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Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    WARNING:

    Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

    WARNING:

    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.

    Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

    • Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
    • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
      • Visually and functionally inspect the gloves before use.
      • Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

    Failure to follow the procedures exactly as written may result in serious injury or death.

  1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System Draining and Filling (GE 47716) .
  2. Disable the high voltage system. Refer to High Voltage Disabling .
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Reposition the secondary air injection pump inlet hose. Refer to Secondary Air Injection Pump Inlet Hose Replacement .
    5. Fig 1: Radiator Inlet Hose Bracket Bolt
    GM2531316Courtesy of GENERAL MOTORS COMPANY
  5. Remove the radiator inlet hose bracket bolt (1) and the radiator inlet hose clamp (2).
  6. Reposition the radiator inlet hose (3).
    7. Fig 2: Starter Generator Hoses
    GM2531307Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Place a clean cloth in the starter generator coolant tubes to prevent coolant leakage.

  7. Remove the starter generator hoses (1) and reposition hoses away from the Starter Generator.
    8. Fig 3: Drive Motor Generator Battery Cable Cover Nuts
    GM2531315Courtesy of GENERAL MOTORS COMPANY
  8. Remove the drive motor generator battery cable cover nuts (1) and the drive motor generator battery cable cover (2).
    9. Fig 4: Starter Generator
    GM2531312Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The terminals are very sensitive to contamination. Be sure to protect the terminals from engine coolant or debris.

  9. Remove the drive motor generator battery cable terminal bolts (1) and reposition the drive motor generator battery cable.
    10. Fig 5: Drive Motor Generator Battery Connector
    GM2531306Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The terminals are very sensitive to contamination. Be sure to protect the connector from debris or engine coolant.

  10. Remove and cover the drive motor generator battery connector (1).
    11. Fig 6: Drive Belt Tensioner Stop Bolt
    GM2531310Courtesy of GENERAL MOTORS COMPANY
  11. Remove the drive belt tensioner stop bolt (1) and the drive belt tensioner stop (2).
    12. Fig 7: EN-48932 Compressor Tool
    GM2536624Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure the EN-48932  compressor tool is not on the Generator bracket and A/C Compressor bracket.

  12. Install the EN-48932  compressor tool (2) to the drive belt tensioner spring.
  13. Tighten the nut (1) on the EN-48932  compressor tool (2) until the tensioner spring reaches its internal stop.
    14. NOTE:

    Try not to remove the drive belt from the other pulleys.

  14. Release the tension from the other drive belt tensioner and remove the drive belt from the starter generator pulley.
    15. Fig 8: Stud/Nut
    GM2531304Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    If stud is seized, place 2 nuts on the end of the stud and remove with a socket.

  15. Remove the stud/nut (1) from the starter generator.
  16. Raise the vehicle.
  17. Remove the starter generator bolts (2).
  18. Remove the starter generator (3).
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