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Home › Chevrolet › 2004 › Impala SS › Repair and Diagnosis › External Pages › Different car › Section 871 (Hybrid Energy Storage System) › Repair Instructions › Generator Battery Disconnect Control Module Replacement › Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Battery Disconnect Control Module & Pigtail
    GM1892896Courtesy of GENERAL MOTORS CORP.
  1. Install the generator battery disconnect control module (1).
    2. NOTE: Refer to Fastener Notice .
  2. Install the 4 generator battery disconnect control module bolts.

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

  3. Clip the fan harness retainer to the battery.
  4. Install the generator battery disconnect control module pigtail (2) clip to the side of the battery carrier.
    5. Fig 2: Identifying Generator Battery Temperature Sensor Wiring Harness Electrical Connectors
    GM1831951Courtesy of GENERAL MOTORS CORP.
  5. Position the generator battery temperature sensor wiring harness and the battery cables to the generator control module.
  6. Connect the generator battery temperature sensor wiring harness electrical connectors (2, 5) to the generator control module.
  7. Connect the wiring harness electrical connector (1) to the vent fan electrical connector.
    8. Fig 3: Identifying Battery Cables & Nuts
    GM1831950Courtesy of GENERAL MOTORS CORP.
  8. Ensure that the generator battery temperature sensor wiring harness terminals (5, 6) and installed on the generator battery control module studs.
  9. Install the battery cable (7), and the generator battery control module nut (8) to the stud.

    Tighten:  Tighten the nut to 8 N.m (71 lb in).

  10. Install the battery cable (3), and the generator battery control module nut (4) to the stud.

    Tighten:  Tighten the nut to 8 N.m (71 lb in).

    11. Fig 4: Identifying Generator Battery Cable Leads
    GM1892895Courtesy of GENERAL MOTORS CORP.
  11. Install the 2 small temperature sensor wiring harness terminal leads to the batteries.
  12. Install the generator battery cable leads (1, 2, and 3) to the batteries.
  13. Install the generator battery cable nuts.

    Tighten:  Tighten the nut to 8 N.m (71 lb in).

  14. Install the generator battery terminal covers.
    15. Fig 5: Identifying Generator Battery Cover
    GM1892893Courtesy of GENERAL MOTORS CORP.
  15. Install the generator battery cover (1).
    16. Fig 6: Identifying Generator Battery Vent Fan & Cover Bolts
    GM1892888Courtesy of GENERAL MOTORS CORP.
  16. Install the 12 generator battery cover bolts (1).

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

  17. Install the 2 generator battery vent fan cover bolts (2).

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

    18. Fig 7: Locating Body Wiring Harness Electrical Connector
    GM1892879Courtesy of GENERAL MOTORS CORP.
  18. Connect the body wiring harness electrical connector (1) to the generator battery disconnect control module pigtail.
    19. Fig 8: Locating 36-Volt Positive Battery Cable Nuts
    GM1892886Courtesy of GENERAL MOTORS CORP.
  19. Install the 36-volt positive battery cable leads (2).
  20. Install the 36-volt positive battery cable lead nut (1).

    Tighten:  Tighten the nut to 9 N.m (18 lb in).

  21. Install a NEW 36-volt positive battery cable lead nut (3). Start the nut finger tight, and then torque to the specification given.

    Tighten:  Tighten the nut to 15 N.m (11 lb ft).

    22. Fig 9: Identifying Generator Battery Fuse
    GM1892885Courtesy of GENERAL MOTORS CORP.
  22. Install the generator battery fuse (1) to the generator battery disconnect module negative stud.
    23. Fig 10: View Of Negative Battery Cable Lead
    GM1892883Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Position the plastic nut to the negative battery cable and ensure that the nipple is inserted to the terminal prior to installing the negative cable to the generator battery, Otherwise damage to the nut may occur.
  23. Position the plastic nut (2) to the 36-volt negative battery cable lead ensuring that the nipple on the plastic nut is inserted through the hole in the terminal.
  24. Install the 36-volt negative battery cable lead (1) and nut to the generator battery disconnect module negative stud.

    Tighten:  Tighten the nut to 10.7 N.m (95 lb in).

  25. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
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