Danger: 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.

Preliminary Procedures

1. Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling.
2. Remove the drive motor generator battery from the vehicle. Refer to Drive Motor Generator Battery Replacement.
3. Remove all components in this procedure from the disabled drive motor generator battery and install onto the new drive motor battery with case kit.

1

Drive Motor Battery Cable Terminal Extension Cover Bolt (Qty: 4)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
6 N·m (53 lb in)

2

Drive Motor Battery Cable Terminal Extension Cover

3

Drive Motor Battery Case Upper Cover Bolt (Qty: 21)

Tighten
8 N·m (71 lb in)

4

Drive Motor Battery Case Upper Cover Nut (Qty: 6)

Tighten
8 N·m (71 lb in)

5

Drive Motor Battery Case Upper Cover

6

Drive Motor Battery Case Front Cover Bolt (Qty: 9)

Tighten
8 N·m (71 lb in)

7

Drive Motor Battery Case Front Cover Push Rivet

8

Drive Motor Battery Case Front Cover

9

Drive Motor Battery Case Right Cover Nut

Tighten
8 N·m (71 lb in)

10

Drive Motor Battery Case Right Cover Bolt (Qty: 3)

Tighten
8 N·m (71 lb in)

11

Drive Motor Battery Case Right Cover

1

Battery Cooling Air Outlet Duct

2

Drive Motor Battery Cable Terminal Nut

Caution: Refer to Fastener Caution in the Preface section.

Tip
Remove cable retainer from battery fan assembly.

Tighten
5 N·m (44 lb in)

3

Battery Vent Fan Duct Retainer

4

Drive Motor Generator Battery Cooling Outlet Duct

5

Drive Motor Generator Battery Cooling Blower Nut (Qty: 2)

Tighten
6 N·m (53 lb in)

6

Drive Motor Battery Cooling Blower Bolt

Tighten
6 N·m (53 lb in)

7

Battery Fan Assembly

1

Drive Motor Battery Cable Terminal Nut (Qty: 2)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
5 N·m (44 lb in)

2

Drive Motor Battery Positive and Negative w/Wiring Harness Cable Assembly

Warning: High Voltage (HV) cables are not repairable. After disconnecting HV cables, protect and insulate ring terminal ends immediately with the EL-48569 terminal covers and UL® Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement.

Special Tools

EL-48569 Terminal Covers

3

Drive Motor Battery Housing Relay Nut (Qty: 2)

Tighten
3 N·m (27 lb in)

4

Drive Motor Battery Negative High Voltage Contactor Relay Assembly

5

Drive Motor Generator Battery Negative Relay Bracket Nut (Qty: 2)

Tighten
6 N·m (53 lb in)

6

Drive Motor Battery Negative Relay Bracket Bolt

Tighten
6 N·m (53 lb in)

7

Drive Motor Battery Negative Relay Bracket

8

Generator Battery Vent Fan Relay

1

Drive Motor Battery Cable Terminal Nut

Caution: Refer to Fastener Caution in the Preface section.

Tighten
5 N·m (44 lb in)

2

Drive Motor Battery Cable Terminal Nut

Tighten
5 N·m (44 lb in)

3

Drive Motor Battery Sensor Bracket Bolt (Qty: 2)

Tighten
5 N·m (44 lb in)

4

Drive Motor Battery Current Sensor Assembly with Bracket

5

Drive Motor Generator Battery Positive Relay Insulator Nut (Qty: 3)

Tighten
6 N·m (53 lb in)

6

Drive Motor Generator Battery Control Module Assembly

Procedure:

After the drive motor generator battery control module assembly has been replaced and the re-assembly of the drive motor generator battery, enable the HV system. Refer to High Voltage Enabling.