Drive Motor/Generator: Service and Repair

Generator with Starter Replacement

Removal Procedure

1. Disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
3. Remove the drive belt. Refer to Drive Belt Replacement (LE5) (Service and Repair)Drive Belt Replacement (LAT) (Service and Repair).




4. Remove the ECM bracket bolts (1), nuts (2) and ECM bracket.
5. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill With HP5) (Service and Repair)Cooling System Draining and Filling (Static Fill Without HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill With HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill Without HP5) (Service and Repair).
6. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (With HP5) (Refrigerant Recovery and Recharging)Refrigerant Recovery and Recharging (Without HP5) (Refrigerant Recovery and Recharging).
7. Unclip the battery positive cable jumper block (1) from the engine control module (ECM) bracket (4).
8. Disconnect the ECM electrical connectors (2) and the transmission control module (TCM) electrical connector (3).




9. Remove the generator control module cover bolts (1) and cover (2).





Warning

To help avoid personal injury, additional precautions must be taken prior to working on the generator control module or the generator starter. After removing the 36V battery cables from the generator battery, remove both engine wiring harness connectors from the generator control module. Wait at least 5 minutes and then remove the generator control module cover. Verify voltage levels at all 36V, 12V, and 3-phase connections, are less than 3 volts using a DMM before proceeding.

10. Check the generator control module for voltage potential, in order to ensure that the module has been disabled.

1. Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts.
2. Measure from the 12-volt positive terminal (4) to a known good chassis ground. The voltage should be less than 3 volts.
3. Measure from the ground terminal (2) to a known good chassis ground, checking for continuity.

Warning

To help avoid personal injury, always treat the 3-phase cable and connectors as if voltage is present and as if the surface of all parts of the cable is hot.

11. Verify that the generator control module 3-phase cables are disabled.

1. Measure from each phase 1, 2 and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts.
2. After verifying that there is no voltage present, the generator control module 3-phase cables can now be removed from the generator control module.
3. If 3 volts or more is present, repeat the disconnect procedure. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).




12. Remove the battery positive terminal block nuts (1) and reposition the battery positive terminal block (2).
13. Remove the 3-phase cable terminal block nuts (3) and reposition the 3-phase cable terminal block (4).




14. Remove the bolt (1) securing the 3-phase cables to the oil level indicator bracket.




15. Disconnect the radiator inlet hose from the cylinder head water outlet and secure it out of the way.
16. Disconnect the engine wiring harness electrical connectors next to the generator starter and secure them out of the way.
17. Remove the upper generator starter bolt (1).
18. Raise the vehicle and disconnect the air conditioning (A/C) compressor hose assembly lines from the A/C compressor. Refer to Air Conditioning Compressor Hose Replacement (LZ4) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LAT) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LY7) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LE5) (Air Conditioning Compressor Hose Replacement).
19. Remove the lower generator starter bolts (2).
20. Remove the generator starter from the vehicle with the 3-phase cables.




21. Remove the generator starter cover bolts (1) and the 3-phase cable bracket bolts (2).
22. Remove the 3-phase cable nuts underneath the cover.




23. Remove the 3-phase cable bolts (1).

Installation Procedure





Caution: Refer to Fastener Caution (Fastener Caution).

1. Install the 3-phase cable bolts (1) to the new generator starter and tighten to 8 Nm (71 lb in).
2. Install the 3-phase cable nuts underneath the generator starter cover and tighten to 8 Nm (71 lb in).




3. Install the generator starter cover bolts (1) and the 3-phase cable bracket bolts (2) and tighten to 5 Nm (44 lb in).




4. Install the generator starter to the vehicle with the 3-phase cables.
5. Install the lower generator starter bolts (2) and tighten to 58 Nm (43 lb ft).
6. Install the A/C compressor hose assembly lines to the A/C compressor. Refer to Air Conditioning Compressor Hose Replacement (LZ4) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LAT) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LY7) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LE5) (Air Conditioning Compressor Hose Replacement).
7. Install the upper generator starter bolt (1) and tighten to 58 Nm (43 lb ft).
8. Connect the engine wiring harness electrical connectors next to the generator starter.
9. Install the upper radiator hose to the cylinder head.




10. Install the bolt (1) securing the 3-phase cables to the oil level indicator bracket and tighten to 10 Nm (89 lb in).




11. Install the 3-phase cable terminal block (4) and nuts (3) and tighten to 10 Nm (89 lb in).
12. Install the battery positive terminal block (2) and nuts (1) and tighten to 10 Nm (89 lb in).




13. Install the generator control module cover bolts (1) and cover (2) and tighten to 10 Nm (89 lb in).




14. Install the ECM bracket (3), bolts (1) and nuts (2) and tighten to 10 Nm (89 lb in).




15. Connect the ECM electrical connectors (2) and the TCM electrical connectors (3).
16. Clip in the battery positive cable jumper block (1) to the ECM bracket (4).
17. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging (With HP5) (Refrigerant Recovery and Recharging)Refrigerant Recovery and Recharging (Without HP5) (Refrigerant Recovery and Recharging).
18. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill With HP5) (Service and Repair)Cooling System Draining and Filling (Static Fill Without HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill With HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill Without HP5) (Service and Repair).
19. Install the drive belt. Refer to Drive Belt Replacement (LE5) (Service and Repair)Drive Belt Replacement (LAT) (Service and Repair).
20. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
21. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect (Procedures).
22. Using a Tech 2, command an autostart in order to verify that the system is working properly.