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300 Volt Battery Positive and Negative Cable Replacement - Drive Motor Battery-to-APM 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 drive motor battery. Refer to Drive Motor Battery Replacement and Shipping Preparation .
  3. Support the fuel tank with an appropriate jack.

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  4. Remove the nuts (1) and the bolts (2) securing the floor panel bar (3) to the frame.
  5. Remove the floor panel bar (3).

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

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  7. Detach the 300 V battery positive/negative cable (3) from the fuel rail fasteners (1).
  8. Swing the individual fuel line clips (2) open.

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  9. Working towards the rear of the vehicle, detach the fuel line clip (1) and cables ties (2).

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  10. Unclip the fuel line clip (1) and the cable ties (2).

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  11. Disconnect the high-voltage inter-lock loop connector (1) and the 300 V battery positive/negative cable connector (2).
  12. Remove the 300 V battery positive/negative cable fastener nut (3).

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  13. Remove the 300 V battery positive/negative cable (1) from the vehicle.

Installation Procedure

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  1. Position the 300 V battery positive/negative cable (1) below the vehicle.

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


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  2. Connect the 300 V battery positive/negative retainer and nut (3) to the bracket stud. Tighten to 8 N·m (71 lb in).
  3. Connect the 300 V battery positive/negative cable connector (2) to the accessory DC power control module.
  4. Connect the high-voltage inter-lock loop connector (1) to the accessory DC power control module.

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

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

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  7. Install the floor panel bar (3) to the frame mounts. Tighten the following:
    8. • Floor panel bar nuts (1) to 22 N·m (16 lb ft).
    • Floor panel bar bolts (2) to 58 N·m (43 lb ft).

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  8. Connect the 300 V battery positive/negative cable into the fuel line retainer clips (1).
  9. Install the drive motor battery. Refer to Drive Motor Battery Replacement and Shipping Preparation .

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  10. Install the 300 V battery positive/negative cable retainer to the stud and tighten nut (1) to 8 N·m (71 lb in).

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  11. Connect the 300 V battery positive/negative cable connector (3) to the drive motor battery (3).
  12. Connect the high-voltage inter-lock loop connector (1).

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  13. Connect the high-voltage inter-lock loop connector (1).
  14. Install the connector (3) and tighten the bolt (1) to 8 N·m (71 lb in).

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  15. Connect the drive motor battery coolant cooler inlet hose fitting (1).
  16. Fill the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling .
  17. Enable the high-voltage system. Refer to High-Voltage Enabling .
  18. Clear the secure high-voltage DTCs. Refer to Clear Secured High-Voltage DTCs .
  19. Rest the Hybrid/EV battery pack data. Refer to Hybrid/EV Battery Pack Data Reset .
  20. Perform a Hybrid/EV battery pack capacity learn procedure. Refer to Hybrid/EV Battery Pack Capacity Learn .
   


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