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

Special Tool(s) / General Equipment

	414-016 Battery Lift Fixture
Floor Crane
Powertrain Jack
Locking Pliers

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.

1. 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 - 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 ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Remove the muffler and tailpipe.
   Refer to: Muffler and Tailpipe - Full Hybrid Electric Vehicle (FHEV) (309-00C Exhaust System, Removal and Installation).
   

1. NOTE: Right side shown, left side similar.

   Both sides
   Remove the pushpins, nuts and the rear underbody shields.
   

1. NOTE: Right side shown, left side similar.

   Both sides, if equipped
   Remove the pushpins and the side underbody shields.
   

1. NOTE: Right side shown, left side similar.

   1. Both sides
      Remove the fasteners.
      
   2. If equipped, remove the pushpin.
      
   3. Remove the pushpin.
      
   4. Remove the screws and the front underbody shields.
      

1. Remove the screws, nuts and the center and rear exhaust heat shields.
   

1. NOTICE: Before disconnecting the high voltage battery electrical connectors, the electrical connectors must be cleaned with a nylon brush and free of debris. Blow any dirt or debris from the electrical connectors 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 the high voltage battery electrical connectors with a nylon brush. Blow any dirt or debris from the electrical connectors with compressed air.
      
   2. Disconnect the electrical connectors from the high voltage battery.
      Refer to: High Voltage Connector Disconnect and Connect (414-03A High Voltage Battery, Mounting and Cables, General Procedures).
      
   3. Fully loosen the bolt and disconnect the high voltage battery electrical connector.
      Torque: 93 lb.in (10.5 Nm)

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.
      

1. Remove the center bolts from the high voltage battery.
   

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.

   NOTICE: A powertrain jack with a nonslip mat must be used to prevent movement of the high voltage battery.

   Position a powertrain jack with a nonslip mat below the high voltage battery.
   Use the General Equipment: Powertrain Jack

1. Remove the nuts, bolts and with the aid of an assistant, remove the high voltage battery.
   

Installation

1. To install, reverse the removal procedure, except for the steps below.
   

1. If replacing the high voltage battery, using the battery lift fixture and a floor crane remove the high voltage battery from the powertrain jack.
   Use Special Service Tool: 414-016  Battery Lift Fixture.
   Use the General Equipment: Floor Crane

1. NOTE: If replacing the high voltage battery, transfer the high voltage battery rear shields and vent tube.

   
   
   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.
      
   3. Release the retainers and remove the high voltage battery rear inner shields.
      

1. NOTICE: When installing the high voltage battery, finger-start the mounting bolts before tightening or component damage may occur.

   With the aid of an assistant position the high voltage battery, finger-start and tighten the mounting bolts.
   Torque: 35 lb.ft (47.5 Nm)

1. Remove the powertrain jack from the high voltage battery.
   

1. 1. Install and tighten the bolts.
      Torque: 35 lb.ft (47.5 Nm)
   2. Install and tighten the nuts.
      Torque: 35 lb.ft (47.5 Nm)
   3. Install and tighten the bolts.
      Torque: 35 lb.ft (47.5 Nm)
   4. Install and tighten the bolts.
      Torque: 35 lb.ft (47.5 Nm)

1. Bleed the cooling system.
   Refer to: Cooling System Filling and Bleeding (303-03D Electric Powertrain Cooling - Hybrid Electric Vehicle (HEV), 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 high voltage battery, use the diagnostic scan tool and start a new vehicle session. Reprogram the PCM using the latest FDRS software release.