Battery Box Replacement

BATTERY BOX REPLACEMENT

REMOVAL PROCEDURE




1. Remove the battery.
2. Remove the air conditioning (A/C) evaporator outlet hose bolt from the battery box.
3. Position the A/C evaporator outlet hose out of the way.




4. Remove the underhood fuse block (UHFB) cover (1).
5. Remove the positive battery cable and electronic power steering (EPS) wire connection nut.
6. Remove the positive battery cable and electronic power steering (EPS) wire (2) from the B+ terminal at UHFB.




7. Remove the engine wire harness retainer (1) from the battery box.
8. Remove the engine wire harness connector (2) from the battery box.




9. Loosen the UHFB connector retaining bolts.
10. Unclip and remove the UHFB from the UHFB housing.
11. Disconnect the forward lamp harness connectors from the UHFB.
12. Disconnect the UHFB connectors from the UHFB.
13. Remove the UHFB connectors from the UHFB housing.

IMPORTANT: Protect the disconnected harness from contamination during service.

14. Position all the electrical harnesses/connectors and battery cables out of the way of the battery box.




15. Remove the coolant surge tank bolts from the inner fender.
16. Lift the coolant surge tank up to gain access to the battery box bolt on the inner fender.




17. Remove the battery box bolt (2) from under the coolant surge tank.
18. Remove the battery box bolts (1) from inside the battery box.




19. Separate the air inlet duct from the battery box.
20. Remove the battery box from the vehicle.

INSTALLATION PROCEDURE




1. Install the battery box to the vehicle while aligning the air inlet and outlet ducts to the battery box.

IMPORTANT: Alignment of the air inlet and outlet ducts with the battery box is critical to ensure proper airflow to the battery.




2. Install the battery box bolts (1) inside the battery box.

Tighten the bolts (1) to 15 N.m (11 lb ft).

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: Insure the battery box is sitting properly on the battery tray and the air inlet and outlet ducts are properly installed to the battery box.

3. Install the battery box outer bolt (2) under the coolant surge tank.

Tighten the bolt (2) to 10 N.m (89 lb in).




4. Install the coolant surge tank to the inner fender.

IMPORTANT: Insure the coolant surge tank alignment tab is inserted into the inner fender slot when installed.

5. Install the coolant surge tank bolts

Tighten the bolts to 6 N.m (53 lb in).




6. Position the battery cables into the battery box.
7. Install the UHFB connectors to the UHFB housing.
8. Connect the forward lamp harness connectors to the UHFB.
9. Install the UHFB to the UHFB housing while insuring that all UHFB electrical connectors are properly aligned.
10. Insure the UHFB is fully installed and clipped into the UHFB housing.

Tighten the UHFB connector bolts to 4 N.m (35 lb in).




11. Install the engine wire harness connector (2) to the battery box.
12. Install the engine wire harness retainer (1) to the battery box.




13. Install the positive battery cable and electronic power steering (EPS) wire (2) to the B+ terminal at UHFB.
14. Install the positive battery cable and electronic power steering (EPS) wire connection nut.

Tighten the nut to 15 N.m (11 lb ft).

15. Install the underhood fuse block (UHFB) cover (1).




16. Position the A/C evaporator outlet hose to the battery box.
17. Install the A/C evaporator outlet hose bolt to the battery box.

Tighten the bolt to 15 N.m (11 lb ft).

18. Install the battery.