Drive Motor Battery Disconnect Control Module Replacement

Drive Motor Battery Disconnect Control Module Replacement

Special Tool

EL-48569 - Terminal Covers

Removal Procedure




1. Review the high voltage safety information prior to performing the High Voltage Disabling. Refer to High Voltage Safety (High Voltage Safety).
2. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling (High Voltage Disabling).
3. Remove the drive motor generator control module. Refer to Drive Motor Generator Battery Control Module Replacement (Drive Motor Generator Battery Control Module and Bracket Replacement).
4. Remove the drive motor battery coolant cooler cover. Refer to Drive Motor Battery Coolant Cooler Cover Replacement (Drive Motor Battery Coolant Cooler Cover Replacement).
5. Remove the battery center cover fasteners (1) and the center cover (2).





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(R) Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement.

6. Remove the plastic terminal covers (1).




7. Remove the terminal fasteners (1).




8. One at a time, reposition the battery terminal cables (1) and using the EL-48569 - covers , cover the terminals.




9. Remove the module fasteners (1).
10. Disconnect the electrical connectors (2).
11. Remove the drive motor battery disconnect control module (3).

Installation Procedure




1. Install the drive motor battery disconnect control module (3).
2. Connect the electrical connectors (2).

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the module fasteners (1) and tighten to 9 Nm (80 lb in).




4. Remove the EL-48569 - covers from the terminals (1).




5. Remove the EL-48569 - covers, one at a time , from the 300 Volt positive and negative terminals.
6. One at a time, reposition the cable terminals and install the terminal fasteners (1) and tighten to 9 Nm (80 lb in).




7. Install the plastic terminal covers (1).




8. Install the battery center cover fasteners (1) and the center cover (2).
9. Install the drive motor generator control module. Refer to Drive Motor Generator Battery Control Module Replacement (Drive Motor Generator Battery Control Module and Bracket Replacement).
10. Enable the high voltage system. Refer to High Voltage Enabling (High Voltage Enabling).
11. If replacing, reprogram the module. Refer to Control Module References (Programming and Relearning).