Drive Motor Battery Cover Replacement

Drive Motor Battery Cover Replacement

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. Remove the battery cover fasteners (1).




4. Remove the battery cover fasteners (1).

5. Insert fingers at the 2 corners where the BBDU (Relay assembly), tray and cover meet. Gently lift the front cover up, off the BBDU assembly.

Note:

Prying cover off with tools can crack the cover.





Note: Use insulated tools when servicing components beneath the drive motor generator cover.

6. Remove the battery cover (1).

Installation Procedure

1. Replace the butyl tape at the cover, tray and BBDU assembly and where fingers were inserted to remove the cover.





Caution: Refer to Fastener Caution Fastener Caution.

2. Install the battery cover (1) by aligning the MSD housing opening with the base (connector) and gently push the front of the cover down against the BBDU assembly.




3. Clean all cover fasteners (1) and apply butyl tape to the bottom of the fasteners. Tighten to 9 Nm (80 lb in).




4. Clean all cover fasteners (1) and apply a medium strength thread-locker to the threads.




5. Tighten the cover fasteners in the following above sequence to 9 Nm (80 lb in).

6. Perform a smoke test on the rechargeable energy storage system. Refer to Rechargeable Energy Storage System Smoke Test Component Tests and General Diagnostics.

7. Install the drive motor battery. Refer to Drive Motor Battery Replacement and Shipping Preparation (Volt) Procedures.

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