Ford Escape: High Voltage Battery Charging System - Plug-In Hybrid Electric Vehicle (PHEV) / Removal and Installation - Charge Port - 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.

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

NOTE: The external high voltage battery charger must be disconnected before performing the following steps.

1.   WARNING: Before beginning any service procedure in this manual, refer to health and 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. De-energize the high voltage system.
   Refer to: High Voltage System De-energizing (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Remove the CSI .
   Refer to: Charge Status Indicator (CSI) - Plug-In Hybrid Electric Vehicle (PHEV) (414-03B High Voltage Battery Charging System - Plug-In Hybrid Electric Vehicle (PHEV), Removal and Installation).
   

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.

   NOTICE: High voltage electrical connectors may require unique methods to be disconnected. If not properly disconnected, 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. Disconnect the charge port electrical connector.
      Refer to: High Voltage Connector Disconnect and Connect (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
      
   3. Remove the bolt, detach the retainers and position the wire harness aside.
      Torque: 26 lb.ft (35 Nm)

1. Disconnect the electrical connector, detach the retainers, remove the bolts and the charge port.
   Torque: 93 lb.in (10.5 Nm)

Installation

1. To install, reverse the removal procedure.