Battery Cassette Replacement - VUE
Battery Cassette Replacement VUEImportant:
Dust may be an irritant to skin and eyes. Avoid skin and eye contact. If battery dust is present, remove carefully to avoid inhalation. Wear safety glasses and butyl rubber, natural rubber, neoprene, nitrile or Tyvek protective gloves when handling any corroded hybrid batteries, and when cleaning the inside of the hybrid battery case. Discard the gloves after each use and dispose of any corrosion material that was removed from the case.
1. Remove the ignition key from the ignition switch. Secure the ignition key in order to ensure that the key CANNOT be reinstalled without your knowledge.
2. Disconnect the 12-volt negative battery cable.
3. Remove the rear compartment closeout panels.
4. Remove the generator battery disconnect control module cover bolt.
5. Slide the generator battery disconnect control module cover to the right and remove the cover.
6. WAIT at least 5 minutes in order to allow the generator control module capacitors to discharge.
Important:
Never assume the battery pack is disabled when the generator battery disconnect control module cover is opened.
7. The generator battery will have to be checked for voltage potential using a voltmeter. First, verify that the voltmeter works.
1. Set the voltmeter to DC voltage.
2. Measure the vehicle's 12-volt battery voltage (at 12-volt positive jumper location and negative battery cable).
3. The meter should read greater than +12 volts DC.
8. Now, check the generator battery for voltage potential in order to ensure that the generator battery has been disabled.
1. Measure from the positive (3) stud to the negative stud (2). The voltage should be less than 3 volts.
2. Measure from the positive (3) stud to the vehicle chassis ground (1). The voltage should be less than 3 volts.
3. Measure from the negative (2) stud to the vehicle chassis ground (1). The voltage should be less than 3 volts.
4. After verifying that there is no voltage present, the vehicle is now safe to work on.
9. Remove the driver and passenger side rear compartment load floor stowage tray retainers (1, 3).
10. Remove the driver and passenger side rear compartment load floor stowage trays (2, 4).
11. Carefully remove the driver and passenger side foam insulators.
12. Fold down the rear seat back.
13. Remove the rear seat rear bolts.
14. Partially remove the left side rear quarter lower trim panel.
15. Disconnect the generator battery wiring harness electrical connector (1) from the body wiring harness electrical connector (2).
16. Remove the 36-volt negative battery cable ground nut (8) and cable from the body stud.
17. Remove the cable shield lead nut (3) and cable lead (4) from the carrier.
18. Remove the 36-volt positive battery cable lead nut (6).
19. Remove the 36-volt positive battery cable lead (5).
20. Remove the generator battery front bolts (1) at the shock towers.
21. Pull the generator battery carrier towards the rear of the vehicle and carefully remove the carrier from the vehicle. Place the carrier assembly on a workbench.
22. Remove the two upper generator battery fan bolts (2).
23. Remove the 12 generator battery cover bolts (1).
24. Remove the generator battery wiring harness from the clip (3) on the generator battery cover.
25. Remove the generator battery cover.
Important:
Removing the interconnect cables will disable the 36 volts within the generator battery control module.
26. Remove the generator battery terminal covers (1).
27. Remove the generator battery cable nuts (2).
28. Remove and reposition the generator battery cable leads (3, 4, 5) from the batteries.
29. Disconnect the generator battery temperature sensor wiring harness electrical connectors (1) from the battery temperature sensors.
30. Cut the tie straps securing the battery cables to the generator battery temperature sensor wiring harnesses.
31. Disconnect the generator battery temperature sensor wiring harness electrical connectors (2, 5) from the generator control module.
32. Remove the generator battery temperature sensor wiring harness.
33. Remove the remaining generator battery cable from the battery.
34. Remove all the mounting bolts (1) from the 3 generator batteries.
Important:
Each hybrid battery must be placed in two (double) polyethylene 6 mil bags that were provided with the new batteries. If the bags were not included with the batteries, contact your Saturn Parts Service Analysis (PSA) or the Saturn Saab Service Parts Assistance Centre (SPAC) for Canadian retailers. This double bagging procedure must be performed as soon as the hybrid batteries are removed from the vehicle. After bagging the individual battery cassettes, place the batteries in the original shipping container.
35. Remove all 3 generator batteries.
36. Remove the 3 temperature sensors from the batteries.
37. Remove the four generator battery control module assembly bolts.
38. Remove the generator battery control module assembly from the carrier.
39. Remove the two remaining lower vent fan bolts and fan from the carrier.
40. Clean any corrosion or battery acid that is present on the inside of the hybrid battery case by using a sponge that is lightly dampened with soapy water. It is not necessary to use a neutralizer, such as baking soda.
41. Dry the inside of the hybrid battery case using several shop towels.
42. Apply black paint to any areas inside of the hybrid battery case where bare metal is present.
43. Install the vent fan to the carrier and secure with two lower bolts.
44. Install the generator battery control module assembly to the carrier.
45. Install the generator battery control module assembly bolts.
46. Install the 3 temperature sensors to the new batteries. Polarity does NOT matter.
47. Install the new generator batteries.
48. Install the generator battery bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
49. Position and install the generator battery temperature sensor wiring harness.
50. Connect the generator battery temperature sensor wiring harness electrical connectors to the battery temperature sensors.
51. Connect the generator battery temperature sensor wiring harness electrical connectors to the generator control module.
Important:
The cable leads must be installed correctly to prevent low voltage DTCs. It is recommended that the disassembly and reassembly be performed at the same time to ensure reinstalling the cables in the correct location. In the event that the battery cable routing is in question, it is important to remember that the battery cable stud and plate covers up (not visible) the polarity indicator in the plastic case. The polarity that is visible is for the terminal NEXT to the stud. This visible polarity indicator is NOT for the battery stud. This was covered in the BAS hybrid training.
52. Position and install the generator battery cable leads to the battery terminals.
53. Install the generator battery cable nuts to the batteries.
Tighten
Tighten the nuts to 8 N.m (71 lb in).
54. Install the generator battery terminal covers.
55. Install NEW tie straps in order to secure the battery cables to the generator battery temperature sensor wiring harness.
56. Install the generator battery cover.
57. Install the 12 generator battery cover bolts.
Tighten
Tighten the bolts to 8 N.m (71 lb in).
58. Install the two generator battery fan bolts.
Tighten
Tighten the bolts to 8 Nm (71 lb in).
59. Carefully install the generator battery carrier to the vehicle.
60. Loosely install the generator battery front bolts at the shock towers.
61. Connect the generator battery wiring harness electrical connector to the body wiring harness electrical connector.
62. Reinstall the left side rear quarter lower trim panel.
63. Install the rear seat rear bolts.
Tighten
Tighten the rear seat rear bolts to 50 Nm (37 lb ft).
64. Lift up the rear seat back.
65. Tighten the generator battery bolts at the rear shock towers to 10 N.m (89 lb in).
66. Install the 36-volt negative battery cable to the body ground stud and reinstall the nut.
Tighten
Tighten the nut to 9 N.m (80 lb in).
67. Install the 36-volt positive battery cable lead to the generator battery.
Notice:
Vehicles produced prior to July 15, 2006, were produced with a torque prevailing (lock) nut (1). DO NOT reuse this lock nut when performing any procedure that requires the removal of the positive battery cable. If the lock nut is reused, damage to the battery cable stud may occur. The hybrid battery pack requires a new positive battery cable nut, P/N 11610091, to be installed if the original nut is a torque prevailing (lock) nut (1). The new nut, P/N 11610091, should be finger-started and then torqued to the correct specification (15 N.m(11 lb ft). DO NOT replace the nut unless it is a torque prevailing (lock) nut (1); use the nut removed in Step 18. Refer to illustration.
68. Install a NEW 36-volt positive battery cable lead nut, if required. Start the nut finger-tight, and then torque to the specification given.
Tighten
Tighten the nut to 15 N.m (11 lb ft).
69. Install the cable shield lead and the nut to the carrier.
Tighten
Tighten the nut to 9 N.m (80 lb in).
70. Install the driver and passenger side rear compartment load floor stowage trays.
71. Carefully install the driver and passenger side foam insulators.
72. Install the driver and passenger side rear compartment load floor stowage tray retainers.
73. Install and close the generator battery disconnect control module cover.
74. Install the generator battery cover bolt.
Tighten
Tighten the bolt to 10 N.m (89 lb in).
75. Install the rear compartment closeout panels.
76. Connect the 12-volt negative battery cable.
77. Reprogram the ECM with the latest calibrations if a P1A5A DTC was stored with the P1A59 DTC.
78. After programming, clear any DTC codes that may be present.
79. CALIFORNIA, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
80. Refer to section titled "Returning the Battery".