Generator Control Module Replacement

Generator Control Module Replacement

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 includes the following steps:


* 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 may result in serious injury or death.


1. Ignition OFF, disable the high voltage at the A4 hybrid battery pack. Refer to High Voltage Disabling, for Servicing Internal Components within the A4 Hybrid/EV Battery Pack High Voltage Disabling High Voltage Disabling.




2. Disconnect the generator control module X4 connector (1).




3. Remove the fasteners (1) securing the battery energy control module wiring junction block assembly (2), to the top of the generator control module.

4. Remove the fasteners (3), securing the drive motor battery wire junction block relay assembly (4), to the top of the generator control module.




5. Remove the high voltage bus fasteners (1) from the drive motor battery wiring junction block relay assembly (2).




6. Lift the drive motor battery wire junction block relay (2) and the battery energy control module wiring junction block (1) with the harness attached, and place on top of the battery energy control module (3).




7. Remove the generator control module mounting fasteners (1) and (2).

8. Remove the generator control module (3) from the support tray.




9. Remove the generator control module cooling air outlet duct (2) from the generator control module. Refer to Drive Motor Battery Cooling Blower Outlet Duct Replacement Drive Motor Battery Cooling Blower Outlet Duct Replacement.




10. Remove the generator control module cooling air outlet duct lower fasteners (1) and remove the generator control module cooling air outlet duct (2).


Installation Procedure




1. Install the generator control module cooling air outlet duct (2).




2. Install the lower fasteners (1) but do not tighten.

3. Inspect the foam seals for tears and leak paths, to ensure they will not compromise the internal air flow through the generator control module assembly.





Caution: Refer to Fastener Caution Fastener Caution.

4. Install the generator control module (3) to the support tray studs. Tighten the fastener (1) to 9 Nm (80 lb in).

Note: Do not slide the generator control module on the foam seals as the seals may become damaged.

5. Tighten the remaining fasteners (2) to 9 Nm (80 lb in).




6. Place the drive motor battery wire junction block relay (2) and the battery energy control module wiring junction block (1), on top of the generator control module.




7. Install the high voltage bus fasteners (1) to the drive motor battery wiring junction block relay assembly (2) and tighten to 9 Nm (80 lb in).




8. Install the battery energy control module wiring junction block fasteners (1) and tighten to 9 Nm (80 lb in).

9. Install the drive motor battery wiring junction block relay fasteners (3) and tighten to 9 Nm (80 lb in).




10. Connect the generator control module X4 connector (1).

11. Enable the high voltage at the A4 hybrid battery pack. Refer to High Voltage Enabling High Voltage Enabling.

12. Program the generator control module. Refer to Control Module References Control Module References.