GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

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.


    Object Number: 1892883  Size: SH
  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. Object Number: 1892885  Size: SH
  5. Remove the generator battery fuse (1) from the generator battery disconnect module negative stud.

  6. Object Number: 1892886  Size: SH
  7. Remove and discard the 36-volt positive battery cable lead nut (3).
  8. Remove the 36-volt positive battery cable lead nut (1).
  9. Remove the 36-volt positive battery cable leads (2).
  10. Secure the cables out of the way, ensuring that the cables CANNOT be re-installed without your knowledge.

  11. Object Number: 1892879  Size: SH
  12. Disconnect the body wiring harness electrical connector (1) from the generator battery disconnect control module pigtail.

  13. Object Number: 1892888  Size: SH
  14. Remove the 2 generator battery vent fan cover bolts (2).
  15. Remove the 12 generator battery cover bolts (1).

  16. Object Number: 1892893  Size: SH
  17. Remove the generator battery cover (1).

  18. Object Number: 1892895  Size: SH

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

  19. Remove the generator battery terminal covers.
  20. Remove the generator battery cable nuts.
  21. Remove the generator battery cable leads (1, 2, and 3) from the batteries.
  22. Remove the 2 small temperature sensor wiring harness terminal leads located under the battery cable leads from the batteries.

  23. Object Number: 1831950  Size: SH
  24. Remove the generator battery control module nut (4), and the battery cable (3) from the stud.
  25. Remove the generator battery control module nut (8), and the battery cable (7) from the stud.

  26. Object Number: 1831951  Size: SH
  27. Disconnect the wiring harness electrical connector (1) from the vent fan electrical connector.
  28. Disconnect the generator battery temperature sensor wiring harness electrical connectors (2, 5) from the generator control module.
  29. Reposition the battery cables and the generator battery temperature sensor wiring harness out of the way.

  30. Object Number: 1892896  Size: SH
  31. Remove the generator battery disconnect control module pigtail (2) clip from the side of the battery carrier.
  32. Unclip the fan harness retainer from the battery.
  33. Remove the 4 generator battery disconnect control module bolts.
  34. Remove the generator battery disconnect control module (1).

Installation Procedure


    Object Number: 1892896  Size: SH
  1. Install the generator battery disconnect control module (1).
  2. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the 4 generator battery disconnect control module bolts. Tighten the bolts to 8 N·m (71 lb in).
  4. Clip the fan harness retainer to the battery.
  5. Install the generator battery disconnect control module pigtail (2) clip to the side of the battery carrier.

  6. Object Number: 1831951  Size: SH
  7. Position the generator battery temperature sensor wiring harness and the battery cables to the generator control module.
  8. Connect the generator battery temperature sensor wiring harness electrical connectors (2, 5) to the generator control module.
  9. Connect the wiring harness electrical connector (1) to the vent fan electrical connector.

  10. Object Number: 1831950  Size: SH
  11. Ensure that the generator battery temperature sensor wiring harness terminals (5, 6) and installed on the generator battery control module studs.
  12. Install the battery cable (7), and the generator battery control module nut (8) to the stud. Tighten the nut to 8 N·m (71 lb in).
  13. Install the battery cable (3), and the generator battery control module nut (4) to the stud. Tighten the nut to 8 N·m (71 lb in).

  14. Object Number: 1892895  Size: SH
  15. Install the 2 small temperature sensor wiring harness terminal leads to the batteries.
  16. Install the generator battery cable leads (1, 2, and 3) to the batteries.
  17. Install the generator battery cable nuts. Tighten the nut to 8 N·m (71 lb in).
  18. Install the generator battery terminal covers.

  19. Object Number: 1892893  Size: SH
  20. Install the generator battery cover (1).

  21. Object Number: 1892888  Size: SH
  22. Install the 12 generator battery cover bolts (1). Tighten the bolts to 8 N·m (71 lb in).
  23. Install the 2 generator battery vent fan cover bolts (2). Tighten the bolts to 8 N·m (71 lb in).

  24. Object Number: 1892879  Size: SH
  25. Connect the body wiring harness electrical connector (1) to the generator battery disconnect control module pigtail.

  26. Object Number: 1892886  Size: SH
  27. Install the 36-volt positive battery cable leads (2).
  28. Install the 36-volt positive battery cable lead nut (1). Tighten the nut to 9 N·m (18 lb in).
  29. 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).

  30. Object Number: 1892885  Size: SH
  31. Install the generator battery fuse (1) to the generator battery disconnect module negative stud.

  32. Object Number: 1892883  Size: SH

    Note: 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.

  33. 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.
  34. Install the 36-volt negative battery cable lead (1) and nut to the generator battery disconnect module negative stud. Tighten the nut to 10.7 N·m (95 lb in).
  35. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect.