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Hybrid Engine Controls - Repair Instructions: Removal & Installation GMC Yukon III

Engine Control Systems ~2461 words

Removal Procedure

  1. Perform the high voltage disabling. Refer to «High Voltage Disabling»(ref-364532-S04350868292010063000000) .
  2. Remove the power inverter module (PIM) 3 phase cable terminal fasteners (1).
  3. Remove the PIM 3 phase cable mounting fasteners (2, 4).
  4. Remove the PIM 3 phase cables (3, 5) from the PIM distribution box.
  5. Remove and discard the seals (6).
  6. Remove the 3 phase cable retainer nut (2).
  7. Remove the 3 phase cable retainer (1) from the bracket.
  8. Remove and lower the transmission enough to gain access to the 3 phase cable bracket bolts (1). Refer to «Transmission Replacement»(ref-364531-S37817276552010063000000) .
  9. Remove the 3 phase cable bracket bolts (1).
  10. Remove the 3 phase cover bolts (9) and transmission cover terminal housing (8).
  11. Remove the 3 phase cover (7).
  12. Disconnect the 3 phase cable cover connector.
  13. Remove the 3 phase cable bolt protective cover (5).
  14. Remove the 3 phase cable retaining bolts (4).
  15. Remove the 3 phase cables and housing (3).
  16. Finish removal of the transmission while allowing the 3 phase cables to remain in the vehicle. Refer to «Transmission Replacement»(ref-364531-S37817276552010063000000) .
  17. Remove the 3 phase cables from the vehicle.

Installation Procedure

CAUTIONTo avoid high voltage 3-phase cable or vehicle damage properly attach the cables and brackets, and check for and correct any interference.
  1. Position the 3 phase cables in the vehicle.
  2. Begin installation of the transmission. Refer to «Transmission Replacement»(ref-364531-S37817276552010063000000) .
  3. Install a new 3 phase cable housing seal (2).
  4. Install the 3 phase cables and housing (3).
  5. Install the 3 phase cable retaining bolts (4). Tighten: Tighten the bolts to 12 N.m (106 lb in).
  6. Install the 3 phase cable bolt protective cover (5).
  7. Install a new 3 phase cable cover seal (6).
  8. Reconnect the 3 phase cable cover connector.
  9. Install the 3 phase cable cover (7).
  10. Install the transmission cover terminal housing (8).
  11. Install the 3 phase cable cover bolts (9). Tighten: Tighten the bolts to 12 N.m (106 lb in).
  12. Install the 3 phase cable bracket bolts (1). Tighten: Tighten the bolts to 12 N.m (106 lb in).
  13. Complete installation of the transmission. Refer to «Transmission Replacement»(ref-364531-S37817276552010063000000) .
  14. Lower the vehicle.
  15. Install the 3 phase cable retainer (1) to the bracket.
  16. Install the 3 phase cable retainer nut (2). Tighten: Tighten the nut to 9 N.m (80 lb in).
  17. Install the PIM 3 phase cables (3, 5) into the PIM distribution box with new seals (6).
  18. Install the PIM 3 phase cable mounting fasteners (2, 4). Tighten: Tighten the mounting fastener to 9 N.m (80 lb in).
  19. Install the PIM 3 phase cable terminal fasteners (1). Tighten: Tighten the terminal fastener to 9 N.m (80 lb in).
  20. Install a new seal (3) on the PIM distribution box.
  21. Position the terminal cover (2) onto the PIM distribution box ensuring the seal remains in place.
  22. Tighten the terminal cover fasteners (1). Tighten: Tighten the fasteners to 9 N.m (80 lb in).
  23. Perform the high voltage enabling. Refer to «High Voltage Enabling»(ref-364532-S08767662232010063000000) .

Removal

  1. Remove the fender brace. Refer to «Front Fender Rear Upper Bracket Replacement»(ref-364470-S23498112462010063000000) .
  2. Loosen the sight shield mounting fastener (1) and lift the sight shield from the ball studs (2).
  3. Perform the High Voltage Disabling procedure. Refer to «High Voltage Disabling»(ref-364532-S04350868292010063000000) .

Installation

  1. Install the sight shield onto the ball studs (2) and tighten the sight shield mounting fastener (1). Tighten the fastener to 5 N.m (44 lb in).
  2. Install the fender brace. Refer to «Front Fender Rear Upper Bracket Replacement»(ref-364470-S23498112462010063000000) .
  3. Enable high voltage. Refer to «High Voltage Enabling»(ref-364532-S08767662232010063000000) .
  1. Perform the High Voltage Disabling procedure. Refer to «High Voltage Disabling»(ref-364532-S04350868292010063000000) .
  2. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-364536-S00643431952010063000000) .
  3. Disconnect the drive motor generator control module assembly connector (1).
  4. Drain the power electronics cooling system. Refer to «Generator Control Module Cooling System Draining and Filling»(ref-364561-S31954848312010063000000) .
  5. Remove the drive motor generator power inverter control module (PIM) 3 phase cable terminal fasteners (1).
  6. Remove the PIM 3 phase cable mounting fasteners (2, 4).
  7. Remove the PIM 3 phase cables (3, 5) from the PIM distribution box.
  8. Remove and discard the seals (6).
  9. Remove the HV dc electric air conditioning compressor module (ACCM) cable terminal fasteners (1).
  10. Remove the HV dc electric ACCM cable mounting fasteners (3).
  11. Remove the HV dc electric ACCM cable (4) from the PIM distribution box.
  12. Remove the HV dc battery cable terminal fasteners (2).
  13. Remove the HV dc battery cable mounting fasteners (5).
  14. Remove the HV dc battery cable (6) from the PIM distribution box.
  15. Inspect and retain the seals (7).
  16. Remove the drive motor generator position sensor shield circuit fastener (2).
  17. Remove the shield circuit harness (1).
  18. Remove the PIM cooling inlet (4) and outlet (5) hoses.
  19. Cap the coolant pipes (3, 6) to prevent coolant spillage when lifting the drive motor generator control module assembly from the vehicle.
  20. Disconnect the APM assembly connector (2) using the following procedure: Push the green tab. Squeeze the gray side tabs, then rotate the lever.
  21. Disconnect the APM assembly connector (3) using the following procedure: Remove the locking tab. Insert a small flat blade screwdriver into the locking tab area and raise the tab while pulling on the connector.
  22. Disconnect the remaining APM assembly connector (1).
  23. Remove the sight shield circuit breaker fasteners (1).
  24. Remove the sight shield circuit breaker (2).
  25. Remove the APM ground strap fastener (2) and ground strap (1).
  26. Remove the drive motor generator control module assembly mounting fasteners (3) and retainers (4).
  27. Remove the ball studs (1) from the drive motor generator control module.
  28. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations.
  29. Lift the drive motor generator control module assembly from the vehicle.
  30. To replace the drive motor generator power inverter module (PIM) assembly, refer to «Drive Motor Generator Power Inverter Module Removal and Installation»(ref-364527-S08643029362010063000000) . To replace the accessory DC power control module, refer to «Accessory DC Power Control Module Removal and Installation»(ref-364527-S17901358752010063000000) .
  1. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations.
  2. Lift the drive motor generator control module assembly into the vehicle.
  3. Remove the lifting device and install the ball studs (1). Tighten the ball studs to 10 N.m (89 lb in).
  4. Install the drive motor generator control module assembly retainers (4) and mounting nuts (3). Tighten the mounting nuts to 9 N.m (80 lb in).
  5. Install the APM ground strap (1) and APM ground strap nut (2). Tighten the nut to 9 N.m (80 lb in).
  6. Install the sight shield circuit breaker (2) and secure with bolts (1). Tighten the bolts to 5 N.m (44 lb in).
  7. Connect the APM assembly connectors (1 and 3) and install any removed locking tabs.
  8. Connect the APM assembly connector (2) using the following procedure: Push the lever up. NOTE: Install the connector (2) without disturbing the position of the lever. DO NOT use the lever to install the connector in place. Install the connector (2) onto the terminals by pushing on the connector only. Rotate the lever after the terminals are engaged. Push the green tab to lock the lever.
  9. Remove the caps (3, 6) from the drive motor generator power inverter coolant pipes.
  10. Connect the drive motor generator power inverter module (PIM) cooling inlet and outlet hoses (4, 5).
  11. Install the shield circuit harness (1) and terminal fastener (2). Tighten the terminal fastener to 9 N.m (80 lb in).
  12. Install the PIM 3 phase cables (3, 5) into the PIM distribution box with new seals (6).
  13. Install the PIM 3 phase cable mounting fasteners (2, 4). Tighten the mounting fastener to 9 N.m (80 lb in).
  14. Install the PIM 3 phase cable terminal fasteners (1). Tighten the terminal fastener to 9 N.m (80 lb in).
  15. Install the HV dc battery cable (6) with seal (7) into the PIM distribution box.
  16. Install the HV dc battery cable mounting fasteners (5). Tighten the mounting fastener to 9 N.m (80 lb in).
  17. Install the high voltage (HV) dc battery cable terminal fasteners (2). Tighten the terminal fastener to 9 N.m (80 lb in).
  18. Install the HV dc electric air conditioning compressor module (ACCM) cable (4) with seal (7) into the PIM distribution box.
  19. Install the HV dc electric ACCM cable mounting fasteners (3). Tighten the mounting fasteners to 9 N.m (80 lb in).
  20. Install the HV dc electric ACCM cable terminal fasteners (1). Tighten the terminal fastener to 9 N.m (80 lb in).
  21. Install a new seal (3) on the PIM distribution box.
  22. Clean the sealing surface of the 3 phase cable cover as necessary.
  23. Position the 3 phase cable cover (2) onto the PIM distribution box ensuring the seal remains in place.
  24. Tighten the 3 phase cable cover fasteners (1) to 9 N.m (80 lb in).
  25. Connect the drive motor generator control module assembly connector (1).
  26. Fill the power electronics cooling system and test for leaks at all serviced connections. Refer to «Generator Control Module Cooling System Draining and Filling»(ref-364561-S31954848312010063000000) .
  27. Install the sight shield. Refer to «Drive Motor Generator Control Module Sight Shield Replacement»(ref-364527-S24491217952010063000000) .
  28. Install the fender cross brace. Refer to «Front Fender Rear Upper Bracket Replacement»(ref-364470-S23498112462010063000000) .
  29. Perform the High Voltage Enabling procedure. Refer to «High Voltage Enabling»(ref-364532-S08767662232010063000000) .
  30. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-364536-S00643431952010063000000) .
  31. For control module programming and setup procedures, refer to «Control Module References»(ref-364489-S22329914082010063000000) .

Drive Motor Generator Power Inverter Module Removal and Installation

Special Tools

  1. GE-48494: Power Electronics Pressure Test Adapter Kit
  2. J 24460-01: Cooling System Pressure Tester
  1. Remove the drive motor generator control module from the vehicle. Refer to «Drive Motor Generator Control Module Assembly Replacement»(ref-364527-S05588488292010063000000) .
  2. Remove the temporary coolant pipe caps (1).
  3. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains.
  4. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1).
  5. Remove the PIM cover (2). Discard the cover seal (3).
  6. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket.
  7. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1).
  8. Rotate the drive motor generator control module assembly onto the PIM cover.
  9. Remove the APM to PIM mounting fasteners (1).
  10. Remove the APM (2) and discard the coolant seal (3).
  11. Remove the drive motor generator power inverter coolant pipes: Remove the drive motor generator power inverter coolant pipe bolts (4, 7). Remove the drive motor generator power inverter coolant pipes (5, 8). Remove and discard coolant seals (6, 9).
  1. Install new APM coolant seal (3).
  2. Position the APM (2) onto the PIM ensuring the seals remain in place.
  3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 N.m (89 lb in).
  4. Install the drive motor generator power inverter coolant pipes unless a service replacement PIM is being installed: Lubricate the new seals (6, 9) with pre-mixed DEX-COOL®. Install new seals (6, 9) onto the drive motor generator power inverter coolant pipes (5, 8). Install the coolant pipes (5, 8) to the PIM assembly with bolts (4, 7). Tighten the fasteners to 5 N.m (44 lb in).
  5. Rotate the drive motor generator control module assembly onto the APM.
  6. Clamp GE-48494: adapter kit components (2, 3) to a coolant pipe.
  7. Plug the remaining coolant pipe with the GE-48494: adapter kit plug and clamp (1).
  8. Apply 20 psi (138 kPa) pressure with J 24460-01: pressure tester (4).
  9. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seal. If pressure remains at the specified value, proceed to the next step.
  10. Remove all GE-48494: adapter kit components.
  11. Remove the PIM cover retaining bolts (1).
  12. Remove the PIM cover (2).
  13. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 N.m (80 lb in).
  14. Install a new PIM cover seal (3).
  15. Clean the sealing surface of the PIM cover as necessary.
  16. Position the PIM cover (2) onto the PIM ensuring the seal remains in place.
  17. Install the PIM cover fasteners (1). Tighten the fasteners to 5 N.m (44 lb in).
  18. Install the drive motor generator control module. Refer to «Drive Motor Generator Control Module Assembly Replacement»(ref-364527-S05588488292010063000000) .

Accessory DC Power Control Module Removal and Installation

Special Tools

  1. J 24460-01: Cooling System Pressure Tester
  2. GE-48494: Power Electronics Pressure Test Adapter Kit
  1. Remove the drive motor generator control module from the vehicle. Refer to «Drive Motor Generator Control Module Assembly Replacement»(ref-364527-S05588488292010063000000) .
  2. Remove the APM ground strap bolt (1) and ground strap (2).
  3. Remove the temporary coolant pipe caps (1).
  4. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains.
  5. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1).
  6. Remove the PIM cover (2). Discard the cover seal (3).
  7. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket.
  8. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1).
  9. Rotate the drive motor generator control module assembly onto the PIM cover.
  10. Remove the APM to PIM mounting fasteners (1).
  11. Remove the APM (2) and discard the coolant seal (3).
  1. Install new APM coolant seal (3).
  2. Position the APM (2) onto the PIM ensuring the seals remain in place.
  3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 N.m (89 lb in).
  4. Rotate the drive motor generator control module assembly onto the APM.
  5. Clamp GE-48494: adapter kit components (2, 3) to a coolant pipe.
  6. Plug the remaining coolant pipe with GE-48494: adapter kit plug and clamp (1).
  7. Apply 20 psi (138 kPa) pressure with J 24460-01: pressure tester (4).
  8. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seals. If pressure remains at the specified value, proceed to the next step.
  9. Remove all GE-48494: adapter kit components.
  10. Remove the PIM cover retaining bolts (1).
  11. Remove the PIM cover (2).
  12. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 N.m (80 lb in).
  13. Install a new PIM cover seal (3).
  14. Clean the sealing surface of the PIM cover as necessary.
  15. Position the PIM cover (2) onto the PIM ensuring the seal remains in place.
  16. Install the PIM cover fasteners (1). Tighten the fasteners to 5 N.m (44 lb in).
  17. Install the ground strap (2) and bolt (1). Tighten the bolt to 22 N.m (16 lb ft).
  18. Install the drive motor generator control module. Refer to «Drive Motor Generator Control Module Assembly Replacement»(ref-364527-S05588488292010063000000) .

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