Battery Positive Cable Extension Cable Replacement
Battery Positive Cable Extension Cable Replacement
Removal Procedure
1. Disconnect the hybrid battery.
2. Remove the air cleaner outlet duct.
3. Remove the air conditioning (A/C) condenser.
4. Remove the fan shroud.
5. Remove the radiator.
6. Remove the 36 volt positive battery cable clip (4) from the engine control module (ECM) bracket.
Important: It is not necessary to disconnect the engine wiring and body wiring harnesses electrical connectors from the ECM prior to repositioning. It is also not necessary to remove the ECM from the bracket prior to repositioning.
7. Remove the ECM bracket (1) from the battery hold down bracket. Reposition the ECM bracket out of the way.
8. Remove the forward lamp wiring harness electrical connector (1) from the positive battery cable bracket.
9. Remove the engine wiring harness auxiliary bussed electrical center (BEC) (1) from the wiring harness relay block bracket.
10. Remove the engine wiring harness clip (2) from the positive battery cable bracket.
11. Reposition the engine wiring harness auxiliary BEC out of the way.
12. Remove the underhood bussed electrical center (UBEC) cover (1).
13. Loosen the UBEC bolts (2).
14. Remove the UBEC.
15. Remove the body wiring harness UBEC electrical connector (1) from the UBEC bracket.
16. Reposition the body wiring harness electrical connector out of the way.
17. Remove the forward lamp wiring harness UBEC electrical connector (1) from the UBEC bracket.
18. Remove the forward lamp wiring harness clips (2) from the positive battery cable bracket.
19. Reposition the forward lamp wiring harness electrical connector out of the way.
20. Remove the engine wiring harness UBEC electrical connector (1) from the UBEC bracket.
21. Remove the engine wiring harness clip (2) from the battery tray.
22. Reposition the engine wiring harness electrical connector out of the way.
23. Remove the 12 volt positive battery cable clips (4) from the UBEC bracket.
24. Remove the 12 volt positive battery cable clip (3) from the positive battery cable bracket.
25. Remove the UBEC bracket bolts (1) and bracket.
26. Remove the air conditioning compressor and condenser line nut (1) from the generator control module bracket stud.
27. Remove the positive battery cable bracket (2) from the stud.
28. Remove the battery hold down bracket nuts (1, 4).
29. Remove the wiring harness relay block bracket nut (3) and bracket (2).
30. Remove the battery hold down retainer (5).
31. Remove the generator control module bracket bolts and stud.
32. Remove the generator control module bracket.
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.
33. Disconnect the 2 engine wiring harness electrical connectors (1) from the generator control module.
34. WAIT at least 5 minutes in order to allow the voltage stored in the generator control module to discharge.
35. Remove the generator control module cover bolts and cover.
36. 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.
37. Now, check the generator control module for voltage potential in order to ensure that the module has been disabled.
1. Measure from the positive terminal to vehicle chassis ground. The voltage should be less than 3 volts.
2. Measure from the negative terminal to vehicle chassis ground. The voltage should be less than 3 volts.
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.
38. Verify that the generator control module 3 Phase cables are disabled.
Measure from the phase 1, 2, and 3 connections to ground. The voltage should be less than 3 volts.
39. Remove the 12 volt positive battery cable nut at the generator control module.
40. Raise and support the vehicle half way. Refer to Vehicle Lifting.
41. Remove the 12 volt positive battery cable bolt at the generator control module.
42. Remove the 12 volt positive battery cable from the generator control module.
43. Lower the vehicle.
44. Reposition the body wiring harness junction block protector.
45. Remove the positive battery cable lead nut (1) at the UBEC stud.
46. Remove the 12 volt positive battery cable lead (2) from the UBEC stud.
47. Remove the 12 volt positive battery cable clips (4) from the UBEC.
48. Remove the 12 volt positive battery cable clip (3) from the positive battery cable bracket.
49. Remove the 12 volt positive battery cable from the vehicle.
Installation Procedure
1. Install the 12 volt positive battery cable to the vehicle.
2. Install the 12 volt positive battery cable lead (2) to the UBEC stud.
Notice: Refer to Fastener Notice.
3. Install the positive battery cable lead nut (1) at the UBEC stud.
Tighten the nut to 10 N.m (89 lb in).
4. Install the 12 volt positive battery cable clips (4) to the UBEC.
5. Install the 12 volt positive battery cable clip (3) to the positive battery cable bracket.
6. Position the body wiring harness junction block protector.
7. Raise and support the vehicle half way.
8. Install the 12 volt positive battery cable to the generator control module.
9. Install the 12 volt positive battery cable bolt at the generator control module.
Tighten the bolt to 10 N.m (89 lb in).
10. Lower the vehicle.
11. Install the 12 volt positive battery cable nut at the generator control module.
Tighten the nut to 10 N.m (89 lb in).
12. Install the generator control module cover bolts and cover.
Tighten the bolts to 10 N.m (89 lb in).
13. Connect the 2 engine wiring harness electrical connectors (1) to the generator control module.
14. Install the generator control module bracket.
15. Install the generator control module bracket bolts and stud.
Tighten the bolts/stud to 10 N.m (89 lb in).
16. Install the battery hold down retainer (5).
17. Install the battery hold down bracket nuts (1, 4).
Tighten the nuts to 10 N.m (89 lb in).
18. Install the wiring harness relay block bracket (2) and nut (3).
Tighten the nut to 10 N.m (89 lb in).
19. Install the positive battery cable bracket (2) to the stud.
20. Install the air conditioning compressor and condenser line nut (1) to the generator control module bracket stud.
Tighten the nut to 20 N.m (15 lb ft).
21. Install the UBEC bracket and bolts (1).
Tighten the bolts to 9 N.m (80 lb in).
22. Install the 12 volt positive battery cable clip (3) to the positive battery cable bracket.
23. Install the 12 volt positive battery cable clips (4) to the UBEC bracket.
24. Position the engine wiring harness electrical connector.
25. Install the engine wiring harness UBEC electrical connector (1) to the UBEC bracket.
26. Install the engine wiring harness clip (2) to the battery tray.
27. Position the forward lamp wiring harness electrical connector.
28. Install the forward lamp wiring harness UBEC electrical connector (1) to the UBEC bracket.
29. Install the forward lamp wiring harness clips (2) to the positive battery cable bracket.
30. Position the body wiring harness electrical connector.
31. Install the body wiring harness UBEC electrical connector (1) to the UBEC bracket.
32. Install the UBEC.
33. Tighten the UBEC bolts (2).
Tighten the bolts to 4 N.m (35 lb in).
34. Install the UBEC cover (1).
35. Position the engine wiring harness auxiliary BEC.
36. Install the engine wiring harness auxiliary bussed electrical center (BEC) (1) to the wiring harness relay block bracket.
37. Install the engine wiring harness clip (2) to the positive battery cable bracket.
38. Install the forward lamp wiring harness electrical connector (1) to the positive battery cable bracket.
39. Position and install the ECM bracket (1) to the battery hold down bracket.
40. Install the 36 volt positive battery cable clip (4) to the engine control module ECM bracket.
41. Install the radiator.
42. Install the fan shroud.
43. Install the air cleaner outlet duct.
44. Connect the hybrid battery.