HV Battery (RWD) (Remove and Install)
Correction code
16010101
FRT
3.18
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 Flat Rate Times 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 Ergonomic Precautions for safe and healthy working practices.
Torque Specifications
| Description | Torque Value | Recommended Tools | Reuse/Replace | Notes |
|---|---|---|---|---|
| LH and RH front footwell HV battery bolts (x4) |
![]() 136 Nm (100.3 lbs-ft) |
|
Reuse | |
| HV battery bolt below the rear end of the LH front seat cushion |
![]() 66 Nm (48.7 lbs-ft) |
|
Reuse | |
| LH and RH rear HV battery interior bolts (x2) |
![]() 66 Nm (48.7 lbs-ft) |
|
Reuse | |
|
Bolt that secures the charge port busbar access door Bolts that attach the charge port busbar kit to the HV header |
![]() 9 Nm (6.6 lbs-ft) |
|
Reuse | |
| Nut that attaches the positive LV output to the power conversion system (PCS) cable |
![]() 9 Nm (6.6 lbs-ft) |
|
Replace | |
| Bolts (x2) that attaches the LH and RH front wheel liners to skid plate |
![]() 5 Nm (3.7 lbs-ft) |
|
Reuse | |
| Nut that attaches the rear drive unit HV cable bracket to the HV battery |
![]() 10 Nm (7.4 lbs-ft) |
|
Reuse | |
| Middle bolts (x4) that secure the HV battery center ski cover |
![]() 34 Nm (25.1 lbs-ft) |
|
Reuse | |
| Bolts (x8) that attach the LH and RH front support brackets to vehicle |
![]() 110 Nm (81.1 lbs-ft) |
|
Reuse | |
| LH and RH bolts (x16) that attach the HV battery to vehicle |
![]() 35 Nm (25.8 lbs-ft) |
|
Reuse |
Remove
- Remove the LH and RH rocker panel lower covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
- Open all doors and lower all windows.
- Move the LH front seat rearward.
- Remove the LH front floor mat.
- Remove the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
- Remove the lower A-pillar assembly. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Remove the LH front seat bolts (x4). See Seat Assembly - 1st Row - LH (Remove and Replace).
- Remove the driver side footwell cover. See Cover - Footwell - Driver (Remove and Replace).
- Remove the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
-
Remove the LH front main cabin carpet
clips (x2).
NoteNumber of clips on new vehicles may vary.
- Tilt the LH front seat backward.
-
Fold the LH front main cabin carpet
aside for access.
NoteFoot rest and foam block are parts of the carpet.
-
Remove the LH front footwell HV
battery bolts (x2).
TIpUse of the following tool(s) is recommended:
- Torx Plus EP20 socket - 1139807-00-A
-
Remove the HV battery bolt below the
rear end of the LH front seat cushion.
TIpUse of the following tool(s) is recommended:
- 16 mm socket
-
Repeat step 3 to 14 to the RH side.
NoteFor the passenger side footwell cover, see Cover - Footwell - Front Passenger (Remove and Replace).
- Remove the 2nd row floor mat from vehicle.
- Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
-
Pull back the rear carpet to access
the rear interior battery bolts.
-
Remove the LH and RH rear HV battery
interior bolts (x2).
NoteLift up the carpet for access.TIpUse of the following tool(s) is recommended:
- 16 mm deep socket
-
Close the LH and RH rear door latches
manually.
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
- Place the vehicle in Service Mode Plus. See Service Mode Plus.
- Unlock the vehicle gateway. See Gateway Unlock.
-
Perform the following
routine using Service Mode or Toolbox (see 0005 - Service Modes):
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox:(link)
NoteThermal Fill Drain routine has a 5-hour time limit. After 5 hours, the routine must be performed again.
- Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
-
Remove the bolt that secures the
charge port busbar access door.
TIpUse of the following tool(s) is recommended:
- Insulated 10 mm 12-point deep socket
- Electrical Protective Gloves
-
Remove the bolts (x2) that attach the
charge port busbar kit to the HV header.
TIpUse of the following tool(s) is recommended:
- Insulated 10 mm 12-point deep socket
- Electrical Protective Gloves
-
Lift and remove the charge
port busbar connector from the HV header.
NoteWiggle the connector back and forth to ease removal.WarningThe video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.
- Remove the HV insulating gloves.
-
Disconnect the HVC logic connector and
install the logic cap.
NoteRelease the locking tab then push the handle downward to release the connector.
- Remove the DCDC ground busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
-
Remove and discard the nut that
attaches the positive LV output to the power conversion system (PCS) cable, and then
move the cable aside.
TIpUse of the following tool(s) is recommended:
- 13 mm socket
- 13 mm 12-point deep socket
- Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
- Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
-
Remove the push clips (x3) that attach
the lower rear edge of LH front wheel liner to vehicle for access to coolant hose.
-
Remove the bolt that attaches the LH
front wheel liner to skid plate.
TIpUse of the following tool(s) is recommended:
- 10 mm deep socket
-
Use bungee strap to pull back the LH
front wheel liner and secure it to the subframe.
- Repeat step 35 to 37 to the RH side.
-
Position the coolant drain container underneath the RH front of the HV battery.
-
If equipped, release the front drive unit inverter inlet hose from the RH side of the
vehicle, and plug the ends of fittings as soon as possible to avoid coolant loss.
NoteCoolant loss greater than 1L requires vacuum fill.
-
Release the spring clip to disconnect
the powertrain supply hose from the powertrain supply tube.
NotePlug hoses as required.
- Position the coolant drain container underneath the LH front of the HV battery.
-
Release the spring clip to disconnect the HV battery return tube from the HV battery
hose.
NoteLocated on the LH front of the HV battery.NotePlug hoses as required.NoteCoolant loss greater than 1L requires vacuum fill.
-
Release the HV battery front manifold hose from the body (1x clip).
-
Disconnect the HV battery manifold
hose.
NotePlug hoses as required.
-
Disconnect the A/C compressor HV
harness connector.
NoteUnlock by pulling back the red tab, then pushing the orange lip and pulling back the connector at the same time, and then pushing the green lip and pulling back the connector again to disconnect the connector.
- Remove the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
- Remove the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
-
Position a coolant drain container
underneath the LH rear of the HV battery.
-
Disconnect the LH coolant hose from
the rear of HV battery.
NotePlug the coolant hose and the passthrough.
-
Remove the fir tree clip that attaches
the coolant hose to the rear subframe shear plate.
-
Disconnect the rear drive unit
inverter inlet tube from the LH rear of HV battery.
NotePlug the hose connections as needed. Coolant loss greater than 1L requires vacuum fill.
-
Position the coolant drain container
underneath the RH rear of vehicle.
-
Disconnect the rear powertrain supply
hose from the rear of HV battery.
NotePlug the hose connections as needed. Coolant loss greater than 1L requires vacuum fill.
- Support the front portion of the rear subframe.
- Remove the LH shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
-
Hand tighten the bolt that attaches
the LH side of subframe to body.
- Remove the RH shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
-
Hand tighten the bolt that attaches
the RH side of subframe to body.
-
Remove the support stand from under
the vehicle.
-
Remove the nut that attaches the rear
drive unit HV cable bracket to the HV battery.
NoteNumber of fasteners may vary.TIpUse of the following tool(s) is recommended:
- 10mm Deep Magnetic Nutsetter
-
Disconnect the connector that connects
the rear drive unit HV cable and HV battery.
NoteRelease locking tab and rotate the release lever up to disengage the connector. Do not force the release lever up. Ensure the alignment tabs on the rear drive unit header are not damaged.
-
With assistance, place the HV battery
table into position, and lower the vehicle to support the HV battery.
NoteLine up the table so the middle 4 bolts are accessible through the opening in table. Adjust the final battery table position using adjustable caster jacks on the table.
-
Remove the middle bolts (x4) that
secure the HV battery center ski cover.
TIpUse of the following tool(s) is recommended:
- Socket 3/8in Dr EP14 - 1133570-00-A
-
Remove the bolts (x8) that attach the
LH and RH front support brackets to vehicle.
TIpUse of the following tool(s) is recommended:
- 16 mm socket
-
Remove the LH and RH bolts (x16) that
attach the HV battery to vehicle.
TIpUse of the following tool(s) is recommended:
- 13 mm socket
- With assistance, raise the vehicle free of HV battery.
- With assistance, remove the battery from under the vehicle.
Install
-
Install the ancillary bay engagement
seal onto the HV battery pack.
NoteThis seal is a one-time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped.
-
Install HV battery alignment rods
(x4).
NoteInstall 2 rods to the body at front of vehicle and the other 2 rods to battery near the ancillary bay.
-
With assistance, position the HV
battery under the vehicle.
-
With assistance, lower the vehicle
onto the HV battery and align the holes.
NoteUse alignment rods. Be sure that the coolant hoses do not get caught on the alignment rods. Caution not to damage HV cable. Do not fully lower the vehicle onto battery (this will help with installing battery bolts).
-
Set the LH and RH bolts (x16) that
attach the HV battery to vehicle with cordless impact.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting. Flush down the bolts. Do not over tighten bolts. Fully torque at later step.
- Remove the HV battery alignment rods.
-
Set the bolts (x8) that attach the LH
and RH front support brackets to vehicle with cordless impact.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting. Flush down bolts. Do not over tighten the bolts. Fully torque at later step.
-
Set the middle bolts (x4) that attach
the HV battery center ski cover with cordless impact.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting. Flush down bolts. Do not over tighten the bolts. Fully torque at later step.
-
Hand-tighten the bolts (x4) that
attach the HV battery to body at LH and RH shear plate area.
NoteTorque at later step.
-
Connect the rear drive unit HV cable
to HV battery.
NoteMake sure the connector lock is 90 degrees from the connector before beginning to secure the connector. Use one hand to support the connector while the other latching the locking tab. Once installed, verify that the latch is not damaged and is fully secured in the latched position.
-
Install the nut that attaches the rear
drive unit HV cable bracket to the HV battery.
10 Nm (7.4 lbs-ft)NoteNumber of fasteners may vary.TIpUse of the following tool(s) is recommended:- 10mm Deep Magnetic Nutsetter
-
Remove the hose plugs and connect the
rear drive unit outlet hose to powertrain return tube.
NotePerform a push-pull-push test to make sure hose is fully engaged. Use shop towel to clean any coolant residue if necessary. Coolant loss greater than 1L requires vacuum fill.
-
Remove the plugs and connect the rear
drive unit inverter inlet hose to the LH rear of HV battery.
NotePerform a push-pull-push test to make sure the hose is fully engaged. Coolant loss greater than 1L requires vacuum fill.
- Install the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
- Lower vehicle onto pack completely.
-
Torque the LH and RH bolts (x16) that
attach the HV battery to vehicle.
35 Nm (25.8 lbs-ft)TIpUse of the following tool(s) is recommended:- 13 mm socket
-
Torque the bolts (x8) that attach the
LH and RH front support brackets to vehicle.
110 Nm (81.1 lbs-ft)TIpUse of the following tool(s) is recommended:- 16 mm socket
-
Torque the middle bolts (x4) that
secure the HV battery center ski cover.
34 Nm (25.1 lbs-ft)TIpUse of the following tool(s) is recommended:- Socket 3/8in Dr EP14 - 1133570-00-A
-
With assistance, raise the vehicle and
lower it onto locks, then remove the battery table from under the vehicle.
NoteSet vehicle to comfortable working height. Make sure there's an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to the side.
-
Support the front portion of rear
subframe.
- Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
- Install the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
-
Remove the plugs and connect the HV
battery manifold hose.
-
Remove the plugs and connect the
powertrain supply hose.
NotePerform a push-pull-push test to make sure the hose is fully engaged. Coolant loss greater than 1L requires vacuum fill.
-
Remove the plugs and connect the
powertrain return hose.
NotePerform a push-pull test to verify hoses are fully engaged. Coolant loss greater than 1L requires vacuum fill.
- Install the LH and RH front skid plates. See Skid Plate - HV Battery - Front (Remove and Replace).
-
Install the push clip that attaches the lower edge of the RH front wheel liner to the
vehicle.
-
Connect the HV battery return
hose.
-
Release the LH front wheel liner from
the bungee strap, and remove the strap from the vehicle.
-
Install the push clip that attaches the lower edge of the LH front wheel liner to the
vehicle.
-
Connect the A/C compressor HV harness
connector.
NoteEngage the locking tab.
- Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
- Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
- Inspect and put on the HV insulating gloves and leather over gloves.
-
Clean the HV connector contact surface
of residual Penetrox, and allow at least 1 minute to dry.
-
Apply Penetrox onto the HV connector
joints.
NoteApply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
-
Position the busbar kit connector and
lower it onto the HV header.
NoteShift the rear end of busbar assembly upward to help ease installation. If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
-
Install the bolts that attach the
charge port busbar kit to the HV header.
9 Nm (6.6 lbs-ft)TIpUse of the following tool(s) is recommended:- Insulated 10 mm 12-point deep socket
- Electrical Protective Gloves
-
Perform Hioki resistance test at each
HV joint from HV busbar lead to bolt head.
NotePerform zero adjust to Hioki meter prior to testing.
- If the resistance is greater than 0.195 mΩ (195 μΩ), remove the fastener, clean the areas with isopropyl alcohol, and then install the fastener back and test again.
- If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.
- If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to the next step.
-
Install the bolt that secures the
charge port busbar access door.
9 Nm (6.6 lbs-ft)TIpUse of the following tool(s) is recommended:- Insulated 10 mm 12-point deep socket
- Electrical Protective Gloves
- Install the DCDC ground busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
-
Connect the DCDC positive cable to the
right body harness (1x connector,1x clip).
NoteConnect the connector and push in the red locking tab.
-
Install a new nut that attaches the
positive LV output to the power conversion system (PCS) cable.
9 Nm (6.6 lbs-ft)NoteMake sure the rubber boot is not pinched between the cable terminal and the pass through.TIpUse of the following tool(s) is recommended:- 13 mm socket
- 13 mm 12-point deep socket
-
Remove the logic cap and connect the
HVC logic connector.
NoteAlign the connector then pull the handle to locking position. Get the connector fully seated.
- Connect the LV battery power. See LV Power (Disconnect and Connect).
- Remove the lift arms from below the vehicle, and move the vehicle away from the lift.
- Unlock the vehicle gateway. See Gateway Unlock.
-
Perform the following
routine using Service Mode or Toolbox (see 0005 - Service Modes):
PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Service Mode:
- Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
- Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
- Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
- Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
-
Inspect the coolant level, top off as
necessary.
NoteEnsure that the coolant level is at the "Max" line.
-
Select , click Run, and then allow the routine to complete.
Note
- The routine will last for a while after the stop message displays. The coolant pumps are audible.
- The test lasts for approximately 10 mins. Do not start another routine during this time.
- Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
- The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
- If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
-
Install the LH and RH rear HV battery
interior bolts (x2).
66 Nm (48.7 lbs-ft)NoteLift up the carpet for access.TIpUse of the following tool(s) is recommended:- 16 mm deep socket
-
Install the push clips (x2) that
secures the rear carpet section.
NoteTuck the corners under the lower C pillar trim.
- Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
-
Close the LH and RH rear doors.
NoteRelease the latches before closing if manually latched.
- Open the LH front door.
-
Install the LH front footwell HV
battery bolts (x2).
136 Nm (100.3 lbs-ft)TIpUse of the following tool(s) is recommended:- Torx Plus EP20 socket - 1139807-00-A
-
Install HV battery bolts below rear
end of LH and RH front seat cushions.
66 Nm (48.7 lbs-ft)NoteDepending on market region or vehicle configuration, the vehicle may not be equipped with this bolt.TIpUse of the following tool(s) is recommended:- 16 mm socket
Figure 1. LH Shown, RH Similar -
Install the push clips (x2) that
attach the LH front main cabin carpet to vehicle.
NoteNumber of clips on new vehicles may vary.
- Install the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
- Install the driver side footwell cover. See Cover - Footwell - Driver (Remove and Replace).
- Install the LH front seat bolts (x4). See Seat Assembly - 1st Row - LH (Remove and Replace).
- Install the lower A-pillar assembly. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Install the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
- Install the LH front floor mat.
-
Repeat step 56 to 64 for the RH side.
NoteFor the passenger side footwell cover, see Cover - Footwell - Front Passenger (Remove and Replace).
- Close the RH front door.
-
Inspect coolant level and top off as
necessary, and then install the coolant bottle cap.
NoteEnsure that the fluid level is at Max line.
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Install the LH and RH rocker panel lower covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
- Disable Service Mode. See Service Mode.
- Raise all windows and close the LH front door.