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

Special Tool(s) / General Equipment

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.

NOTE: Removal steps in this procedure may contain installation details.

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: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, 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. 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 retainers.
      
   2. Remove the pushpins and RH side aero deflector shield.
      

1. 1. Attach the hose clamp pliers to the coolant hoses.
      Use the General Equipment: Locking Pliers
   2. Disconnect the coolant hoses.
      

1. NOTE: Be prepared to collect escaping fluid.

   Remove the bolts and the high voltage battery coolant cover.
   

Installation

1. To install, reverse the removal procedure.
   

NOTE: Inspect the high voltage battery coolant cover seal and replace with a new seal if necessary.

NOTE: This step is only required if replacing the high voltage battery coolant cover seal.

NOTE: Make sure the high voltage battery coolant cover seal is fully seated in the high voltage battery tray groove.

1. 1. Position the new high voltage battery coolant cover seal and press into the high voltage battery tray in the direction shown.
      

1. Install the high voltage battery coolant cover. Finger-start the bolts and tighten in the sequence shown.
   Torque:
     Stage 1:  62 lb.in (7 Nm)
     Stage 2:  133 lb.in (15 Nm)

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