Removal Procedure
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.
- Disable the high voltage system. High Voltage Disabling
- Drain the drive motor generator power inverter module cooling system. Drive Motor Generator Power Inverter Module Cooling System Draining and Filling
- Radiator Surge Tank Support Bracket (RESS) - Remove - Radiator Surge Tank Support Bracket Replacement (Radiator)Radiator Surge Tank Support Bracket Replacement (Heater)Radiator Surge Tank Support Bracket Replacement (RESS)
- High Voltage Battery Control Wiring Junction Block - Remove - High Voltage Battery Control Wiring Junction Block Replacement (With quick charge) High Voltage Battery Control Wiring Junction Block Replacement (Without quick charge)
Engine Wiring Harness Bracket Bolt (1) @ Accessory DC Power Control Module (3) - Remove
- Engine Wiring Harness Bracket (2) @ Accessory DC Power Control Module (3) - Reposition
Drive Motor Power Inverter Module Shield Bolt (1, 2) - Remove
- Ground Cable (4) - Remove
- Drive Motor Power Inverter Module Shield (3) - Remove
Engine Wiring Harness Connector Handle (2) - Release catch, Rotate forward
- Engine Wiring Harness Connector (3) - Remove
Drive Motor Power Inverter Module 3-Phase Cable Cover Nut (1) - Remove [2x]
- Drive Motor Power Inverter Module 3-Phase Cable Cover (2) - Remove
- Drive Motor Power Inverter Module 3-Phase Cable Cover Seal (3) - Remove and DISCARD
- Drive Motor Power Inverter Module 3-Phase Cable Bolt (4) - Loosen [3x]
- Drive Motor Power Inverter Module 3-Phase Cable (5) - Remove
- Drive Motor Power Inverter Module 3-Phase Cable Seal (6) - Remove and DISCARD
Drive Motor Generator Control Module Radiator Outlet Hose (2) - Release Clamp (1) and Remove the Hose
- Drive Motor Generator Control Module Cooling Outlet Hose (3) - Release Clamp (1) and Remove the Hose
Drive Motor Power Inverter Module Bolt (1) - Remove [2x]
- Drive Motor Power Inverter Module Nut (2) - Remove
Drive Motor Power Inverter Module (1) - Remove