WARNING:
Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.
WARNING:
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
- Safety glasses with appropriate side shields when within 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 at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedure exactly as written may result in serious injury or death.
WARNING:
Improper High Voltage (HV) Bus Bar location during battery reassembly may result in section shorting. Arcing may occur when shorted, resulting in molten metal splattering and arc-flash hazards. To reduce the risk of death, personal injury and/or high voltage battery damage, identify the existing location of HV Bus Bars prior to disassembly and reinstall only in the proper location.
Preliminary Procedure
- Remove the drive motor battery. Drive Motor Battery Replacement and Shipping Preparation , or Drive Motor Battery Replacement and Shipping Preparation (Forklift Method) , or Drive Motor Battery Replacement and Shipping Preparation (Engine Hoist/Pallet Jack Method)
- Ensure the proper procedures for the battery cable - bus bars are followed once the battery upper cover is removed. Hybrid/EV Battery Cable Bus Bar Orientation Verification
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| 1 |
Battery Upper Cover Fastener [50x]
Procedure
- When removing the bolts, follow the release sequence shown in the above left graphic.
- Tighten the cover fasteners in the sequence shown in the above illustration.
- Loosely tighten the No. 1 - 4 bolts first.
- Tighten the No. 1 - 50 bolts to 2.5 N.m (22 lb in).
- Tighten the No. 1 - 50 bolts to 9 N.m (80 lb in) again.
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| 2 |
High Voltage Disconnect Connector Fastener [6x]
Procedure
Tighten the fasteners in the sequence shown in the above illustration.
Tighten
9 N.m (80 lb in) |
| 3 |
Battery Upper Cover Procedure
- If needed, replace the battery upper cover.
- If needed, replace the battery cover seal. Battery Cover Seal Replacement
- Perform the rechargeable energy storage system smoke test. Rechargeable Energy Storage System Smoke Test
- Perform the hybrid/EV battery system verification. Hybrid/EV Battery System Verification
- Install the drive motor battery. Drive Motor Battery Replacement and Shipping Preparation , or Drive Motor Battery Replacement and Shipping Preparation (Forklift Method) , or Drive Motor Battery Replacement and Shipping Preparation (Engine Hoist/Pallet Jack Method)
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