36-Volt Battery Positive Cable Replacement Passenger Compartment to Module

Warning: 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 and discard the 36-volt positive battery cable lead nut (3).
3. Remove the 36-volt positive battery cable lead nut (1).
4. Remove the 36-volt positive battery cable leads (2).



5. Remove the 36-volt positive battery cable retainer bolt (1).
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



7. Remove the 36-volt positive battery cable clip nut (4).
8. Remove the 36-volt positive battery cable casting nuts (3).
9. Carefully lower the 36-volt positive battery cable casting (2) until the cable connector and 36-volt positive battery cable pigtail connector (1) is accessible.



10. Disconnect the 36-volt positive battery cable pigtail connector (1) from the 36-volt positive battery cable casting (3) by rotating the connector ring (2) on the pigtail counterclockwise.
11. Lower the vehicle



12. Remove the 36-volt positive battery cable pigtail connector (1).

1. Install the 36-volt positive battery cable pigtail connector (1).
2. Raise and suitably support the vehicle.



3. Align the 36-volt positive battery cable pigtail connection keyway (2) with the paint dot (1) on the 36-volt positive battery cable casting. Once aligned, rotate the pigtail lock ring (3) securing the connection.



4. Carefully feed the 36-volt positive battery cable pigtail into the rear compartment panel until the 36-volt positive battery cable casting (2) is seated onto the studs.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the 36-volt positive battery cable casting nuts (3). Tighten the nuts to 9 N·m (80 lb in).
6. Install the 36-volt positive battery cable clip nut (4). Tighten the nuts to 9 N·m (80 lb in).
7. Lower the vehicle.



8. Position the 36-volt positive battery cable retainer (2) to the fan cover.
9. Install the 36-volt positive battery cable retainer bolt (1). Tighten the bolt to 8 N·m (71 lb in).



10. Install the 36-volt positive battery cable leads (2).
11. Install the 36-volt positive battery cable lead nut (1). Tighten the nut to 9 N·m (18 lb in).
12. Install a NEW 36-volt positive battery cable lead nut (3). Start the nut finger tight, and then torque to the specification given. Tighten the nut to 15 N·m (11 lb ft).
13. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect.

36-Volt Battery Positive Cable Replacement Engine to Passenger Compartment

Special Tools

J 45059 Angle Meter

1. Disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect.
2. Remove the fuel tank. Refer to Fuel Tank Replacement.
3. Remove the (12-volt) battery tray. Refer to Battery Tray Replacement.
4. Remove the left rear frame bolts (4).
5. Remove the left rear frame reinforcement (3).
6. Lower the vehicle.



7. Disconnect the 2 connector position assurance (CPA) retainers (3).

Warning: To help avoid personal injury, additional precautions must be taken prior to working on the generator control module or the generator starter. After removing the 36V battery cables from the generator battery, remove both engine wiring harness connectors from the generator control module. Wait at least 5 minutes and then remove the generator control module cover. Verify voltage levels at all 36V, 12V, and 3-phase connections, are less than 3 volts using a DMM before proceeding.

8. Disconnect the 2 engine wiring harness electrical connectors (2) from the generator control module.
9. WAIT at least 5 minutes in order to allow the voltage stored in the generator control module to discharge.



10. Remove the generator control module bracket reinforcement bolt (1) and nuts (2).
11. Remove the generator control module bracket reinforcement (3).



12. Loosen the generator control module cover integral bolts (1) and remove the cover (2).



13. The generator control module will have to be checked for voltage potential using a voltmeter. First, verify that the voltmeter works:

13.1.

Set the voltmeter to DC voltage.

13.2.

Measure the vehicle's 12-volt battery voltage.

13.3.

The meter should read greater than plus 12 volts DC.

14. Now, check the generator control module for voltage potential, in order to ensure that the module has been disabled.

14.1.

Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts.

14.2.

Measure from the 12-volt positive terminal (2) to a known good chassis ground. The voltage should be less than 3 volts.

14.3.

Measure from the ground terminal (4) to a known good chassis ground, checking for continuity.

Warning: To help avoid personal injury, always treat the 3-phase cable and connectors as if voltage is present and as if the surface of all parts of the cable is hot.

15. Verify that the generator control module 3-phase cables are disabled.

15.1.

Measure from each phase 1, 2, and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts.

15.2.

After verifying that there is no voltage present, the 12-volt and 36-volt positive battery cables can now be removed from the generator control module.




16. Remove the 36-volt terminal block nuts (1) from the generator control module.
17. Lift up, and reposition the 36-volt terminal block (2). Discard the terminal block seal.



18. Remove the 36-volt terminal block to cable bolt (1).
19. Remove the 36-volt contact (2) and retainer (3).
20. Remove the 36-volt cable insulator (4).
21. Remove the 36-volt cable to terminal block bolt (6).
22. Remove the 36-volt cable terminal block (5) from the cable.



23. Remove the 36-volt positive battery cable clip (1) from the side rail.
24. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
25. Remove the 36-volt positive battery cable clips (2) from the side rail and the front of dash.



26. Remove the 36-volt positive battery cable clip nut (4).
27. Remove the 36-volt positive battery cable casting nuts (3).
28. Carefully lower the 36-volt positive battery cable casting (2) until the cable connector and 36-volt positive battery cable pigtail connector (1) is accessible.



29. Disconnect the 36-volt positive battery cable pigtail connector (1) from the 36-volt positive battery cable casting (3) by rotating the connector ring (2) on the pigtail counterclockwise.



30. Have an assistant support the 36-volt positive battery cable.
31. Remove the 36-volt positive battery cable to underbody nuts (2).
32. Remove the 36-volt positive battery cable (1) from the vehicle.

1. With the aid of an assistant, position the 36-volt positive battery cable (1) to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the 36-volt positive battery cable to underbody nuts (2). Tighten the nuts to 9 N·m (80 lb in).



3. Align the 36-volt positive battery cable pigtail connection keyway (2) with the paint dot (1) on the 36-volt positive battery cable casting. Once aligned, rotate the pigtail lock ring (3) securing the connection.



4. Carefully feed the 36-volt positive battery cable pigtail into the rear compartment panel until the 36-volt positive battery cable casting (2) is seated onto the studs.
5. Install the 36-volt positive battery cable casting nuts (3). Tighten the nuts to 9 N·m (80 lb in).
6. Install the 36-volt positive battery cable clip nut (4). Tighten the nuts to 9 N·m (80 lb in).



7. Install the 36-volt positive battery cable clips (2) to the side rail and the front of dash.
8. Lower the vehicle.
9. Install the 36-volt positive battery cable clip (1) to the side rail.



10. Install the 36-volt cable terminal block (5) to the cable.
11. Install the 36-volt cable to the terminal block bolt (6). Tighten the bolt to 9 N·m (80 lb in).
12. Install the 36-volt cable insulator (4).
13. Install the 36-volt retainer (3) and contact (2).
14. Install the 36-volt terminal block to cable bolt (1). Tighten the bolt to 9 N·m (80 lb in).



15. Place a NEW terminal block seal onto the generator control module.
16. Position the 36-volt terminal block (2) to the generator control module.
17. Install the 36-volt terminal block nuts (1) to the generator control module. Tighten the nuts to 10 N·m (89 lb in).



18. Place the generator control module cover (2) on top of the generator control module and tighten the bolts (1). Tighten the nuts to 10 N·m (89 lb in).



19. Install the generator control module bracket reinforcement (3).
20. Install the generator control module bracket reinforcement bolt (1) and nuts (2). Tighten the nuts to 10 N·m (89 lb in).



21. Connect the 2 engine wiring harness electrical connectors (2) to the generator control module.
22. Connect the 2 CPA retainers (3).
23. Raise and suitably support the vehicle.



24. Install the left rear frame reinforcement (3).
25. Install the left rear frame bolts (4). Tighten the bolts to 100 N·m (74 lb ft) plus an additional 90 degrees using the J 45059 .
26. Install the (12-volt) battery tray. Refer to Battery Tray Replacement.
27. Install the fuel tank. Refer to Fuel Tank Replacement.
28. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect.