DTC 62

DTC P1445 (62): Bypass Contactor Malfunction
1. Turn the ignition switch ON (II).
2. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P1634 or P1570 indicated?
YES - Do the troubleshooting for DTC P1634, or DTC P1570.
NO - Go to step 3.
3. Check the MPI VOLTAGE, TOTAL VOLTAGE IMA BATT. MDLS in the DATA LIST with the HDS.
Is there more than 18 V difference between MPI VOLTAGE and TOTAL VOLTAGE IMA BATT. MDLS?
YES - Go to step 4.
NO - intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the high voltage contactor, the bypass contactor, the DC-DC converter, and the MCM.
4. Check the battery module switch.
Is the battery module switch ON?
YES - go to step 5.
NO - Turn the battery module switch ON, then go to step 27.
5. Turn the ignition switch OFF.
6. Turn the battery module switch OFF.
7. Remove the IPU lid.
8. Turn the battery module switch ON.





9. Measure voltage between battery module terminals + (A) and - (B).
Is there more than 120 V?
YES - Go to step 10.
NO - Replace the battery module, then go to step 27.
10. Turn the battery module switch OFF.





11. Measure resistance between high voltage contactor terminal (A) and bypass contactor terminal (B).
Is there 38- 42 ohms?
YES - Go to step 12.
NO - Replace the bypass resistor, then go to step 27.
12. Turn the ignition switch OFF.
13. Disconnect the bypass contactor RED connector.
14. Disconnect MCM connector B (24P).





15. Check for continuity between MCM connector terminal B12 and bypass contactor RED connector terminal No. 1.
Is there continuity?
YES - Go to step 16.
NO - Repair short in the wire between the bypass contactor and the MCM (B1), then go to step 27.





16. Check for continuity between body ground and bypass contactor BLU connector terminal No. 1 (A).
Is there continuity?
YES - Go to step 17.
NO - Repair open in the wire between the bypass contactor and G652, then go to step 27.
17. Turn the ignition switch OFF.
18. Reconnect all connectors.
19. Disconnect the DC-DC converter 4P connector.
20. Turn the battery module switch ON.
21. Turn the ignition switch ON (II).
22. Check the MPI VOLTAGE, TOTAL VOLTAGE IMA BATT. MDLS in the DATA LIST with the HDS.
Is there more than 18 V difference between MPI VOLTAGE and TOTAL VOLTAGE IMA BATT. MDLS?
YES - Go to step 23.
NO - Replace the DC-DC converter, then go to step 27.
23. Turn the ignition switch OFF.
24. Remove the bypass contactor.





25. Connect battery terminal to bypass contactor terminals No. 1 (A) and No. 2 (B).

NOTE: When connecting the battery terminal, connect to bypass contactor terminal first, then connect to battery.

26. Check for continuity between bypass contactor terminals No. 3 (C) and No. 4 (D).
Is there continuity?
YES - Replace the MPI module, then go to step 33.
NO - Replace the bypass contactor, then go to step 27.
27. Turn the ignition switch OFF.
28. Reconnect all connectors.
29. Reinstall the IPU lid, then turn the battery module switch ON.
30. Turn the ignition switch ON (II).
31. Reset the MCM.
32. Check for Temporary DTCs or DTCs with the HDS.
Are any Temporary DTCs or DTCs indicated?
YES - if DTC P1445 is indicated, check for poor connections or loose terminals at the high voltage contactor, the bypass contactor, the DC-DC converter, and the MCM, then go to step 1. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.
NO - Troubleshooting is complete.
33. Turn the ignition switch OFF.
34. Reconnect all connectors.
35. Reinstall the IPU lid, then turn the battery module switch ON.
36. Turn the ignition switch ON (II).
37. Reset the MCM.
38. Update the MCM if it does not have the latest software, or substitute a known-good MCM.
39. Check for Temporary DTCs or DTCs with the HDS.
Are any Temporary DTCs or DTCs indicated?
YES - if DTC P1445 is indicated, check for poor connections or loose terminals at the high voltage contactor, the bypass contactor, the DC-DC converter, and the MCM, then go to step 1. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.
NO - if the MCM was updated, troubleshooting is complete. If the MCM was substituted, replace the original MCM.