FixVault
Home › Chevrolet › 2016 › Spark EV › Repair and Diagnosis › Hybrid/Electric Powertrain › Battery Management Systems › Hybrid/EV Energy Storage System › Repair Instructions › Auxiliary Battery Wiring Harness Replacement (Battery Cell Connectors, Battery Energy Control Module, Battery Interface Control Module) › Removal Procedure

Removal Procedure

    WARNING:

    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.

  1. Remove the drive motor battery. Refer to Drive Motor Battery Replacement and Shipping Preparation .
  2. Remove the drive motor battery cover. Refer to Drive Motor Battery Cover Replacement .
  3. Remove the cell battery cooling manifold outlet hose. Refer to High Voltage Battery Cooling Manifold Outlet Hose Replacement (Coolant to all Battery Cells)High Voltage Battery Cooling Manifold Outlet Hose Replacement (Individual Battery Cell Coolant Outlet Hose) .
  4. Remove the cell battery cooling manifold inlet hose. Refer to High Voltage Battery Cooling Manifold Inlet Hose Replacement (Coolant to all Battery Cells)High Voltage Battery Cooling Manifold Inlet Hose Replacement (Individual Battery Cell Coolant Inlet Hose) .
    5. Fig 1: Battery Energy Control Module Connectors (With Disconnect Sequence)
    GM4072888Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Damage to the battery energy control module may occur if connector removal sequence to the module is not followed. Battery energy control module connector installation sequence is reverse of the removal sequence and must be performed after all sections have been reconnected.

  5. Disconnect the battery energy control module connectors in the sequence shown.
    6. Fig 2: Battery Energy Control Module Connectors (With Disconnect Sequence)
    GM4072891Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Damage to the battery energy control module may occur if connector sequence to the module is not followed.

  6. Disconnect the battery energy control module connectors in the sequence shown.
    7. Fig 3: Retaining Tabs And Thin Film Harness
    GM3715436Courtesy of GENERAL MOTORS COMPANY
  7. Depress the retaining tabs (1) and reposition the connector being careful not to tear the thin film harness (2).
    8. Fig 4: Auxiliary Battery Wiring Harness Connector, Battery Cell 1 Connector And Thin Film Harness
    GM3715437Courtesy of GENERAL MOTORS COMPANY
  8. Disconnect the auxiliary battery wiring harness connector (1) from the battery cell connectors (2) being careful not to tear the thin film harness (3).
    9. Fig 5: Battery Cell Connectors
    GM3946932Courtesy of GENERAL MOTORS COMPANY
  9. Disconnect the battery cell connectors (1) from all the remaining battery cells.
    10. Fig 6: Battery Energy Control Module And Connectors
    GM3946933Courtesy of GENERAL MOTORS COMPANY
  10. Remove the connectors (1) from the battery energy control module (2). Refer to Battery Energy Control Module Replacement .
  11. Detach the harness retainers attached to the module bracket.
    12. Fig 7: Battery Interface Control Module, Retainers And Connectors
    GM3946934Courtesy of GENERAL MOTORS COMPANY
  12. Remove the connectors (1) to the battery interface control module (3). Refer to High Voltage Battery Interface Control Module Replacement .
  13. Detach the harness retainers (2) attached to the battery interface control module bracket.
    14. Fig 8: Auxiliary Battery Wiring Harness, Retainers And Foam Harness Retainers
    GM3946935Courtesy of GENERAL MOTORS COMPANY
  14. Detach the auxiliary battery wiring harness retainers (1) and remove the auxiliary battery wiring harness (3) from the foam harness retainers (2).
About FixVault