LI-ION BATTERY UPFIT KIT
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1 LI-ION BATTERY UPFIT KIT P/N APPLICATION E2, E4, E6, and el XD BEFORE YOU BEGIN Read these instructions and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information. KIT CONTENTS Full installation of this kit also requires the following additional parts (sold separately): 12V Battery, PN Li-Ion Control Module, PN Full installation of this kit also requires one of the following additional parts (sold separately): 12.4 kw Brammo Battery, 15v/4.1 kw, PN Brammo Battery, 30v/8.3 kw, PN kw Brammo Battery, 44v/8.9 Kw, PN Full installation of this kit also requires one of the following additional parts (sold separately): Li-Ion Harness e2/el XD, PN Li-Ion Harness e4, PN Li-Ion Harness e6, PN Instr Rev Page 1 of 11
2 This Kit includes: REF QTY PART DESCRIPTION PART NUMBER 1 1 Weld Battery Tray, Li-ion (Unused) Li-ion Battery Cable, Positive, Short Li-ion Battery Cable, Positive, Long Li-ion Battery Cable, Negative, 12V Li-ion Battery Cable, Interconnect Positive Terminal Battery Bracket, Support Battery Bracket, Hold Panduit Strap, 11" Mount Bracket Terminal Edge Clip, with Side Strap Screw, Socket Head, M5 X 0.8 X Screw, Hex Flange Head, M6 X 1.0 X Screw, Hex Flange Head, M8 X 1.25 X Screw, Hex Flange Head, M6 X 1.0 X Screw, Hex Flange Head, M8 X 1.25 X Instr Rev Page 2 of 11
3 REF QTY PART DESCRIPTION PART NUMBER 18 4 Screw, Hex Flange head, M8 X 1.25 X Screw, Hex Flange Head, M10 X 1.25 X Screw, Phillips Hex Head, M6 X 1.0 X Screw, Hex Head, M6 X 1 X Nut, Nylon Locking, M5 X Nut, Flange, Nylon Locking, M8 X Nut, Flange, Nylon Locking, M10 X Nut, Flange, Nylon Locking, M6 X 1.0, Nyloc Battery Nut, M6 X 1, LPS Washer - 3/8, Spring Lock Washer X.750 X Washer X 18.0 X Washer - 3/ Washer X.563 X Instructions TOOLS REQUIRED Safety Glasses Pliers, Side Cutting Screwdriver, Slotted Socket Set, Hex Bit, Metric Socket Set, Metric Socket Set, SAE Socket Set, Deep Well, SAE Torque Wrench Wrench Set, Metric Wrench Set, Ratcheting, SAE IMPORTANT Your Li-Ion Battery Upfit Kit is exclusively designed for your vehicle. Please read the installation instructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For your safety, and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown. ASSEMBLY TIME Approximately 75 minutes Instr Rev Page 3 of 11
4 INSTALLATION INSTRUCTIONS VEHICLE PREPARATION 1. Place gear selector in N. Apply parking brake. Turn key to OFF position and remove from vehicle. 2. Flip open charge port door and remove two thumb screws A. Pull hood in direction of arrow (parallel to ground) and remove from vehicle. 4. Battery access cover removal. a. For e2, e4, and e6 : Remove rear battery access cover C. NOTE Battery access cover is attached with Velcro to the rear aluminum frame. 3. Disconnect front vehicle main connector B. b. For el XD: Remove six hex head screws D and three screws E to remove rear battery access cover C. Instr Rev Page 4 of 11
5 DISCONNECT AND REMOVE STOCK BATTERY 1. Disconnect all battery cables starting with main ground cable A and battery temperature sensor B on front-most post on far right battery, followed by main harness connections C by removing nuts D and washers EF. 3. Remove nuts J and washers K from long tie down bolts L. Remove battery hold down brackets M and long tie down bolts L. 4. Remove old flooded batteries N or maintenance free batteries from battery tray. REPLACE BATTERY TRAY 2. Remove and retain screw G and washer H. Disconnect +12V connector J from Battery Management Controller. Wrap cable end with electrical tape and tape or cable tie to main battery cable. Instr Remove nuts A and washers B from screws C holding battery tray D in place and remove battery tray from vehicle. Rev Page 5 of 11
6 2. Install terminal mounting bracket s to lithium ion battery tray q with screws j, washers 3!, and nuts 2%. Install terminal u to bracket s with screws f, washers 3!, and nuts 2@. Torque fastener to specification. M6 Screw j: 96 in. lbs. (11 Nm) M5 Screw f: 24 in. lbs. (3 Nm) 4. Install new lithium-ion battery tray q with four screws l, washers 3), and nuts 2$. Torque fasteners 2$ to specification. 37 ft. lbs. (50 Nm) 3. Install 12V battery E (Sold Separately, PN ) and hold down bracket o with screws h, washers 2*, and nuts 2#. Install Lithium ion module F (Sold Separately, PN ) with two screws g, two washers 3! and two nuts 2%. Torque fasteners to specification. Battery Bracket Screw h: 18 ft. lbs. (24 Nm) Li-Ion Module Screw g: 24 in. lbs. (3 Nm) Instr Rev Page 6 of 11
7 ASSEMBLE AND INSTALL LI-ION BATTERIES 1. Install battery bracketsito both ends of lithium ion batteries: A (Sold separately, PN ), B (Sold separately, PN ) for 12.4 kw battery pack, and C (Sold separately, PN ) for 8.9 kw battery pack with screws 1(, washers 2( Torque fasteners to specification. 66 in. lbs (7.5 Nm) 2. Install assembled batteries and bracketsionto battery tray q with screws k, washers 2*, and nuts 2#. Note different positions for 12.4 kw battery pack and 8.9 kw battery pack kw A and B 18 ft. lbs (24 Nm) 12.4 kw A and B 8.9 kw C 8.9 kw C Instr Rev Page 7 of 11
8 3. Install appropriate Li-Ion Harness E by plugging large connector F into Li-Ion Module. Now plug connector G into large battery, remove blank plug from connector H and plug into small battery. Connect small cable J to positive battery terminal on small battery. Torque ALL already connected battery terminal connectors to specification. CONNECT BATTERY WIRING NOTE Vehicle not shown for clarity KW BATTERY CABLES AND LI-ION HARNESS 1. Install Positive Short battery cable e and positive cable from main harness A to positive terminal mount u. Install opposite end of Positive Short Cable e to post on small Li-Ion Battery B. DO NOT Torque battery post fasteners at this time. WARNING DO NOT Connect Main Harness Negative Battery Cable At This Time, or serious injury or damage to components may occur. WARNING 8 ft. lbs. (11 Nm) DO NOT Connect Main Harness Negative Battery Cable At This Time, or serious injury or damage to components may occur. 8.9 KW BATTERY CABLES 2. Connect Battery Cable Interconnect y between battery posts using two battery post washers C and screws D as shown. DO NOT torque battery connections at this time. 1. Install Positive Long Battery Cable r and main harness A to positive terminal mount u. Install opposite end of Positive Long Cable r to post on Li-Ion Battery B. DO NOT Torque battery post fasteners at this time. WARNING DO NOT Connect Main Harness Negative Battery Cable At This Time, or serious injury or damage to components may occur. Instr Rev Page 8 of 11
9 2. Install appropriate Li-Ion Harness E by plugging large connector F into Li-Ion Module and connector G into large battery. Connect small cable H to positive battery terminal on large battery. Torque ALL already connected battery terminal connectors to specification. WARNING DO NOT Connect Main Harness Negative Battery Cable At This Time, or serious injury or damage to components may occur. 8 ft. lbs. (11 Nm) 2. Insert battery nut 2^ into negative battery post. Connect Negative 12V Battery Cable t to 12v battery negative post using supplied battery screw 2). Route cable around rear along main harness as shown to main negative post. Torque screw to specification. WARNING DO NOT Connect Main Harness Negative Battery Cable At This Time, or serious injury or damage to components may occur. 45 in. lbs. (5 Nm) INSTALL 12V ACCESSORY BATTERY CABLES 1. Insert battery nut 2^ into positive battery post. Connect positive cable A to 12v battery positive post using supplied battery screw 2). Torque screw to specification. 45 in. lbs. (5 Nm) Instr Rev Page 9 of 11
10 HARNESS ROUTING 1. Route harnesses and attach to vehicle using cable ties a and edge clips d as shown. 3. Remove eight push rivets D from upper dash panel E. Slowly lift upper dash and disconnect switch F. 4. Route rest of harness through front plastic splash guard G. Install terminal harness H to accessory block J. Install harness connector K. 2. Plug lithium harness connector A into diagnostic port connector B and replace diagnostic port connector B with other lithium harness connector C. 5. Install relay L in fuse box M as shown. NOTE If vehicle is equipped with EPS or other CAN-Based accessories, see ACCESSORIES - CAN-BASED section of GEM Service Manual for more details on sequence of connections. 6. Reinstall upper dash panel E with retained pushpin rivets D. Make sure to connect all switches F. Instr Rev Page 10 of 11
11 7. Connect main harness N and 12v battery harness t Negative cables to negative battery post P. Torque fastener to specification. 8. Reconnect main vehicle disconnect. Reinstall battery cover and reinstall hood with thumb screws. 8 ft. lbs. (11 Nm) FEEDBACK FORM A feedback form has been created for the installer to provide any comments, questions or concerns about the installation instructions. The form is viewable on mobile devices by scanning the QR code or by clicking HERE if viewing on a PC. FEEDBACK FORM Instr Rev Page 11 of 11
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