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.
Removal Procedure
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 includes the following steps:
- 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 may result in serious injury or death.
- Disable the high voltage system. High Voltage Disabling
- Drain the drive motor generator power inverter module cooling system. Drive Motor Generator Power Inverter Module Cooling System Draining and Filling
- Battery Tray - Remove - Battery Tray Replacement
- Radiator Surge Tank - Remove - Radiator Surge Tank Replacement
- Accessory DC Power Control Module - Remove - Accessory DC Power Control Module Replacement
{ If Equipped } Using a flat bladed screwdriver (1), pry the edge of the connector handle lock (2) from the holding tab.
- { If Equipped } Release the connector handle lock by rotating the connector handle forward.
- { If Equipped } With the connector handle in the release position, disconnect the high voltage charger connector from the high power distribution module.
Disconnect the high voltage connectors in the following sequence:
- Release the CPA. Push down on the connector tab, and release the connector.
Low Voltage Electrical Connector (1) @ High Voltage Battery Control Wiring Junction Block - Disconnect
- After releasing the 2-stage safety connectors, remove the A/C control module electrical connector (5) and the drive motor battery charger & auxiliary power module connector (4) @ High Voltage Battery Control Wiring Junction Block
- Remove the RESS heater electrical connector (3) and the drive motor battery charger & auxiliary power module to RESS electrical connector (2) @ High Voltage Battery Control Wiring Junction Block
Engine Wiring Harness Bracket Bolt (1) - Remove
- Engine Wiring Harness Bracket (2) - Remove
Drive Motor Battery Charger Electrical Connector (1) (3) - Disconnect
- Signal & AC Electrical Connector (2) - Disconnect
Drive Motor Power Inverter Module Cooling Inlet Hose (2) - Release Clamp (1) and Remove the Hose
- Electric Differential Drive Motor Power Inverter Module Cooling Hose (3) - Release Clamp (1) and Remove the Hose
Drive Motor Battery Charger Bolt (1, 2) - Remove [ 3x ]
- Drive Motor Battery Charger Nut (3) - Remove
Drive Motor Battery Charger (1) - Remove
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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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.