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Drive Motor Generator Control Module Replacement



Drive Motor Generator Control Module Replacement

Removal


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.

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

Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling.




1. Remove the air cleaner.
2. Disconnect the drive motor generator control module assembly connector (1).

Caution: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper:

* Cable sealing

* Electrical shielding

* Terminal position assurance

Drain the power electronics cooling system. Refer to Generator Control Module Cooling System Draining and Filling.






Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage.

3. Remove the drive motor generator power inverter control module (PIM) 3 phase cable terminal fasteners (1).
4. Remove the PIM 3 phase cable mounting fasteners (2, 4).
5. Remove the PIM 3 phase cables (3, 5) from the PIM distribution box.
6. Remove and discard the seals (6).






Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage.

7. Remove the HV dc electric air conditioning compressor module (ACCM) cable terminal fasteners (1).
8. Remove the HV dc electric ACCM cable mounting fasteners (3).
9. Remove the HV dc electric ACCM cable (4) from the PIM distribution box.
10. Remove the HV dc battery cable terminal fasteners (2).
11. Remove the HV dc battery cable mounting fasteners (5).
12. Remove the HV dc battery cable (6) from the PIM distribution box.
13. Remove and discard the seals (7).




14. Remove the drive motor generator position sensor shield circuit fastener (2).
15. Remove the shield circuit harness (1).
16. Remove the PIM cooling inlet (5) and outlet (4) hoses.
17. Cap the coolant pipes (3, 6) to prevent coolant spillage when lifting the drive motor generator control module assembly from the vehicle.




18. Disconnect the accessory dc power control module (APM) assembly connectors (1, 2, and 3).




19. Remove the sight shield circuit breaker fasteners (1).
20. Remove the sight shield circuit breaker (2).




21. Remove the APM ground strap fastener (2) and ground strap (1).
22. Remove the drive motor generator control module assembly mounting fasteners (3) and retainers (4).




23. Remove the ball studs (1) from the drive motor generator control module.
24. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations.
25. Lift the drive motor generator control module assembly from the vehicle.

Installation






Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations.
2. Lift the drive motor generator control module assembly into the vehicle.
3. Remove the lifting device and install the ball studs (1).

Tighten the ball studs to 10 N.m (89 lb in).




4. Install the drive motor generator control module assembly retainers (4) and mounting nuts (3).

Tighten the mounting fasteners to XX N.m.

5. Install the ground strap (1) and nut (2).

Tighten the ground strap fasteners to XX N.m.




6. Install the sight shield circuit breaker (2) and secure with bolts (1).

Tighten the bolts to XX N.m.




7. Connect the APM assembly connectors (1, 2, and 3).




8. Remove the caps (3, 6) from the coolant tubes.
9. Connect the drive motor generator power inverter module (PIM) cooling inlet and outlet hoses (4, 5).
10. Install the shield circuit harness (1) and terminal fastener (2).

Tighten the terminal fastener to XX N.m.




11. Install the PIM 3 phase cables (3, 5) into the PIM distribution box with new seals (6).
12. Install the PIM 3 phase cable mounting fasteners (2, 4).

Tighten the mounting fastener to XX N.m.


Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage.

13. Install the PIM 3 phase cable terminal fasteners (1).

Tighten the terminal fastener to 9 N.m (80 lb in).




14. Install the HV dc battery cable (6) into the PIM distribution box with new seals (7).
15. Install the HV dc battery cable mounting fasteners (5).

Tighten the mounting fastener to XX N.m.


Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage.

16. Install the high voltage (HV) dc battery cable terminal fasteners (2).

Tighten the terminal fastener to 9 N.m (80 lb in).

17. Install the HV dc electric air conditioning compressor module (ACCM) cable (4) into the PIM distribution box with a new seal (7).
18. Install the HV dc electric ACCM cable mounting fasteners (3).

Tighten the mounting fasteners to XX N.m.


Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage.

19. Install the HV dc electric ACCM cable terminal fasteners (1).

Tighten the terminal fastener to 9 N.m (80 lb in).




20. Install a new seal (3) on the PIM distribution box.
21. Position the terminal cover (2) onto the PIM distribution box ensuring the seal remains in place.
22. Tighten the terminal cover fasteners (1).

Tighten the fasteners to 4.7 N.m (41.6 lb in).




23. Connect the drive motor generator control module assembly connector (1).
24. Fill the power electronics cooling system and test for leaks at all serviced connections. Refer to Generator Control Module Cooling System Draining and Filling.
25. Install the sight shield.
26. Install the fender cross brace.

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

27. Perform the High Voltage Enabling procedure. Refer to High Voltage Enabling. High Voltage Enabling
28. Install the air cleaner.
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