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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 287 (HYBRID ENERGY STORAGE SYSTEM)REPAIR INSTRUCTIONSDRIVE MOTOR GENERATOR BATTERY REPLACEMENT
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Drive Motor Generator Battery Replacement

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Drive Motor Generator Battery Replacement
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: Drive Motor Generator Battery
GM1971858Courtesy of GENERAL MOTORS CORP.
Callout Component Name
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.

Failure to follow the procedures exactly as written may result in serious injury or death.
Preliminary Procedures:: Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling .
1 Drive Motor Battery Positive, Negative, and Ground Shield Cable Terminal Fastener Nut (Qty: 3)
NOTE: Refer to Fastener Notice .

Tighten:  9 N.m (80 lb in)
2 Drive Motor Battery 300 Volt Positive and Negative Cable
CAUTION: High Voltage (HV) cables are not repairable. After disconnecting HV cables, protect and insulate ring terminal ends immediately with the EL-48569 terminal covers and UL® Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement.

Special Tools: 
EL-48569  Terminal Covers. See Special Tools .
3 Battery Vent Tube
Tip:  Remove the vent tube from the vehicle.
4 Drive Motor Generator Battery Retainer Nut (Qty: 2)

Tighten:  50 N.m (37 lb ft)
5 Drive Motor Generator Battery Ground Nut
Tip:  The cooling duct must be removed in order to access the ground nut.

Tighten:  25 N.m (18 lb ft)
6 Drive Motor Generator Battery Mounting Nut

Tighten:  25 N.m (18 lb ft)
7 Drive Motor Generator Battery Ground Bolt

Tighten:  25 N.m (18 lb ft)
8 Drive Motor Battery Cable Terminal Extension Cover

Procedure:

  1. Install the terminal extension cover.
  2. Disconnect the X350 harness connector from the drive motor generator battery.
  3. Protect the drive motor generator battery assembly while removed from the vehicle.
9 Drive Motor Battery Cable Terminal Extension Cover Bolt (Qty: 4)

Tighten:  6 N.m (53 lb in)
10 Lifting Point - Right Side
11 Lifting Points - Left Side
12 Drive Motor Battery Assembly
WARNING: The high voltage (HV) battery must be protected when outside of the vehicle.
Storage Guidelines
  • Store the HV battery flat, do not exceed 45 degrees when handling.
  • Store the HV battery in an environmentally protected area.
  • Maintain the HV battery at room temperature.
  • Protect the HV battery from exposure to liquids.
  • Protect the HV battery from physical damage.

Unqualified Access Guidelines
  1. Cover all exposed high voltage openings with UL® listed, or equivalent, insulation tape rated at a minimum of 600 volts.
  2. Store the HV battery in a limited-access area.

Failure to follow these guidelines may result in serious injury or death.

Procedure:: 
After the battery assembly has been replaced and the re-assembly of the drive motor generator battery, enable the HV system. Refer to High Voltage Enabling .
Tip:  Some portable lifting devices may require raising the vehicle or the removal of the rear tire to permit access of boom into the vehicle.
Special Tools: 
EL-48265  Battery Lifting Fixture. See Special Tools .
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.