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Hybrid Service Disable Procedures Chevrolet Malibu VII

Body Electrical 1 illustration ~420 words

SAFETY PRECAUTIONS

WARNINGTo help avoid personal injury, always ensure the ignition switch is in the OFF position and the ignition key has been removed prior to working on any 36V components. After the key has been removed, disconnect the negative 12V battery cable and then open the generator battery disconnect control module cover. After waiting for at least 5 minutes, measure the voltage potential using a DMM between the following: 36V positive and negative battery cables 36V positive battery cable and vehicle ground 36V negative battery cable and vehicle ground All measured voltage levels must be below 3 volts. After confirming that voltage levels are less than 3 volts, remove the 36V negative and then the positive battery cable.

SPECIAL TOOLS

Note. No special tools are required for this procedure.

DISCONNECT

  1. Remove the ignition key from the ignition switch. Secure the ignition key in order to ensure that the key CANNOT be re-installed without your knowledge.
  2. Disconnect the 12 volt negative battery cable
  3. Fold down both rear seat backs.
  4. Carefully lift up on the load floor rear compartment cover (1) at the retaining clip (2) locations. (Scheme 1)
  5. Tilt the load floor rear compartment cover (2) towards the rear of the vehicle slightly, disengaging the tabs (1) and remove the load floor rear compartment cover. see scheme 2
  6. Remove the generator battery disconnect control module cover bolt (1). see scheme 3
  7. Open and slide the generator battery disconnect control module cover (2) to the right, removing the cover. see scheme 3
  8. WAIT at least 5 minutes in order to allow the generator control module capacitors to discharge.

ISOLATION CHECK

  1. The generator battery will have to be checked for voltage potential using a voltmeter first, verify that the voltmeter works: Set the voltmeter to DC voltage. Measure the vehicle's 12-volt battery voltage (at 12-volt positive jumper location and negative battery cable). The meter should read greater than +12 volts DC.
  2. Now, check the generator battery for voltage potential in order to ensure that the generator battery has been disabled. Measure from the positive (3) stud to the negative stud (2). The voltage should be less than 3 volts. see scheme 4 Measure from the positive (3) stud to vehicle chassis ground (1). The voltage should be less than 3 volts. see scheme 4 Measure from the negative (2) stud to vehicle chassis ground (1). The voltage should be less than 3 volts. see scheme 4 After verifying that there is no voltage present, the vehicle is now safe to work on.

Scheme 1

Scheme 1
Scheme 1

CONNECT

  1. Install and close the generator battery disconnect control module cover (2). see scheme 5
  2. Install the generator battery cover bolt (1). see scheme 5 Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Tilt the load floor rear compartment cover (2) towards the rear of the vehicle slightly in order to insert the tabs (2) into the battery tray rear support. see scheme 6
  4. Set the load floor rear compartment cover (1) down ensuring that the retaining clips (2) align to the proper locations, carefully push down securing the cover. see scheme 7
  5. Return both rear seats backs to their proper positions.
  6. Connect the 12 volt negative battery cable

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