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.
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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).
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Position vehicle on the hoist.
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
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De-energize the high voltage system.
Refer to: High Voltage System De-energizing (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
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Disconnect the battery negative terminal.
Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
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Remove the bolts and the suspension support bar.
Torque:
22 lb.ft (30 Nm)
High Voltage Battery Cable
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Remove the cowl panel.
Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
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Remove the push pins.
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Remove the fasteners.
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Remove the stamp nuts.
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Remove the nuts.
Torque:
53 lb.in (6 Nm)
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Remove the nuts.
Torque:
53 lb.in (6 Nm)
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Remove the screws.
Torque:
27 lb.in (3 Nm)
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Remove the fasteners.
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Remove the bolts.
Torque:
97 lb.in (11 Nm)
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Remove the nuts and the RH floor heat shield.
Torque:
97 lb.in (11 Nm)
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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).
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Disconnect the high voltage battery cable electrical connector.
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Remove the nuts and position aside the wire harness.
Torque:
53 lb.in (6 Nm)
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Remove the nuts and position aside the wire harness.
Torque:
53 lb.in (6 Nm)
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Remove the nut.
Torque:
97 lb.in (11 Nm)
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Remove the screw.
Torque:
97 lb.in (11 Nm)
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Remove the trim pin and the position aside the RH side heat shield.
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Remove the nuts and position aside the wire harness.
Torque:
53 lb.in (6 Nm)
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Remove the RH head lamp.
Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
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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).
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Detach the wiring harness retainers and position aside the harness.
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Detach the wiring harness retainers and position aside the harness.
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Remove the bolts and the PCM bracket.
Torque:
53 lb.in (6 Nm)
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Disconnect the IAT sensor electrical connector.
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Detach the clip.
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Detach electrical wire clips.
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Loosen the clamps and position the air cleaner outlet pipes LH and RH aside.
Torque:
44 lb.in (5 Nm)
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Remove the nut.
Torque:
80 lb.in (9 Nm)
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Detach and remove the air cleaner from the isolators.
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Loosen the clamp and remove the upper air cleaner outlet pipe.
Torque:
44 lb.in (5 Nm)
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Loosen the RH
CAC intake pipe clamp.
Torque:
44 lb.in (5 Nm)
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Loosen the bolt and remove the RH
CAC intake pipe.
Torque:
106 lb.in (12 Nm)
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Loosen the clamp and remove RH
CAC intake pipe.
Torque:
44 lb.in (5 Nm)
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Remove the hose clip and position aside the hose.
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Loosen the hose clamp.
Torque:
44 lb.in (5 Nm)
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Loosen the clamp and remove the CAC Y-pipe.
Torque:
44 lb.in (5 Nm)
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Release the wire guides and position aside the wire harness.
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Remove the fender splash shield.
Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
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Remove the fasteners and the fender flange finisher.
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Disconnect the electrical connector and release the wire guides.
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Release the wire guides.
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Disconnect the electrical connectors and release the wire guides.
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Release the wire guides and position aside the wire harness.
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Disconnect the electrical connectors from the DCDC and remove the High Voltage Battery Cables from the vehicle.
compressor high voltage cable
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Disconnect the electrical connector.
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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
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Remove the retainers, disconnect the electrical connectors from the ISC and position aside the harness.
Torque:
97 lb.in (11 Nm)
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Remove the harness retainer.
Torque:
53 lb.in (6 Nm)
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Detach the wire guides.
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Remove the retainers.
Torque:
53 lb.in (6 Nm)
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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).
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Remove the retainers and the hybrid drive unit electrical connector.
Torque:
97 lb.in (11 Nm)
Installation
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To install, reverse the removal procedure.
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NOTICE:
If the transmission is not positioned on the dowel pins, damage to the transmission may occur.
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If the dowel pins were pulled out of the engine
block during removal, install new dowel pins in the engine block.
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Clean and inspect the high voltage electrical connector gasket.
Removal
WARNING:
To prevent the risk of high-voltage shock, always follow
precisely all warnings and service instructions, including instructions
to depower the system...
Other information:
Special Tool(s) /
General Equipment
Hose Clamp Remover/Installer
Removal
Drain the cooling system.
Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 3.0L EcoBoost, General Procedures)...
Special Tool(s) /
General Equipment
Hose Clamp Remover/Installer
Removal
Remove the air cleaner.
Refer to: Air Cleaner (303-12 Intake Air Distribution and Filtering - 3.0L EcoBoost/3.0L EcoBoost – Hybrid (BQ), Removal and Installation)...