2025-09-12

HV Battery (AWD) (3-Phase) (Model YL) (Remove and Install)

Correction code 16010100001 FRT 3.42 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.

Equipment:
  • 1936724-00-A - KIT, BATTERY REMOVAL LIFT ADAPTER
  • 1083188-01-B - Digital Multimeter Unit, EXTECH 355
  • 1130480-02-B - Slim Test Probes, CAT III 1000V
  • 1080568-00-A - OIL COOLANT CATCHER
  • 1020566-00-G - ASY, BATTERY TABLE, MANUAL LIFT
  • 1134523-00-B - M3/Y HV Battery Alignment Rods
  • 1076927-00-A - HIOKI RM 3548
  • 1076928-00-A - TEST PROBES - HIOKI 9461
  • 1140311-00-A - LEVER LOCK, HV CONNECTOR, MODEL 3
  • 1143066-00-A - BARRICADE, RETRACTABLE BELT POST HV AREA
  • 1081765-00-A - 3/4 TON UNDERHOIST STAND
  • 1135762-00-A - KIT, SVC PLUG, COOLING HOSE, MODEL 3
  • 1108272-00-B - CAP, LOGIC CONN, INV, 3DU
  • 1082502-00-A - Inflatable Air Bag
  • 1754057-00-A - CURRENT PROBE, GEN, CLAMP, DC, 600V
  • 1115247-01-A - Electronic Test Lead, CAT IV 1000V

Torque Specifications

Table 1. Torque Specifications:HV Battery (AWD) (3-Phase) (Model YL) (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
LH and RH middle inner HV battery bolts (x2)
66 Nm (48.7 lbs-ft)
  • 16 mm socket
 Reuse
Front inner HV battery bolts (x4)
136 Nm (100.3 lbs-ft)
  • Torx Plus EP20 socket
 Reuse
Rear inner HV battery bolts (x2)
66 Nm (48.7 lbs-ft)
  • 16 mm socket
 Reuse
Rear outer HV battery bolts (x2)
45 Nm (33.2 lbs-ft)
  • 15 mm socket
 Reuse
Nut that attaches the rear drive unit HV cable bracket to the HV battery
10 Nm (7.4 lbs-ft)
  • 10 mm deep socket
 Reuse

Bolt that secures the busbar cover access door

Bolts (x2) that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • 10 mm socket
 Reuse

Nut that attaches the PCS2 lite cable to the LV passthrough output

Nut that attaches the DCDC ground busbar to the HV battery
9 Nm (6.6 lbs-ft)
  • 13 mm deep socket
 Replace 1523698-00-A
Bolt that attaches the front drive unit HV harness to the front drive unit
10 Nm (7.4 lbs-ft)
  • 10 mm socket
 Reuse
Front drive unit ground strap bolt
10 Nm (7.4 lbs-ft)
  • Ratcheting Combination wrench Flex head 10mm
 Reuse
Center bolts (x4) that secure the HV battery center ski cover
34 Nm (25.1 lbs-ft)
  • External Torx Plus EP14
 Reuse
Bolts (x8) that attach the LH and RH front support brackets to the vehicle
110 Nm (81.1 lbs-ft)
  • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
 Reuse
LH and RH bolts (x18) that attach the HV battery to the vehicle
35 Nm (25.8 lbs-ft)
  • 13 mm socket
 Reuse

Remove

  1. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  2. Remove the LH footwell cover. See Hush Panel - Footwell - Driver (Remove and Replace).
  3. Remove the LH front console side panel. See Side Panel - Front - Center Console - LH (Model YL) (Remove and Replace).
  4. Fold the LH front cabin carpet rearward.
  5. Pry the foam plug out to gain access to the LH front inner HV battery bolts.
  6. Remove the LH 2nd row seat bolts (x4) and adjust the seat to prepare for removing. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Install).
  7. Repeat step 1 through 6 for the RH side.
  8. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  9. Unlock the vehicle gateway. See Gateway (Unlock).
  10. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Start Thermal Fill/Drain, enter 1 to the Coolant fill field and 0 in the Refrigerant fill field, then click Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    The "Thermal Fill/Drain" routine has a 5-hour limit. Perform the routine again after 5 hours.
  11. Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  12. Remove the air intake duct. See Duct - Air Intake (Remove and Replace).
  13. Remove the LH and RH 2nd row seats. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Install).
  14. Remove the 3rd row LH seat bolster. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace).
  15. Remove the 3rd row RH seat bolster. See Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  16. Open the carpet openings below the rear of the LH and RH front seats to access the middle inner HV battery bolts.
    Figure 1. LH Shown, RH Similar
  17. Remove the LH and RH middle inner HV battery bolts (x2).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 16 mm socket
    Figure 2. LH Shown, RH Similar
  18. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Model YL) (Remove and Replace).
  19. Remove the rear cabin carpet harness clips (x2) and fold the carpet to gain access to the rear inner HV battery bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull out the carpet from the side trunk trim on both sides. When remove, please make sure to thread the harness of the 2nd row seats through the carpet.
  20. Remove the clips (x2) that attach the 2nd row LH and RH seat harness to the ancillary bay.
  21. Remove the front inner HV battery bolts (x4).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
  22. Remove the rear inner HV battery bolts (x2).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 16 mm socket
  23. Remove the rear outer HV battery bolts (x2).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  24. Remove the LH and RH rocker carriers. See Rocker Carrier - LH (Model YL) (Remove and Replace).
  25. Remove and discard the butyl patches (x4) that cover the LH and RH rocker access holes, and use IPA wipes to clean excess butyl from the area.
  26. Install the lift pad adapters (x4) onto the lift, and then raise the vehicle with the battery removal lift.
  27. Set the multimeter to measure voltage, and then measure the voltage across the LV auxiliary battery terminals.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the voltage across the battery terminals is less than 13 volts or greater than 16 volts, the multimeter is not measuring reliably and must not be used.
  28. Remove the mid aero shield. See Aero Shield - Rear (Remove and Replace).
  29. Remove the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  30. Remove all jewelry and empty your pockets before continuing this procedure.
  31. Put on HV insulating gloves, leather outer gloves, and safety glasses before continuing this procedure.
  32. Power on the current clamp meter, and then zero out the meter for measurement.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure to set the clamp meter to measure DC amps ("Adc").
  33. Install the current clamp meter onto one cable of the rear drive unit HV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the meter is facing the correct direction as shown.
    • If the current is within the range of -0.5 A to 0.5 A, continue to the next step.
    • If the current is outside the range of -0.5 A to 0.5 A, for example -0.8 A or 1.3 A, re-perform the LV power disconnect procedure. See LV Power (Disconnect and Connect) (Modify). If the measurement is still outside the range of -0.5 A to 0.5 A, escalate for assistance.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      DO NOT DISCONNECT any HV harness when the current measurement is outside the range of -0.5 A to 0.5 A.
  34. Remove the nut that attaches the rear drive unit HV cable bracket to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
  35. Disconnect the rear drive unit HV cable from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the 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.
  36. Use the high voltage multimeter with CAT III or higher probes to verify that no high voltage is present at the HV battery LH HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    In order to limit potential exposure to high voltage, measure for high voltage in the order specified below.
    Measure the following voltages:
    1. B+ to ground
    2. B- to ground
    3. B+ to B-
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If any voltage is greater than 10V, the contactors are closed or welded. Escalate to Service Engineering.
  37. Lower the vehicle to a comfortable working height and set the lift onto locks.
  38. Release the LH body harness from the rear body and move it aside.
  39. Remove the bolt that secures the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  40. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  41. Lift the busbar kit connector to remove it from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an inflatable air bag to suspend the busbar away from the HV header during removal and installation. Hold the busbar firmly as there is tension on it. Avoid damaging the harness bracket.
  42. Disconnect the AC chargeport inlet harness from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab and rotate the lever arm to release.
  43. Remove the leather over gloves and the HV insulating gloves.
  44. Disconnect the HVC logic connector and install the logic cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab then push the handle downward to release the connector.
  45. Release the positive LV output cover from the PCS2 lite cable.
  46. Remove the nut that attaches the PCS2 lite cable to the LV passthrough output.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  47. Remove the nut that attaches the DCDC ground busbar to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  48. Gently lift the DCDC ground busbar upward.
    Informational PurposesAn informational icon, calling your attention
    Note
    Don't bend excessively.
  49. Remove the front aero shield. See Aero Shield - Front (Remove and Replace).
  50. Remove the clips (x2) that attach the LH and RH wheel liners to the body, and then use bungee cord to secure the wheel liners to the subframe.
    Figure 3. LH Shown, RH Similar
  51. Remove the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  52. Put on the HV insulating gloves and the leather over gloves.
  53. Disconnect the AC compressor HV harness connector from the HV Ancillary harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    The connector is a 3-stage locking connector. Disengage the red locking tab by pulling it away from the connector, then depress yellow tab and pull the connector backward, and then depress the green tab to release.
  54. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  55. Release the front drive unit HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red 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 front drive unit header are not damaged.
  56. Release the front drive unit HV harness from the casting and move it aside.
  57. Remove the leather over gloves and the HV insulating gloves.
  58. Remove the front drive unit ground strap bolt from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratcheting Combination wrench Flex head 10mm
  59. Position the coolant drain container underneath the LH front of the HV battery.
  60. Release the spring clip to disconnect the HV battery return hose, and then plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  61. Release the clip to release the chiller to battery hose from the body.
  62. Release the spring clip to disconnect the HV battery front manifold hose from the chiller to battery hose, and then plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  63. Position the coolant drain container underneath the RH front of HV battery.
  64. Release the spring clip to disconnect the front drive unit inverter inlet hose from the rear powertrain return hose, and then plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the battery is returned to Reman, remove the special tool plugs.
  65. Release the spring clip to disconnect the powertrain supply hose, and then plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  66. Position the coolant drain container under the LH rear of the vehicle.
  67. Disconnect the rear drive unit inverter inlet hose from the PCS outlet hose coupling, and then plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    The connection is located at the LH rear of the HV Battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the battery is returned to Reman, remove the special tool plugs.
  68. Position the coolant drain container underneath the RH rear of the HV battery.
  69. Release the spring clip to disconnect the coolant outlet hose from the rear return hose, and then plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use shop towel to clean any residue coolant inside the RH rocker panel if necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the battery is returned to Reman, remove the special tool plugs.
  70. Position the support stand to support the front portion of the rear subframe.
  71. Remove the LH shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  72. Hand-tighten the bolt (21 mm) that attaches the LH side of the rear subframe to the body.
  73. Repeat step 71 and 72 for the RH side.
  74. Remove the support stand from under the vehicle.
  75. With assistance, place the HV battery table into position and lower the vehicle to support the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Line up the table so that the center 4 bolts are accessible through the opening of the table. Adjust the final battery table position using adjustable caster jacks on the table.
  76. Remove the center bolts (x4) that secure the HV battery center ski cover.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
  77. Remove the bolts (x8) that attach the LH and RH front support brackets to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
  78. Remove the LH and RH bolts (x18) that attach the HV battery to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  79. With assistance, raise the vehicle free of the HV battery, and then remove the battery from under the vehicle.
  80. Remove and discard the ancillary bay engagement seal from the HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the seal anytime the HV battery is removed from the vehicle.

Install

  1. Install new ancillary bay engagement seal to the HV battery pack.
  2. Install the HV battery alignment rods (x4).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install 2 rods to the body at the front of the vehicle. Install the other 2 rods to the battery near the ancillary bay.
  3. With assistance, position the HV battery under the vehicle.
  4. With assistance, lower the vehicle onto the HV battery and align the holes to the rods.
    Informational PurposesAn informational icon, calling your attention
    Note
    When installing the HV battery, ensure that the coolant hoses and the HV cable at the back of the HV battery are not stuck. Be careful not to damage the coolant hoses and the HV cable.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not fully lower the vehicle onto the battery (this will help with installing the battery bolts).
  5. Hand-tighten the LH and RH bolts (x18) that attach the HV battery to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement. Do not over tighten the bolts, they will be torqued at later.
  6. Remove the HV battery alignment rods.
  7. Hand-tighten the rear inner HV battery bolts (x2).
  8. Hand-tighten the rear outer HV battery bolts (x2).
  9. Hand-tighten the LH and RH middle inner HV battery bolts (x2).
    Figure 4. LH Shown, RH Similar
  10. Hand-tighten the front inner HV battery bolts (x4).
  11. Use cordless impact to set the bolts (x8) that attach the LH and RH front support brackets to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not torque it now.
  12. Use cordless impact to set the center bolts (x4) that secure the HV battery center ski cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the thread engagement is smooth and the bolts are not cross threaded into casting. Flush down the bolts. Do not over tighten the bolts, they will be torqued at later.
  13. With assistance, lower the vehicle onto the pack completely.
  14. Torque the LH and RH bolts (x18) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  15. Torque the bolts (x8) that attach the LH and RH front support brackets to the vehicle.
    110 Nm (81.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
  16. Torque the center bolts (x4) that secure the HV battery center ski cover.
    34 Nm (25.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
  17. With assistance, raise the vehicle to a comfortable work height, and lower the lift onto locks, then remove the battery table from under the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION

    Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.

    Make sure that the doors are clear of surrounding objects.

  18. Position the support stand to support the front portion of the rear subframe.
  19. Remove and discard the bolt (21 mm) that attaches the LH side of the rear subframe to the body.
  20. Install the LH shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  21. Repeat step 19 and 20 for the RH side.
  22. Remove the support stand from under the vehicle.
  23. Put on the HV insulating gloves and the leather over gloves.
  24. Connect the rear drive unit HV cable to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make 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.
  25. Install the nut that attaches the rear drive unit HV cable bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
  26. Connect the AC compressor HV harness connector to the HV Ancillary harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    The connector is a 3-stage locking connector. After the connector is seated and there is an audible click, engage the second lock by pressing towards the connector. And then engage the locking tab.
  27. Install the front drive unit HV harness to the casting.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the HV connector lever lock to the front drive unit HV cable connector.
  28. Connect the front drive unit HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the connector to the front drive unit, then remove the HV connector lever lock before fully latching 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.
  29. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  30. Remove the leather over gloves and the HV insulating gloves.
  31. Position the coolant drain container underneath the RH rear of the HV battery.
  32. Remove the plugs on the ends of fittings, and then secure the spring clip to connect the coolant outlet hose to the rear return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use shop towel to clean any residue coolant inside the RH rocker panel if necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  33. Install the clip that attaches the coolant hoses to the RH shear plate.
  34. Position the coolant drain container under the LH rear of the vehicle.
  35. Remove the plugs on the ends of fittings, and then connect the rear drive unit inverter inlet hose to the PCS outlet hose coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  36. Install the clips (x2) that attach the coolant hoses to the LH shear plate.
  37. Remove the coolant drain container from underneath the vehicle.
  38. Install the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  39. Install the mid aero shield. See Aero Shield - Rear (Remove and Replace).
  40. Position the coolant drain container underneath the LH front of the HV battery.
  41. Remove the plugs on the ends of fittings, and then secure the spring clip to connect the HV battery front manifold hose to the chiller to battery hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  42. Secure the clip to install the chiller to battery hose to the body.
  43. Remove the plugs on the ends of fittings, and then secure the spring clip to connect the HV battery return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  44. Position the coolant drain container underneath the RH front of the HV battery.
  45. Remove the plugs on the ends of fittings, and then secure the spring clip to connect the front drive unit inverter inlet hose to the rear powertrain return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  46. Remove the plugs on the ends of fittings, and then secure the spring clip to connect the powertrain supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  47. Remove the coolant drain container from underneath the vehicle.
  48. Install the front drive unit ground strap bolt to the HV battery.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratcheting Combination wrench Flex head 10mm
  49. Install the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  50. Release the LH and RH wheel liners from the subframe, and then install the clips (x2) that attach the wheel liners to the body.
    Figure 5. LH Shown, RH Similar
  51. Install the front aero shield. See Aero Shield - Front (Remove and Replace).
  52. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not need to connect LV battery power and run routine at this time. These will be performed at later steps.
  53. Install new butyl patches (x4) (1120356-00-A) to cover the LH and RH rocker access holes, and use IPA wipes to clean excess butyl from the area.
    Informational PurposesAn informational icon, calling your attention
    Note
    The butyl patches need to be cut to the required size, roughly 2" x 2 1/2".
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply pressure along each patch to verify it is fully secured to the body.
  54. Install the LH and RH rocker carriers. See Rocker Carrier - LH (Model YL) (Remove and Replace).
  55. Gently press down the DCDC ground busbar.
  56. Install a new nut that attaches the DCDC ground busbar to the HV battery.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  57. Install a new nut that attaches the PCS2 lite cable to the LV passthrough output.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  58. Install the positive LV output cover to the PCS2 lite cable.
  59. Remove the logic cap and connect the HVC logic connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the connector and then pull the handle to the locking position to get the connector fully seated.
  60. Put on the HV insulating gloves and the leather over gloves.
  61. Use IPA wipes to clean the HV connector contact surface of residual Penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    New busbar comes with penetrox applied to the HV connector.
  62. Use IPA wipes to clean the busbar HV connector contact surface of residual Penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean the HV connector during the re-use of the busbar.
  63. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads of each HV connector joints, and then spread evenly to verify the contact surface is fully covered.
  64. Remove the inflatable air bag from under the HV header.
  65. Position the busbar kit connector to the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
  66. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  67. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    • If the resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ), Hioki test passed, proceed to next step.
    • If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.
    • 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 next step.
  68. Remove the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  69. Connect the AC chargeport inlet harness to the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the lever arm and secure the locking tab.
  70. Remove the HV insulating gloves.
  71. Install the LH body harness to the rear body.
  72. Torque the rear inner HV battery bolts (x2).
    66 Nm (48.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 16 mm socket
  73. Torque the rear outer HV battery bolts (x2).
    45 Nm (33.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  74. Install the clips (x2) that attach the 2nd row LH and RH seat harness to the ancillary bay.
  75. Return the rear cabin carpet assembly to its original position.
    Informational PurposesAn informational icon, calling your attention
    Note
    When installing, first thread the seat wire harness through the carpet, and then insert the carpet under the trunk side trim on both sides.
  76. Install the rear cabin carpet harness clips (x2).
  77. Install the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Model YL) (Remove and Replace).
  78. Torque the LH and RH middle inner HV battery bolts (x2).
    66 Nm (48.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 16 mm socket
    Figure 6. LH Shown, RH Similar
  79. Return the LH and RH rear main carpets to the original position.
  80. Install the 3rd row RH seat bolster. See Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  81. Install the 3rd row LH seat bolster. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace).
  82. Install the LH and RH 2nd row seats. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Install).
  83. Unlock the vehicle gateway. See Gateway (Unlock).
  84. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  85. Tap Thermal > Coolant System > Coolant Purge Start > Rerun, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    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.
  86. Install the front inner HV battery bolts (x4).
    136 Nm (100.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
  87. Restore the LH front cabin carpet and the foam plug under it.
  88. Install the LH footwell cover. See Hush Panel - Footwell - Driver (Remove and Replace).
  89. Install the LH front console side panel. See Side Panel - Front - Center Console - LH (Model YL) (Remove and Replace).
  90. Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  91. Repeat step 87 through 90 for the RH side.
  92. After the coolant air purge routine is finished, inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
  93. Install the air intake duct. See Duct - Air Intake (Remove and Replace).
  94. Exit Service Mode. See Service Mode.