2026-10-01

Ancillary Bay Air Leak Test (Inspection)

Correction code 16100400 FRT 0.48 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.

Equipment:
  • 1140501-00-A Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-A Kit, Encl Leak Test Adapters, HV Battery
  • 1813553-00-A 5-Way Air Splitter

Procedure

  1. Open all four doors and lower the windows.
  2. Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  3. Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace)
  4. Remove and discard the breather plug from the ancillary bay probe lid cover.
  5. Install the leak test adapter into the ancillary bay probe lid cover.
  6. Connect the pack enclosure leak tester to the leak test adapter.
  7. Close both valves on the pack enclosure leak tester by turning valve knobs to the vertical position.
  8. Connect the pack enclosure leak tester to air supply.
    Note
    Make sure that the pack enclosure leak tester valves are both in the closed position.
  9. Turn the inlet valve to the open position by turning the valve knob to the horizontal position.
  10. Set the pack enclosure leak tester to 0.150 psi.
  11. Open the outlet valve to inject air into the ancillary bay, and allow 60 seconds for the pressure to stabilize to 0.150 psi.
  12. Close the inlet valve and allow 45 seconds for the pressure to stabilize.
  13. Check the pressure.
    • If pressure is below 0.142 psi, check the hose, adapter, plug fittings, and check the pressure regulator, then retest. If pressure is still below 0.142 psi, further investigate possible causes for the pressure leak, starting with Toolbox article 41588.
    • If pressure is at 0.142 psi or above, continue to the next step.
  14. Record value of starting pressure.
  15. Wait 60 seconds to test pressure and record value of ending pressure.
  16. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.024 psi, check the hose, adapter, and plug fittings, close the outlet valve and open the inlet valve, check the pack enclosure leak tester pressure, and then retest from step 11. If the difference is still greater than 0.024 psi, further investigate possible causes for the pressure leak, starting with Toolbox article 41588.
    • The difference is 0.024 psi or less, continue the procedure.
  17. Disconnect the air supply from the pack enclosure leak tester.
  18. Disconnect the pack enclosure leak tester from the leak test adapter.
  19. Remove the leak test adapter from the ancillary bay probe lid cover.
  20. Install a new breather plug (1108907-00-B) onto the ancillary bay probe lid cover.
  21. Install the rear drive unit HV cable connector to the HV battery and install other components that were removed to perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  22. Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace)
  23. Connect LV power. See LV Power (Disconnect and Connect) (Modify).
  24. Raise all windows and close the doors.