Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Circuit/System Testing
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure includes the following steps:
- Identify how to disable high voltage.
- Identify how to test for the presence of high voltage.
- Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
- Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
- Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
- Visually and functionally inspect the gloves before use.
- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures may result in serious injury or death.
- Connect known good drive motor battery charger cable to vehicle.
- Monitor drive motor battery charger cable status LEDs.
- If the drive motor battery charger cable status LEDs are flashing red
- Disconnect drive motor batter charger cable.
- Disable High Voltage High Voltage DisablingNOTE:
When the T18 Battery Charger or the T18B Battery Charger 2 vehicle charging is disabled. The indicator status LEDs will still be enabled.
- Disconnect X1 connector at the T18B Battery Charger 2. Reconnect drive motor battery charger cable and check if status LEDs are still flashing red.
- Go to next step: If the drive motor battery charger cable status LEDs are NOT flashing red
Go to next step: Replace - T18B Battery Charger 2
- If the drive motor battery charger cable status LEDs are flashing red
- Go to next step: If the drive motor battery charger cable status LEDs are NOT flashing red
- Reconnect X1 connector at the T18B Battery Charger 2.
- Disconnect X5 connector at the T18 Battery Charger. Reconnect drive motor battery charger cable and check if status LEDs are still flashing red.
- Go to next step: If the drive motor battery charger cable status LEDs are NOT flashing red
Go to next step: Replace - T18 Battery Charger
- If the drive motor battery charger cable status LEDs are flashing red
- Go to next step: If the drive motor battery charger cable status LEDs are NOT flashing red
- Disconnect: X1 connector at the T18B Battery Charger 2 and X5 connector at the T18 Battery Charger.
- Test for infinite resistance between X1 connector and chassis ground.
- If less than infinite resistance - repair the short to ground on the circuit.
- If infinite resistance - replace the component: X98 Hybrid/EV Battery Charger Coupler
- Test for infinite resistance between X5 connector and chassis ground.
- If less than infinite resistance - repair the short to ground on the circuit.
- If infinite resistance - replace the component: X98 Hybrid/EV Battery Charger Coupler
- Connect the customer's drive motor battery charger cable to household power outlet, but not the vehicle battery charger coupler.
- After 25 seconds, verify the drive motor battery charger cable status LEDs indicate a ready to charge condition without any faults.
- If the drive motor battery charger cable status LEDs do not indicate a ready to charge condition
- Connect a known good drive motor battery charger cable to the same household power outlet.
- After 25 seconds, verify the known good drive motor battery charger cable status LEDs indicate a ready to charge condition.
- If the known good drive motor battery charger cable indicates a ready to charge condition, replace the customer's drive motor battery charger cable.
- If the known good drive motor battery charger cable indicates a fault, have the service provider inspect the household power outlet for conditions including, but not limited to, insufficient voltage, high frequency noise, or open/high resistance.
If the drive motor battery charger cable status LEDs
- Go to next step: If the drive motor battery charger cable status LEDs indicate a ready to charge condition
- Test for greater than 1 V between the low voltage circuits listed below on drive motor battery charger cable.
- Control pilot signal circuit terminal 4
- Proximity status signal circuit terminal 3
- If less than 1 V
Drive Motor Battery Charger Cable - Replace
- Go to next step: If greater than 1 V
- NOTE:
The following tests are performed at the X98 Hybrid/EV Battery Charger Coupler and not at the harness connector to the X98 Hybrid/EV Battery Charger Coupler.
This step should be performed at the specific household power outlet at which the customer connects.
Refer to Diagnostic Aids for CHARGE CORD Status LED Definition.
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.