2026-08-25

Luftleckprüfung HV-Gehäuse (Structural Pack)

Korrekturcode 16100420 0.55 HINWEIS: Sofern im Verfahren nicht ausdrücklich anders angegeben, spiegeln der obige Korrekturcode und die FRT den gesamten für die Durchführung dieses Verfahrens erforderlichen Aufwand wider, einschließlich der damit verbundenen Verfahren. Schichten Sie keine Korrekturcodes, wenn Sie nicht ausdrücklich dazu aufgefordert werden. HINWEIS: Unter Richtzeiten erfahren Sie mehr über FRTs und wie sie erstellt werden. HINWEIS: Siehe Persönlicher Schutz, um sicherzustellen, dass Sie die richtige persönliche Schutzausrüstung tragen, wenn Sie das folgende Verfahren durchführen. HINWEIS: Siehe Maßnahmen zur Ergonomie für sichere und gesunde Arbeitsmethoden.

  • 2026-08-21: Major revision as a result of new procedure validation.
  • 2025-09-05: Cleaned up procedure and removed redundant illustration.

Procedure

  1. Open all doors and lower the windows.
  2. Open the hood.
  3. Remove the rear apron.
    Anmerkung
    14x clips
  4. Remove the bolt that attaches the underhood storage unit to the washer fluid reservoir neck.
  5. Remove the HEPA filter assembly. See Baugruppe – Filter – HEPA (Ausbauen und Ersetzen)
  6. Move LH front seat forward
  7. Move RH front seat forward
  8. Remove the rear aero shield. See Verkleidung – Windabweiser – Hinten (Ausbauen und Ersetzen).
  9. Disconnect LV power. See 12-V-/Niederspannungsversorgung (Trennen und Verbinden)
  10. Perform the vehicle HV disablement procedure. See HV-Abschaltverfahren des Fahrzeugs (Strukturpack)
  11. Lower the vehicle until the tires are touching the floor.
  12. Remove the LH lower C-pillar trim. See Verkleidung – C-Säule – Unten – LH (Ausbauen und Ersetzen).
  13. Remove the 2nd row 60 seat back assembly from the vehicle. See Rückenlehne – 2. Sitzreihe – LH (Ausbauen und Ersetzen).
  14. Disconnect the HV inlet harness from the HV battery.
  15. Remove the bolt that attaches the busbar cover access door.
  16. Remove the bolts (x2) that attach the charge port busbars to the HV header at the ancillary bay.
  17. Release the clip that attaches the LH body harness to the rear body and move the harness aside.
  18. Lift the busbar kit connector to remove it from the HV header.
    Anmerkung
    Use an inflatable air bag to move the busbar away from the HV header during removal and installation. Firmly hold the busbar as there is tension on it.
  19. Install a dummy plug onto the DC input assembly.
  20. Install a dummy plug onto the 3-phase input assembly.
  21. If present, cut away the insulation that covers the pyro cover.
  22. Remove and discard the breather from the pyro cover.
  23. Install the air splitter hose onto the pyro cover.
  24. Close both valves on the regulator test tool, and then connect the regulator to air supply.
  25. Turn the right side regulator valve to the open position.
  26. Set the regulator to 0.3 psi.
  27. Open the left side regulator valve to inject air into the ancillary bay.
    Anmerkung
    Allow 30 seconds fill time. Close the right side regulator valve when the pressure reaches 0.3 psi.
  28. Wait 15 seconds for the pressure to settle.
  29. Record the value of the starting pressure.
  30. Wait 30 seconds to test pressure.
  31. Record the value of the end pressure.
    Anmerkung
    Subtract ending pressure from starting pressure. If the difference is greater than 0.0484 psi, then inspect the tools and retest. If the difference is still greater than 0.0484 psi, then proceed to the Combined Platter and Ancillary Bay leak down test. If difference is 0.0484 psi or less, then proceed with the current procedure.
  32. Disconnect the air supply from regulator tool.
  33. Remove the air splitter hose from the pyro cover.
  34. Remove the dummy plug from the DC input assembly.
  35. Remove the dummy plug from the 3-phase input assembly.
  36. Install a new breather onto the pyro cover.
  37. Install the busbar connector onto the HV header.
    Anmerkung
    Hold busbar firmly as there is tension on it.
  38. Install the bolts (x2) that attach the charge port busbars to the HV header.
    9 Nm (6.6 lbs-ft)
  39. Perform a zero adjust of the Hioki resistance meter. See Widerstandsmessgerät (Nullpunkteinstellung).
  40. Put on HV insulation gloves and leather over gloves.
  41. Use the Hioki resistance meter to measure the resistance between the charge port busbar lead and the HV header bolt head. Also perform this test on the other lead and bolt head.
    Anmerkung
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again, as appropriate.
    Anmerkung
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  42. Install the bolt that attaches the busbar cover access door.
    9 Nm (6.6 lbs-ft)
  43. Install the clip that attaches the LH body harness to the rear body.
  44. Connect the HV inlet harness to the HV battery.
  45. Install the 2nd row 60 seat back assembly. See Rückenlehne – 2. Sitzreihe – LH (Ausbauen und Ersetzen).
  46. Install the LH lower C-pillar trim. See Verkleidung – C-Säule – Unten – LH (Ausbauen und Ersetzen).
  47. Raise the vehicle.
  48. Connect the RDU HV harness connector to the HV battery.
    Anmerkung
    Verify lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully secure the lever and make sure that the red tab is locked.
  49. Install the rear aero shield. See Verkleidung – Windabweiser – Hinten (Ausbauen und Ersetzen).
  50. Install the push clips (x2) at the left and right wheel house liner to the rear aero shield.
  51. Connect LV power. See 12-V-/Niederspannungsversorgung (Trennen und Verbinden).
  52. Install the HEPA filter assembly. See Baugruppe – Filter – HEPA (Ausbauen und Ersetzen).
  53. Attach the washer tank neck onto the washer tank.
    Anmerkung
    1x O-ring. Make sure that the washer hose is properly routed.
  54. Install the bolt that attaches the underhood storage unit to the washer fluid reservoir neck.
    5 Nm (3.7 lbs-ft)
  55. Install the rear apron.
  56. Close the hood.
  57. Install the 2nd row seat cushion.
    Anmerkung
    1x connector. Slide the rear cushion rearward, then align foam with the seat rail. Make sure that the cushion is fully seated with push & pull test.
  58. Move LH and RH front seats to their original position.