Generator Control and Battery Module Replacement and Shipping Preparation

Generator Control and Battery Module Replacement and Shipping Preparation

Special Tools

* EL-48264 - Battery Pack Lifting Adapter

* EL-48900 - High Voltage Safety Kit

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 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. Remove both rear compartment floor trim panels. 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. Ignition OFF, disable high voltage at the A4 hybrid battery pack. Refer to High Voltage Disabling High Voltage Disabling.

3. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement Rear End Trim Finish Panel 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 cooling air outlet duct (2). Refer to Drive Motor Battery Cooling Air Outlet Duct Replacement Drive Motor Battery Cooling Air Outlet Duct Replacement.




8. Remove the drive motor battery cooling blower outlet upper duct fasteners (1) and remove the drive motor battery cooling blower outlet upper duct (2). Refer to Drive Motor Battery Cooling Blower Outlet Duct Replacement Drive Motor Battery Cooling Blower Outlet Duct Replacement.




9. Remove the drive motor generator bracket and cooling blower fasteners (1).

10. Remove the drive motor battery cooling blower assembly (2).





Note: Make sure the duct is flush against the seal for efficient generator control and battery module cooling.

11. Remove the drive motor battery cooling air inlet lower duct retainers (1).





Note: Do not bend the vent tube.

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




13. Remove the generator control and battery module mounting bolts (1).




14. 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.

15. With assistance, use gloves to slide the generator control and battery module (1) into the trunk area.




16. Using the EL-48264 - battery pack lifting adapter center the eye bolt (2) on the generator control and battery module and insert the hooks (1) into the generator control and battery module holes.

17. Attach a portable lift to the center eye bolt (2) of the battery pack lifting adapter.




18. 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. Slide the generator control and battery module into position and install the vent tube (1) into the floor.

3. Remove the EL-48264 - battery pack lifting adapter.





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 (16 lb ft).




5. Install the body harness connectors (1).





Note: Make sure the duct is flush against the seal for efficient generator control and battery module cooling.

6. Install the drive motor battery cooling air inlet lower duct retainers (1).




7. Install the drive motor generator bracket and drive motor battery cooling blower (2). Tighten the fasteners (1) to 9 Nm (80 lb in).





Note: Make sure the duct is flush against the seal for efficient generator control and battery module cooling.

8. Install the drive motor battery cooling blower outlet upper duct (2) and tighten the fasteners to 9 Nm (80 lb in).




9. 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).

10. Install the 12V cable (3) to the generator control and battery module. Tighten the nut (4) to 9 Nm (80 lb in).

11. Install both rear compartment floor panels. 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).

12. Install the rear end trim finish panels. Refer to Rear End Trim Finish Panel Replacement Rear End Trim Finish Panel Replacement.

13. Enable the high voltage 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 to Battery Energy Control Module Programming and Setup Testing and Inspection.