Volt

Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, Refer toSpecial Tools

Note: Replace corroded hose clamps and brackets.

1. Drain the cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling
2. Remove the air conditioning compressor and evaporator hose. Refer to Air Conditioning Compressor and Evaporator Hose Replacement
3. Reposition the air conditioning evaporator thermal expansion valve tubes from the TXV valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Tube Replacement



4. Remove the drive motor battery coolant cooler inlet hose assembly clamp (1) at the drive motor battery coolant cooler using BO-38185 Hose Clamp Pliers .
5. Remove the drive motor battery coolant cooler inlet hose assembly clamps (2) at the drive motor battery coolant flow control valve using BO-38185 Hose Clamp Pliers .
6. Remove the drive motor battery coolant cooler inlet hose assembly (3) from the drive motor battery coolant cooler and drive motor battery coolant flow control valve.
7. Remove the exhaust pipe heat shield front. Refer to Exhaust Pipe Heat Shield Replacement : Rear → Center → Front



8. Disconnect the drive motor battery coolant cooler inlet hose assembly quick disconnect fitting (1) at the battery.
9. Remove the drive motor battery coolant cooler inlet hose assembly (2) from the battery.



10. Disconnect the drive motor battery coolant cooler inlet hose assembly quick disconnect fitting (1) from drive motor battery inlet hose and drive motor battery coolant cooler outlet hose and drive motor battery coolant cooler inlet hose.
11. Remove the drive motor battery coolant cooler inlet hose assembly bracket nuts (2) from the body.
12. Remove the drive motor battery coolant cooler inlet hose from the vehicle.

1. Install the drive motor battery coolant cooler inlet hose from the vehicle.



2. Install the drive motor battery coolant cooler inlet hose assembly bracket nuts (2) to the body.
3. Connect the drive motor battery coolant cooler inlet hose assembly quick disconnect fitting (1) to the drive motor battery inlet hose and drive motor battery coolant cooler outlet hose and drive motor battery coolant cooler inlet hose.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the drive motor battery coolant cooler inlet hose assembly (2) to the battery and tighten to 9 N·m (80 lb in).



5. Connect the drive motor battery coolant cooler inlet hose assembly quick disconnect fitting (1) at the battery.
6. Install the exhaust pipe heat shield front. Refer to Exhaust Pipe Heat Shield Replacement : Rear → Center → Front



7. Install the drive motor battery coolant cooler inlet hose assembly (3) to the drive motor battery coolant cooler and drive motor battery coolant flow control valve.
8. Install the drive motor battery coolant cooler inlet hose assembly clamps (2) at the drive motor battery coolant flow control valve using BO-38185 Hose Clamp Pliers .
9. Install the drive motor battery coolant cooler inlet hose assembly clamp (1) at the drive motor battery coolant cooler using BO-38185 Hose Clamp Pliers.
10. Reposition the air conditioning evaporator thermal expansion valve tubes from the TXV valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Tube Replacement
11. Install the air conditioning compressor and evaporator hose. Refer to Air Conditioning Compressor and Evaporator Hose Replacement
12. Fill the cooling system. Refer to Cooling System Draining and Filling