Chevrolet Malibu Hybrid and 2007 Saturn AURA Green Line Hybrid

Chevrolet Malibu Hybrid and 2007 Saturn AURA Green Line Hybrid
Chevrolet Malibu Hybrid and
2007 Saturn AURA Green Line Hybrid
GM Service Technical College provides First Responder
Guides (FRG) and Quick Reference (QR) Sheets free of charge
to First Responders. FRGs and QRs can be displayed in a
classroom as long as they are represented as GM information
and are not modified in any way.
This guide specifically addresses the Chevrolet Malibu and
Saturn AURA Green Line Hybrid vehicles.
While a majority of the systems installed on these hybrids are
common to traditional GM vehicles, a number of components
are different and may affect how a rescue procedure is
We will note those differences as well as highlight ways to
easily identify our hybrids from their non-hybrid counterparts.
Finally, we will illustrate where the cut zones are to help you
safely extricate occupants from the vehicle.
System Operation
The Chevrolet Malibu and Saturn AURA Green Line Hybrid
are gasoline-electric vehicles that use a 36 volt electrical
system and traditional 12 volt battery to achieve significant fuel
economy improvements.
Both vehicles are equipped with a 2.4 liter, 4-cylinder engine
and a traditional 12 volt starter motor, which is used only for
initial starts of the vehicle.
2.4 L Engine
36 Volt Hybrid Battery
System Operation (cont.)
During braking and deceleration, energy is recovered and stored
in the hybrid battery (also known as the generator battery). The
engine’s fuel supply is interrupted and the engine temporarily shuts off as the vehicle comes to a full stop. This is referred to
as Auto Stop.
There are conditions when the engine will be restarted by a
special starter generator. Some of these conditions include:
The gear shift lever is moved from Drive to another gear
The hybrid battery charge is low and requires recharging
Auto Stop has timed out (maximum of 120 seconds)
Normal A/C mode is selected
Full front Defrost mode is selected
The accelerator pedal is applied
The brake pedal is released
NOTE: The starter generator cannot provide sustained vehicle
propulsion by itself. It is primarily used for starting the engine
after an autostop and for engine assist during accelerations.
System Operation (cont.)
Several factors affect how long the engine remains off during
Auto Stop. Some of these factors are:
Air Conditioning setting (A/C is affected by outside
temperature when Hybrid A/C light is illuminated)
Hybrid Battery state of charge is low
Time limit (maximum of 120 seconds)
A/C Button
System Operation (cont.)
Auto Stop
will not
shut down thethat
if any of
are many
the engine
apply: of these conditions are:
Stop. Some
Engine is not warmed up
Shift lever is in any gear except Drive
Hybrid battery state of charge is low
12v vehicle battery charge is low, or charge
requirements are high
Hood is not fully closed
Full front Defrost mode
Blower speed on high
A/C in normal
Vehicle Identification (cont.)
A hybrid badge is attached to the driver and
passenger front doors.
Note: Saturn AURA Green Line shown,
Chevrolet Malibu Hybrid similar.
Vehicle Identification
Special badging is attached to the trunk lid.
Note: Saturn AURA Green Line shown,
Chevrolet Malibu Hybrid similar.
NOTE: Green Line
emblem only on
Saturn AURA
Vehicle Identification (cont.)
A tachometer with Auto Stop indicator and a Charge/Assist gauge are
part of the instrument panel cluster.
Charge/Assist Gauge
Tachometer with Auto Stop Indicator
Vehicle Identification (cont.)
Under the hood is:
A hybrid badge attached to the 12 volt battery cover
A label showing the battery locations (attached to the radiator core support)
Vehicle Identification (cont.)
A battery cover with an imprint of a GM hybrid
logo sits directly behind the rear passenger
DC/AC Voltage Classifications
Electricity is categorized as either low,
intermediate, or high voltage.
Low voltage – from 0 to 30
volts DC / 0 to 15 volts AC
Intermediate voltage – from
30 volts or greater to 60 volts
DC / 15 volts or greater to 30
volts AC
High voltage – any voltage
greater than 60 volts DC / 30
volts AC
Color coding is used to identify the
different levels of voltage – blue for
intermediate and orange for high.
The Saturn AURA Green Line and
Chevrolet Malibu hybrids fall within the
intermediate range.
Two-mode hybrids and GM’s Silverado and Sierra Parallel Hybrid Trucks are a
combination of intermediate and high
voltage systems (see chart footnote).
Intermediate Voltage
High Voltage
DC ≤ 30v —
AC ≤ 15v
DC > 30 ≤ 60v —
AC > 15 ≤ 30v RMS
DC > 60v
AC > 30v RMS
Saturn VUE and AURA
Green Line Hybrids
Two-mode Hybrid
Chevrolet Malibu Hybrid
** GMC Sierra/Chevrolet
Silverado Parallel Hybrid
* GMC Sierra/Chevrolet
Silverado Parallel Hybrid
* Applicable to 36v DC Hybrid Battery Pack, 36v DC Power Steering System and 36v DC
Starter Generator Control Module (input)
** Applicable to Starter Generator Control Module (inverted APO output) and 120v AC
Accessory Power Outlets (APO)
Note: Presently there are no industry standards to identify intermediate voltage.
GM has chosen BLUE for the cable color.
DC Voltage Classifications (cont.)
Even though the Chevrolet Malibu and the Saturn AURA Green
Line Hybrid uses lower voltage than other hybrids you may
encounter, they must still be approached with caution.
Key Hybrid Components
This illustration shows the location of the hybrid components.
Note: Chevrolet Malibu Hybrid shown, Saturn AURA Green
Line similar.
36v Wire Routing
12v Battery
(not shown)
36v Hybrid Battery
Hybrid Battery Disconnect
Control Module with Disconnect
Switch for 36v Battery
Starter Generator
Key Hybrid Components (cont.)
The Chevrolet Malibu and Saturn AURA Green Line Hybrid use a
conventional internal combustion engine coupled with a starter
generator to efficiently power the vehicle.
Note that all intermediate voltage cables used on the hybrid model
are covered in blue sheathing for easy identification. The
exception is when the hybrid battery cable is routed beneath the
vehicle in a rigid, metal conduit tubing.
Conventional Engine
with a starter generator
Key Hybrid Components (cont.)
A 3-phase starter generator, capable of generating more than
5000 Watts of electrical power, starts the engine when the
vehicle is in the Auto Stop mode. The unit is mounted on the
right side of the engine and replaces the standard generator
used on non-hybrid models.
Intermediate voltage cables are routed through the back of the
starter generator. The cables carry 36-42 volts of electricity.
Always use caution when you are near these cables until you
are sure the hybrid electrical system is disabled!
Starter generator
Key Hybrid Components (cont.)
The generator control module, which is mounted on the left side of
the engine, manages the routing of the 36 volt electrical system.
The generator control module receives the electrical current
through two central terminal blocks that contain the 3-phase, 12
volt battery and 36 volt generator battery cables. These cables
enter the blocks from the bottom and side. A protective plate
covers the terminal blocks and cables.
Two coolant hoses, attached to the back of the module, connect
the generator control module with the engine’s cooling system. These hoses may contain hot coolant that could scald if they are
disconnected or cut.
Note that blue wiring is used to indicate intermediate voltage.
Cables from the starter generator, 12v
battery and 36v battery enter the side and
bottom of the generator control module
(cover removed for clarity)
Key Hybrid Components (cont.)
A Nickel Metal Hydride (NiMH) 36 volt hybrid battery is mounted
in the trunk compartment directly behind the rear passenger
Battery cover removed for clarity
A 10 mm hex head bolt secures the
Hybrid Battery Disconnect Control
Key Hybrid Components (cont.)
A separate box, called the hybrid battery disconnect
control module, is attached to the hybrid battery case.
Within the box are the negative and positive battery
cables for the hybrid battery. Opening the hinged
cover causes a spring-loaded disconnect switch to
interrupt electrical flow from the hybrid battery and
quickly discharge stored electrical energy in the
generator control module.
Hinges attached to the
battery hold the cover
in place
Disconnect Switch
(shown with Hybrid
Battery Disconnect
Control Module
cover open)
Key Hybrid Components (cont.)
A 12 volt battery provides power for the vehicle’s accessories such as the radio, HVAC, and lighting. It is also used during the
initial start-up of the vehicle.
Two negative (-) cables attach to the negative (-) battery terminal.
Key Hybrid Components (cont.)
A hood ajar switch is mounted near the hood latch and prevents
Auto Stop from functioning if the hood of the vehicle is not fully
If the hood is opened while the vehicle is in Auto Stop, the
tachometer will move to the OFF position and the engine will be
disabled from restarting unless the ignition key is used.
Note the hood ajar switch will not prevent current flow through the
36 volt electrical system.
Airbag Deployment*
A contactor inside the hybrid battery is
designed to open upon rear impact
detection or one or more air bags
deploy. This will cause current flow in
the 36 volt cable to be reduced to a low
After air bag deployment, wait at least
10 seconds to allow any undeployed air
bag reserve energy to dissipate.
To ensure personal safety, it is essential
to disable the 12 volt power if one or
more air bags remains undeployed.
*For more information on air bags go to the Emergency Personnel Information link at
Run/Crank Relay
Disabling 12 Volt Power
Perform EACH of the following steps to
disable the 12 volt electrical system. This
includes power to the airbag system.
Cut here to
disable BOTH
12v negative
cables at once
Turn the ignition key to the
OFF position
OR if the ignition key is not
accessible, remove the run/
crank relay located in the
underhood fuse block
Disconnect or cut BOTH 12v
negative (-) battery cables
Verify tachometer needle is
pointing to OFF
WAIT a minimum of 10 seconds to allow
any undeployed airbag reserve energy to
WARNING: WAIT a minimum of 10
seconds to allow the undeployed
airbag reserve energy to dissipate.
36 Volt Electrical System
Do NOT cut the intermediate voltage
(36v) cable, because there is a higher
arc potential.
CAUTION: Cutting the
intermediate voltage cable
may result in an arc hazard.
First perform the “Disabling 12 Volt Power” procedure on the previous page to eliminate current flow on the 12 volt
electrical system. This also reduces the
36 volt current flow to a low level in the
intermediate voltage (36v) cable. No
further action is required.
CAUTION: Cutting the intermediate
voltage cable may result in an arc
Note: The intermediate voltage
cable routed under vehicle is
not colored blue but is housed
in a metal conduit
DO NOT CUT HERE. Roof rails may contain
side impact air bag inflator canisters
Cut Zones
CAUTION: DO NOT cut the vehicle
until all of the electrical systems have
been deactivated and isolated. Cutting
into the vehicle prior to disconnecting
and isolating the electrical energy
sources may cause an electrical arc
and/or personal injury.
Do not cut the:
Center of the vehicle.
Intermediate 36 volt wiring is
routed in a conduit tube
beneath the vehicle.
Roof rails between the
windshield pillars and ‘sail’ panels.
Hybrid battery. The hybrid
battery has 36 volt electrical
potential at all times.
Battery has 36v electrical
potential at all times
DO NOT CUT HERE. Conduit tube
beneath the vehicle contains
intermediate 36v electrical wire
Highlighted areas indicate
As a first responder, it is essential that
you manage the risks associated with
an emergency event.
Responding to a situation involving a
hybrid vehicle requires additional
forethought and planning.
We are confident this guide will
contribute positively toward attaining
that goal.
For information regarding modification of
GM’s First Responder Information for other uses, contact GM’s Licensing Manager at:
GM Licensing Program Headquarters
5775 Enterprise Ct
Warren, MI 48092
Attn: Licensing Coordinator
© Copyright 2007, General Motors Corporation
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