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Home >> GMC >> 2002 >> Jimmy 4D Utility, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1848 (Hybrid Energy Storage System) >> Repair Instructions >> 36-Volt Battery Positive Cable Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Cable And Channel
    GM1831669Courtesy of GENERAL MOTORS CORP.
  1. Install the 36-volt positive battery cable to the battery cable channel.
  2. Install NEW tie straps securing the 36-volt positive battery cable to the battery cable channel.
    3. Fig 2: Underbody Bolts
    GM1820192Courtesy of GENERAL MOTORS CORP.
  3. With the aid of an assistant, position the 36-volt positive battery cable channel to the vehicle.
  4. Feed the 36-volt cable up through the floor panel, and secure the grommet into place.
  5. Install the 36-volt positive battery cable channel to underbody bolts (1, 2).

    Tighten: 

    • Tighten the bolts (1) to 22 N.m (16 lb ft).
    • Tighten the bolts (2) to 10 N.m (89 lb in).

    6. Fig 3: 36-Volt Positive Battery Cable Rear Suspension Bracket Bolts
    GM1820185Courtesy of GENERAL MOTORS CORP.
  6. Install the 36-volt positive battery cable rear suspension bracket bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  7. Lower the vehicle.
    8. Fig 4: Locating Battery Components
    GM1820195Courtesy of GENERAL MOTORS CORP.
  8. From inside the rear of the vehicle, install the 36-volt positive battery cable shield lead (4) to the generator battery stud.
  9. Install the 36-volt positive battery cable shield lead nut (3) to the generator battery.

    Tighten:  Tighten the nut to 6 N.m (53 lb in).

    10. Fig 5: Identifying Hybrid-Related Harness Retainers
    GM1820895Courtesy of GENERAL MOTORS CORP.
  10. Install the 36-volt positive battery cable bracket to the front of dash studs.
  11. Install the 36-volt positive battery cable bracket nuts (5) to the front of dash studs.

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

  12. Install the 36-volt positive battery cable retainer (2) to the shock tower bracket.
    13. Fig 6: 36-Volt Terminal Block Nuts
    GM1831652Courtesy of GENERAL MOTORS CORP.
  13. Install a NEW terminal block seal to the generator control module.
  14. Position and install the 36-volt terminal block to the generator control module.
  15. Install the 36-volt terminal block nuts to the generator control module.

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

  16. Install the 36-volt positive battery cable nut to the generator control module.

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

    17. Fig 7: Positive Battery Cable Nut And Bolt
    GM1831557Courtesy of GENERAL MOTORS CORP.
  17. Install the 12-volt positive battery cable to the generator control module.
  18. Install the 12-volt positive battery cable bolt (2) to the generator control module.

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

  19. Install the 12-volt positive battery cable nut (1) to the generator control module.

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

    20. Fig 8: Generator Control Module Cover Bolts And Cover
    GM1816289Courtesy of GENERAL MOTORS CORP.
  20. Install the generator control module cover and bolts.

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

    21. Fig 9: Engine Wiring Harness Electrical Connectors
    GM1816292Courtesy of GENERAL MOTORS CORP.
  21. Connect the 2 engine wiring harness electrical connectors to the generator control module.
  22. Install the (12-volt) battery tray. Refer to Battery Tray Replacement (2.2L (L61)) or Battery Tray Replacement (2.4L (LAT)) or Battery Tray Replacement (3.5L (L66)) .
  23. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
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