Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2009TAHOE BASE, 4.8 CREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 107 (HYBRID ENERGY STORAGE SYSTEM)REPAIR INSTRUCTIONSDRIVE MOTOR BATTERY CABLE TERMINAL EXTENSION REPLACEMENT
2009 Chevrolet Tahoe Base, 4.8 C
Drive Motor Battery Cable Terminal Extension Replacement
2009 Chevrolet Tahoe Base, 4.8 CSECTION Drive Motor Battery Cable Terminal Extension Replacement
WARNING: This page is about a different car, the 2008 GMC Yukon and 2008 Chevrolet Tahoe. However, it is still accessible from the selected car via links, so may be relevant.
| Callout | Component Name |
|---|---|
|
WARNING:
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:
Failure to follow the procedures exactly as written may result in serious injury or death. Preliminary Procedures:
|
|
| 1 | Drive Motor Battery Positive, Negative, and Ground Shield Cable Terminal Fastener Nut (Qty: 3)
NOTE:
Refer to Fastener Notice
.
Tighten: 9 N.m (80 lb in) |
| 2 | Drive Motor Battery 300 Volt Positive and Negative Cable
CAUTION:
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® Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement. Tip: Remove the drive motor generator battery retaining nuts and bolt, raise and support the drive motor generator battery assembly on the right side approximately 76 mm (3 in). Special Tools: EL-48569 Terminal Covers. See Special Tools . |
| 3 | Drive Motor Battery Cover Side Bolt (Qty: 2) Tighten: 6 N.m (53 lb in) |
| 4 | Battery Cable Terminal Retainer |
| 5 | Drive Motor Battery High Voltage Manual Disconnect Knob Housing |
| 6 | Drive Motor Battery Positive and Negative (300V) Cable Bolt (Qty: 2) Tighten: 6 N.m (53 lb in) |
| 7 | Drive Motor Battery Positive and Negative (w/Wiring Harness) Cable Assembly
CAUTION:
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® Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement. Special Tools: EL-48569 Terminal Covers. See Special Tools . |
| 8 | HVIC Inline Connector |
| 9 | Drive Motor Battery Cable Terminal Extension Bolt Tighten: 6 N.m (53 lb in) |
| 10 | Drive Motor Battery Cable Terminal Block Nut (Qty: 2) Tighten: 6 N.m (53 lb in) |
| 11 | Drive Motor Battery Cable Terminal Extension Procedure:: After the extension has been replaced and the re-assembly of the drive motor generator battery, enable the HV system. Refer to High Voltage Enabling . |
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.