High Voltage Service Disconnect

Procedure to safely disconnect and reconnect the high-voltage battery service disconnect on the 2023 Chevrolet Bolt EUV, de-energizing the high-voltage electrical system for service work.

Warnings

Tools required

Parts

• High-voltage service disconnect lock (single-use) × 1 — GM 24285109 or equivalent
• High-voltage warning labels × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is in Park and powered off completely
3. Remove key fob to minimum 20 feet away from vehicle
4. Place warning cones or barriers around vehicle to prevent interruption
5. Verify work area is dry and free from water or moisture
6. Remove all metal jewelry, watches, and rings
7. Put on Class 0 insulated gloves and verify they have no damage or holes
8. Verify multimeter is functioning and rated for high-voltage work (CAT III 1000V minimum)
9. Open driver's door and disable automatic door locks to prevent lockout

Procedure

1. 1

   Disconnect 12V battery negative terminal
   Open the hood. Locate the 12-volt battery in the front compartment. Using a 10mm socket, loosen and disconnect the negative (-) terminal first, then the positive (+) terminal. Isolate terminals so they cannot contact battery posts or each other. Wait 2 minutes for vehicle systems to power down completely.
2. 2

   Remove rear seat bottom cushion
   Enter rear passenger compartment. Firmly pull up on the front edge of the rear seat bottom cushion to release the retaining clips. Lift the seat cushion forward and up to remove it completely from the vehicle. Set aside in a safe location.
3. 3

   Access service disconnect cover
   Locate the high-voltage service disconnect cover on the rear floor panel, centered under where the seat cushion was positioned. The cover will have high-voltage warning labels. Note the orientation of the cover for reinstallation.
4. 4

   Remove service disconnect cover
   Using an 8mm socket and torque wrench, remove the cover screws securing the service disconnect access cover. Lift the cover off to expose the high-voltage service disconnect assembly. Inspect the area for any signs of damage, moisture, or corrosion before proceeding.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
5. 5

   Remove service disconnect handle lock
   The orange service disconnect handle has a single-use plastic locking tab to prevent inadvertent disconnection. Using diagonal cutters, carefully cut the lock tab. This lock tab cannot be reused and must be replaced with a new one during reassembly.
6. 6

   Remove high-voltage service disconnect
   Grasp the orange service disconnect handle firmly. Pull straight up with steady force to disconnect the high-voltage service plug from the battery pack. The plug may require 20-30 lbs of pull force. Once free, remove the service plug completely from the vehicle and place it in a secure location where it cannot be accidentally reinstalled.
   ⚠️Once removed, DO NOT touch any exposed terminals on the service plug or in the receptacle. High voltage may still be present.
7. 7

   Wait for capacitor discharge period
   Wait a MINIMUM of 5 minutes without touching any high-voltage components. This allows high-voltage capacitors throughout the system to discharge. Set a timer to ensure full 5-minute wait period. Do not skip or shorten this critical safety step.
   ⚠️Failure to wait full 5 minutes can result in electric shock even with service disconnect removed.
8. 8

   Verify system de-energization at service disconnect
   Put on insulated gloves. Using the CAT III rated multimeter set to DC voltage, carefully measure voltage across the exposed terminals in the service disconnect receptacle (where the plug was removed from). Reading must be less than 3 volts DC. If voltage is higher than 3V, wait an additional 5 minutes and retest.
   ⚠️If voltage remains above 3V DC after extended wait, do not proceed. System fault is present. Seek professional service immediately.
9. 9

   Verify system de-energization at drive unit
   For additional verification, access the drive unit high-voltage connector located under the vehicle at the front motor assembly. Verify the orange high-voltage cable connectors are not damaged. Using the multimeter, verify less than 3 volts DC across the drive unit high-voltage terminals. System is now verified de-energized.
   ⚠Even with verified de-energization, always treat high-voltage components as if energized. Use insulated tools only.
10. 10

    Secure service disconnect and label vehicle
    Store the removed service disconnect plug in a secure location where it cannot be accidentally reinstalled. Ideally, keep it with the technician performing the work. Place high-voltage warning tags on the steering wheel and near the service disconnect opening indicating that high-voltage service work is in progress and the service disconnect has been removed.

Reassembly

1. Ensure all high-voltage service work is complete before reconnecting
2. Remove all tools and equipment from high-voltage component areas
3. Verify all high-voltage connectors serviced during repair are properly secured and torqued to specification
4. Inspect service disconnect plug for any damage to terminals or housing before reinstallation
5. Align service disconnect plug with receptacle and push straight down firmly until fully seated with a positive click
6. Install NEW single-use service disconnect lock through the handle - do not reuse old lock
7. Reinstall service disconnect cover with cover screws, torque to 11.0 Nm (8 lb-ft)
8. Reinstall rear seat bottom cushion, ensuring all clips engage properly
9. Reconnect 12V battery: positive terminal first, then negative terminal
10. Remove all warning tags from vehicle

Verification

• Verify service disconnect lock is properly installed and secure
• Verify service disconnect cover is installed with all screws torqued properly
• Verify rear seat cushion is properly reinstalled and secured
• With key fob present, attempt to power on vehicle - READY indicator should illuminate
• Check instrument cluster for any high-voltage system fault codes or warning messages
• Verify all high-voltage system warnings clear and vehicle shows normal ready status
• Perform a brief test drive to confirm normal operation of drive system and all vehicle functions
• If any warning lights remain illuminated or system faults are present, re-verify all high-voltage connections and service disconnect installation

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