Installation Procedure
Drive Motor Rear Mount (2) - Install
- Drive Motor Rear Mount Bolt-M12 x 60.9 (1) - Install NEW and tighten [3x] - Fastener Specifications
- WARNING:
The transmission may weigh in excess of 215 kg (475 lbs), either by itself or in combination with additional components, use extreme care when installing, removing, or moving the transmission. Assistance from a hoist and/or an assistant may be required.
- Ensure that lifting equipment can properly support the transmission and any additional components.
- Ensure rigging applies vertical force to the lifting points and never horizontal.
- The use of a load leveler is recommended.
Failure to follow these guidelines can result in personal injury and/or component damage.
CAUTION:Prior to installing an electric drive transmission, make sure the shipping lifting brackets are removed from the transmission. Failure to remove the shipping lifting brackets can cause damage to the vehicle.
Install the front electric drive transmission module (1).
Drive Motor Mount (1) - Install
- Drive Motor Mount Bolt (2) - Install NEW and tighten [3x] - Fastener Specifications
- Drive Motor Mount Bolt (3) - Install NEW and tighten - Fastener Specifications
- Connect the wiring harness retainers as necessary.
- NOTE:
Some components not shown for graphic clarity.
Drive Motor Mount (2) - Install
- Drive Motor Mount Bolt (1) - Install NEW and tighten - Fastener Specifications [4x]
- Drive Motor Mount Bolt (3) - Install NEW and tighten - Fastener Specifications
- Connect the wiring harness retainers as necessary.
- NOTE:
Some components not shown for graphic clarity.
CAUTION:Refer to Torque-to-Yield Fastener Caution .
Drive Motor Rear Mount Bolt (2) - Install NEW and tighten - Fastener Specifications
Remove the 2 EN-36857 Engine Lift Bracket (2) then remove the 2 EN-52059 Engine Support Fixture Adapter Bolts - M10 (1).
Install the engine wiring harness (1) and engine wiring harness conduit (2) as necessary.
- Engine Wiring Harness Conduit Bolt (3) - Install and tighten - Fastener Specifications
- Connect the wiring harness retainers as necessary.
Engine Wiring Harness Ground Nut (1) - Install and tighten [2x] - Fastener Specifications
- Engine Wiring Harness Battery Lead Nut (2) - Install and tighten - Fastener Specifications
- Install the wiring harness.
Output Shaft Seal - Left Side (2) - Install NEW
- Output Shaft Retaining Ring - Left Side (1) - Install NEW
Front Wheel Drive Shaft Washer - Left Side (1) - Install NEW
- Apply a thin coating of grease to the splines of the left front wheel drive half shaft. Adhesives, Fluids, Lubricants, and Sealers
- CAUTION:
Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.
Front Wheel Drive Half Shaft - Left Side (1) - Install
- With the aid of an assistant, reposition the steering knuckle and install the left front wheel drive half shaft into the steering knuckle.
Install the left front control front link (1) and left front control rear link (2) into the steering knuckle.
Front Upper Control Arm Ball Stud Nut - Left Side (1) - Install and tighten - Fastener Specifications
Front Upper Control Arm Ball Stud Nut - Left Side (1) - Install and tighten - Fastener Specifications
Steering Linkage Outer Tie Rod Nut - Left Side (1) Install and tighten - Fastener Specifications
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Remove loose debris from internal and external threads using compressed air.
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
- Install the brake caliper and bracket assembly - Left Side (1)
- Front Brake Caliper Bracket Bolt - Left Side (2) - Install and tighten [2x] - Fastener Specifications
Front Brake Hose - Left Side (2) @ Steering Knuckle - Reposition
- Front Brake Hose Bracket Bolt - Left Side (1) - Install and tighten - Fastener Specifications
Apply a light coat of wheel speed anti-corrosion grease to the left front wheel speed sensor (1) and mounting pad on the steering knuckle. Adhesives, Fluids, Lubricants, and Sealers
- Front Wheel Speed Sensor - Left Side (2) @ Steering Knuckle - Install
- Front Wheel Speed Sensor Bolt - Left Side (1) - Install and tighten [2x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Output Shaft Seal - Right Side (2) - Install NEW
- Output Shaft Retaining Ring - Right Side (1) - Install NEW
- NOTE:
Left side shown, right side similar.
Front Wheel Drive Shaft Washer - Right Side (1) - Install NEW
- Apply a thin coating of grease to the splines of the right front wheel drive half shaft. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Left side shown, right side similar.
CAUTION:Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.
Front Wheel Drive Half Shaft - Right Side (1) - Install
- With the aid of an assistant, reposition the steering knuckle and install the right front wheel drive half shaft into the steering knuckle.
- NOTE:
Left side shown, right side similar.
Install the right front control front link (1) and right front control rear link (2) into the steering knuckle.
- NOTE:
Left side shown, right side similar.
Front Upper Control Arm Ball Stud Nut - Right Side (1) - Install and tighten - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Front Upper Control Arm Ball Stud Nut - Right Side (1) - Install and tighten - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Steering Linkage Outer Tie Rod Nut - Right Side (1) Install and tighten - Fastener Specifications
- NOTE:
Left side shown, right side similar.
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Remove loose debris from internal and external threads using compressed air.
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
- Install the brake caliper and bracket assembly. (1)
- Front Brake Caliper Bracket Bolt - Right Side (2) - Install and tighten [2x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Front Brake Hose - Right Side (2) @ Steering Knuckle - Reposition
- Front Brake Hose Bracket Bolt - Right Side (1) - Install and tighten - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Apply a light coat of wheel speed anti-corrosion grease to the left front wheel speed sensor (1) and mounting pad on the steering knuckle. Adhesives, Fluids, Lubricants, and Sealers
- Front Wheel Speed Sensor - Right Side (2) @ Steering Knuckle - Install
- Front Wheel Speed Sensor Bolt - Right Side (1) - Install and tighten [2x] - Fastener Specifications
- Have an assistant apply the brakes.
- CAUTION:
DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.
Front Wheel Drive Shaft Nut - Left Side and Right Side (1) - Install and tighten [2x] - Fastener Specifications
- Have an assistant release the brakes.
- Install the front tire and wheel assembly. Tire and Wheel Removal and Installation
Drive Motor Power Distribution Control Module Hose Clip (2) - Install
- Drive Motor Battery Coolant Flow Control Valve Hose (1) @ Drive Motor Battery Coolant Cooler - Install
- Retainer (3) - Engage
Drive Motor Control Module Radiator Outlet Hose (1) @ Automatic Transmission Fluid Cooling Exchanger - Install
- Retainer (2) - Engage
- Connect the electrical connectors and install the wiring harness retainers as necessary.
Wiring Harness Retainer (1) - Install
- Electrical Connector (2) @ Drive Motor Battery Coolant Cooler - Connect
Drive Motor Power Distribution Control Module Hose Strap (3) - Install
Drive Motor Control Module Cooling Inlet Hose (2) @ Front Electric Drive Transmission Module - Install
- Retainer (1) - Engage
High Voltage Battery Heater Module Coolant Hose (3) @ High Voltage Battery Heater Module - Install
- Retainer (1) - Engage
- Install the high voltage battery heater module coolant hose retainers as necessary.
Auxiliary Heater Inlet and Outlet Hose Clip (4) - Install
High Voltage Battery Coolant Inlet Secondary Hose Clip (2) - Install
- High Voltage Battery Coolant Inlet Hose (1) @ Drive Motor Battery Coolant Cooler - Install
- Retainer (3) - Engage
Drive Motor Battery Control Module Bracket Nut (4) - Install and tighten - Fastener Specifications
- Drive Motor Power Distribution Control Module Hose Clip (1) - Install
- High Voltage Battery Heater Module Coolant Hose Retainer (3) - Install
High Voltage Battery Coolant Inlet Secondary Hose Clip (4) - Install
- High Voltage Battery Coolant Cooler Inlet Hose (2) @ Drive Motor Battery Coolant Cooler - Install
- Retainer (1) - Engage
- Electrical Connector (3) - Connect
High Voltage Battery Coolant Cooler Inlet Hose (1) @ High Voltage Battery Radiator Outlet Hose - Install
- Retainer (2) - Engage
Auxiliary Drive Motor Control Module Cooling Inlet Hose (2) - Install
- Drive Motor Battery Control Module Bracket Nut (4) - Install and tighten - Fastener Specifications
- Retainer (1) - Engage
- Electrical Connector (3) - Connect
- Install the drive motor control module coolant pump hose strap.
Auxiliary Drive Motor Control Module Cooling Inlet Hose (2) @ Hybrid/Electric Vehicle Propulsion System Coolant Control Valve 1 - Install
- Retainer (1) - Engage
- CAUTION:
Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution .
Air Conditioning Evaporator Seal (3) - Install NEW
- Air Conditioning Evaporator Hose (2) @ Air Conditioning with Motor Compressor - Install
- Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) @ Air Conditioning with Motor Compressor - Install and tighten - Fastener Specifications
Electrical Connector (1) @ Air Conditioning Refrigerant Pressure and Temperature Sensor - Connect
Air Conditioning Compressor and Condenser Hose Seal - Small (2) - Install NEW
- Air Conditioning Compressor and Condenser Hose Seal - Large (1) - Install NEW
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe (3) @ Heater and Air Conditioning Evaporator and Blower Module - Install
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe Nut (5) @ Heater and Air Conditioning Evaporator and Blower Module - Install and tighten - Fastener Specifications
- Electrical Connector (4) @ Air Conditioning Refrigerant Temperature Sensor - Connect
Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe (2) @ Front Wheelhouse Panel - Right Side - Install
- Air Conditioning Evaporator Tube Bracket Nut (1) - Install and tighten - Fastener Specifications
Air Conditioning Evaporator Seal (3) - Install NEW
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe (2) @ Air Conditioning Receiver and Dehydrator - Install
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe Nut (1) @ Air Conditioning Receiver and Dehydrator - Install and tighten - Fastener Specifications
Install the windshield washer nozzle extension hose retainers as necessary.
- Air Conditioning Condenser Refrigerant Flow Valve Bracket Bolt (4) - Install and tighten [2x] - Fastener Specifications
- Electrical Connector (2) @ Air Conditioning Condenser Refrigerant Flow Valve - Connect
- Air Conditioning Evaporator Tube Bracket Nut (1) @ Air Conditioning Receiver and Dehydrator - Install and tighten - Fastener Specifications
Air Conditioning Compressor and Condenser Hose Seal (1) - Install NEW
- Air Conditioning Compressor Hose (2) @ Air Conditioning Condenser Refrigerant Flow Valve - Install
- Air Conditioning Compressor Hose Nut (3) @ Air Conditioning Condenser Refrigerant Flow Valve - Install and tighten - Fastener Specifications
Air Conditioning Evaporator Seal - Small (2) - Install NEW
- Air Conditioning Evaporator Seal - Large (3) - Install NEW
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Auxiliary Pipe - Install
Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe Nut (1) @ Heater and Air Conditioning Evaporator and Blower Module (2) - Install and tighten - Fastener Specifications
- Connect the electrical connectors and install the wiring harness retainers as necessary.
Air Conditioning Evaporator Seal - Small (1) - Install NEW [2x]
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Auxiliary Pipe (2) - Install [2x]
- Air Conditioning Condenser Hose Bolt (3) @ Air Conditioning Refrigerant Heat Exchanger - Install and tighten [2x] - Fastener Specifications
Air Conditioning Evaporator Tube Bracket Nut (1) @ Floor Panel Number 1 Cross Bar - Install and tighten - Fastener Specifications
Air Conditioning Evaporator Tube Nut (1) @ Front Wheelhouse Front Panel - Install and tighten - Fastener Specifications
Install the engine wiring harness with the wiring harness bracket (3).
- Wiring Harness Bracket (3) @ Front Wheelhouse Panel - Right Side - Install
- Wiring Harness Bracket Nut (2) @ Wiring Harness Bracket (3) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Connector (1) @ Body Wiring Harness - Connect
Wiring Harness Bracket Nut (3) - Install and tighten - Fastener Specifications
- Retainer (2) @ Wiring Harness Bracket - Install
- Engine Wiring Harness Ground Bolt (1) - Install and tighten - Fastener Specifications
Air Conditioning Evaporator Seal - Large (3) Install NEW
- Air Conditioning Evaporator Seal - Small (2) - Install NEW
- Air Conditioning Cooler Valve Hose (1) @ Drive Motor Battery Coolant Cooler - Install
Air Conditioning Cooler Valve Hose (3) @ Drive Motor Battery Coolant Cooler - Install
- Air Conditioning Cooler Valve Hose Nut (2) - Install and tighten [2x] - Fastener Specifications
- Electrical Connector (1) @ Air Conditioning Refrigerant Temperature Sensor - Connect
Air Conditioning Evaporator Seal - Large (1) - Install NEW
- Air Conditioning Evaporator Seal - Small (4) - Install NEW
- Air Conditioning Cooler Valve Hose (2) @ Heater and Air Conditioning Evaporator and Blower Module Refrigerant Auxiliary Pipe - Install
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe Nut (3) @ Air Conditioning Cooler Valve Hose (2) - Install and tighten - Fastener Specifications
Air Conditioning Evaporator Seal - Small (3) - Install NEW
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Auxiliary Pipe (2) @ Receiver and Dehydrator - Install
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe Nut (1) @ Receiver and Dehydrator - Install and tighten - Fastener Specifications
Air Conditioning Evaporator Seal - Large (4) - Install NEW
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Auxiliary Pipe (2) @ Air Conditioning Evaporator Hose - Install
- Heater and Air Conditioning Evaporator and Blower Module Refrigerant Pipe Nut (1) @ Air Conditioning Evaporator Hose - Install and tighten - Fastener Specifications
- Electrical Connector (3) @ Air Conditioning Refrigerant Pressure and Temperature Sensor - Connect
Battery Tray (1) - Install
Battery Tray Brace Nut (2) - Install and tighten - Fastener Specifications
- Battery Tray Support Bolt (1) - Install and tighten - Fastener Specifications
Battery Tray Support Bolt (1) - Install and tighten [3x] - Fastener Specifications
Install the body wiring harness retainers (1).
Engine Wiring Harness Fuse Block Bracket (4) - Install
- Install the three electrical connectors (3).
- Engine Wiring Harness Junction Block Shield Bolt (2) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Junction Block Shield Nut (1) - Install and tighten [2x] - Fastener Specifications
Engine Wiring Harness Junction Block (2) - Install
- Engine Wiring Harness Junction Block (1) - Tighten - Fastener Specifications
Install wiring harness terminals (4).
- Engine Wiring Harness Fuse Block Nut-Small (3) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Battery Lead Nut (2) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Fuse Block Nut-Large (1) - Install and tighten - Fastener Specifications
Engine Wiring Harness Fuse Block Cover (2) - Install
- Retaining Tab (1) - Engage [2x]
Engine Wiring Harness Fuse Block Cover (2) - Install
- Retaining Tab (1) - Engage [2x]
Battery (1) - Install
Battery Hold Down Retainer (2) - Install
- Battery Hold Down Retainer Bolt (1) - Install and tighten [2x] - Fastener Specifications
Battery Distribution Engine Compartment Fuse Block (3) - Install
- Retaining Tab (2) - Engage [2x]
- Battery Distribution Engine Compartment Fuse Block (1) - Tighten - Fastener Specifications
Battery Distribution Engine Compartment Fuse Block Cover (2) - Install
- Retaining Tab (1) - Engage [2x]
Battery Hold Down Retainer (2) - Install
- Battery Retainer Nut (1) - Install and tighten [2x] - Fastener Specifications
Front Trim Finish Compartment Support (2) - Install
- Front Trim Finish Compartment Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Connect the electrical connectors and install the wiring harness retainers as necessary.
Front Compartment Front Sight Shield (2) Install
With the aid of an assistant, install the hood. (2)
- Hood Hinge Nut (1) - Install and tighten [4x] - Fastener Specifications
- NOTE:
Ensure the clip is fully seated when the rod is reinstalled. If the clip cannot be fully seated, a new rod should be installed.
Hood Strut - Left Side and Right Side (1) - Install [2x]
- Install the 4 metal clips to each ends of the left and right side hood struts (1).
- Recharge the refrigerant. Refrigerant Recovery and Recharging
- Fill the cooling system. Drive Motor Battery Cooling System Draining and Filling
- Fill the electric drive transmission. Transmission Fluid Drain and Fill
- Enable the high voltage system. High Voltage Enabling
- Perform the necessary programming and setup procedure: Control Module References
Refer to Torque-to-Yield Fastener Caution .
Refer to Fastener Caution
Refer to Torque-to-Yield Fastener Caution .
Refer to Torque-to-Yield Fastener Caution .
Refer to Torque-to-Yield Fastener Caution .