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

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.

   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. Remove the high voltage battery.
   Refer to: High Voltage Battery - Hybrid Electric Vehicle (HEV) (414-03A High Voltage Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the bolts and the high voltage battery cover.
   

1. Disconnect the electrical connectors from the high voltage BJB and position the cables aside.
   

1. 1. Disconnect the electrical connectors.
      
   2. Disconnect the retainers and position the wire harness aside.
      

1. 1. Release the electrical connector retainers.
      
   2. Remove the high voltage battery wiring harness.
      

Installation

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

1. NOTE: Inspect the seal and replace with a new seal if necessary.

   
   

1. NOTE: This step is only required if you are replacing the battery cover seal.

   
   Install the new battery cover seal.
   

   • NOTE: Do not add lubrication.

     Match the seal profile to the groove geometry.
     

   • NOTE: Do not slide along the seal.

     Press the seal in at multiple places until fully seated.
     

1. NOTE: Finger-start the bolts.

   1. Install the high voltage battery cover and tighten the bolts in the sequence shown.
      Torque:
        Stage 1:  62 lb.in (7 Nm)
        Stage 2:  18 lb.ft (25 Nm)