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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1967 (Hybrid Energy Storage System - 2.4L (Hp7)) >> Repair Instructions >> 36-Volt Battery Positive Cable 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.
    Fig 1: Positive Battery Cable Lead Nut
    GM2034008Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
  2. Remove the battery. Refer to Battery Replacement (HP7)
  3. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
  4. Remove the carbon canister. Refer to Evaporative Emission Canister Replacement .
    5. 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.
  5. Remove and discard the 36-volt positive battery cable lead nut (1).
  6. Remove the wiring harness ground nut (2).
  7. Reposition the 36-volt positive battery cable leads (3) out of the way.
    8. Fig 2: Generator Control Module Cover Bolts And Cover
    GM1998181Courtesy of GENERAL MOTORS CORP.
  8. Remove the generator control module cover bolts (1) and cover (2).
    9. Fig 3: Positive And Ground Terminal
    GM1998192Courtesy of GENERAL MOTORS CORP.
    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.
  9. Check the generator control module for voltage potential, in order to ensure the module has been disabled.
    1. Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts.
    2. Measure from the 12-volt positive terminal (4) to a known good chassis ground. The voltage should be less than 3 volts.
    3. Measure from the ground terminal (2) to a known good chassis ground, checking for continuity.
    10. 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.
  10. Verify the generator control module 3-phase cables are disabled.
    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.
    2. After verifying there is no voltage present, the generator control module 3-phase cables can now be removed from the generator control module.
    3. If 3 volts or more are present, repeat the disconnect procedure. Refer to Hybrid Battery Service Disconnect/Connect .
    11. Fig 4: Battery Positive Cable Nut And Bolt
    GM1999027Courtesy of GENERAL MOTORS CORP.
  11. Remove the 36-volt battery positive cable nut (1) and bolt (2).
  12. Remove the 36-volt battery positive cable (3).
    13. Fig 5: Plastic Retainer Clip
    GM1999167Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the plastic retainer clip (1).
  14. Remove the 36 volt battery positive cable nut (2).
  15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  16. Remove the 36 volt battery positive cable nut (3).
    17. Fig 6: Battery Positive Bolts
    GM1999169Courtesy of GENERAL MOTORS CORP.
  17. Remove the 36-volt battery positive bolts (1).
    18. Fig 7: Battery Positive Bolts And Nuts
    GM1999233Courtesy of GENERAL MOTORS CORP.
  18. Remove the 36-volt battery positive bolts (1) and nuts (2).
  19. Squeeze the rubber grommet (3) from the top of the vehicle and push the 36-volt battery positive cable out.
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