GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 Hybrid 🢒 Hybrid Energy Storage 🢒 Generator Battery Temperature Sensor Wiring Harness Replacement

Removal Procedure

    Object Number: 1892888 Size: SH
  1. Disconnect the generator battery. Refer to Hybrid Battery Service Disconnect/Connect.
  2. Remove the 2 generator battery vent fan cover bolts (2).
  3. Remove the 12 generator battery cover bolts (1).

    4. Object Number: 1892893 Size: SH
  4. Remove the generator battery cover (1).

    5. Object Number: 1892895 Size: SH

    Note: Removing the interconnect cables will disable the 36 volts within the generator battery control module.

  5. Remove the generator battery terminal covers.
  6. Remove the generator battery cable nuts.
  7. Remove the generator battery cable leads (1, 2, and 3) from the batteries.
  8. Remove the 2 small temperature sensor wiring harness terminal leads located under the battery cable leads from the batteries.

    9. Object Number: 1831951 Size: SH
  9. Disconnect the generator battery temperature sensor wiring harness electrical connectors (2, 5) from the generator control module.

    10. Object Number: 1895985 Size: SH
  10. Disconnect the generator battery temperature sensor wiring harness electrical connectors (1) from the battery temperature sensors.
  11. Remove the generator battery terminal covers and nuts securing the generator battery cable leads (2 and 3).
  12. Remove the generator battery cable leads (2 and 3) from the batteries.
  13. Remove the 2 small temperature sensor wiring harness terminal leads located under the battery cable leads (2 and 3) from the batteries.
  14. Cut the tie straps securing the battery cables to the generator battery temperature sensor wiring harness.

    15. Object Number: 1896001 Size: SH
  15. Unclip the wiring harness retainers.
  16. Remove the generator battery temperature sensor wiring harness (1) from the generator battery assembly.

Installation Procedure

    Object Number: 1896001 Size: SH
  1. Install the generator battery temperature sensor wiring harness (1) to the generator battery assembly.
  2. Clip the wiring harness retainers.

    3. Object Number: 1895985 Size: SH
  3. Install the 2 small temperature sensor wiring harness terminal leads to the batteries.
  4. Install the generator battery cable leads (2 and 3) to the batteries.

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the generator battery cable lead nuts and terminal covers.

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

  6. Connect the generator battery temperature sensor wiring harness electrical connectors (1) to the battery temperature sensors.
  7. Install NEW tie straps in order to secure the battery cables to the generator battery temperature sensor wiring harness.

    8. Object Number: 1831951 Size: SH
  8. Connect the generator battery temperature sensor wiring harness electrical connectors (2, 5) to the generator control module.

    9. Object Number: 1892895 Size: SH
  9. Install the 2 small temperature sensor wiring harness terminal leads to the batteries.
  10. Install the generator battery cable leads (1, 2, and 3) to the batteries.
  11. Install the generator battery cable nuts.

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

  12. Install the generator battery terminal covers.

    13. Object Number: 1892893 Size: SH
  13. Install the generator battery cover (1).

    14. Object Number: 1892888 Size: SH
  14. Install the 12 generator battery cover bolts (1).

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

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

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

  16. Connect the generator battery. Refer to Hybrid Battery Service Disconnect/Connect.