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.
- Disable the high voltage system. Refer to High Voltage Disabling .
- Remove the drivetrain and front suspension frame assembly. Refer to Drivetrain and Front Suspension Frame Replacement .
- Remove the drive motor battery coolant flow control valve. Refer to Drive Motor Battery Coolant Flow Control Valve Replacement .
- Remove the heater coolant pump. Refer to Heater Coolant Pump Replacement .
- Remove the accessory DC power control module. Refer to Accessory DC Power Control Module Replacement .
- Remove the drive motor battery charger. Refer to Drive Motor Battery Charger Replacement .
- Remove the following from the rear of the drivetrain front and electronic system power supply module frame (1) :
- Battery Positive Cable Ground (2)
- Engine Wiring Harness Ground (3)
- Drive Motor Battery Charger Connector (4)
- Engine Wiring Harness Ground (5)
- High Voltage Cable Conduit Fastener (6)
- High Voltage Cable Conduit (7)
- Remove the drive motor battery coolant flow control valve (1) from the right side of the drivetrain front and electronic system power supply module frame (3).
- Remove the auxiliary ground cable (2).
- Remove the accessory DC power control module connector (4).
- Remove the following from the front drive front and electronic system power supply module frame :
- Engine Wiring Harness Ground (1)
- Transmission 3 Phase Cable Retainer (2)
- Accessory DC Power Control Module Cable Ground (3)
- Auxiliary Battery Negative Cable Ground (4)
- Engine Wiring Harness Grounds (5)
- Transmission 3 Phase Cable Retainer (6)
- Transmission 3 Phase Cable (7)
- Battery Negative Cable Ground (8)
- Remove the drivetrain front and electronic system power supply module frame mounting nuts (1).
- Remove the drivetrain front and electronic system power supply module frame mounting bolts (1).
- With the help of a second technician, remove the frame (2) from the vehicle.