U0412:00

Normal Operation and Fault Conditions

REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module - System Operation and Component Description (414-05 Voltage Converter/Inverter, Description and Operation).

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U0412:00 Invalid Data Received From Battery Energy Control Module "A": No Sub Type Information Sets in the DCDC when invalid data is received from the BECM.

Possible Sources

  • ECM/ PCM
  • BECM
  • Low 12V voltage
  • CAN concern
K1
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, carry out the self-test for the module in question sending the invalid data.

Are any Diagnostic Trouble Codes (DTCs) present from the module sending the invalid data?
Yes DIAGNOSE the module sending the invalid data. REFER to the appropriate section in the Workshop Manual.
No DIAGNOSE the observable symptom present.

PINPOINT TEST L : U3000:04

Normal Operation and Fault Conditions

REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module - System Operation and Component Description (414-05 Voltage Converter/Inverter, Description and Operation).

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U3000:04 Control Module: System Internal Failures This DTC can be set due to an improper jump start (reverse polarity jump starting), a loose B+ connection from the 12V battery to the DCDC or due to an internal fault.

Possible Sources

  • Reverse polarity jump
  • Open B+ circuit
  • Loose B+ connection
  • Fuse(s)
  • DCDC
L1 CHECK THE HIGH CURRENT FUSE

NOTE: DTC U3000:04 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Verify the high current fuse box fuse 201 (275A) is OK.
  • CHECK all B+ cable connections between the 12V battery and the DCDC.

Are all of the B+ cable connections between the 12V battery and the DCDC secure?
Yes GO to L2
No SECURE any loose B+ cable connections between the 12V battery and the DCDC.

L2 CHECK FOR CONTINUITY BETWEEN THE 12V BATTERY B+ AND THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) B+

NOTE: DTC U3000:04 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Ignition OFF.
  • REFER to the wiring diagram for locations of all the B+ cable connections.
  • CHECK for continuity between the 12V battery B+ and C1475C (12V DCDC B+)
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) 12V BATTERY B+

Is the resistance less than 5 ohms?
Yes GO to L3
No VERIFY the high current fuse box fuse 201 (275A) is OK. If not OK, If not OK, INSTALL a new high current fuse box fuse 201 (275A). U3000:04 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the wiring diagram to identify the possible causes of the open circuit. INSTALL new B+ cables if necessary.

L3 CHECK ALL B+ CONNECTIONS TO THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE)
  • Ignition OFF.
  • REFER to the wiring diagram for locations of all the B+ cable connections.
  • CHECK all B+ cable connections between the 12V battery and the DCDC.

Are all of the B+ cable connections between the 12V battery and the DCDC secure?
Yes GO to L4
No SECURE any loose B+ cable connections between the 12V battery and the DCDC.

L4 CARRY OUT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF TEST
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • CARRY OUT the DCDC self-test.

Did the DTC return?
Yes INSTALL a new DCDC.
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.

PINPOINT TEST M : U3000:41, U3000:42, U3000:45, U3000:49

Normal Operation and Fault Conditions

REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module - System Operation and Component Description (414-05 Voltage Converter/Inverter, Description and Operation).

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U3000:41 Control Module: General Checksum Failure Sets when the DCDC detects an internal fault.
DCDC U3000:42 Control Module: General Memory Failure Sets when the DCDC detects an internal fault.
DCDC U3000:45 Control Module: Program Memory Failure Sets when the DCDC detects an internal fault.
DCDC U3000:49 Control Module: Internal Electronic Failure Sets when the DCDC detects an internal fault.

Possible Sources

  • DCDC
M1 CARRY OUT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF TEST
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • CARRY OUT the DCDC self-test.

Did the DTC return?
Yes INSTALL a new DCDC.
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.

PINPOINT TEST N : U3000:96

Normal Operation and Fault Conditions

REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module - System Operation and Component Description (414-05 Voltage Converter/Inverter, Description and Operation).

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
DCDC U3000:96 Control Module: Component Internal Failure Sets when the DCDC detects an internal fault.

Possible Sources

  • Loose B+ connection
  • DCDC
N1 CHECK THE HIGH CURRENT FUSE

NOTE: DTC U3000:96 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse.

  • Verify the high current fuse box fuse 201 (275A) is OK.
  • CHECK all B+ cable connections between the 12V battery and the DCDC.

Are all of the B+ cable connections between the 12V battery and the DCDC secure?
Yes GO to N2
No SECURE any loose B+ cable connections between the 12V battery and the DCDC.

N2 CHECK FOR CONTINUITY BETWEEN THE 12V BATTERY B+ AND THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) B+
  • Ignition OFF.
  • Refer to the wiring diagram for locations of all the B+ cable connections.
  • Check for continuity between the 12V battery B+ and C1475C (12V DCDC B+)
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    C1457C (12V DC/DC B+) 12V BATTERY B+

Is the resistance less than 5 ohms?
Yes GO to N3
No VERIFY the high current fuse box fuse 201 (275A) is OK. If not OK, If not OK, INSTALL a new high current fuse box fuse 201 (275A). U3000:96 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the wiring diagram to identify the possible causes of the open circuit. INSTALL new B+ cables if necessary.

N3 CHECK ALL B+ CONNECTIONS TO THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE)
  • Ignition OFF.
  • Refer to the wiring diagram for locations of all the B+ cable connections.
  • Check all B+ cable connections between the 12V battery and the DCDC.
  • Inspect the DCDC C1475C (12V DCDC B+) stud for:
    • Verify there are at least 3 threads above the nut. If not, disassemble and inspect the terminal and stud, clean or replace one or both.
    • Signs or arching, replace the B+ cable, REFER to appropriate removal and installation section in 414-01 Battery, Mounting and cables.
    • Obvious sings of a short, replace the B+ cable, REFER to appropriate removal and installation section in 414-01 Battery, Mounting and cables.

Are all of the B+ cable connections between the 12V battery and the DCDC secure?
Yes GO to N4
No SECURE any loose B+ cable connections between the 12V battery and the DCDC.

N4 CARRY OUT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) SELF TEST
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • CARRY OUT the DCDC self-test.

Did the DTC return?
Yes CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition.


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