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Home › GMC › 2002 › Jimmy 2D Utility, Part Time, Automatic › Repair and Diagnosis › External Pages › Different car › Section 1848 (Hybrid Energy Storage System) › Repair Instructions › 36-Volt Battery Positive Cable Replacement › Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Engine Wiring Harness Electrical Connectors
    GM1816292Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
  2. Remove the (12-volt) battery tray. Refer to Battery Tray Replacement (2.2L (L61)) or Battery Tray Replacement (2.4L (LAT)) or Battery Tray Replacement (3.5L (L66)) .
    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.
  3. Disconnect the 2 engine wiring harness electrical connectors (1) from the generator control module.
  4. WAIT at least 5 minutes in order to allow the voltage stored in the generator control module to discharge.
    5. Fig 2: Generator Control Module Cover Bolts And Cover
    GM1816289Courtesy of GENERAL MOTORS CORP.
  5. Remove the generator control module cover bolts and cover.
  6. The generator control module will have to be checked for voltage potential using a voltmeter. First, verify that the voltmeter works:
    1. Set the voltmeter to DC voltage.
    2. Measure the vehicle's 12-volt battery voltage.
    3. The meter should read greater than +12 volts DC.
    7. Fig 3: Identifying Generator Control Module Terminals
    GM1824550Courtesy of GENERAL MOTORS CORP.
  7. Now, check the generator control module for voltage potential, in order to ensure that the module has been disabled.
    1. Measure from the 36-volt positive terminal (3) to vehicle chassis ground (2). The voltage should be less than 3 volts.
    2. Measure from the 12-volt positive terminal (5) to vehicle chassis ground (2). The voltage should be less than 3 volts.
    3. Measure from the negative terminal (4) to vehicle chassis ground (2). The voltage should be less than 3 volts.
    8. 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.
  8. Verify that the generator control module 3-phase cables are disabled.
    1. Measure from each phase 1, 2, and 3 connection (1) to ground (2). The voltage should be less than 3 volts.
    2. After verifying that there is no voltage present, the 12-volt and 36-volt positive battery cables can now be removed from the generator control module.
    9. Fig 4: Positive Battery Cable Nut And Bolt
    GM1831557Courtesy of GENERAL MOTORS CORP.
  9. Remove the 12-volt positive battery cable nut (1) from the generator control module.
  10. Remove the 12-volt positive battery cable bolt (2) from the generator control module.
  11. Remove the 12-volt positive battery cable from the generator control module.
    12. Fig 5: 36-Volt Terminal Block Nuts
    GM1831652Courtesy of GENERAL MOTORS CORP.
  12. Remove the 36-volt positive battery cable nut from the generator control module.
  13. Remove the 36-volt terminal block nuts from the generator control module.
  14. Lift up, and remove the 36-volt terminal block position the block out of the way. Discard the terminal block seal.
    15. Fig 6: Identifying Hybrid-Related Harness Retainers
    GM1820895Courtesy of GENERAL MOTORS CORP.
  15. Remove the 36-volt positive battery cable retainer (2) from the shock tower bracket.
  16. Remove the 36-volt positive battery cable bracket nuts (5) from the front of dash studs.
  17. Remove the 36-volt positive battery cable bracket to the front of dash studs.
    18. Fig 7: Locating Battery Components
    GM1820195Courtesy of GENERAL MOTORS CORP.
  18. From inside the rear of the vehicle, remove the 36-volt positive battery cable shield lead nut (3) from the generator battery.
  19. Remove the 36-volt positive battery cable shield lead (4) to the generator battery stud.
    20. Fig 8: Grommet
    GM1831665Courtesy of GENERAL MOTORS CORP.
  20. Squeeze the grommet sides together and push the grommet through the floor panel.
  21. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    22. Fig 9: 36-Volt Positive Battery Cable Rear Suspension Bracket Bolts
    GM1820185Courtesy of GENERAL MOTORS CORP.
  22. Remove the 36-volt positive battery cable rear suspension bracket bolts.
    23. Fig 10: Underbody Bolts
    GM1820192Courtesy of GENERAL MOTORS CORP.
  23. Have an assistant support the 36-volt positive battery cable channel.
  24. Remove the 36-volt positive battery cable channel to underbody bolts (1, 2).
  25. With the aid of the assistant, remove the 36-volt positive battery cable channel from the vehicle.
  26. Place the 36-volt positive battery cable channel on a clean work surface.
    27. Fig 11: Cable And Channel
    GM1831669Courtesy of GENERAL MOTORS CORP.
  27. Cut the tie straps securing the 36-volt positive battery cable to the battery cable channel.
  28. Remove the 36-volt positive battery cable from the battery cable channel.
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