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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1534 (HYBRID ENGINE CONTROL SYSTEM)REPAIR INSTRUCTIONSACCESSORY DC POWER CONTROL MODULE REMOVAL AND INSTALLATIONINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2008 GMC Yukon and 2008 Chevrolet Tahoe. 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 CORP.
  1. Install new APM coolant seal (3).
  2. Position the APM (2) onto the PIM ensuring the seals remain in place.
    3. NOTE: Refer to Fastener Notice .
  3. Install the APM mounting fasteners (1).

    Tighten:  Tighten the mounting fasteners to 10 N.m (89 lb in).

    4. Fig 2: Identifying GE-48494 Adapter Kit & Related Components
    GM1971297Courtesy of GENERAL MOTORS CORP.
  4. Rotate the drive motor generator control module assembly onto the APM.
  5. Clamp the GE-48494  components (2, 3) to a coolant pipe. See Special Tools .
  6. Plug the remaining coolant pipe with the GE-48494  plug and clamp (1). See Special Tools .
  7. Apply the specified pressure with J 24460-01  (4).

    Pressure:  Apply 20 psi (138 kPa) pressure.

  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  components. See Special Tools .
    10. Fig 3: Identifying PIM Cover & Retaining Bolts
    GM1971293Courtesy of GENERAL MOTORS CORP.
  10. Remove the PIM cover retaining bolts (1).
  11. Remove the PIM electronics cover (2).
    12. Fig 4: Identifying HV DC APM Terminal Fasteners
    GM1971292Courtesy of GENERAL MOTORS CORP.
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.