36-Volt Battery Positive Cable Replacement

36-Volt Battery Positive Cable Replacement

Removal Procedure




1. Disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).
2. Remove the battery. Refer to Battery Replacement (HP7) (Service and Repair)
3. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
4. Remove the carbon canister. Refer to Evaporative Emission Canister Replacement (Service and Repair).

Warning

To help avoid personal injury, additional precautions must be taken prior to working on the generator control module or the generator starter. After removing the 36V battery cables from the generator battery, remove both engine wiring harness connectors from the generator control module. Wait at least 5 minutes and then remove the generator control module cover. Verify voltage levels at all 36V, 12V, and 3-phase connections, are less than 3 volts using a DMM before proceeding.

5. Remove and discard the 36-volt positive battery cable lead nut (1).
6. Remove the wiring harness ground nut (2).
7. Reposition the 36-volt positive battery cable leads (3) out of the way.




8. Remove the generator control module cover bolts (1) and cover (2).





Warning

To help avoid personal injury, additional precautions must be taken prior to working on the generator control module or the generator starter. After removing the 36V battery cables from the generator battery, remove both engine wiring harness connectors from the generator control module. Wait at least 5 minutes and then remove the generator control module cover. Verify voltage levels at all 36V, 12V, and 3-phase connections, are less than 3 volts using a DMM before proceeding.

9. Check the generator control module for voltage potential, in order to ensure the module has been disabled.

1. Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts.
2. Measure from the 12-volt positive terminal (4) to a known good chassis ground. The voltage should be less than 3 volts.
3. Measure from the ground terminal (2) to a known good chassis ground, checking for continuity.

Warning

To help avoid personal injury, always treat the 3-phase cable and connectors as if voltage is present and as if the surface of all parts of the cable is hot.

10. Verify the generator control module 3-phase cables are disabled.

1. Measure from each phase 1, 2 and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts.
2. After verifying there is no voltage present, the generator control module 3-phase cables can now be removed from the generator control module.
3. If 3 volts or more are present, repeat the disconnect procedure. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).




11. Remove the 36-volt battery positive cable nut (1) and bolt (2).
12. Remove the 36-volt battery positive cable (3).




13. Disconnect the plastic retainer clip (1).
14. Remove the 36 volt battery positive cable nut (2).
15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
16. Remove the 36 volt battery positive cable nut (3).




17. Remove the 36-volt battery positive bolts (1).




18. Remove the 36-volt battery positive bolts (1) and nuts (2).
19. Squeeze the rubber grommet (3) from the top of the vehicle and push the 36-volt battery positive cable out.

Installation Procedure





Caution: Refer to Fastener Caution (Fastener Caution).

1. Install the 36-volt positive battery cable grommet (3), bolts (1) and nuts (2) and tighten the nuts/bolts to 10 Nm (89 lb in).




2. Install the 36-volt battery positive bolts (1) and tighten to 10 Nm (89 lb in).




3. Install the 36-volt battery positive nut (3) from underneath the vehicle.
4. Install the 36-volt battery positive nut (2).
5. Connect the plastic retainer clip (1).
Tighten the nuts to 10 Nm (89 lb in).




6. Install the 36-volt battery positive cable (3).
7. Install the 36-volt battery positive nut (1) and bolt (2) and tighten the nuts/bolts to 10 Nm (89 lb in).




8. Install the generator control module cover bolts (1) and cover (2) and tighten the bolts to 10 Nm (89 lb in).




9. Install the 36-volt battery positive cable leads (3).
10. Install the wiring harness ground nut (2) and tighten to 10 Nm (89 lb in).
11. Install a new 36-volt battery positive cable lead nut (1) and tighten to 10 Nm (89 lb in).
12. Install the carbon canister. Refer to Evaporative Emission Canister Replacement (Service and Repair).
13. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
14. Install the battery. Refer to Battery Replacement (HP7) (Service and Repair).
15. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).