2026-04-09

HV Battery Air Leak Test (Test/Adjust)

Correction code 16102100 FRT 0.66 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.

Procedure

  1. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  2. Disconnect RH pressurized pack line.
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    Note
    1x VOSS fitting, 12mm, 8 Nm
  3. Install plug onto RH pressurized pack line.
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    Note
    1x plug, Line must be disconnected from pyro fuse access cover
  4. Install enclosure leak test adapter onto open thermal vent.
  5. Connect enclosure leak tester onto adapter.
  6. Close both valves on regulator.
  7. Connect regulator to air supply.
  8. Turn right side regulator valve to open position.
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    Note
    Turn valve knob to horizontal position.
  9. Set regulator to 0.3 psi.
  10. Open left side regulator valve to inject air into platter.
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    Note
    Close right side regulator valve when pressure reaches 0.3 psi and stabilizes, Allow platter to fill for 120 seconds.
  11. Wait 30 seconds for pressure to settle.
  12. Record value of starting pressure.
  13. Wait 30 seconds to test pressure.
  14. Record value of end pressure.
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    Note
    Subtract ending pressure from starting pressure, If difference is greater than 0.006 psi then inspect tools and retest, If difference is still greater than 0.006 psi then escalate to Service Engineering, If difference is 0.006 psi or less then proceed with current procedure.
  15. Disconnect air supply from regulator.
  16. Disconnect enclosure leak tester from adapter.
  17. Remove enclosure leak test adapter from open thermal vent.
  18. Remove plug from RH pressurized pack line.
  19. Connect RH pressurized pack line.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x VOSS fitting, 12mm, 8Nm, Remove plug as needed.
  20. Remove butyl from remaining thermal vents.
  21. Install a new breather plug onto the thermal vent.
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    Note
    Press the plug evenly.
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    Note
    Make sure the tabs are fully engaged and plug is flush with vent.
  22. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
  23. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect).
  24. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  25. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  26. Raise the LH front window and close the LH front door.