Generator Control Module Cover Replacement

Generator Control Module Cover Replacement

Removal Procedure

Danger:
Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.


Danger: 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 includes the following steps:


* 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.


Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:


* Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.


* Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.


- Visually and functionally inspect the gloves before use.


- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.


Failure to follow the procedures may result in serious injury or death.


1. Remove both rear compartment floor panels. Refer to Rear Compartment Floor Panel Trim Replacement (With Battery Cover, HP6) Rear Compartment Floor Panel Trim Replacement (With Battery Cover, HP6)Rear Compartment Floor Panel Trim Replacement (With Blower Cover, HP6) Rear Compartment Floor Panel Trim Replacement (With Blower Cover, HP6).

2. Remove the drive motor battery cooling blower outlet duct. Refer to Drive Motor Battery Cooling Blower Outlet Duct Replacement Drive Motor Battery Cooling Blower Outlet Duct Replacement.




3. Remove the upper fasteners (1) on the generator control module cooling air outlet duct.




4. Remove the lower fasteners (1) holding the generator control module cooling outlet duct (2) to the generator control module and remove the duct.




5. Disconnect and unclip the drive motor battery cooling blower electrical harness.

6. Remove the drive motor battery cooling blower and bracket fasteners (1).

7. Remove the drive motor battery cooling blower and bracket (2) as an assembly.

8. If the hybrid battery has not been disabled in a previous step, disable the hybrid battery. Refer to high voltage disabling for servicing any internal components within the A4 Hybrid/EV Battery Pack.High Voltage Disabling High Voltage Disabling.




9. Remove the body harness connectors (1) from the generator control and battery module.




10. Remove the high voltage 3-phase cable terminal nuts (1) and the 12V terminal branch nut (4).

11. Remove the high voltage cable (2) and the 12V cable (3) from the generator control and battery module.

12. Remove the drive motor battery cooling air inlet upper duct. Refer to Drive Motor Battery Cooling Air Inlet Upper Duct Replacement Drive Motor Battery Cooling Air Inlet Upper Duct Replacement.




13. Remove the generator control module cover fasteners (1).

14. Remove the generator control module cover fastener (2) and remove the generator control module cover (3).

Installation Procedure




1. Install the generator control module cover (3).

2. Install the generator control module cover fasteners (1) and tighten to 9 Nm (80 lb in).

3. Install the generator control module cover fastener (2) and tighten to 9 Nm (80 lb in).




4. Install the drive motor battery cooling blower motor and bracket (2). Tighten the fasteners (1) to 9 Nm (80 lb in).




5. Install the generator control module air outlet duct (2) and tighten the upper fasteners (1) to 9 Nm (80 lb in).




6. Install the lower generator control module cooling air outlet duct lower fasteners (1) and tighten to 9 Nm (80 lb in).




7. Install the high voltage 3-phase cable (2) to the generator control and battery module. Tighten the nuts (1) to 9 Nm (80 lb in).

8. Install the 12V cable (3) to the generator control and battery module. Tighten the nut (4) to 9 Nm (80 lb in).




9. Install the body harness connectors (1).

10. Install the drive motor battery cooling air inlet upper duct. Refer to Drive Motor Battery Cooling Air Inlet Upper Duct Replacement Drive Motor Battery Cooling Air Inlet Upper Duct Replacement.




11. Install the drive motor battery cooling blower outlet duct (1). Refer to Drive Motor Battery Cooling Blower Outlet Duct Replacement Drive Motor Battery Cooling Blower Outlet Duct Replacement.

Note: Make sure the duct is flush against the seal for efficient generator control and battery module cooling.

12. Enable the hybrid battery. Refer to High Voltage Enabling High Voltage Enabling.