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.
- Disable the high-voltage system. Refer to High Voltage Disabling .
- Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
- Remove the drive motor battery coolant cooler inlet hose asembly. Refer to Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement .
- Disconnect the high-voltage inter-lock loop connector (3) from the drive motor battery charger.
- Remove the 300 V battery positive/negative cable retaining nut (1) and the 300V battery positive/negative connector (2).
- Remove the 300 V battery positive/negative cable retainer nut (1) from the underbody stud.
- Remove the 300 V battery positive/negative cable retainer nuts (1) from the chassis frame.
- Remove the drive motor battery coolant cooler inlet hose fitting (1) and set aside the drive motor battery coolant cooler hose (2).
- Remove the drive motor battery coolant outlet hose, if necessary. Refer to Drive Motor Battery Coolant Outlet Hose Replacement .
- Remove the high-voltage inter-lock loop connector (1).
- Remove the bolt (2) and set aside the connector (3).
- Remove the high-voltage inter-lock loop connector (2) and the 300 V battery positive/negative connector (1), from the drive motor battery.
- Remove the 300 V battery positive/negative cable from the vehicle.
Installation Procedure
- Connect the 300 V battery positive/negative cable connector (1) and the high-voltage inter-lock loop connector (2), to the drive motor battery.
- Install the drive motor battery coolant outlet hose, if necessary. Refer to Drive Motor Battery Coolant Outlet Hose Replacement .
Caution: Refer to Fastener Caution in the Preface section.
- Connect the high-voltage connector (3) and tighten bolt (2) to 8 N·m (71 lb in).
- Install the drive motor battery coolant cooler inlet hose fitting (1).
- 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).
- 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).
- Install the 300 V battery positive/negative cable into the fuel line retainer with clip (1).
- 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.
- Install the 300 V battery positive/negative cable retainer (4) and nut (1) and tighten to 8 N·m (71 lb in).
- Install the 300 V battery positive/negative cable retainer to the stud and tighten nut (1) to 8 N·m (71 lb in).
- Install the drive motor battery coolant cooler inlet hose asembly. Refer to Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement .
- Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
- Enable the high-voltage system. Refer to High-Voltage Enabling .
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