Generator Control Module 3-Phase Cable Assembly Replacement 5.3L Engine w/RPO HP2

1. Disconnect the generator battery carrier. Refer to Hybrid Battery Service Disconnect/Connect .
2. Remove the intake manifold. Refer to Intake Manifold Replacement .
3. If vehicle is a 2-wheel drive (2WD), support the engine with a suitable adjustable jack.

Important: If the vehicle is a 2WD, it is necessary to remove the crossbar, in order to lower the transmission to access the 3-phase cable connections.

4. If vehicle is a 2WD, remove the crossbar bolts and bar.



5. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement in Propeller Shaft.
6. Remove the front propeller shaft, if equipped with 4 wheel drive (4WD). Refer to Front Propeller Shaft Replacement in Propeller Shaft.
7. Support the transmission with a transmission jack.
8. Remove the transmission mount nuts.



9. Remove the transmission support bolts and nuts.
10. Raise the transmission slightly and remove the transmission support.
11. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.



12. Remove the transmission heat shield bolts and shield.
13. Lower the rear of the transmission, until the 3-phase cable cover is accessible.
14. Remove the transmission fill tube nut.
15. Remove the transmission fill tube from the transmission and position aside.



16. Remove the 3-phase cable cover nuts (3) and cover (2).
17. Remove the 3-phase cable nuts (4).
18. Remove the 3-phase cable from the stator studs.



19. Raise the transmission.
20. Reinstall the transmission support and bolts.
21. Lower the transmission onto the support.
22. Remove the transmission jack.
23. Lower the vehicle.



24. Remove the generator control module (GCM) cover bolts, and cover.
25. Remove the 3-phase cable nuts.
26. Remove the 3-phase cable from the GCM studs.



27. Remove the passenger side rear spark plug wire from the coil.
28. Remove the 3-phase cable bracket nuts (2).
29. Remove the 3-phase cable (with bracket) from the vehicle.
30. Remove the 3-phase cable bracket cover bolt (1) and cover (5), if necessary.
31. Remove the 3-phase cable from the bracket, if necessary.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the 3-phase cable to the bracket, if necessary.
2. Install the 3-phase cable bracket cover (5) and install the bolt (1), if necessary.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

3. Install the 3-phase cable (with bracket) to the vehicle.
4. Install the 3-phase cable bracket nuts.

Tighten
Tighten the nuts to 9 N·m (80 lb in).

5. Connect the passenger side rear spark plug wire to the coil.



6. Install the 3-phase cable to the GCM studs.
7. Install the 3-phase cable nuts.

Tighten
Tighten the nuts to 15 N·m (11 lb ft).

8. Install the GCM cover and bolts.

Tighten
Tighten the bolts to 9 N·m (80 lb in).




9. Raise the vehicle.
10. Install the transmission jack.
11. Raise the transmission off the support.
12. Remove the transmission support bolts and support.
13. Lower the rear of the transmission.



14. Install the 3-phase cable to the stator studs.
15. Install the 3-phase cable nuts (4).

Tighten

1. Tighten the nuts a first pass to 14 N·m (10 lb ft).
2. Tighten the nuts a final pass to 14 N·m (10 lb ft).

Important: The 3-phase cable cover studs may have a tendency to spread apart when the nuts are torqued. Once they have spread apart, they may not align with the holes in the cover. The studs can be realigned by squeezing them together at the tips. Each stud has a hex on the tip end where a tool cane be place without damaging the threads.

16. Install the 3-phase cable cover (2) and nuts (3).

Tighten
Tighten the nuts to 9 N·m (80 lb in).

17. Install the transmission fill tube into the transmission.
18. Position the transmission fill tube bracket onto the stud and install the nut.

Tighten
Tighten the nut to 18 N·m (13 lb ft).




19. Raise the rear of the transmission.
20. Install the transmission heat shield and bolts.

Tighten
Tighten the bolts to 17 N·m (13 lb ft).




21. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
22. Raise the transmission slightly and install the transmission support.
23. Install the transmission support bolts and nuts.

Tighten
Tighten the bolts to 70 N·m (50 lb ft).

24. Lower the transmission onto the support.



25. Install the transmission mount nuts.

Tighten
Tighten the nuts to 40 N·m (29 lb ft).

26. Remove the support from the transmission.
27. Install the front propeller shaft, if equipped with 4WD. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
28. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement in Propeller Shaft.



29. If vehicle is a 2WD, install the crossbar and bolts.

Tighten
Tighten the bolts to 100 N·m (74 lb ft).

30. If vehicle is a 2WD, remove the support from the engine.
31. Install the intake manifold. Refer to Intake Manifold Replacement .
32. Connect the generator battery carrier. Refer to Hybrid Battery Service Disconnect/Connect .