Ski - Center Rail - HV Battery (RWD) (Remove and Replace)

Correction code 1610260216102602
  • 1140311-00-ALever Lock, HV Connector, Model 3

SPECIAL TOOLS

Lever Lock, HV Connector, Model 3 (1140311-00-A)
Warning:

Only technicians who have been trained in High Voltage Awareness are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Parent topic: 1610 - HV Battery Enclosure

Remove

  1. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  2. Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  3. Disconnect the PTC heater HV electrical harness, and then remove the PTC heater HV electrical harness from the connector bracket.
  4. Disconnect the A/C compressor HV electrical harness, and then remove the A/C compressor HV electrical harness from the connector bracket.
  5. Position a coolant drain under the LH front of the HV battery.
  6. Release the clip, disconnect the HV battery RH supply manifold from the HV battery LH supply manifold, and then immediately plug the male and female fittings.
  7. Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
  8. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  9. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  10. Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
  11. Release the locking tab of the rear drive unit HV electrical harness.
  12. Raise the handle, and them disconnect the rear drive unit HV electrical harness from the HV battery connector.
  13. Position a coolant drain under the RH rear of the HV battery.
  14. Release the clip and disconnect the RH inner HV battery return hose fitting from the RH end of the HV battery platter enclosure.
  15. Quickly plug both the male and female fittings.
  16. Release the locking tab, raise the handle, and then disconnect the PTC heater and A/C electrical harness from the HV battery connector.
  17. Release the clips that attach the PTC heater and A/C electrical harness to the HV battery.
  18. With an assistant, remove the bolts that attach the center rail ski to the HV battery.
  19. Remove the center rail ski from the vehicle.
  20. Remove the cap cover at the front of the HV battery center rail ski.
  21. Remove the cap cover at the rear of the HV battery center rail ski.
  22. Remove the PTC heater and A/C compressor electrical harnesses from the sides of the HV battery center rail ski.
1Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
2Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
3Disconnect the PTC heater HV electrical harness, and then remove the PTC heater HV electrical harness from the connector bracket.
4Disconnect the A/C compressor HV electrical harness, and then remove the A/C compressor HV electrical harness from the connector bracket.
5Position a coolant drain under the LH front of the HV battery.
6Release the clip, disconnect the HV battery RH supply manifold from the HV battery LH supply manifold, and then immediately plug the male and female fittings.
7Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
8Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
9Release the clips that attach the RH inner HV battery return hose to the HV battery.
10Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
11Release the locking tab of the rear drive unit HV electrical harness.
12Raise the handle, and them disconnect the rear drive unit HV electrical harness from the HV battery connector.
13Position a coolant drain under the RH rear of the HV battery.
14Release the clip and disconnect the RH inner HV battery return hose fitting from the RH end of the HV battery platter enclosure.
15Quickly plug both the male and female fittings.
16Release the locking tab, raise the handle, and then disconnect the PTC heater and A/C electrical harness from the HV battery connector.
17Release the clips that attach the PTC heater and A/C electrical harness to the HV battery.
18With an assistant, remove the bolts that attach the center rail ski to the HV battery.
19Remove the center rail ski from the vehicle.
20Remove the cap cover at the front of the HV battery center rail ski.
21Remove the cap cover at the rear of the HV battery center rail ski.
22Remove the PTC heater and A/C compressor electrical harnesses from the sides of the HV battery center rail ski.

Install

  1. Install the PTC heater and A/C compressor electrical harness into the sides of the HV battery center rail ski.
  2. Install the cap cover at the rear of the HV battery center rail ski.
  3. Install the cap cover at the front of the HV battery center rail ski.
  4. With an assistant, install the center rail ski to the HV battery.
  5. Install the bolts that attach the center rail ski to the HV battery.
    Torque 38 Nm
    Torque 38 Nm
  6. Fasten the clips that attach the electrical harness to the HV battery.
  7. Connect the electrical harness to the HV battery connector, lower the handle, and attach the locking tab.
  8. Remove the plugs from the male and female fittings, quickly connect the RH inner HV battery return hose to the HV battery platter enclosure, and then fasten the clip.
  9. Remove the coolant drain from under the RH rear of the HV battery.
  10. Fully raise the handle on the rear drive unit HV electrical harness.
  11. Attach the HV connector lever lock onto the back of the HV electrical harness.
  12. Firmly connect the HV electrical harness to the HV battery connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  13. While pressing the harness to the connector, remove the HV connector lever lock.
  14. While pressing the harness to the connector, fully lower the handle.
  15. Slide the release to lock the HV electrical harness.
  16. Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
    Torque 10 Nm
  17. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
  18. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  19. Position the coolant drain under the LH front of the HV battery.
  20. Install the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
  21. Remove the plugs from the HV battery RH supply manifold and the HV battery LH supply manifold, immediately connect the male and female fittings, and then fasten the clip.
  22. Install the A/C HV electrical harness into the connector bracket, and then connect the A/C HV electrical harness.
  23. Install the PTC heater HV electrical harness into the connector bracket, and then connect the PTC heater HV electrical harness.
  24. Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  25. Perform a penthouse air leak test. See Penthouse Air Leak Test.
  26. Connect 12V power. See 12V Power (Disconnect and Connect).
  27. Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).
1Install the PTC heater and A/C compressor electrical harness into the sides of the HV battery center rail ski.
2Install the cap cover at the rear of the HV battery center rail ski.
3Install the cap cover at the front of the HV battery center rail ski.
4With an assistant, install the center rail ski to the HV battery.
5Install the bolts that attach the center rail ski to the HV battery.
Torque 38 Nm
Torque 38 Nm
6Fasten the clips that attach the electrical harness to the HV battery.
7Connect the electrical harness to the HV battery connector, lower the handle, and attach the locking tab.
8Remove the plugs from the male and female fittings, quickly connect the RH inner HV battery return hose to the HV battery platter enclosure, and then fasten the clip.
9Remove the coolant drain from under the RH rear of the HV battery.
10Fully raise the handle on the rear drive unit HV electrical harness.
11Attach the HV connector lever lock onto the back of the HV electrical harness.
12Firmly connect the HV electrical harness to the HV battery connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
13While pressing the harness to the connector, remove the HV connector lever lock.
14While pressing the harness to the connector, fully lower the handle.
15Slide the release to lock the HV electrical harness.
16Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
Torque 10 Nm
17Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
18Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
19Position the coolant drain under the LH front of the HV battery.
20Install the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
21Remove the plugs from the HV battery RH supply manifold and the HV battery LH supply manifold, immediately connect the male and female fittings, and then fasten the clip.
22Install the A/C HV electrical harness into the connector bracket, and then connect the A/C HV electrical harness.
23Install the PTC heater HV electrical harness into the connector bracket, and then connect the PTC heater HV electrical harness.
24Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
25Perform a penthouse air leak test. See Penthouse Air Leak Test.
26Connect 12V power. See 12V Power (Disconnect and Connect).
27Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).