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

Ford Escape: 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).


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).


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 diagnostic trouble codes (DTCs) present?
Yes DIAGNOSE any DCDC diagnostic trouble codes (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 diagnostic trouble codes (DTCs) present?
Yes DIAGNOSE any BECM diagnostic trouble codes (DTCs),
REFER to: High Voltage Battery, Mounting and Cables - Hybrid Electric Vehicle (HEV) (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.
REFER to: Cooling System Filling and Bleeding (303-03D Electric Powertrain Cooling - Hybrid Electric Vehicle (HEV), General Procedures).

C2 CHECK BECM (BATTERY ENERGY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
  • Ignition ON.
  • Using a diagnostic scan tool, clear the BECM diagnostic trouble codes (DTCs).
  • Using a diagnostic scan tool, carry out 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 diagnostic trouble codes (DTCs).
REFER to: High Voltage Battery, Mounting and Cables - Hybrid Electric Vehicle (HEV) (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, carry out the 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 - Hybrid Electric Vehicle (HEV) (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: Cooling Fan Control (303-03C Engine Cooling, Diagnosis and Testing).

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.
    REFER to: Electric Powertrain Cooling - Overview (303-03D Electric Powertrain Cooling - Hybrid Electric Vehicle (HEV), Description and Operation).
  • 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 carrying out next steps.

  • Using a diagnostic scan tool, clear the DCDC diagnostic trouble codes (DTCs).
  • Using a diagnostic scan tool, carry out the DCDC self-test.

Are any DCDC diagnostic trouble codes (DTCs) present?
Yes For U3000:49 GO to Pinpoint Test M
For P0D32:00 only, GO to C8
For all other diagnostic trouble codes (DTCs), DIAGNOSE any remaining diagnostic trouble codes (DTCs) in this section, REFER to the DTC chart in this section.
No The system is operating correctly at this time. The diagnostic trouble codes (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 diagnostic trouble codes (DTCs).
  • Using a diagnostic scan tool, carry out 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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).
No The system is operating correctly at this time. The diagnostic trouble codes (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 120 volts for HEV and 168 volts for PHEV , it sets P0E56:00. The DCDC also compares that high-voltage reading with the high-voltage available to the ISC/ SOBDMC , which is communicated via a HS-CAN message. When the DCDC compares its available high-voltage to that available to the ISC/ SOBDMC and determines the difference to be 120 volts or more, it sets DTC P0E56:13. Both diagnostic trouble codes (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 120 volts for HEV and 168 volts for PHEV .
DCDC P0E56:13 DC/DC Converter Input Voltage Too Low: Circuit Open Sets in the DCDC when the difference in high voltage between the ISC/ 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 ISC/ 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 ISC/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 ISC/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 C495 for PHEV Escape and Corsair, or C4236D for HEV Escape .
  • Inspect DCDC C1457A and high voltage battery C495 for PHEV Escape and Corsair, or C4236D for HEV Escape 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) DIAGNOSTIC TROUBLE CODES (DTCS)
  • Connect DCDC C1457A .
  • Connect High voltage battery C495 for PHEV Escape and Corsair, or C4236D for HEV Escape .
  • Verify the high voltage DCDC C1457A and high voltage battery C495 for PHEV Escape and Corsair, or C4236D for HEV Escape are fully seated.
  • Ignition ON.
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, carry out the DCDC self-test.

Are diagnostic trouble codes (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 C495 for PHEV Escape and Corsair, or C4236D for HEV Escape.
  • Measure:
    Click to display connectors

      For PHEV Escape and Corsair


    Positive Lead Measurement / Action Negative Lead
      C1457A-2   C495-1
      C1457A-3   C495-2
  • Measure:
    Click to display connectors

      For HEV Escape


    Positive Lead Measurement / Action Negative Lead
      C1457A-2   C4236D-1
      C1457A-3   C4236D-2

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.
    REFER to: High Voltage Low Current Fuse - Hybrid Electric Vehicle (HEV) (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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).
No INSTALL a new high voltage low current fuse.
REFER to: High Voltage Low Current Fuse - Hybrid Electric Vehicle (HEV) (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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).

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 258 volts for HEV and 362 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 258 volts for HEV and 362 volts for PHEV .

Possible Sources

  • High voltage battery system fault
  • High voltage cables
  • DCDC
E1 CHECK THE ISC/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, carry out the ISC/SOBDMC self-test and record the results.

Is ISC/SOBDMC DTC P1A07:00 reported?
Yes
REFER to: Electric Powertrain Control (303-14D Electric Powertrain Control, 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 258 volts for HEV and 362 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 CARRY OUT the BECM self-test. If BECM diagnostic trouble codes (DTCs) are present, DIAGNOSE the BECM diagnostic trouble codes (DTCs) first.
If there are no BECM diagnostic trouble codes (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 C495 for PHEV Escape and Corsair, or C4236D for HEV Escape.
  • Inspect DCDC C1457A and high voltage battery C495 for PHEV Escape and Corsair, or C4236D for HEV Escape 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 C495 for PHEV Escape and Corsair, or C4236D for HEV Escape.
  • Connect the high voltage battery.
  • Ignition ON.
  • Using the scan tool, clear the DCDC diagnostic trouble codes (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, carry out 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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).
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

Visual Inspection and Pre-checks

  • High-Current BJB fuse 4 (300A).
F1 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 F2
No VERIFY the High-Current BJB fuse 4 (300A) is OK. If OK, REPAIR circuit. If not OK, INSTALL a new High-Current BJB fuse 4 (300A). U3003:16 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short. INSTALL new B+ cables, if necessary.

F2 TEST 12V BATTERY CONDITION
  • Ignition OFF.
  • Carry out 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 F3
No INSTALL a new 12V battery.
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

F3 CHECK FOR DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS) 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, carry out the DCDC self-test.

Are diagnostic trouble codes (DTCs) P0E56:00 or P0E56:13 present?
Yes GO to Pinpoint Test D
No GO to F4

F4 REMOVE AND INSPECT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) VBATT FUSE
  • Ignition OFF.
  • Remove and inspect BJB fuse 159 (5A) 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 F5

F5 CARRY OUT 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 diagnostic trouble codes (DTCs).
  • Using a diagnostic scan tool, carry out the DCDC self-test and record any diagnostic trouble codes (DTCs).
  • Using the scan tool, clear the PCM diagnostic trouble codes (DTCs).
  • Using a diagnostic scan tool, carry out the PCM self-test and record any diagnostic trouble codes (DTCs).

Did both the DCDC and PCM carry out a self-test?
Yes GO to F6
No DIAGNOSE the scan tool communication with the DCDC and/or PCM .
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

F6 COMPARE VOLTAGE AT THE DCDC (DIRECT CURRENT/DIRECT CURRENT CONVERTER CONTROL MODULE) TO THE 12V 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.
  • Connect the 12V battery.
    REFER to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  • 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 F7
For DCDC DTC U3003:16 with or without PCM DTC P0562:00 OR if there are NO DTC's, GO to F10
No GO to F10

F7 REMOVE AND INSPECT THE PCM (POWERTRAIN CONTROL MODULE) VPWR FUSE
  • Ignition OFF.
  • Remove and inspect BJB fuse 6 (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 F8

F8 CHECK THE PCM (POWERTRAIN CONTROL MODULE) VPWR CIRCUITS
  • Ignition OFF.
  • Disconnect PCM C1381B .
  • Connect a 5A fused jumper between:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1381B-20   Ground
  • Ignition ON.
  • Measure and record:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1381B-97   Ground
      C1381B-99   Ground

Is the measured voltage within 0.5V of 12V battery?
Yes GO to F9
No REPAIR the affected circuit.

F9 CHECK THE PCM (POWERTRAIN CONTROL MODULE) GROUND CIRCUITS
  • Ignition OFF.
  • Disconnect the fused jumper.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1381B-5 12V BATTERY B+
      C1381B-100 12V BATTERY B+
      C1381B-102 12V BATTERY B+
      C1381B-103 12V BATTERY B+

Does the test lamp illuminate on all pins?
Yes GO to F13
No REPAIR the affected circuit or chassis ground.

F10 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 the G102 body connection is 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 F11 If there are NO DTC's, GO to F14
No VERIFY the High-Current BJB fuse 4 (300A) is OK. If OK, REPAIR circuit. If not OK, INSTALL a new High-Current BJB fuse 4 (300A). U3003:16 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short. INSTALL new B+ cables, if necessary.

F11 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 F12
No INSPECT and REPAIR the DCDC case ground issue or the battery ground for corrosion.

F12 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 diagnostic trouble codes (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, carry out DCDC self-test.

Is DTC U3003:16 present?
Yes GO to F14
No The system is operating correctly at this time. The concern may have been caused by a discharged battery.

F13 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,
   VIN required to access Guided Routine (PCM)
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.

F14 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 F10 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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).

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 16.5 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

Visual Inspection and Pre-checks

  • High-Current BJB fuse 4 (300A).
G1 CARRY OUT 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 Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, carry out the DCDC self-test and record Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
  • Using a diagnostic scan tool, carry out 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 G2
No The vehicle concern is not present at this time.

G2 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 G4
No GO to G3

G3 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 G4

G4 REMOVE AND INSPECT THE PCM (POWERTRAIN CONTROL MODULE) VPWR FUSE
  • Ignition OFF.
  • Remove and inspect BJB fuse 6 (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 G5

G5 CHECK THE PCM (POWERTRAIN CONTROL MODULE) VPWR CIRCUITS
  • Ignition OFF.
  • Disconnect PCM C1381B .
  • Connect a 5A fused jumper between:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1381B-20   Ground
  • Ignition ON.
  • Measure and record:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1381B-97   Ground
      C1381B-99   Ground

Is the measured voltage within 0.5V of 12V battery?
Yes GO to G6
No REPAIR the affected circuit.

G6 CHECK THE PCM (POWERTRAIN CONTROL MODULE) GROUND CIRCUITS
  • Ignition OFF.
  • Disconnect the fused jumper.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1381B-5 12V BATTERY B+
      C1381B-100 12V BATTERY B+
      C1381B-102 12V BATTERY B+
      C1381B-103 12V BATTERY B+

Does the test lamp illuminate on all pins?
Yes GO to G7
No REPAIR the affected circuit or chassis ground.

G7 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 the G102 body connection is 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 G8 If there are NO DTC's, GO to G9
No VERIFY the High-Current BJB fuse 4 (300A) is OK. If OK, REPAIR circuit. If not OK, INSTALL a new High-Current BJB fuse 4 (300A). U3003:17 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short. INSTALL new B+ cables, if necessary.

G8 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 G10
For DCDC DTC U3003:17 with or without PCM DTC P0563:00 GO to G9
No INSPECT and REPAIR the DCDC case ground issue or the battery ground for corrosion.

G9 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, carry out 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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).
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.

G10 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,
   VIN required to access Guided Routine (PCM)
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

Visual Inspection and Pre-checks

  • High-Current BJB fuse 4 (300A).
H1 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 H2
No VERIFY the High-Current BJB fuse 4 (300A) is OK. If OK, REPAIR circuit. If not OK, INSTALL a new High-Current BJB fuse 4 (300A). U3003:62 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short. INSTALL new B+ cables, if necessary.

H2 CARRY OUT 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, carry out 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 H3
No The vehicle concern is not present at this time.

H3 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 H4
No GO to H5

H4 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 H6
No COMMUNICATE the accessory concern to the customer.

H5 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 H6
If the voltage at the C1457B connector pin 1 is less than 12 volts. VERIFY the BJB fuse 159 (5A) 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 H9

H6 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 the G102 body connection is 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 H7
No VERIFY the High-Current BJB fuse 4 (300A) is OK. If OK, REPAIR circuit. If not OK, INSTALL a new High-Current BJB fuse 4 (300A). U3003:62 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short. INSTALL new B+ cables, if necessary.

H7 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 H8
No INSPECT and REPAIR the DCDC case ground issue or the battery ground for corrosion.

H8 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 H9
No Concern is not present at this time. DTC U3003:62 was most likely set due to module connections.

H9 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, carry out the DCDC self-test.

Is DTC U3003:62 present?
Yes INSTALL a new DCDC .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).
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, carry out 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, carry out 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, carry out 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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).

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, carry out 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, carry out 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, carry out 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 - Hybrid Electric Vehicle (HEV) (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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).

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 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 DTC 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

Visual Inspection and Pre-checks

  • High-Current BJB fuse 4 (300A).
L1 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 L2
No VERIFY the High-Current BJB fuse 4 (300A) is OK. If OK, REPAIR circuit. If not OK, INSTALL a new High-Current BJB fuse 4 (300A). U3000:04 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short. INSTALL new B+ cables, if necessary.

L2 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 L3
No SECURE any loose B+ cable connections between the 12V battery and the DCDC .

L3 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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).
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 .
REFER to: Direct Current/Direct Current (DC/DC) Converter Control Module (414-05 Voltage Converter/Inverter, Removal and Installation).
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

Visual Inspection and Pre-checks

  • High-Current BJB fuse 4 (300A).
N1 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 N2
No VERIFY the High-Current BJB fuse 4 (300A) is OK. If OK, REPAIR circuit. If not OK, INSTALL a new High-Current BJB fuse 4 (300A). U3000:96 can set from improper jump starting (reverse polarity jump starting), causing an open high current fuse. REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short. INSTALL new B+ cables, if necessary.

N2 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 N3
No SECURE any loose B+ cable connections between the 12V battery and the DCDC .

N3 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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