2026-03-19

PCS2 Lite - Ancillary Bay (Model YL) (Remove and Replace)

Correction code 16300500202 FRT 2.64 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

Table 1. Torque Specifications:PCS2 Lite - Ancillary Bay (Model YL) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x5) that attach the PCS2 Lite to the HV battery
15 Nm (11.1 lbs-ft) - 180 degrees
15 Nm (11.1 lbs-ft)
  • Skt, 1/4" Sq Dr, 8mm, HV Insulated
 Replace 1115833-00-B

Remove

  1. Start the thermal fill/drain routine.
    1. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
    2. Unlock the vehicle gateway. See Gateway (Unlock).
    3. Tap the Service Mode "wrench" at the bottom of the touchscreen UI, and then tap Thermal > Actions > Start Thermal Fill/Drain, and select Run to start the routine.
      Informational PurposesAn informational icon, calling your attention
      Note
      This routine has a 5-hour limit. After 5 hours, this routine must be performed again.
    Informational PurposesAn informational icon, calling your attention
    Note
    The EPB Selection field can also be selected as Left/Right as needed.
  2. Remove the air intake duct. See Duct - Air Intake (Remove and Replace).
  3. Remove the ancillary bay cover. See Cover - Ancillary Bay (Model YL) (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install the rear skid plate and mid aero shield at this step. Both will be installed later.
  4. Place the coolant drain container underneath the LH rear of the vehicle.
  5. Disconnect the LH coolant hose from the rear of the HV battery by releasing the spring clip, then plug both the hose and passthrough with 2 plugs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the special tool plugs if returning the battery to Reman.
  6. Disconnect the RDU inverter inlet hose from the PCS2 Lite outlet hose coupling at the LH rear of the HV battery by releasing the spring clip, then plug both the hose and coupling with 2 plugs once disconnected.
    Informational PurposesAn informational icon, calling your attention
    Note
    • Coolant loss greater than 1 L will require vacuum fill.
    • Remove the special tool plugs if returning the battery to Reman.
  7. Connect the 90-degree coolant drain and fill adapter to the PCS2 Lite outlet hose coupling at the LH rear of the HV battery, ensuring the locking clip is fully seated and the valve is open (inline with the adapter).
  8. Connect the coolant hose extension to the coolant drain and fill adapter by pressing the hose end onto the adapter until it clicks into place.
  9. Connect the coolant hose extension to the coolant drain hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  10. Place the coolant drain container underneath the RH rear of the HV battery.
  11. Disconnect the rear powertrain supply hose from the PCS2 Lite inlet hose coupling at the RH rear of the HV battery by releasing the spring clip, then plug both the hose and coupling with 2 plugs once disconnected.
    Informational PurposesAn informational icon, calling your attention
    Note
    • Coolant loss greater than 1 L will require vacuum fill.
    • Remove the special tool plugs if returning the battery to Reman.
  12. Connect the coolant leak test adapter to the PCS2 Lite inlet hose coupling at the RH rear of the HV battery, remove the rubber plug from the coupler if installed, and ensure the locking clip is fully seated.
  13. Connect the coolant leak test fixture hose to the leak test adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand-tighten the hose connection; no tool is required for tightening.
  14. Remove the coolant drain container from underneath the vehicle.
  15. Connect compressed air to the coolant pressure tester, ensuring all valves on the pressure regulator are closed.
  16. Open the RH regulator valve and slowly adjust the regulator to 50 psi.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  17. Open the LH regulator valve slowly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  18. Wait at least 2 minutes for the coolant to completely drain.
  19. Close the RH regulator valve.
  20. Disconnect compressed air from the coolant pressure tester.
  21. Disconnect the coolant leak test adapter from the PCS2 Lite inlet hose coupling by releasing the spring clip at the RH rear of the HV battery, while keeping the leak test fixture inlet hose connected to the adapter.
  22. Disconnect the coolant drain and fill adapter from the PCS2 Lite outlet hose coupling by releasing the spring clip at the LH rear of the HV battery, while keeping the extension hose attached to the adapter.
  23. Connect the coolant leak test adapter with the coolant leak test fixture hose to the PCS2 Lite outlet hose coupling by securing the spring clip at the LH rear of the HV battery, ensuring the locking tab is fully seated.
  24. Connect the coolant drain and fill adapter with the extension hose to the PCS2 Lite inlet hose coupling by securing the spring clip at the RH rear of the HV battery, ensuring the locking tab is fully seated.
  25. Repeat step 15 to 20 to drain the coolant.
  26. Disconnect the coolant hose extension from the coolant drain hose by pressing the gray button to release the hose fitting.
  27. Disconnect the coolant hose extension from the coolant drain and fill adapter by pressing the gray button to release the hose fitting.
  28. Disconnect the coolant drain hose adapter from the PCS2 Lite inlet hose coupling by releasing the spring clip, and install a plug on the inlet hose coupling once disconnected.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the special tool plugs if returning the battery to Reman.
  29. Disconnect the coolant leak test fixture hose from the leak test adapter.
  30. Disconnect the coolant leak test adapter from the PCS2 Lite outlet hose coupling using by releasing the spring clip, and install a plug on the outlet hose coupling once disconnected.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the special tool plugs if returning the battery to Reman.
  31. Install the high voltage controller (HVC) logic cap.
  32. Remove the pyro disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  33. Use the bungee cords to lift and secure high voltage controller (HVC) to the body.
  34. Place absorbent sheets below and around the PCS2 Lite coolant inlet and outlet hoses to prevent excess coolant from dripping.
  35. Disconnect the PCS2 Lite coolant inlet hose from the PCS2 Lite by releasing the clips (x2) with the PCS Coolant Connector Removal Tool (1111868-00-B), place an absorbent sheet under the hose to catch excess coolant, visually inspect for coolant residue and clean with a shop towel if needed, install 2 plugs on the PCS2 Lite and hose, and discard the O-ring.
  36. Disconnect the PCS2 Lite coolant outlet hose from the PCS2 Lite by releasing the clips (x2) with the PCS Coolant Connector Removal Tool (1111868-00-B), place an absorbent sheet under the hose to catch excess coolant, visually inspect for coolant residue and clean with a shop towel if needed, install 2 plugs on the PCS2 Lite and hose, and discard the O-ring.
  37. Disconnect the AC filter harness connector from the PCS2 Lite by pulling the locking tab upward.
  38. Disconnect the HV DC harness connector from the PCS2 Lite by pulling the locking tab upward.
  39. Disconnect the PCS2 Lite logic connector from the PCS2 Lite.
  40. Disconnect the PCS2 Lite LV connector from the PCS2 Lite.
  41. Remove and discard the bolts (x5) that attach the PCS2 Lite to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure only the 8mm fasteners are removed; do not remove the T20 fasteners.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Skt, 1/4" Sq Dr, 8mm, HV Insulated
  42. Secure suction cups to the PCS2 Lite by pressing the plunger continuously until the red line is no longer visible.
  43. Lift the PCS2 Lite up and remove it from the ancillary bay by releasing the datums (x2) and slightly tilting the rear upward.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect for missing insulators underneath and install any if needed, then visually check for coolant residue and clean with a shop towel if necessary.

Replace

  1. Align the datums (x2) into the PCS2 Lite holes, slightly tilt the rear upward and lower it into the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that all busbar insulators beneath PCS2 Lite are present.
  2. Remove suction cups from the PCS2 Lite.
  3. Install new bolts (x5) that attach the PCS2 Lite to the HV battery.
    15 Nm (11.1 lbs-ft) - 180 degrees
    15 Nm (11.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Skt, 1/4" Sq Dr, 8mm, HV Insulated
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 15 Nm.
  4. Connect the AC filter harness connector to the PCS2 Lite by pushing it downward, then pressing the locking tab down to secure it.
  5. Connect the PCS2 Lite LV connector to the PCS2 Lite by pushing it downward, then pressing the locking tab down to secure it.
  6. Connect the PCS2 Lite logic connector to the PCS2 Lite.
  7. Connect the HV DC harness connector to the PCS2 Lite by pushing it downward, then pressing the locking tab down to secure it.
  8. Connect the PCS2 Lite coolant inlet hose to the PCS2 Lite as follows:
    1. Remove 2 plugs from the coupling and hose.
    2. Place an absorbent sheet under the hose to catch excess coolant.
    3. Apply a light amount of Krytox 203 to install a new O-ring (1803223-00-A).
      Informational PurposesAn informational icon, calling your attention
      Note
      If the O-ring is unavailable, order the inlet hose instead.
    4. Align the hose to the coupling and secure the clips (x2); use caution not to damage the O-ring.
    5. Perform a push-pull-push test to ensure the coolant hose is fully latched, then visually verify the clips are fully seated.
  9. Connect the PCS2 Lite coolant outlet hose to the PCS2 Lite as follows:
    1. Remove 2 plugs from the coupling and hose.
    2. Place an absorbent sheet under the hose to catch excess coolant.
    3. Apply a light amount of Krytox 203 to install a new O-ring (1803223-00-A).
      Informational PurposesAn informational icon, calling your attention
      Note
      If the O-ring is unavailable, order the outlet hose instead.
    4. Align the hose to the coupling and secure the clips (x2); use caution not to damage the O-ring.
    5. Perform a push-pull-push test to ensure the coolant hose is fully latched, then visually verify the clips are fully seated.
  10. Release the bungee cords and position the HVC onto the PCS2 Lite.
  11. Install the pyro disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  12. Remove the HVC logic cap.
  13. Install the ancillary bay cover. See Cover - Ancillary Bay (Model YL) (Remove and Install).
  14. Remove the plug from the PCS2 Lite inlet hose coupling, then install the 90-degree coolant leak test adapter with NPT plug and secure the spring clip, ensuring the locking clip is fully seated.
  15. Remove the plug from the PCS2 Lite outlet hose coupling, then install the coolant leak test adapter and secure the spring clip, ensuring the locking clip is fully seated.
  16. Connect the coolant leak test fixture hose to the leak test adapter.
  17. Connect compressed air to the coolant pressure tester, ensuring all valves on the pressure regulator are closed.
  18. Open the RH regulator valve and slowly adjust the regulator to 50 psi.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  19. Open the LH regulator valve slowly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  20. Wait for 110 seconds to allow the pressure to stabilize within the system, close the RH regulator valve, and record the starting pressure.
  21. Start a 240-second timer; after 240 seconds, record the ending pressure.
  22. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.5 psi, check the hose, adapter, and plug fittings, close the outlet valve and open the inlet valve, check the regulator pressure, and then retest from step 17. If the difference is still greater than 0.5 psi, escalate a Toolbox session.
    • The difference is 0.5 psi or less, continue the procedure.
  23. Disconnect the coolant leak test fixture hose from the leak test adapter.
  24. Remove the coolant leak test adapter from the PCS2 Lite outlet hose coupling by releasing the spring clip.
  25. Remove the plug from the RDU inverter inlet hose, and connect the hose to the PCS2 Lite outlet hose coupling at the LH rear of the HV battery by securing the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    • Perform a push-pull-push test to ensure that the hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  26. Connect the LH coolant hose to the rear of the HV battery by removing the plugs (x2) and securing the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    • Perform a push-pull-push test to ensure that the hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  27. Remove the coolant leak test adapter from the PCS2 Lite inlet hose coupling by releasing the spring clip.
  28. Remove the plug from the rear powertrain supply hose, and connect the hose to the PCS2 Lite inlet hose coupling at the RH rear of the HV battery by releasing the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    • Perform a push-pull-push test to ensure that the hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  29. Install the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  30. Perform a vacuum refill of the cooling system. See Cooling System - Vacuum Refill (Test/Adjust).
  31. Install the air intake duct. See Duct - Air Intake (Remove and Replace).
  32. Exit the Service Mode. See Service Mode.