PIC5903C

Bulletin No.: PIC5903C
Published date: 01/17/2020
Preliminary Information
PIC5903C Spark EV Chevrolet Volt Opel Ampera Models With Or
Without Service Vehicle Soon Lamp - SVS - or Check Engine Lamp
On With DTC P0534 Set Current Or History
Models
Brand:
Model:
Model Years:
VIN:
from
Engine:
to
Transmissions:
Chevrolet
Volt
2011 - 2014
All
All
All
All
Chevrolet
Spark EV
2014
All
All
All
All
Opel
Ampera
2012 - 2014
All
All
All
All
Supersession Statement
This PI was superseded to update warranty statement. Please discard PIC5903b.
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.
Condition / Concern
A customer may comment that the Service Vehicle Soon Lamp (SVS) or Check Engine Lamp is
on.
On Spark EV the yellow indicator resembles an outline of a car with an exclamation mark
that is
located on the upper left side of the IPC.
Volt and Ampera models may display the Check Engine Lamp.
DTC P0534 may be set as current or history in either case.
Recommendations / Instructions
PRELIMINARY INSPECTION - ALL MODELS
1. Using GDS2 Select the Vehicle Wide DTC Check with Module information. DO NOT CLEAR
ANY DTCs!
2. Capture any Freeze Frame data in a GDS2 Session Log. Review the Freeze Frame and
Failure Record data.
IMPORTANT: DO NOT remove the Rechargeable Energy Storage System (RESS) Cooler
unless the vehicle falls within the date range listed or if the RESS Cooler has already been
replaced.
1. If the Freeze Frame / Failure Record data shows that the P0534 set during Active
Cooling, check to see if the vehicle build date is between 1/15/2013 and 9/15/2013. If it
is on or between these dates, inspect the RESS Cooler.
2. The RESS Cooler passes inspection if the RESS Cooler has two notches. If there are
three notches, replace the RESS Cooler. (see photos below).
3. If the vehicle build does not fall within the suspect date range, continue to operate the
vehicle with GDS2 connected.
4. Refer to SI diagnostics for P0534 or the Air Conditioning A/C System Performance Test
and proceed with the following steps for each model listed below.
A. : Shown below is a picture of the RESS Cooler from the Spark EV. The black insulator
cover can be easily pulled back to inspect the Cooler Plate notches without removal.
For Volt and Ampera models the inspection remains the same once the RESS Cooler
has been removed from the vehicle.
3 Notches equals replace cooler.
2 Notches equals DO NOT replace cooler.
VOLT AND AMPERA MODELS
1. Follow the Preliminary Inspection before proceeding.
2. If Freeze Frame / Failure Record data for P0534 shows Air Conditioner Compressor
Speed (ACCM) greater than 800 RPM and Low Side Refrigerant Pressure above 100 kPa,
then check the Hybrid Processor Control Module 2 (HPCM2) has the latest software. If
so, proceed to Step 3. If not, update the Hybrid Powertrain Control Module 2 (HPCM2)
software. (2011 -2013 Volt Models Only. Refer to PIC5769A)
3. Using GDS2 select “Diagnostics”, choose the Vehicle and then select Module
Diagnostics / Hybrid Powertrain Control Module 2 (HPCM2) / Data Display / HVAC System
Data.
4. If the A/C System operates, turn on the A/C temperature to maximum cold, high blower
speed and monitor the High and Low Side Refrigerant Pressures with the ACCM on.
5. If the vehicle resets P0534, follow published SI Diagnostics for the P0534 and the Air
Conditioning A/C System Performance Test as required.
6. If both the High and Low Side Refrigerant Pressures are found to be low per the Air
Conditioning A/C System Performance Test in SI, connect the Refrigerant
Recovery/Recharge A/C machine and check the Refrigerant level. The Refrigerant level
recovered should be a minimum of 800 grams. (A full charge for Volt and Ampera
models is 950g). If it is not within specification, check for a Refrigerant loss per SI
Diagnostics.
SPARK EV
1. Follow the Preliminary Inspection before proceeding.
2. If the Chiller passed the Preliminary Inspection shown above, connect the GE 50300
Refrigerant Recovery/Recharge A/C machine and check the R1234yf Refrigerant level.
3. Note if the machine indicates there are any faults and print all results.
4. Was the R1234yf Refrigerant level recovered at least 500g? (A full charge for LHD
Models is 575g). If so, proceed to Step 5. If not, check for a Refrigerant loss per SI
Diagnostics.
5. Using GDS2 check the K33 Remote Heater and Air Conditioning Module (ECC) software.
If the software is not 13591955 or newer, update the K33 Remote Heater and Air
Conditioning Module (ECC) software.
ALL MODELS:
In any case if you are uncertain on how to proceed, contact the General Motors Technical
Assistance Center (TAC) in the United States @ 877-446-8227 or in Canada 800-263-7740
(English)
Warranty Information
For vehicles repaired under Warranty, use the following labor operation. Reference the
Applicable Warranties section of Investigate Vehicle History (IVH) for coverage
information.
Labor code 4417169, 4029929 and 2810015 would fall under the bumper to bumper
warranty. Labor code 2810265 and 5020450 will fall under the Voltec warranty.
Reference the Applicable Warranties section of Investigate Vehicle History (IVH) for
coverage information.
Labor Operation
4417169
Description
A/C System Analysis (Base) *
Labor Time
0.3 hr
4029929
GDS2 Diagnostic Time
K33 HVAC System Control Module (ECC)
Reprogramming with SPS
K114B Hybrid Powertrain Control Module 2
Reprogramming with SPS
0.2 hr
2810015
2810265
0.3 hr
0.4 hr
See Published Labor
Time
Add
To Recover and Recharge A/C System
0.2 hr
Add
RESS Cooler Inspection (Spark EV only)
0.1 hr
* Note: Use this labor code for A/C System Leak Diagnostic checks when using the Recovery
/Recharge equipment
and if no leaks were found or performance is normal.
5020450
Drive Motor Battery Coolant Cooler Replacement
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is
resolved without completing every step, the remaining steps do not need to be performed.
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