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

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 drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
  3. Remove the drive motor battery coolant cooler inlet hose asembly. Refer to Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement .

    4. 2394635
  4. Disconnect the high-voltage inter-lock loop connector (3) from the drive motor battery charger.
  5. Remove the 300 V battery positive/negative cable retaining nut (1) and the 300V battery positive/negative connector (2).

    6. 2394632
  6. Remove the 300 V battery positive/negative cable retainer nut (1) from the underbody stud.

    7. 2394629
  7. Remove the 300 V battery positive/negative cable retainer nuts (1) from the chassis frame.

    8. 2401290
  8. Remove the drive motor battery coolant cooler inlet hose fitting (1) and set aside the drive motor battery coolant cooler hose (2).
  9. Remove the drive motor battery coolant outlet hose, if necessary. Refer to Drive Motor Battery Coolant Outlet Hose Replacement .

    10. 2394747
  10. Remove the high-voltage inter-lock loop connector (1).
  11. Remove the bolt (2) and set aside the connector (3).

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  12. Remove the high-voltage inter-lock loop connector (2) and the 300 V battery positive/negative connector (1), from the drive motor battery.
  13. Remove the 300 V battery positive/negative cable from the vehicle.

Installation Procedure

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  1. Connect the 300 V battery positive/negative cable connector (1) and the high-voltage inter-lock loop connector (2), to the drive motor battery.
  2. Install the drive motor battery coolant outlet hose, if necessary. Refer to Drive Motor Battery Coolant Outlet Hose Replacement .

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


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  3. Connect the high-voltage connector (3) and tighten bolt (2) to 8 N·m (71 lb in).

    4. 2401290
  4. Install the drive motor battery coolant cooler inlet hose fitting (1).

    5. 2394629
  5. Install the 300 V battery positive/negative retainers (2) and nuts (1) to the chassis frame studs and tighten to 8 N·m (71 lb in).

    6. 2394632
  6. Connect the 300 V battery positive/negative cable retainer (2) and nut (1), to the panel stud, and tighten to 8 N·m (71 lb in).

    7. 2394635
  7. Install the 300 V battery positive/negative cable into the fuel line retainer with clip (1).

    8. 2394746
  8. Connect the 300 V battery positive/negative cable connector (2) and the high-voltage inter-lock loop connector (3), to the drive motor battery charger.
  9. Install the 300 V battery positive/negative cable retainer (4) and nut (1) and tighten to 8 N·m (71 lb in).
  10. Install the 300 V battery positive/negative cable retainer to the stud and tighten nut (1) to 8 N·m (71 lb in).
  11. Install the drive motor battery coolant cooler inlet hose asembly. Refer to Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement .
  12. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
  13. Enable the high-voltage system. Refer to High-Voltage Enabling .
   


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