Ford Escape: High Voltage Battery, Mounting and Cables / Removal and Installation - High Voltage Battery - Hybrid Electric Vehicle (HEV)

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, refer to health and safety warnings in section 100-00 General Information within workshop manual. 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. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, 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. Disconnect the battery negative terminals.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. 1. Remove the underbody shield screws.
      
   2. Remove the underbody shield pushpins.
      
   3. Remove the nuts and the underbody shield.
      

1. 1. Remove the exhaust shield nuts.
      
   2. Remove the bolt and position the exhaust shield aside.
      

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. 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.
      
   3. Detach the retainers and position the wire harness aside.
      

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. 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.
      
   3. Detach the retainers and position the wire harness aside.
      

1. 1. Clamp the high voltage battery coolant hoses.
      Use the General Equipment: Locking Pliers
   2. Disconnect the coolant hoses from the high voltage battery.
      
   3. Disconnect the retainers from the high voltage battery and position coolant hoses aside.
      

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 a powertrain jack under the high voltage battery.
   Use the General Equipment: Powertrain Jack

1. 1. Remove the high voltage battery mounting bolts.
      Torque: 46 lb.ft (62.5 Nm)
   2. With the aid of an assistant and using the powertrain jack, lower the high voltage battery assembly.
      

Installation

1. To install, reverse the removal procedure.
   

1. If replacing the battery, transfer the high voltage battery mounting brackets. Remove and discard the bolts and tighten the new bolts in the sequence shown.
   Torque: 155 lb.in (17.5 Nm)

1. Bleed the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03C Engine Cooling, 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 the battery, use the diagnostic scan tool and start a new vehicle session. Reprogram the PCM using the latest FDRS software release.