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

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.

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.

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

   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 (100-02 Jacking and Lifting, Description and Operation).
   

1. NOTE: This step is only necessary when installing a new component.

   NOTE: Use the previous FDRS vehicle session or start a session manually by entering the VIN.

   Download the BECM information to the diagnostic tool using the Programmable Modules Installation routine.
   Refer to: Module Programming (418-01 Module Configuration, General Procedures).
   Use the General Equipment: Ford Diagnostic Equipment

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

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

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

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

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

1. Remove the bolts and the hanger brackets.
   Torque: 30 lb.ft (40 Nm)

1. Remove the rear driveshaft.
   Refer to: Rear Driveshaft (205-01 Driveshaft, Removal and Installation).
   

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

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

1. NOTICE: Before disconnecting the high voltage battery electrical connector, the electrical connector must be cleaned with a nylon brush and free of debris. Blow any dirt or debris from the electrical connector with compressed air before disconnecting or component damage may occur.

   1. Clean high voltage battery electrical connector with a nylon brush. Blow any dirt or debris from the electrical connector with compressed air.
      
   2. Detach the retainer and position the wire harness aside.
      

   3. NOTE: To aid in disconnecting the high voltage battery electrical connector, gently pull the base of the connector while releasing the lock lever.

      Release the lock lever and disconnect the high voltage battery electrical connector.
      

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

1. NOTICE: Before disconnecting the high voltage battery electrical connector, the electrical connector must be cleaned with a nylon brush and free of debris. Blow any dirt or debris from the electrical connector with compressed air before disconnecting or component damage may occur.

   1. Clean high voltage battery electrical connector with a nylon brush. Blow any dirt or debris from the electrical connector with compressed air.
      
   2. Detach the retainer and position the wire harness aside.
      

   3. NOTE: To aid in disconnecting the high voltage battery electrical connector, gently pull the base of the connector while releasing the lock lever.

      Release the lock lever and disconnect the high voltage battery electrical connector and position the wire harness aside.
      

1. Remove the coolant hoses.
   Use the General Equipment: Hose Clamp(s)

1. NOTICE: Only apply enough pressure from the powertrain jack to contact and support the high voltage battery during the removal. Excessive pressure placed under the high voltage battery may cause damage to the high voltage battery.

   Position the powertrain jack and support the high voltage battery assembly.
   Use the General Equipment: Powertrain Jack

1. 1. Remove the bolt.
      
   2. Remove the bolts.
      
   3. With the aid of an assistant and using the powertrain jack, lower the high voltage battery assembly.
      

Installation

1. 1. Install the high voltage battery assembly.
      
   2. Install the bolts.
      Torque: 35 lb.ft (48 Nm)
   3. Install the bolt.
      Torque: 106 lb.in (12 Nm)

1. To install, reverse the removal procedure.
   

1. Bleed the high voltage battery cooling system.
   Refer to: Cooling System Filling and Bleeding (303-03C Electric Powertrain Cooling - 3.0L EcoBoost – Hybrid (BQ), General Procedures).
   

1. NOTE: This step is only necessary when installing a new component.

   Upload the BECM information from the diagnostic tool using the Programmable Modules Installation routine.
   Refer to: Module Programming (418-01 Module Configuration, General Procedures).
   

1. NOTE: Updating the PCM with the latest calibration will update the appropriate modules as required by the software update.

   NOTE: Calibration files can be obtained at www.motorcraft.com

   If replacing a battery, use the diagnostic scan tool and start a new vehicle session. Reprogram the PCM using the latest IDS software release.