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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) >> Disassembly Procedure

Disassembly 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. Remove the energy storage box (ESB) carrier. Refer to Energy Storage Box (ESB) Carrier Replacement (5.3L Engine w/RPO HP2) .
  2. Remove the ESB intermediate cover screws.
  3. Remove the ESB intermediate cover.
    4. Fig 1: View Of ESB Intermediate Cover & Screws (5.3L Engine w/RPO HP2)
    GM1403617Courtesy of GENERAL MOTORS CORP.
  4. Remove the control module nuts.
  5. Lift the control module up off of the studs.
  6. Disconnect the control module electrical connectors.
  7. Remove the control module.
    8. Fig 2: View Of Energy Storage Control Module (5.3L Engine w/RPO HP2)
    GM1403618Courtesy of GENERAL MOTORS CORP.
  8. Remove the maxi-fuse cover.
    9. Fig 3: View Of Maxi-Fuse Cover (5.3L Engine w/RPO HP2)
    GM1403619Courtesy of GENERAL MOTORS CORP.
  9. Remove the maxi-fuse nuts (1).
  10. Remove the maxi-fuse (2).
    11. Fig 4: View Of Maxi-Fuse & Nuts (5.3L Engine w/RPO HP2)
    GM1456037Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the battery resistor electrical connector (1), labeled XR3 from the number 3 battery negative terminal resistor.
    12. Fig 5: View Of Battery Resistor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1459627Courtesy of GENERAL MOTORS CORP.
  12. Remove the power cable nut (2) from the current sensor.
  13. Remove the battery 2 to battery 3 power cable nuts (1).
  14. Remove the battery resistor (4) from the number 3 battery negative terminal.
  15. Cut the tie straps securing the power cables to the ESB.
  16. Remove the power cables (3).
    17. Fig 6: View Of Power Cable, Nuts & Battery Resistor (5.3L Engine w/RPO HP2)
    GM1403620Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the outlet duct from the ESB duct.
  18. Disconnect the battery vent tube that is inside the outlet duct.
  19. Disconnect the fan electrical connector.
  20. Remove the fan screws.
  21. Remove the push pin fasteners.
  22. Remove the screws attaching the air duct hose to the ESB.
  23. Remove the fan and air duct hose.
    24. Fig 7: View Of Fan & Air Duct Hose (5.3L Engine w/RPO HP2)
    GM1403621Courtesy of GENERAL MOTORS CORP.
  24. Remove the receptacle outlet cover screws.
  25. Carefully pull the receptacle box out of the ESB.
  26. Insert a flat-bladed screwdriver into the openings on top of the receptacle box in order to release the tabs securing the outlet cover.
  27. Remove the receptacle outlet cover.
    28. Fig 8: View Of Receptacle Outlet Cover & Screws (5.3L Engine w/RPO HP2)
    GM1403622Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the battery vent hose(s) from the batteries.
  29. Disengage the retainers securing the battery vent hose(s).
  30. Remove the battery vent hose(s) from the ESB.
    31. Fig 9: View Of Battery Vent Hose (5.3L Engine w/RPO HP2)
    GM1403623Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the battery resistor electrical connector (1), labeled XR1 from the number 1 battery negative terminal.
  32. Remove the battery cut-off switch nuts (2).
  33. Remove the battery resistor from the number 2 battery terminal.
  34. Disconnect the battery cut-off switch electrical connector.
  35. Disconnect the high current sensor electrical connector (3).
    36. Fig 10: View Of Battery Cut-Off Switch, Electrical Connectors & Nuts (5.3L Engine w/RPO HP2)
    GM1403624Courtesy of GENERAL MOTORS CORP.
  36. Remove the battery cut-off switch (1) and high current sensor (2).
    37. Fig 11: View Of High Current Sensor & Battery Cut-Off Switch (5.3L Engine w/RPO HP2)
    GM1456043Courtesy of GENERAL MOTORS CORP.
  37. Remove the high current sensor carrier nut.
  38. Remove the high current sensor carrier.
    39. Fig 12: View Of High Current Sensor Carrier & Nut (5.3L Engine w/RPO HP2)
    GM1403625Courtesy of GENERAL MOTORS CORP.
  39. Disconnect the battery resistor electrical connector (1), labeled XR2 from the number 1 battery positive terminal.
    40. Fig 13: View Of Battery Resistor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1459628Courtesy of GENERAL MOTORS CORP.
  40. Remove the power cable nuts (1) from battery 1 and battery 2.
  41. Remove the power cable (3) from battery 1 and battery 2.
  42. Remove the battery resistor (2) from the number 1 battery positive terminal.
    43. Fig 14: View Of Battery Resistor, Power Cable & Nuts (5.3L Engine w/RPO HP2)
    GM1403626Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the battery resistor electrical connector (1), labeled XR4 from the number 3 battery positive terminal.
    44. Fig 15: View Of Battery Resistor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1459621Courtesy of GENERAL MOTORS CORP.
  44. Remove the power cable nuts (1) from the number 3 battery and high current connector.
  45. Remove the battery resistor (3) from the number 3 battery positive terminal.
  46. Remove the power cable (2).
    47. Fig 16: View Of High Current Power Cable (5.3L Engine w/RPO HP2)
    GM1403627Courtesy of GENERAL MOTORS CORP.
  47. Remove the service disconnect power cable nuts (1) from the high current connector and the service disconnect switch.
  48. Remove the power cable (2).
    49. Fig 17: View Of Service Disconnect Power Cable & Nut (5.3L Engine w/RPO HP2)
    GM1403628Courtesy of GENERAL MOTORS CORP.
  49. Cut the tie straps securing the power cable to the ESB.
  50. Remove the service disconnect power cable nut from the service disconnect switch.
    51. Fig 18: View Of Service Disconnect Switch Power Cable & Nut (5.3L Engine w/RPO HP2)
    GM1403629Courtesy of GENERAL MOTORS CORP.
  51. Remove the power cable.
  52. Remove the 120-volt cable connector screws.
    53. Fig 19: View Of 120-Volt Cable Connector Screws (5.3L Engine w/RPO HP2)
    GM1403630Courtesy of GENERAL MOTORS CORP.
  53. Disconnect the retainers securing the 120-volt cable to the ESB.
  54. Remove the 120-volt cable.
    55. Fig 20: View Of 120-Volt Cable (5.3L Engine w/RPO HP2)
    GM1403631Courtesy of GENERAL MOTORS CORP.
  55. Remove the fuse holder screws.
    56. Fig 21: View Of Fuse Holder & Screws (5.3L Engine w/RPO HP2)
    GM1403632Courtesy of GENERAL MOTORS CORP.
  56. Remove the fuse holder.
  57. Remove the high current connector screws.
    58. Fig 22: View Of HCC Screws (5.3L Engine w/RPO HP2)
    GM1403634Courtesy of GENERAL MOTORS CORP.
  58. Remove the high current connector.
    59. Fig 23: View Of HCC (5.3L Engine w/RPO HP2)
    GM1403635Courtesy of GENERAL MOTORS CORP.
  59. Remove the service disconnect switch nuts.
    60. Fig 24: View Of Service Disconnect Switch Nuts (5.3L Engine w/RPO HP2)
    GM1456045Courtesy of GENERAL MOTORS CORP.
  60. Remove the service disconnect switch screws.
    61. Fig 25: View Of Service Disconnect Switch Screws (5.3L Engine w/RPO HP2)
    GM1403636Courtesy of GENERAL MOTORS CORP.
  61. Remove the service disconnect switch.
    62. Fig 26: View Of Service Disconnect Switch (5.3L Engine w/RPO HP2)
    GM1403637Courtesy of GENERAL MOTORS CORP.
  62. Remove the battery hold down bracket nuts.
    63. Fig 27: View Of Battery Hold Down Bracket & Nut (5.3L Engine w/RPO HP2)
    GM1403638Courtesy of GENERAL MOTORS CORP.
  63. Remove the battery hold down brackets.
  64. Remove the battery hold down bolts.
    65. Fig 28: View Of Battery Hold Down Bolts (5.3L Engine w/RPO HP2)
    GM1403639Courtesy of GENERAL MOTORS CORP.
  65. Using J 43679  , remove the batteries.
    66. Fig 29: View Of Battery (5.3L Engine w/RPO HP2)
    GM1403640Courtesy of GENERAL MOTORS CORP.
  66. Remove the ground wire bolt.
  67. Disengage the retainers securing the internal signal harness to the ESB.
  68. Remove the internal signal harness from the ESB.
  69. If necessary, remove any retainers (1), clips (2), or fasteners (3).
    70. Fig 30: View Of Retainers & Fasteners (5.3L Engine w/RPO HP2)
    GM1403641Courtesy of GENERAL MOTORS CORP.
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