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Drive Motor Generator Control Module Assembly Replacement




Drive Motor Generator Control Module Assembly Replacement

Removal Procedure

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.

1. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling (High Voltage Disabling).




2. Disconnect the drive motor generator control module assembly connector (3).
3. Slide the wire harness clip from the drive motor generator position sensor shield circuit harness terminal fastener.
4. Remove the drive motor generator position sensor shield circuit harness terminal fastener (5).
5. Remove the shield circuit harness terminal (4).
6. Disconnect the accessory DC power control module (APM) assembly connector (2) using the following procedure:

1. Remove the locking tab.
2. Insert a small flat blade screwdriver into the locking tab area and raise the tab while pulling on the connector.

7. Disconnect the remaining APM assembly connector (1).
8. Drain the power electronics cooling system. Refer to Generator Control Module Cooling System Draining and Filling (Generator Control Module Cooling System Draining and Filling).




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




15. Remove the windshield washer solvent container filler tube assembly bolt.
16. Remove the drive motor generator control module support bracket bolts (1) and the support bracket (2).
17. Place a protective guard (3) such as wiring conduit along the sharp edge of the front crossmember to protect the high voltage cables.





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

18. Remove the drive motor generator power inverter control module (PIM) 3 phase cable housing cover fasteners (1).
19. Remove the PIM 3 phase cable housing cover (2).
20. Remove the PIM 3 phase cable terminal fastener (4).
21. Remove the PIM 3 phase cable housing assembly (5).
22. Remove the PIM 3 phase cable terminal seals (3) and discard.
23. Remove the sight shield circuit breaker fasteners (6).
24. Remove the sight shield circuit breaker (7).




25. Remove the PIM 3 phase cable terminal fasteners (1) and installation guide assembly (2).
26. Remove the PIM 3 phase cable mounting fasteners (3) and terminal (4).
27. Remove the PIM 3 phase cable terminal seal (5) and discard.




28. Remove the hybrid cooling surge tank fasteners (1, 3) and pull the surge tank (2) off of the control module stud (4).




29. Remove the APM ground strap nut (1) and APM ground strap (2) from the left front inner fender.




30. Remove the underhood fuse block support fastener (1) and pull the support away from the control module.
31. Remove the engine coolant recovery reservoir support fastener (2).

Note: A service replacement APM does not have the engine coolant recovery reservoir support stud installed. Remove and save the stud for installation onto the replacement APM.

32. Remove the engine coolant recovery reservoir support stud (3) from the control module.




33. Remove the generator control module coolant inlet hose (2) and hose clamp (1) from the control module radiator.




34. Remove the generator control module coolant outlet hose (2) and hose clamp (1) from the radiator surge tank air separator.




35.
Remove the control module assembly mounting retainer bolt (1) and assembly mounting nuts (2).




36. Attach a lifting device (1 and 2) to the drive motor generator control module assembly at the 3 identified locations.
37. Lift the drive motor generator control module assembly from the vehicle while feeding the coolant hoses through the support opening.
38. To replace the drive motor generator power inverter module (PIM) assembly, refer to Drive Motor Generator Power Inverter Module Removal and Installation (Drive Motor Generator Power Inverter Module Removal and Installation). To replace the accessory DC power control module (APM), refer to Accessory DC Power Control Module Removal and Installation (Accessory DC Power Control Module Removal and Installation).

Installation Procedure




1. Attach a lifting device (1-2) to the drive motor generator control module assembly at the three identified locations.
2. Lower the drive motor generator control module assembly into the vehicle while feeding the coolant hoses through the support opening.




3. Install the generator control module coolant inlet hose (2) and hose clamp (1) onto the control module radiator.




4. Install the generator control module coolant outlet hose (2) and hose clamp (1) to the radiator surge tank air separator.





Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the control module assembly mounting retaining bolt (1) and assembly mounting nuts (2). Tighten the mounting bolt and nuts to 9 Nm (80 lb in).




6. Install the underhood fuse block support and fastener (1) onto the control module. Tighten the bolt to 5 Nm (44 lb in).
7. Install the engine coolant recovery reservoir support stud (3) through the support and into the control module. Tighten the stud to 9 Nm (80 lb in).
8. Install the engine coolant recovery reservoir support fastener (2) onto the control module stud. Tighten the fastener to 5 Nm (44 lb in).




9. Install the APM ground strap (2) and APM ground strap nut (1) onto the left front inner fender stud and tighten to 9 Nm (80 lb in).




10. Install the hybrid cooling surge tank (2) onto the control module and body support stud (4). Install the control module fasteners (1, 3) and tighten to 7.5 Nm (66 lb in).




11. Install a new seal (5) and the PIM 3 phase cable assembly terminal (4).
12. Install the PIM 3 phase cable terminal mounting fasteners (3) and tighten to 9 Nm (80 lb in).
13. Install the PIM 3 phase cable terminal installation guide assembly (2) and cable terminal fasteners (1). Tighten to 9 Nm (80 lb in).




14. Install NEW PIM 3 phase cable terminal seals (3).
15. Install the PIM 3 phase cable housing assembly (5).
16. Install the PIM 3 phase cable terminal fasteners (4) and tighten to 9 Nm (80 lb in).

Note: DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended.

17. Clean the sealing surface of the housing cover as necessary.
18. Install the PIM 3 phase cable housing cover (2).
19. Install the PIM 3 phase cable housing cover fasteners (1) and tighten to 9 Nm (80 lb in).
20. Install the sight shield circuit breaker (7).
21. Install the sight shield circuit breaker fasteners (6) and tighten to 9 Nm (80 lb in).




22. Remove the protective guard (3) from the front crossmember.
23. Install the drive motor generator control module support bracket (2) and start all of the support bracket bolts (1). Tighten the bolts to 11 Nm (97 lb in).
24. Install the windshield washer solvent container filler tube assembly bolt and tighten to 10 Nm (89 lb in).




25. Inspect and install the seals (3).
26. Install the HV dc battery cable (7) onto the PIM distribution box.
27. Install the HV dc battery cable mounting fasteners (6) and tighten to 9 Nm (80 lb in).
28. Install the HV dc electric ACCM cable (4) onto the PIM distribution box.
29. Install the HV dc electric ACCM cable mounting fasteners (5) and tighten to 9 Nm (80 lb in).
30. Install the HV dc battery and ACCM cable terminal bolt installation guide assembly (2).
31. Install the HV dc battery and ACCM cable terminal fasteners (1) and tighten to 9 Nm (80 lb in).




32. Install a new HV dc cable cover seal (3).

Note: DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended.

33. Clean the sealing surface of the cable cover (2) as necessary.
34. Install the HV dc cable cover (2) and cover fasteners (1) and tighten to 9 Nm (80 lb in).




35. Connect the APM assembly connectors (1-2) and install any removed locking tabs.
36. Connect the drive motor generator control module assembly connector (3) using the following procedure:

1. Push the lever up.

Note: Install the connector (3) without disturbing the position of the lever. DO NOT use the lever to install the connector in place.

2. Install the connector (3) onto the terminals by pushing on the connector only.
3. Rotate the lever after the terminals are engaged.
4. Push the green tab to lock the lever.

37. Install the shield circuit harness terminal (4) and terminal fastener (5). Tighten to 9 Nm (80 lb in).
38. Slide the wire harness clip onto the protruding stud of the shield circuit harness fastener.
39. Fill the power electronics cooling system and test for leaks at all serviced connections. Refer to Generator Control Module Cooling System Draining and Filling (Generator Control Module Cooling System Draining and Filling).
40. Install the sight shield. Refer to Drive Motor Generator Power Inverter Module Cover Replacement (Drive Motor Generator Power Inverter Module Removal and Installation).
41. Perform the High Voltage Enabling procedure. Refer to High Voltage Enabling (High Voltage Enabling)
42. For control module programming and setup procedures, refer to Control Module References (Programming and Relearning).

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