2026-10-01

HV Battery Air Leak Test (Test/Adjust)

Correction code 16102100 FRT 0.54 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.

Equipment:
  • 1076921-00-B Insulation Multimeter, Fluke 1507
  • 1130480-00-A Test Probes, Slim, Fluke TP38
  • 1813553-00-A 5-Way Air Splitter
  • 1140501-00-A Enclosure Leak Test Kit

Procedure

  1. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  2. Take off the HV insulating gloves.
  3. Remove and discard the breather from the ancillary bay probe lid cover.
  4. Install the air splitter hose (1813553-00-A) to the ancillary bay probe lid cover.
  5. Remove and discard the breather from the RH HV battery thermal vent.
  6. Remove and discard the breather from the LH HV battery thermal vent.
  7. Install the air splitter hoses (x2) to the shroud assembly.
  8. Connect the pack enclosure leak tester (1140501-00-A) to the air splitter.
  9. Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
  10. Fully close the pack enclosure leak tester, and then open the inlet valve.
  11. Set the pack enclosure leak tester to 0.150 psi.
  12. Open the outlet valve, and allow at least 60 seconds (180 seconds for E3 4860 packs) for the pressure to stabilize to 0.150 psi.
  13. Close the inlet valve.
  14. 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.
  15. Record the value of the starting pressure.
  16. After 45 seconds (60 seconds for E3 4860 packs), record the value of the ending pressure.
  17. Subtract the ending pressure from the starting pressure.
    • If the difference is greater than 0.006 psi (Standard Range models) or 0.008 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 12. If the difference is still greater than 0.06 psi (Standard Range models) or 0.008 psi (Long Range models), refer to Toolbox Article 41588 for next steps.
    • If the difference is 0.006 psi or less (Standard Range models) or 0.008 psi or less (Long Range models), continue the procedure.
  18. Disconnect the air supply from the pack enclosure leak tester.
  19. Open the inlet valve, and then disconnect the pack enclosure leak tester from the air splitter at the HV battery shroud assembly.
  20. Remove the air splitter hoses (x2) from the HV battery thermal vents, and then install new breathers (x2) into the thermal vents.
  21. 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.
  22. Remove the air splitter hose from the ancillary bay probe lid cover.
  23. Install a new breather into the ancillary bay probe lid cover.
  24. Connect LV battery power. See LV Power (Disconnect and Connect) (Modify).