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

Special Tool(s) / General Equipment

Materials

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. 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 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. 
   
   1. Remove the pushpins and the high voltage battery rear outer shield.
      
   2. Remove the pushpins and the high voltage battery rear outer shield and vent tube.
      

1. Remove and discard the high voltage battery cover nuts.
   

1. Remove the high voltage battery cover bolts. Discard the center high voltage battery cover bolts.
   

1. NOTICE: Only use an oscillating saw with a maximum blade length of 57 mm (2.25 in) to cut the high voltage battery cover seal. Do not use a reciprocating saw or a blade greater than 57 mm (2.25 in) in length to cut the high voltage battery cover seal or damage to the high voltage battery may occur.

   NOTICE: Use the oscillating saw with the flat side of the blade facing the high voltage battery cover and the beveled side of the blade facing the high voltage battery tray. Be careful not to scratch the upper portion of the high voltage battery tray. If the high voltage battery tray is scratched to bare metal, a primer must be applied.

   Click here to view a video version of this procedure.

   Cutting the High Voltage Battery Cover Seal

   Using a power fixed glass removal tool such as an Air Windshield Remover, Rotunda ASTWINDKO or equivalent with a maximum blade length of 57 mm (2.25 in), cut the seal high voltage battery cover seal in an upward motion and discard the high voltage battery cover.
   Use the General Equipment: Power Fixed Glass Removal Tool

1. If equipped, remove and discard the high voltage inside cover nut seals.
   

Installation

1. NOTICE: The high voltage battery cover must be installed within 2 hours of skim cutting the urethane adhesive. Exposed cut surface of urethane become oxidized and inactive beyond 2 hours, this reduces the effectiveness of the high voltage battery cover bond.

   NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces.

   1. Skim cut the existing urethane adhesive below the height of the new high voltage battery cover spacers.
      
   2. If a bare metal scratch is shown on the top of the high voltage battery mating surface, a primer must be applied. Apply the primer according to the manufacturer's instructions and allow at least 10 minutes to dry.
      Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207

1. NOTICE: Remove all debris from inside of the high voltage battery tray or component damage may occur.

   Remove all debris from inside of the high voltage battery tray.
   Use the General Equipment: Vacuum Cleaner

1. Install the new high voltage inside cover nut seals.
   

1. Attach the new high voltage battery cover spacers to the top of the high voltage battery tray.
   

1. NOTE: The high voltage battery cover must be installed within 10 minutes of applying the urethane adhesive.

   Cut the urethane adhesive applicator tip to specification.
   Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express

1. Apply a urethane adhesive bead 14 mm (0.55 in) high and 7 mm (0.27 in) wide on top of the existing trimmed urethane adhesive bead on the high voltage battery tray.
   

1. NOTICE: Make sure the urethane bead is uniform to prevent air and water leaks.

   NOTE: Use a power caulk gun that applies the urethane adhesive with less effort and a continuous bead.

   1. Apply a 7 mm (.27 in) bead of urethane adhesive to the top of the high voltage battery tray.
      Use the General Equipment: Power Caulk Gun
   2. 80 mm (3.14 in) minimum distance of urethane adhesive overlap.
      
   3. 14 mm (.55 in) minimum height of urethane adhesive.
      

1. With the aid of an assistant, install the high voltage battery cover.
   

1. 1. Install the high voltage battery cover bolts.
      Torque: 106 lb.in (12 Nm)
   2. Install the new high voltage battery cover bolts.
      Torque: 119 lb.in (13.5 Nm)
   3. Install the high voltage battery cover bolts.
      Torque: 133 lb.in (15 Nm)

High Voltage Batteries Built with Silicon Applied to Cover Nuts

1. 1. Install the new nuts until contact is made with the high voltage battery cover.
      
   2. Tighten the high voltage battery cover nuts.
      Torque: 59 lb.ft (80 Nm)

1. Apply a 4 mm (0.15 in) bead of silicone sealant with a 25 mm (0.98 in) overlap between the nuts and the high voltage battery cover.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. Apply the silicone sealant between the nuts and the high voltage battery cover to ensure a proper seal.
   

High Voltage Batteries Built without Silicon Applied to Cover Nuts

1. 1. Install the new nuts until contact is made with the high voltage battery cover.
      
   2. Tighten the high voltage battery cover nuts.
      Torque: 74 lb.ft (100 Nm)

All Vehicles

1. NOTICE: For proper adhesion of the high voltage battery cover label, the mating surface must be clean and free of foreign material.

   1. Clean the metal surface with an alcohol wipe where the high voltage battery cover label is being placed.
      
   2. Remove the back-liner from the new high voltage battery cover label and firmly place onto the high voltage battery cover as shown.
      

1. Check the high voltage battery 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. 
   
   1. Install the high voltage battery rear outer shield and pushpins.
      
   2. Install the high voltage battery vent tube, outer shield and pushpins.
      

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).