GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Tahoe - 4WD 🢒 Hybrid 🢒 Hybrid Energy Storage 🢒 Drive Motor Battery High Voltage Manual Disconnect Knob Housing Replacement

Object Number: 1869657 Size: MF

Callout

Component Name

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.

The High Voltage Disabling procedure will perform the following tasks:

   • 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.
Failure to follow the procedures exactly as written may result in serious injury or death.

Preliminary Procedures:

  1. Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling.
  2. Remove the upper cover. Refer to Drive Motor Battery Case Upper Cover, Front Cover, and Right Side Cover Replacement.

1

Drive Motor Battery Positive, Negative, and Ground Shield Cable Terminal Fastener Nut (Qty: 3)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
9 N·m (80 lb in)

2

Drive Motor Battery 300 Volt Positive and Negative Cable

Caution: 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.

Tip
Remove the drive motor generator battery retaining nuts and bolt, raise and support the drive motor generator battery assembly on the right side approximately 76 mm (3 in).

Special Tools

EL-48569 Terminal Covers

3

Drive Motor Battery Cover Side Bolt (Qty: 4)

Tighten
6 N·m (53 lb in)

4

Battery Cable Terminal Retainer

5

Drive Motor Battery High Voltage Manual Disconnect Knob Housing

6

Drive Motor Battery 300V Positive and Negative Cable Bolt (Qty: 2)

Tighten
6 N·m (53 lb in)

7

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

Caution: 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

8

HVIC Inline Connector

9

Drive Motor Battery Cooling Air Outlet Duct Seal

Procedure:

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