2025-09-11

Ancillary Bay Air Leak Test (Model YL) (Test/Adjust)

Correction code 16010100100 FRT 0.72 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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 KIT, ENCL LEAK TEST, HV BATTERY
  • 1080978-00-B KIT, FORCE GAUGE MARK-10

Procedure

  1. Remove the 2nd row RH seat. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Replace).
  2. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Model YL) (Maintenance).
  3. Separate the carpet holes under the 2nd row RH seat to access the passthrough combine breather, expanding the hole if needed.
  4. Remove and discard the breather plug from the passthrough combine breather.
    Informational PurposesAn informational icon, calling your attention
    Note
    Avoid dropping the breather plug into the ancillary bay.
  5. Install the enclosure leak test adapter to the passthrough combine breather, and connect it to the enclosure leak tester.
  6. Close both valves on the pack enclosure leak tester by turning valve knobs to a vertical position.
  7. 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.
  8. Turn the inlet valve to the open position by turning the valve knob to a horizontal position.
  9. Set the pack enclosure leak tester to 0.15 psi.
  10. Open the outlet valve to inject air, and allow 60 seconds for air to fill the system.
  11. Once the pressure reaches 0.15 psi, close the inlet valve, and wait for 45 seconds to allow the pressure to settle within the system.
  12. Record the starting pressure, then start a 60-second timer; after 60 seconds, record the final pressure.
  13. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.0228 psi, 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 6. If the difference is still greater than 0.0228 psi, escalate a Toolbox session.
    • The difference is 0.0228 psi or less, continue the procedure.
  14. Disconnect the air supply from the pack enclosure leak tester.
  15. Remove the enclosure leak test adapter from the passthrough combine breather, and disconnect it from the enclosure leak tester.
  16. Install a new breather plug (1108907-00-A) onto the passthrough combine breather. Use a MARK-10 force gauge to apply 200 N of force to secure the plug. Ensure force is applied perpendicular to the breather plug.
  17. Inspect the breather plug to ensure it is fully seated by applying sideways force with a finger; replace if loose or damaged, otherwise no action is needed.
  18. Fold the carpet hole under the 2nd row RH seat to its original position.
  19. Install the 2nd row RH seat. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Replace).