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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2184 (HYBRID/EV CONTROL SYSTEM)REPAIR INSTRUCTIONSACCESSORY DC POWER CONTROL MODULE REMOVAL AND INSTALLATIONINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different car, the 2012 GMC Yukon, 2012 Chevrolet Tahoe, and 2012 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of APM, Coolant Seal & Fasteners
    GM1971296Courtesy of GENERAL MOTORS COMPANY
  1. Install new accessory DC power control module coolant seal (3).
  2. Position the accessory DC power control module (2) onto the power inverter module ensuring the seals remain in place.
    3. CAUTION:

    Refer to Fastener Caution .

  3. Install the accessory DC power control module mounting fasteners (1). Tighten the mounting fasteners to 10 N.m (89 lb in).
    4. Fig 2: Pressure Adapter Kit & Related Components
    GM1971297Courtesy of GENERAL MOTORS COMPANY
  4. Rotate the drive motor generator control module assembly onto the accessory DC power control module.
  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. Fig 3: Identifying PIM Cover & Retaining Bolts
    GM1971293Courtesy of GENERAL MOTORS COMPANY
  10. Remove the power inverter module cover retaining bolts (1).
  11. Remove the power inverter module cover (2).
    12. Fig 4: Identifying HV DC APM Terminal Fasteners
    GM1971292Courtesy of GENERAL MOTORS COMPANY
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.