Ford Explorer: High Voltage Battery, Mounting and Cables / Removal and Installation - High Voltage Battery Cables - Hybrid Electric Vehicle (HEV)

Removal

  WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. De-energize the high voltage system.
   Refer to: High Voltage System De-energizing (414-03 High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Remove the upper intake manifold.
   Refer to: Upper Intake Manifold (303-01D Engine - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

High Voltage Battery Cable

1. Drain the electric powertrain cooling system.
   Refer to: Cooling System Filling and Bleeding (303-03E Electric Powertrain Cooling - 3.3L Duratec-V6 – Hybrid (BP), General Procedures).
   

1. 1. Remove the screw.
      Torque: 27 lb.in (3 Nm)
   2. Remove the retainers.
      
   3. Remove the nuts.
      Torque: 53 lb.in (6 Nm)

1. 1. Remove the fasteners.
      
   2. Remove the push pins.
      

1. Remove the RH catalytic converter.
   Refer to: Catalytic Converter RH (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Remove the bolts and position aside the wire shield.
   Torque: 97 lb.in (11 Nm)

1. Disconnect the high voltage battery cable electrical connector.
   

1. 1. Remove the bolts.
      Torque: 97 lb.in (11 Nm)
   2. Position aside the shield.
      
   3. Remove the nuts and the RH floor heat shield.
      Torque: 97 lb.in (11 Nm)

1. Remove the nuts and position aside the wire harness.
   Torque: 53 lb.in (6 Nm)

1. Remove the nuts and position aside the wire harness.
   Torque: 53 lb.in (6 Nm)

1. 1. Remove the screw and the trim pin.
      Torque: 97 lb.in (11 Nm)
   2. Position aisde the RH side engine protection cover.
      

1. Remove the nuts and position aside the wire harness.
   Torque: 53 lb.in (6 Nm)

1. Release the wire guides and position aside the wire harness.
   

1. Disconnect the electrical connector from the A/C compressor, release the wire guides and position aside the wire harness.
   

1. Release the wire guides and position aside the wire harness.
   

1. Remove the PCM.
   Refer to: Powertrain Control Module (PCM) (303-14C Electronic Engine Controls - 3.3L Duratec-V6/3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Detach the wiring harness retainers and position aside the harness.
   

1. Detach the wiring harness retainers and position aside the harness.
   

1. Remove the bolts and the PCM bracket.
   Torque: 53 lb.in (6 Nm)

1. Disconnect the electrical connectors from the DCDC and remove the High Voltage Battery Cables from the vehicle.
   

High Voltage 3 Phase AC -ISC (Inverter System Controller) to E-Motor Cable

1. 1. Remove the retainers, disconnect the electrical connectors from the ISC.
      Torque: 97 lb.in (11 Nm)
   2. Release the wire guide.
      
   3. Release the wire guide and position aside the harness.
      

1. Remove the retainers.
   

1. Disconnect the electrical connectors from the transmission and remove the High Voltage Battery Cables from the vehicle.
   Torque: 97 lb.in (11 Nm)

Installation

1. To install, reverse the removal procedure.
   

1. NOTICE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur.

   1. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
      
   2. Clean and inspect the high voltage electrical connector gasket.