Lincoln Aviator 2020-2022 Service Manual / Electrical / Battery and Charging System / High Voltage Battery, Mounting and Cables / Removal and Installation - High Voltage Battery Cables - Plug-In Hybrid Electric Vehicle (PHEV)

Lincoln Aviator: High Voltage Battery, Mounting and Cables / Removal and Installation - High Voltage Battery Cables - Plug-In Hybrid Electric Vehicle (PHEV)

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.

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).

Position vehicle on the hoist.
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

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

Disconnect the battery negative terminal.
Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Remove the bolts and the suspension support bar.
Torque: 22 lb.ft (30 Nm)

High Voltage Battery Cable

Remove the cowl panel.
Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).

1. Remove the push pins.
1. Remove the fasteners.
1. Remove the stamp nuts.
1. Remove the nuts.
  Torque: 53 lb.in (6 Nm)

1. Remove the nuts.
  Torque: 53 lb.in (6 Nm)
1. Remove the screws.
  Torque: 27 lb.in (3 Nm)
1. Remove the fasteners.

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

Remove the RH catalytic converter.
Refer to: Catalytic Converter RH - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
Refer to: Catalytic Converter RH - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).

Disconnect the high voltage battery cable electrical connector.

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

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

1. Remove the nut.
  Torque: 97 lb.in (11 Nm)
1. Remove the screw.
  Torque: 97 lb.in (11 Nm)
1. Remove the trim pin and the position aside the RH side heat shield.

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

Remove the RH head lamp.
Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

Remove the PCM.
Refer to: Powertrain Control Module (PCM) (303-14A Electronic Engine Controls - 3.0L EcoBoost/3.0L EcoBoost – Hybrid (BQ), Removal and Installation).

Detach the wiring harness retainers and position aside the harness.

Detach the wiring harness retainers and position aside the harness.

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

1. Disconnect the IAT sensor electrical connector.
1. Detach the clip.
1. Detach electrical wire clips.
1. Loosen the clamps and position the air cleaner outlet pipes LH and RH aside.
  Torque: 44 lb.in (5 Nm)

1. Remove the nut.
  Torque: 80 lb.in (9 Nm)
1. Detach and remove the air cleaner from the isolators.

Loosen the clamp and remove the upper air cleaner outlet pipe.
Torque: 44 lb.in (5 Nm)

Loosen the RH CAC intake pipe clamp.
Torque: 44 lb.in (5 Nm)

Loosen the bolt and remove the RH CAC intake pipe.
Torque: 106 lb.in (12 Nm)

Loosen the clamp and remove RH CAC intake pipe.
Torque: 44 lb.in (5 Nm)

Remove the hose clip and position aside the hose.

1. Loosen the hose clamp.
  Torque: 44 lb.in (5 Nm)
1. Loosen the clamp and remove the CAC Y-pipe.
  Torque: 44 lb.in (5 Nm)

Release the wire guides and position aside the wire harness.

Remove the fender splash shield.
Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).

Remove the fasteners and the fender flange finisher.

Disconnect the electrical connector and release the wire guides.

Release the wire guides.

Disconnect the electrical connectors and release the wire guides.

Release the wire guides and position aside the wire harness.

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

compressor high voltage cable

Disconnect the electrical connector.

Release the wire guides, disconnect the electrical connector and remove the harness.

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

Remove the retainers, disconnect the electrical connectors from the ISC and position aside the harness.
Torque: 97 lb.in (11 Nm)

1. Remove the harness retainer.
  Torque: 53 lb.in (6 Nm)
1. Detach the wire guides.

Remove the retainers.
Torque: 53 lb.in (6 Nm)

NOTICE: Only lower the transmission far enough to access the electrical connector or damage to the wiring harness can occur.
Remove the transmission.
Refer to: Transmission - 3.0L EcoBoost – Hybrid (BQ) (307-01B Automatic Transmission - 10-Speed Automatic Transmission – 10R80 MHT, Removal and Installation).

Remove the retainers and the hybrid drive unit electrical connector.
Torque: 97 lb.in (11 Nm)

Installation

To install, reverse the removal procedure.

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.
1. Clean and inspect the high voltage electrical connector gasket.

Removal and Installation - High Voltage Low Current Fuse - Plug-In Hybrid Electric Vehicle (PHEV)

Removal WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system...

High Voltage Battery Charging System

Other information:

Lincoln Aviator 2020-2022 Owners Manual: Ordering Additional Owner's Literature

To order the publications in this portfolio, contact Helm, LLC at: HELM, LLC 47911 Halyard Drive, Suite 200 Plymouth, Michigan 48170 Attention: Customer Service Or to order a free publication catalog, call toll free: 1-800-782-4356 Monday-Friday 8:00 a...

Lincoln Aviator 2020-2022 Service Manual: Diagnosis and Testing - Instrumentation, Message Center and Warning Chimes

Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation). Diagnostic Trouble Code Chart Module DTC Description Action ABS C0049:01 Brake Fluid Level:General Electrical Failure GO to Pinpoint Test L ABS C0049:7B Brake Fluid Level:Low Fluid Level GO to Pinpoint Test L IPC P0460:11 Fuel Level Sensor "A" Circuit:Circuit Short To Ground GO to Pinpoint Test D IPC P0460:13 Fuel Level Sensor "A" Circuit:Circuit Open GO to Pinpoint Test D IPC U0100:00 Lost Communication With ECM/PCM "A":No Sub Type Information GO to Pinpoint Test CC IPC U0103:00 Lost Communication With Gear Shift Control Module A:No Sub Type Information GO to Pinpoint Test CE IPC U0111:00 Lost Communication With Battery Energy Control Module "A":No Sub Type Information GO to Pinpoint Test CF IPC U0121:00 Lost Communication With Anti-Lock Brake System (ABS) Control Module: No Sub Type Information GO to Pinpoint Test CG IPC U013F:00 Lost Communication With Pedestrian Alert Control Module:No Sub Type Information GO to Pinpoint Test CI IPC U0140:00 Lost Communication With Body Control Module: No Sub Type Information GO to Pinpoint Test CJ IPC U0151:00 Lost Communication With Restraints Control Module: No Sub Type Information GO to Pinpoint Test CM IPC U0158:00 Lost Communication With Head Up Display:No Sub Type Information GO to Pinpoint Test CN IPC U0159:00 Lost Communication With Parking Assist Control Module "A": No Sub Type Information GO to Pinpoint Test CP IPC U0193:00 Lost Communication With "Digital Audio Control Module A": No Sub Type Information GO to Pinpoint Test CQ IPC U0199:00 Lost Communication With "Door Control Module A":No Sub Type Information GO to Pinpoint Test CR IPC U0212:00 Lost Communication With Steering Column Control Module: No Sub Type Information GO to Pinpoint Test CS IPC U0212:82 Lost Communication With Steering Column Control Module:Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CS IPC U0232:00 Lost Communication With Side Obstacle Detection Control Module - Left: No Sub Type Information GO to Pinpoint Test CU IPC U0233:00 Lost Communication With Side Obstacle Detection Control Module - Right: No Sub Type Information GO to Pinpoint Test CU IPC U023A:00 Lost Communication With Image Processing Module A: No Sub Type Information GO to Pinpoint Test CW IPC U023B:82 Lost Communication With Image Processing Module B:Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CX IPC U0241:00 Lost Communication With Headlamp Control Module "A":No Sub Type Information GO to Pinpoint Test CY IPC U0253:00 Lost Communication With Accessory Protocol Interface Module:No Sub Type Information GO to Pinpoint Test CZ IPC U0260:00 Lost Communication With Seat Control Switch Module "A":No Sub Type Information GO to Pinpoint Test DA IPC U0293:00 Lost Communication with Hybrid/EV Powertrain Control Module:No Sub Type Information GO to Pinpoint Test CD IPC U0293:82 Lost Communication with Hybrid/EV Powertrain Control Module:Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CD IPC U0401:00 Invalid Data Received from ECM/PCM A:No Sub Type Information GO to Pinpoint Test CC IPC U0401:81 Invalid Data Received from ECM/PCM A:Invalid Serial Data Received GO to Pinpoint Test CC IPC U0401:82 Invalid Data Received from ECM/PCM A:Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CC IPC U0401:86 Invalid Data Received from ECM/PCM A:Signal Invalid GO to Pinpoint Test CC IPC U0405:56 Invalid Data Received From Cruise Control Module:Invalid/Incompatible Configuration GO to Pinpoint Test CK IPC U0412:86 Invalid Data Received From Battery Energy Control Module "A":Signal Invalid GO to Pinpoint Test CF IPC U0415:00 Invalid Data Received From Anti-Lock Brake System (ABS) Module: No Sub Type Information GO to Pinpoint Test CG IPC U0415:82 Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A":Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CG IPC U0420:82 Invalid Data Received from Power Steering Control Module "A":Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CH IPC U0422:00 Invalid Data Received From Body Control Module:No Sub Type Information GO to Pinpoint Test CJ IPC U0424:80 Invalid Data Received From HVAC Control Module:ISO/SAE Reserved GO to Pinpoint Test CL IPC U0424:81 Invalid Data Received From HVAC Control Module:Invalid Serial Data Received GO to Pinpoint Test CL IPC U0424:82 Invalid Data Received From HVAC Control Module:Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CL IPC U0431:82 Invalid Data Received From Body Control Module "A":Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CJ IPC U0452:81 Invalid Data Received From Restraints Control Module:Invalid Serial Data Received GO to Pinpoint Test CM IPC U045A:82 Invalid Data Received From Parking Assist Control Module "A":Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CP IPC U049C:82 Invalid Data Received From Battery Charger Control Module "A":Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CO IPC U0531:82 Invalid Data Received From Rear Gate Module:Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CT IPC U0533:00 Invalid Data Received From Side Obstacle Detection Control Module-Left: No Sub Type information GO to Pinpoint Test CU IPC U0533:56 Invalid Data Received From Side Obstacle Detection Control Module "A":Invalid/Incompatible Configuration GO to Pinpoint Test CV IPC U0534:00 Invalid Data Received From Side Obstacle Detection Control Module-Right: No Sub Type Information GO to Pinpoint Test CU IPC U0534:56 Invalid Data Received From Side Obstacle Detection Control Module "B":Invalid/Incompatible Configuration GO to Pinpoint Test CV IPC U0542:82 Invalid Data Received From Headlamp Control Module "A":Alive/Sequence Counter Incorrect/Not Updated GO to Pinpoint Test CY IPC U0594:86 Invalid Data Received From Hybrid/EV Powertrain Control Module:Signal Invalid GO to Pinpoint Test CD IPC U2100:00 Initial Configuration Not Complete:No Sub Type Information GO to Pinpoint Test DB IPC U3000:04 Control Module:System Internal Failures GO to Pinpoint Test DC IPC U3000:46 Control Module:Calibration/Parameter Memory Failure GO to Pinpoint Test DC IPC U3003:16 Battery Voltage: Circuit Voltage Below Threshold GO to Pinpoint Test DE IPC U3003:17 Battery Voltage: Circuit Voltage Above Threshold GO to Pinpoint Test DF IPC U300A:64 Ignition Switch:Signal Plausibility Failure GO to Pinpoint Test DD PCM P0461:00 Fuel Level Sensor "A" Circuit Range/Performance:No Sub Type Information GO to Pinpoint Test D PCM P0462:00 Fuel Level Sensor "A" Circuit Low:No Sub Type Information GO to Pinpoint Test D PCM P0463:00 Fuel Level Sensor "A" Circuit High:No Sub Type Information GO to Pinpoint Test D PCM P0522:00 Engine Oil Pressure Sensor/Switch "A" Circuit Low:No Sub Type Information GO to Pinpoint Test W PCM P0523:00 Engine Oil Pressure Sensor/Switch "A" Circuit High:No Sub Type Information GO to Pinpoint Test W PCM P25B0:00 Fuel Level Sensor "A" Stuck:No Sub Type Information GO to Pinpoint Test D SIMA B1380:4A Steering Wheel Right Switch Pack:Incorrect Component Installed GO to Pinpoint Test AG SIMA B1380:71 Steering Wheel Right Switch Pack:Actuator Stuck GO to Pinpoint Test AG Symptom Chart(s) Symptom Chart: Instrument Panel Cluster (IPC) Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...

Fastening the Seatbelts

The front outboard and rear safety restraints in the vehicle are combination lap and shoulder belts.

Insert the belt tongue into the proper buckle (the buckle closest to the direction the tongue is coming from) until you hear a snap and feel it latch. Make sure that you securely fasten the tongue in the buckle.

Lincoln Aviator. Fastening the Seatbelts

To unfasten, press the release button and remove the tongue from the buckle.