300-Volt Battery Positive and Negative Cable Replacement (Drive Motor Battery-to-APM Module)

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 includes the following steps:


* 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 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 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. Refer to Drive Motor Battery Replacement and Shipping Preparation (Volt) Procedures.

3. Support the fuel tank with an appropriate jack.





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).





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





7. Detach the 300V battery positive/negative cable (3) from the fuel rail fasteners (1).

8. Swing the individual fuel line clips (2) open.





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





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





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

12. Remove the 300V battery positive/negative cable fastener nut (3).





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

Installation Procedure





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





Caution:
Refer to Fastener Caution Fastener Caution.

2. Connect the 300V battery positive/negative retainer and nut (3) to the bracket stud. Tighten to 8 Nm (71 lb in).

3. Connect the 300V 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.





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





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





7. Install the floor panel bar (3) to the frame mounts. Tighten the following:

* Floor panel bar nuts (1) to 22 Nm (16 lb ft).

* Floor panel bar bolts (2) to 58 Nm (43 lb ft).





8. Connect the 300V 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 (Volt) Procedures.





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





11. Connect the 300V battery positive/negative cable connector (3) to the drive motor battery (3).

12. Connect the high voltage inter-lock loop connector (1).





13. Connect the high voltage inter-lock loop connector (1).

14. Install the connector (3) and tighten the bolt (1) to 8 Nm (71 lb in).





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 Drive Motor Battery Cooling System Draining and Filling.

17. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.

18. Clear the secure high voltage DTCs. Refer to Clear Secured High Voltage DTCs Reading and Clearing Diagnostic Trouble Codes.

19. Reset the Hybrid/EV battery pack data. Refer to Hybrid/EV Battery Pack Data Reset Hybrid/EV Battery Pack Data Reset.

20. Perform a Hybrid/EV battery pack capacity learn procedure. Refer to Hybrid/EV Battery Pack Capacity Learn Hybrid/EV Battery Pack Capacity Learn.