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300 Volt Battery Positive and Negative Cable Replacement - Drive Motor Battery-to-Inverter

Removal Procedure

Danger: 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 will perform the following tasks:

   • Identify how to disable high voltage.
   • Identify how to test for the presence of high voltage.
   • Identify conditions 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 goggles with appropriate side shields when within 15 metres (50 feet) of the vehicle, either indoors or outdoors.
   • Certified and up-to-date Class "0" Insulation gloves rated at 1000 V 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 energised or not.
Failure to follow the procedures exactly as written may result in serious injury or death.

Danger: The Volt Battery Pack will utilise an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Centre (1-877-446-8227) if you have any questions.

  1. Disable the high-voltage system. Refer to High Voltage Disabling .
  2. Remove the exhaust pipe front heat shield. Refer to Exhaust Pipe Heat Shield Replacement : Rear  → Center  → Front .

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  3. Remove the bolt (2) holding the 300 V battery positive and negative cable connector (1), to the drive motor generator power inverter module.

    4. Note: Replace the 300 V battery positive and negative connector seal.

  4. Drain the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling .

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  5. Remove the drive motor battery coolant cooler inlet hose fitting (1) and set aside the drive motor battery coolant cooler hose (2).

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  6. Remove the high-voltage interlock loop connector (1) and the bolt (2) holding the connector (3) to the drive motor battery.

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  7. Disconnect the 300 V battery positive and negative cable retainers (1) from the studs.

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  8. Remove the 300 V battery positive and negative cable retainers (2) from the heater coolant shut-off valve bracket (1).

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  9. Remove the 300 V battery positive and negative cable (1) from the vehicle.

Installation Procedure

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  1. Position the 300 V battery positive and negative cable (1) in the engine compartment.

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  2. Connect the 300 V battery positive and negative cable retainers (2) to the heater coolant shut-off valve bracket (1).

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  3. Install the 300 V battery positive and negative cable retainers (1) to the tunnel studs.

    4. Caution: Refer to Fastener Caution in the Preface section.


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  4. Install the 300 V battery positive and negative connector bolt (2) and tighten to 8 N·m (71 lb in).
  5. Connect the high voltage interlock loop connector (1) to the 300 V battery positive and negative cable connector (3).

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  6. Install the drive motor battery coolant cooler inlet hose fitting (1).
  7. Fill the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling .
  8. Enable the high-voltage system. Refer to High-Voltage Enabling .
   


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