2022-06-17

HV Battery Air Leak Test (On Table)

Correction code 16102110 0.18 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 proper PPE is worn when performing the below procedure.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.

Procedure

  1. Install the low voltage dummy plug onto the low voltage connector.
  2. Install the front drive unit dummy plug squarely onto the front drive unit HV header, lower the black release handle, and then slide the red locking tab.
  3. Install the A/C compressor dummy plug squarely onto the compressor HV header, lower the black release handle, and then slide the red locking tab.
  4. Install a rear drive unit dummy plug squarely onto the LH rear drive unit HV header, lower the black release handle, and then slide the red locking tab.
  5. Install a rear drive unit dummy plug squarely onto the RH rear drive unit HV header, lower the black release handle, and then slide the red locking tab.
  6. Install the busbar type DC input dummy plug onto the DC input HV header, and then install the bolt that attaches the dummy plug onto the HV header.
    9 Nm (6.6 lbs-ft)
  7. Carefully remove the gore breathers (x4) from the breather assembly at the rear of the HV battery pack.
  8. Insert tapered plugs into three breather holes so that they fit snugly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not push plugs too far inside.
  9. Install the leak test adapter into the fourth breather hole.
  10. Turn valve P2 (left) and valve P1 (right) to the closed (vertical) position on the enclosure leak tester.
  11. Connect the enclosure leak tester hose to the leak test adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Restrain the enclosure leak tester hose so that it will not tug the leak test adapter out of the HV battery.
  12. Turn the knob on the regulator to the fully closed setting.
  13. Connect the supply compressed air line to the enclosure leak tester.
  14. Turn valve P1 (right) to the open (horizontal) position and slowly adjust the regulator so that 0.3 psi is displayed on the gauge.
  15. Make sure that the regulator is set to 0.3 psi.
  16. Slowly turn valve P2 (left) to the open (horizontal) position and allow air to enter the HV battery.
  17. Allow 60 seconds for the pressure to stabilize.
  18. Turn valve P1 (right) to the close (vertical) position.
  19. Record the beginning pressure value and start a 30 second timer.
  20. After 30 seconds has elapsed, record the end pressure value, and then substract the end pressure value from the beginning pressure value.
    • If the pressure difference is more than 0.026 psi, inspect the HV battery for leaks, turn valve P2 (left) to the close (vertical) position, and retest from step 14.
    • If the pressure difference is 0.026 psi or less, continue to the next step.
  21. Disconnect the supply compressed air line from the enclosure leak tester.
  22. Slowly turn valve P1 (right) to the open (horizontal) position, and allow air to exit the HV battery.
  23. Disconnect the enclosure leak tester hose from the leak test adapter.
  24. Remove the leak test adapter from the fourth breather hole.
  25. Remove the tapered plugs from the three breather holes.
  26. Carefully install the gore breathers (x4) into the breather assembly at the rear of the HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    If damaged, replace with part number 1108907-00-B.
  27. Remove the bolt that secures the busbar type DC input dummy plug to the DC input HV header,and then remove the dummy plug from the HV header.
  28. Slide the red locking tab, raise the black release handle, and then remove the rear drive unit dummy plug from the RH rear drive unit HV header.
  29. Slide the red locking tab, raise the black release handle, and then remove the rear drive unit dummy plug from the LH rear drive unit HV header.
  30. Slide the red locking tab, raise the black release handle, and then remove the A/C compressor dummy plug from the compressor HV header.
  31. Slide the red locking tab, raise the black release handle, and then remove the front drive unit dummy plug from the front drive unit HV header.
  32. Press the release tab and then remove the low voltage dummy plug from the low voltage connector.