Removal Procedure
- Disconnect the hybrid battery. Refer to
Hybrid Battery Service Disconnect/Connect.
- Remove the 2 connector position assurance (CPA) retainers (3).
Caution: To help avoid personal injury, additional precautions must be taken prior to working on the generator control module or the generator starter. After removing the 36V battery cables from the generator battery, remove both
engine wiring harness connectors from the generator control module. Wait at least 5 minutes and then remove the generator control module cover. Verify voltage levels at all 36V, 12V, and 3-phase connections, are less than 3 volts using
a DMM before proceeding.
- Disconnect the 2 engine wiring harness electrical connectors (2) from the generator control module.
- WAIT at least 5 minutes in order to allow the voltage stored in the generator control module to discharge.
- Remove the generator control module bracket reinforcement bolt (1) and nuts (2).
- Remove the generator control module bracket reinforcement (3).
- Loosen the generator control module cover integral bolts (1) and remove the cover (2).
- The generator control module will have to be checked for voltage potential using a voltmeter. First, verify that the voltmeter works:
| 8.1. | Set the voltmeter to DC voltage. |
| 8.2. | Measure the vehicle's 12-volt battery voltage. |
| 8.3. | The meter should read greater than +12 volts DC. |
- Now, check the generator control module for voltage potential, in order to ensure that the module has been disabled.
| 9.1. | Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts. |
| 9.2. | Measure from the 12-volt positive terminal (2) to a known good chassis ground. The voltage should be less than 3 volts. |
| 9.3. | Measure from the ground terminal (4) to known good chassis ground, checking for continuity. |
Caution: To help avoid personal injury, always treat the 3-phase cable and connectors as if voltage is present and as if the surface of all parts
of the cable is hot.
- Verify that the generator control module 3-phase cables are disabled.
| 10.1. | Measure from each phase 1, 2, and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts. |
| 10.2. | After verifying that there is no voltage present, the battery positive fuse can now be removed from the generator control module. |
- Remove the battery positive cable extension cable nut (2) from the generator
control module.
- Carefully lift the extension cable off of the lug and position aside.
- Remove the 175 AMP fuse nut (1).
- Remove the 175 AMP fuse (2) from the generator control module.
Installation Procedure
- Install the battery 175 AMP fuse (2) to the generator control module.
- Loosely install the 175 AMP fuse nut (1).
- Carefully install the extension cable to the lug.
- Install the battery positive cable extension cable nut (2) to the generator control module.
Notice: Refer to Fastener Notice in the Preface section.
- Tighten the fuse and the battery positive cable extension cable nuts.
Tighten
Tighten the nuts to 10 N·m (89 lb in).
- Place the generator control module cover (2) on top of the generator control module and tighten the bolts (1).
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Install the generator control module bracket reinforcement (3).
- Install the generator control module bracket reinforcement bolt (1) and nuts (2).
Tighten
Tighten the bolt/nuts to 10 N·m (89 lb in).
- Connect the 2 engine wiring harness electrical connectors (2) to the generator
control module.
- Install the 2 CPA retainers (3).
- Connect the hybrid battery. Refer to
Hybrid Battery Service Disconnect/Connect.
