Hybrid Battery Fuse: Service and Repair

High-Voltage Low-Current Fuse









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.

WARNING: Never install the service disconnect plug with the high-voltage bussed electrical center (BEC) cover removed. Always install the cover prior to connecting the service disconnect plug. The high-voltage BEC cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.

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

2. 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.





3. Remove the 4 nuts, 2 bolts and the high-voltage BEC cover.
- To install, tighten to 9 Nm (80 lb-in).

4. Remove the high-voltage/high-current fuse.

1. Remove the high-voltage/high-current positive cable nut.
- To install, tighten to 15 Nm (133 lb-in).

2. Position the high-voltage/high-current positive cable aside.

3. Remove the 2 high-voltage/low-current fuse nuts on each end of the fuse.
- To install, tighten to 4 Nm (35 lb-in).

4. Remove the high-voltage/low-current circuit bus bar.

5. Remove the high-voltage/low-current fuse (40A).





5. To install, reverse the removal procedure.