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Removal Procedure

WARNING:

Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps:

  • Identify how to disable high voltage.
  • Identify how to test for the presence of high voltage.
  • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

  • Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
  • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
    • Visually and functionally inspect the gloves before use.
    • Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

  1. Disable the high voltage system. Refer to High Voltage Disabling .
  2. Remove the front compartment sight shield. Refer to Front Compartment Front Sight Shield Replacement .
  3. Remove the engine control module (ECM) bracket. Refer to Engine Control Module Bracket Replacement .
  4. Remove the battery tray. Refer to Battery Tray Replacement .
  5. Remove the heater coolant heater. Refer to Heater Coolant Heater Replacement .
    6. Fig 1: Disconnecting Connectors
    GM3232221Courtesy of GENERAL MOTORS COMPANY
  6. Disconnect the connectors (1), (2) from the left side of the drive motor battery charger.
    7. Fig 2: Heater Coolant Heater Bracket Fasteners
    GM3232219Courtesy of GENERAL MOTORS COMPANY
  7. Remove the heater coolant heater bracket fasteners (1, 2).
    8. Fig 3: Coolant Heater Coolant Bracket And Drive Motor Battery Coolant Inlet Hose Retainer
    GM3232218Courtesy of GENERAL MOTORS COMPANY
  8. Remove the drive motor battery coolant inlet hose retainer (1) and the battery positive cable retainer (1), from the heater coolant heater bracket (2).
  9. Remove the coolant heater coolant bracket (2) from the vehicle.
    10. Fig 4: Engine Wiring Harness Upper Connector
    GM3232217Courtesy of GENERAL MOTORS COMPANY
  10. Disconnect the engine wiring harness upper connector (2) and the lower connector (1), from the pigtail connection off the right side of the drive motor battery charger.
  11. Disconnect the drive motor generator control module cooling outlet hoses (Auxiliary Radiator to Drive Motor Battery Charger) to the drive motor battery charger. Refer to Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Auxiliary Radiator to Drive Motor Battery Charger) , Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Long Hose) , Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Two Bending) , Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Straight Hose) .
  12. Disconnect the drive motor generator control module cooling outlet hoses (Two Bending) to the drive motor battery charger. Refer to Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Auxiliary Radiator to Drive Motor Battery Charger) , Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Long Hose) , Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Two Bending) , Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Straight Hose) .
    13. Fig 5: Drive Motor Battery Charger Mounting Fasteners
    GM3232213Courtesy of GENERAL MOTORS COMPANY
  13. Remove the drive motor battery charger mounting fasteners (1) and remove the engine wiring harness terminals (2, 3).
  14. Remove the drive motor battery charger (4), from the vehicle.
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