Removal Procedure
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.
- Disable the high voltage system. High Voltage Disabling
- Drain the drive motor generator power inverter module cooling system. Drive Motor Generator Power Inverter Module Cooling System Draining and Filling
Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection .
Battery Negative Cable Ground Nut (1) - Remove
Battery Current Sensor (1) @ Battery Tray - Remove
- Battery Current Sensor Connector (2) - Disconnect
- NOTE:
Note the orientation of the battery current sensor when removing.
Battery Current Sensor (2) @ Battery Negative Cable (1) - Remove
Battery Tray Reinforcement Nut (1) - Remove
- Battery Tray Reinforcement Bolt (2) - Remove
- Battery Tray Reinforcement (3) - Remove
Battery Positive Cable Terminal Cover (1) - Remove
- Battery Positive Cable Clamp Fastener (2) - Loosen
- Battery Positive Cable (3) @ Battery Positive Post - Remove
Battery Tray Support Nut (1) - Remove
- Battery Tray Support (2) - Remove
Battery Retainer Bolt (1) - Remove
- Battery Retainer Assembly (2) - Remove
- NOTE:
Use a battery lifting tool to remove.
Battery (1) - Remove
Engine Control Module (1) @ Battery Tray - Remove
Battery Positive Cable Retainer (1) @ Battery Tray - Remove [4x]
- {If equipped} Drive Motor Battery Charger Receptacle Retainer (2) @ Battery Tray - Remove
Battery Tray Bolt (1) - Remove [4x]
Battery Tray (1) - Remove
Front Compartment Front Sight Shield Retainer (1) - Remove [8x]
- Front Compartment Front Sight Shield (2) - Remove
Radiator Surge Tank Bracket Bolt (1) - Remove
- Radiator Surge Tank Bracket Nut (2) - Remove
- Reposition the radiator surge tank and bracket (3) to remove the drive motor battery charger.
Remove the battery to battery positive cable retainers. (1) [3x]
Accessory DC Power Control Module High Voltage Connector Protector Nut (1) - Remove
- Accessory DC Power Control Module High Voltage Connector Protector Bolt (2) - Remove
- Accessory DC Power Control Module High Voltage Connector Protector Bolt (3) - Remove
- Accessory DC Power Control Module High Voltage Connector Protector (4) - Remove
When disconnecting the 2 stage high voltage cable connector, perform in the following sequence.
- Release the CPA.
- Push down the connector tab.
- Release the 2 retaining tabs. (1) (2)
- Disconnect the high voltage cable connector.
After releasing the 2-stage safety connectors, remove the accessory DC power control module connector (1).
Electrical Connector (1) @ Accessory DC Power Control Module - Disconnect
Hose Clamp (1) - Disengage [2x]
- Drive Motor Generator Control Module Cooling Outlet Hose (2) - Remove
- Drive Motor Control Module Radiator Outlet Hose (3) - Remove
Battery Negative Cable Extension Cable Fastener (1) - Remove
- Battery Negative Cable Extension Cable (2) - Remove
- Engine Wiring Harness Connector Protector (3) - Remove
- Battery Positive Cable and Nut (4) - Remove
Engine Wiring Harness Bracket Bolt (1) - Remove
- Accessory DC Power Control Module Nut (2) - Remove
- Engine Wiring Harness Bracket Stud (3) - Remove
Engine Wiring Harness Bracket (1) - Position aside [2x]
Accessory DC Power Control Module (1) - Remove
When disconnecting the 2 stage high voltage cable connector, perform in the following sequence.
- Release the CPA.
- Push down the connector tab.
- Release the 2 retaining tabs. (1) (2)
- Disconnect the high voltage cable connector.
Disconnect the 4 high voltage cable connectors (1) by releasing the 2 stage safety connector.
- Disconnect the electrical connector. (2)
Engine Wiring Harness Bracket Bolt (1) - Remove [3x]
- Wiring Harness Retainer (2) - Remove [2x]
- Engine Wiring Harness Bracket (3) - Remove
High Voltage Electrical Connector (1) - Disconnect [2x]
- Electrical Connector (2) - Disconnect
Hose Clamp (1) - Disengage [2x]
- Drive Motor Power Inverter Module Cooling Inlet Hose (2) - Remove
- Drive Motor Control Module Radiator Outlet Hose (3) - Remove
Drive Motor Battery Charger Bolt (1) - Remove [3x]
- Drive Motor Battery Charger Nut (2) - Remove
Drive Motor Battery Charger (1) - Remove