2026-09-03

Ancillary Bay Coolant Leak Test (Inspection)

Correction code 16200200 FRT 0.90 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.

Procedure

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Open all four doors and lower all four windows.
  3. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  4. Enable Service Mode and unlock the vehicle gateway. See 0005 - Service Modes.
  5. On the touchscreen, select Thermal > Coolant System > Coolant Fill/Drain and select Run to run the routine. Close once the routine is completed.
    Note
    Thermal Fill Drain routine has a 5 hour time limit. If the run time exceeds 5 hours, the routine must be performed again.
  6. Disconnect the LV power. See LV Power (Disconnect and Connect).
  7. Raise the vehicle fully and lower lift onto locks.
  8. Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  9. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  10. Position a coolant drain under the rear RH side of the HV battery.
  11. Position coolant drain container underneath LH rear of HV battery.
  12. Disconnect the rear drive unit inverter inlet tube from LH rear of HV battery.
    Note
    Plug hose connections as needed. Coolant loss greater than 1 L will require a vacuum fill.
  13. Attach the coolant drain hose adapter to PCS outlet hose coupling.
    Note
    Use adapter with 90 degree angle. Make sure the locking tab is fully seated and the valve is open.
  14. Connect the waste coolant container hose to the drain and fill adaptor.
    Note
    Push until an audible click is heard, then perform a push-pull-push test to verify the connection is fully seated.
  15. Position the coolant drain container underneath RH rear of vehicle.
  16. Disconnect rear powertrain supply hose from PCS inlet hose coupling.
    Note
    1x spring clip. Plug hose connections as needed. Coolant loss greater than 1 L will require vacuum fill.
  17. Connect the coolant leak test adapter to the PCS inlet hose coupling.
    Note
    Remove the rubber plug from the coupler if installed. Make sure the locking clip is fully seated.
  18. Connect the coolant leak test fixture outlet hose to leak test adapter.
  19. Connect the outlet hose to the leak test fixture tool.
  20. Close both valves on the coolant leak test fixture tool.
  21. Connect compressed air to coolant leak test fixture tool.
    Note
    Air supply source should be above 50 psi.
  22. Turn the inlet valve on leak test fixture tool clockwise to open it, turn on the digital gauge and set to "psi", and then adjust the regulator to 50 psi.
    Note
    Turn the regulator knob clockwise to increase pressure and counterclockwise to decrease pressure.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  23. Set the timer to 2 minutes.
  24. Slowly open the outlet valve on the leak test fixture tool until the valve knob is inline with the airline.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  25. Start the 2-minute timer. Once the timer is complete, select Stop Reset.
  26. Close both valves on the coolant leak test fixture tool.
  27. Disconnect the coolant leak test adapter with hose from the PCS inlet hose coupling, and disconnect the coolant drain and fill adapter with hose from the PCS outlet hose coupling.
  28. Attach coolant leak test adapter with hose to PCS outlet hose coupling.
    Note
    1x spring clip. Make sure the locking tab is fully seated.
  29. Attach coolant drain and fill adapter with extension hose to PCS inlet hose coupling.
    Note
    1x spring clip. Make sure the locking tab is fully seated.
  30. Repeat step 22 to step 26.
  31. Disconnect compressed air from the leak test fixture tool.
  32. Disconnect waste coolant container from the drain and fill adapter.
  33. Disconnect coolant drain and fill adapter from the PCS inlet hose coupling.
    Note
    Install plug to inlet hose coupling. If the battery is returned to Reman, remove the special tool plugs.
  34. Disconnect the coolant leak test fixture outlet hose from the leak test adapter.
  35. Disconnect the coolant leak test adapter from the PCS outlet hose coupling.
    Note
    1x spring clip
  36. Connect the coolant leak test adapter plug to the PCS outlet hose coupling.
    Note
    Remove the rubber plug from PCS outlet hose coupling if present. Install 90 degree leak test adapter with NPT plug. Make sure the locking clip is fully seated.
  37. Connect the coolant leak test adapter to the PCS inlet hose coupling.
    Note
    Remove the rubber plug from PCS outlet hose coupling if present. Make sure the locking clip is fully seated.
  38. Connect the coolant leak test fixture outlet hose to leak test adapter.
  39. Connect the outlet hose to the leak test fixture tool.
  40. Close both valves on the coolant leak test fixture tool.
  41. Connect compressed air to coolant leak test fixture tool.
    Note
    Air supply source should be above 50 psi.
  42. Turn the inlet valve on leak test fixture tool clockwise to open it, turn on the digital gauge and set to "psi", and then adjust the regulator to 50 psi.
    Note
    Turn the regulator knob clockwise to increase pressure and counterclockwise to decrease pressure.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  43. Slowly open the outlet valve on the leak test fixture tool until the valve knob is inline with the airline.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  44. Allow the pressure in the PCS coolant loop to stabilize at 50 psi.
  45. Set the timer to 4 minutes.
  46. Record the PCS coolant loop leak check starting pressure.
  47. Close the inlet valve on the coolant leak test fixture tool.
  48. Start the 4-minute timer. Once the timer is complete, select Stop Reset.
  49. Record the PCS coolant loop leak check end pressure value after the 4-minute timer is complete. The max delta between the start and end pressures is 0.35 psi.
    Note
    Check the coolant hose to see if it is fully seated if the pressure test fails.
  50. Disconnect compressed air from the leak test fixture tool.
  51. Slowly open the inlet valve on the leak test fixture tool to discharge air from coolant system.
  52. Disconnect the coolant leak test fixture hose from the leak test adapter.
  53. Disconnect the coolant leak test adapter from the PCS inlet hose coupling.
  54. Position the coolant drain container underneath RH rear of vehicle.
  55. Connect the rear powertrain supply hose to the PCS inlet hose coupling.
    Note
    Remove the plug, and perform push-pull-push test to make sure hose is fully seated.
  56. Disconnect the coolant leak test adapter plug from the PCS outlet hose coupling.
  57. Position coolant drain container underneath LH rear of the vehicle.
  58. Connect the RDU inverter inlet tube to PCS outlet hose coupling.
    Note
    Remove plugs and perform push-pull-push test to make sure hose is fully engaged.
  59. Remove the coolant drain container from underneath vehicle.
  60. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  61. Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  62. Lower the vehicle fully.
  63. Perform the cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  64. Exit Service Mode.
  65. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  66. Raise all four windows and close all four doors.
  67. Remove the vehicle from the lift.