300-Volt Battery Positive and Negative Cable Replacement (Inverter-to-Compressor/Heater Module)

300-Volt Battery Positive and Negative Cable Replacement (Inverter-to-Compressor/Heater 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 air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement Air Cleaner Resonator Outlet Duct Replacement.

3. Remove the throttle body. Refer to Throttle Body Assembly Replacement Removal and Replacement.





4. Remove the inverter to compressor/heater module cable (1) from the power inverter module (2).

Note:
Replace the 300V battery positive and negative connector seal.





5. Locate the connectors (1) to the heater coolant heater module.





6. Detach the high voltage inter-lock loop connector (1) and the 300V battery positive and negative cable (2), from the heater coolant heater module (3).





7. Disconnect the 300V battery positive and negative cable retainers (1) from the A/C compressor hose.





8. Remove the 300V battery positive and negative cable (1) from the vehicle.

Installation Procedure





1. Position the 300V battery positive and negative cable (1) in the engine compartment.





2. Connect the 300V battery positive and negative cable connector (2) to the heater coolant heater module (3).

3. Connect the high voltage inter-lock loop connector (1) to the heater coolant heater module (3).





4. Install the 300V battery positive and negative cable retainers (1) to the A/C compressor hose.





5. Install the 300V battery positive and negative connector (2) to the A/C and drive motor battery cooling compressor.

6. Connect the 300V battery positive and negative cable retainers (1) to the A/C compressor hose.





Caution:
Refer to Fastener Caution Fastener Caution.

7. Connect the 300V battery positive and negative cable connector (1) to the drive motor generator power inverter module. Tighten to 8 Nm (71 lb in).

8. Install the throttle body. Refer to Throttle Body Assembly Replacement Removal and Replacement.

9. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement Air Cleaner Resonator Outlet Duct Replacement.

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