Ski - Center Rail - HV Battery (Dual Motor) (Remove and Replace)

Correction code 1610261216102612
  • 1140311-00-ALever Lock, HV Connector, Model 3

SPECIAL TOOLS

Lever Lock, HV Connector, Model 3 (1140311-00-A)
Warning:

Only technicians who have been trained in High Voltage Awareness 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 safety information.

Remove

  1. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  2. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  3. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
  4. Slide the red release tab to unlock the front drive unit HV harness connector.
  5. Slowly unlatch the release handle on the front drive unit HV harness connector, and then disconnect the connector from the front drive unit.
    Caution:
    Do not apply excessive force to the handle; doing so could damage the connector alignment tabs.
  6. Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  7. Disconnect the PTC heater HV electrical harness, and then remove the PTC heater HV electrical harness from the connector bracket.
  8. Disconnect the A/C compressor HV electrical harness, and then remove the A/C compressor HV electrical harness from the connector bracket.
  9. Position a coolant drain under the LH front of the HV battery.
  10. Release the clip, disconnect the HV battery RH supply manifold from the HV battery LH supply manifold, and then immediately plug the male and female fittings.
  11. Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
  12. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  13. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  14. Position the coolant drain under the RH rear of the HV battery.
  15. Release the clip, and then disconnect the RH inner HV battery return hose fitting from the RH end of the HV battery platter enclosure.
  16. Quickly plug both the male and female fittings.
  17. Remove the coolant drain from under the vehicle.
  18. Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
  19. Release the locking tab of the rear drive unit HV electrical harness.
  20. Raise the handle, and them disconnect the rear drive unit HV electrical harness from the HV battery connector.
  21. Release the locking tab, raise the handle, and then disconnect the PTC heater and A/C compressor electrical harness from the HV battery connector.
  22. Release the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
  23. With an assistant, remove the bolts that attach the center rail ski to the HV battery.
  24. Remove the center rail ski from the vehicle.
  25. Remove the cap cover at the front of the HV battery center rail ski.
  26. Remove the cap cover at the rear of the HV battery center rail ski.
  27. Remove the HV battery to front drive unit harness from the center of the HV battery center rail ski.
  28. Remove the PTC heater and A/C compressor electrical harnesses from the sides of the HV battery center rail ski.
1Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
2Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
3Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
4Slide the red release tab to unlock the front drive unit HV harness connector.
5Slowly unlatch the release handle on the front drive unit HV harness connector, and then disconnect the connector from the front drive unit.
Caution:
Do not apply excessive force to the handle; doing so could damage the connector alignment tabs.
6Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
7Disconnect the PTC heater HV electrical harness, and then remove the PTC heater HV electrical harness from the connector bracket.
8Disconnect the A/C compressor HV electrical harness, and then remove the A/C compressor HV electrical harness from the connector bracket.
9Position a coolant drain under the LH front of the HV battery.
10Release the clip, disconnect the HV battery RH supply manifold from the HV battery LH supply manifold, and then immediately plug the male and female fittings.
11Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
12Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
13Release the clips that attach the RH inner HV battery return hose to the HV battery.
14Position the coolant drain under the RH rear of the HV battery.
15Release the clip, and then disconnect the RH inner HV battery return hose fitting from the RH end of the HV battery platter enclosure.
16Quickly plug both the male and female fittings.
17Remove the coolant drain from under the vehicle.
18Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
19Release the locking tab of the rear drive unit HV electrical harness.
20Raise the handle, and them disconnect the rear drive unit HV electrical harness from the HV battery connector.
21Release the locking tab, raise the handle, and then disconnect the PTC heater and A/C compressor electrical harness from the HV battery connector.
22Release the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
23With an assistant, remove the bolts that attach the center rail ski to the HV battery.
24Remove the center rail ski from the vehicle.
25Remove the cap cover at the front of the HV battery center rail ski.
26Remove the cap cover at the rear of the HV battery center rail ski.
27Remove the HV battery to front drive unit harness from the center of the HV battery center rail ski.
28Remove the PTC heater and A/C compressor electrical harnesses from the sides of the HV battery center rail ski.

Install

  1. Install the PTC heater and A/C compressor electrical harness into the sides of the HV battery center rail ski.
  2. Install the HV battery to front drive unit harness into the center of the HV battery center rail ski.
  3. Install the cap cover at the rear of the HV battery center rail ski.
  4. Install the cap cover at the front of the HV battery center rail ski.
  5. With an assistant, install the center rail ski to the HV battery.
  6. Install the bolts that attach the center rail ski to the HV battery.
    Torque 38 Nm
    Torque 38 Nm
  7. Fasten the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
  8. Connect the PTC heater and A/C compressor electrical harness to the HV battery connector, lower the handle, and attach the locking tab.
  9. Fully raise the handle on the rear drive unit HV electrical harness.
  10. Attach the HV connector lever lock onto the back of the HV electrical harness.
  11. Firmly connect the HV electrical harness to the HV battery connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  12. While pressing the harness to the connector, remove the HV connector lever lock.
  13. While pressing the harness to the connector, fully lower the handle.
  14. Slide the release to lock the HV electrical harness.
  15. Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
    Torque 10 Nm
  16. Position the coolant drain under the RH rear of the HV battery.
  17. Remove the plugs from the male and female fittings, quickly connect the RH inner HV battery return hose to the HV battery platter enclosure, and then fasten the clip.
  18. Remove the coolant drain from under the RH rear of the HV battery.
  19. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
  20. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  21. Position the coolant drain under the LH front of the HV battery.
  22. Install the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
  23. Remove the plugs from the HV battery RH supply manifold and the HV battery LH supply manifold, immediately connect the male and female fittings, and then fasten the clip.
  24. Install the A/C HV electrical harness into the connector bracket, and then connect the A/C HV electrical harness.
  25. Install the PTC heater HV electrical harness into the connector bracket, and then connect the PTC heater HV electrical harness.
  26. Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  27. Fully raise the handle on the front drive unit HV electrical harness
  28. Attach the HV connector lever lock onto the back of the HV electrical harness.
  29. Firmly connect the HV electrical harness to the front drive unit connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  30. While pressing the harness to the connector, remove the HV connector lever lock.
  31. While pressing the harness to the connector, fully lower the handle.
  32. Slide the release to lock the HV electrical harness.
  33. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    Torque 10 Nm
  34. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  35. Perform a penthouse air leak test. See Penthouse Air Leak Test.
  36. Connect 12V power. See 12V Power (Disconnect and Connect).
  37. Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).
1Install the PTC heater and A/C compressor electrical harness into the sides of the HV battery center rail ski.
2Install the HV battery to front drive unit harness into the center of the HV battery center rail ski.
3Install the cap cover at the rear of the HV battery center rail ski.
4Install the cap cover at the front of the HV battery center rail ski.
5With an assistant, install the center rail ski to the HV battery.
6Install the bolts that attach the center rail ski to the HV battery.
Torque 38 Nm
Torque 38 Nm
7Fasten the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
8Connect the PTC heater and A/C compressor electrical harness to the HV battery connector, lower the handle, and attach the locking tab.
9Fully raise the handle on the rear drive unit HV electrical harness.
10Attach the HV connector lever lock onto the back of the HV electrical harness.
11Firmly connect the HV electrical harness to the HV battery connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
12While pressing the harness to the connector, remove the HV connector lever lock.
13While pressing the harness to the connector, fully lower the handle.
14Slide the release to lock the HV electrical harness.
15Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
Torque 10 Nm
16Position the coolant drain under the RH rear of the HV battery.
17Remove the plugs from the male and female fittings, quickly connect the RH inner HV battery return hose to the HV battery platter enclosure, and then fasten the clip.
18Remove the coolant drain from under the RH rear of the HV battery.
19Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
20Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
21Position the coolant drain under the LH front of the HV battery.
22Install the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
23Remove the plugs from the HV battery RH supply manifold and the HV battery LH supply manifold, immediately connect the male and female fittings, and then fasten the clip.
24Install the A/C HV electrical harness into the connector bracket, and then connect the A/C HV electrical harness.
25Install the PTC heater HV electrical harness into the connector bracket, and then connect the PTC heater HV electrical harness.
26Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
27Fully raise the handle on the front drive unit HV electrical harness
28Attach the HV connector lever lock onto the back of the HV electrical harness.
29Firmly connect the HV electrical harness to the front drive unit connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
30While pressing the harness to the connector, remove the HV connector lever lock.
31While pressing the harness to the connector, fully lower the handle.
32Slide the release to lock the HV electrical harness.
33Install the bolt that attaches the front drive unit HV harness to the front drive unit.
Torque 10 Nm
34Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
35Perform a penthouse air leak test. See Penthouse Air Leak Test.
36Connect 12V power. See 12V Power (Disconnect and Connect).
37Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).