LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 981 (Battery, Charging System & Starting System) >> Repair Instructions >> Energy Storage Box (ESB) Carrier Disassemble/Assemble (5.3L w/RPO HP2) >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If necessary, install any retainers (1), clips (2), or fasteners (3).
    2. Fig 1: View Of Retainers & Fasteners (5.3L Engine w/RPO HP2)
    GM1403641Courtesy of GENERAL MOTORS CORP.
  2. Install the internal signal harness from the ESB.
  3. Engage the retainers securing the internal signal harness to the ESB.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the ground wire bolt.

    Tighten:  Tighten the bolt to 2 N.m (18 lb in).

  5. Using J 43679  , install the batteries.
    6. Fig 2: View Of Battery (5.3L Engine w/RPO HP2)
    GM1403640Courtesy of GENERAL MOTORS CORP.
  6. Ensure that the batteries (1, 2, and 3) have the positive and negative terminals properly oriented.
    7. Fig 3: Battery Proper Installation Positions (5.3L Engine w/RPO HP2)
    GM1456047Courtesy of GENERAL MOTORS CORP.
  7. Install the battery hold down bolts.
    8. Fig 4: View Of Battery Hold Down Bolts (5.3L Engine w/RPO HP2)
    GM1403639Courtesy of GENERAL MOTORS CORP.
  8. Install the battery hold down brackets.
  9. Install the battery hold down bracket nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    10. Fig 5: View Of Battery Hold Down Bracket & Nut (5.3L Engine w/RPO HP2)
    GM1403638Courtesy of GENERAL MOTORS CORP.
  10. Install the service disconnect switch.
    11. Fig 6: View Of Service Disconnect Switch (5.3L Engine w/RPO HP2)
    GM1403637Courtesy of GENERAL MOTORS CORP.
  11. Install the service disconnect switch screws.

    Tighten:  Tighten the screws to 6 N.m (53 lb in).

    12. Fig 7: View Of Service Disconnect Switch Screws (5.3L Engine w/RPO HP2)
    GM1403636Courtesy of GENERAL MOTORS CORP.
  12. Install the service disconnect switch nuts.

    Tighten:  Tighten the nuts to 6 N.m (53 lb in).

    13. Fig 8: View Of Service Disconnect Switch Nuts (5.3L Engine w/RPO HP2)
    GM1456045Courtesy of GENERAL MOTORS CORP.
  13. Install the high current connector.
    14. Fig 9: View Of HCC (5.3L Engine w/RPO HP2)
    GM1403635Courtesy of GENERAL MOTORS CORP.
  14. Install the high current connector screws.

    Tighten:  Tighten the screws to 5 N.m (44 lb in).

    15. Fig 10: View Of HCC Screws (5.3L Engine w/RPO HP2)
    GM1403634Courtesy of GENERAL MOTORS CORP.
  15. Install the fuse holder.
  16. Install the fuse holder screws.

    Tighten:  Tighten the screws to 2 N.m (18 lb in).

    17. Fig 11: View Of Fuse Holder & Screws (5.3L Engine w/RPO HP2)
    GM1403632Courtesy of GENERAL MOTORS CORP.
  17. Install the 120-volt cable.
  18. Connect the retainers securing the 120-volt cable to the ESB.
    19. Fig 12: View Of 120-Volt Cable (5.3L Engine w/RPO HP2)
    GM1403631Courtesy of GENERAL MOTORS CORP.
  19. Install the 120-volt cable connector screws.

    Tighten:  Tighten the screws to 6 N.m (53 lb in).

    20. Fig 13: View Of 120-Volt Cable Connector Screws (5.3L Engine w/RPO HP2)
    GM1403630Courtesy of GENERAL MOTORS CORP.
  20. Install the power cable from the service disconnect switch to the fuse block.
    21. Fig 14: View Of Service Disconnect Switch Power Cable & Nut (5.3L Engine w/RPO HP2)
    GM1403629Courtesy of GENERAL MOTORS CORP.
  21. Install the service disconnect power cable nut to the service disconnect switch.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

  22. Install NEW tie straps securing the power cable to the ESB.
    23. IMPORTANT: The power cable must be installed to the negative side of the high current connector.
  23. Install the power cable (2) to the service disconnect switch and to the high current connector.
  24. Install the service disconnect power cable nuts (1) to the high current connector and service disconnect switch.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    25. Fig 15: View Of Service Disconnect Power Cable & Nut (5.3L Engine w/RPO HP2)
    GM1403628Courtesy of GENERAL MOTORS CORP.
  25. Install the battery resistor (3) to the number 3 battery positive terminal.
  26. Install the power cable (2) to the high current connector and the number 3 battery.
  27. Install the power cable nuts (1) to the number 3 battery and high current connector.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    28. Fig 16: View Of High Current Power Cable (5.3L Engine w/RPO HP2)
    GM1403627Courtesy of GENERAL MOTORS CORP.
  28. Connect the battery resistor electrical connector (1), labeled XR4 to the number 3 battery positive resistor.
    29. Fig 17: View Of Battery Resistor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1459621Courtesy of GENERAL MOTORS CORP.
  29. Install the battery resistor (2) to the number 1 battery positive terminal.
  30. Install the power cable (3) to battery 1 and battery 2.
  31. Install the power cable nuts (1) to battery 1 and battery 2.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    32. Fig 18: View Of Battery Resistor, Power Cable & Nuts (5.3L Engine w/RPO HP2)
    GM1403626Courtesy of GENERAL MOTORS CORP.
  32. Connect the battery resistor electrical connector.
  33. Connect the battery resistor electrical connector (1), labeled XR2 to the number 1 battery positive resistor.
    34. Fig 19: View Of Battery Resistor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1459628Courtesy of GENERAL MOTORS CORP.
  34. Install the high current sensor carrier.
  35. Install the high current sensor carrier nut.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    36. Fig 20: View Of High Current Sensor Carrier & Nut (5.3L Engine w/RPO HP2)
    GM1403625Courtesy of GENERAL MOTORS CORP.
  36. Install the battery resistor to the number 1 battery negative terminal.
    37. IMPORTANT: The high current sensor orientation is VERY important. The sensor wiring MUST be pointed towards the rear of the vehicle, and also the etched numbers on one side of the sensor terminal MUST be on the battery cut-off switch side.
  37. Install the high current sensor (2).
  38. Install the battery cut-off switch (1).
    39. Fig 21: View Of High Current Sensor & Battery Cut-Off Switch (5.3L Engine w/RPO HP2)
    GM1456043Courtesy of GENERAL MOTORS CORP.
  39. Connect the battery cut-off switch electrical connector (3).
  40. Connect the battery resistor electrical connector (1), labeled XR1 to the number 1 battery negative terminal resistor.
  41. Install the battery cut-off switch nuts (2).

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    42. Fig 22: View Of Battery Cut-Off Switch, Electrical Connectors & Nuts (5.3L Engine w/RPO HP2)
    GM1403624Courtesy of GENERAL MOTORS CORP.
  42. Connect the high current sensor electrical connector.
  43. Install the battery vent hose(s) to the ESB.
  44. Engage the retainers securing the battery vent hose(s).
  45. Connect the battery vent hose(s) to the batteries.
    46. Fig 23: View Of Battery Vent Hose (5.3L Engine w/RPO HP2)
    GM1403623Courtesy of GENERAL MOTORS CORP.
  46. Install the receptacle outlet cover.
  47. Install the receptacle outlet cover screws.

    Tighten:  Tighten the screws to 0.5 N.m (4.4 lb in).

    48. Fig 24: View Of Receptacle Outlet Cover & Screws (5.3L Engine w/RPO HP2)
    GM1403622Courtesy of GENERAL MOTORS CORP.
  48. Install the fan and air duct hose.
  49. Install the screws attaching the air duct hose to the ESB.

    Tighten:  Tighten the nuts to 0.5 N.m (4.4 lb in).

  50. Install the push pin fasteners.
  51. Install the fan screws.

    Tighten:  Tighten the nuts to 1 N.m (9 lb in).

    52. Fig 25: View Of Fan & Air Duct Hose (5.3L Engine w/RPO HP2)
    GM1403621Courtesy of GENERAL MOTORS CORP.
  52. Connect the fan electrical connector.
  53. Connect the ESB vent tube to the outlet duct.
  54. Connect the outlet duct to the ESB air duct.
  55. Install the battery resistor (4) to the number 3 battery negative terminal.
  56. Install NEW tie straps securing the power cables to the ESB.
  57. Install the power cables (3).
  58. Install the battery 2 to battery 3 power cable nuts (1).
  59. Install the power cable nut (2) to the current sensor.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    60. Fig 26: View Of Power Cable, Nuts & Battery Resistor (5.3L Engine w/RPO HP2)
    GM1403620Courtesy of GENERAL MOTORS CORP.
  60. Connect the battery resistor electrical connector (1), labeled XR3 to the number 3 battery negative terminal resistor.
    61. Fig 27: View Of Battery Resistor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1459627Courtesy of GENERAL MOTORS CORP.
  61. Install the maxi-fuse (2).
  62. Install the maxi-fuse nuts (1).

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    63. Fig 28: View Of Maxi-Fuse & Nuts (5.3L Engine w/RPO HP2)
    GM1456037Courtesy of GENERAL MOTORS CORP.
  63. Install the maxi-fuse cover.
    64. Fig 29: View Of Maxi-Fuse Cover (5.3L Engine w/RPO HP2)
    GM1403619Courtesy of GENERAL MOTORS CORP.
  64. Connect the control module electrical connectors.
  65. Install the control module.
  66. Install the control module nuts.

    Tighten:  Tighten the nuts to 6 N.m (53 lb in).

    67. Fig 30: View Of Energy Storage Control Module (5.3L Engine w/RPO HP2)
    GM1403618Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the ESB intermediate cover is installed between the ESB metal carrier and the 120-volt receptacle faceplate.
  67. Install the ESB intermediate cover.
  68. Install the ESB intermediate cover screws.

    Tighten:  Tighten the screws to 6 N.m (53 lb in).

    69. Fig 31: View Of ESB Intermediate Cover & Screws (5.3L Engine w/RPO HP2)
    GM1403617Courtesy of GENERAL MOTORS CORP.
  69. Install the ESB carrier. Refer to Energy Storage Box (ESB) Carrier Replacement (5.3L Engine w/RPO HP2) .
scientia non olet · About LEMON Manuals