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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1597 (Hybrid Energy Storage System) >> Repair Instructions >> Drive Motor Generator Battery Replacement and Shipping Preparation >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2010 GMC Sierra and 2010 Chevrolet Silverado. 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.
    Fig 1: Identifying Battery Cable Terminal Fasteners
    GM2153770Courtesy of GENERAL MOTORS CORP.
  1. Disable the high voltage at both the drive motor generator battery assembly and the drive motor generator control module assembly. Refer to High Voltage Disabling .
  2. Remove the high voltage terminal extension cover. Refer to Drive Motor Battery Cable Terminal Extension Cover Replacement 
  3. Remove the battery cable terminal fasteners (1) and reposition the cable terminals.
    4. Fig 2: Identifying Battery Cable Terminal Fasteners
    GM2154159Courtesy of GENERAL MOTORS CORP.
    WARNING: High Voltage (HV) cables are not repairable. After disconnecting HV cables, protect and insulate ring terminal ends immediately with the EL-48569 terminal covers and UL® Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement.
  4. Using the EL-48569:  covers, cover the 300 Volt positive and negative terminals (2).
    5. Fig 3: Identifying Battery Vent Tube & Retaining Clips
    GM2154271Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the retaining clips (1) and remove the battery vent tube (2).
    6. Fig 4: Identifying Air Outlet Duct & Retainer
    GM2154905Courtesy of GENERAL MOTORS CORP.
  6. Remove the air outlet duct retainer (1) and the air outlet duct (2).
    7. Fig 5: Identifying Generator Battery Retaining Nuts
    GM2155131Courtesy of GENERAL MOTORS CORP.
  7. Remove the generator battery retaining nuts (1).
    8. Fig 6: Locating Motor Battery Cable Terminal Extension Cover Bolts
    GM2155143Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  8. Install the drive motor battery cable terminal extension cover (1) and bolts (2) and tighten to 6 N.m (53 lb in).
  9. Disconnect the X350 harness connector from the drive motor generator battery.
    10. Fig 7: Identifying Drive Motor Battery Lifting Points
    GM2155152Courtesy of GENERAL MOTORS CORP.
  10. Using the EL-48265:  fixture, secure the drive motor battery at the lifting points (1).
    11. Fig 8: Removing/Installing Drive Motor Generator Battery Assembly
    GM2154163Courtesy of GENERAL MOTORS CORP.
    WARNING: The high voltage (HV) battery must be protected when outside of the vehicle.
    Storage Guidelines
    • Store the HV battery flat, do not exceed 45 degrees when handling.
    • Store the HV battery in an environmentally protected area.
    • Maintain the HV battery at room temperature.
    • Protect the HV battery from exposure to liquids.
    • Protect the HV battery from physical damage.

    Unqualified Access Guidelines
    1. Cover all exposed high voltage openings with UL® listed, or equivalent, insulation tape rated at a minimum of 600 volts.
    2. Store the HV battery in a limited-access area.

    Failure to follow these guidelines may result in serious injury or death.
    NOTE: If preparing the drive motor generator battery for shipment, Install the terminal extension cover assembly and retaining bolts. Using UL® listed or equivalent insulation tape, rated at a minimum of 600 V, tape over the manual disconnect opening and the high voltage cable openings on the terminal extension cover.
  11. Remove the drive motor generator battery assembly (1).
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