Generator Battery Positive and Negative Cable Replacement

Danger: 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.

Removal Procedure
  1. Disable the high voltage system.High Voltage Disabling

    2. 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.

  2. 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
  3. Disconnect the battery negative cable.Battery Negative Cable Disconnection and Connection

    4. Object ID: 5913287
  4. Hybrid/Electric Vehicle Battery Pack(1)»Remove—Hybrid/Electric Vehicle Battery Pack Removal and Installation

    5. Object ID: 5901652
  5. Front Compartment Fuse Block Cover(1)»Remove

    6. Object ID: 5901653
  6. Remove the generator battery positive and negative cable retainer (1).
  7. Battery Positive Cable Junction Block Lead Nut(2)»Remove
  8. Generator Battery Positive and Negative Cable(3)»Remove

    9. Object ID: 5898403
  9. Disconnect the electrical connectors.(1)

    10. Object ID: 5898404
  10. Hybrid Powertrain Control Module 2 Nut(1)»Remove[4x]
  11. Battery Energy Control Module 2(2)»Remove

    12. Object ID: 5901138
  12. Multiuse Relay and Fuse Cover(1)»Remove

    13. Object ID: 5901662
  13. Battery Positive Cable Junction Block Lead Nut(1)»Remove[2x]
  14. Remove the 2 generator battery positive and negative cables (2).
  15. Remove the generator battery positive and negative cable retainers (3).
  16. Release the wiring harness grommet (4).

    17. Object ID: 5837768

    Note: Left side shown, right side similar.

  17. Front Wheelhouse Liner- Right Side(3)»Remove—Front Wheelhouse Front Liner Replacement

    18. Object ID: 5901664
  18. Remove the generator battery positive and negative cable retainers (1).

    19. Object ID: 5901665
  19. Remove the generator battery positive and negative cable retainers (1).

    20. Object ID: 5901666
  20. Remove the generator battery positive and negative cable retainers (1).
  21. With the aid of an assistant, maneuver the wiring harness grommet (2) through the sheet metal and into the front wheelhouse area.

    22. Object ID: 5901667
  22. Remove the generator battery positive and negative cable retainers (1).

    23. Object ID: 5901668
  23. Remove the generator battery positive and negative cable retainers (1).

    24. Object ID: 5901669
  24. Remove the generator battery positive and negative cable retainers (1).
  25. Disconnect the electrical connector.(2)

    26. Object ID: 5901670
  26. Battery Cable Clip Bolt(2)»Remove[4x]

    27. Object ID: 5901671
  27. Battery Cable Clip Bolt(2)»Remove[4x]

    28. Object ID: 5901672
  28. Generator Battery Positive and Negative Cable(1)»Remove
Installation Procedure

    Object ID: 5901672
  1. Generator Battery Positive and Negative Cable (1)»Install

    2. Object ID: 5901671

    Caution: Refer to Fastener Caution.

  2. Battery Cable Clip Bolt(2)»[4x]Install and tighten—Fastener Specifications

    3. Object ID: 5901670
  3. Battery Cable Clip Bolt(2)»Install and tighten[4x]—Fastener Specifications

    4. Object ID: 5901669
  4. Connect the electrical connector.(2)
  5. Install the generator battery positive and negative cable retainers (1).

    6. Object ID: 5901668
  6. Install the generator battery positive and negative cable retainers (1).

    7. Object ID: 5901667
  7. Install the generator battery positive and negative cable retainers (1).

    8. Object ID: 5901666
  8. With the aid of an assistant, maneuver the wiring harness grommet (2) through the sheet metal and into the battery area.
  9. Install the generator battery positive and negative cable retainers (1).

    10. Object ID: 5901665
  10. Install the generator battery positive and negative cable retainers (1).

    11. Object ID: 5901664
  11. Install the generator battery positive and negative cable retainers (1).

    12. Object ID: 5837768

    Note: Left side shown, right side similar.

  12. Front Wheelhouse Liner- Right Side(3)»Install—Front Wheelhouse Front Liner Replacement

    13. Object ID: 5901662
  13. Install the wiring harness grommet (4).
  14. Install the generator battery positive and negative cable retainers (3).
  15. Install the 2 generator battery positive and negative cables (2).
  16. Battery Positive Cable Junction Block Lead Nut(1)»Install and tighten[2x]—Fastener Specifications

    17. Object ID: 5901138
  17. Multiuse Relay and Fuse Cover(1)»Install

    18. Object ID: 5898404
  18. Battery Energy Control Module 2(2)»Install
  19. Hybrid Powertrain Control Module 2 Nut(1)»Install and tighten[4x]—Fastener Specifications

    20. Object ID: 5898403
  20. Electrical Connector(1)»Connect[2x]

    21. Object ID: 5901653
  21. Generator Battery Positive and Negative Cable(3)»Install
  22. Battery Positive Cable Junction Block Lead Nut(2)»Install and tighten—Fastener Specifications
  23. Install the generator battery positive and negative cable retainer (1).

    24. Object ID: 5901652
  24. Front Compartment Fuse Block Cover(1)»Install

    25. Object ID: 5840625
  25. Front Bumper Fascia(1)»Install—Front Bumper Fascia Removal and Installation
  26. Enable the high voltage system.High Voltage Enabling

    27. Object ID: 5913287
  27. Hybrid/Electric Vehicle Battery Pack(1)»Install—Hybrid/Electric Vehicle Battery Pack Removal and Installation
  28. Connect the battery negative cable.Battery Negative Cable Disconnection and Connection