2026-03-18

Cover - Ancillary Bay (Model YL) (Remove and Replace)

Correction code 16300501702 FRT 1.50 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:Cover - Ancillary Bay (Model YL) (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the PCS cable to the LV pass through output
9 Nm (6.6 lbs-ft)
  • 13 mm deep socket
 Replace 1523698-00-A
Bolts (x4) that attach the ancillary bay cover to the high voltage controller
5 Nm (3.7 lbs-ft) + 30 degrees
  • External Torx E10
 Reuse
Bolts (x18) that attach the ancillary bay cover to the HV battery
10.5 Nm (7.7 lbs-ft)
  • EP10 5-Lobe
  • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
 Reuse The fasteners are captive and will stay attached to the ancillary bay cover

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2-Post Lift.
  2. Remove the 2nd row LH and RH seats. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Replace).
  3. Remove the 3rd row LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace) and Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  4. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Model YL) (Remove and Replace).
  5. Remove the clips (x2) that attach the rear cabin carpet harness to the body.
  6. Release the datums (x2), then fold the rear cabin carpet to access the rear inner HV battery ancillary bay.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Pull the carpet out from both side trunk trims, and ensure the 2nd row seat harness is threaded through the carpet.
  7. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Model YL) (Maintenance).
  8. Release the clips (x2) that attach the 2nd row LH and RH seat harnesses to the ancillary bay.
  9. Release the locking tab, push the handle downward to release the high voltage controller (HVC) logic connector, and then install the HVC logic cap.
  10. Release the positive LV output cover from the PCS2 Lite cable.
  11. Remove and discard the nut that attaches the PCS2 Lite cable to the LV pass through output.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  12. Remove the bolts (x4) that attach the ancillary bay cover to the HVC.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10
  13. Remove the bolts (x18) that attach the ancillary bay cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • EP10 5-Lobe
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  14. Remove the HVC logic cap.
  15. Put on HV insulating gloves and leather over gloves.
  16. Remove the ancillary bay cover from the HV battery by raising the front part and sliding the ancillary bay cover upward.

Replace

  1. Use IPA wipes to clean the ancillary bay cover, and allow 1 minute dry time.
  2. Position the ancillary bay cover to the HV battery.
  3. Remove the HV insulating gloves and leather over gloves.
  4. Install the HVC logic cap.
  5. Install the bolts (x18) that attach the ancillary bay cover to the HV battery in the torque sequence shown in the image.
    10.5 Nm (7.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • EP10 5-Lobe
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  6. Install the bolts (x4) that attach the ancillary bay cover to the HVC.
    5 Nm (3.7 lbs-ft) + 30 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10
  7. Install a new nut that attaches the PCS2 Lite cable to the LV pass through 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
  8. Install the positive LV output cover to the PCS2 Lite cable.
  9. Remove the logic cap, align the connector, then pull the handle to the locking position to get the connector fully seated.
  10. Install the clips (x2) that attach the 2nd row LH and RH seat harnesses to the ancillary bay.
  11. Perform the ancillary bay air leak test. See Ancillary Bay Air Leak Test (Model YL) (Test/Adjust).
  12. Align the datums (x2), then fold the rear cabin carpet to its original position.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Insert the carpet under the trunk side trim on both sides, and ensure the 2nd row seat harness is threaded through the carpet.
  13. Install the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Model YL) (Remove and Replace).
  14. Install the clips (x2) that attach the rear cabin carpet harness to the body.
  15. Install the 3rd row LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace) and Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  16. Install the 2nd row LH and RH seats. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Replace).
  17. Remove the vehicle from the lift.