2026-10-01

HV Battery Air Leak Test

Correction code 16102100 0.50 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
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1813553-00-A 5-WAY AIR SPLITTER

Procedure

  1. Raise and support the vehicle. See .
  2. Open all four doors and lower all four windows.
  3. Move the LH and RH front seats fully forward.
  4. Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  5. Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace)
  6. Remove and discard the breather plug from the ancillary bay probe lid cover.
  7. Disconnect the HVC logic connector and install a logic cap.
  8. Install the leak test adapter into the ancillary bay probe lid cover.
  9. Connect the pack enclosure leak tester to the leak test adapter.
  10. Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  11. Remove and discard the breather plugs (x2) from the HV battery vent shroud assembly.
  12. Install the air splitter hoses (x2) to the shroud assembly.
  13. Connect the pack enclosure leak tester (1140501-00-A) to the air splitter.
  14. Close both valves on the pack enclosure leak tester by turning valve knobs to a vertical position.
  15. Connect the pack enclosure leak tester to air supply.
    Note
    Make sure the pack enclosure leak tester valves are both in the closed position.
  16. Turn the inlet valve to the open position by turning the valve knob to a horizontal position.
  17. Set the pack enclosure leak tester to 0.150 psi.
  18. Open the outlet valve to inject air into the battery cavity, and allow 60 seconds for the pressure to stabilize to 0.150 psi.
  19. Close the inlet valve and allow 45 seconds for the pressure to settle.
  20. 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.
  21. Record the value of the starting pressure.
  22. Wait 60 seconds to test pressure and record the value of ending pressure.
  23. Subtract the ending pressure from the starting pressure.
    • If the difference is greater than 0.006 psi (Standard Range models) or 0.008 psi (Long Range models), 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 0.006 psi (Standard Range models) or 0.008 psi (Long Range models), refer to Toolbox Article 41588 for next steps.
    • If the difference is 0.006 psi or less (Standard Range models) or 0.008 psi or less (Long Range models), continue the procedure.
  24. Disconnect the air supply from the pack enclosure leak tester.
  25. Remove the air splitter hoses (x2) from the thermal vents.
  26. Install new breather plugs (x2) to the HV battery vents.
  27. 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).
  28. Disconnect the pack enclosure leak tester from the leak test adapter at the ancillary bay.
  29. Remove the leak test adapter from the ancillary bay probe lid cover.
  30. Install a new breather plug onto the ancillary bay probe lid cover.
  31. Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  32. Connect LV power. See LV Power (Disconnect and Connect) (Modify).
  33. Move the LH and RH front seats back to their original positions.
  34. Raise all windows and close the doors.
  35. Remove the vehicle from the lift.