Lincoln Aviator: High Voltage Battery, Mounting and Cables / Removal and Installation - High Voltage Battery Junction Box - 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.

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. Remove the high voltage battery.
   Refer to: High Voltage Battery - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the fasteners and the high voltage battery cover.
   

1. Disconnect the electrical connectors.
   

1. Remove the nuts and position aside the electrical connectors.
   Torque: 97 lb.in (11 Nm)

1. Disconnect the electrical connectors and release the wire guide.
   

1. Disconnect the electrical connectors and release the wire guides.
   

1. Remove the nuts, then remove the high voltage junction box.
   Torque: 97 lb.in (11 Nm)

Installation

1. To install, reverse the removal procedure.
   

1. NOTE: Make sure the correct position of seal, replace with new seal if necessary.

   
   

1. The fasteners must be installed by hand before final tightening.
   Tighten the fasteners in sequence shown in 2 stages.
   Torque:
     Stage 1:  53 lb.in (6 Nm)
     Stage 2:  80 lb.in (9 Nm)

1. Check the high voltage battery pack for leaks.
   Refer to: High Voltage Battery Leak Test - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Install the high voltage battery.
   Refer to: High Voltage Battery - Plug-In Hybrid Electric Vehicle (PHEV) (414-03A High Voltage Battery, Mounting and Cables, Removal and Installation).