Danger: Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

Danger: Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Important: Use the correct procedure, depending on components being serviced, to disable the High Voltage system.

Refer to one of the following procedures below depending on components being serviced:

1. Review the high voltage safety information prior to performing the High Voltage Disabling procedure. Refer to High Voltage Safety.
2. Disable the voltage sources to the 2 mode hybrid vehicle.

2.1.	Remove the ignition key.

2.2.	Remove the rear seat frame front finish cover.

2.3.	Remove the high voltage manual disconnect lever. Attach the ignition key to the lever and put the lever and the ignition key in a secure place.

⇒	Wait 5 minutes before continuing, to allow the capacitors to discharge.

Important: The 12 V battery must be disconnected to ensure proper test results.

3. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection.
4. Remove the rear seat riser finish cover.




Important: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.

5. Remove the terminal extension cover assembly.



6. To verify that the voltage has been disabled at the drive motor generator battery assembly terminals, perform the following:

6.1.	Set the digital multimeter (DMM) to DC mode. Verify the DMM works by measuring the voltage of the 12 V battery.

6.2.	Using the DMM, verify the voltage measures less than 3 V at the following points:

6.2.1.

Across the HVDC (+) positive (3) and HVDC (-) negative (4) terminals

⇒	If the test result was greater than 3 V, the drive motor generator control module internal capacitors are still charged. Keep the insulation gloves on and install the cable cover. Wait 5 minutes and then remove the cover and return to the beginning of this step.

6.2.2.

HVDC (+) positive (3) to vehicle chassis ground

6.2.3.

HVDC (-) negative (4) to vehicle chassis ground

⇒	If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the drive motor generator battery assembly. Refer to High Voltage Contactor Relay Always Closed.

7. Using a DMM test for voltage from the High Voltage manual disconnect terminal (1) to the High Voltage DC positive and negative terminal connections (3, 4). The result should be less than 3 V.

⇒	If the test result was greater than 3 V, a high voltage positive contactor relay or the precharge relay is stuck closed. Refer to High Voltage Contactor Relay Always Closed.

8. Using a DMM test for voltage from the High Voltage manual disconnect terminal (2) to the high voltage DC positive and negative terminal connections (3, 4). The result should be less than 3 V.

⇒	If the test result was greater than 3 V, the high voltage negative contactor relay is stuck closed. Refer to High Voltage Contactor Relay Always Closed.

9. Retest the DMM by measuring the 12 V battery.

⇒	If the DMM does not properly measure the 12 V battery, repair or replace the DMM and repeat all voltage measurements.

⇒	If all the test results were less than 3 V, the 300 V DC cables can now be removed from the drive motor generator battery assembly.

1. Disable the voltage sources to the 2 mode hybrid vehicle.

1.1.	Remove the ignition key.

1.2.	Remove the rear seat frame front finish cover.

1.3.	Remove the high voltage manual disconnect lever. Attach the ignition key to the lever and put the lever and the ignition key in a secure place.

⇒	Wait 5 minutes before continuing, to allow the capacitors to discharge.

Important: The 12 V battery must be disconnected to ensure proper test results.

2. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the drive motor generator control module sight shield. Refer to Drive Motor Generator Control Module Sight Shield Replacement.




Important: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.

4. Remove the 3 phase cable cover.



5. To verify that no voltage is present at the high voltage connection for the drive motor generator control module, perform the following:

5.1.	Set the digital multimeter (DMM) to DC mode. Verify the DMM works by measuring the voltage of the 12 V battery.

5.2.	Using the DMM, verify the voltage measures less than 3 V at the following points:

5.2.1.

Across the HVDC (+) positive (1) and HVDC (-) negative (2) terminals

⇒	If the test result was greater than 3 V, the drive motor generator control module internal capacitors are still charged. Keep the insulation gloves on and install the 3 phase cable cover. Wait 5 minutes and then remove the 3 phase cable cover and return to the beginning of this step.

5.2.2.

HVDC (+) positive (1) to vehicle chassis ground

5.2.3.

HVDC (-) negative (2) to vehicle chassis ground

⇒	If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the drive motor generator battery assembly. Refer to High Voltage Contactor Relay Always Closed.

6. Retest the DMM by measuring the 12 V battery.

⇒	If the DMM does not properly measure the 12 V battery, repair or replace the DMM and repeat all voltage measurements.

⇒	If all the test results were less than 3 V, the cables can now be removed from the drive motor generator control module assembly.