HV Inverter Surge Tank Repla. and Jumper Harness Install
HV Battery/Inverter Surge Tank Replacement and Coolant Level Sensor Jumper Harness InstallationCaution
Do not attempt to charge the vehicle or power the vehicle ON prior to filling the battery with coolant. After the initial battery coolant fill, the vehicle should be powered ON and then run the MDI/GDS2 "Hybrid/EV Battery Pack Coolant Pump Bleed Procedure.
1. Remove battery reservoir cap from coolant surge tank.
2. Remove front compartment sight shield.
3. Remove windshield washer filler tube (1) by pulling up on it.
4. Remove radiator upper mounts (2).
Caution
Do NOT use a prybar or similar tool to move the radiator module rearward, or damage to the radiator module can result.
Note
If accessing the surge tank-to-fan shroud fasteners is difficult, remove the radiator upper crossbar to gain access to the fasteners.
5. Push condenser/radiator/fan/module rearward and remove the two coolant surge tank fasteners (1).
6. Empty the power inverter module cooling system reservoir using the Vac-N-Fill system with 152 mm (6 in) hose extension.
7. Clamp shut power inverter module cooling system reservoir hoses.
8. Disconnect all hoses for both reservoirs of the coolant surge tank. Remove the battery coolant pump inlet hose, battery coolant cooler outlet hose, battery radiator outlet hose and generator control module coolant tank hose.
9. Remove the coolant surge tank.
1. Remove engine/intake cover.
2. Remove A/C refrigerant pressure sensor connector (1).
3. Wiggle coolant surge tank out of engine compartment.
10. Install coolant level sensor jumper harness.
1. Unplug refrigerant temperature sensor (3)
2. Pull out the wire harness.
3. Unseat Christmas tree retainer (1).
4. Disconnect compressor connector (2).
5. Remove harness clip from hose (4).
6. Cut off the wires at the back of the refrigerant temperature sensor (1) connector and strip 13mm (1/2 in) of insulation from the two wire ends (2).
7. Locate the coolant level sensor jumper from service kit 19260759 and strip 13 mm (1/2 in) of insulation from the two wire ends.
8. Crimp connect white and black wires on the new kit harness to the white/blue and black/violet wires respectively using the splice clip provided in the service kit. Refer to the instructions provided in the kit for proper procedure and tools.
9. Apply heat to the splice clip/heat shrink to seal it to the wire insulation. Proper tools must be used to protect the wire insulation from excess heat.
10. Install the new corrugated tube (1) that is provided in the service kit over the harness splice. The corrugated tube should overlap existing harness corrugated tube on both sides.
11. Completely wrap new corrugated tube with black electrical tape.
12. Reinstall the wire harness.
13. Install harness clip on hose in specified area.
14. Replug the compressor connector.
15. Reseat the Christmas tree retainer (replace if damaged).
16. Install new harness clip (1) (from the kit) on the A/C line above existing harness clip on the ACCM high voltage pigtail.
17. Put a dime-sized dab of RTV, P/N 88861417 (in Canada, use 88861418), (or equivalent) over exposed refrigerant temperature sensor (1) to cover exposed terminals.
11. Install the new coolant surge tank.
12. Connect coolant level sensor to new coolant surge tank.
13. Reconnect all coolant surge tank hoses.
14. Push radiator toward the engine and secure the driver's side (left) mount coolant surge tank fastener (1) by installing and tightening the one bolt.
15. Reconnect A/C refrigerant pressure sensor connector.
16. Remove manual clamp from power inverter module cooling system reservoir hoses.
Note
Vac-N-Fill equipment must be used along with proper coolant. The Power Electronics / Charging and Battery Cooling systems require a 50/50 mix of DEX-COOL(R) and de-ionized water. This mixture is available in a pre-mix with bitterant, P/N 12378390 USA, P/N10953456, Canada. The pre-mixed coolant is no longer available without the bitterant chemical. Refer to P/I #PIP4910.
17. Vac-N-Fill the power inverter module cooling system reservoir.
1. Use the VAC-N-FILL equipment without the 152 mm (6 in) hose extension.
2. Pull vacuum (at least 15 in Hg) for five (5) minutes.
3. Fill while under vacuum.
4. Remove reservoir overflow port cap.
5. Install overflow tubing and reservoir cap.
Note
Vac-N-Fill equipment must be used along with proper coolant. The Power Electronics / Charging and Battery Cooling systems require a 50/50 mix of DEX-COOL(R) and de-ionized water. This mixture is available in a pre-mix with bitterant, P/N 12378390 USA, P/N10953456, Canada. The pre-mixed coolant is no longer available without the bitterant chemical. Refer to P/I #PIP4910.
18. Vac-N-Fill the battery cooling system reservoir.
1. Use the VAC-N-FILL equipment without the 152 mm (6 in) hose extension.
2. Pull vacuum (at least 15 in Hg) for 5 minutes.
3. Fill while under vacuum.
4. Again pull vacuum (at least 15 in Hg) for 5 minutes.
5. Fill to top of reservoir.
6. Re-enable the high voltage battery. Refer to Drive Motor Battery Replacement and Shipping in SI.
Note
Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. When using the MDI for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 02/10/12 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided.
For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal.
19. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming.
20. Reprogram the modules listed in step 20.3. Refer to SI and Service Programming System (SPS) documentation for programming instructions.
1. Connect the MDI to the vehicle. Connect the MDI to the programming terminal with a cable.
2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen.
Note
Ensure that the hood is open andturn the vehicle ON to Service Mode. The Service Mode can be attained by pressing and holding the power button for 5 to 8 seconds WITHOUT depressing the brake pedal. Make sure that the ICE does not come on during this process.
3. Determine module year of vehicle.
Note
For 2011 vehicles, ensure that the most recent version of field action bulletin 11137 has been completed BEFORE performing the programming event in this bulletin.
- For 2011 model year vehicles, select SEQ Programming Sequence Battery Energy Control Module (K15) and Hybrid Powertrain Control Module 2 (K114B) from the Supported Controllers screen.
- For 2012 model year vehicles, select Hybrid Powertrain Control Module 2 (K114B) from the Supported Controllers screen.
4. Follow the on-screen instructions.
Caution
The Coolant level will drop below reservoir during this process. If it does, do not break vacuum, but use the Vac-N-Fill equipment to fill the reservoir. Next, re-establish the 15 in Hg vacuum for the remainder of the fill procedure. You may have to fill the reservoir several times during this procedure to prevent a low coolant condition, which will induce air into the system. If at the end of the procedure, the fluid level is below the reservoir, fill the reservoir and repeat the MDI/GDS Hybrid/EV Battery Pack Coolant Pump Bleed Procedure.
21. Run MDI/GDS2 "Hybrid/EV Battery Pack Coolant Pump Bleed Procedure" test while maintaining the 15 in Hg vacuum throughout the process. This procedure will take about an hour to complete.
1. Launch GDS2 and select Diagnostics.
2. Ensure information is accurate on the Vehicle Selection screen and then press ENTER.
3. Select Module Diagnostics and then press ENTER.
4. Select Hybrid Powertrain Control Module 2 and then press ENTER.
5. Select Control Function and then press ENTER.
6. Select Hybrid/EV Battery Pack Coolant Pump Bleed Procedure and then press ENTER.
7. Adjust (remove or add) coolant level to max fill line.
8. Install overflow tubing and reservoir cap.
22. Clear diagnostic codes (DTCs) if necessary.
23. Disconnect the low voltage battery charger.
24. Turn vehicle off.
25. Reinstall radiator mounts (2). Tighten bolts to 22 Nm (16 lb-ft).
26. Reinstall windshield washer filler tube (1).
27. Reinstall engine/intake cover.
28. Road test the vehicle in Mountain Mode with the vehicle in Low Gear for approximately 5 miles (8 km). When performing the 5 mile (8 km) mile drive cycle, drive vehicle in slalom (side to side motion) to purge any remaining air.
29. Re-check coolant level. Ensure the coolant level is to the top of the tank seam (1).
30. Install locking bracket (1) on vehicle right side reservoir securing the bracket and the reservoir with the bolt provided in the kit. Tighten bolt from front side of tie bar.
31. Reinstall front compartment sight shield.
32. Wash the vehicle.
33. Fill the fuel tank.
34. Check tire pressure. Add air to tires if required.
35. Fully charge the high-voltage battery before returning the vehicle to the customer.