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Home >> Chevrolet >> 2009 >> Malibu Hybrid >> Repair and Diagnosis >> Electrical >> Body Electrical >> Hybrid Engine Control System >> Repair Instructions >> Generator Control Module 3-Phase Cable Assembly Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Rear Generator Control Module 3-Phase Cable Assembly
    GM1892034Courtesy of GENERAL MOTORS CORP.
  1. Install the a NEW generator control module 3-phase cable assembly (2) to the generator starter (1).
    2. Fig 2: View Of Rear Generator Starter Cover & Bolts
    GM1892031Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  2. Inside the generator starter, install the generator control module 3-phase cable to the studs and install the generator starter nuts.

    Tighten:  Tighten the nuts to 8 N.m (71 lb in).

  3. Install the generator control module 3-phase cable bracket (4) and bolts (3).

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

  4. Install the generator starter cover (2) and bolts (1).

    Tighten:  Tighten the bolts to 5 N.m (44 lb in).

    5. Fig 3: View Of Rear Generator Control Module 3-Phase Cable & Bolts
    GM1892033Courtesy of GENERAL MOTORS CORP.
  5. Install the rear generator control module 3-phase cable bolts (1).

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

    6. Fig 4: View Of Generator Control Module 3-Phase & Cables
    GM1891967Courtesy of GENERAL MOTORS CORP.
  6. Position the generator starter (with the generator control module 3-phase cables attached) (3) to the vehicle and install the upper bolt (1) until snug.
  7. Raise and suitably support the vehicle.
  8. Install the 2 lower generator starter bolts (1) until snug.
  9. Install the generator starter 3-phase cable clip bolt (2) to the oil level indicator tube bracket.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    10. Fig 5: Identifying generator starter Bolt Tightening Sequence
    GM1891969Courtesy of GENERAL MOTORS CORP.
  10. Tighten the generator starter bolts in the sequence shown.

    Tighten:  Tighten the bolts to 58 N.m (43 lb ft).

    11. Fig 6: View Of Air Conditioning (A/C) Condenser/Evaporator Tube & Clip
    GM1966745Courtesy of GENERAL MOTORS CORP.
  11. Position the A/C condenser/evaporator tube (2) to the front end upper tie bar reinforcement.
  12. Install the A/C condenser/evaporator tube clip (1) to the front end upper tie bar reinforcement.
    13. Fig 7: View Of Generator Control Module 3-Phase Cable Terminal Block Nuts & Generator Control Module
    GM1891965Courtesy of GENERAL MOTORS CORP.
  13. Place a NEW terminal block seal onto the generator control module.
  14. Install the generator control module 3-phase cable terminal block (2) onto the generator control module.
  15. Install the generator control module 3-phase cable terminal block nuts (1) until snug.
    16. Fig 8: Identifying Generator Control Module Cable Terminal Block Nut Tightening Sequence
    GM1891968Courtesy of GENERAL MOTORS CORP.
  16. Tighten the generator control module 3-phase cable terminal block nuts in the sequence shown.

    Tighten:  Tighten the nuts to 8 N.m (71 lb in).

    17. Fig 9: View Of 36-Volt Terminal Block & Nuts
    GM1891966Courtesy of GENERAL MOTORS CORP.
  17. Place a NEW terminal block seal onto the generator control module.
  18. Unsecure, and position the 36-volt terminal block (2) to the generator control module.
  19. Install the 36-volt terminal block nuts (1) to the generator control module.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    20. Fig 10: View Of Engine Wiring Harness
    GM1891963Courtesy of GENERAL MOTORS CORP.
  20. Position the engine wiring harness.
  21. Connect the engine wiring harness electrical connectors (1 and 2) to the starter generator.
    22. Fig 11: View Of Generator Control Module Cover & Integral Bolts
    GM1891961Courtesy of GENERAL MOTORS CORP.
  22. Place the generator control module cover (2) on top of the generator control module and tighten bolts (1).

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    23. Fig 12: View Of Generator Control Module Bracket Reinforcement Bolt & Nuts
    GM1891960Courtesy of GENERAL MOTORS CORP.
  23. Install the generator control module bracket reinforcement (3).
  24. Install the generator control module bracket reinforcement bolt (1) and nuts (2).

    Tighten:  Tighten the bolt/nuts to 10 N.m (89 lb in).

    25. Fig 13: Locating Generator Control Module Coolant Inlet Hose & Clamp
    GM1891970Courtesy of GENERAL MOTORS CORP.
  25. Install the generator control module coolant inlet hose (2) to the generator control module.
  26. Position the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185  or equivalent.
    27. Fig 14: Identifying Connector Position Assurance (CPA) Retainers & Battery Positive Cable Fuse
    GM1891759Courtesy of GENERAL MOTORS CORP.
  27. Connect the 2 engine wiring harness electrical connectors (2) to the generator control module.
    28. Fig 15: Identifying Booster Vacuum Hose, Clamp & Intake Manifold
    GM1892160Courtesy of GENERAL MOTORS CORP.
  28. Position and install the power brake booster vacuum hose (2) to the intake manifold.
  29. Position the power brake booster vacuum hose clamp at the intake manifold.
  30. Install the power brake booster vacuum hose to the clamp (2) to the generator control module coolant outlet hose.
  31. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LZE, LZ4) or Radiator Inlet Hose Replacement (LAT) or Radiator Inlet Hose Replacement (LE5) or Radiator Inlet Hose Replacement (LY7) .
  32. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (LAT) or Drive Belt Tensioner Replacement (LE5) .
  33. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
  34. Using a Tech 2, command an autostart in order to verify that the system is working properly.
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