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

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

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 exhaust pipe front heat shield. Refer to Exhaust Pipe Heat Shield Replacement (Rear) Exhaust Pipe Heat Shield Replacement (Rear)Exhaust Pipe Heat Shield Replacement (Front) Exhaust Pipe Heat Shield Replacement (Front)Exhaust Pipe Heat Shield Replacement (Center) Exhaust Pipe Heat Shield Replacement (Center).

3. Remove the bolt (2) holding the 300V battery positive and negative cable connector (1), to the drive motor generator power inverter module.

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

4. Drain the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling Drive Motor Battery Cooling System Draining and Filling.

5. Remove the drive motor battery coolant cooler inlet hose fitting (1) and set aside the drive motor battery coolant cooler hose (2).

6. Remove the high voltage interlock loop connector (1) and the bolt (2) holding the connector (3) to the drive motor battery.

7. Disconnect the 300V battery positive and negative cable retainers (1) from the studs.

8. Remove the 300V battery positive and negative cable retainers (2) from the heater coolant shut-off valve bracket (1).

9. 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 retainers (2) to the heater coolant shut-off valve bracket (1).

3. Install the 300V battery positive and negative cable retainers (1) to the tunnel studs.

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the 300V battery positive and negative connector bolt (2) and tighten to 8 Nm (71 lb in).

5. Connect the high voltage interlock loop connector (1) to the 300V battery positive and negative cable connector (3).

6. Install the drive motor battery coolant cooler inlet hose fitting (1).

7. 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.

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