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HOMESERVICE MANUALSPONTIAC2006G6 GTP, 2D COUPE, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1181 (HYBRID ENGINE CONTROL SYSTEM)REPAIR INSTRUCTIONSGENERATOR CONTROL MODULE REPLACEMENTINSTALLATION PROCEDURE
2006 Pontiac G6 GTP, 2D Coupe, Standard

Installation Procedure

2006 Pontiac G6 GTP, 2D Coupe, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Control Module & Bracket
    GM1892177Courtesy of GENERAL MOTORS CORP.
  1. If the generator control module was replaced. install the transaxle auxiliary pump control module. Refer to Auxiliary Fluid Pump Control Module Replacement .
    2. NOTE: Refer to Fastener Notice .
  2. Position the generator control module (1) to the bracket (3), and install the generator control module bracket to module bolts (2).

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

    3. Fig 2: View Of Control Module & Nuts
    GM1892176Courtesy of GENERAL MOTORS CORP.
  3. Install the generator control module (with bracket) (2) to the vehicle.
  4. Install the generator control module bracket nuts.

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

    5. Fig 3: Identifying Generator Control Module Ground Strap, Stud & Nut
    GM1892175Courtesy of GENERAL MOTORS CORP.
  5. Install the generator control module ground strap (2) to the stud and install the ground strap nut (1) to the module.

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

    6. Fig 4: Identifying Connector Position Assurance (CPA) Retainers
    GM1891759Courtesy of GENERAL MOTORS CORP.
  6. Connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump.
    7. Fig 5: View Of Generator Control Module 3-Phase Cable Terminal Block Nuts & Generator Control Module
    GM1891965Courtesy of GENERAL MOTORS CORP.
  7. Place a NEW terminal block seal onto the generator control module.
  8. Install the generator control module 3-phase cable terminal block (2) onto the generator control module.
  9. Install the generator control module 3-phase cable terminal block nuts (1) until snug.
    10. Fig 6: Identifying Generator Control Module Cable Terminal Block Nut Tightening Sequence
    GM1891968Courtesy of GENERAL MOTORS CORP.
  10. Tighten the generator control module 3-phase cable terminal block nuts in the sequence shown.

    Tighten:  Tighten the nuts to 8 N.m (71 lb in).

    11. Fig 7: View Of 36-Volt Terminal Block & Nuts
    GM1891966Courtesy of GENERAL MOTORS CORP.
  11. Place a NEW terminal block seal onto the generator control module.
  12. Unsecure, and position the 36-volt terminal block (2) to the generator control module.
  13. Install the 36-volt terminal block nuts (1) to the generator control module.

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

    14. Fig 8: View Of Generator Control Module Cover & Integral Bolts
    GM1891961Courtesy of GENERAL MOTORS CORP.
  14. Place the generator control module cover (2) on top of the generator control module and tighten bolts (1).

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

    15. Fig 9: View Of Generator Control Module Coolant Outlet Hose
    GM1892174Courtesy of GENERAL MOTORS CORP.
  15. Install the generator control module coolant outlet hose (2) to the generator control module.
  16. Position the generator control module coolant outlet hose clamp (1) at the generator control module using the J 38185  or equivalent.
    17. Fig 10: Locating Generator Control Module Coolant Inlet Hose & Clamp
    GM1891970Courtesy of GENERAL MOTORS CORP.
  17. Install the generator control module coolant inlet hose (2) to the generator control module.
  18. Position the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185  or equivalent.
    19. Fig 11: View Of Generator Control Module Bracket Reinforcement Bolt & Nuts
    GM1891960Courtesy of GENERAL MOTORS CORP.
  19. Install the generator control module bracket reinforcement (3).
  20. Install the generator control module bracket reinforcement bolt (1) and nuts (2).

    Tighten:  Tighten the bolt/nuts to 10 N.m (89 lb in).

    21. Fig 12: Identifying Connector Position Assurance (CPA) Retainers
    GM1891759Courtesy of GENERAL MOTORS CORP.
  21. Connect the 2 engine wiring harness electrical connectors (2) to the generator control module.
  22. Install the 2 CPA retainers (3).
    23. Fig 13: Identifying Booster Vacuum Hose, Clamp & Intake Manifold
    GM1892160Courtesy of GENERAL MOTORS CORP.
  23. Position and install the power brake booster vacuum hose (2) to the intake manifold.
  24. Position the power brake booster vacuum hose clamp at the intake manifold.
  25. Install the power brake booster vacuum hose to the clamp (2) to the generator control module coolant outlet hose.
  26. Install the battery tray. Refer to Battery Tray Replacement (LAT) .
  27. Fill the cooling system. Refer to Cooling System Draining and Filling (LAT Static Fill) .
  28. Connect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
  29. If the generator control module was replaced, program the NEW module. Refer to Control Module References .
  30. Using a Tech 2, command an autostart in order to verify that the system is working properly.
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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.