HV Battery Air Leak Test

Correction code 161020010161020010
  • 1026636-00-A Pack Enclosure Leak Tester, HV Battery
  • 1140501-00-A Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-A Kit, Encl Leak Test Adapters, HV Battery

SPECIAL TOOLS

Pack Enclosure Leak Tester, HV Battery (1026636-00-A)
Pack Kit, Enclosure, Leak Test, HV Battery, Complete (1140501-00-A)
Kit, Encl Leak Test Adapters, HV Battery (1144879-00-A)

Procedure

  1. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  2. Remove the penthouse HV and penthouse 12V caps.
  3. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  4. Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
  5. Remove the bolts that attach the charge port to HV battery harness bracket at the penthouse, and then remove the bracket from the vehicle.
    Torque 10 Nm
  6. Release the clip that attaches the wiring harness to the LH lower C-pillar.
  7. Raise the handle to disconnect the wiring harness from the DC input assembly.
  8. Install the dummy plug to the DC input assembly.
  9. Install the dummy plug into the HVC connector.
  10. Remove and discard the breather from the penthouse probe lid cover.
  11. Install the leak test adapter plug into the penthouse probe lid cover.
  12. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  13. Remove and discard the breather from the RH HV battery vent shroud assembly.
  14. Install the second leak test adapter plug into the RH shroud assembly.
  15. Remove and discard the breather from the LH HV battery vent shroud assembly.
  16. Install the leak test adapter into the LH shroud assembly.
  17. Connect the pack enclosure leak tester to the leak test adapter in the LH HV battery shroud assembly.
  18. Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
  19. Fully close the regulator, and then open the inlet valve.
  20. Set the regulator to 0.15 psi.
  21. Open the outlet valve, and allow at least 45 seconds for the pressure to stabilize to 0.15 psi.
  22. Close the inlet valve, record the starting pressure displayed, and then start a 60-second timer.
  23. After 60 seconds record the ending pressure displayed.
  24. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.0054 psi, check the hose, adapter, and plug fittings, close the outlet valve and open the inlet valve, check the regulator pressure, and then retest from step 21. If the difference is still greater than 0.0054 psi, escalate a Toolbox session.
    • The difference is 0.0054 psi or less, continue the procedure.
  25. Disconnect the air supply from the pack enclosure leak tester.
  26. Open the inlet valve, and then disconnect the pack enclosure leak tester from the leak test adapter in the LH HV battery shroud assembly.
  27. Remove the leak test adapter from the LH HV battery shroud assembly, and then install a new breather into the LH shroud assembly.
  28. Remove the leak test adapter plug from the RH HV battery shroud assembly, and then install a new breather into the RH shroud assembly.
  29. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  30. Remove the leak test adapter from the penthouse probe lid cover.
  31. Install a new breather into the penthouse probe lid cover.
  32. Remove the logic connector cap and dummy plug from the high voltage controller connector and the DC input assembly.
  33. Connect the charge port to HV battery wiring harness to the DC input assembly and lower the handle.
  34. Fasten the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
  35. Install the charge port to HV battery wiring harness bracket to the penthouse, and then install the bolts that attach the bracket to the penthouse.
    Torque 10 Nm
  36. Fasten the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
  37. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  38. Install the penthouse HV and penthouse 12v caps.
  39. Connect 12 V power. See 12V Power (Disconnect and Connect).
1Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
2Remove the penthouse HV and penthouse 12V caps.
3Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
4Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
5Remove the bolts that attach the charge port to HV battery harness bracket at the penthouse, and then remove the bracket from the vehicle.
Torque 10 Nm
6Release the clip that attaches the wiring harness to the LH lower C-pillar.
7Raise the handle to disconnect the wiring harness from the DC input assembly.
8Install the dummy plug to the DC input assembly.
9Install the dummy plug into the HVC connector.
10Remove and discard the breather from the penthouse probe lid cover.
11Install the leak test adapter plug into the penthouse probe lid cover.
12Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
13Remove and discard the breather from the RH HV battery vent shroud assembly.
14Install the second leak test adapter plug into the RH shroud assembly.
15Remove and discard the breather from the LH HV battery vent shroud assembly.
16Install the leak test adapter into the LH shroud assembly.
17Connect the pack enclosure leak tester to the leak test adapter in the LH HV battery shroud assembly.
18Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
19Fully close the regulator, and then open the inlet valve.
20Set the regulator to 0.15 psi.
21Open the outlet valve, and allow at least 45 seconds for the pressure to stabilize to 0.15 psi.
22Close the inlet valve, record the starting pressure displayed, and then start a 60-second timer.
23After 60 seconds record the ending pressure displayed.
24Subtract the ending pressure from the starting pressure, and if:
  • The difference is greater than 0.0054 psi, check the hose, adapter, and plug fittings, close the outlet valve and open the inlet valve, check the regulator pressure, and then retest from step 21. If the difference is still greater than 0.0054 psi, escalate a Toolbox session.
  • The difference is 0.0054 psi or less, continue the procedure.
25Disconnect the air supply from the pack enclosure leak tester.
26Open the inlet valve, and then disconnect the pack enclosure leak tester from the leak test adapter in the LH HV battery shroud assembly.
27Remove the leak test adapter from the LH HV battery shroud assembly, and then install a new breather into the LH shroud assembly.
28Remove the leak test adapter plug from the RH HV battery shroud assembly, and then install a new breather into the RH shroud assembly.
29Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
30Remove the leak test adapter from the penthouse probe lid cover.
31Install a new breather into the penthouse probe lid cover.
32Remove the logic connector cap and dummy plug from the high voltage controller connector and the DC input assembly.
33Connect the charge port to HV battery wiring harness to the DC input assembly and lower the handle.
34Fasten the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
35Install the charge port to HV battery wiring harness bracket to the penthouse, and then install the bolts that attach the bracket to the penthouse.
Torque 10 Nm
36Fasten the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
37Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
38Install the penthouse HV and penthouse 12v caps.
39Connect 12 V power. See 12V Power (Disconnect and Connect).