Hybrid Battery Bus / Cable: Service and Repair

High-Voltage Cables









Removal and Installation

WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage hybrid system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

1. Discharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

2. Disconnect the 12-volt battery. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

3. Depower the High Voltage Traction Battery (HVTB). For additional information, refer to High-Voltage Traction Battery Systems Depowering High-Voltage Traction Battery Systems Depowering.

4. Fold the RH backrest down.
- Between the HVTB and the sheet metal, locate the seat backrest latch release lever.

- Push the release lever toward the outboard side of the vehicle and fold the backrest down.





5. Remove the RH rear seat bolster. For additional information, refer to Seating Seat Bolster - Rear.

6. NOTICE: Failure to disconnect high-voltage cable connectors as instructed may result in damage to the connectors.

NOTE: DC to DC Converter Control Module (DC/DC) connector shown, high-voltage/low-current connector at high-voltage Bussed Electrical Center (BEC) similar.

Release the locking lever and locking tabs and disconnect the interlock connector and the 2 high voltage cables at the high-voltage BEC.

- Press the locking clip on the white interlock connector and disengage the white connector before releasing the locking clip on the orange portion of the high-voltage connector. The white interlock connector will not come completely apart until the orange portion is released.





7. Remove the HVTB cooling inlet duct plate.

8. Remove the pushpin that retains the high-voltage cables to the bracket on the HVTB case.

9. Remove the passenger side front seat. For additional information, refer to Seating Seat - Front.

10. Remove the front door scuff plate trim panel.

11. Remove the rear door scuff plate trim panel.

12. Remove the lower B-pillar trim panel.
- Slide the lower B-pillar trim panel down to disengage it from the upper B-pillar trim panel.

13. Remove the rear seat cushion. For additional information, refer to Seating Seat Cushion - Rear.

14. Remove the high-voltage cable shield retaining screw.

15. Partially raise the LR seat back and pull the high-voltage cables out from under the rear seat backrest, then position both rear seat backrests in the upright position.

16. NOTE: The high-voltage cables are routed under the passenger side rear carpet.

Disconnect the high-voltage cable from the DC/AC inverter and remove the 5 retaining clips. Position the cable aside.

17. NOTICE: Make sure that the rear of the floor console is lifted away from the floor as specified. Failure to follow this procedure will result in damage to the floor console and the tabs at the top of the floor console end cover.

Remove the floor console end cover in the following sequence.

1. Remove the floor console rear screws.

2. Lift the floor console about 25 mm (0.984 in) away from the floor.

3. Remove the floor console end cover by pulling the cover away at the bottom and rotating out. Lower the cover 7-13 mm (0.275-0.511 in) to clear the tabs on the top of the floor console end cover.





18. Disconnect the AC power point connector.

19. Release the 2 pushpins that hold the high-voltage cables to the floor pan and pull the high-voltage cable out from underneath the carpet and floor console.

20. Remove the 3 nuts at the floor pan grommet cover.

21. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

22. Remove the 5 nuts that retain the high-voltage cable shield to the floor pan and remove the cables from the studs.
- To install, tighten to 9 Nm (80 lb-in).

23. Remove the 2 nuts that retain the high-voltage cable shield to the bulkhead and remove the cables from the studs.
- To install, tighten to 9 Nm (80 lb-in).

24. Remove the pushpin that retains the high-voltage harness to the bulkhead.

25. Push the high-voltage cables through the opening of the vehicle floor pan.

26. Remove the engine cover.

27. Remove the high-voltage cable strain relief bolt and remove the strain relief clamp from the bracket.
- To install, tighten to 9 Nm (80 lb-in).

28. Disconnect the high-voltage electrical connector from the transmission and position the cable aside.

29. Using a screwdriver or other suitable tool, release the clip that locks the high-voltage junction block to the bracket by pushing the tool between the high-voltage junction block and the bracket from the LH side. Remove the cable from the retainer on the bulkhead and position the cable aside.

30. Lift the high-voltage cables from the 2 studs on the front of the engine and disengage the pushpin at the intake manifold.

31. NOTICE: Failure to disconnect high-voltage cable connectors as instructed may result in damage to the connectors.

NOTE: DC/DC connector shown, high-voltage/low-current connector at Air Conditioning Compressor Module (ACCM) similar.

Release the clips and locking tabs and disconnect the interlock connector and the high-voltage cable connector at the ACCM.

- Press the locking clip on the white interlock connector and disengage the white connector before releasing the locking clip on the orange portion of the high-voltage connector. The white interlock connector will not come completely apart until the orange portion is released.





32. NOTICE: Failure to disconnect high-voltage cable connectors as instructed may result in damage to the connectors.

Release the clips and locking tabs and disconnect the interlock connector and the high-voltage cable connector at the DC/DC.

- Press the locking clip on the white interlock connector and disengage the white connector before releasing the locking clip on the orange portion of the high-voltage connector. The white interlock connector will not come completely apart until the orange portion is released.





33. Remove the A/C evaporator inlet fitting nut from the low side and disconnect the fitting nut. Discard the gasket seal.
- To install, tighten to 15 Nm (133 lb-in).

34. Remove the A/C compressor manifold and suction tube fitting nut (low side) and disconnect the fitting. Remove the tube and discard the gasket seal.
- To install, tighten to 15 Nm (133 lb-in).

35. Wrap mechanic's wire around the Hydraulic Control Unit (HCU) motor from above and support the HCU.

36. Remove the 3 bolts that retain the HCU bracket to the frame.
- To install, tighten to 23 Nm (17 lb-ft).

37. An assistant is needed to help feed the cable down through the engine compartment and remove the high-voltage cable assembly from the bottom of the vehicle.

38. To install, reverse removal procedure.