Battery Replacement
Removal Procedure

    Warning: Always ensure the Battery Maintenance Mode is inactive before disconnecting the low voltage 12 volt battery (or batteries). This mode can be active with the ignition off, regardless of whether the vehicle charging cord is plugged in or not. When this mode is active, the on-board high voltage battery charger(s) will energize the 12 volt battery cables and charge the 12 volt battery (or batteries). Disconnecting any battery cables while this mode is active may result in an electrical shock or a burn from hot battery cable leads.

  1. Check the 12 volt battery voltage with a digital multimeter before disconnecting any battery cable leads. If the voltage is 13.5 volts or above, the Battery Maintenance Mode is active. The technician must wait for the on-board battery charger(s) to deactivate before disconnecting any battery cables.Charging System Description and Operation
  2. Disconnect the battery negative cable.Battery Negative Cable Disconnection and Connection

    3. Object ID: 6304319
  3. Disconnect the electrical connector.(1)
  4. Remove the battery positive cable extension cable retainers (2).
  5. Remove the high voltage safety lockout electrical connector. (3)
  6. Reposition the battery positive cable extension cable clamp cover (4).
  7. Remove the battery positive cable extension cable clamp nut (5).
  8. Battery Positive Cable Extension Cable(6)»Reposition away

    9. Object ID: 5901313
  9. Disconnect the wiring harness retainers and reposition the harness as necessary.
  10. Battery Hold Down Strap Bolt(1)»Remove

    11. Object ID: 6375617
  11. Rotate the battery hold down retainer (1) upwards until the retainer can be removed at the sheet metal bracket.

    12. Object ID: 5901411
  12. Battery Hold Down Retainer Bolt(1)»Remove
  13. Battery Hold Down Retainer Bolt Retainer(2)»Remove
  14. Disconnect the battery vent tube (3) at the battery.

    15. Object ID: 5901412
  15. Battery(1)»Remove

    16. Object ID: 6304349
  16. Battery Negative Post Clamp Nut(1)»Loosen
  17. Battery Monitor Module(2)»Remove
Installation Procedure

    Object ID: 6304349
  1. Battery Monitor Module(2)»Install

    2. Caution: Refer to Fastener Caution.

  2. Battery Negative Post Clamp Nut(1)»Tighten—Fastener Specifications

    3. Object ID: 5901412
  3. Battery(1)»Install

    4. Object ID: 6372997

    Note: Some components not shown for graphic clarity.

  4. Verify the battery is properly engaged in the tray and not sitting on top of the edges (1).

    5. Object ID: 5901411
  5. Connect the battery vent tube (3) at the battery.
  6. Battery Hold Down Retainer Bolt Retainer(2)»Install
  7. Battery Hold Down Retainer Bolt(1)»Install and tighten—Fastener Specifications

    8. Object ID: 6375617
  8. Install the battery hold down retainer (1) at the sheet metal bracket and rotate the retainer downwards.

    9. Object ID: 5901313
  9. Battery Hold Down Strap Bolt(1)»Install—Fastener Specifications
  10. Position the wiring harness and connect the harness retainers.

    11. Object ID: 6304319
  11. Battery Positive Cable Extension Cable(6)»Install
  12. Install and tighten the battery positive cable extension cable clamp nut (5). Fastener Specifications
  13. Install the battery positive cable extension cable clamp cover (4).
  14. Install the high voltage safety lockout electrical connector. (3)
  15. Install the battery positive cable extension cable retainers (2).
  16. Connect the electrical connector.(1)
  17. Connect the battery negative cable.Battery Negative Cable Disconnection and Connection
  18. Learn the battery sensor module. Battery Sensor Module Learn