Battery Tunnel Reinforcement Installation
Battery Tunnel Reinforcement InstallationNote
The following tools are required to complete the battery tunnel reinforcement procedure:
- A compact quality drill.
- Drill bits that will drill through high strength steel. The drill bits are provided in kit P/N22920448.
- A pneumatically powered pop rivet gun that accepts 6.35 mm (1/4 in), 4.76 mm (3/16 in), 3.96 mm (5/32 in) and 3.17 mm (1/8 in) rivets. This tool is available at multiple discount tool providers, such as Harbor Freight Industrial.
- Dual Cartridge Applicator for Pliogrip two-part polyurethane
- Small disposable brush for spreading the Pliogrip two-part polyurethane
- Butyl, 3M P/N 08578, or equivalent.
- RTV, P/N 88861417 (in Canada, use 88861418), (or equivalent)
Danger
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure includes the following steps:
- Identify how to disable high voltage.
- Identify how to test for the presence of high voltage.
- Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
- Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
- Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
- Visually and functionally inspect the gloves before use.
- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures may result in serious injury or death.
1. Disconnect and remove the high-voltage battery from the vehicle. Refer to Drive Motor Battery Replacement and Shipping in SI.
Caution
Do not pry on or contact the battery RESS cover while removing the aluminum crush limiters with screwdriver.
2. Remove the 4th and 5th aluminum crush limiters (indicated with red arrows in illustration) from the driver's and passenger's side of the battery RESS cover.
1. Place the tip of a small flat-blade screwdriver against the bottom of each aluminum crush limiter. Access the bottom of the crush limiter through the hole on the bottom side of the battery RESS cover.
2. Gently tap the end of the screwdriver with a small hammer. You may have to work around the bottom of the aluminum crush limiter, tapping it in a few locations to completely free the aluminum crush limiter from the cover.
Note
Butyl should only be applied in the chamfer (red face) of the crush limiter. Refer to illustration. Butyl should not be present in the metal-to-metal joint between RESS cover, reinforcement plate and longitudinal rails.
3. Apply a butyl-based sealer such as 3M Strip-Caulk 08578 (or equivalent) on the chamfer of the new aluminum crush limiters.
Note
The aluminum crush limiters are chamfered and must be installed with chamfer side down.
4. Press the four new aluminum crush limiters (1), into the battery RESS cover where the aluminum crush limiters were removed.
5. Install the new aluminum crush limiters by tapping lightly and evenly with small hammer.
6. Remove the excess butyl on the RESS cover.
7. Attach the reinforcement assembly (1) to the car body using the four shorter M10 bolts from the kit. Tighten bolts to 25 Nm (19 lb-ft). Make sure the reinforcement assembly is centered from side to side within the tunnel of the vehicle body.
8. Locate the front and rear plates to the car body and hold in position using two hand clamps or "C" clamps. Make sure the front and rear plates are centered from side to side on the tunnel reinforcement of the vehicle body.
9. Center punch all of the holes in the plates and reinforcement assembly before drilling the 3mm (1/8 in) pilot holes.
Caution
To increase the useful life of the drill bit, drill the holes into the vehicle body at a low speed. The appropriate drill speed will allow the drill bit to cut into the metal efficiently. The drill bit will remove metal chips or metal shavings from the high strength steel quickly if the appropriate drill speed is used. Ensure the drill used at a low speed for steps 10-14.
10. Drill 3mm (1/8 in) pilot holes into the vehicle body through the 20 existing holes in the front and rear plates. The three lower holes per plate will also go through the reinforcement assembly.
11. Drill 6.75mm (17/64 in) holes through the 20 pilot holes.
12. Remove the clamps and the front and rear plates. Set aside the plates.
Caution
To avoid vehicle damage, place a drill stop on drill bits to ensure drill does NOT enter the vehicle beyond 19 mm (¾ in) in depth.
13. Drill 3mm (1/8 in) pilot holes into the vehicle body through the 28 existing holes in the reinforcement assembly. Do not allow the drill bit to enter the vehicle body beyond 19 mm (3/4 in) in depth for the six upper holes on each side.
Caution
To avoid vehicle damage, place a drill stop on drill bits to ensure drill does NOT enter the vehicle beyond 19 mm (3/4 in) in depth.
14. Drill 6.75mm (17/64 in) holes through the 28 pilot holes from step 13. Use a drill stop or otherwise do not allow the drill bit to enter the car body beyond 19 mm (3/4 in) in depth for the six upper holes on each side.
15. Remove the four M10 bolts and the reinforcement assembly from the vehicle body. Set aside the reinforcement assembly and the bolts.
16. Deburr all of the drilled holes in the front and rear plates, the reinforcement assembly, and the vehicle body. Remove any metal shavings from the surfaces of the front and rear plates, the reinforcement assembly, and the vehicle body.
17. Clean all mating surfaces of the front and rear plates, the reinforcement assembly, and the vehicle body using isopropyl (rubbing) alcohol and a clean, lint-free cloth. Allow the alcohol to dry.
Caution
Ensure the Pliogrip two-part polyurethane mix is uniform in color BEFORE applying it to the parts. Discard the first 25 mm (1 in) of the mix that is not uniform. The color of the polyurethane varies. The illustrations in this bulletin show the polyurethane mix in black or green. The Pliogrip two-part polyurethane has a 30-minute open time. The application of the Pliogrip two-part polyurethane and the assembly of the reinforcement assembly must be completed in 30 minutes.
18. Apply approximately 5mm (3/16 in) beads of Pliogrip two-part polyurethane, P/N 7770B220, in the patterns shown onto the reinforcement assembly and the front and rear plates. Use a new mixing and dispensing tip, and ensure that both components of the polyurethane are dispensing and mixing from the dispensing tip prior to applying the polyurethane to the parts.
19. Coat drill holes and exposed metal with Pliogrip, P/N 7770B220, two-part polyurethane using a brush as shown in illustration.
20. Re-attach the reinforcement assembly to the vehicle body using the four shorter M10 bolts (1). Tighten bolts to 25 Nm (19 lb-ft). Make sure the reinforcement assembly is centered from side to side within the tunnel of the vehicle body. Ensure that the 6.75mm (17/64 in) holes drilled into the reinforcement assembly are aligned.
Caution
To ensure the pop rivets are installed correctly, use two hand clamps or "C" clamps to hold the plates into position. Make sure the rear plate is pressed against the vehicle body in each location as each rivet is being installed.
21. Re-locate the rear plate and install the 7 pop rivets (2), P/N 11561547, through the upper 6.75mm (17/64 in) holes. Make sure the rear plate is pressed against the vehicle body in each location as each pop rivet is being installed.
22. Re-locate the front plate and install 7 pop rivets (2), P/N 11561547, through the upper 6.75mm (17/64 in) holes. Make sure the front plate is pressed against the vehicle body in each location as each pop rivet is being installed.
23. Install the remaining 28 pop rivets (2), P/N 11561547, through the 6.75mm (17/64 in) holes of the reinforcement assembly. Make sure the reinforcement assembly is pressed against the vehicle body in each location as each pop rivet is being installed.
Note
The six longer rivets (3), P/N 11569698 are to be located in bottom of the front and rear plates.
24. Install the six pop rivets (3), P/N 11569698, through the lower 6.75mm (17/64 in) holes that were also drilled through the reinforcement assembly. Ensure the plate is pressed against the reinforcement assembly in each location as each pop rivet is being installed.
25. Grind flush any pop rivet mandrels that did not break off flush with the rivet head.
26. Wipe off any excess polyurethane that squeezed out around the reinforcement assembly or around the front and rear plates.
27. Apply RTV, P/N 88861417 (in Canada, use 88861418) (or equivalent), on and around each of the six upper rivet heads along each side of the reinforcement assembly. The other rivet head locations do not require sealer.
Caution
Remove and discard the four short M10 bolts from the reinforcement assembly. Discard the M10 and M8 bolts removed from the high-voltage battery. Thebattery tunnel reinforcement kit, PN 22920448, contains new M8 and M10 bolts. Use the new bolts to install the high-voltage battery to avoid vehicle damage.
28. Remove the four M10 bolts from the reinforcement assembly. Discard the M10 bolts.
29. Re-install and re-connect the high voltage battery using the 18 new M10 bolts, P/N 11588740, and four new M8 bolts, P/N 11588724, from the kit. Refer to Drive Motor Battery Replacement and Shipping in SI.
30. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.