Removal and Replacement

Generator Battery Disconnect Control Module Replacement

Removal Procedure

Caution: To help avoid personal injury, be careful when working in the vicinity of the generator battery disconnect control module. Internal components will still be live, 36V potential, even when the cover has been opened or removed.




1. Disconnect the hybrid battery.
2. Remove the 2 generator battery fan bolts (2).
3. Remove the 12 generator battery cover bolts (1).
4. Remove the generator battery wiring harness from the clip (3) on the generator battery cover.




5. Remove the generator battery cover.






Important: Disconnecting the generator battery temperature sensor wiring harness electrical connectors will disable the 36 volts within the generator battery control module.

6. Disconnect the generator battery temperature sensor wiring harness electrical connectors from the battery temperature sensors in the following order:

* 3
* 2
* 1




7. Remove the generator battery control module nut (4), and the battery cable (3) from the stud.
8. Remove the generator battery control module nut (8), and the battery cable (7) from the stud.




9. Disconnect the wiring harness electrical connector (1) from the vent fan electrical connector.
10. Disconnect the generator battery temperature sensor wiring harness electrical connectors (2, 5) from the generator control module.
11. Reposition the battery cables and the generator battery temperature sensor wiring harness out of the way.




12. Remove the generator battery control module bolts.
13. Remove the generator battery control module.

Installation Procedure




1. Install the generator battery control module.

Notice: Refer to Fastener Notice.

2. Install the generator battery control module bolts.

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




3. Position the generator battery temperature sensor wiring harness and the battery cables to the generator control module.
4. Connect the generator battery temperature sensor wiring harness electrical connectors (2, 5) to the generator control module.
5. Connect the wiring harness electrical connector (1) to the vent fan electrical connector.




6. Ensure that the generator battery temperature sensor wiring harness terminals (5, 6) and installed on the generator battery control module studs.
7. Install the battery cable (7), and the generator battery control module nut (8) to the stud.

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

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

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




9. Connect the generator battery temperature sensor wiring harness electrical connectors to the battery temperature sensors in the following order:

* 1
* 2
* 3




10. Install the generator battery cover.




11. Install the 12 generator battery cover bolts (1).

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

12. Install the 2 generator battery fan bolts (2).

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

13. Install the generator battery wiring harness to the clip (3) on the generator battery cover.
14. Connect the hybrid battery.