Generator Battery Carrier Replacement 5.3L Engine w/RPO HP2

Caution: To help avoid personal injury, disable the 36V system anytime you perform service work on or around the generator battery carrier. The 36V system will still be active after you have disabled the generator battery carrier.

Caution: To help avoid personal injury, always disconnect the 36V generator battery carrier before doing any work to the generator battery carrier system. To disconnect the generator battery carrier, turn the engine off and turn OFF the service disconnect switch, which is located on the passenger side of the generator battery carrier.

1. Remove the generator battery carrier trim cover. Refer to Battery Cover Replacement - Rear Seat .
2. Disconnect the generator battery carrier. Refer to Hybrid Battery Service Disconnect/Connect .
3. Remove the 42-volt positive/negative cable retainer nuts, and retainer.



4. Remove the red connector position assurance (CPA) retainer from the 42-volt connector.
5. Disconnect the 42-volt positive/negative cable electrical connector (4).
6. Disconnect the 120-volt AC electrical connector (3).
7. Remove the ground strap nut (1).
8. Remove the ground straps from the stud (2).
9. Disconnect the 12-volt harness electrical connector on the passenger side.



10. Disconnect the low voltage cable electrical connector (1) on the driver side of the generator battery carrier.
11. Remove the retaining clip (2) from generator battery carrier.



12. Remove the nuts that retain the generator battery carrier to the floor.
13. Reposition the generator battery carrier in order to disconnect the HVAC duct from the ESB.
14. With the aid of an assistant, remove the generator battery carrier.

1. With the aid of an assistant, install the generator battery carrier.
2. Position the generator battery carrier in order to connect the HVAC duct to the generator battery carrier.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the generator battery carrier nuts.

Tighten
Tighten the nuts to 47 N·m (35 lb ft).




4. Connect the low voltage cable electrical connector (1) on the driver side of the generator battery carrier.
5. Install the retaining clip (2) to generator battery carrier.



6. Connect the 12-volt harness electrical connector on the passenger side.
7. Install the ground straps to the stud (2).
8. Install the ground strap nut (1).

Tighten
Tighten the nut to 10 N·m (89 lb in).

9. Connect the 120-volt AC electrical connector (3).
10. Connect the 42-volt positive/negative cable electrical connector (4).
11. Install the red CPA retainer to the 42-volt connector.



12. Install the 42-volt positive/negative cable retainer and nuts.
13. Connect the generator battery carrier. Refer to Hybrid Battery Service Disconnect/Connect .
14. Install the generator battery carrier trim cover. Refer to Battery Cover Replacement - Rear Seat .