2026-08-19

Cover - Front Access - HV Battery (Remove and Install)

Correction code 16101011 5.58 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT 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 proper PPE is worn when performing the below procedure.

  • 2026-08-19: Simplified procedure in line with most recent procedure re-evaluation.
  • 2025-07-29: Added instructions for sealant application.
  • 2023-04-07: Added conditional steps for when there is a doubler around the front access cover.
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) 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 glove and safety information.

Torque Specifications

Table 1. Torque Specifications: Cover - Front Access - HV Battery (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x17) that attach the HV battery front access cover to the HV battery
4 Nm (2.9 lbs-ft)
  • 7 mm socket
Replace 1476754-00-A
Nuts (x2) that attach the HV battery front access cover to the HV battery
4 Nm (2.9 lbs-ft)
10 mm socket Reuse
Bolts (x2) that attach the PCS inlet hose fitting to the front access cover
3 Nm (2.2 lbs-ft)
Reuse
Bolts (x2) that attach the PCS outlet hose fitting to the front access cover
3 Nm (2.2 lbs-ft)

Remove

  1. Remove the HV battery. See HV Battery (AWD) (Remove and Install).
  2. Release the clip that attaches the power conversion system outlet hose to the HV battery.
  3. Release the clip that attaches the PCS outlet hose to the to the HV battery fitting, and then disconnect the hose from the HV battery.
  4. Install coolant hose plugs to the PCS inlet and outlet fittings.
  5. Put on HV insulating gloves and leather over gloves.
  6. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  7. Remove and discard the bolts (x17) and nuts (x2) that attach the HV battery front access cover to HV battery.
    Note
    Earlier vehicles may not have the nuts.
    Tip
    Use of the following tool(s) is recommended:
    • 7 mm socket (for the bolts)
    • 10 mm socket (for the nuts)
  8. If installed, remove the doubler from around the front access cover.
    Note
    Lift the doubler from the rear, and slide forward and out from under the coolant fittings.
  9. If there is no doubler installed, use non-conductive plastic chisels to break the seal and separate the HV battery front access cover from the HV battery.
    Note
    Be careful not to severely bend or deform the access cover, or to damage the internal components.
    Note
    If there is no sealant present, the seal can be reused and no sealant needs to be applied during installation.
  10. Release the bolts (x2) that attach the PCS inlet hose fitting to the HV front access cover.
  11. Release the bolts (x2) that attach the PCS outlet hose fitting to the HV front access cover.
  12. Remove the HV battery front access cover from the HV battery.

Install

  1. Use non-conductive plastic chisels or other non-marring tools to remove the sealant from the HV battery and HV battery front access cover.
    Note
    If there is no sealant present, the seal can be reused and no sealant needs to be applied. Skip to step 5 to proceed with installation.
  2. Use an ESD-safe vacuum cleaner to remove debris, wipe the sealing surfaces with an alcohol wipe, and then allow to dry.
  3. Load a cartridge of sealant into the caulking gun and cut the tip of the sealant at an angle to make a hole of 5-10 mm wide.
  4. Apply the sealant onto the sealing surface of the HV battery in a continuous, smooth bead.
  5. Install the PCS inlet and outlet hoses into the cover. Make sure that the rubber seals of the inlet/outlet hoses are not damaged. Replace if damage is present.
  6. Install the bolts (x2) that attach the PCS inlet hose fitting to the HV front access cover.
    3 Nm (2.2 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T20 socket
  7. Install the bolts (x2) that attach the PCS outlet hose fitting to the HV front access cover.
    3 Nm (2.2 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T20 socket
  8. Carefully set the HV battery front access cover onto the HV battery.
  9. Install new bolts (x17) and install the nuts (x2, where fitted) to attach the HV battery front access cover to the HV battery.
    4 Nm (2.9 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 7 mm socket (for the bolts)
    • 10 mm socket (for the nuts)
    Note
    Tighten the bolts in a crosswise pattern.
  10. Put on HV insulating gloves and leather over gloves.
  11. Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  12. Remove the coolant hose plugs from the PCS inlet and outlet fittings.
  13. Install the PCS outlet hose to the to the HV battery fitting.
  14. Install the clip that attaches the power conversion system outlet hose to the HV battery.
  15. Remove the HV battery. See HV Battery (AWD) (Remove and Install).