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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1961 (Hybrid Controls - 3.6L (Hp5) - Introduction) >> Repair Instructions >> Drive Motor Generator Control Module Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Lifting Device
    GM2175729Courtesy of GENERAL MOTORS CORP.
  1. Attach a lifting device (1-2) to the drive motor generator control module assembly at the three identified locations.
  2. Lower the drive motor generator control module assembly into the vehicle while feeding the coolant hoses through the support opening.
    3. Fig 2: Generator Control Module Coolant Inlet Hose
    GM2152484Courtesy of GENERAL MOTORS CORP.
  3. Install the generator control module coolant inlet hose (2) and hose clamp (1) onto the control module radiator.
    4. Fig 3: Generator Control Module Coolant Outlet Hose At Radiator Surge Tank Air Separator
    GM2152396Courtesy of GENERAL MOTORS CORP.
  4. Install the generator control module coolant outlet hose (2) and hose clamp (1) to the radiator surge tank air separator.
    5. Fig 4: Control Module Assembly Mounting Retainer Bolt And Nut
    GM2175728Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  5. Install the control module assembly mounting retaining bolt (1) and assembly mounting nuts (2). Tighten the mounting bolt and nuts to 9 N.m (80 lb in).
    6. Fig 5: Underhood Fuse Block Support & Engine Coolant Recovery Reservoir Support Fasteners
    GM2175726Courtesy of GENERAL MOTORS CORP.
  6. Install the underhood fuse block support and fastener (1) onto the control module. Tighten the bolt to 5 N.m (44 lb in).
  7. Install the engine coolant recovery reservoir support stud (3) through the support and into the control module. Tighten the stud to 9 N.m (80 lb in).
  8. Install the engine coolant recovery reservoir support fastener (2) onto the control module stud. Tighten the fastener to 5 N.m (44 lb in).
    9. Fig 6: APM Ground Strap & Nut
    GM2175725Courtesy of GENERAL MOTORS CORP.
  9. Install the APM ground strap (2) and APM ground strap nut (1) onto the left front inner fender stud and tighten to 9 N.m (80 lb in).
    10. Fig 7: Hybrid Cooling Surge Tank
    GM2175724Courtesy of GENERAL MOTORS CORP.
  10. Install the hybrid cooling surge tank (2) onto the control module and body support stud (4). Install the control module fasteners (1, 3) and tighten to 7.5 N.m (66 lb in).
    11. Fig 8: PIM 3 Phase Cable Mounting Fasteners, Terminal & Seals
    GM2175743Courtesy of GENERAL MOTORS CORP.
  11. Install a new seal (5) and the PIM 3 phase cable assembly terminal (4).
  12. Install the PIM 3 phase cable terminal mounting fasteners (3) and tighten to 9 N.m (80 lb in).
  13. Install the PIM 3 phase cable terminal installation guide assembly (2) and cable terminal fasteners (1). Tighten to 9 N.m (80 lb in).
    14. Fig 9: PIM 3 Phase Cable Housing, Cover, Fasteners & Seals
    GM2175742Courtesy of GENERAL MOTORS CORP.
  14. Install NEW PIM 3 phase cable terminal seals (3).
  15. Install the PIM 3 phase cable housing assembly (5).
  16. Install the PIM 3 phase cable terminal fasteners (4) and tighten to 9 N.m (80 lb in).
    17. NOTE: DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended.
  17. Clean the sealing surface of the housing cover as necessary.
  18. Install the PIM 3 phase cable housing cover (2).
  19. Install the PIM 3 phase cable housing cover fasteners (1) and tighten to 9 N.m (80 lb in).
  20. Install the sight shield circuit breaker (7).
  21. Install the sight shield circuit breaker fasteners (6) and tighten to 9 N.m (80 lb in).
    22. Fig 10: Drive Motor Generator Control Module Support Bracket & Bolts
    GM2175741Courtesy of GENERAL MOTORS CORP.
  22. Remove the protective guard (3) from the front crossmember.
  23. Install the drive motor generator control module support bracket (2) and start all of the support bracket bolts (1). Tighten the bolts to 11 N.m (97 lb in).
  24. Install the windshield washer solvent container filler tube assembly bolt and tighten to 10 N.m (89 lb in).
    25. Fig 11: HV dc Battery And Air Conditioning Compressor Module (ACCM) Cable Terminals & Fasteners
    GM2175740Courtesy of GENERAL MOTORS CORP.
  25. Inspect and install the seals (3).
  26. Install the HV dc battery cable (7) onto the PIM distribution box.
  27. Install the HV dc battery cable mounting fasteners (6) and tighten to 9 N.m (80 lb in).
  28. Install the HV dc electric ACCM cable (4) onto the PIM distribution box.
  29. Install the HV dc electric ACCM cable mounting fasteners (5) and tighten to 9 N.m (80 lb in).
  30. Install the HV dc battery and ACCM cable terminal bolt installation guide assembly (2).
  31. Install the HV dc battery and ACCM cable terminal fasteners (1) and tighten to 9 N.m (80 lb in).
    32. Fig 12: HV dc Cable Cover Seal
    GM2203565Courtesy of GENERAL MOTORS CORP.
  32. Install a new HV dc cable cover seal (3).
    33. NOTE: DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended.
  33. Clean the sealing surface of the cable cover (2) as necessary.
  34. Install the HV dc cable cover (2) and cover fasteners (1) and tighten to 9 N.m (80 lb in).
    35. Fig 13: Identifying Generator Control Module Assembly Connectors & Fasteners
    GM2175739Courtesy of GENERAL MOTORS CORP.
  35. Connect the APM assembly connectors (1-2) and install any removed locking tabs.
  36. Connect the drive motor generator control module assembly connector (3) using the following procedure:
    1. Push the lever up.
      2. NOTE: Install the connector (3) without disturbing the position of the lever. DO NOT use the lever to install the connector in place.
    2. Install the connector (3) onto the terminals by pushing on the connector only.
    3. Rotate the lever after the terminals are engaged.
    4. Push the green tab to lock the lever.
  37. Install the shield circuit harness terminal (4) and terminal fastener (5). Tighten to 9 N.m (80 lb in).
  38. Slide the wire harness clip onto the protruding stud of the shield circuit harness fastener.
  39. Fill the power electronics cooling system and test for leaks at all serviced connections. Refer to Generator Control Module Cooling System Draining and Filling .
  40. Install the sight shield. Refer to Drive Motor Generator Power Inverter Module Cover Replacement .
  41. Perform the High Voltage Enabling procedure. Refer to High Voltage Enabling
  42. For control module programming and setup procedures, refer to Control Module References .
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