Drive Motor Battery Coolant Cooler Replacement
Single Use Fasteners and Components

Air Conditioning Compressor Hose Seal[2x]

Removal Procedure

  1. Drain the cooling system.Drive Motor Battery Cooling System Draining and Filling
  2. Recover the refrigerant.Refrigerant Recovery and Recharging

    3. Object ID: 5844130
  3. Retainer(2)»Release
  4. Drive Motor Generator Control Module Coolant Pump Hose(1)@Drive Motor Battery Radiator Surge Tank»Remove
  5. Depress the retainers (4) on each side of the drive motor battery surge tank inlet hose (3) and remove the hose from the drive motor battery surge tank.

    6. Object ID: 5830431
  6. Radiator Surge Tank Nut(2)»Remove[2x]
  7. Drive Motor Battery Radiator Surge Tank(1)»Remove

    8. Object ID: 5844139
  8. Radiator Surge Tank Bracket Bolt(1)»Remove[2x]

    9. Object ID: 5830645
  9. Radiator Surge Tank Bracket(1)»Remove

    10. Object ID: 5835322
  10. Disconnect the electrical connector.
  11. Air Conditioning Evaporator Electronic Expansion Valve Nut(1)»Remove
  12. Air Conditioning Evaporator Hose(2)@Drive Motor Battery Coolant Cooler»Remove
  13. Air Conditioning Compressor Hose Seal(3)»Remove and DISCARD

    14. Object ID: 5921613
  14. Air Conditioning Evaporator Electronic Expansion Valve Nut(2)»Remove
  15. Air Conditioning Evaporator Tube(1)@Drive Motor Battery Coolant Cooler»Remove
  16. Air Conditioning Compressor Hose Seal(3)»Remove and DISCARD
  17. Raise and support the vehicle.Lifting and Jacking the Vehicle

    18. Object ID: 5911971
  18. Front Compartment Insulator Bolt(1)»Remove[9x]
  19. Front Compartment Air Deflector Bolt(2)»Remove[4x]

    20. Object ID: 5911973
  20. Front Compartment Air Deflector(1)»Remove

    21. Object ID: 5914883
  21. Electrical Connector(1)»Disconnect
  22. Wiring Harness Clip(2)»Remove

    23. Object ID: 5914881
  23. Drive Motor Battery Coolant Cooler Bracket Bolt(1)»Remove[2x]

    24. Object ID: 5864766
  24. Instrument Panel Compartment Bolt(1)»Remove[12x]

    25. Object ID: 5864768
  25. Reposition the instrument panel compartment (1) to access the instrument panel wiring harness.
  26. Disconnect all electrical connectors.
  27. Instrument Panel Compartment(1)»Remove

    28. Object ID: 5898420
  28. Instrument Panel Tie Bar Brace Bolt(1)»Remove[3x]

    29. Object ID: 5898423
  29. Radio Speaker Amplifier Nut(1)»Remove
  30. Accessory DC Power Control Module Bracket Nut(2)»Remove
  31. Accessory DC Power Control Module Bracket(3)»Remove

    32. Object ID: 5898421
  32. Instrument Panel Center Support Bracket Nut(1)»Remove[3x]
  33. Instrument Panel Lower Bracket Nut(2)»Remove

    34. Object ID: 5898422
  34. Instrument Panel Tie Bar Brace(1)»Remove

    35. Object ID: 5898450
  35. Dash Extension Panel Bolt(1)@Module »Remove[5x]
  36. Disconnect the electrical connectors.

    37. Object ID: 5898452
  37. Dash Extension Panel Bolt(1)»Remove[11x]
  38. Dash Panel Side Extension(2)»Remove

    39. Object ID: 5910742

    Note: Some components not shown for graphic clarity.

  39. Electrical Connector(1)»Disconnect

    40. Object ID: 5910745
  40. Retainer(1)»Release
  41. High Voltage Battery Coolant Cooler Inlet Hose(3)@Drive Motor Battery Coolant Cooler»Remove
  42. Heater Inlet Hose Clip(2)»Remove

    43. Object ID: 6150686
  43. Electrical Connector(1)»Disconnect
  44. Retainer(3)»Release
  45. High Voltage Battery Coolant Inlet Hose(2)@Drive Motor Battery Coolant Cooler»Remove

    46. Object ID: 5914880
  46. Electrical Connector(1)»Disconnect

    47. Object ID: 5914882
  47. Drive Motor Battery Coolant Cooler Bracket Nut(1)»Remove[2x]
  48. Drive Motor Battery Coolant Cooler(2)»Remove

Installation Procedure


    Object ID: 5914882
  1. Drive Motor Battery Coolant Cooler(2)»Install

    2. Caution: Refer to Fastener Caution.

  2. Drive Motor Battery Coolant Cooler Bracket Nut(1)»Install and tighten[2x]—Fastener Specifications

    3. Object ID: 5914880
  3. Electrical Connector(1)»Connect

    4. Object ID: 6150686
  4. High Voltage Battery Coolant Inlet Hose(2)@Drive Motor Battery Coolant Cooler»Install
  5. Retainer(3)»Engage
  6. Electrical Connector(1)»Connect

    7. Object ID: 5910745
  7. Heater Inlet Hose Clip(2)»Install
  8. High Voltage Battery Coolant Cooler Inlet Hose(3)@Drive Motor Battery Coolant Cooler»Install
  9. Retainer(1)»Engage

    10. Object ID: 5910742

    Note: Some components not shown for graphic clarity.

  10. Electrical Connector(1)»Connect

    11. Object ID: 5898452
  11. Dash Panel Side Extension(2)»Install
  12. Dash Extension Panel Bolt(1)»Install and tighten[11x]—Fastener Specifications

    13. Object ID: 5898450
  13. Connect the electrical connectors.
  14. Dash Extension Panel Bolt(1)@Module »Install and tighten[5x]—Fastener Specifications

    15. Object ID: 5898422
  15. Instrument Panel Tie Bar Brace(1)»Install

    16. Object ID: 5898421
  16. Instrument Panel Center Support Bracket Nut(1)»Install and tighten[3x]—Fastener Specifications
  17. Instrument Panel Lower Bracket Nut(2)»Install and tighten—Fastener Specifications

    18. Object ID: 5898423
  18. Accessory DC Power Control Module Bracket(3)»Install
  19. Accessory DC Power Control Module Bracket Nut(2)»Install and tighten—Fastener Specifications
  20. Radio Speaker Amplifier Nut(1)»Install and tighten—Fastener Specifications

    21. Object ID: 5898420
  21. Instrument Panel Tie Bar Brace Bolt(1)»Install and tighten[3x]—Fastener Specifications

    22. Object ID: 5864768
  22. Connect the electrical connector.

    23. Object ID: 5864766
  23. Instrument Panel Compartment(1)»Install

    24. Object ID: 5914881
  24. Drive Motor Battery Coolant Cooler Bracket Bolt(1)»Install and tighten[2x]—Fastener Specifications

    25. Object ID: 5914883
  25. Wiring Harness Clip(2)»Install
  26. Electrical Connector(1)»Connect

    27. Object ID: 5911973

    Note: The proper position of the front compartment air deflector is between the front bumper lower fascia and the front cradle.

  27. Front Compartment Air Deflector(1)»Install

    28. Object ID: 5911971
  28. Front Compartment Air Deflector Bolt(2)»Install and tighten[4x]—Fastener Specifications
  29. Front Compartment Insulator Bolt(1)»Install and tighten[9x]—Fastener Specifications
  30. Remove the support and lower the vehicle.

    31. Object ID: 5921613

    Note: Some components not shown for graphic clarity.

    Caution: Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution.

  31. Air Conditioning Compressor Hose Seal(3)»Install NEW
  32. Air Conditioning Evaporator Tube(1)@Drive Motor Battery Coolant Cooler»Install
  33. Air Conditioning Evaporator Electronic Expansion Valve Nut(2)»Install and tighten—Fastener Specifications

    34. Object ID: 5835322
  34. Air Conditioning Compressor Hose Seal(3)»Install NEW
  35. Air Conditioning Evaporator Hose(2)»Install
  36. Air Conditioning Evaporator Electronic Expansion Valve Nut(1)»Install and tighten—Fastener Specifications
  37. Connect the electrical connector.

    38. Object ID: 5830645
  38. Radiator Surge Tank Bracket(1)»Install

    39. Object ID: 5844139
  39. Radiator Surge Tank Bracket Bolt(1)»Install and tighten[2x]—Fastener Specifications

    40. Object ID: 5830431
  40. Drive Motor Battery Radiator Surge Tank(1)»Install
  41. Radiator Surge Tank Nut(2)»Install and tighten[2x]—Fastener Specifications

    42. Object ID: 5844130

    Note: Ensure that the drive motor battery surge tank inlet hose (3) is fully seated at the drive motor battery radiator surge tank.

  42. Drive Motor Battery Surge Tank Inlet Hose(3)@Drive Motor Battery Radiator Surge Tank»Install
  43. Drive Motor Generator Control Module Coolant Pump Hose(1)@Drive Motor Battery Radiator Surge Tank»Install
  44. Retainer(2)»Engage
  45. Recharge the refrigerant.Refrigerant Recovery and Recharging
  46. Fill the drive motor battery cooling system to the proper level. Drive Motor Battery Cooling System Draining and Filling
  47. Inspect for coolant leaks.