Procedures

Hybrid Battery Service Disconnect/Connect

Disconnect Procedure




1. Remove the ignition key from the ignition switch. Secure the ignition key in order to ensure that the key CANNOT be re-installed without your knowledge.
2. Disconnect the 12 volt negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Tilt the rear seats forward by releasing the latches on the inside of the rear seat riser.

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.

4. Remove the generator battery disconnect control module cover nut (2).
5. Slide the generator battery disconnect control module cover (1) to the right and remove the cover.
6. WAIT at least 5 minutes in order to allow the generator control module capacitors to discharge.

Warning

To help avoid personal injury, always ensure the ignition switch is in the OFF position and the ignition key has been removed prior to working on any 36V components. After the key has been removed, disconnect the negative 12V battery cable and then open the generator battery disconnect control module cover. After waiting for at least 5 minutes, measure the voltage potential using a DMM between the following:

1. 36V positive and negative battery cables
2. 36V positive battery cable and vehicle ground
3. 36V negative battery cable and vehicle ground

All measured voltage levels must be below 3 volts.

7. If 3 volts or more is present, repeat the disconnect procedure.





Note: Never assume the battery pack is disabled when the generator battery disconnect control module cover is opened.

8. Check the generator battery for voltage potential in order to ensure that the generator battery has been disabled.

1. Measure from the positive (3) stud to the negative stud (2). The voltage should be less than 3 volts.
2. Measure from the positive (3) stud to vehicle chassis ground (1). The voltage should be less than 3 volts.
3. Measure from the negative (2) stud to vehicle chassis ground (1). The voltage should be less than 3 volts.

• If the voltage is not less than 3 volts, remove the generator control module cover to discharge the generator control module capacitors. Removal of both covers is only necessary when the capacitors are not being discharged due to one of the discharge resistors may be open.


Connect Procedure




1. Install and close the generator battery disconnect control module cover (1) and nut (2).

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the generator battery cover bolt. Tighten the bolt to 10 Nm (89 lb in).
3. Connect the 12 volt negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).