Hybrid Drive Systems: Service and Repair

High-Voltage Traction Battery Systems Depowering

WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death.

WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death.

WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death.

WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death.

1. Set up the buffer zone around the vehicle. For additional information, refer to Buffer Zone. Buffer Zone






2. Remove the service disconnect plug in the following sequence.
1. Rotate the service disconnect plug from the lock (1) position to the unlock (2) position.
2. Remove the service disconnect plug and place in the servicing shipping (3) position.






3. NOTICE: Place the service disconnect plug into the servicing shipping position while the High Voltage Traction Battery (HVTB) is being removed and/or while the high-voltage system is having repairs carried out. If the service disconnect plug is left out and placed on the bench or toolbox, dirt or other contaminants may enter the HVTB, which can cause damage.

Insert the service disconnect plug into the servicing shipping position. This disconnects the High Voltage Traction Battery (HVTB).

4. To connect, reverse the disconnect procedure.