2026-10-01

HV Battery Air Leak Test

Correction code 16102100 0.60 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 wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-09-30: Updated test pressure decay values.
  • 2023-09-19: Removed mention of deprecated EU specific tool.
Equipment:
  • 1076921-00-B Insulation Multimeter, Fluke 1507
  • 1130480-00-A Test Probes, Slim, Fluke TP38
  • 1813553-00-A 5-Way Air Splitter
  • 1140501-00-A Enclosure Leak Test Kit

Procedure

  1. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  2. Take off the HV insulating gloves.
  3. Remove and discard the breather from the ancillary bay probe lid cover.
  4. Install the air splitter hose (1813553-00-A) to the ancillary bay probe lid cover.
  5. Remove and discard the breather from the RH HV battery thermal vent.
  6. Remove and discard the breather from the LH HV battery thermal vent.
  7. Install the air splitter hoses (x2) to the thermal vents.
  8. Connect the pack enclosure leak tester (1140501-00-A) to the air splitter.
  9. Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
  10. Open the inlet valve.
  11. Set the pack enclosure leak tester to 0.150 psi.
  12. Open the outlet valve, and allow at least 45 seconds for the pressure to stabilize to 0.150 psi.
  13. Check the air 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, diagnose enclosure for leaks.
    • If pressure is at 0.142 psi or above, continue to the next step.
  14. Close the inlet valve, record the starting pressure displayed, and then start a 60-second timer.
  15. After 60 seconds, record the ending pressure displayed.
  16. 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 12. 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.
  17. Disconnect the air supply from the pack enclosure leak tester.
  18. Open the inlet valve, and then disconnect the pack enclosure leak tester from the air splitter in the HV battery shroud assembly.
  19. Remove the air splitter hoses (x2) from the HV battery shroud assembly, and then install new breather plugs (1108907-00-B x2) into the thermal vents.
    Note
    Use a force gauge to apply 200N of force to install the breather valve into the vent shroud assembly.
    Note
    When using the force gauge, make sure to press perpendicular to the vent shroud.
  20. Install the rear drive unit HV cable connector to the HV battery and install other parts that were removed to perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  21. Remove the air splitter hose from the ancillary bay probe lid cover.
  22. Install a new breather plug (1108907-00-B) into the ancillary bay probe lid cover.
    Note
    Use a force gauge to apply 200N of force to install the breather valve into the probe lid cover.
    Note
    When using the force gauge, make sure to press perpendicular to the probe lid cover.
  23. Connect 12V power. See 12V/LV Power (Disconnect and Connect).