18445.01D 041608 R1.02 Ig

Course #18445.
01D
Two-mode Hybrid
Diagnosis & Repair
Service Technical College
Instructor Guide
Revised: 04/16/08
Background History of
Two-mode Hybrid Diagnosis & Repair
History: This IDL course component provides GM Dealership Automotive Technicians
with the information, concepts and applications to diagnose and repair the Two-Mode
Hybrid system and its components.
1st Broadcast Date: 11/14/07
The first version of this course number was published in October 2007.
Team Members
Paul Burke, GMU Program Coordinator ..................................................... 586-576-3334
George Aiken, Field Operations Manager .................................................. 586-576-3305
Ralph Gallo, Lead Instructor ....................................................................... 586-576-3306
Raphaela Fodale, Process Owner ............................................................. 248-837-6812
Robert LeMaigre, IPT Lead, GM STC ........................................................ 248-837-6519
Christopher Merkle, IDL Instructor............................................................... 586-576-3310
Michael Sculthorpe, IDL Instructor ............................................................. 586-576-3312
Gladys Quince, IDL Lead Instructional Systems Designer ......................... 248-837-6813
Lucian Noble III, Instructional Systems Designer ....................................... 248-837-6806
2007, 2008
Revised 04/16/08
2008 General Motors Corporation

All Rights Reserved
Course Information & Materials

Module Times:
Introduction ............................................................................................................. 5 min.
Module 1: Two-mode Hybrid System Overview ................................................... 35 min.
Module 2: Safe Work Practices ............................................................................ 30 min.
Module 3: Two-mode Special Tools ..................................................................... 30 min.
Module 4: Two-mode Hybrid Diagnostics ............................................................. 65 min.
Posttest (included in modules) .............................................................................. 10 min.
Summary / Evaluation ............................................................................................ 5 min.
Total Broadcast Time
180 min.
Broadcast Materials:
To teach this course you will need:
1. Instructor Guide
2. PowerPoint file
3. PAT stack
4. Video Segments (9 segments, TRT: 27.53)
5. Animation Segments (2 segments, looped)
6. Overheads (1)
7. Prop(s):
Class 0 gloves
EL-48571 High voltage battery pin-out box
EL-48458 Pre-Charge Test Tool
PIM / APM Assembly
300V Hybrid Battery
8. Participant Guide
9. Other support material if necessary
Laptop
Long microphone cord
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Broadcast Setup Instructions

Technical Setup:
1.
2.
3.
4.
5.
Set up microphones for instructor and 1 SME

Set up laptop for instructor use
Ensure connectivity in studio for internet use
Adjust camera angles for SMEs
Battery in studio or Video #7 EL-48571 High Voltage Battery Pin-Out Box
Instructor Setup:
1.
2.
3.
4.
Fill in information on overheads

Label SME as an expert on the OneTouch System
Log into appropriate section of website
Review content with SME
Check special request form (SRF) for additional instructions (if

applicable).
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Instructional Materials
Approved Icons
Use these approved icons when developing the Instructor

Guide to cue the production staff to take an action.
PowerPoint Slide: Indicates a PPT slide is on screen.
Slide number under icon, in 12 pt. Arial font, all caps

Slide title under slide number, in 12 pt. Arial font (if
title is long, truncate using an ellipse)
PPT #1
Slide Title
3 BUILDS
Number of builds next to slide content text, in 16 pt.

Arial font, all caps (i.e., BUILDS/RUN-TIME style)
PowerPoint slides must be numbered both in the Instructor
Guide and on the slide itself (lower right corner, outside safe
title area).
Histogram: Indicates the results of a keypad question.
Typically an instructor cue such as Debrief results
accompanies this icon, in the Broadcast Presentation column.
Video: Indicates a video segment. The exact length of the
video segment is listed below the icon using 16 pt. Arial font, all
caps (i.e., BUILDS/RUN-TIME style).
The title of the video segment is indicated in the Broadcast
Presentation column as an instructor cue written as VIDEO:
Title of Video (14 pt. Arial font, italics, highlighted in yellow).
2:36
This icon is also used for a video countdown clock (e.g., for
breaks, timed exercises). Indicate this using an instructor cue
in the Broadcast Presentation column, written as VIDEO:
Countdown Clock.
The countdown video is provided by studio operations.
Instructor: Indicates the instructor is on camera.
Subject Matter Expert: Indicates a SME is on camera.
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Instructional Materials (cont.)

Call-in: Indicates the instructor ask participants to voluntarily
call in with their questions or comments.
Call-in
Random
Random Call: Indicates the instructor calls out to participants,

allowing the OneTouch system to randomly select among the
people watching.
Flag: Indicates the instructor conducts an anonymous poll by

requesting that participants press their flag button.
OH #6
Overhead Title
Or
Overhead: Indicates the overhead camera is used to show a

document or a prop. Documents shown in this way are
numbered in sequential order. The number of the overhead (or
the name of the prop) is indicated below the icon using 12 pt.
Arial font.
PROP
Prop Name
Telestrator: Indicates the instructor draws on the screen using
the telestration tools to emphasize a point or explain an item
visually.
2:00
(PPT WITH
MUSIC)
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Clock: Indicates a timed activity such as an exercise, break or

test where no video countdown is used. The length of the
activity is listed beneath the icon as a cue using 16 pt. Arial
font in all caps (i.e., BUILDS/RUN-TIME style).
Additional production or instructor cues may be added to the
Broadcast Presentation column as required.

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Laptop: Indicates a screen will be displayed using a laptop at

the instructor desk.
Chalkboard: Indicates the instructor will write on a blank

screen using the telestrator. The studio staff will provide an
empty background (plain color or texture) for this purpose.
Still
Still #
Or
Title
Clip #
X:XX
Still: Indicates a still is on the screen. Stills can be

photographs, computer generated backgrounds, or captured
images from any source in the studio. They can either be
provided by the supplier on CD or could already exist on the
studio production console. Contact the production staff
regarding which stills already exist in the console. The still
number or title is placed under the icon in 12 pt. Arial font.
Clip: Indicates a clip is shown on screen. A clip refers to short

pieces of live video or animation both without audio. Clips
should be provided on Betacam SP, separate from the video
roll-ins. The exact length of the clip is listed below the icon as a
cue using 16 pt. Arial font (i.e., BUILDS/RUN-TIME style).
Camera 2: Indicates a second camera is needed for shots

other than for an SME (e.g., props, cars).
Squeeze Time: Indicates a portion of the script that can be

eliminated or shortened due to time constraints. This must not
include the posttest.
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Chroma Key
Approved Icons
Use these approved icons when developing the Instructor

Guide to cue the production staff to take an action. Only use
these icons when Chroma Key technology is being used.
Note: On all Chroma Key icons, the instructor figure is
placed on the side of the icon that matches where they will
be standing with relationship to the television screen
being viewed by students. For example, if the instructor
icon is on the right, students will see the instructor
standing to the right of the screen.
CHROMA KEY
Instructor inserted over PowerPoint slide: Indicates the

instructors image is inserted over a PPT slide.
PPT #
Slide Title
3 BUILDS
CHROMA KEY
PPT #
Slide Title
Slide number under icon in 12 pt. Arial font, all caps

Slide title under slide number in 12 pt. Arial font (if the full
title exceeds two lines in the Cues column, truncate it using
an ellipse)
Number of builds next to slide content text in 16 pt. Arial
font, all caps (i.e., BUILDS/RUN-TIME style)
PowerPoint slides must be numbered both in the Instructor
Guide (in both the Cues and Broadcast Presentation columns)
and on the slide itself (lower, right corner, outside safe title
area).
3 BUILDS
CHROMA KEY
Still
Still # or Title
CHROMA KEY
Still
Instructor inserted over still: Indicates the instructors image

is inserted over a still. Stills can either be pictures, computer
generated backgrounds, or images captured from any source
in the studio. They can either be provided by the Supplier on
CD or could already exist on the Studio Production Console.
Contact the production staff regarding which stills already exist
in the console. The still number or title is placed under icon in
12 pt. Arial font.
Still # or Title
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CHROMA KEY
X:XX
CHROMA KEY
Instructor inserted over video: Indicates the instructors

image is inserted over a video segment. The exact length of
the video segment is listed below the icon as a cue using 16 pt.
Arial font (i.e., BUILDS/RUN-TIME style).
The title of the video segment is indicated in the Broadcast
Presentation column as an instructor cue written as Video:
Title of the Video (14 pt. Arial font, italics, highlighted in
yellow).
X:XX
CHROMA KEY
OH #5
CHROMA KEY
Instructor inserted over overhead: Indicates the instructors

image is inserted over the overhead camera showing a
document or prop. Documents shown in this way are
numbered in sequential order. Props require no number, only a
unique name. The number of the overhead or name of the prop
is indicated below the icon in 12 pt. Arial font.
Prop Name
CHROMA KEY
CHROMA KEY
Revised 04/16/08
Instructor inserted over histogram: Indicates the instructors

image is inserted over the histogram. Typically, an instructor
cue such as Debrief results appears in the Broadcast
Presentation column to accompany this icon (14 pt. Arial font,
italics, highlighted in yellow).

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CHROMA KEY
CHROMA KEY
Instructor inserted over laptop: Indicates the instructors

image is inserted over a laptop computer screen.
CHROMA KEY
X:XX
CHROMA KEY
Instructor inserted over clip: Indicates the instructors image

is inserted or a clip. A clip refers to short pieces of live video
animation without audio. Clips should be provided on Betacam
SP, separate from the video roll-ins. The exact length of the
clip is listed below the icon using 16 pt. Arial font (i.e.,
BUILDS/RUN-TIME style)
The title of the clip is indicated in the Broadcast Presentation
column as an instructor cue written as Clip: Title of the Clip
(14 pt. Arial font, italics, highlighted in yellow).
X:XX
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Two-mode Hybrid
Diagnosis & Repair
Introduction
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i-2
Cues
Broadcast Presentation
PPT #1
GM Logo
PPT #2
Course Title
PPT #3
Disclaimer
Welcome to the Two-mode Hybrid Diagnosis

& Repair IDL.
Introduce yourself
There is a place to write my name under the

Table of Contents in your Participant Guide.
Before we continue, lets go over the basic
course information.
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Introduction
i-3
Cues
Course Materials
Identify course materials for participants
We recommend that you use the most

recent Participant Guide for todays
broadcast.
Place PG under document camera and point out:
Course title
PG
Course number
Revision date
The Participant Guide is your tool for

following along with this IDL broadcast.
Your guide includes:
Subject information
Areas to write notes
Diagnostic charts and exercises
Graphics and other pertinent information
4
Web Site
PPT #4
Web Site
www.gmtraining.com
Instructor Note: Direct Technicians to Participant Guide

location - Click Resources, then Training Materials, then IDL
Participant Guides, and then Service Technical.
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i-4
Cues
Introduction Question
Lets continue. Id like to find out where
everyones at today so go ahead and answer
this question for me.
5
Question 1
PPT #5
Question 1
In which of the following regions is your

dealership located?
A. Atlanta
B. Chicago
C. Dallas
D. Los Angeles
E. New York
SHOW HISTOGRAM
Comment on Feedback received
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Introduction
Cues
i-5
Course Goal and Session Objectives

Lets look at the course goal and todays
objectives.
Elaborate as indicated below the slide
6
Course Goal
PPT #6
Course Goal
Upon successful completion of this course,

you will be able to apply concepts and
procedures to diagnose and repair the Twomode Hybrid system and its components.
Keep in mind this is an IDL component

course.
It is recommended that you complete the
WBT component of the course prior to
taking the IDL component.
Here are the Objectives for todays session.
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i-6
Cues
Elaborate as indicated below the slide
7
Session Objectives
PPT #7
Session Objectives
4 BUILDS
Identify current & future Two-mode Hybrid

vehicle applications
Describe the Two-mode Hybrid system and its
major components
Identify Danger, Caution & Warning labels and
their locations
Identify protective equipment for
diagnosing/repairing a Two-mode vehicle
Identify current and future Two-mode Hybrid vehicle
applications
Describe the Two-mode Hybrid system and its
major components
Identify Danger, Caution and Warning labels and
their locations
Identify proper protective equipment to use when
diagnosing and repairing a Two-mode vehicle
We will also:
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Introduction
Cues
i-7
Elaborate as indicated below slide
8
Session Objectives cont.

PPT #8
Session Objectives
cont.
4 BUILDS
Discuss tool safety for diagnosing/repairing a

Two-mode vehicle
Discuss procedures for disabling/enabling the
HV system
Identify special tools for the Two-mode Hybrid
system
Discuss procedures for Two-mode special
tools for diagnosis/repair
Discuss tool safety for diagnosing and repairing a
Two-mode vehicle
Discuss proper procedures for disabling and
enabling the high voltage system
system
Discuss procedures for using the Two-mode
Hybrid special tools during diagnosis and repair
Finally, we will:
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i-8
Cues
9
Session Objectives cont.

PPT #9
Session Objectives
cont.
3 BUILDS
Identify Two-mode Hybrid Tech 2 Special

Functions
Describe the operation for key Special
Functions with the Tech 2
Discuss procedures for diagnosing/repairing
the Two-mode Hybrid system
Functions for diagnosing the Two-mode Hybrid
System
Describe the operation performed for key Special
Functions with the Tech 2and we will
Discuss proper procedures for use during
diagnosis and repair of the Two-mode Hybrid
system
As you can see, well be covering many

topics today about the Two-mode Hybrid
system.
We may use some terms and acronyms
which you may not be familiar with, so
weve provided a list of terms and their
definitions for you in an Appendix at the
back of your Participant Guide.
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Introduction
Cues
i-9
Strategy Based Diagnosis
Remember, well be using the NEW Strategy
Based Diagnosis (SBD) process when we
diagnose vehicle concerns on page i-2 in
your Participant Guide.
Refer to SI for a complete explanation of the
process.
Read the SBD steps.
Strategy Based Diagnostic (SBD) Steps
Step 1: Understand & verify customers concern
Step 2: Check that vehicle is operating as designed
Step 3: Conduct Preliminary Checksvisual and
operational
Step 4: Perform Diagnostic System Check--Vehicle
Step 5: Check Bulletins, Recalls and Preliminary
Information (PI)
Step 6: Perform Diagnostics
Step 7: Re-examine the Concern
Step 8: Repair and Verify Fix
This course has 4 modules, and well take a

break about halfway through the course.
Ten Posttest questions will be split up and
presented at the end of each module, so
keep that in mind as we proceed.
Lets continue on to Module 1.
End of Introduction
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Two-mode Hybrid
Diagnosis & Repair
Module 1
Two-mode Hybrid System Overview
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1-2
Cues
This page is intentionally left blank
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Cues
1-3
Module 1
Introduction to Two-mode Hybrid System
Module 1 objectives are listed on Page 1-1 in
your Participant Guide. At the end of this
module you should be able to:
10
Module 1 Objectives
PPT #10
Module 1
Objectives
3 BUILDS
Identify Two-mode Hybrid vehicle applications

Describe the Two-mode Hybrid system
Describe components of the Two-mode Hybrid
system
Identify current and future Two-mode Hybrid vehicle
applications;
Describe the Two-mode Hybrid system; and
Describe major components of the Two-mode
Hybrid system.
The first thing well do is to briefly describe

the applications that are currently available.
We will also review with you any future
applications that we are aware of.
Information about this product is evolving,
so be sure that you have the most current
information prior to servicing the Two-mode
Hybrid system or any of the systems
components.
Lets get started by looking at the Two-mode
Hybrid Vehicle Applications.
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1-4
Cues
Two-mode Hybrid Vehicle Applications
Elaborate/telestrate as indicated below chart
11
PPT #11
GMs Hybrid
Portfoilo
4 BUILDS
In 2003 GM introduced a Two-mode Hybrid bus,

which is the basis to what will be introduced in the
full-size pickup and utility vehicles.
In 2004 hybrid truck (Silverado/Sierra) was
introduced. This technology used the 42V Hybrid
system.
For the 2007 model year the GM Hybrid was
introduced.
This system consists of a belt-driven Starter
Generator, which is used to recharge the hybrid
battery and also to restart the engine after AutoStop.
This system also only uses intermediate voltage.
The system is found on the Saturn VUE, Saturn
AURA Greenline and the 2008 Chevrolet Malibu.
Beginning Model Year 2008GM introduced the
Two-mode Hybrid. This system is introduced in the
2008 Chevrolet Tahoe and GMC Yukon. The
system will be used in many rear wheel drive and
front wheel drive platforms in the future.
Heres a description of Two-mode Hybrid

technology.
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Cues
1-5
Two-mode Hybrid Technology
Elaborate as indicated below image
PPT #12
Two-mode Hybrid
Technology
Two-mode Hybrid Technology
12
The two-mode is patented hybrid technology with

two modes optimized for city and highway driving.
Like other GM hybrids, the Two-mode Hybrid
system shuts the engine OFF at a stop.
Unlike other GM hybrids, the Two-mode Hybrid
system allows the driver to operate the vehicle in
full electric mode during low speeds and Reverse.
PT Q#1
The first mode is used for speeds under 25 MPH,
allowing the vehicle to operate using just the
electric motor, if conditions allow.
The most fuel is saved during low-speed, stopand-go traffic because the vehicle has the ability
to propel itself without engaging the Internal
Combustion Engineor ICEfor long periods of
time.
The Two-mode integrates sophisticated
electronic controls, such as Active Fuel
Managementor AFMand cam phasing,
allowing even more efficient engine operation in
both modes.
Two-mode Hybrid Cables next
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1-6
Cues
PPT #13
Hybrid Voltage
Levels
Lets take a look at the nominal voltage
levels in GMs hybrid vehicles compared to
house voltage.
Elaborate/telestrate as indicated below slide
13
110 volts is the amount of voltage that can be found

in a typical house.
42 volts is the nominal amount of voltage found in
the GM Hybrid system that is used in the Chevy
Malibu Hybrid and in the Saturn VUE and AURA
Greenline.
300 volts is the nominal voltage found in Two-mode
systems that is used in the GMC Yukon and Chevy
Tahoe Two-mode Hybrids, although the Two-mode
also uses intermediate voltage for the power
steering.
As you can see, Two-mode voltage is considerably
higher than what is found in the 42 volt hybrid, and
higher than voltage found in a typical house.
Due to the voltage levels in this system, be sure to
follow all safety practices when servicing the Twomode Hybrid vehicle.
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Cues
1-7
Next, lets look at the GM standards for
color coding for Hybrid vehicles.
PPT #14
Color Coding for
Hybrid Vehicles

14
GM categorizes voltage levels as Low, Intermediate

or High.
Low voltage ranges from 0 to 30 volts DC and 0
to 15 volts AC.
Intermediate voltage ranges from 30 volts to 60
volts DC and 15 volts to 30 volts AC. Cables with
Intermediate voltage are blue in color.
The Saturn AURA and VUE Greenline hybrid and
the Chevrolet Malibu hybrids fall within the
Intermediate voltage range.
Also, the power steering on the rear wheel drive
Two-mode uses intermediate voltage.
High voltage is any voltage greater than 60 volts
DC and 30 volts AC. Cables that are colored
orange indicate that high voltage may be present.
Here are the Two-mode Hybrid components

that well be discussing with you.
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1-8
Cues
Two-mode Hybrid Components

PPT #15
Two-mode Hybrid
Components
4 BUILDS
15
Power Inverter Module

Accessory Power Module
Drive Motor Generator Battery
2ML70 Electrically Variable Transmission (RPO
M99)
Power Inverter Module or PIM
Accessory Power Module or APM
2ML70 Electrically Variable Transmission (RPO
M99)
There is also the:

Two-mode Hybrid Components cont.

PPT #16
Two-mode Hybrid
Components cont.
16
300V Electric Air Conditioning Compressor

42V Electric Power Steering Pump
Two-mode High Voltage Cables
3 BUILDS
42V Electric Power Steering Pump and the
Two-mode High Voltage Cables
You can use the image on page 1-4 in your

Participant Guide to mark the locations of
the various components as I show them to
you.
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Cues
1-9
The power electronics in the Two-mode
Hybrid system are located under the hood.
Power electronics is now referred to as
Drive Motor Generator Control Module
Assembly. For purposes of this course, we
will use the term Power Electronics.
The power electronics consist of the Power
Inverter Module and the Accessory Power
Module.
Both of these components are attached
together and share a dedicated cooling
system.
Lets take a look at the Two-mode Hybrid
components, starting with the PIM and APM
assembly.
Telestrate location of PIM/APM asembly
Two-mode Hybrid Vehicle Components
17
PPT #17
Two-mode Hybrid
Vehicle
Components
Here is where the Power Inverter Moduleor

PIMand the Accessory Power Moduleor APM
are located.
Lets take a closer look at the PIM.

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1-10
Cues
Elaborate/telestrate as indicated below image
PIM & APM Assembly
18
PPT #18
PIM & APM
Assembly
OR Live Demo
on Camera 2
The PIM consists of three internal modules and an

inverter.
The inverter inverts 300 volts DC to 3-phase 300
volts AC to power motors internal to the
transmission.
The inverter also inverts 300 volts 3-phase AC
generated by the drive motor generators internal to
the transmission into 300 volts DC that is used to
recharge or maintain state of charge of the hybrid
battery.
The 3 internal modules consist of:
One Hybrid Powertrain Control Module or
HPCM and
Two Motor Control Modules or MCMs
Within the PIM, the HPCM is the master controller
for all hybrid operations, such as determining when
to perform engine Autostop and regenerative
braking.
PIM and APM Assembly continued next page
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1-11
Cues
All of these modules are serviced by replacement of
the PIM.
PPT #18
PIM & APM
Assembly cont.
OR Live Demo
on Camera 2
The HPCM also commands the BECM to enable or

disable the high voltage contactors within the
Hybrid Battery.
The HPCM directly interfaces with the:
Transmission Internal Mode Switch direction
Engine RPM
High Voltage Interlock Circuit or HVIC and
the
Automatic Transmission Auxiliary Fluid Pump
The BECM and both MCMs monitor the entire high
voltage system to ensure it is isolated from the
vehicle chassis.
PT Q#2
Heres a Tech Tip for you on page 1-5 in

Read the Tech Tip
Tech Tip:
PPT #19
Tech Tip
The MCMs are able to communicate ONLY data

parameters through the Tech 2.
Any DTCs associated with the MCMs are retrieved
via the HPCM and the BECM.
PIM and APM assembly continued on next page
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19

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1-12
Cues
PIM & APM Assembly
20
PPT #20
PIM & APM
Assembly
OR Live Demo
on Camera 2
This is the Accessory Power Module (APM)

component of the assembly.
The Drive Motor Generator Battery also referred
to as the Hybrid Battery supplies voltage to the
Power Electronics.
The APM then converts 300 volts into 42 volts for
electric power steering, and 14 volts for traditional
power for accessories and charging of the 12 volt
battery.
The next component is the Drive Motor

Generator Battery.
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Cues
1-13
Telestrate location of Drive Motor Generator Battery as
desired
21
PPT #21
Two-mode Hybrid
Vehicle
Components
Here is where the Drive Motor Generator

Battery, also known as the Hybrid Battery, is
located.
Lets take a closer look at the battery.
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1-14
Cues
Elaborate/telestrate as indicated below graphic
22
PPT #22
Drive Motor
Generator Battery
The Hybrid Battery consists of 40 Nickel-Metal

Hydride batteries rated at 7.2 volts each.
The battery is cooled by a fan that pulls air through
a duct in the floor panel.
Inlet and outlet temperature sensors monitor the
temperatures that are then used by the BECM to
determine air flow.
The 40 individual batteries that make up the Drive
Motor Generator Battery are connected through a
manifold.
The battery is vented through the manifold using a
single hose that is routed through the floor pan to
the exterior of the vehicle to exhaust the fumes.
The next component well look at is the

2ML70 Electrically Variable Transmission.
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Cues
1-15
Telestrate location of 2ML70 Electrically Variable
Transmission
23
PPT #23
Two-mode Hybrid
Vehicle
Components
Heres the location of the 2ML70 Electrically

Variable Transmission (RPO M99).
Lets take a closer look.
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1-16
Cues
Elaborate/telestrate as indicated below graphic
2ML70 Electrically Variable Transmission
24
(RPO M99)
PPT #24
2ML70 Electrically
Variable
Transmission (RPO
M99)
The 300-volt battery provides electric energy for the

Hybrid system.
The 2ML70 Electrically Variable Transmission
(RPO M99) has two 60 kilowatt electric motors, 4
fixed gear ratios and an auxiliary fluid pump.
The interconnect between the engine and the
transmission has a dampner instead of the
traditional torque converter.
The dampner is used to absorb vibration caused
during Auto Starts / Auto Stops.
Next is the 300V Electrical Air Conditioning

Compressor.
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Cues
1-17
Telestrate location of 300-volt Electrical Air
Conditioning Compressor

PPT #25
Two-mode Hybrid
Vehicle
Components
Heres where the 300 volt Electric Air

Conditioning Compressor is located.
Lets look closer.
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25
1-18
Cues
26
PPT #26
300V Electric Air
Conditioning
Compressor
300 volts from the Hybrid Battery are routed

through a buss bar in the PIM to the Air
Conditioning Compressor cables.
The 300-volt air conditioning electric compressor
provides sustained occupant comfort (cooling,
dehumidification) in Auto-Stop mode (Engine
OFF).
Compressor speed and power consumption can be
varied to balance needs of comfort and noisevibration-harshness, regardless of engine speed.
The Air Conditioning Compressor and the Air
Conditioning Control Module or ACCM are
housed in a single unit.
REMEMBER: Any diagnosis done on any

high voltage component or wiring requires
the high voltage system to be disabled.
Next, lets take a look at the 42-volt
Electrical Power Steering system.
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Telestrate location of 42-volt Electrical Power Steering
System
27
PPT #27
Two-mode Hybrid
Vehicle
Components
The 42 volt Electric Power Steering system is

attached to the base of the steering gear housing.
Heres a closer look.
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Cues
42V Electric Power Steering System
28
PPT #28
42V Electric Power
Steering System
A conventional power steering system is beltdriven. If a belt driven system is still being used in
this vehicle, it will not be operational while in AutoStop or Electric Vehicle mode.
The rear wheel drive Two-mode uses a 42-volt
power steering system.
This system utilizes an electric motor that is
mounted directly to the rack and pinion.
The motor is supplied voltage through the Power
Steering Control Module or PSCMfrom the
APM.
Now, lets take a look at the Two-mode

Hybrid high-voltage cables.
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Telestrate location Two-mode Hybrid high-voltage
cables
Two-mode Hybrid High-Voltage Cables
29
PPT #29
Two-mode Hybrid
High-Voltage
Cables
Here are the Two-mode Hybrid high-voltage

cables.
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Cues
Two-mode Hybrid High-Voltage Cables
30
PPT #30
Two-mode Hybrid
High-Voltage
Cables
The two-mode high voltage cables are orange.

The cables have a braided-shielding around the
inner conductor that reduces Electro-Magnetic
Interference or EMI.
The three-phase AC cables run from the PIM to the
transmission.
The cables are routed over the transmission, and
are encased in an anodized aluminum housing to
protect them from heat and abrasion.
In addition to the 3-phase AC cables, there are also
300-volt DC cables.
The 300-volt DC cables are routed from the hybrid
battery to the PIM and from the PIM to the 300-volt
air conditioning compressor.
Heres a Tech Tip for you on page 1-8 in

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Cues
Read the Tech Tip
Tech Tip:
PPT #31
Tech Tip
Arcing or failure of the components and/or

cables may result if a torque wrench is not
used for terminal fastener torque.
If damage DOES occur to the cables, the
cables are NOT repairable and MUST be
replaced.
Always refer to SI for the correct torque
specifications.
Next, I have a feature to show you in an
animation of the IPC in the Two-mode.
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Cues
Elaborate Economy Gauge & Auto Stop button as
indicated on looped graphic
Instrument Panel Cluster (IPC)
Instrument Panel
Cluster (IPC)
looped
The economy gauge is the easiest identifiable

feature of the Two-mode Hybrid Instrument Panel
Clusteror IPC.
This gauge replaces the volt gauge, and it indicates
whether the vehicle is generating or if it is in power
consumption mode.
An additional feature is the Auto Stop position
indicator on the tachometer. Engine OFF and Auto
Stop modes are indicated on the tachometer
display.
When the tachometer needle indicates OFF, the
engine is not running and will remain OFF until
the ignition key is placed in the Crank position or
a remote vehicle start request is received from
the keyless entry transmitter.
When the tachometer needle indicates Auto
Stop, the ICE is not running but may Auto Start
at any time without notice.
When the brake pedal is released, the rear motor
and planetary gear set, within the transmission,
propel the vehicle up to 25 miles per hour
depending on conditions.
IPC continued next page
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Instrument Panel
Cluster (IPC) cont.
1-25
At this time, the front motor in the transmission,
which is connected directly to the ICE through the
front planetary gear set, spins the ICE at
approximately 1000 RPM starting the ICE.
Reverse is performed electrically by the rear motor
only.
I just used the term ICE again.

Just to clarify for youICE or Internal
Combustion Engine is an engine of one
or more working cylinders where the
process of combustion takes place within
the cylinders.
Lets try a Call-in Question.
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Cues
Read the question
32
Question
PPT #32
Call-In Question
1 BUILD
Which component supplies voltage to the

Power Electronics of the Two-mode Hybrid
system?
Take calls
Call-in
Debrief correct answer:

Drive Motor Generator Battery (also referred to as
Hybrid Battery)
PREP TO SHOW INSTRUCTORS

COMPUTER
Our final topic in Module 1 is the Two-mode
Hybrid Navigation Radio.
Were going to show you that in an
animation as well.
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Elaborate as indicated below image
Two-mode Hybrid Navigation Radio
Two-mode Hybrid
Navigation Radio
A new feature of the Two-mode navigation radio

includes a display to show power flow of the Hybrid
system.
The display allows the user to view the current
operational mode of the vehicle.
For example, the display screen will show the
status of ENGINE IDLE, BATTERY CHARGING,
BATTERY POWER, ENGINE POWER, HYBRID
POWER OR AUTOSTOP.
Ask for questions
Are there any questions about what weve

covered so far today? If so, press your Call
button and Ill get an answer for you.
While were waiting for your call to get
through, Im going to summarize what we
covered in Module 1.
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Cues
Module 1 Summary
33
Module 1 Summary
PPT #33
Module 1 Summary
3 BUILDS
Identified current and future Two-mode

Hybrid vehicle applications
Described the Two-mode Hybrid system
Described major components of the Twomode Hybrid system.
In this module we:

Identified current and future Two-mode Hybrid
vehicle applications;
Described the Two-mode Hybrid system; and
Described major components of the Two-mode
Hybrid system.
Take calls, if necessary
Call-in
Answer questions, if required
Lets move on to our Posttest questions.
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1-29
Posttest Questions
Introduce Posttest
The Posttest questions are now given at the

end of each module, but the results of your
answers will be scored and graded the same
as in the past.
You will have 30 seconds from the time I
finish reading the question to enter your
answer.
Be sure to choose your answers carefully
because once you enter your selection on
the keypad, your answer cannot be
changed.
Here is Posttest Question #1.
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Cues
Posttest Question #1
Read the question
PPT #34
Posttest
Question 1
1 BUILD
34
Posttest Question 1
The Two-mode Hybrid system allows the
driver to operate the vehicle in full electric
mode ____________.
A. at speeds over 25 mph
B. at speeds between 50-70 mph
C. at low speeds and Reverse
D. only when idling
IG 1-5
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Read the question
PPT #35
Posttest
Question 2
1 BUILD
35
Posttest Question 2
The _________ and both MCMs monitor
the entire high voltage system to ensure it
is isolated from the vehicle chassis.
A. Air Conditioning Compressor
B. Body Control Module
C. Accessory Power Module
D. Battery Energy Control Module
IG 1-11
End of Module 1
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Two-mode Hybrid
Diagnosis & Repair
Module 2
Safe Work Practices
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Two-Mode Hybrid Diagnosis & Repair
Cues
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2-3
Module 2
Two-mode Hybrid Safe Work Practices
Module 2 Objectives are listed on Page 2-1
in your Participant Guide. At the end of this
Read the slide
36
Module 2 Objectives
PPT #36
Module 1
Objectives
4 BUILDS
Identify Danger, Caution & Warning labels &

their locations
Identify proper protective equipment when
diagnosing & repairing a Two-mode vehicle
Apply tool safety when diagnosing & repairing a
Two-mode vehicle
Use proper procedures to disable & enable the
high voltage system
Identify Danger, Caution and Warning labels and
their locations
Identify proper protective equipment to use when
Apply tool safety when diagnosing and repairing a
Two-mode vehicleand
Use proper procedures to disable and enable the
high voltage system
There are some safe work practices that

must be strictly adhered to when servicing
the Two-mode hybrid vehicle.
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Cues
Before performing any diagnostic

procedures that pertain to the High Voltage
system, the high voltage must be physically
disabled using the high voltage disabling
procedure.
For additional information on Two-mode
Hybrid safe work practices, refer to:
High Voltage System Safety WBT, course#
18440.01 and
Two-mode Introduction and Safety WBT, course
#18440.05
Failure to follow the safety procedure

exactly as written may result in serious
injury or death.
First, lets review the various Danger,
Caution and Warning labels that you should
be aware of during diagnosis and repair of
Two-mode hybrid vehicles.
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Cues
2-5
Danger, Caution and Warning Labels
Labels are used to identify where likely
accessible potential shock hazards exist in
high voltage systems.
Here are some areas where these labels may
be found.
Areas for High Voltage Labels

PPT #37
Areas for High
Voltage Labels
5 BUILDS
37
High Voltage Cables

Hybrid Battery
Power ElectronicsPIM/APM Assembly
Transmission
300V Air Conditioning Compressor
High voltage cables
Hybrid Battery
Power electronicsPIM / APM Assembly
Transmission and
300-volt Air Conditioning Compressor
Lets look at the DANGER HIGH VOLTAGE

labels.
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Cues
Read the label and elaborate as indicated below slide
DANGER HIGH VOLTAGE Labels
38
PPT #38
DANGER HIGH
VOLTAGE Labels
The first label well look at is the DANGER

HIGH VOLTAGE label.
DANGER labels are red.
Danger labels can be found on the hybrid battery.
For procedures involving High Voltage systems
death may occur if proper procedures are not
followed.
Next, we have the WARNING HIGH

VOLTAGE labels.
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2-7
WARNING HIGH VOLTAGE Labels
39
PPT #39
WARNING HIGH
VOLTAGE Labels
WARNING labels are orange.

Warning labels can be found on the high voltage
cables, PIM, APM and the Air Conditioning
Compressor.
To avoid burns or electrical shock while servicing
hybrid components with this label, be sure to
disable the high voltage system.
Last, we have CAUTION labels.
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Cues
CAUTION Labels
40
PPT #40
CAUTION Labels
CAUTION labels are yellow.

Caution labels can be found on 42-volt systems.
To prevent personal injury while servicing the 42
volt system, the 300 volt system must first be
disabled.
There is no way to isolate the 42-volt system to
disable separately.
Next, lets look at some Protective

Equipment that is required when servicing
Two-mode Hybrid vehicles.
Required Personal Protective equipment
consists of Safety Glasses with side shields
and Class 0 gloves.
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2-9
Personal Protective Equipment
Class 0 Gloves
41
PPT #41
Class 0 Gloves
Class 0 gloves are a protective system consisting

of a leather outer glove and a rubber inner glove.
The rubber inner glove provides insulation and
protects you from electrical current. The protective
leather glove shields the inner rubber glove from
being damaged or destroyed.
These gloves are required when servicing high
voltage systems. They create a barrier between
electrical current and the user.
DANGER: Class 0 gloves are designed to

resist voltage up to 1000 volts. The gloves
MUST be worn when servicing high voltage
systems.
If Class 0 gloves are not used, serious
injury or death could occur.
I have some Class 0 gloves in the studio
with me today, so lets take a look at them.
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Cues
Show gloves and elaborate as indicated below
Here is the proper procedure to visually and
functionally inspect Class 0 gloves.
PROP
Class 0 Gloves
The first thing you should do is to check the

certification date stamp to ensure that the gloves
are certified and have not expired.
Class 0 gloves are required to be worn by
technicians servicing any high voltage systems
REGARDLESS if the system is energized or not.
It is important to note that this inspection should be
completed prior to performing service on high
voltage systems.
First, remove the rubber glove from the outer
leather protector.
Next, inflate the glove by pinching the opening
tightly to seal the air in the glove and prevent any
air loss.
Then, increase the pressure inside of the gloves
and make sure none of the following are present:
pin holes
air leaks
wear, tears, or abrasions
damp or wet material
If any of the criteria mentioned are not met; do NOT
use the gloves.
This procedure is a very important part of

safety practices.
Following this procedure will reduce the
potential for electricity to pass through the
gloves.
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Lets next review some tool safety for the
Two-mode Hybrid.
DMM & Leads Safety
42
PPT #42
DMM & Leads
Safety
One thing you should always remember is that you

must use a DMM with leads that are classified as
Category III/1000 volt rated.
Some DMMs are marked on the front cover by the
lead connection points. The leads themselves are
also marked with the Category and Voltage
markings.
If you have any doubt about the meter classification
or rating, consult the DMM's Owners Manual for the
category rating.
If the meter that you are using is not Category
III/1000 volt rated, do NOT use it. Serious injury or
death could occur.
Before any diagnosis can be performed on

the high voltage system, the high voltage
system must be disabled. So this is the first
procedure we want to cover.
Lets watch our technician perform the
disabling procedure in a video.
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Cues
VIDEO: High Voltage Disabling
Video Outline:
Before servicing any High Voltage components such as the

Drive Motor Generator Battery Assembly, or the 300 Volt
DC Cables, the high voltage system must be disabled using
the following procedure.
You must first eliminate all potential sources of voltage.

Begin by removing the ignition key.
Remove the close out panel from the right side drive motor
generator battery assembly.
With the cover off, remove the high voltage manual

disconnect lever. Wait at least 5 minutes for the capacitors
to discharge before continuing.
Attach the ignition key to the manual disconnect lever and

secure them in a safe place.
This ensures the system cannot be re-enabled without your

knowledge.
To ensure proper test results, the vehicles 12-volt battery

must be disconnected.
Remove the trim cover from the drive motor generator

battery assembly.
Remove the terminal extension cover assembly.
Before continuing, you must verify that the voltage has

been disabled at the drive motor generator battery
assembly terminals using a voltmeter.
Set the meter to read DC voltage. Test the meter by

measuring the voltage of the vehicles 12 volt battery.
With the meter still set to DC voltage, measure across the

High Voltage DC positive and negative terminals. There
should be less than 3 volts present.
If there are more than 3 volts present, the drive motor

generator control module internal capacitors havent fully
discharged. Replace the cable cover and wait 5 additional
minutes. Remove the cover and start the process again.
High Voltage
Disabling
TRT: 5:24
Video outline continued next page
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Cues
VIDEO: High Voltage Disabling cont.
Video Outline cont:
Next, check for DC voltage between the High Voltage DC

positive terminal and vehicle ground and between the
High Voltage DC negative terminal and ground.
The result in both measurements should be less than 3

volts.
If the result was more than 3 volts, a stuck contactor and a

loss of isolation is present within the drive motor generator
battery assembly.
Follow the High Voltage Contractor Relay Always Closed

Service Information procedure.
The next step in the High Voltage disabling procedure is to

check for DC voltage between the High Voltage manual
disconnect terminal A and the High Voltage DC positive
terminal.
Also check between High Voltage manual disconnect

terminal A and the High Voltage DC negative terminal.
The result in both measurements should be less than 3

volts.
Repeat these measurements between High Voltage manual

disconnect terminal B and the High Voltage DC positive
and negative terminals.
Again, the result in both measurements should be less than

3 volts.
High Voltage
Disabling cont.
TRT: 5:24
A result of more than 3 volts for any of the four

measurements would again indicate that a stuck contactor
is present within the drive motor generator battery
assembly.
Retest the meter by measuring the 12 volt battery. If it fails

to properly measure the 12 volt battery, repair or replace it
and repeat ALL of the voltage measurements.
If the meter is functioning properly and all of the

measurements were below 3 volts, the 300 volt DC cables
can be safely removed from the drive motor generator
battery assembly.

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Cues
VIDEO: High Voltage Disabling cont.
Video Outline cont.:
The High Voltage Disabling procedure is different if you are

servicing the Drive Motor Generator Control Module
Assembly or Cable Connections.
High Voltage
Disabling cont.
TRT: 5:24
The initial steps are the same, however.

Attach the ignition key to the manual disconnect lever and
secure them in a safe place.
Wait at least 5 minutes for the capacitors to discharge.

Disconnect the vehicles 12 volt battery.
Remove the drive motor generator control module sight
shield.
Remove the 3-phase cable cover.

Verify that the meter is functioning properly by setting it to
DC mode and measuring the output of the vehicles 12-volt
battery.
With the meter still set to read DC voltage, measure

between the High Voltage DC positive and negative
terminals.
If there is more than 3 volts present, the drive motor

generator control module internal capacitors havent fully
discharged. Replace the cable cover and wait 5 additional
minutes. Remove the cover and start the process again.
Next, measure between the High Voltage DC positive and

negative terminals and chassis ground.
If the result was more than 3 volts, a stuck contactor and a

loss of isolation is present within the drive motor generator
battery assembly.
Follow the High Voltage Contactor Relay Always Closed

Service Information procedure.
Retest the meter by measuring the 12-volt battery.

If the meter is functioning properly and all of the
measurements were below 3 volts, the cables can be safely
removed from the drive motor generator control module
assembly.
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Cues
2-15
Debrief video
As you can see there are two different places High
Voltage can be disabled which are dependent upon
the service that is performed.
One procedure is used if there is service to be
performed at the Hybrid Battery or the High Voltage
Battery Cables.
The other procedure is performed only if there is
service being performed with the PIM/APM or any
of the connections that are related to the PIM/APM
assembly (Drive Motor Generator Control Module
Assembly).
In our video you may have noticed that the

technician was not wearing Class 0 gloves
during some of the Disabling procedure.
The gloves are only required when there is
potential of contact with high voltage.
Refer to SI for instructions on when it is
appropriate to use the required Personal
Protective Equipment.
Once againmake sure that the DMM and
leads are Category 3 or 1000 volt rated for
high voltage testing.
Lets stop here and go to a Call-in Question.
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Cues
Read the question
43
Question
PPT #43
Call-In Question
1 BUILD
Why do you check for voltage at the Hybrid

Battery with the manual disconnect removed?
Take calls
Call-in
Debrief correct answers using High Voltage Manual

Disconnect schematic next page
If youll turn to page 2-8, you can follow

along with me while we look at the High
Voltage Manual Disconnect schematic on
page 2-9 in your Participant Guide.
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Cues
Elaborate/telestrate numbers as indicated below chart
OH #1
Drive Motor Generator Power
Inverter Module
OH #1
High Voltage
Manual Disconnect
Schematic
300 V+
Battery Module 11
Battery Module 30
Battery Module 31
Battery Module 9
Battery Module 12
Battery Module 29
Battery Module 32
Battery Module 8
Battery Module 13
Battery Module 28
Battery Module 33
Battery Module 7
Battery Module 14
Battery Module 27
Battery Module 10
Drive
Motor
Generator
Battery
300 V-
Battery Module 26
Battery Module 6
Battery Module 15
Battery Module 35
Battery Module 25
Battery Module 5
Battery Module 16
Drive Motor Battery

Negative High Voltage
Contactor Relay
Drive Motor Battery

Inverter Current
Limit Relay
Drive Motor Battery

Positive High Voltage
Contactor Relay
Battery Module 34
Battery Module 36
Battery Module 4
Battery Module 17
Battery Module 24
Battery Module 3
Battery Module 18
Battery Module 23
Battery Module 38
Battery Module 2
Battery Module 19
Battery Module 22
Battery Module 39
Battery Module 1
Battery Module 20
Drive Motor Battery

High Voltage Manual
Disconnect Lever
Battery Module 40
Battery Module 37
2
2
Battery Module 21
Drive Motor Battery
Inverter Current Limit
Resistor
To check for a stuck contactor or to make sure the

PIM has discharged the capacitors, the manual
disconnect is wired in series with batteries 21 and
22 of the Hybrid battery.
If each battery is 7 volts, there is a potential of
there being 137 volts on one side, and 151 volts on
the other side.
(1) When checking voltage at the Hybrid Battery
positive and negative cable connections, you are
checking to see if the PIM has discharged the
capacitors.
(1 & 2) When checking the Hybrid Battery positive
and negative cable connections to the service
disconnect points, you are checking to see if the
high voltage contactor relays or the precharge
relay is stuck closed.
High Voltage Manual Disconnect continued next page
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Cues
Elaborate/telestrate as indicated below chart
OH #1
High Voltage
Manual Disconnect
cont.
When checking the battery at the service

disconnect points, be sure you do NOT distort the
terminals.
If more than 3 volts are present while checking the
cable connections to ground, there is a loss of
isolation and also a contactor stuck closed.
If voltage above 3 volts is found during the
disconnect procedure, one or both of the contactor
relays could be stuck closed.
Introduce video
After a repair has been made to the high

voltage system, you will need to enable the
system to verify it has been repaired.
PT Q#3
Lets watch that procedure in this next

video.
COMPUTER AFTER VIDEO
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Cues
VIDEO: High Voltage Enabling
Video Outline:
High Voltage
Enabling
Before enabling the High Voltage system after service, you

must perform some preliminary checks.
TRT: 1:58
First, confirm that the 12 volt battery is still disconnected.
Make sure that all of the High Voltage fasteners are

tightened to the specified torque.
Verify High Voltage system integrity and that all the

connectors are installed.
Make sure that all High Voltage Interlock Circuit connectors

and covers are installed.
Finally, make sure that all tools and any loose components
have been removed.
With all the preliminary checks complete, install the High

Voltage manual disconnect lever.
Replace the High Voltage manual disconnect lever cover.
Reconnect the 12 volt battery.
With the ignition ON, connect a scan tool and clear all
DTCs.
Turn the ignition OFF and wait for 2 minutes.
Turn the ignition back ON and check for DTCs.
Diagnose and repair any DTCs that have set.
If there are no DTCs, check the Hybrid Powertrain Control

Module 300 Volt Circuit Voltage parameter on the scan tool
to verify that the High Voltage system has been enabled.
Start the engine and let it idle for 2 minutes.
Turn the ignition OFF and wait 5 minutes.
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VIDEO: High Voltage Enabling cont.
High Voltage
Enabling cont.
TRT: 1:58
Turn the ignition ON and confirm that the following have run
and passed since codes were cleared.
Contactor DTCs
Discharge and Pre-Charge DTCs
Motor Position Sensor Learn DTCs
High Voltage Loss of Isolation DTCs
If any of the DTCs are set, diagnose and repair them.
If any of the codes have not run, operate the vehicle as

described in Conditions for Running the DTC.
If all of the DTCs have run and passed, test-drive the

PT Q#4
vehicle and verify that no DTCs set.
Debrief video
As you can see, this procedure is different

from what you may be used to whether you
are working on a 42V hybrid or a non-hybrid
vehicle.
You MUST wait 5 minutes to allow the PIM
to run isolation and contactor condition
DTCs after turning the ignition OFF.
REMEMBER: If all of the DTCs have run
and passed, you should test drive the
vehicle and verify that no DTCs set. PT Q#4
Instructor navigates to High Voltage Enabling,
Document ID# and reviews DTCs that must run and
pass
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Cues
Lets go over to SI and take a look at those
DTCs in Document ID#1983358.
Hybrid
Hybrid Energy Storage
Diagnostic Information and Procedures
High Voltage Enabling
Review Document ID#1983358 next
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Document ID# 1983358
2008 Chevrolet Tahoe - 4WD
High Voltage Enabling

High Voltage
Enabling, Document
ID#1983358
Danger: Ensure all High Voltage safety procedures are followed.

Failure to follow the procedure exactly as written may result in
serious injury or death.
Danger: Before working on any high voltage system, be sure to
wear the following Personal Protection Equipment:
Safety glasses with appropriate side shields when within 50 feet
of the vehicle, either indoors or outdoors. Certified and up-todate Class "0" Insulation gloves rated at 1000V with leather
protectors.
Visually and functionally inspect the gloves before use.
Wear the Insulation gloves at all times when working with the
high voltage battery assembly, whether the system is energized
or not.
12. Ignition ON, verify with the scan tool HPCM DTC Information
that the following DTCs have Ran Since Code Clear and have not
set:
Contactor relay DTCs P0ADC, P0AE7 and P0AE0

Discharge and Pre-charge DTCs P0C76, P0C77, P0C78,
P1A20 and P1A56
Motor position sensor learn DTCs P0C17 and P0C18

High voltage loss of isolation DTCs P1AE7, P1AF0 and
P1AF2
If the DTCs have Ran and Passed, test-drive the
vehicle and verify no DTCs are set.
If the DTCs are set, go to the appropriate DTC
information.
If the DTCs have Not Ran Since Code Clear, review
and operate the vehicle according to the applicable
DTC Conditions for Running and ensure the DTCs run
and pass.
Be sure to review the high voltage safety

information prior to performing the High
Voltage Enabling procedure.
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Thats all we have for Safety information and
that also completes what we have for
Module 2.
covered so far?
While were waiting for your calls to get
through, Im going to go ahead and
summarize what we just covered.
After the Summary well go to our next 2
Posttest questions, and then well take our
8-minute break.
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Cues
Module 2 Summary
44
Module 2 Summary
PPT #44
Module 2 Summary
4 BUILDS
Identified Danger, Caution & Warning labels

and their locations
Identified proper protective equipment for
Discussed proper tool safety when diagnosing
and repairing a Two-mode vehicle
Discussed proper procedures to disable and
enable the high voltage system
Heres what we did in Module 2. We

Identified Danger, Caution and Warning labels and
their locations
Identified proper protective equipment to use when
Discussed tool safety when diagnosing and
repairing a Two-mode vehicleand we
Discussed proper procedures to disable and enable
the high voltage system
Take calls
Call-in
Answer questions, if necessary

Introduce Posttest next
Revised 04/16/08

All Rights Reserved
Safe Work Practices
2-25
Cues
Here are your next 2 Posttest questions.
Remember to choose your answers
carefully because once you enter your
selection on the keypad, the answer cannot
be changed.
Here is Posttest Question 3.
Read the question
PPT # 45
Posttest
Question 3
1 BUILD
45
Posttest Question 3
After servicing the high voltage system, you
need to perform the ________ procedure to
verify it has been repaired.
A. disable
B. enable
C. visual
D. manual
IG 2-18
Revised 04/16/08

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Cues
Read the question
PPT # 46
Posttest
Question 4
1 BUILD
46
Posttest Question 4
When enabling high voltage, if all of the
DTCs have run and passed, you should
____________.
A. wait 2 minutes
B. wait 5 minutes
C. test drive the vehicle
D. reconnect the 12-volt battery
IG 2-20
SHOW COUNTDOWN VIDEO

8:00
TMS Promotion
PPT
(Show current broadcast information

and schedule Studio insert)
End of Module 2
Revised 04/16/08

All Rights Reserved
Two-mode Hybrid
Diagnosis & Repair
Module 3
Two-mode Special Tools
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Cues
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Cues
3-3
Module 3
Two-mode Hybrid Safe Work Practices
Welcome back from your break.
Read the slide
Module 3 Objectives
PPT #47
Module 3
Objectives

system
2 BUILDS
Apply procedures for using Two-mode Hybrid

special tools
47

systemand
Apply procedures for using the Two-mode Hybrid
special tools during diagnosis and repair
To achieve these objectives, well be

discussing the following topics:
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Cues
Module 3 Topics
PPT #48
Module 3 Topics
2 BUILDS
48
Pre Charge Test Tool

High Voltage Battery Pin Out Box
The EL-48458 Pre-Charge Test Tooland

The EL-48571 High Voltage Battery PinOut Box or
Battery Energy Control Module (BECM) break-out
box.
ALWAYS check SI for the most current

information concerning this vehicle and its
diagnosis or repair.
Now lets look at the Special Tools for the
Two-mode hybrid vehicle starting with the
Pre-Charge Test Tool and the connector.
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3-5
EL-48458 Pre-Charge Test Tool
PPT #49
EL-48458 PreCharge Test Tool &
Connector
EL-48458 PreCharge Test Tool

& Connector
49
The EL-48458 PreCharge Test Tool is used

whenever DTC P1AF0 or P1AF2 sets in the PIM.
P1AF0 is the DTC for Drive Motor 1 Control
Module Hybrid Battery Voltage System Isolation
Lost and
P1AF2 is for Drive Motor 2 Control Module
Hybrid Battery Voltage System Isolation Lost.
The tool is designed to assist in the diagnosis of
fault conditions that may be difficult to differentiate
between the Hybrid Battery and the power inverter
module. PT Q#7
The internal workings of the pre-charge test tool
include high voltage bulk capacitors to simulate the
capacity of the PIM.
Externally, the pre-charge test tool incorporates a
high voltage meter and LED to alert the operator of
the presence of high voltage.
Now that weve seen the EL-48458 PreCharge Test Tool, lets look at how wed use
it in this quick diagnostic customer concern.
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Cues
Diagnostic Concern
PPT #50
Diagnostic Concern
Vehicle:
50
2008 GMC Yukon

w/1,000 miles
Customer Concern: DIC Message

The customer brought in a 2008 GMC Yukon with
the DIC illuminated with the Service Hybrid
System message.
After completing the Diagnostic System Check
Vehicle, we found that DTCs P1AF2 and P1AF0
have set.
Usually when DTC P1AF2 sets, other DTCs will
also set.
We checked Service Information and found that
DTC P1AF2 is for a loss of isolation in the Drive
Motor 2 Control Module for the Hybrid Battery
Voltage System.
If you go to Service Information, you can

find the procedure for High Voltage System
Diagnosis.
This procedure directs us to use the
EL-48458 Pre-Charge Test Tool to check the
high voltage system.
Introduce video
Instead of going through each of the

diagnostic steps, lets follow along with the
video as our technician performs the
procedure.
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Cues
VIDEO: Using the EL-48458 Pre-Charge Test Tool to
Diagnose DTC P1AF2
Using the EL-48458

Pre-Charge Test
Tool to Diagnose
DTC P1AF2
Video Outline:
A check for trouble codes reveals that two DTCs have set:
P1AF2, Drive Motor 2 Control Module Hybrid Battery
Voltage System Isolation Lostand
P1AF0, Drive Motor 1 Control Module Hybrid Battery
Voltage System Isolation Lost
TRT: 5:26
Two conditions could cause these codes to set. Either the

ratio between Mid-Pack Voltage and hybrid battery high
voltage is less than 0.27 or more than 1.85; or the Mid-Pack
Voltage is less than 35 volts or more than 975 volts.
Either of these conditions must be present for 52 seconds

for P1AF0 and P1AF2 to set.
Since P1AF0 and P1AF2 are Type C DTCs, the MIL does
not illuminate.
A Service Hybrid System message will appear on the

Driver Information Center.
Before beginning diagnosis, ensure that DTC P1AE7 has

run and passed. If this code is set, diagnose it first.
Also check to see if the following codes have set:

P0A78 and P0A79
P0C01 and P0C04
P0BFD and P0BFE
Any of these codes would indicate a loss of isolation in the

three-phase components. Diagnose these codes before
proceeding.
Start diagnosis with the ignition OFF for at least two

minutes, the hood closed and the transmission in PARK.
All observations must be accomplished within 52 seconds,

the amount of time it takes to set the DTC.
With the ignition ON, record the HPCM 300 Volt Circuit
parameter.
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Cues
Video Outline cont.
Using the EL-48458

Pre-Charge Test
Tool to Diagnose
DTC P1AF2 cont.
Navigate to the MCM 1 and MCM 2 Isolation Voltage

parameters.
The values of the two MCM parameters and the HPCM 300
volt circuit parameter should be within 20 volts of each
other.
If only one of the MCM parameters was within the 20
volt range, the PIM would be replaced.
TRT: 5:26
If both of the MCM voltages were within range,

diagnosis would continue with Drive Motor Generator
Phase Testing.
Since neither MCM parameter is within 20 volts of the

HPCM 300 volt circuit parameter, testing continues by
disabling the High Voltage system.
Remove the Air Conditioning Control Modules high voltage

cable connector from the PIM.
Immediately cover the terminal ends with terminal covers

and UL listed insulation tape rated for at least 600 volts.
Temporarily install the PIMs high voltage distribution cover.
Install the drive motor generator module sight shield.
Install the high voltage manual disconnect lever.
Connect the 12 volt battery.
Make sure the hood is closed and the transmission is in

PARK.
Turn the ignition ON and compare the HPCM 300 Volt

Circuit parameter and the MCM 1 Isolation Voltage
parameter.
If the voltages were within 20 volts, the Air Conditioning

Control Module (ACCM) would be replaced.
Since they are not, diagnosis continues using the EL-48458

Pre-Charge Test Tool.
Before the EL-48458 can be used, the High Voltage

System must be disabled.
With the ACCM still disconnected, disconnect and remove

the drive motor generator battery high voltage cables from
the high voltage distribution box.

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Cues
Video Outline cont.
Connect the cables to the EL-48458.
Using the EL-48458

Pre-Charge Test
Tool to Diagnose
DTC P1AF2 cont.
Make sure that the tools safety cover is properly reinstalled.
Set the HV Contactor Relay switch to the OPEN position.
TRT: 5:26
Connect the tools HVIC connector to the Drive Motor

Generator Control Module sight shield HVIC connector.
Connect the tools alligator clip to chassis ground.
Install the high voltage manual disconnect lever.
Connect the 12 volt battery.
Turn the ignition to RUN.
The 12 volt power LED should light up on the EL-48458.
Use the HV Contactor Relay switch on the EL-48458 to

close the high voltage contactors. The GREATER THAN
60 Volts LED should light.
With the EL-48458 enabled, use the scan tool to activate

the BECM Isolation Test device control.
The Isolation Test should complete within 1 minute.
If the Isolation Test indicates PASSas it does herethe

PIM and the Accessory DC Power Control Module would be
replaced.
Remove the 56-way X1 connector from the PIM and

connect the vehicle side of the harness to the EL-48458.
Debrief video next page
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Cues
Debrief video
As you just saw in the video, the procedure for
installing the EL-48458 Pre-Charge Test Tool is
not difficult.
P1AE7 is the DTC for a loss of isolation internal to
the Hybrid Battery.
If this DTC is set, diagnose the P1AE7 FIRST.
PT Q #6
ALWAYS perform the High Voltage Disabling
procedure prior to servicing any High Voltage
component or connection.
Failure to follow the procedures exactly as written
may result in serious injury or death.
Once the EL-48458 Pre-Charge Test Tool

has been connected, any required tests or
diagnostics can be performed.
After the diagnostics have been completed,
the EL-48458 Pre-Charge Test Tool can be
removed.
Introduce Video
Lets watch our technician removing the

EL-48458 Pre-Charge Test Tool in this next
video.
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Cues
VIDEO: Disconnecting the EL-48458 Pre-Charge
Test Tool
Disconnecting the
EL-48458 PreCharge Test Tool
To disconnect the EL-48458, first move the contactor duty

cycle switch to the OPEN position.
Let the High Voltage discharge until the Greater than 60

Volts LED turns off and the Less than 60 Volts LED turns
ON briefly and then turns OFF.
Turn the ignition to OFF.
Disconnect the X1 harness connector from the EL-48458.
Remove the tools alligator clip from chassis ground.
Disconnect the tools HVIC connector from the sight

shields HVIC connector.
Wait 5 minutes before performing the High Voltage

Disabling procedure.
Open the High Voltage Safety Cover on the Pre-Charge

Test Tool.
While wearing all the required Personal Protection

Equipment, use a digital multi-meter to measure the High
Voltage connections inside the tool.
Be sure to verify the integrity of the meter by testing it on

the 12 volt battery before and after the High Voltage
connections.
Check for voltage between the positive and negative

terminals, as well as between each of the two terminals and
chassis ground.
Once there is less than three volts present, it is safe to

disconnect the High Voltage cables.
The EL-48458 can now be removed from the vehicle.
TRT: 1:26
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Cues
Debrief video
The procedure for removing the EL-48458 PreCharge Test Tool is the reverse order of installation.
Remember to follow ALL safety precautions and
procedures.
Okay. Weve just come to the conclusion

that the PIM and APM both have to be
replaced.
After removal of the assembly from the
vehicle, the coolant should be drained and
returned to the parts counter for the
warranty parts center.
These parts for the first 12 months will be
on restriction and will be serviced as an
assembly. The new PIM and APM are going
to be sent to the dealer separately along
with a seal and bolt kit.
It is important to note that you will be
required to assemble these parts as a unit
before installing the components in the
vehicle.
Introduce Video
Lets watch our technician assemble these

two individual parts before they are installed
on the vehicle.
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Cues
VIDEO: Drive Motor Generator Power Inverter
Module RemovalPart 1
Drive Motor
Generator Power
Inverter Module
RemovalPart 1
TRT: 2:49
Video Outline:
Install four fasteners for the PIM electronics cover just

finger-tight to hold the cover in place temporarily. Turn the
assembly over to rest on the cover
Install a new APM coolant seal.
Position the APM onto the new PIM ensuring the seals
remain in place.
Install and tighten the APM mounting fasteners to

specification.
Lubricate new seals with pre-mixed DEX-COOL and

install them onto the coolant tubes.
Use only pre-mixed DEX-COOL.
Install the coolant tubes to the PIM and tighten the

fasteners to specification.
To pressure test the assembly, you will need a Coolant

System Pressure Tester, J 24460-01 or its equivalent,
together with the Pressure Test adapter kit GE-48494.
Rotate the drive motor generator control module assembly

onto the APM.
Attach the GE-48494 adapter components to a coolant

pipe.
Block the remaining coolant pipe with the GE-48494 plug.
Apply 20 psi (138 kPa) of pressure with the J 24460-01, or

its equivalent.
Monitor the pressure tester gauge for 5 minutes and ensure

that pressure remains at the specified value.
If the specified pressure cannot be maintained,

disassemble the drive motor generator control module
assembly and replace the coolant seal.
If pressure remains at the specified value, remove all GE48494 components.
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Cues
Module RemovalPart 1 cont.
Drive Motor
Generator Power
Inverter Module
RemovalPart 1
cont.
Video Outline cont.

Remove the PIM cover retaining bolts and the electronics
cover.
NEVER touch the exposed electronic circuit board surface

or components. Dropped fasteners or physical contact may
result in electronic circuit board damage.
TRT: 2:49
Install the internal High Voltage terminal fasteners using a

magnetic socket.
Tighten the terminal fasteners to specification.

Proper torque is especially critical when dealing with High
Voltage terminals. Do NOT vary from the specification.
Install a new PIM cover seal. Position the cover while

ensuring the seal remains in place.
Then install the PIM cover fasteners and tighten to

specification.
Debrief video
We just replaced the PIM and APM assembly.
However, there are some DTCs that may require
that you replace only ONE of these components.
After the 12 month restriction the PIM and APM are
able to be serviced separately, if needed.
When replacing these components separately
there are some additional steps required to replace
the components individually.
Lets watch our technician while he

completes those extra steps.
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Cues
Module RemovalPart 2
Drive Motor
Generator Power
Inverter Module
RemovalPart 2
Video outline:
To prevent electronic circuit damage, the drive motor

generator control module assembly must be drained of all
residual coolant before replacing either the Accessory
Power ModuleAPM or the Power Inverter Module
PIM.
To drain the coolant from the assembly, you will use

pressure-regulated shop air.
Place a container under the coolant outlet pipe to capture

the coolant as it drains. Then, remove the temporary
coolant pipe caps.
Using the regulated compressed air supply, apply 30 psi to

the coolant inlet pipe and allow the module to drain until no
coolant remains.
Remove the power inverter control module electronics

cover fasteners and the cover. Discard the cover seal, as it
is not reused.
Using a magnetic socket, remove the two internal High

Voltage terminal fasteners.
ONLY use a magnet tipped socket to remove and install the

internal High Voltage terminal fasteners.
Never touch the exposed electronic circuit board surface or

components. Dropped fasteners or physical contact may
result in electronic circuit board damage.
Install four fasteners for the PIM electronics cover just

finger-tight to hold the cover in place temporarily.
Turn the assembly over to rest on the cover so the PIM to

APM fasteners can be accessed.
Remove the APM and discard the coolant seal.
TRT: 1:54
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Cues
Debrief video
What you just saw in the second video are

ONLY the extra steps required to replace
either the PIM or APM individually.
The most important thing to remember is to
be sure that the coolant is removed with 30
psi regulated shop air.
If this is not done coolant could get into the
PIM and cause an isolation concern.
Be sure to review the removal and
installation steps in SI prior to replacing the
PIM or APM.
Lets stop here and go to a call-in question.
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3-17
Cues
Read the question
PPT #51
Call-In Question
1 Build
51
Question
If DTC P1AE7 is set along with a P1AF2
what should be done next?
Take calls
Call-in
PREP
PRESET
CAMERA 2
PRESET 2
P1AE7 is the DTC for a loss of isolation internal to

the Hybrid Battery and should always be diagnosed
first.
PT Q #6
Slide or video next
Next, lets take a look at the EL48571 High

Voltage Battery PinOut Box and how it is
used.
PRODUCER ISSUES NEXT SLIDE
Instructor moves to battery while slide is up
OR
PRODUCER ISSUES SLIDE, THEN THE

VIDEO (AS APROPRIATE)
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Cues
El-48571 High Voltage Battery PinOut Box
Elaborate / (telestrate) as indicated below slide
PPT #52
EL-48571 High
Voltage Battery
PinOut Box
EL-48571 High Voltage Battery

PinOut Box
52
Heres a graphic of the EL-48571 High Voltage

Battery Pin-Out Box.
Test Points
Dials
Connector
The EL-48571 High Voltage Battery PinOut Box is
used whenever you get a DTC related to Circuit
Voltage Sense Wire issues in the Hybrid Battery.
The PinOut Box is designed to allow probe access
to the voltage monitor circuits of the Hybrid Battery.
Externally, the PinOut Box has a 22 pin connector
that connects to the X4 harness connector of the
BECM, 2 Test Points for checking voltage and 5
dials for selecting the pair of batteries.
For demonstration purposes, we have the

EL-48571 High Voltage Battery PinOut Box
in the studio that has been removed from
the vehicle.
SHOW TOOL OR SKIP TO VIDEO
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Cues
Instructor demonstrates how to use the EL-48571 High
Voltage Battery PinOut Box
CAMERA 2
PRESET 2
PROP
EL48571 High
Voltage Battery
Pin-Out Box
OR
If EL-48571 High Voltage Battery PinOut Box NOT in
studio, skip to EL-48571 High Voltage Battery Pin-Out
Box video, page 3-21
Discuss how to use the EL-48571 High Voltage
Battery PinOut Box
We use this tool to check the Hybrid Battery voltage
and harness for any faulted conditions.
Again, the first thing we need to do is to complete
the High Voltage Disabling procedure.
The MAIN thing you need to remember here is that
High Voltage Disabling ONLY disables the system.
It does NOT remove the High Voltage potential in
the Hybrid Battery. PT Q#5
Just like any other battery, the Hybrid Battery is a
storage device that will maintain voltage potential
until discharged.
For our purposes, the High Voltage Disabling
procedure has been completed.
Next, we remove the battery cover from the Hybrid
Battery.
At this point, once the cover has been removed, the
potential for exposure to High Voltage is present at
ALL times.
PRODUCER ISSUES NEXT SLIDE

Heres a DANGER warning you should keep
in mind when servicing high-voltage
components or connections.
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Cues
Read the slide
DANGER
PPT #53
DANGER
53
ALWAYS perform the High Voltage Disabling

procedure prior to servicing any High Voltage
component or connection. Even after disabled,
High Voltage potential is ALWAYS PRESENT
inside the Hybrid Battery.
Personal Protection Equipment (PPE) and
proper procedures must be followed. Failure to
follow the procedures EXACTLY as written may
result in serious injury or death.
INSTRUCTOR BACK ON CAMERA

Next, disconnect the X4 harness connector at the
BECM.
CAMERA 2
PRESET 3
EL48571 High
Voltage Battery
Pin-Out Box cont.
Connect the EL-48571 High Voltage Battery Pin

Out Box to the X4 harness connector.
Install the High Voltage Manual Disconnect Lever.
This step is required to check the #11 sensing
wire because the disconnect is in series between
batteries 21 and 22.
Now, test for 11 to 19 volts across all 20-battery
reference circuits.
If any of these circuits are NOT within the
specified range, we are directed to replace the
Hybrid Battery assembly.
If all circuits test normal, we are directed to
replace the BECM.
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Cues
3-21
Instructor demonstrates how to check battery voltage
reference circuits
To check the individual circuits:

CAMERA 2
PRESET 3
EL48571 High
Voltage Battery
PinOut Box cont.
First, use the dial to select the battery you are

checking after disconecting the X4 connector and
connecting the pinout box to the X4 connector.
Next, check the voltage at the test point for the
specific battery
As you saw in our demonstration, be sure that you
are using the proper PPE that includes the class 0
high voltage gloves. There is high voltage present
that can NOT be disabled.
NOTE TO INSTRUCTOR: Video #7OPTIONALor
Demo w/special tool
Introduce Video
Lets watch this next video as the technician

demonstrates how to use the EL48571 High
Voltage Battery PinOut Box.
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Cues
VIDEO: EL-48571 High Voltage Battery Pin-Out Box
Video Outline:
EL-48571 High
Voltage Battery PinOut Box
TRT: 1:05
OR
PROP
EL-48571 Special
Tool
Being sure to follow all applicable warnings and cautions,

disable High Voltage at the drive motor generator battery.
Remove the drive motor generator battery cover.
Once the cover is removed, the potential of exposure to

High Voltage is present at all times.
Disconnect the X4 harness at the Battery Energy Control

Module, or BECM.
Connect the EL-48571 High Voltage Battery PinOut Box to

the X4 harness connector.
Re-install the High Voltage manual disconnect lever.
The manual disconnect must be in place in order to check

the number 11 sensing wire because the disconnect is in
series between batteries 21 and 22.
Use the pinout box to test for 11 to 19 volts across all 20

battery voltage reference circuits.
If ANY of the circuits are out of range, replace the entire

drive motor battery assembly.
If all of the circuits test normal, replace the BECM.
Debrief video
Remember to follow ALL safety precautions and
procedures.
Always use your Class 0 gloves and the proper
protective equipment when servicing the hybrid
system.
We are only checking pairs of batteries but,
remember, we still have a 300-volt potential.
Ask for questions next
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Cues
3-23
covered?
If so, press your Call button and well get
your call answered.
While were waiting for your calls to get
through, Im going to summarize what we
covered in Module 3.
Instructor moves to desk
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Cues
Module 3 Summary
Module 3 Summary
PPT #54
Module 3 Summary
2 BUILDS
54
Identified special tools for the Two-mode

Hybrid system
Discussed procedures for using the Twomode Hybrid special tools during diagnosis
and repair
Heres what we did in Module 3.

Identified special tools for the Two-mode Hybrid
systemand
Discussed procedures for using the Two-mode
Hybrid special tools during diagnosis and repair
Call-in
Answer questions, if necessary
Here are the Posttest questions for

Module 3.
Again, remember to choose your answers carefully.
Once you enter your selection on the keypad, the
answer cannot be changed.
Lets continue.
Here is Posttest Question 5.
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3-25
Cues
Read the question
PPT #55
Posttest
Question 5
1 BUILD
55
Posttest Question 5
The High Voltage Disabling procedure
disables the _________.
A. High Voltage System only
B. Hybrid Battery only
C. Both Hybrid System & Battery
D. Battery Energy Control Module
IG 3-19
Read the question
PPT #56
Posttest
Question 6
1 BUILD
56
Posttest Question 6
Which DTC should RUN and PASS before
using the EL-48458 Pre-Charge Test Tool?
A. P1AF2
B. P1AE7
C. P1B06
D. P2797
IG 3-10, 3-17
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Cues
Read the question
PPT #57
Posttest
Question 7
1 BUILD
57
Posttest Question 7
The EL-48458 ________ assists in
diagnosing fault conditions that may be
difficult to differentiate between the drive
motor generator battery and the PIM.
A. Pre-Charge Test Tool
B. HV PinOut Box
C. Battery Lift Tool
D. HVIC Substitution Box
IG 3-5
End of Module 3
Revised 12/17/07

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Two-mode Hybrid
Diagnosis & Repair
Module 4
Two-mode Hybrid Diagnostics
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Cues
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4-3
Module 4
Module 4 Objectives
PPT #58
Module 4
Objectives
3 BUILDS
58

Functions
Describe Two-mode Special Function operation
Apply proper procedures to diagnose and
repair the Two-mode Hybrid system
Functions used when diagnosing the Two-mode
Hybrid System
Describe the operation performed for key Special
Functions with the Tech 2 and
Apply proper procedures to diagnose and repair
the Two-mode Hybrid system
The first thing well look at is the Tech 2 and

the Special Functions that are available for
the Two-mode Hybrid.
Special Functions for the Two-Mode Hybrid
can be found on the Scan Tool under
Powertrain, and then Engine after building
the vehicle.
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Cues
Two-mode Hybrid Tech 2 Special Functions
PPT #59
Module Selections
6 BUILDS
OR
Note to instructor: Elaborate as indicated below slide

OR show scan tool on overhead
Module Selections
59
Accessory Power Module

Battery Energy Control Module
Engine Control Module
Scan Tool
Hybrid Powertrain Control Module

Motor Control Modules
Transmission Control Module
Once built, you will find 6 choices by

module:
F0: Accessory Power Module or APM
F1: Battery Energy Control Module or BECM
F2: Engine Control Module or ECM
F3: Hybrid Powertrain Control Module or HPCM
F4: Motor Control Modules or MCM and
F5: Transmission Control Module or TCM
Well discuss each of the Special Functions briefly
with our primary focus on the Accessory Power
Module, Battery Energy Control Module and Hybrid
Powertrain Control Module.
Each category has the same standard Data Display
options and Special Functions.
Lets look at the Special Functions that youll use to
diagnose a vehicle with the Two-mode Hybrid.
Lets begin with the APM Special Functions.

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4-5
PPT #60
APM Special
Functions
3 BUILDS
OR
Scan Tool
APM Special Functions
60
Jump Assist
Intermediate Voltage
APM Set Point Control
In the APM menu under Special Functions,

there are 3 Output Control selections:
F0: Jump Assist
F1: Intermediate Voltage and
F2: APM Set Point Control
Lets start with Jump Assist.

JUMP ASSIST is accessed through the scan
tool.
It allows on-vehicle charging of the hybrid
drive motor batteries, using the 12 volts DC
vehicle systems.
COMPUTER
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A severely depleted Hybrid Battery may not
have sufficient energy needed to crank or
start the engine.
If the battery voltage drops below 20% state
of charge, charging of the Hybrid battery will
be required.
In this case the APM may be placed in a
special operating mode called Jump Assist.
When this occurs, the APM is able to
convert 12 volts to 300 volts to charge the
Hybrid Battery through forced Jump Assist.
Forced Jump Assist is initiated by using the
Tech 2 and an external charging source
connected to the 12 volt battery.
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Jump Assist
PPT #61
Jump Assist
4 BUILDS
61
Commands HPCM to command APM

Battery voltage MUST be >194V
12V charger >20 amp required
Higher continuous rating = less charging time
required
Jump Assist commands the HPCM to command
the APM into Jump Assist and places the APM into
High Voltage Charge Enable mode.
Jump Assist will only work if Hybrid Battery voltage
is greater than 194 volts. PT Q#8
If Hybrid Battery voltage is less than 194 volts,
Jump Assist will NOT initiate and the Hybrid
Battery must be replaced.
A 12volt charger that is rated at greater than 20
amps continuous is required.
The higher the continuous rating of the charger,
the less time it will take for jump assist to complete.

COMPUTER
Im going to show you some Jump Assist
messages you may see in the DIC.
First lets build our vehicle.
Instructor navigates to Document ID# 1983522
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2008/GMC Truck/Yukon 2WD
Service Manual/ Bulletins
Instructor Builds
Vehicle
Hybrid
Hybrid Energy Storage
Diagnostic Information & Procedures
Jump Assist
Review the messages
JUMP ASSIST READY TURN KEY TO OFF will
appear once the system is ready for jump assist to
begin.
Jump Assist
Document ID#
1983522
After Jump Assist mode has been entered, the

scan tool can be removed and the function will
continue.
JUMP ASSIST ACTIVE BATTERY CHARGING will
appear once the vehicle has entered Jump Assist
mode.
JUMP ASSIST COMPLETE will display once the
Hybrid Battery has been charged.
The criteria for finishing a scan tool initiated
Jump Assist Complete is that each pair of
batteries must be at its maximum module
voltage of 17.9 volts.
Also, the current being applied by the APM must
be less than .5 amps for more than 30 seconds.
JUMP ASSIST ABORTED will appear for several
reasons if the following occur:
The ignition is cycled to ON during Jump Assist;
The 12-volt circuit has dropped below 11 volts;
DTCs have been set by the HPCM, APM or
BECM;
The Hybrid Battery voltage is GREATER than
358V or LESS than 180V.
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You may also get a JUMP ASSIST ABORTED
message if you are using a poorly
performing charger or with a poor
connection at either of the 12 volt battery
charger connections.
If you want to know how long it may take to
complete the Jump Assist you can look at
BECM Data Display on the scan tool and
then monitor the Hybrid Battery current.
The total amount of time for a successful
Jump Assist can be estimated with the
Jump Assist Current vs. Time Table.
Lets take a look at that table on page 4-3 in
Review Jump Assist Current vs. Time Table
Jump Assist
Document ID#
1983522
Jump Assist continued next page
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These are just a few of the known messages
that will display in the DIC.
NOTE: This information is current as of the
date of development of this course.
As always, refer to SI for current information
for the vehicle or component that you are
servicing.
Next, lets look at Intermediate Voltage.
Intermediate Voltage
PPT #62
Intermediate
Voltage
2 BUILDS
62
HPCM commands APM to 300V to 42V

supplies Power Steering Control Module
No limit on controls:
Vehicle must be in P or N
PRNDL DTCs must NOT be present
Vehicle speed MUST be zero
The HPCM commands the APM to convert high
voltage 300 volts to intermediate voltage 42
volts which supplies the Power Steering Control
Module. PT Q#10
No control limits, however:
Vehicle must be in PARK or NEUTRAL
PRNDL DTCs must NOT be present
Vehicle speed MUST be zero
And finally, APM Set Point Control
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APM Set Point Control
63
HPCM commands APM to convert 300V to 12V

PPT #63
APM Set Point
Control
HPCM commands APM to maintain 12.5V

15.5V
Ign. ON enables HV for max. 10 mins.
3 BUILDS
The HPCM commands the APM to convert high
voltage 300 volts to low voltage 12 volts.
The HPCM commands the APM to maintain
between 12.5 volts 15.5 volts on the 12V circuit
and can be controlled in .5V increments.
When the ignition is ON, high voltage is ENABLED
for a maximum time limit of 10 minutes.
The next topic that were going to cover is

the High Voltage Isolation Test.
Note that the High Voltage Isolation Test
and Contactors Special Functions can be
found in the BECM Menu of the Tech 2.
As we saw in Module 3 we used the HVIT
Special Function along with the EL-48458
Pre-Charge Test Tool to help locate a High
Voltage Isolation fault. PT Q#9
If the Pre-Charge test tool is not installed,
the scan tool will display DEVICE CONTROL
NOT ALLOWED.
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High Voltage Isolation Test

PPT #64
High Voltage
Isolation Test
3 BUILDS
64
Function isolates a fault detected by the PIM

Function is used w/EL-48458 Pre-Charge Test
Tool
Test can be used for isolation test on HV
cables
The High Voltage Isolation Function is used to
isolate where a fault is located when an isolation
fault is detected by the PIM.
This function must be used with the EL-48458 PreCharge Test Tool to help locate the High Voltage
Isolation Fault.
PT Q#9
If the Pre-Charge test tool is not installed, the
scan tool will display DEVICE CONTROL NOT
ALLOWED.
The BECM can be commanded through the scan
tool to perform an isolation test on the high voltage
system when the contactor relays are closed.
Instructor moves to Battery
Next, were going to discuss the 3 Special

Functions for the different contactors
associated with the Two-mode Hybrid
Battery.
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Elaborate as indicated below
Instructor show Pre-charge, Positive and Negative
Contactors
CAMERA ____
PRESET ____
PROP
Hybrid Battery
The Negative, Positive and Pre-Charge contactors

are controlled individually.
They can NOT be commanded ON at the same
time in any possible combination.
Before we discuss the Contactors, answer

this True/False question for me.
PRODUCER ISSUES QUESTION
Read the question
Instructor returns to desk
65
PPT #65
Question 2
Question 2
The Two-mode Hybrid battery is NOT
required to crank or start the engine.
TRUE
FALSE
Debrief correct answer: False

Comment on responses, if necessary
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Ill show you where the Contactors are
located. The Contactors are marked with
numbers in your Participant Guide on page
4-5 in your Participant Guide.
Hybrid Battery Contactors
66
PPT #66
Hybrid Battery
Contactors
In order to use the Contactor Special Function, for

any of the three different contactors, the Service
Disconnect must be removed.
When using this function, the BECM commands
the selected CONTACTOR closed for 15
seconds.
If the contactor is not open when commanded
closed, ________ CONTACTOR IS NOT OPEN
will display on the scan tool.
If the Service Disconnect at the Hybrid Battery is
not removed when commanded closed,
SERVICE DISCONNECT PRESENT will display
on the scan tool.
In addition to being able to control the

contactors in the battery, you can also
control the speed of the cooling fan.
Theres information for BECM Output
Controls and Hybrid Battery Fan Speed in
your Participant Guide on page 4-5.
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Instructor may choose to show Special Function for
HPCM on scan tool
Scan Tool
Next, well look at the Special Function for

the Hybrid Powertrain Control Module.
PPT #67
IMPORTANT
Lets start with an IMPORTANT statement

about the AutoStop and AutoStart hybrid
operation modes
Read the slide
IMPORTANT
67
The hood MUST remain closed while

commanding EITHER AutoStop or
AutoStart with the scan tool.
Opening the hood while commanding
AutoStop or AutoStart will cause an
engine stall, start/stall, or vehicle disable
condition. The disable condition will
remain until the hood is closed.
The HPCM controls AutoStop and AutoStart
hybrid operation modes.
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AutoStop
PPT #68
AutoStop
68
Ignition ON
Engine RUNNING
Hybrid Battery SOC > than 50%
ECT 68-109C (154-228F)
When operating in AutoStop mode:

The ignition MUST be ON.
The engine MUST be RUNNING.
State of charge of the Hybrid Battery must be
greater than 50%.
Engine coolant temperature must be between 68C
and 109C (154F228F).
When operating in AutoStart mode:

PPT #69
Autostart
AutoStart
Ignition ON
MUST be operating in AutoStop
The ignition MUST be ON.
The vehicle MUST be in the AutoStop Hybrid
mode.
Heres some IMPORTANT information for

you.
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4-17
Read the statement
IMPORTANT
PPT #70
IMPORTANT
70
When working on the Two-mode Hybrid

vehicle, ALWAYS visually check to make
sure the ignition is CYCLED to OFF.
This will ensure the vehicle is NOT in an
AutoStop condition and will NOT AutoStart
unexpectedly causing potential injury to the
technician or unexpected movement and
possible damage to the vehicle.
You can also release the hood and the
vehicle will NOT enter AutoStop.
Instructor may choose to show Regenerative Braking
on scan tool
Scan Tool
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Next, lets take a look at Regenerative

Braking.

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Regenerative Braking Control

PPT #71
Regenerative
Braking Control
71
HPCM Enables or Disables

Ignition ON No limits to control
The HPCM also ENABLES or DISABLES blended
regenerative braking for testing base brake
operation.
The ignition must be ON to control this function.
Next were going to discuss Auxiliary

Transmission Pump Speed.
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Aux. Trans. Pump Speed

PPT #72
Aux. Trans. Pump
Speed
72
HPCM commands Aux. Trans. Pump ON / OFF

HPCM commands Aux. Trans. Pump to operate
at certain speeds
Control limits for Aux. Trans. Pump:
ICE OFF
Electric motor speed 0 RPM
The HPCM commands the Aux. Trans. Fluid Pump
control module to turn the Auxiliary Pump ON and
OFF.
The HPCM also commands the Auxiliary Pump to
operate at a certain speed.
Unlike the Auxiliary Trans Pump Pressure, there
ARE control limits for Auxiliary Transmission Pump
Speed and those control limits are:
The Internal Combustion Engine MUST be OFF.
The electric motor speed MUST be 0 RPM.
Here are some important points about the

Auxiliary Transmission Fluid Pump Control
Module.
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Aux. Trans. Fluid Pump Control Notes

PPT #73
Aux. Trans. Fluid
Pump Control Notes
4 BUILDS
73
Inverts 12V DC to 3-Phase 12V

Does NOT communicate over GMLAN
Communicates over dedicated circuits
HPCM will NOT store Auto. Trans. Aux. Fluid
Pump DTCs
The Aux. Trans. Fluid Pump Control Module

inverts 12 Volts DC to 3-Phase 12 Volts AC that is
then supplied to the Aux. Transmission Fluid
Pump.
The Aux. Fluid Pump Control Module does NOT
communicate over GMLAN.
Communication between the HPCM and the Aux.
Fluid Pump Control Module occurs over dedicated
circuits.
The HPCM will NOT store Aux. Fluid Pump DTCs
while operating in the scan tool output control
mode.
You will have to monitor the HPCM Aux. Fluid
Pump Fault Status 1 and 2 parameters on the
scan tool while commanding the auxiliary pump.
Real-time Aux. Fluid Pump Control Module
diagnostic status can be determined by
monitoring this parameter.
Instructor may choose to show Clear 300V Present
DTC on scan tool
OR
Next, well review some Important

information about the Clear 300V Present
DTC function.
Scan Tool
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First, heres an Important statement for you
on page 4-8 in your Participant Guide.
Read the slide
IMPORTANT
PPT #74
IMPORTANT
74
Perform the high voltage disable procedure

and repair or replace damaged high voltage
components as specified in the applicable
diagnostic prior to using this control.
When using this control, the HPCM monitors

for a high voltage present condition after the
high voltage contactor relays have been
opened.
If high voltage is present, a latched DTC will
set.
If a High Voltage Present DTC sets, an
additional procedure is required after
system integrity is restored.
Here are the parameters for performing this
procedure.
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Clear 300V Present DTC Control Limits

PROP
Scan Tool
OR
75
Ignition MUST be ON
High voltage NOT present
NO communication DTCs
PPT #75
Clear 300V Present
DTC Control Limits
3 BUILDS
Clear 300V Present DTC control limits

include:
The ignition MUST be ON;
The HPCM must monitor that high voltage is not
currently present; and
Communication DTCs must not be present.
PPT #76
Clear 300V Present
DTC
2 BUILDS
Clear 300V Present DTC
76
NOT cleared conventionally

Used when P0C76 is present
To clear the 300V Present DTC:

You will NOT be able to clear these codes the
conventional way using the scan tool through the
Clear DTC function
This is the special function that must be used to
clear a P0C76 High Voltage Present DTC after a
repair has been made.
Next, well discuss Impact Detection.

Instructor may choose to show Impact Detection on
scan tool
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4-23
If there is an impact detected by the Serial
Data Gateway Moduleor SDGMthe
SDGM is designed to notify the HPCM of the
impact and the high voltage contactors will
then open.
Before clearing any of these latched codes,
the integrity of the high voltage system
MUST be inspected.
High Voltage Reset

PROP
Scan Tool
OR
PPT #77
High Voltage Reset
77
SDGM Special Functions - FIRST

HPCM Special Functions
This high voltage impact reset MUST be

performed in two different locations:
First in the SDGM Special Functions, and then in
HPCM Special Functions
Next we have the Clear 300V Impact Detection

DTC.
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Clear 300V Impact Detection DTC

PROP
Scan Tool
OR
78
SDGM Crash Sensor Reset

SDGM hybrid crash status NORMAL
Ignition ON
NO communication DTCs
PPT #
PPT #78
Clear 300V Impact
Detection DTC
4 BUILDS
To clear the 300V Impact Detection DTC:

The SDGM Crash Sensor Reset must be
performed prior to performing this Output Control.
The SDGM hybrid crash status must be reporting
NORMAL.
Ignition must be ON.
NO Communication DTCs present.
Next, lets take a look at the Serial Data

Gateway Module.
Serial Data Gateway Module is found in the
Body Menu on the Tech 2.
Instructor may choose to show Serial Data Gateway
Module on scan tool
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4-25
Serial Data Gateway Module
PROP
Scan Tool
OR
Serial Data Gateway Module
79
Crash Sensor reset is w/in the SDGM

Function commands SDGM to reset crash
sensing parameter
PPT #79
Serial Data Gateway
Module
High voltage contactor relays will not close
3 BUILDS
Within the SDGM, there is a special function for
crash sensor reset.
If a crash is detected, the function is used to
command the SDGM to reset the crash sensing
parameter to No Crash status.
Also, if a crash is detected, the high voltage
contactor relays will NOT close.
There is some information about the

Commanded States for the HPCM in your
Participant Guide on pages 4-8 and 4-9.
Thats all we have for Special Functions on
the Tech 2 for the Two-mode Hybrid system.
Lets continue by looking at a Diagnostic
Scenario on page 4-10 in your Participant
Guide.
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Diagnostic Scenario 1
PPT #80
Diagnostic
Scenario #1
Diagnostic Scenario #1
Vehicle:
80
2008 GMC Yukon

w/2,200 miles
Customer Concern: Service Hybrid System

in DIC
A customer brought in a 2008 GMC Yukon with
2,200 miles that was towed to the dealership.
A quick check of the vehicles IPC confirms that
warning messages are being displayed in the DIC.
The customers concern has been verified, which is
always the first step in Strategy Based Diagnostics.
We have completed the Diagnostic System

CheckVehicle. During our check we found
DTCs relating to the HVIC.
Theres diagnostic information from SI that
you may see in your Participant Guide
which we may not cover step-by-step in the
show. These steps are for your information
onlybut they are covered in the video.
Be sure to refer to SI for information on all
repairs.
PREP TO SHOW INSTRUCTORS COMPUTER
Instructor may choose to skip the on-line diagnostic
review and introduce Diagnosing DTC P1AE2 video on
page 4-31
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Cues
The next step is to go into SI and look at the
Diagnostic Information and Procedures for
the vehicle we are working on beginning
with the Diagnostic Starting Point.
So, lets build the vehicle.
SHOW INSTRUCTORS COMPUTER
Instructor builds vehicle in SI 2008 GMC Yukon 2WD
Service Manual/ Bulletins
Hybrid
Instructor Builds
Vehicle
Hybrid Controls
Diagnostic Information & Procedures
Diagnostic Starting Point Hybrid Controls
Instructor navigates to Document ID# 1999488
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Once we get into Diagnostic Starting Point
Hybrid Controls, we are then directed to
complete the Diagnostic System Check
Vehicle.
Review the chart
Diagnostic Starting
PointHybrid
Controls, Document
ID# 1999488
Diagnostic Starting PointHybrid Controls

2008 GMC Truck Yukon - 2WD
Begin the system diagnosis with Diagnostic System Check - Vehicle.
The Diagnostic System Check - Vehicle will provide the following
information:
The identification of the control modules which command the
system.
The ability of the control modules to communicate through the
serial data circuit.
The identification of any stored diagnostic trouble codes (DTCs)
and their status.
The use of the Diagnostic System CheckVehicle will identify the
correct procedure for diagnosing the system and where the procedure
is located.
NOTE TO INSTRUCTOR:
Navigate to Document ID# 2014192

Select Diagnostic System CheckVehicle
Select Diagnostic System CheckVehicle with HP2
When selecting Diagnostic System CheckVehicle

we are taken to the Document Selection page with
two choices:
Diagnostic System CheckVehicle without HP2
which is for a Non-Hybrid vehicle and
Diagnostic System CheckVehicle with HP2
which is for the Hybrid vehicle.
We select Diagnostic System CheckVehicle with
HP2.
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Review the chart
The Diagnostic System CheckVehicle document
identifies the correct procedure for diagnosing the
system and where the procedures are located.
Steps 1 through 6 of the Diagnostic System
CheckVehicle direct us to complete the normal
checks associated with the DSCV.
Diagnostic System
CheckVehicle (with NOTE TO INSTRUCTOR: Sub-bullets of Steps 1-6
are not shown in chart below
RPO HP2),
Document ID#
2014192
Diagnostic System CheckVehicle (with HP2)
(Steps 1- 6):
1. Verify that none of the following preliminary
inspections/tests reveal the cause of the vehicle concern
before beginning diagnosis:
2. Install a scan tool. Verify that the scan tool powers up.
3. Ignition ON, Engine OFF, verify communication with all of
the control modules on the vehicle. Refer to Data Link
References for information on the modules you should
expect to communicate.
4. Verify that the following DTCs are not set: U1814, B1428.
Important: Open the driver door to ensure
retained accessory power (RAP) mode is inactive
during this test. The engine may start during this
test. Turn the engine OFF as soon as the crank
power mode has been observed.
5. With a scan tool, access the Body Control Module Power
Mode data display list.
6. Ignition ON, view the security indicator. The security
indicator should not remain illuminated after the vehicle
bulb check has completed.
Document ID# 2014192, Step 7 continued next page
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In Step 7, we are directed to check for the
SERVICE HYBRID SYSTEM message in the DIC
and, if displayed, refer to Diagnostic Trouble Code
(DTC) List - Vehicle.
Diagnostic System CheckVehicle (with HP2)
Diagnostic System
CheckVehicle,
Document ID#
2014192 cont.
7. Ignition ON, view the DIC message display. Verify the

SERVICE HYBRID SYSTEM message is not displayed.
If the SERVICE HYBRID SYSTEM message is

displayed, refer to Diagnostic Trouble Code (DTC)
List - Vehicle and diagnose any Hybrid Powertrain
Control Module (HPCM) and Battery Energy
Control Module (BECM) DTCs set as current.
We checked our vehicle earlier with the

scan tool. We found that DTC P1AE2 has
set, along with DTCs P1B05 and P1B06.
END
When we checked the DTC List Vehicle, we

found that DTC P1AE2 along with P1B05
and P1B06 are a result of either an OPEN or
HIGH RESISTANCE in the HVIC.
Introduce video
Lets watch this next video as our technician

demonstrates the procedure for diagnosing
a concern with the HVIC.
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4-31
VIDEO: Diagnosing DTC P1AE2
Video Outline:
Diagnosing DTC
P1AE2
TRT: 3:03
A check for trouble codes reveals three DTCs,

P1B06, P1B05 and P1AE2.
Code P1B05 indicates a concern with the Drive
Motor 1 Control Module High Voltage System
Interlock Circuit, or HVIC. P1B06 indicates the
same concern with the Drive Motor 2 Control
Module HVIC.
These two codes should always pass and fail
together. If one passes and one fails, the PIM
should be replaced.
DTC P1AE2 indicates an open or high resistance
on the Battery Energy Control Module HVIC.
P1AE2 should only set together with P1B05 and
P1B06.
When these codes are set, the Hybrid Powertrain
Control Module, or HPCM, commands the Battery
Energy Control Module, or BECM, to open the
High Voltage contactor relays when vehicle speed
is less than 3 miles per hour, or 5 kilometers per
hour, for six seconds.
Before beginning diagnosis, make sure that the
High Voltage manual disconnect lever is fully
engaged. It must be fully pressed down to engage
the HVIC terminals.
Turn the ignition OFF and wait at least two
minutes.
Disconnect the PIMs X1 connector.
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VIDEO: Diagnosing DTC P1AE2 cont.
Diagnosing DTC
P1AE2 cont.
TRT: 3:03
Install a 3 amp fused jumper between terminal 1

(the HVIC return circuit) and terminal 23 (the HVIC
source circuit.)
The drive motor generator control module sight
shield must be installed for all testing in order to
complete the HVIC current loop.
Turn the ignition ON and observe the BECM HVIC
Source Current parameter.
A reading between 5 and 18 milliamps would point
to either a faulty PIM or a terminal contact concern.
Since the reading is NOT between 5 and 18
milliamps, diagnosis continues with the removal of
the jumper wire.
Check for 5 to 18 milliamps between the HVIC
source circuit at terminal 23 and ground.
Next, check for an open on the HVIC return circuit
between PIM connector X1 and X350. If the circuit
is OK disable the High Voltage system.
Check for an open on the HVIC return circuit
between connector X350 and BECM connector X1.
If theres no open in the circuit, as is the case here,
the BECM would be replaced.
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Debrief video
As you saw in the video, diagnosing a HVIC
concern is no different from the normal circuit
testing performed on non-hybrid vehicles.
While you are working internal to the Hybrid
Battery, be sure to use your personal protective
equipment because high voltage potential is
present at ALL times.
However, diagnosing an HVIC concern may be
one of the most important procedures that you will
use on this vehicle.
REMEMBER: DTC P1B05 and P1B06 should

always pass and fail together.
With that thought in mind, I have a Call-in
question for you on page 4-13 in your
Participant Guide.
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Cues
Read the question
81
PPT #81
Call-In Question
1 BUILD
Question
What has to be done if DTC P1B05 has passed
but DTC P1B06 has failed?
Take calls
Call-in

This was covered in the previous video and in case
you missed it
These two codes should always pass and fail
together.
If one passes and one fails, the PIM should be
replaced.
Now, lets take a look at our next diagnostic

scenario on page 4-14 in your Participant
Guide.
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Diagnostic Scenario 2
Diagnostic Scenario #2
PPT #82
Diagnostic
Scenario #2
Vehicle:
82
2008 GMC Yukon

w/1,800 miles
Customer Concern: Vehicle will NOT enter

AutoStop
INSTRUCTOR NOTE: P2797 is a B Type DTC (Aux.
Trans. Fluid Pump Performance) that causes the PIM
to disable Autostop
The customer brought a 2008 Yukon with 1,800
miles into the dealership and stated that the vehicle
would NOT go into Autostop.
We test drove the vehicle and found that the vehicle
would NOT enter Autostop.
So, our customers concern has been verified.
Once again, we have completed the

Diagnostic System Check Vehicle.
During our check, we found DTCs relating to
the Auxiliary Transmission Fluid Pump.
PREP TO SHOW INSTRUCTORS COMPUTER
Instructor may choose to skip on-line diagnostic review
and introduce DTC P2797Auxiliary Transmission Fluid
Pump video on page 4-38
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Instructor builds vehicle
Just as we did previously, the first thing we

need to do is to build the vehicle.
2008 GMC Yukon 2WD
Select Service Manual/ Bulletins
Select Hybrid
Build the vehicle
Select Hybrid Controls

Select Diagnostic Information & Procedures
Select Diagnostic Starting PointHybrid Controls,
Instructor navigates to Diagnostic System Check
Vehicle Document ID# 2014192
Diagnostic System
Check Vehicle
Document ID#
2014192
Steps 1-6
Once we get into Diagnostic Starting Point

Hybrid Controls our next step is to
complete the Diagnostic System Check
Vehicle.
We have already completed Steps 1-6 of the
Diagnostic System CheckVehicle.
We didnt find anything that would cause us a
concern.
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4-37
Step 7 directs us to check the DIC for the SERVICE
HYBRID SYSTEM message and since there is
none we go to Step 8.
Steps 8 and 9 direct us to attempt to start and run
the vehicle.
Diagnostic System
Check Vehicle
Document ID#
2014192 cont.
Since the vehicle DOES start and run we are now

directed in Step 10 to check for DTCs.
Diagnostic System Check - Vehicle (with HP2)
7. Ignition ON, view the DIC message display. Verify the
SERVICE HYBRID SYSTEM message is not displayed.
If the SERVICE HYBRID SYSTEM message is
displayed, refer to Diagnostic Trouble Code (DTC) List Vehicle and diagnose any Hybrid Powertrain Control
Module (HPCM) and Battery Energy Control Module
(BECM) DTCs set as current.
8. Attempt to start the engine. Verify that the engine cranks.
If the engine does not crank, refer to Symptoms - Hybrid
Controls .
9. Attempt to start the engine. Verify the engine starts and idles.
If the engine does not start and idle, refer to Engine
Cranks but Does Not Run for the 6.0L (LFA) engine.
Important: Do not clear any DTCs unless instructed to do so by
a diagnostic procedure.
Important: If any DTCs are Powertrain related DTCs, select
Capture Info in order to store the DTC information with the scan
tool.
10. Use the appropriate scan tool selections to obtain DTCs from
each of the vehicle modules. Verify there are no DTCs reported
from any module.
If any DTCs are present, refer to Diagnostic Trouble
Code (DTC) List - Vehicle and diagnose any current
DTCs in the following order:
When checking the vehicle with the scan

tool, we found that DTC P2797 has set, so
lets take a look at that code next.
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Cues
Instructor navigates to Diagnostic Trouble Code (DTC)
List Vehicle Document ID# 1992134.
Diagnostic Trouble Code (DTC) ListVehicle
Diagnostic Trouble
Code (DTC) List
Vehicle
Document ID#
1992134
DTC
Module
That Sets Diagnostic
the DTC Procedure
DTC Descriptor
Auxiliary Transmission Fluid

Pump Performance
P2797
HPCM
DTC
P2797
Here we find that DTC P2797 is for Auxiliary

Transmission Fluid Pump Performance.
Instructor navigates to DTC P2797, Document ID#
1986023
DTC P2797,
Document ID#
1986023
DTC P2797
Circuit
Trans.
Aux. Oil
Pump
Control
Short to
Ground
Open/High
Resistance
P2797
P2797
Short to
Signal
Voltage Performance
P2797
--
We see here that P2797 can be the result of a short

to ground, an open or high resistance, or a short to
voltage.
END
Introduce Video
Lets watch our technician perform the

Circuit System Testing procedure for the
Auxiliary Transmission Fluid Pump in our
next video.
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Cues
4-39
VIDEO: DTC P2797Auxiliary Transmission Fluid
Pump
Video Outline
DTC P2797Auxiliary
Transmission Fluid
Pump
TRT: 2:49
A check for DTCs reveals that a code P2797 for Auxiliary

Transmission Fluid Pump Performance is currently set.
Service Information indicates that this code sets when the
Hybrid Powertrain Control Module, or HPCM, detects that
the difference between actual and commanded pump
speed is more than 500 RPM for 2.5 out of 3 seconds.
The Hybrid Autostop mode is disabled when this code is
current.
The scan tool can be used to verify the concern.
With the ignition ON, command the Auxiliary Transmission
Fluid Pump speed, or ATFP speed, to 50 percent.
The actual pump speed should be within 10 percent of the
commanded speed.
An actual speed within 10 percent of commanded would
eliminate electrical fault conditions, and diagnosis would
continue with a check of the pumps line pressure.
Since these results are outside the specification, circuit
testing is called for.
If DTC P0C2B is present, indicating a short or open in the
pump diagnostic circuit, be sure to diagnose and repair that
condition first.
With the ignition ON and the engine OFF, set the scan tool
to observe the Auxiliary Transmission Fluid Pump Fault
Status 1 and Fault Status 2 parameters.
Use the scan tool to command the pump speed to 50
percent.
If the scan tool displays a fault status, continue diagnosis of
that fault.
In this case, the scan tool indicates a Pulse Width
Modulated Input Fault.
Begin diagnosis of this fault by disconnecting the Power
Inverter Modules X1 connector.
With the ignition ON, check for 11 to 13 volts between X1
terminal 5 and chassis ground.
This is the ATFP control circuit.
DTC P2797-Auxiliary Transmission Fluid Pump video

continued next page
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Cues
VIDEO: DTC P2797-Auxiliary Transmission Fluid
Pump cont.
DTC P2797Auxiliary
Transmission Fluid
Pump cont.
TRT: 2:49
Video outline cont.:

Since the results were within range, testing continues with
the J 38522 Variable Signal Generator.
Set the J 38522 to 50 percent duty cycle at 250 Hertz.
Duty cycles of less than 50 percent might damage the
ATFP assembly.
Connect the signal generator to the ATFP control circuit
between X1 terminal 5 and chassis ground.
Listen for the sound of ATFP operation.
If you can hear the pump operating, it is not the source of
the concern and the Power Inverter Module should be
replaced.
If the pump cant be heard, as is the case here, the ATFP
Control Module should be replaced.
Debrief video
Replacement of the Auxiliary Transmission Fluid
Pump Control Module is a relatively simple
procedure.
It is a non-GMLAN device and, therefore, it does
NOT require SPS programming when replaced.
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Cues
4-41
Our final step before returning the vehicle is
to complete Repair Verification.
Since we know that this module doesnt
need programming by looking at Control
Module References in SI, all that's left to do
is to test-drive the vehicle and ensure that it
goes into Autostop.
Ask for questions next
That concludes Module 4 of the Two-mode

Hybrid Diagnosis & Repair IDL course, and
that will also wrap up the course.
Are there any questions before we
continue?
While Im waiting for any calls to come in,
Im going to go ahead and summarize what
we covered in Module 4.
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Cues
Module 4 Summary
Read the slide
Module 4 Summary
PPT #83
Module 4 Summary
3 BUILDS
83
Identified Two-mode Hybrid Tech 2 Special

Functions
Described the operation for Tech 2 Special
Functions
Discussed procedures for diagnosing /
repairing a Two-mode Hybrid system
Identified Two-mode Hybrid Tech 2 Special
Functions for diagnosing the Two-mode Hybrid
System
Described the operation performed for key Special
Functions with the Tech 2 and we
Discussed proper procedures for diagnosing and
repairing a Two-mode Hybrid system
Call-in
Answer questions, if required
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4-43
Cues
Posttest Questions
Introduce Posttest
Lets continue on with the Posttest.

After you have answered these 3 Posttest
questions, you will have completed the
Posttest for the Two-Mode Hybrid Diagnosis
& Repair IDL.
Here is Posttest Question #8.
Read the question
PPT #84
Posttest
Question 8
1 BUILD
Posttest Question 8
Jump Assist will ONLY work if Hybrid
Battery voltage is greater than _____.
A. 175 Volts
B. 188 Volts
C. 194 Volts
D. 358 Volts
IG 4-7
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84
4-44
Cues
Read the question
PPT #85
Posttest
Question #9
1 BUILD
Posttest Question 9
85
Which tool is used to perform an isolation

test on the high voltage cables if there is an
isolation fault present?
A.
B.
C.
D.
Pre-Charge Test Tool

HV rated Digital Multi-Meter
Over-Charge Test Tool
Battery Lift Tool
IG 4-11, 4-12

Read the question
PPT #86
Posttest
Question 10
1 BUILD
Posttest Question 10
The APM converts 300V to 42V which is
used for the ________________.
A.
B.
C.
D.
Transmission
Power Steering
Heater Coolant Pump
Powertrain Control Module
IG 4-10
End of Module 4
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86
4-45
Cues
IDL Close
87
To Obtain
Posttest Results
PPT #87
Posttest Results
After 5 Business Days go to:

www.gmtraining.com
Select Training Records from menu
Select View Your Training Records
Thank participants
PPT #88
Course Title
Signoff
PPT #89
GM Logo
Revised 12/17/07

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Course #18445.

2008 General Motors Corporation

Course Information & Materials

Total Broadcast Time

2008 General Motors Corporation

Broadcast Setup Instructions

Set up microphones for instructor and 1 SME

Fill in information on overheads

Check special request form (SRF) for additional instructions (if

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Use these approved icons when developing the Instructor

Slide number under icon, in 12 pt. Arial font, all caps

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Instructional Materials (cont.)

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Instructional Materials (cont.)

Laptop: Indicates a screen will be displayed using a laptop at

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Clip: Indicates a clip is shown on screen. A clip refers to short

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Instructional Materials (cont.)

Use these approved icons when developing the Instructor

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Instructional Materials (cont.)

Instructor inserted over video: Indicates the instructors

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Instructional Materials (cont.)

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Two-mode Hybrid Diagnosis & Repair

Welcome to the Two-mode Hybrid Diagnosis

There is a place to write my name under the

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We recommend that you use the most

The Participant Guide is your tool for

Instructor Note: Direct Technicians to Participant Guide

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Two-mode Hybrid Diagnosis & Repair

In which of the following regions is your

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Course Goal and Session Objectives

Upon successful completion of this course,

Keep in mind this is an IDL component

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Two-mode Hybrid Diagnosis & Repair

Identify current & future Two-mode Hybrid

2008 General Motors Corporation