vehicle must verify that the system remains powered down during high
voltage repairs.
• This is done by removing the test points access cover.
• The high voltage power down procedure must be performed to
ensure that the high voltage battery is properly powered down.
• The technician must know the whereabouts of the test points access
cover throughout the repair.
• The technician must ensure that the test points access cover is not
reinstalled while service is being performed.
• The technician must recheck that the test points access cover has not
been reinstalled in cases where the vehicle was unattended.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 16

Service Procedure [Continued]
3. Prepare the work area and familiarize yourself with all HIGH-VOLTAGE
SAFETY PROCEDURES related to personal safety and vehicle safety
associated with working on a Plug-In Hybrid Electric Vehicle (PHEV). See
High Voltage Safety Procedures in Service Library section 08, Standard
Procedures.
4. Inspect all orange high-voltage cables, and high-voltage components labeled
with the high-voltage symbol for physical damage. If damage is present, extra
caution must be taken to avoid contact with unprotected high-voltage. Do not
insert probes, tools, objects or fluids into damaged high-voltage cables or
components.
5. Disconnect any charging equipment. Do not plug in the EVSE Recharge
Coupler when working on the vehicle.
6. Turn the ignition to Off by pressing
the keyless go button (1) and move
keys away from the car a minimum
of 20 feet (Figure 1).

Figure 1 – Keyless Go Button

NOTE: If the READY indicator is NOT illuminated in instrument cluster,
the vehicle is already shut off. DO NOT push the start/stop button as the
vehicle may start.
7. Wait five minutes to allow the high-voltage system to shut down without
setting a fault code.
8. Disconnect the IBS wire harness connector. Remove and isolate the negative
battery cable using Covers, HEV Battery Terminal 2035100082.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 17

Service Procedure [Continued]
9. Remove the F09 (5 amp) fuse from the Power Distribution Center (PDC).
NOTE: This removes the fused B+ power supply to the IDCM. Disabling
the IDCM disables the DC/DC conversion between the HV battery and the
charging output to the low voltage side of the system.
10. Verify the multi-meter is operating correctly by measuring voltage from a
known good power source, such as the vehicle’s 12-volt battery. If at any point
during the procedure, the multi-meter settings are changed, or the probes are
repositioned in the meter, verification with a known good power source must be
repeated.
11. Using a multi-meter, check for voltage at the PDC fused B+ terminal to verify
the low voltage system is powered down. The 12 volt electrical system is now
powered down. There should be no voltage present with the IDCM disabled and
the 12 volt battery disconnected.
12. The high voltage service test points
access cover is located on the battery
pack, under driver side rear seat
cushion (Figure 2).
13. Remove the M6 Torx screws from
the high voltage service test points
access cover (Figure 2).
14. Carefully remove the test points
access cover and set in a protected
location such that the cover plate
alignment and HVIL pins are not
damaged (Figure 2).

Figure 2 – High Voltage Test Point
Access Cover

NOTE: Lift the cover straight up to avoid bending or damaging the pin on
the cover that is used to engage the HVIL switch.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 18

Service Procedure [Continued]
15. Removal of the test points access cover will affect the following:
• Disables the High Voltage Battery System by disengaging the internal High
Voltage Interlock (HVIL) pin from the switch.
• Provides access to the high voltage positive and high voltage negative test
points.
NOTE: These circuits are a sense circuit connected through large resistors
inside the high voltage battery to the high voltage bus cables after the
contactors. These circuits are safe even when high voltage is present on the
circuits due to the large resistors reducing these circuits to milliamperes.
• Provides access to the fuse cover screw.
• Allows access to a service lockout loop.
16. Install a lockout-tagout padlock to
the service lockout loop (5) to
prevent test points access cover
installation and re-engaging HVIL
pin (Figure 3).

Figure 3 – Service Lockout Loop
1 - Fuse Cover Screw
2 - Switch
3 - High Voltage (+) Test Port
4 - High Voltage (-) Test Port
5 - Service Lockout Loop

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 19

Service Procedure [Continued]
17. Use of an insulation tester such as
the Fluke Meter, Multi 126-1587 is
recommended for PHEV circuit
testing. Perform the multi-meter
functionality tests per the
manufactures directions. Verify the
multi-meter is operating correctly by
measuring voltage from a known
good power source, such as the
vehicle’s 12-volt battery. If at any
point during the procedure, the
multi-meter settings are changed, or
the probes are repositioned in the
meter, verification with a known
good power source must be repeated
(Figure 4).

Figure 4 – Fluke Meter, Multi 126-1587

NOTE: Always observe these precautions prior to taking a high-voltage
measurement:
• Be sure to utilize the proper Personal Protection Equipment (PPE)
when working on any high voltage system.
• Rated and non-expired rubber insulating gloves with leather
protectors.
• Have known good test leads.
• Verify the multi-meter leads are rated “CAT III 1,000V”. This
should be printed on the multi-meter leads.
• Install the multi-meter leads in the BLACK and RED sockets on the
right side of the Fluke 1587 (VΩ (RED) and COM (BLACK)).
• Switch the FLUKE 1587 to the DC Volts selection and press the
RANGE button until the 500V range is selected - just one digit (a
zero) is displayed.
• Test the multi-meter operation by measuring the voltage across the
12 volt Battery.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 20

Service Procedure [Continued]
18. Using the Fluke multi-meter, measure
the voltage at the high voltage positive
and high voltage negative test points
(Figure 5):
• Measure for voltage between the
positive and negative high voltage
test points.
• Measure for voltage between positive
test point and chassis ground.
• Measure for voltage between
negative test point and chassis
ground.
Figure 5 – Measuring at High Voltage
Test Points

19. The voltage reading should be 0 volts. (Some residual voltage may be present,
up to 2.0 volts may be normal) (Figure 5).
• If the voltage measured is below 2 volts, it is safe to work on the high-voltage
components with the exception of the high-voltage battery internal
components.
• If the voltage is greater than 60 volts, an internal condition exists within the
high voltage battery such as stuck contactors, that are preventing it from being
powered down. This should be accompanied by contactor stuck DTCs. Do not
attempt to carry out testing on any of the vehicle’s high-voltage components
or wiring. The HV Battery Pack requires replacement. Reference the HV
BATTERY SERVICING WITH WELDED CONTACTOR(S) procedure at
the top of the HV PHEV BATTERY REMOVAL AND INSTALLATION
procedure for safely removing a high voltage battery that will not power down
(Refer to 08 - Electrical/Battery System/BATTERY/Removal and
Installation).

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 21

Service Procedure [Continued]
• If the voltage is between 2.0 volts and 60 volts, the HV system is safe to work
on, however there is a problem that should be diagnosed. Disconnect each of
the following HV modules one at a time and check the voltage at the test
points. If the voltage drops to 2.0 volts or less, the faulted module has been
found. Reconnect each module before continuing to the next.
o Integrated Dual Charger Module (IDCM)
o Electronic A/C Compressor (EAC)
o Battery Coolant Heater
o HV Coolant Heater
o Power Inverter Module (PIM)
20. After confirming that the high voltage battery is powered down and locked out
it is safe to power up the 12-volt system if needed to perform diagnostics or
repairs.

B. HV Battery Removal
21. Loosen the cap on the high voltage cooling reservoir.
22. Raise and support the vehicle.
23. Position a drain pan under the
coolant hoses (Figure 6).
24. Remove the coolant hoses from the
coolant line and drain the power
electronics cooling system
(Figure 6).
25. Once the system is completely
drained, reinstall the coolant hose to
the coolant line (Figure 6).

COOLANT HOSES

Figure 6 – Coolant Hoses

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 22

Service Procedure [Continued]
26. Remove the fasteners (1) and the
skid plate (2) from the vehicle
(Figure 7).

Figure 7 – Skid Plate

27. Disconnect the HV wire harness
connectors (1) and (2) from the HV
battery (Figure 8).
28. Cap the HV cables using Covers,
HEV Battery Terminal 2035100082.
NOTE: A Plug-in Hybrid Electric
Vehicle (PHEV) HV Battery
Cover/Plug Kit is also available
from Mopar® Parts.
29. Remove the support and lower the
vehicle.

Figure 8 – HV Battery Wiring
Connectors

30. Using a trim stick, release and
remove the B-pillar trim cover (1)
(Figure 9).

Figure 9 – B-pillar Trim Cover

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 23

Service Procedure [Continued]
31. Disconnect the wire harness
connector (2) and release the door
tether from the support bracket (1)
(Figure 10).

Figure 10 – Harness to Support
Bracket

32. Remove the bolt (2) securing the
door check (1) (Figure 11).

Figure 11 – Door Check Bolt

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 24

Service Procedure [Continued]
33. Remove the nuts (3) and lift the door
up off hinges (1) and remove
(Figure 12).

34. Raise the rear seat cushion.

Figure 12 – Hinge Pin Nuts

35. Remove the fasteners (1) from the
side high voltage battery trim panels
(2) (Figure 13).
36. Using a trim stick or equivalent,
remove the high voltage trim panel
upward to release the retainers and
remove the trim panel. Repeat for
the passenger side.
37. Lower the rear seat cushion.
Figure 13 – HV Battery Side Trim

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 25

Service Procedure [Continued]
38. Using a trim stick or equivalent,
release the retainers from the front
high voltage battery closeout and
remove from vehicle (Figure 14).

Figure 14 – HV Battery Front Trim

39. Remove the rear seat to load floor gap
hider (Figure 15).

Figure 15 – Gap Hider

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 26

Service Procedure [Continued]
40. Disconnect the wire harness
connectors, if equipped (4)
(Figure 16).
41. Remove the nut for the center seat
belt anchor (6). Remove the seat
belts from the floor stud (Figure 16).
42. Remove the rear seat fasteners (2) at
the rear of the seat (Figure 16).
Figure 16 – Rear Seat Components
1 - Rear Seat

4 - Wire Harness
Connector

2 - Rear Seat Nuts

5 - Seat Belts

3 - Wire Harness
Connector

6 - Center Seat Belt
Anchor nut

43. Disconnect the wire harness
connectors (3), if equipped
(Figure 17).
44. Remove the bolts (1) at the front of
the rear seat. Discard the old bolts.
(Figure 17).

Figure 17 – Rear Seat Components
1 - Rear Seat Bolts
2 - Wire Harness Connectors
3 - Rear Seat

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 27

Service Procedure [Continued]
45. Remove silencer pad (Figure 18).
46. Remove the seat from the vehicle.

SILENCER PAD

Figure 18 – Silencer Pad

47. Remove the fastener (1) and the
chassis ground cable from the HV
battery (2) (Figure 19).

Figure 19 – HV Battery Fastener and
Ground Cable

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 28

Service Procedure [Continued]
48. Disconnect the HV wire harness
connectors (1) (Figure 20).

Figure 20 – HV Wire Harness
Connectors

NOTE: Use an absorbent pad to collect any coolant that may leak from the
battery into the interior of the vehicle.

49. Disconnect and plug the HV battery
coolant line connectors (1)
(Figure 21).

Figure 21 – HV Battery Coolant
Connectors

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 29

Service Procedure [Continued]
NOTE: The HV battery pack weighs 167 kg (368 lb.).
50. Remove the bolts (1) securing
the HV battery to the vehicle
(Figure 22).

Figure 22 – HV Battery Bolts

51. Install two Eyebolt, 10mm
2035203080 with the nuts to the
front support mounting holes (1)
(Figure 23).

Figure 23 – Support Mounting Holes

52. Thread the other two Eyebolt,
10mm 2035203080 (1) into the
threaded holes next to the HV
battery pack mounting bolt holes
(2) on the rear side of the HV
battery pack (Figure 24).

Figure 24 – Eyebolt Installation

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 30

Service Procedure [Continued]
53. Connect the Lift Straps, HV
Battery 2035200080 to the
eyebolts and the lifting device.
Adjust the straps so that the
battery will be level during
lifting as shown in the picture
(Figure 25).
54. Remove the HV battery pack
from the vehicle.

Figure 25 – Lift Straps

NOTE: When the HV battery pack is being replaced:
• Refer to the information supplied with the NEW battery. I-sheets for
the HV batteries, how to open the containers and handle the
batteries, can be found on DealerCONNECT on the PARTS tab
under RETURNS.
• All coolant must be removed from the battery. Use a shop air supply
hose connected to the battery coolant inlet port. Adjust the air
pressure regulator to not exceed 100 kPa (15 psi) and force the
coolant from the battery coolant outlet port.
• All coolant ports and electrical connections must be capped.
• Place the HV battery pack in the shipping container or on the
containers lid attached foam pads to prevent damage to the
underside of the battery.
• The battery terminals shall be covered with protection caps while
handling to avoid short circuits and other electrical hazards and to
protect the terminals from dust, dirt and moisture.
• Operate this Li-Ion cell based high voltage battery system only if you
are fully acquainted with all the controls/connections and the safety
procedures/instructions.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 31

Service Procedure [Continued]
• Keep the battery system always in position equivalent to the
mounting position in the car (note: slight tilting of the HVBS while
moving by a fork-lift trolley is OK).
• Never place the HVBS on any surface, such as a table or the ground,
other than the supplied crate/dunnage, or the designed vehicle
position.
• Do not store the battery system together with metal or other heavy
objects which can fall onto or hit the HVBS possibly leading to
electrolyte leakage, overheating, smoke, burst and/or ignition.
• SDI storage requirements: