Generator Control and Battery Module Replacement

Generator Control and Battery Module Replacement

Special Tools

EL-48264 - Battery Pack Lifting Adapter

For equivalent regional tools , refer to Special Tools Tools and Equipment.

Removal Procedure

Danger: Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.


Danger: 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.


Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:


* Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

* Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.


- Visually and functionally inspect the gloves before use.

- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.


Failure to follow the procedures exactly as written may result in serious injury or death.


1. Remove the rear compartment floor panel. Refer to Rear Compartment Floor Panel Trim Replacement (with Battery Cover, HP6) Rear Compartment Floor Panel Trim Replacement (with Battery Cover, HP6)Rear Compartment Floor Panel Trim Replacement (with Blower Cover, HP6) Rear Compartment Floor Panel Trim Replacement (with Blower Cover, HP6).
2. Disable the hybrid battery. Refer to High Voltage Disabling High Voltage Disabling.
3. Remove the drive motor generator battery bracket. Refer to Drive Motor Generator Battery Bracket Replacement Drive Motor Generator Battery Bracket Replacement.




4. Remove the body harness connectors (1) from the generator control and battery module.




5. Remove the high voltage 3-phase cable terminal nuts (1) and the 12V terminal branch nut (4).
6. Remove the high voltage cable (2) and the 12V cable (3) from the generator control and battery module.




7. Remove the drive motor battery generator intermediate cooling duct fasteners (1).




8. Detach the intermediate duct retainers (1) from the generator control and battery module.




9. Detach the drive motor battery cooling air inlet lower duct retainers (1). Refer to Drive Motor Battery Cooling Air Inlet Upper Duct Replacement Drive Motor Battery Cooling Air Inlet Upper Duct Replacement.





Note: Do not bend the vent tube.

10. Remove the generator control and battery module vent tube (1).




11. Place a protective cloth over the trunk-to-rear bumper area.

Note: Do not insert fingers into vent area of the generator control and battery module while rotating.

12. Use gloves to rotate the generator control and battery module (1) into the trunk area.




13. Using the EL-48264 - Battery Pack Lifting Adapter center the eye bolt (2) on the generator control and battery module and thread the stud inserts (1) onto the generator control and battery module.
14. Attach a portable lift to the center eye bolt (2) of the battery pack lifting adapter.




15. Remove the generator control and battery module (2) from the rear trunk area.

Installation Procedure




1. Install the generator control and battery module (2) in through the trunk opening.
2. Remove the EL-48264 - Battery Pack Lifting Adapter.
3. Install the generator control and battery module carrier nuts (2).





Caution: Refer to Fastener Caution Fastener Caution.

4. Install the generator control and battery module into position and tighten the mounting bolts (1) to 22 Nm (18 lb ft).




5. Install the high voltage 3-phase cable (2) to the generator control and battery module. Tighten the nuts (1) to 9 Nm (80 lb in).
6. Install the 12V cable (3) to the generator control and battery module. Tighten the nut (4) to 9 Nm (80 lb in).




7. Install the body harness connectors (1).




8. Install the generator control and battery module vent tube (1).




9. Install the drive motor battery cooling air inlet lower duct.
Note: Make sure the duct is flush against the seal for efficient generator control and battery module cooling.




10. Install the intermediate duct retainers (1) to the generator control and battery module.
Note: Make sure the duct is flush against the seal for efficient generator control and battery module cooling.

11. Install the drive motor battery cooling blower. Refer to Drive Motor Generator Battery Bracket Replacement Drive Motor Generator Battery Bracket Replacement.
12. Install the rear compartment floor panel. Refer to Rear Compartment Floor Panel Trim Replacement (with Battery Cover, HP6) Rear Compartment Floor Panel Trim Replacement (with Battery Cover, HP6)Rear Compartment Floor Panel Trim Replacement (with Blower Cover, HP6) Rear Compartment Floor Panel Trim Replacement (with Blower Cover, HP6).
13. Enable the hybrid battery. Refer to High Voltage Enabling High Voltage Enabling.
14. Program the generator control module, if replaced. Refer to Control Module References Control Module References.
15. Program the battery energy control module, if replaced. Refer toBattery Energy Control Module Programming and Setup Testing and Inspection.