Removal Procedure
- 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.
- Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling .
- Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
- Disconnect the drive motor generator control module assembly connector (1).
- Drain the power electronics cooling system. Refer to Generator Control Module Cooling System Draining and Filling .
- Remove the drive motor generator power inverter control module 3 phase cable terminal fasteners (1).
- Cable sealing
- Electrical shielding
- Terminal position assurance
- Remove the power inverter module 3 phase cable mounting fasteners (2, 4).
- Remove the power inverter module 3 phase cables (3, 5) from the power inverter module distribution box.
- Remove and discard the seals (6).
- Remove the high voltage dc electric air conditioning compressor module cable terminal fasteners (1).
- Remove the high voltage dc electric air conditioning compressor module cable mounting fasteners (3).
- Remove the high voltage dc electric air conditioning compressor module cable (4) from the power inverter module distribution box.
- Remove the high voltage dc battery cable terminal fasteners (2).
- Remove the high voltage dc battery cable mounting fasteners (5).
- Remove the high voltage dc battery cable (6) from the power inverter module distribution box.
- Inspect and retain the seals (7).
- Remove the drive motor generator position sensor shield circuit fastener (2).
- Remove the shield circuit harness (1).
- Remove the power inverter module cooling inlet (4) and outlet (5) hoses.
- Cap the coolant pipes (3, 6) to prevent coolant spillage when lifting the drive motor generator control module assembly from the vehicle.
- Disconnect the accessory DC power control module assembly connector (2) using the following procedure:
- Push the green tab.
- Squeeze the gray side tabs, then rotate the lever.
- Disconnect the accessory DC power control module assembly connector (3) using the following procedure:
- Remove the locking tab.
- Insert a small flat blade screwdriver into the locking tab area and raise the tab while pulling on the connector.
- Disconnect the remaining accessory DC power control module assembly connector (1).
- Remove the sight shield circuit breaker fasteners (1).
- Remove the sight shield circuit breaker (2).
- Remove the accessory DC power control module ground strap fastener (2) and ground strap (1).
- Remove the drive motor generator control module assembly mounting fasteners (3) and retainers (4).
- Remove the ball studs (1) from the drive motor generator control module.
- Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations.
- Lift the drive motor generator control module assembly from the vehicle.
- To replace the drive motor generator power inverter module assembly, refer to Drive Motor Generator Power Inverter Module Removal and Installation . To replace the accessory DC power control module, refer to Accessory DC Power Control Module Removal and Installation .
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 will perform the following tasks:
Failure to follow the procedures exactly as written may result in serious injury or death.
Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage.
High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper:
Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage.
The gray side tabs on the accessory dc power control module assembly connector (2) must be pressed in before rotating the lever.