Generator Battery Replacement

Generator Battery 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. Disable the hybrid battery. Refer to High Voltage Disabling High Voltage Disabling.

2. Remove the battery energy control module. Refer to Battery Energy Control Module Replacement Battery Energy Control Module Replacement.

3. Remove the battery energy control module wiring junction block. Refer to Battery Energy Control Module Wiring Junction Block Replacement Battery Energy Control Module Wiring Junction Block Replacement.





Note:
Remember the location of fastener (1) as not to interfere with the installation of the generator control and battery module cover.

4. Remove the generator battery fasteners (1) and (2).





5. Remove the fasteners (1) and (2).

Note:
Remember the location of fastener (1) as not to interfere with the installation of the generator control and battery module cover.

6. Remove the mounting location fastener (3).





Note:
Use high voltage protective gloves.

7. Slide the generator battery (1) in the direction shown.





8. With the help of a second technician, lift the generator battery (1) into the rear compartment area.

9. Inspect the intermediate duct seals (2) and replace if damaged.

Installation Procedure





Caution:
Refer to Fastener Caution Fastener Caution.

1. With the help of a technician, install the generator battery (1) to the mounting studs.





2. Slide the generator battery towards the intermediate duct seals and install the locating fastener (3). Tighten the fastener (3) to 22 Nm (16 lb ft).

3. Install the generator battery fastener (2) and tighten to 22 Nm (16 lb ft).

4. Install the generator battery fasteners (2) and tighten to 22 Nm (16 lb ft).





5. Install the generator battery fasteners (1) and tighten to 22 Nm (16 lb ft).

6. Install the generator battery fasteners (2) and tighten to 22 Nm (16 lb ft).

7. Install the battery energy control module. Refer to Battery Energy Control Module Replacement Battery Energy Control Module Replacement.

8. Install the battery energy control module wiring junction block. Refer to Battery Energy Control Module Wiring Junction Block Replacement Battery Energy Control Module Wiring Junction Block Replacement.

9. Install the battery energy control module harness. Refer to Battery Energy Control Module Wiring Harness Replacement (BDU,BECM and BPIM) Battery Energy Control Module Wiring Harness Replacement (BDU,BECM and BPIM)Battery Energy Control Module Wiring Harness Replacement (HV Measuring Harness 1 and 2) Battery Energy Control Module Wiring Harness Replacement (HV Measuring Harness 1 and 2).

10. Enable the hybrid battery. Refer to High Voltage Enabling High Voltage Enabling.