Drive Motor Power Inverter Module Pump Cooling Inlet Hose Replacement - Rear Electric Drive Transmission Module Coolant Extension Hose to Drive Motor Power Inverter Module Pump Cooling Inlet Hose
Special Tools

GE-52200-A Propulsion System Lift

Equivalent regional tools:Special Tools

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. Drain the drive motor battery cooling system.Drive Motor Battery Cooling System Draining and Filling
  2. Disable the high voltage system.High Voltage Disabling
  3. Raise and support the vehicle.Lifting and Jacking the Vehicle

    4. Object ID: 6120462
  4. High Voltage Battery Tray Reinforcement Nut(1)»Remove[6x]

    5. Object ID: 6120500
  5. High Voltage Battery Tray Reinforcement Bolt(1)»Remove[18x]
  6. High Voltage Battery Tray Reinforcement Bolt(2)»Remove[2x]

    7. Object ID: 6120504

    Note: The floor panel cross bar (2) is located directly above the high voltage battery tray lower rear reinforcement and is secured by two high voltage battery tray lower rear reinforcement bolts.

  7. With the aid of an assistant remove the high voltage battery tray lower rear reinforcement (1) and the floor panel cross bar (2) together.

    8. Object ID: 6463402
  8. Battery Positive and Negative Cable Bolt(1)»Remove
  9. Disconnect the wiring harness retainers as necessary.
  10. High Voltage Connector(2)»Disconnect—High Voltage Connectors

    11. Object ID: 6116951
  11. High Voltage Connector(1)»Disconnect—High Voltage Connectors

    12. Object ID: 6116954
  12. Electrical Connector(1)»Disconnect[2x]
  13. Retainer(2)»Remove

    14. Object ID: 6116958
  14. Retainer(3)»Disengage[2x]
  15. Drive Motor Power Distribution Control Module Hose(1)»Disconnect
  16. Drive Motor Power Inverter Module Pump Cooling Inlet Hose(2)»Disconnect

    17. Object ID: 6117042
  17. Retainer(3)»Disengage[2x]
  18. Drive Motor Power Distribution Control Module Hose(1)»Disconnect
  19. Drive Motor Control Module Cooling Inlet Hose(2)»Disconnect

    20. Object ID: 6093488
  20. Battery Negative Cable Ground Nut(2)»Remove[2x]
  21. Starter Generator Negative Ground Cable(1)»Remove[2x]

    22. Object ID: 6463550
  22. Position the GE-52200-A Propulsion System Lift (1) underneath the power electric carrier frame.
  23. Use wood blocks, as necessary, to make up the distance between the GE-52200-A Propulsion System Lift (1) and the power electric carrier frame.

    24. Object ID: 6117071
  24. Power Electric Carrier Frame Bolt(1)»Remove[4x]

    25. Object ID: 6117043
  25. Remove the battery charger and the power electric carrier frame (1) as an assembly.

    26. Object ID: 6120132
  26. Wiring Harness Retainer(1)»Remove
  27. Retainer(3)»Disengage
  28. Drive Motor Control Module Cooling Inlet Hose(2)»Disconnect

    29. Object ID: 6120135
  29. Drive Motor Power Distribution Control Module Bolt(1)»Remove[4x]
  30. Remove the power electric carrier frame (2) from the battery charger.

    31. Object ID: 6152340
  31. Drive Motor Power Inverter Module Cooling Inlet Hose Bracket Bolt(2)»Remove[2x]
  32. Transmission Fluid Cooler Pipe Clip(1)»Remove
  33. Drive Motor Power Inverter Module Pump Cooling Inlet Hose(3)»Remove
Installation Procedure

    Object ID: 6152340
  1. Drive Motor Power Inverter Module Pump Cooling Inlet Hose(3)»Install
  2. Transmission Fluid Cooler Pipe Clip(1)»Install

    3. Caution: Refer to Fastener Caution.

  3. Drive Motor Power Inverter Module Cooling Inlet Hose Bracket Bolt(2)»Install and tighten[2x]—Fastener Specifications

    4. Object ID: 6120135
  4. Install the battery charger to the power electric carrier frame (2).
  5. Drive Motor Power Distribution Control Module Bolt(1)»Install and tighten[4x]—Fastener Specifications

    6. Object ID: 6120132
  6. Drive Motor Control Module Cooling Inlet Hose(2)»Install
  7. Retainer(3)»Engage
  8. Wiring Harness Retainer(1)»Install

    9. Object ID: 6117043
  9. Install the battery charger and the power electric carrier frame (1) as an assembly.

    10. Object ID: 6117071
  10. Power Electric Carrier Frame Bolt(1)»Install and tighten[4x]—Fastener Specifications

    11. Object ID: 6463550
  11. Remove the GE-52200-A Propulsion System Lift (1) and wood blocks from underneath the power electric carrier frame.

    12. Object ID: 6093488
  12. Starter Generator Negative Ground Cable(1)»Install[2x]
  13. Battery Negative Cable Ground Nut(2)»Install and tighten[2x]—Fastener Specifications

    14. Object ID: 6117042
  14. Drive Motor Control Module Cooling Inlet Hose(2)»Connect
  15. Drive Motor Power Distribution Control Module Hose(1)»Connect
  16. Retainer(3)»Engage[2x]

    17. Object ID: 6116958
  17. Drive Motor Power Inverter Module Pump Cooling Inlet Hose(2)»Connect
  18. Drive Motor Power Distribution Control Module Hose(1)»Connect
  19. Retainer(3)»Engage[2x]

    20. Object ID: 6116954
  20. Retainer(2)»Install
  21. Electrical Connector(1)»Connect[2x]

    22. Object ID: 6116951
  22. High Voltage Connector(1)»Connect—High Voltage Connectors

    23. Object ID: 6463402
  23. High Voltage Connector(2)»Connect—High Voltage Connectors
  24. Connect the wiring harness retainers as necessary.
  25. Battery Positive and Negative Cable Bolt(1)»Install and tighten—Fastener Specifications

    26. Object ID: 6120504
  26. With the aid of an assistant install the floor panel cross bar (2) and the high voltage battery tray lower rear reinforcement (1) together.

    27. Object ID: 6120500
  27. High Voltage Battery Tray Reinforcement Bolt(2)»Install and tighten[2x]—Fastener Specifications
  28. High Voltage Battery Tray Reinforcement Bolt(1)»Install and tighten[18x]—Fastener Specifications

    29. Object ID: 6120462
  29. High Voltage Battery Tray Reinforcement Nut(1)»Install and tighten[6x]—Fastener Specifications
  30. Remove the support and lower the vehicle.
  31. Enable the high voltage system.High Voltage Enabling
  32. Fill the drive motor battery cooling system to the proper level. Drive Motor Battery Cooling System Draining and Filling
  33. Run all necessary programming and setup procedures. Control Module References