2026-10-01

Platter Enclosure Air Leak Test

Correction code 16102000 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.
  • 2025-06-23: Added the vehicle HV disablement procedure, and the part number of the disposable breather plugs.
Equipment:
  • 1144879-00-A - Kit, Encl Leak Test Adapters, HV Battery
  • 1140501-00-A - Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1813553-00-A - ENCLOSURE LEAK TEST AIR SPLITTER
  • 1083188-01-B - Digital Multimeter Unit, EXTECH 355
  • 1108272-00-B - CAP, LOGIC CONN, INV, 3DU
  • 1108907-00-B - BREATHER, NITTO ZH-PLUG-S (2)

Procedure

  1. Place the vehicle on the 2-post lift.
    Tip
    Ensure the vehicle is not charging.
  2. Open all doors and lower all windows.
  3. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  4. Where applicable, make sure that the logic connector cap is snug on the high voltage controller connector to prevent leaks.
  5. Remove and discard the breather plugs (x2) from the LH and RH HV battery vent shroud assemblies.
  6. Install the air splitter hoses (x2) to the thermal vents.
  7. Connect the regulator onto the air splitter.
  8. Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
  9. Open the inlet valve.
  10. Set the regulator to 0.150 psi.
  11. Open the outlet valve to inject air into the HV battery, and allow 60 seconds for the pressure to stabilize to 0.150 psi.
  12. After 60 seconds, 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, 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.
  13. Close the inlet valve, record the starting pressure displayed, and then start a 45-second timer.
  14. After 45 seconds, record the ending pressure displayed.
  15. Subtract the ending pressure from the starting pressure.
    • If the difference is greater than 0.011 psi (Standard Range models) or 0.018 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 11. If the difference is still greater than 0.011 psi (Standard Range models) or 0.018 psi (Long Range models), refer to Toolbox Article 41588 for next steps.
    • If the difference is 0.011 psi or less (Standard Range models) or 0.018 psi or less (Long Range models), continue the procedure.
  16. Disconnect the air supply from the pack enclosure leak tester.
  17. Open the inlet valve, and then disconnect the pack enclosure leak tester from the leak test adapter in the LH HV battery shroud assembly.
  18. Remove the leak test airline adapter from the LH HV battery shroud assembly, and then install a new breather plug (1108907-00-B) into the LH shroud assembly.
    Note
    Use 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.
    Note
    Inspect the breather plug is fully seated into the LH HV battery vent shroud assembly.
  19. Remove the leak test adapter plug from the RH HV battery shroud assembly, and then install a new breather plug (1108907-00-B) into the RH shroud assembly.
    Note
    Use force gauge to apply 200N of force to secure the breather valve into the vent shroud assembly.
    Note
    When using the force gauge, make sure to press perpendicular to the vent shroud.
    Note
    Inspect the breather plug is fully seated into the RH HV battery vent shroud assembly.
  20. 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.
  21. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  22. Install the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  23. Remove the vehicle from the lift.