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300 Volt Battery Positive and Negative Cable Replacement - Inverter-to-Compressor/Heater Module

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 air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  3. Remove the throttle body. Refer to Throttle Body Assembly Replacement .

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  4. Remove the inverter-to-compressor/heater module cable (1) from the power inverter module (2).

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


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  5. Locate the connectors (1) to the heater coolant heater module.

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  6. Detach the high-voltage inter-lock loop connector (1) and the 300 V battery positive and negative cable (2), from the heater coolant heater module (3).

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  7. Disconnect the 300 V battery positive and negative cable retainers (1) from the A/C compressor hose.

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  8. 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 connector (2) to the heater coolant heater module (3).
  3. Connect the high-voltage inter-lock loop connector (1) to the heater coolant heater module (3).

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  4. Install the 300 V battery positive and negative cable retainers (1) to the A/C compressor hose.

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  5. Install the 300 V battery positive and negative connector (2) to the A/C and drive motor battery cooling compressor.
  6. Connect the 300 V battery positive and negative cable retainers (1) to the A/C compressor hose.

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


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  7. Connect the 300 V battery positive and negative cable connector (1) to the drive motor generator power inverter module. Tighten to 8 N·m (71 lb in).
  8. Install the throttle body. Refer to Throttle Body Assembly Replacement .
  9. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  10. Enable the high-voltage system. Refer to High-Voltage Enabling .
   


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