Cell Battery Replacement (Section 1)

Cell Battery Replacement (Section 1)

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 condition 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 glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

* Certified and up-to-date Class "0" Insulation gloves rated at 1000V 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 energized or not.


Failure to follow the procedures exactly as written may result in serious injury or death.


Danger: The Volt Battery Pack will utilize 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 Center (1-877-446-8227) if you have any questions.


1. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.
2. Remove the drive motor battery junction block relay. Refer to Drive Motor Battery Wire Junction Block Relay Replacement Drive Motor Battery Wire Junction Block Relay Replacement.




3. Remove the bus bar fasteners (1) and battery cable (2).




4. Disconnect the electrical connectors and remove the battery energy control module wiring harness (1).




5. Remove the current sensor fasteners (1) and the current sensor (2).




6. Remove the bus bar fastener (1) and bus bar (2).




7. Remove the auxiliary battery wiring harness (1).




8. Remove the battery interface control module (1).




9. Loosen the hose clamps (1).
10. Remove the hold down fasteners (2) and battery hold down (3).
11. With the help of an assistant, remove the battery section (4).
Note: Replace rubber sealant strips if worn or damaged.

Installation Procedure





Caution: Refer to Fastener Caution Fastener Caution.

1. Install the battery section (4).
2. Install the battery hold down (3) and tighten the hold down fasteners (2) to 9 Nm (80 lb in).
3. Tighten the hose clamps (1) to 2 Nm (18 lb in).




4. Install the battery interface control module (1).




5. Install the auxiliary battery wiring harness (1).




6. Install the bus bar (2) and tighten the bus bar fastener (1) to 9 Nm (80 lb in).




7. Install the current sensor (2) and tighten the current sensor fasteners (1) to 9 Nm (80 lb in).




8. Install the battery energy control module wiring harness (1) and connect the electrical connectors.




9. Install the battery cable (2) and tighten the bus bar fasteners (1) to 9 Nm (80 lb in).
10. Install the drive motor battery junction block relay. Refer to Drive Motor Battery Wire Junction Block Relay Replacement Drive Motor Battery Wire Junction Block Relay Replacement.
11. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.