Penthouse Air Leak Test

Correction code 1610040016100400
  • 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
  • 1455410-00-AKit, Dummy Plug
  • 1108272-00-BCap, Logic Conn, Inv, 3DU

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)
Kit, Dummy Plug (1455410-00-A)
Cap, Logic Conn, Inv, 3DU (1108272-00-B)

Procedure

  1. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  2. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  3. Make sure that the high voltage connectors along the rear of the HV battery are fully seated and securely latched.
  4. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  5. Remove the penthouse HV cap. See Cap - Penthouse HV (Remove and Replace).
  6. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  7. Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
  8. 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
  9. Release the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
  10. Raise the handle to disconnect the charge port to HV battery wiring harness from the DC input assembly.
  11. Install the charge port dummy plug onto the DC input assembly.
  12. Remove and discard the breather from the penthouse probe lid cover.
  13. Install the leak test adapter into the penthouse probe lid cover.
  14. Connect the pack enclosure leak tester to the leak test adapter in the penthouse probe lid cover.
  15. Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
  16. Fully close the regulator, and then open the inlet valve.
  17. Set the regulator to 0.15 psi.
  18. Open the outlet valve, and allow at least 45 seconds for the pressure to stabilize to 0.15 psi.
  19. Close the inlet valve, record the starting pressure displayed, and then start a 60-second timer.
  20. After 60 seconds record the ending pressure displayed.
  21. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.0231 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 18. If the difference is still greater than 0.0231 psi, escalate a Toolbox session.
    • The difference is 0.0231 psi or less, continue the procedure.
  22. Disconnect the air supply from the pack enclosure leak tester.
  23. Open the inlet valve, and then disconnect the pack enclosure leak tester from the leak test adapter in the probe lid cover.
  24. Remove the leak test adapter from the penthouse probe lid cover.
  25. Install a new breather into the penthouse probe lid cover.
  26. Remove the charge port dummy plug from the DC input assembly.
  27. Connect the charge port to HV battery wiring harness to the DC input assembly and lower the handle.
  28. Fasten the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
  29. 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
  30. Fasten the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
  31. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  32. Install the penthouse HV and penthouse 12v caps.
  33. Connect 12 V power. See 12V Power (Disconnect and Connect).
1Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
2Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
3Make sure that the high voltage connectors along the rear of the HV battery are fully seated and securely latched.
4Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
5Remove the penthouse HV cap. See Cap - Penthouse HV (Remove and Replace).
6Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
7Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
8Remove 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
9Release the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
10Raise the handle to disconnect the charge port to HV battery wiring harness from the DC input assembly.
11Install the charge port dummy plug onto the DC input assembly.
12Remove and discard the breather from the penthouse probe lid cover.
13Install the leak test adapter into the penthouse probe lid cover.
14Connect the pack enclosure leak tester to the leak test adapter in the penthouse probe lid cover.
15Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
16Fully close the regulator, and then open the inlet valve.
17Set the regulator to 0.15 psi.
18Open the outlet valve, and allow at least 45 seconds for the pressure to stabilize to 0.15 psi.
19Close the inlet valve, record the starting pressure displayed, and then start a 60-second timer.
20After 60 seconds record the ending pressure displayed.
21Subtract the ending pressure from the starting pressure, and if:
  • The difference is greater than 0.0231 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 18. If the difference is still greater than 0.0231 psi, escalate a Toolbox session.
  • The difference is 0.0231 psi or less, continue the procedure.
22Disconnect the air supply from the pack enclosure leak tester.
23Open the inlet valve, and then disconnect the pack enclosure leak tester from the leak test adapter in the probe lid cover.
24Remove the leak test adapter from the penthouse probe lid cover.
25Install a new breather into the penthouse probe lid cover.
26Remove the charge port dummy plug from the DC input assembly.
27Connect the charge port to HV battery wiring harness to the DC input assembly and lower the handle.
28Fasten the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
29Install 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
30Fasten the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
31Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
32Install the penthouse HV and penthouse 12v caps.
33Connect 12 V power. See 12V Power (Disconnect and Connect).