2026-07-21

HV Battery Air Leak Test (Standard) (Test/Adjust)

Correction code 16102200 1.44 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT 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.

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.
Warning
Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.
Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.
  • 2026-05-08: Released new procedure.
  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Open the LH front door and lower the LH front window.
  3. Open the tonneau cover.
  4. Open the tailgate.
  5. Remove the bed floor assembly. See Bed Floor Assembly (Remove and Install).
  6. Remove the NVH barrier. See Tonneau NVH Barrier Assembly (Standard) (Remove and Install).
  7. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  8. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure (without Terrestrial Armor) (Test/Adjust).
  9. Inspect thermal vent breather plugs
    Note
    4x plugs, If plug has laser etchings in line then replace, If plug is loose then press to get audible click
  10. Inspect pyro access cover breather plug
    Note
    1x plug, If plug has laser etchings in line then replace, If plug is loose then press to get audible click
  11. Loosen bolts securing 2x4 header assembly to enclosure
    Note
    4x bolts, 5-lobe E10, 6 Nm, Use hand tools only, Adjust assembly as needed, Do not remove connectors unless soft set is found
  12. Torque bolts securing 2x4 header assembly to enclosure
    Note
    4x bolts, 5-lobe E10, 6 Nm, Use hand tools only, Adjust assembly as needed, Do not remove connectors unless soft set is found
  13. Remove breather plug from thermal vent
    Note
    1x plug, 3x tabs per plug, Discard after removal
  14. Apply butyl onto remaining thermal vents
    Note
    3x butyl patches, 3x thermal vents
  15. Install enclosure leak test adapter onto open thermal vent
    Note
    1x thermal vent
  16. Connect enclosure leak tester onto adapter
    Note
    1x adapter
  17. Close both valves on regulator
  18. Connect regulator to air supply
  19. Turn right side regulator valve to open position
    Note
    Turn valve knob to horizontal position
  20. Set regulator to 0.3 psi
  21. Open left side regulator valve to inject air into platter
    Note
    Close right side regulator valve when pressure reaches 0.3 psi and stabilizes, Allow platter to fill for 120 seconds
  22. Wait 30 seconds for pressure to settle
  23. Record value of starting pressure
  24. Wait 30 seconds to test pressure
  25. Record value of end pressure
    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
  26. Remove enclosure leak test adapter from open thermal vent
    Note
    1x thermal vent
  27. Remove butyl from remaining thermal vents
    Note
    3x butyl patches, 3x thermal vents
  28. Install breather plug onto thermal vent
    Note
    1x plug, 3x tabs per plug, Install new plug, Press plug evenly, Make sure tabs are fully engaged and plug is flush with vent
  29. Remove breather plug from pyro access cover
    Note
    1x plug, 3x tabs per plug, Discard after removal
  30. Install enclosure leak test adapter onto pyro access cover breather hole
    Note
    1x thermal vent
  31. Close both valves on regulator
  32. Turn right side regulator valve to open position
    Note
    Turn valve knob to horizontal position
  33. Set regulator to 0.3 psi
  34. Open left side regulator valve to inject air into ancillary bay
    Note
    Close right side regulator valve when pressure reaches 0.3 psi and stabilizes, Allow bay to fill for 120 seconds
  35. Wait 30 seconds for pressure to settle
  36. Record value of starting pressure
  37. Wait 30 seconds to test pressure
  38. Record value of end pressure
    Note
    Subtract ending pressure from starting pressure, If difference is greater than 0.05 psi then inspect tools and retest, If difference is still greater than 0.05 psi then escalate to Service Engineering, If difference is 0.05 psi or less then proceed with current procedure
  39. Close both valves on regulator
  40. Turn right side regulator valve to open position
    Note
    Turn valve knob to horizontal position
  41. Set regulator to 0.8 psi
  42. Open left side regulator valve to inject air into ancillary bay
    Note
    Close right side regulator valve when pressure reaches 0.8 psi and stabilizes, Allow bay to fill for 120 seconds
  43. Inspect 2x4 header assembly for air leak
    Note
    2x headers, Spray with soapy water as needed, Do not disconnect connectors, If leak found then proceed to replacement procedure
  44. Inspect pyro access cover for air leak
    Note
    Spray with soapy water as needed, If leak found then proceed to replacement procedure
  45. Inspect PCS coolant passthrough for air leak
    Note
    2x hoses, Spray with soapy water as needed, Do not disconnect hoses, If leak found then proceed to replacement procedure
  46. Inspect DU HV headers for air leak
    Note
    3x headers, Spray with soapy water as needed, Do not disconnect connectors, If leak found then proceed to replacement procedure
  47. Inspect ancillary bay flood ports for air leak
    Note
    3x ports, Spray with soapy water as needed, If leak found then proceed to replacement procedure
  48. Lower vehicle until tires are touching the ground
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  49. Remove bolt securing busbar HV connector lid
    Note
    1x bolt, EP10, 9 Nm
  50. Remove bolts securing HV connector to DC FC header
    Note
    2x bolts, 10mm, 9 Nm
  51. Release HV connector from DC FC header
    Note
    1x connector, Use inflatable airbag if needed to suspend busbar assembly above ancillary assembly
  52. Install CP busbar dummy plug onto DC FC header
    Note
    1x bolt, 10mm, 9 Nm, Shift plug up and down a few times to work grease onto seal grooves
  53. Raise vehicle fully
    Note
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  54. Close both valves on regulator
  55. Turn right side regulator valve to open position
    Note
    Turn valve knob to horizontal position
  56. Set regulator to 0.3 psi
  57. Open left side regulator valve to inject air into ancillary bay
    Note
    Close right side regulator valve when pressure reaches 0.3 psi and stabilizes, Allow bay to fill for 120 seconds
  58. Wait 30 seconds for pressure to settle
  59. Record value of starting pressure
  60. Wait 30 seconds to test pressure
  61. Record value of end pressure
    Note
    Subtract ending pressure from starting pressure, If difference is greater than 0.05 psi then inspect tools and retest, If difference is still greater than 0.05 psi then escalate to Service Engineering, If difference is 0.05 psi or less then proceed to repair procedure
  62. Disconnect air supply from regulator
  63. Disconnect enclosure leak tester from adapter
    Note
    1x adapter
  64. Remove enclosure leak test adapter from pyro access cover breather hole
    Note
    1x thermal vent
  65. Install rear skid plate
    Note
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 to mid aero shield bolts and install fasteners
  66. Lower vehicle fully
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  67. Remove CP busbar dummy plug from DC FC header
    Note
    1x bolt, 10mm, 9 Nm
  68. Position busbar connector and lower onto HV header
    Note
    Release bungee cord
  69. Install bolts securing charge port busbar kit to HV Header
    Note
    2x bolts, 10mm, 9 Nm
  70. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Note
    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step
  71. Install bolt securing busbar HV connector lid
    Note
    1x bolt, EP10, 9 Nm
  72. Remove leather over gloves and HV insulating gloves
  73. Install the tonneau NVH barrier assembly. See Tonneau NVH Barrier Assembly (Standard) (Remove and Install).
  74. Install the bed floor assembly. See Bed Floor Assembly (Remove and Install).
  75. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  76. Close the tonneau cover.
  77. Close the tailgate.
  78. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  79. Raise the LH front window and close the LH front door.