2023-12-15

Ancillary Bay Air Leak Test

Correction code 16100400 0.48 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. See Ergonomic Precautions for safe and healthy working practices.

  • 1026636-00-A Pack Enclosure Leak Tester, HV Battery
  • 1140501-00-A Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-A Kit, Encl Leak Test Adapters, HV Battery
  • 1455410-00-A Kit, Dummy Plug
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1813553-00-A MYSP Platter, Enclosure Leak Test, Air Splitter

Procedure

  1. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
  2. Make sure that the logic connector cap is snug on the high voltage controller connector to prevent leaks.
  3. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  4. Make sure that the high voltage connectors along the rear of the HV battery are fully seated and securely latched.
  5. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  6. Remove the ancillary bay HV cap. See Cap - HV - Ancillary Bay (Remove and Replace).
  7. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  8. Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the ancillary bay.
  9. Remove the bolts that attach the charge port to HV battery harness bracket at the ancillary bay, and then remove the bracket from the vehicle.
  10. Slide the release to unlock the DC input connector handle of the charge port to HV battery harness from the secured position.
  11. Fully raise the handle on the DC input connector.
  12. Remove the DC input connector from the ancillary bay DC input header.
  13. If the charge port to HV battery harness has a 3-phase connector, continue to the next step, otherwise skip to step 17.
  14. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
  15. Fully raise the handle on the 3-phase connector.
  16. Remove the 3-phase connector from the ancillary bay 3-phase header.
  17. Release the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
  18. Install the charge port dummy plug onto the DC input assembly.
  19. If the charge port to HV battery harness has a 3-phase connector, install a dummy plug to the 3-phase header.
  20. Remove and discard the breather plug from the ancillary bay probe lid cover.
  21. Install the leak test adapter into the ancillary bay probe lid cover.
  22. Connect the pack enclosure leak tester to the leak test adapter.
  23. Close both valves on the pack enclosure leak tester by turning valve knobs to a vertical position.
  24. Connect the pack enclosure leak tester to air supply.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the pack enclosure leak tester valves are both in the closed position.
  25. Turn the inlet valve to the open position by turning the valve knob to a horizonal position.
  26. Set the pack enclosure leak tester to 0.15 psi.
  27. Open the outlet valve to inject air into the ancillary bay, and allow 60 seconds for the pressure to stabilize to 0.15 psi.
  28. Close the inlet valve and wait 45 seconds for pressure to settle.
  29. Record value of starting pressure.
  30. Wait 60 seconds to test pressure and record value of ending pressure.
  31. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.0231 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 27. If the difference is still greater than 0.0231 psi, further investigate possible causes for the pressure leak, starting with Toolbox article 41588. If the cause for the pressure leak can still not be found and resolved, escalate a Toolbox session.
    • The difference is 0.0231 psi or less, continue the procedure.
  32. Disconnect the air supply from the pack enclosure leak tester.
  33. Disconnect the pack enclosure leak tester from the leak test adapter.
  34. Remove the leak test adapter from the ancillary bay probe lid cover.
  35. Install a new breather plug onto the ancillary bay probe lid cover.
  36. If installed, remove the dummy plug from the 3-phase header.
  37. Remove the charge port dummy plug from the DC input assembly.
  38. Fully raise the handle on the DC input connector of the charge port to HV battery harness.
  39. Use both hands to firmly connect the DC input connector of the charge port to HV battery harness to the ancillary bay DC input header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly.
  40. While pressing the DC input connector onto the DC input header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  41. Slide the release to lock the DC input connector handle in the secured position.
  42. Verfiy that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and charging problems later on.
  43. If the charge port to HV battery harness has a 3-phase connector, continue to the next step, otherwise skip to step 49.
  44. Fully raise the handle on the 3-phase connector of the charge port to HV battery harness.
  45. Use both hands to firmly connect the 3-phase connector of the charge port to HV battery harness to the ancillary bay 3-phase header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly.
  46. While pressing the 3-phase connector onto the 3-phase header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  47. Slide the release to lock the 3-phase connector handle in the secured position.
  48. Verfiy that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and charging problems later on.
  49. Fasten the clip that attaches the charge port to HV battery wiring harness to the LH lower C-pillar.
  50. Install the charge port to HV battery wiring harness bracket to the ancillary bay, and then install the bolts that attach the bracket to the ancillary bay.
    10 Nm (7.4 lbs-ft)
  51. Fasten the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the ancillary bay.
  52. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  53. Connect 12 V power. See 12V/LV Power (Disconnect and Connect).
  54. Install the ancillary bay HV and ancillary bay 12v caps.