2026-08-09

Ski Cover - Center - HV Battery (Model Y L) (Remove and Replace)

Correction code 16010103102 FRT 1.38 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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 you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Equipment:
  • 1080568-00-A - OIL COOLANT CATCHER
  • 1135762-00-A - KIT, SVC PLUG, COOLING HOSE, MODEL 3
  • 2129917-00-B - TAPE,19 MM,PVC,125 C,SELF EXT,WHT

Torque Specifications

Table 1. Torque Specifications:Ski Cover - Center - HV Battery (Model Y L) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the front drive unit HV harness to the front drive unit
10 Nm (7.4 lbs-ft)
  • 10 mm socket
 Reuse
Bolts (x6) that attach the center ski cover assembly to the HV battery
34 Nm (25.1 lbs-ft)
  • External Torx Plus EP14
 Reuse

Remove

  1. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  2. Unlock the vehicle gateway. See Gateway (Unlock).
  3. 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.
    Note
    The "Thermal Fill/Drain" routine has a 5-hour limit. Perform the routine again after 5 hours.
  4. Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  5. Set the multimeter to measure voltage, and then measure the voltage across the LV auxiliary battery terminals.
    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.
  6. Remove the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  7. Remove the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  8. Position the coolant drain container underneath the RH rear of the HV battery.
  9. Release the spring clip to disconnect the RH coolant hose from the rear of the HV battery, and then plug the ends of fittings as soon as possible to avoid coolant loss.
  10. Remove the coolant drain container from underneath the vehicle.
  11. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Model YL) (Maintenance).
  12. Disconnect the HV Ancillary harness connector from the RH rear of the HV battery.
    Note
    The connector is a 2-stage locking connector. Release the red tab before releasing the black locking lever.
  13. Disconnect the front drive unit HV cable from the LH rear of the HV battery.
    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 front drive unit header are not damaged.
  14. Disconnect the AC compressor HV harness connector from the HV Ancillary harness.
    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.
  15. Release the barrel clips (x2) to remove the ancillary harness bracket from the front of the HV battery.
  16. Remove the ancillary harness downwards from the HV battery and manifold tube.
  17. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  18. Release the front drive unit HV harness connector.
    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.
  19. Release the front drive unit HV harness from the casting and move it aside.
  20. Remove the leather over gloves and the HV insulating gloves.
  21. With assistance, remove the bolts (x6) that attach the center ski cover assembly to the HV battery.
    Note
    Remove the ancillary harness downwards from between the HV battery and the manifold tube. Don't damage the coolant hose.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
  22. Release the tabs to remove the front and rear HV harness brackets from the center ski cover assembly.
    Figure 1. Front Shown, Rear Similar
  23. Remove and discard the insulation tapes.
  24. Remove the front drive unit HV harness from the center ski cover assembly.
    Note
    Avoid excessive pulling to prevent damage to the harness insulation. If the insulation layer of the HV harness is damaged, the harness must be replaced.
  25. Remove the ancillary HV harness from the center ski cover assembly.
    Note
    Avoid excessive pulling to prevent damage to the harness insulation. If the insulation layer of the HV harness is damaged, the harness must be replaced.
  26. Remove the front drive unit side and the rear drive unit side bottom HV harness brackets from the center ski cover.
    Note
    Lift up on both sides evenly.

Install

  1. Install the front drive unit side and the rear drive unit side bottom HV harness brackets to the center ski cover.
    Note
    Press down on both sides to secure the brackets.
  2. Install the ancillary HV harness to the groove of the center ski cover assembly.
    Note
    Take tie-wrap as the starting position, with arrow direction pointing toward the front of the vehicle.
    Note
    Avoid excessive pulling to prevent damage to the harness insulation. If the insulation layer of the HV harness is damaged, the harness must be replaced.
  3. Install the front drive unit HV harness to the groove of the center ski cover assembly.
    Note
    Take tie-wrap as the starting position, with arrow direction pointing toward the front of the vehicle.
    Note
    Avoid excessive pulling to prevent damage to the harness insulation. If the insulation layer of the HV harness is damaged, the harness must be replaced.
  4. Install new insulation tapes.
    Note
    Orange insulating tape can also be procured locally.
  5. Secure the tabs to install the front and rear HV harness brackets to the center ski cover assembly.
    Figure 2. Front Shown, Rear Similar
  6. With assistance, install the bolts (x6) that attach the center ski cover assembly to the HV battery.
    34 Nm (25.1 lbs-ft)
    Note
    Install the short bolts (x2) to both ends and the long bolts (x4) to the middle. Route the ancillary harness upwards to between the HV battery and the manifold tube. Don't damage the coolant hose.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
  7. Put on the HV insulating gloves and the leather over gloves.
  8. Install the front drive unit HV harness to the casting.
    Note
    Install the HV connector lever lock to the front drive unit HV cable connector.
  9. Connect the front drive unit HV harness connector.
    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.
  10. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  11. Install the ancillary harness upwards to the HV battery and manifold tube.
  12. Secure the barrel clips (x2) to install the ancillary harness bracket to the front of the HV battery.
  13. Connect the AC compressor HV harness connector to the HV ancillary harness.
    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.
  14. Connect the front drive unit HV cable to the LH rear of the HV battery.
    Note
    Use one hand to support the connector while the other latching locking tab. Once installed, verify that the latch is not damaged and is fully secured in the latched position.
  15. Connect the HV Ancillary harness connector to the RH rear of the HV battery.
    Note
    Rotate the lever arm and then secure the locking tab. Verify that the latch is fully secured and is not damaged.
  16. Remove the leather over gloves and the HV insulating gloves.
  17. Position the coolant drain container underneath the RH rear of the HV battery.
  18. Remove the plugs on the ends of fittings, and then secure the spring clip to connect the RH coolant hose from the rear of the HV battery.
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Note
    Coolant loss greater than 1L requires vacuum fill.
  19. Remove the coolant drain container from underneath the vehicle.
  20. Install the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  21. Install the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  22. Connect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  23. Remove the cap from the coolant bottle.
  24. Fill coolant to the "Max" line.
  25. Unlock the vehicle gateway. See Gateway (Unlock).
  26. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Purge Start > Rerun, 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.
  27. After the coolant air purge routine is finished, inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
  28. Exit Service Mode. See Service Mode.
  29. Install the HEPA filter assembly. See HEPA Filter Assembly (Remove and Replace).