Leapmotor T03 High-Voltage Circuit Inspection and Traction Battery Pack Removal Guide

Fault Background

For Leapmotor T03 high-voltage circuit inspection, there are two rules you must memorize: First, wait 3 minutes — after vehicle power-down and battery disconnection, you must wait 3 minutes before touching any high-voltage connector or terminal; Second, 60±5N·m battery pack torque — after lifting the traction battery pack assembly with a battery removal cart until it is slightly stressed, remove the 10 fixing bolts in the order shown in the figure, torque 60±5N·m. The manual also lists 13 high-voltage inspection precautions, from "do not touch orange wiring and warning labels" to "insulating glove inflation leak test method" (lay sideways → roll the opening 2~3 times → fold and seal → confirm no air leakage), all written in a specific and executable manner. On the BMS side, it uses a self-developed DTC system: P110144/145/146 (RAM/FLASH/EEPROM storage faults) and P1213xx/P1215xx (12V/ON2 power supply voltage threshold faults) are uniformly addressed by replacing the BMS. This article compiles the 13 high-voltage inspection items, battery pack removal, and BMS code table into a reference guide.

13 High-Voltage Circuit Inspection Items

1. Technicians must be professionally trained to repair and inspect high-voltage systems;
2. All high-voltage wires and connectors are orange, and high-voltage components have warning labels, do not touch them arbitrarily;
3. If the high-voltage wiring harness or connector is faulty, do not attempt to repair the wiring or connector — directly replace the damaged part;
4. Before inspection or repair, be sure to follow all safety measures: wear insulating gloves, power down the vehicle, disconnect the battery;
5. After vehicle power-down and battery disconnection, wait 3 minutes before touching any high-voltage connector or terminal;
6. Insulating gloves must be leak-tested before use: lay the glove sideways → roll the opening upward 2~3 times → fold the opening to seal → confirm no air leakage;
7. When servicing the vehicle, do not carry metal items such as rulers to prevent accidental drops causing short circuits;
8. Before touching exposed high-voltage terminals, wear insulating gloves and use testing equipment to confirm the terminal voltage is 0V;
9. After disconnecting or exposing high-voltage wiring harness connectors, immediately insulate and seal with insulating tape;
10. Tighten high-voltage component bolts and nuts to the required torque (insufficient or excessive torque may cause faults);
11. Use "Warning: High Voltage Do Not Touch" signs to inform other technicians;
12. After repair or before power-on, recheck that no parts or tools are left behind, bolts are tightened, and connectors are correctly connected;
13. Use insulated tools when performing high-voltage circuit work.

Traction Battery Pack Assembly Removal

1. Turn off the vehicle power;
2. Disconnect the battery negative terminal;
3. Remove the battery underbody shield;
4. Remove the traction battery pack assembly: a. Disconnect the low-voltage wiring harness connector → b. Disconnect the battery cable assembly connector → c. Use a battery removal cart (recommended equipment) to lift the traction battery pack assembly until it is slightly stressed → d. Remove the 10 fixing bolts in the order shown in the figure, lower and move out the assembly.

• Fixing bolt torque: 60±5N·m (remove and install in the order shown in the figure).

BMS Self-Developed DTC Table (Excerpt)

Drive Motor Control System

• DC charging socket (GV09) directly connects to the traction battery high-voltage circuit;
• Battery power and ON2 power circuits are equipped with 10A fuses;
• CAN1/CAN2 dual communication system;
• The high-voltage power distribution system core is the four-in-one assembly (integrating charging and distribution functions), connecting to the AC charging socket and DC charging socket.

Safety Warnings

• This article is for technical reference only. High-voltage system inspection must be performed by professionally trained technicians according to OEM specifications. Readers who are not familiar with this must not operate on their own.
• After vehicle power-down + battery disconnection, you must wait 3 minutes before touching high-voltage connectors and terminals.
• Insulating gloves must be inflation leak-tested before use; confirm 0V before touching exposed high-voltage terminals.
• After disconnecting high-voltage connectors, seal immediately with insulating tape; post "High Voltage Do Not Touch" signs in the work area.
• Battery pack fixing bolts 60±5N·m, remove and install in the order shown in the figure, use a battery removal cart to lift, never lift by hand.

Repair Insights

The most important things to follow on-site from the Leapmotor T03 manual are the three "times and values": 3 minutes (wait a full 3 minutes after power-down before touching high-voltage components), 60±5N·m (battery pack 10 bolts in order, use battery removal cart to lift), 0V (confirm with testing equipment before touching exposed terminals). And two "counterintuitive" rules: If the high-voltage wiring harness is damaged, replace it, don't repair it — there is no "connect and continue using" option for high-voltage connectors; insulating gloves must be inflation leak-tested — lay sideways, roll the opening 2~3 times, fold and seal, confirm no leakage, a damaged glove is more dangerous than not wearing one. Remember one point from the BMS code table: P1101xx three types of storage faults (RAM/FLASH/EEPROM) and P1213xx/P1215xx power supply threshold faults, the countermeasure is to replace the BMS — the self-developed BMS is not repaired internally, the dealership-level action is to replace the part.

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【This article is for reference only】