- Disconnect the hybrid battery. Refer to
Hybrid Battery Service Disconnect/Connect.
- Remove the battery. Refer to
Battery Replacement
- Remove the radiator surge tank. Refer to
Radiator Surge Tank Replacement.
- Remove the carbon canister. Refer to
Evaporative Emission Canister Replacement.
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.
- Remove and discard the 36-volt positive battery cable lead nut (1).
- Remove the wiring harness ground nut (2).
- Reposition the 36-volt positive battery cable leads (3) out of the way.
- Remove the generator control module cover bolts (1) and cover (2).
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.
- Check the generator control module for voltage potential, in order to ensure the module has been disabled.
| 9.1. | Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts. |
| 9.2. | Measure from the 12-volt positive terminal (4) to a known good chassis ground. The voltage should be less than 3 volts. |
| 9.3. | Measure from the ground terminal (2) 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.
- Verify the generator control module 3-phase cables are disabled.
| 10.1. | Measure from each phase 1, 2 and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts. |
| 10.2. | After verifying there is no voltage present, the generator control module 3-phase cables can now be removed from the generator control module. |
- Remove the 36-volt battery positive cable nut (1) and bolt (2).
- Remove the 36-volt battery positive cable (3).
- Disconnect the plastic retainer clip (1).
- Remove the 36 volt battery positive cable nut (2).
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Remove the 36 volt battery positive cable nut (3).
- Remove the 36-volt battery positive bolts (1).
- Remove the 36-volt battery positive bolts (1) and nuts (2).
- Squeeze the rubber grommet (3) from the top of the vehicle and push the 36-volt battery positive cable out.
