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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 781 (HYBRID/EV CONTROL SYSTEM)REPAIR INSTRUCTIONSACCESSORY DC POWER CONTROL MODULE REMOVAL AND INSTALLATIONINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different car, the 2011 GMC Yukon, 2011 Chevrolet Tahoe, and 2011 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: APM, Coolant Seal And Fasteners
    GM1971296Courtesy of GENERAL MOTORS CORP.
  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: GE-48494 Adapter Kit And Related Components
    GM1971297Courtesy of GENERAL MOTORS CORP.
  4. Rotate the drive motor generator control module assembly onto the accessory DC power control module.
  5. Clamp GE-48494  adapter kitcomponents (2, 3) to a coolant pipe.
  6. Plug the remaining coolant pipe with GE-48494  adapter kitplug 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: PIM Cover And Retaining Bolts
    GM1971293Courtesy of GENERAL MOTORS CORP.
  10. Remove the power inverter module cover retaining bolts (1).
  11. Remove the power inverter module cover (2).
    12. Fig 4: 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.