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Removal Procedure

WARNING:

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.

  1. Disable the high voltage system. Refer to High Voltage Disabling
  2. Drain the drive motor generator power inverter module cooling system. Refer to Drive Motor Generator Power Inverter Module Cooling System Draining and Filling
  3. Remove Radiator Surge Tank Support Bracket (RESS). Refer to Radiator Surge Tank Support Bracket Replacement (Radiator)Radiator Surge Tank Support Bracket Replacement (Heater)Radiator Surge Tank Support Bracket Replacement (RESS)
  4. Remove High Voltage Battery Control Wiring Junction Block. Refer to High Voltage Battery Control Wiring Junction Block Replacement (With quick charge) High Voltage Battery Control Wiring Junction Block Replacement (Without quick charge) 
    5. Fig 1: Engine Wiring Harness Bracket, Bolt And Accessory DC Power Control Module
    GM4529666Courtesy of GENERAL MOTORS COMPANY
  5. Remove Engine Wiring Harness Bracket Bolt (1) @ Accessory DC Power Control Module (3)
  6. Reposition Engine Wiring Harness Bracket (2) @ Accessory DC Power Control Module (3)
    7. Fig 2: Drive Motor Power Inverter Module Shield, Bolts And Ground Cable
    GM4529667Courtesy of GENERAL MOTORS COMPANY
  7. Remove Drive Motor Power Inverter Module Shield Bolts (1, 2)
  8. Remove Ground Cable (4)
  9. Remove Drive Motor Power Inverter Module Shield (3)
    10. Fig 3: Engine Wiring Harness Connector And Handle
    GM4529668Courtesy of GENERAL MOTORS COMPANY
  10. Release Engine Wiring Harness Connector Handle (1) catch, and rotate forward
  11. Remove Engine Wiring Harness Connector (2)
    12. Fig 4: Drive Motor Power Inverter Module 3-Phase Cable, Cover, Nuts, Bolts And Seals
    GM4581955Courtesy of GENERAL MOTORS COMPANY
  12. Remove Drive Motor Power Inverter Module 3-Phase Cable Cover Nuts (1) (Qty: 2)
  13. Remove Drive Motor Power Inverter Module 3-Phase Cable Cover (2)
  14. Remove and DISCARD Drive Motor Power Inverter Module 3-Phase Cable Cover Seal (3)
  15. Loosen Drive Motor Power Inverter Module 3-Phase Cable Bolts (4) (Qty: 3)
  16. Remove Drive Motor Power Inverter Module 3-Phase Cable (5)
  17. Remove and DISCARD Drive Motor Power Inverter Module 3-Phase Cable Seal (6)
    18. Fig 5: Drive Motor Generator Control Module Radiator/Cooling Outlet Hoses And Clamps
    GM4529670Courtesy of GENERAL MOTORS COMPANY
  18. Release Clamp (1) and remove Drive Motor Generator Control Module Radiator Outlet Hose (2)
  19. Release Clamp (1) and remove Drive Motor Generator Control Module Cooling Outlet Hose (3)
    20. Fig 6: Drive Motor Power Inverter Module Bolts And Nut
    GM4529671Courtesy of GENERAL MOTORS COMPANY
  20. Remove Drive Motor Power Inverter Module Bolts (1) (Qty: 2)
  21. Remove Drive Motor Power Inverter Module Nut (2)
    22. Fig 7: Drive Motor Power Inverter Module
    GM4529672Courtesy of GENERAL MOTORS COMPANY
  22. Remove Drive Motor Power Inverter Module (1)
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