Drive Motor Generator Battery Cable Replacement

Drive Motor Generator Battery Cable Replacement

Removal Procedure

Danger:
Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.


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.


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 exactly as written may result in serious injury or death.


1. Ignition OFF, disable the high voltage at the A4 hybrid battery pack. Refer to High Voltage Disabling High Voltage Disabling.

2. Remove the fuel tank. Refer to Fuel Tank Replacement Fuel Tank Replacement.

3. Remove the left front underbody air deflector.

4. Remove the left front frame reinforcement. Refer to Drivetrain and Front Suspension Frame Replacement.





5. Remove the high voltage 3-phase cable terminal nuts (1) and the 12V terminal branch nut (4).

6. Remove the high voltage cable (2) and the 12V cable (3) from the generator battery.





7. Remove the drive motor generator battery bracket nuts (1) and the cable retainer nut (2).

8. Pull the drive motor generator cable (3) through the grommet opening.





9. Remove the drive motor generator retainer nut (1) and bolt (2).

Note:
Replace the fasteners (3) if re-using the drive motor generator battery cable.

10. Detach the drive motor generator battery cable fasteners (3).





11. Remove the drive motor generator battery fastener bolts (1).





12. Within the rear engine compartment, remove the drive motor generator battery cable retainer nut (1).





Note:
Replace the retainers (1) if re-using the drive motor generator battery cable.

13. Disconnect the drive motor generator battery cable retainers (1) and the battery tray cable clip (2).





14. Remove the drive motor generator battery cable terminal (1) , from the underhood fuse block.





15. Remove the generator starter cover nuts (1) and remove the cover (2).





16. Remove the bolts (1) and detach the drive motor generator battery cable from the generator starter.





17. Detach the retainers (1) holding the drive motor generator battery cable to the fuel pump cover and the heater outlet bracket.

Note:
Replace the retainers (1) if re-using the drive motor generator battery cable.

18. Remove the drive motor generator battery cable from the vehicle.

Installation Procedure





1. Starting at the rear of the vehicle, feed the drive motor generator battery cable through the opening in the floor.

Caution:
Refer to Fastener Caution Fastener Caution.

2. Position the pass-through grommet seal and bracket. Tighten the bracket nuts (1) to 22 Nm (16 lb ft).

3. Tighten the retainer nut (2) to 22 Nm (16 lb ft).





4. Install the high voltage 3-phase branch terminals (2) to the generator battery. Tighten the nuts (1) to 9 Nm (80 lb in).

5. Install the 12V cable (3) and tighten the nut (4) to 9 Nm (80 lb in).





6. At the left rear frame rail, attach the drive motor generator battery cable to the frame with NEW fasteners (3).

7. Install the retainer nut (1) and bolt (2) to the underbody. Tighten to 22 Nm (16 lb ft).





8. Working towards the front of the vehicle, attach the drive motor generator battery cable to the underbody. Tighten the nuts (1) to 22 Nm (16 lb ft).





9. Feed the drive motor generator battery cable into the engine compartment and install to the plenum. Tighten the nut (1) to 22 Nm (16 lb ft).





10. Install the drive motor generator battery 12V branch, to the left front frame rail, with NEW fasteners (1).

11. Secure the cable to the battery tray with clip (2).





12. Install the 12V terminal (1) to the underhood fuse block and tighten the nut to 9 Nm (80 lb in).





13. Fasten the drive motor generator battery cable to the heater outlet bracket and fuel pump cover with NEW fasteners (1).





Note:
Be sure the drive motor generator battery cable cover is fully seated against the drive motor generator battery cable housing prior to installing and fastening the nuts. This will ensure proper alignment and engagement of HVIL terminals.

14. Position the drive motor generator battery cable to the starter generator assembly studs. Tighten the bolts (1) to 9 Nm (80 lb in).





15. Install the cover (2) and tighten the nuts (1) to 9 Nm (80 lb in).

16. Install the left front frame reinforcement. Refer to Drivetrain and Front Suspension Frame Replacement.

17. Install the left front underbody air deflector.

18. Install the fuel tank. Refer to Fuel Tank Replacement Fuel Tank Replacement.

19. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.