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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 >> Removal Procedure

Removal 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.
    WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
    The High Voltage Disabling procedure will perform the following tasks:
    • Identify how to disable high voltage.
    • Identify how to test for the presence of high voltage.
    • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

    Failure to follow the procedures exactly as written may result in serious injury or death.
  1. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling .
    2. Fig 1: Identifying Generator Control Module Assembly Connectors & Fasteners
    GM2175739Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the drive motor generator control module assembly connector (3).
  3. Slide the wire harness clip from the drive motor generator position sensor shield circuit harness terminal fastener.
  4. Remove the drive motor generator position sensor shield circuit harness terminal fastener (5).
  5. Remove the shield circuit harness terminal (4).
  6. Disconnect the accessory DC power control module (APM) assembly connector (2) using the following procedure:
    1. Remove the locking tab.
    2. Insert a small flat blade screwdriver into the locking tab area and raise the tab while pulling on the connector.
  7. Disconnect the remaining APM assembly connector (1).
  8. Drain the power electronics cooling system. Refer to Generator Control Module Cooling System Draining and Filling .
    9. Fig 2: HV dc Battery And Air Conditioning Compressor Module (ACCM) Cable Terminals & Fasteners
    GM2175740Courtesy of GENERAL MOTORS CORP.
  9. Remove the HV dc battery and air conditioning compressor module (ACCM) cable terminal fasteners (1) and installation guide assembly (2).
  10. Remove the HV dc electric ACCM cable mounting fasteners (5).
  11. Remove the HV dc electric ACCM cable (4) from the PIM distribution box.
  12. Remove the HV dc battery cable mounting fasteners (6).
  13. Remove the HV dc battery cable (7) from the PIM distribution box.
  14. Inspect and retain the seals (3).
    15. Fig 3: Drive Motor Generator Control Module Support Bracket & Bolts
    GM2175741Courtesy of GENERAL MOTORS CORP.
  15. Remove the windshield washer solvent container filler tube assembly bolt.
  16. Remove the drive motor generator control module support bracket bolts (1) and the support bracket (2).
  17. Place a protective guard (3) such as wiring conduit along the sharp edge of the front crossmember to protect the high voltage cables.
    18. Fig 4: PIM 3 Phase Cable Housing, Cover, Fasteners & Seals
    GM2175742Courtesy of GENERAL MOTORS CORP.
    CAUTION: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper:
    • Cable sealing
    • Electrical shielding
    • Terminal position assurance
  18. Remove the drive motor generator power inverter control module (PIM) 3 phase cable housing cover fasteners (1).
  19. Remove the PIM 3 phase cable housing cover (2).
  20. Remove the PIM 3 phase cable terminal fastener (4).
  21. Remove the PIM 3 phase cable housing assembly (5).
  22. Remove the PIM 3 phase cable terminal seals (3) and discard.
  23. Remove the sight shield circuit breaker fasteners (6).
  24. Remove the sight shield circuit breaker (7).
    25. Fig 5: PIM 3 Phase Cable Mounting Fasteners, Terminal & Seals
    GM2175743Courtesy of GENERAL MOTORS CORP.
  25. Remove the PIM 3 phase cable terminal fasteners (1) and installation guide assembly (2).
  26. Remove the PIM 3 phase cable mounting fasteners (3) and terminal (4).
  27. Remove the PIM 3 phase cable terminal seal (5) and discard.
    28. Fig 6: Hybrid Cooling Surge Tank
    GM2175724Courtesy of GENERAL MOTORS CORP.
  28. Remove the hybrid cooling surge tank fasteners (1, 3) and pull the surge tank (2) off of the control module stud (4).
    29. Fig 7: APM Ground Strap & Nut
    GM2175725Courtesy of GENERAL MOTORS CORP.
  29. Remove the APM ground strap nut (1) and APM ground strap (2) from the left front inner fender.
    30. Fig 8: Underhood Fuse Block Support & Engine Coolant Recovery Reservoir Support Fasteners
    GM2175726Courtesy of GENERAL MOTORS CORP.
  30. Remove the underhood fuse block support fastener (1) and pull the support away from the control module.
  31. Remove the engine coolant recovery reservoir support fastener (2).
    32. NOTE: A service replacement APM does not have the engine coolant recovery reservoir support stud installed. Remove and save the stud for installation onto the replacement APM.
  32. Remove the engine coolant recovery reservoir support stud (3) from the control module.
    33. Fig 9: Generator Control Module Coolant Inlet Hose
    GM2152484Courtesy of GENERAL MOTORS CORP.
  33. Remove the generator control module coolant inlet hose (2) and hose clamp (1) from the control module radiator.
    34. Fig 10: Generator Control Module Coolant Outlet Hose At Radiator Surge Tank Air Separator
    GM2152396Courtesy of GENERAL MOTORS CORP.
  34. Remove the generator control module coolant outlet hose (2) and hose clamp (1) from the radiator surge tank air separator.
    35. Fig 11: Control Module Assembly Mounting Retainer Bolt And Nut
    GM2175728Courtesy of GENERAL MOTORS CORP.

  35. Remove the control module assembly mounting retainer bolt (1) and assembly mounting nuts (2).

    36. Fig 12: Lifting Device
    GM2175729Courtesy of GENERAL MOTORS CORP.
  36. Attach a lifting device (1 and 2) to the drive motor generator control module assembly at the 3 identified locations.
  37. Lift the drive motor generator control module assembly from the vehicle while feeding the coolant hoses through the support opening.
  38. To replace the drive motor generator power inverter module (PIM) assembly, refer to Drive Motor Generator Power Inverter Module Removal and Installation . To replace the accessory DC power control module (APM), refer to Accessory DC Power Control Module Removal and Installation .
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