2026-10-02

HV Battery Air Leak Test (Model YL) (Test/Adjust)

Correction code 16010100000 FRT 0.84 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 you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-10-02: Revised procedure and updated test pressure decay values.
Equipment:
  • 1813553-00-A MYSP ENCLOSURE LEAK TEST AIR SPLITTER
  • 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).
    Note
    DO NOT install the rear skid plate and connect the LV battery power; these steps will be completed in subsequent operations.
  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.
    Note
    Avoid dropping the breather plug into the ancillary bay.
  5. Install the air splitter hose to the passthrough combine breather.
  6. Remove and discard the breather plugs (x2) from the HV battery thermal vents.
  7. Install the air splitter hoses (x2) to the thermal vents.
  8. Connect the pack enclosure leak tester to the air splitter.
  9. Close both valves on the pack enclosure leak tester by turning valve knobs to a vertical position.
  10. Connect the pack enclosure leak tester to air supply.
    Note
    Make sure the pack enclosure leak tester valves are both in the closed position.
  11. Turn the inlet valve to the open position by turning the valve knob to a horizontal position.
  12. Set the pack enclosure leak tester to 0.150 psi.
  13. Open the outlet valve to inject air into the ancillary bay, and allow 60 seconds for the pressure to stabilize to 0.150 psi.
  14. Close the inlet valve and allow 45 seconds for the pressure to stabilize.
  15. Check the 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.
  16. Record value of starting pressure.
  17. Wait 60 seconds to test pressure and record value of ending pressure.
  18. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.015 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 11. If the difference is still greater than 0.015 psi, further investigate possible causes for the pressure leak, starting with Toolbox article 41588.
    • The difference is 0.015 psi or less, continue the procedure.
  19. Disconnect the air supply from the pack enclosure leak tester.
  20. Remove the air splitter hoses (x2) from the HV battery thermal vents.
  21. Disconnect the air splitter from the pack enclosure leak tester.
  22. Install new breather plugs (1108907-00-B) (x2) to the HV battery vents. Use a MARK-10 force gauge to apply 200 N of force perpendicular to the vent shroud.
  23. Inspect the breather plugs to ensure they are fully seated by applying sideways force with a finger; replace if loose or damaged, otherwise no action is needed.
  24. 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 (Model YL) (Maintenance).
  25. Disconnect the air splitter hoses from the passthrough combine breather.
  26. 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.
  27. 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.
  28. Fold the carpet hole under the 2nd row RH seat to its original position.
  29. Connect LV Power. See LV Power (Disconnect and Connect) (Modify).
  30. Install the 2nd row RH seat. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Replace).