Caution: To help avoid personal injury, be careful when working in the vicinity of the generator battery disconnect control module. Internal components will still be live, 36V potential, even when the cover has been opened or removed.

1. Disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
2. Remove the plastic nut (2) from the generator battery disconnect control module negative stud.
3. Remove the 36-volt negative battery cable lead (1) from the generator battery disconnect control module negative stud.



4. Remove the generator battery fuse (1) from the generator battery disconnect module negative stud.



5. Remove and discard the 36-volt positive battery cable lead nut (3).
6. Remove the 36-volt positive battery cable lead nut (1).
7. Remove the 36-volt positive battery cable leads (2).
8. Secure the cables out of the way, ensuring that the cables CANNOT be re-installed without your knowledge.



9. Disconnect the body wiring harness electrical connector (1) from the generator battery disconnect control module pigtail.



10. Remove the 2 generator battery vent fan cover bolts (2).
11. Remove the 12 generator battery cover bolts (1).



12. Remove the generator battery cover (1).




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

13. Remove the generator battery terminal covers.
14. Remove the generator battery cable nuts.
15. Remove the generator battery cable leads (1, 2, and 3) from the batteries.
16. Remove the 2 small temperature sensor wiring harness terminal leads located under the battery cable leads from the batteries.



17. Remove the generator battery control module nut (4), and the battery cable (3) from the stud.
18. Remove the generator battery control module nut (8), and the battery cable (7) from the stud.



19. Disconnect the wiring harness electrical connector (1) from the vent fan electrical connector.
20. Disconnect the generator battery temperature sensor wiring harness electrical connectors (2, 5) from the generator control module.
21. Reposition the battery cables and the generator battery temperature sensor wiring harness out of the way.



22. Remove the generator battery disconnect control module pigtail (2) clip from the side of the battery carrier.
23. Unclip the fan harness retainer from the battery.
24. Remove the 4 generator battery disconnect control module bolts.
25. Remove the generator battery disconnect control module (1).

1. Install the generator battery disconnect control module (1).

Notice: Refer to Fastener Notice in the Preface section.

2. Install the 4 generator battery disconnect control module bolts.

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

3. Clip the fan harness retainer to the battery.
4. Install the generator battery disconnect control module pigtail (2) clip to the side of the battery carrier.



5. Position the generator battery temperature sensor wiring harness and the battery cables to the generator control module.
6. Connect the generator battery temperature sensor wiring harness electrical connectors (2, 5) to the generator control module.
7. Connect the wiring harness electrical connector (1) to the vent fan electrical connector.



8. Ensure that the generator battery temperature sensor wiring harness terminals (5, 6) and installed on the generator battery control module studs.
9. Install the battery cable (7), and the generator battery control module nut (8) to the stud.

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

10. Install the battery cable (3), and the generator battery control module nut (4) to the stud.

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




11. Install the 2 small temperature sensor wiring harness terminal leads to the batteries.
12. Install the generator battery cable leads (1, 2, and 3) to the batteries.
13. Install the generator battery cable nuts.

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

14. Install the generator battery terminal covers.



15. Install the generator battery cover (1).



16. Install the 12 generator battery cover bolts (1).

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

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

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




18. Connect the body wiring harness electrical connector (1) to the generator battery disconnect control module pigtail.



19. Install the 36-volt positive battery cable leads (2).
20. Install the 36-volt positive battery cable lead nut (1).

Tighten
Tighten the nut to 9 N·m (18 lb in).

21. Install a NEW 36-volt positive battery cable lead nut (3). Start the nut finger tight, and then torque to the specification given.

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




22. Install the generator battery fuse (1) yo the generator battery disconnect module negative stud.




Important: Position the plastic nut to the negative battery cable and ensure that the nipple is inserted to the terminal prior to installing the negative cable to the generator battery, Otherwise damage to the nut may occur.

23. Position the plastic nut (2) to the 36-volt negative battery cable lead ensuring that the nipple on the plastic nut is inserted through the hole in the terminal.
24. Install the 36-volt negative battery cable lead (1) and nut to the generator battery disconnect module negative stud.

Tighten
Tighten the nut to 10.7 N·m (95 lb in).

25. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .