GM Service Manual Online
For 1990-2009 cars only

Generator Battery Carrier Disassemble/Assemble 5.3L Engine w/RPO HP2

Tools Required

J 43679 Battery Removal Handles

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.

Disassembly Procedure


    Object Number: 1403617  Size: SH
  1. Remove the generator battery carrier carrier. Refer to Generator Battery Carrier Replacement .
  2. Remove the generator battery carrier intermediate cover screws.
  3. Remove the generator battery carrier intermediate cover.

  4. Object Number: 1403618  Size: SH
  5. Remove the control module nuts.
  6. Lift the control module up off of the studs.
  7. Disconnect the control module electrical connectors.
  8. Remove the control module.

  9. Object Number: 1403619  Size: SH
  10. Remove the maxi-fuse cover.

  11. Object Number: 1456037  Size: SH
  12. Remove the maxi-fuse nuts (1).
  13. Remove the maxi-fuse (2).

  14. Object Number: 1459627  Size: SH
  15. Disconnect the battery resistor electrical connector (1), labeled XR3 from the number 3 battery negative terminal resistor.

  16. Object Number: 1403620  Size: SH
  17. Remove the power cable nut (2) from the current sensor.
  18. Remove the battery 2 to battery 3 power cable nuts (1).
  19. Remove the battery resistor (4) from the number 3 battery negative terminal.
  20. Cut the tie straps securing the power cables to the generator battery carrier.
  21. Remove the power cables (3).

  22. Object Number: 1403621  Size: SH
  23. Disconnect the outlet duct from the generator battery carrier duct.
  24. Disconnect the battery vent tube that is inside the outlet duct.
  25. Disconnect the fan electrical connector.
  26. Remove the fan screws.
  27. Remove the push pin fasteners.
  28. Remove the screws attaching the air duct hose to the generator battery carrier.
  29. Remove the fan and air duct hose.

  30. Object Number: 1403622  Size: SH
  31. Remove the receptacle outlet cover screws.
  32. Carefully pull the receptacle box out of the generator battery carrier.
  33. Insert a flat-bladed screwdriver into the openings on top of the receptacle box in order to release the tabs securing the outlet cover.
  34. Remove the receptacle outlet cover.

  35. Object Number: 1403623  Size: SH
  36. Disconnect the battery vent hose(s) from the batteries.
  37. Disengage the retainers securing the battery vent hose(s).
  38. Remove the battery vent hose(s) from the generator battery carrier.

  39. Object Number: 1403624  Size: SH
  40. Disconnect the battery resistor electrical connector (1), labeled XR1 from the number 1 battery negative terminal.
  41. Remove the battery cut-off switch nuts (2).
  42. Remove the battery resistor from the number 2 battery terminal.
  43. Disconnect the battery cut-off switch electrical connector.
  44. Disconnect the high current sensor electrical connector (3).

  45. Object Number: 1456043  Size: SH
  46. Remove the battery cut-off switch (1) and high current sensor (2).

  47. Object Number: 1403625  Size: SH
  48. Remove the high current sensor carrier nut.
  49. Remove the high current sensor carrier.

  50. Object Number: 1459628  Size: SH
  51. Disconnect the battery resistor electrical connector (1), labeled XR2 from the number 1 battery positive terminal.

  52. Object Number: 1403626  Size: SH
  53. Remove the power cable nuts (1) from battery 1 and battery 2.
  54. Remove the power cable (3) from battery 1 and battery 2.
  55. Remove the battery resistor (2) from the number 1 battery positive terminal.

  56. Object Number: 1459621  Size: SH
  57. Disconnect the battery resistor electrical connector (1), labeled XR4 from the number 3 battery positive terminal.

  58. Object Number: 1403627  Size: SH
  59. Remove the power cable nuts (1) from the number 3 battery and high current connector.
  60. Remove the battery resistor (3) from the number 3 battery positive terminal.
  61. Remove the power cable (2).

  62. Object Number: 1403628  Size: SH
  63. Remove the service disconnect power cable nuts (1) from the high current connector and the service disconnect switch.
  64. Remove the power cable (2).

  65. Object Number: 1403629  Size: SH
  66. Cut the tie straps securing the power cable to the generator battery carrier.
  67. Remove the service disconnect power cable nut from the service disconnect switch.
  68. Remove the power cable.

  69. Object Number: 1403630  Size: SH
  70. Remove the 120-volt cable connector screws.

  71. Object Number: 1403631  Size: SH
  72. Disconnect the retainers securing the 120-volt cable to the generator battery carrier.
  73. Remove the 120-volt cable.

  74. Object Number: 1403632  Size: SH
  75. Remove the fuse holder screws.
  76. Remove the fuse holder.

  77. Object Number: 1403634  Size: SH
  78. Remove the high current connector screws.

  79. Object Number: 1403635  Size: SH
  80. Remove the high current connector.

  81. Object Number: 1456045  Size: SH
  82. Remove the service disconnect switch nuts.

  83. Object Number: 1403636  Size: SH
  84. Remove the service disconnect switch screws.

  85. Object Number: 1403637  Size: SH
  86. Remove the service disconnect switch.

  87. Object Number: 1403638  Size: SH
  88. Remove the battery hold down bracket nuts.
  89. Remove the battery hold down brackets.

  90. Object Number: 1403639  Size: SH
  91. Remove the battery hold down bolts.

  92. Object Number: 1403640  Size: SH
  93. Using J 43679 , remove the batteries.

  94. Object Number: 1403641  Size: SH
  95. Remove the ground wire bolt.
  96. Disengage the retainers securing the internal signal harness to the generator battery carrier.
  97. Remove the internal signal harness from the generator battery carrier.
  98. If necessary, remove any retainers (1), clips (2), or fasteners (3).

Assembly Procedure


    Object Number: 1403641  Size: SH
  1. If necessary, install any retainers (1), clips (2), or fasteners (3).
  2. Install the internal signal harness from the generator battery carrier.
  3. Engage the retainers securing the internal signal harness to the generator battery carrier.
  4. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the ground wire bolt.
  6. Tighten
    Tighten the bolt to 2 N·m (18 lb in).


    Object Number: 1403640  Size: SH
  7. Using J 43679 , install the batteries.

  8. Object Number: 1456047  Size: SH
  9. Ensure that the batteries (1, 2, and 3) have the positive and negative terminals properly oriented.

  10. Object Number: 1403639  Size: SH
  11. Install the battery hold down bolts.

  12. Object Number: 1403638  Size: SH
  13. Install the battery hold down brackets.
  14. Install the battery hold down bracket nuts.
  15. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 1403637  Size: SH
  16. Install the service disconnect switch.

  17. Object Number: 1403636  Size: SH
  18. Install the service disconnect switch screws.
  19. Tighten
    Tighten the screws to 6 N·m (53 lb in).


    Object Number: 1456045  Size: SH
  20. Install the service disconnect switch nuts.
  21. Tighten
    Tighten the nuts to 6 N·m (53 lb in).


    Object Number: 1403635  Size: SH
  22. Install the high current connector.

  23. Object Number: 1403634  Size: SH
  24. Install the high current connector screws.
  25. Tighten
    Tighten the screws to 5 N·m (44 lb in).


    Object Number: 1403632  Size: SH
  26. Install the fuse holder.
  27. Install the fuse holder screws.
  28. Tighten
    Tighten the screws to 2 N·m (18 lb in).


    Object Number: 1403631  Size: SH
  29. Install the 120-volt cable.
  30. Connect the retainers securing the 120-volt cable to the generator battery carrier.

  31. Object Number: 1403630  Size: SH
  32. Install the 120-volt cable connector screws.
  33. Tighten
    Tighten the screws to 6 N·m (53 lb in).


    Object Number: 1403629  Size: SH
  34. Install the power cable from the service disconnect switch to the fuse block.
  35. Install the service disconnect power cable nut to the service disconnect switch.
  36. Tighten
    Tighten the nut to 10 N·m (89 lb in).

  37. Install NEW tie straps securing the power cable to the generator battery carrier.

  38. Object Number: 1403628  Size: SH

    Important: The power cable must be installed to the negative side of the high current connector.

  39. Install the power cable (2) to the service disconnect switch and to the high current connector.
  40. Install the service disconnect power cable nuts (1) to the high current connector and service disconnect switch.
  41. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 1403627  Size: SH
  42. Install the battery resistor (3) to the number 3 battery positive terminal.
  43. Install the power cable (2) to the high current connector and the number 3 battery.
  44. Install the power cable nuts (1) to the number 3 battery and high current connector.
  45. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 1459621  Size: SH
  46. Connect the battery resistor electrical connector (1), labeled XR4 to the number 3 battery positive resistor.

  47. Object Number: 1403626  Size: SH
  48. Install the battery resistor (2) to the number 1 battery positive terminal.
  49. Install the power cable (3) to battery 1 and battery 2.
  50. Install the power cable nuts (1) to battery 1 and battery 2.
  51. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  52. Connect the battery resistor electrical connector.

  53. Object Number: 1459628  Size: SH
  54. Connect the battery resistor electrical connector (1), labeled XR2 to the number 1 battery positive resistor.

  55. Object Number: 1403625  Size: SH
  56. Install the high current sensor carrier.
  57. Install the high current sensor carrier nut.
  58. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 1456043  Size: SH
  59. Install the battery resistor to the number 1 battery negative terminal.
  60. Important: The high current sensor orientation is VERY important. The sensor wiring MUST be pointed towards the rear of the vehicle, and also the etched numbers on one side of the sensor terminal MUST be on the battery cut-off switch side.

  61. Install the high current sensor (2).
  62. Install the battery cut-off switch (1).

  63. Object Number: 1403624  Size: SH
  64. Connect the battery cut-off switch electrical connector (3).
  65. Connect the battery resistor electrical connector (1), labeled XR1 to the number 1 battery negative terminal resistor.
  66. Install the battery cut-off switch nuts (2).
  67. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  68. Connect the high current sensor electrical connector.

  69. Object Number: 1403623  Size: SH
  70. Install the battery vent hose(s) to the generator battery carrier.
  71. Engage the retainers securing the battery vent hose(s).
  72. Connect the battery vent hose(s) to the batteries.

  73. Object Number: 1403622  Size: SH
  74. Install the receptacle outlet cover.
  75. Install the receptacle outlet cover screws.
  76. Tighten
    Tighten the screws to 0.5 N·m (4.4 lb in).


    Object Number: 1403621  Size: SH
  77. Install the fan and air duct hose.
  78. Install the screws attaching the air duct hose to the generator battery carrier.
  79. Tighten
    Tighten the nuts to 0.5 N·m (4.4 lb in).

  80. Install the push pin fasteners.
  81. Install the fan screws.
  82. Tighten
    Tighten the nuts to 1 N·m (9 lb in).

  83. Connect the fan electrical connector.
  84. Connect the generator battery carrier vent tube to the outlet duct.
  85. Connect the outlet duct to the generator battery carrier air duct.

  86. Object Number: 1403620  Size: SH
  87. Install the battery resistor (4) to the number 3 battery negative terminal.
  88. Install NEW tie straps securing the power cables to the generator battery carrier.
  89. Install the power cables (3).
  90. Install the battery 2 to battery 3 power cable nuts (1).
  91. Install the power cable nut (2) to the current sensor.
  92. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 1459627  Size: SH
  93. Connect the battery resistor electrical connector (1), labeled XR3 to the number 3 battery negative terminal resistor.

  94. Object Number: 1456037  Size: SH
  95. Install the maxi-fuse (2).
  96. Install the maxi-fuse nuts (1).
  97. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 1403619  Size: SH
  98. Install the maxi-fuse cover.

  99. Object Number: 1403618  Size: SH
  100. Connect the control module electrical connectors.
  101. Install the control module.
  102. Install the control module nuts.
  103. Tighten
    Tighten the nuts to 6 N·m (53 lb in).


    Object Number: 1403617  Size: SH

    Important: Ensure that the generator battery carrier intermediate cover is installed between the generator battery carrier metal carrier and the 120-volt receptacle faceplate.

  104. Install the generator battery carrier intermediate cover.
  105. Install the generator battery carrier intermediate cover screws.
  106. Tighten
    Tighten the screws to 6 N·m (53 lb in).

  107. Install the generator battery carrier carrier. Refer to Generator Battery Carrier Replacement .