36-Volt Battery Positive Cable Replacement (Passenger Compartment to Module)

36-Volt Battery Positive Cable Replacement (Passenger Compartment to Module)

Removal Procedure

Warning

To help avoid personal injury, be careful when working in the vicinity of the generator battery disconnect control module. Internal components will still be live, 36V potential, even when the cover has been opened or removed.




1. Disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).
2. Remove and discard the 36-volt positive battery cable lead nut (3).
3. Remove the 36-volt positive battery cable lead nut (1).
4. Remove the 36-volt positive battery cable leads (2).




5. Remove the 36-volt positive battery cable retainer bolt (1).
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




7. Remove the 36-volt positive battery cable clip nut (4).
8. Remove the 36-volt positive battery cable casting nuts (3).
9. Carefully lower the 36-volt positive battery cable casting (2) until the cable connector and 36-volt positive battery cable pigtail connector (1) is accessible.




10. Disconnect the 36-volt positive battery cable pigtail connector (1) from the 36-volt positive battery cable casting (3) by rotating the connector ring (2) on the pigtail counterclockwise.
11. Lower the vehicle




12. Remove the 36-volt positive battery cable pigtail connector (1).

Installation Procedure




1. Install the 36-volt positive battery cable pigtail connector (1).
2. Raise and suitably support the vehicle.




3. Align the 36-volt positive battery cable pigtail connection keyway (2) with the paint dot (1) on the 36-volt positive battery cable casting. Once aligned, rotate the pigtail lock ring (3) securing the connection.




4. Carefully feed the 36-volt positive battery cable pigtail into the rear compartment panel until the 36-volt positive battery cable casting (2) is seated onto the studs.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the 36-volt positive battery cable casting nuts (3). Tighten the nuts to 9 Nm (80 lb in).
6. Install the 36-volt positive battery cable clip nut (4). Tighten the nuts to 9 Nm (80 lb in).
7. Lower the vehicle.




8. Position the 36-volt positive battery cable retainer (2) to the fan cover.
9. Install the 36-volt positive battery cable retainer bolt (1). Tighten the bolt to 8 Nm (71 lb in).




10. Install the 36-volt positive battery cable leads (2).
11. Install the 36-volt positive battery cable lead nut (1). Tighten the nut to 9 Nm (18 lb in).
12. Install a NEW 36-volt positive battery cable lead nut (3). Start the nut finger tight, and then torque to the specification given. Tighten the nut to 15 Nm (11 lb ft).
13. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).