Hybrid Engine Electrical System (HP2): Removal & Installation Chevrolet Silverado 3500 HD

Removal Procedure

1. Remove the negative battery cable. Refer to «Battery Negative Cable Replacement»(ref-317183-S18177560212009060900000) .
2. Mark the location of the negative battery cable clip (1) and remove the clip from the cable.
3. Mark the location of the battery current sensor (2) on the battery cable with tape for reference during installation.
4. Remove the tape securing the battery current sensor to the negative battery cable.
5. Squeeze the negative battery cable branches together.
6. Slide the battery current sensor (2) off of the negative battery cable.

Installation Procedure

1. Squeeze the negative battery cable branches together.
2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal.
3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable.
4. Install the negative battery cable clip (1) to the cable to the location previously marked during removal.
5. Install the negative battery cable. Refer to «Battery Negative Cable Replacement»(ref-317183-S18177560212009060900000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-317183-S14131715452009060900000) .
2. Disconnect the engine wiring harness electrical connector (1) from the battery current sensor (2).
3. Remove the negative battery cable clip (1) from the auxiliary bussed electrical center (BEC).
4. Remove the negative battery cable ground terminal bolt (1) from the left side engine block boss.
5. Remove the negative battery cable (3) and the engine wiring harness ground (2) leads from the engine block boss.
6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
7. Remove the engine wiring harness ground lead bolt (1) from the frame.
8. Remove the engine wiring harness ground lead (2) and the negative battery cable lead (3) from the frame.
9. Lower the vehicle.
10. Remove the negative battery cable assembly (1) from under the positive battery cable and from the vehicle.

1. Install the negative battery cable assembly (1) to the vehicle and route the cable under the positive battery cable.
2. Raise and suitably support the vehicle.
3. Position the negative battery cable lead (3) behind the engine wiring harness ground lead (2).
4. Place the engine wiring harness ground lead (2) and the negative battery cable lead (3) to the frame.
5. Insert the anti-rotation tab on the engine harness ground lead into the hole in the frame.
6. Install the engine wiring harness ground lead to the frame bolt (1) and tighten to 9 N.m (80 lb in).
7. Lower the vehicle.
8. Position the engine wiring harness ground lead (2) behind the negative battery cable lead (3).
9. Place the negative battery cable lead (3) and the engine wiring harness ground lead (2) against the engine block boss.
10. Install the negative battery cable ground terminal to the engine block boss bolt (1) and tighten to 50 N.m (37 lb ft).
11. Install the negative battery cable clip (1) to the auxiliary BEC.
12. Connect the engine wiring harness electrical connector (1) to the battery current sensor (2).
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-317183-S14131715452009060900000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-317183-S14131715452009060900000) .
2. Reposition the positive battery cable insulating cover (2) from over the positive terminal.
3. Rotate the lever lock (1) counterclockwise in order to disconnect the positive battery cable.
4. Remove the positive battery cable terminal (3) from the battery.
5. Remove the auxiliary bussed electrical center (BEC) cover (1).
6. Remove the underhood junction block cover.
7. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1).
8. Remove the junction block.
9. Remove the positive battery cable nut (1) from the mega fuse stud.
10. Remove the positive battery cable nut (3) from the auxiliary BEC stud.
11. Disconnect the positive battery cable connector (2) from the underhood BEC.
12. Remove the positive battery cable assembly (1) from the vehicle.

1. Install the positive battery cable assembly (1) to the vehicle.
2. Install the positive battery cable leads to the mega fuse and auxiliary BEC studs.
3. Connect the positive battery cable connector (2) to the underhood BEC.
4. Install the positive battery cable nut (3) to the auxiliary BEC stud and tighten to 9 N.m (80 lb in).
5. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 N.m (80 lb in).
6. Ensure that the junction block retainers are in the open position (1).
7. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3).
8. Install the underhood junction block cover.
9. Install the auxiliary BEC cover (1).
10. Install the positive battery cable terminal (3) to the battery.
11. Rotate the lever lock (1) clockwise until an audible click is heard in order to connect the positive battery cable.
12. Position the positive battery cable insulating cover (2) over the positive terminal.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-317183-S14131715452009060900000) .

1. Disable the high voltage system. Refer to «High Voltage Disabling»(ref-317196-S27384397302009060900000) .
2. Remove the auxiliary bussed electrical center (BEC) cover (1).
3. Remove the positive battery cable nut (1) from the mega fuse stud.
4. Remove the positive battery cable lead (5) from the mega fuse stud.
5. Remove the engine shield. Refer to «Engine Shield Replacement»(ref-317158-S22420849622009060900000) .
6. Remove the positive battery cable clips (2, 3, and 4) from the frame crossmember.
7. Working through the wheel opening, remove the positive battery cable clip (2) from the brake pipe.
8. Working through the wheel opening, remove the positive battery cable clip (3) from the air cleaner adapter bracket
9. Lower the vehicle.
10. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-317198-S42437787332009060900000) .
11. Remove the positive battery cable clip (4) from the air cleaner support bracket.
12. Remove the positive battery cable clip (5) from the fender inner panel.
13. Disconnect the positive battery cable electrical connector (1) from the drive motor generator control module.
14. Remove the positive battery cable (1) from the vehicle.

1. Install the positive battery cable (1) to the vehicle.
2. Connect the positive battery cable electrical connector (1) to the drive motor generator control module.
3. Install the positive battery cable clip (5) to the fender inner panel.
4. Install the positive battery cable clip (4) to the air cleaner support bracket.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-317198-S42437787332009060900000) .
6. Raise and suitably support the vehicle enough to work through the wheel opening.
7. Working through the wheel opening, install the positive battery cable clip (3) to air cleaner adapter bracket
8. Working through the wheel opening, install the positive battery cable clip (2) to the brake pipe.
9. Fully raise the vehicle.
10. Install the positive battery cable clips (2, 3, and 4) to the frame crossmember.
11. Install the engine shield. Refer to «Engine Shield Replacement»(ref-317158-S22420849622009060900000) .
12. Lower the vehicle.
13. Install the positive battery cable lead (5) to the mega fuse stud.
14. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 N.m (80 lb in).
15. Install the auxiliary BEC cover (1).
16. Enable the high voltage system. Refer to «High Voltage Enabling»(ref-317196-S14696573942009060900000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-317183-S14131715452009060900000) .
2. Reposition the positive battery cable insulating cover (2) from over the positive terminal.
3. Rotate the lever lock (1) counterclockwise in order to disconnect the positive battery cable.
4. Remove the positive battery cable terminal (3) from the battery.
5. Remove the battery hold down bolt (1) and hold down (3).
6. Remove the battery assembly (2).

1. Install the battery assembly (2).
2. Install the battery hold down (3) and bolt (1) and tighten to 25 N.m (18 lb ft).
3. Install the positive battery cable terminal (3) to the battery.
4. Rotate the lever lock (1) clockwise until an audible click is heard in order to connect the positive battery cable.
5. Position the positive battery cable insulating cover (2) over the positive terminal.
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-317183-S14131715452009060900000) .

1. Remove the battery. Refer to «Battery Replacement»(ref-317183-S39323065102009060900000) .
2. Reposition the positive and negative battery cables out of the way.
3. Remove the battery tray to battery tray reinforcement bolts (1).
4. Remove the battery tray to battery tray support bolts (2).
5. Remove the battery tray to auxiliary bussed electrical center (BEC) bolt (4).
6. Remove the battery tray (3).

1. Install the battery tray (3) into the vehicle.
2. Install the battery tray to battery tray reinforcement bolts (1) and tighten to 9 N.m (80 lb in).
3. Install the battery tray support bolts (2) and tighten to 9 N.m (80 lb in).
4. Install the battery tray to auxiliary BEC bolt (4) and tighten to 9 N.m (80 lb in).
5. Install the positive and negative battery cables.
6. Install the battery. Refer to «Battery Replacement»(ref-317183-S39323065102009060900000) .

1. Remove the engine wiring harness ground bolt.
2. Reposition the engine wiring harness ground and ground strap.
3. Remove the ground strap nut from the stud at the front of dash.
4. Remove the ground strap from the stud.

1. Install the ground strap to the stud.
2. Install the ground strap nut to the stud at the front of dash and tighten to 9 N.m (80 lb in).
3. Position the ground strap and engine wiring harness ground.
4. Install the engine wiring harness ground bolt and tighten to 16 N.m (12 lb ft).

Generator Control Module Ground Strap Replacement

1. Remove the air cleaner assembly. Refer to «Upper Intake Manifold Cover Replacement»(ref-317249-S42115165322009060900000) .
2. Remove the drive motor generator control module ground strap bolt (1) and strap (2).

1. Position the ground strap (2) to the drive motor generator control module.
2. Install the ground strap bolt (1) and tighten to 9 N.m (80 lb in).
3. Install the air cleaner assembly. Refer to «Upper Intake Manifold Cover Replacement»(ref-317249-S42115165322009060900000) .