2025-04-11

Hose - HV Battery Return (Remove and Replace)

Correction code 1830020082 FRT 0.96 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See for safe and healthy working practices.

Equipment:
  • 1080568-00-A Fluid Catcher
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • 1065131-00-A Battery Coolant Drain Kit

Torque Specifications

Table 1. Torque Specifications: Hose - HV Battery Return (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the LH front wheel arch liner to the skid plate
5 Nm (3.7 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench
  • 10 mm deep socket
Reuse

Remove

  1. Raise and support the vehicle. See .
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Disconnect the LV power. See .
  4. Remove the cabin intake duct. See .
  5. Remove the access panel. See .
  6. Remove the underhood storage unit. See .
  7. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  8. Remove the push clips (x3) and bolt that attach the LH front wheel arch liner to the skid plate.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
    • 10 mm deep socket
  9. Use a bungee strap to pull back the LH front wheel arch liner and secure it to the subframe.
  10. Position a coolant drain container underneath the LH front of the HV battery.
  11. Release the clip, disconnect the HV battery return hose and plug the hose and the HV battery tube as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug the HV battery return tube as quickly as possible to minimize coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the coolant loss is greater then 1L, vacuum fill will be required. See .
  12. Release the clips (x2) that attach the HV battery return hose to the vehicle.
  13. Remove the coolant drain collector from under the vehicle.
  14. Lower the vehicle to a comfortable working height.
  15. Position a fluid catcher underneath the front of vehicle.
  16. Remove the LV battery. See .
  17. Release the clips (x2) that attach the HV battery return hose to the LV battery bracket.
  18. Remove the fresh intake duct. See .
  19. Disconnect the sensor connector from the chiller to battery hose.
  20. Disconnect the sensor connector from the powertrain supply hose.
  21. Release the clip, disconnect the chiller to battery hose from the supermanifold and plug the hose and the supermanifold as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug the supermanifold as quickly as possible to minimize coolant loss.
  22. Release the clip, disconnect the powertrain supply hose from the supermanifold and plug the hose and the supermanifold as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug the supermanifold as quickly as possible to minimize coolant loss.
  23. Release the clip, disconnect the HV battery return hose from the supermanifold and plug the hose and the supermanifold as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug the supermanifold as quickly as possible to minimize coolant loss.
  24. Remove the HV battery return hose from the vehicle.

Install

  1. Position the new HV battery return hose into the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the HV battery return hose from the RH side of vehicle and feed it towards LH side of vehicle and down into wheel arch liner area.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not bend or force the hose during installation, Slowly rotate the hose as required.
  2. Fasten the clips (x2) that attach the HV battery return hose to the LV battery bracket.
  3. Remove the plug from the supermanifold, immediately connect the HV battery return hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  4. Remove the plug from the supermanifold, immediately connect the chiller to battery hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  5. Remove the plug from the supermanifold, immediately connect the powertrain supply hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  6. Connect the sensor connector to the powertrain supply hose.
  7. Connect the sensor connector to the chiller to battery hose.
  8. Install the fresh intake duct. See .
  9. Remove the fluid catcher from underneath the front of the vehicle.
  10. Raise the vehicle fully and then lower the lift until the safety locks are safely engaged.
  11. Position a coolant drain container underneath the LH front of the HV battery.
  12. Remove the plug from the HV battery return tube, immediately connect the HV battery return hose to the HV battery return tube, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  13. Fasten the clips (x2) that attach the HV battery return hose to the vehicle.
  14. Remove the coolant drain collector from under the vehicle.
  15. Remove the bungee strap from the LH front wheel arch liner.
  16. Install the push clips (x3) and bolt that attach the LH front wheel arch liner to the skid plate.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
    • 10 mm deep socket
  17. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  18. Install the LV battery. See .
  19. Connect LV power. See .
  20. Perform the cooling system (partial refill and bleed) procedure. See .
  21. Install the underhood storage unit. See .
  22. Install the access panel. See .
  23. Install the cabin intake duct. See .
  24. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  25. Remove the vehicle from the 2 post lift. See .