2026-10-01

HV Battery Air Leak Test (Structural Pack)

Correction code 16102120 0.65 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 wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  1. Remove the 2nd row seat cushion
    Note
    1x connector, Lift front edge of seat cushion upward to release foam from frame
  2. Disconnect LV power. See 12V/LV Power (Disconnect and Connect)
  3. Remove the rear aero shield. See Panel - Aero Shield - Rear (Remove and Replace).
  4. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Structural Pack)
  5. Remove and discard the breather plugs (x4) from the thermal vents.
  6. Install the air splitter hoses onto the thermal vents.
  7. Lower the vehicle until the tires are touching the floor.
  8. If present, cut away the insulation that covers the pyro cover.
  9. Remove and discard the breather from the pyro cover.
  10. Install the air splitter hose onto the pyro cover.
  11. Connect the enclosure leak tester to the air splitter.
  12. Close both valves on the regulator test tool, and then connect the regulator to air supply.
  13. Turn the right side regulator valve to the open position.
  14. Set the regulator to 0.300 psi.
  15. Open the left side regulator valve to inject air into the ancillary bay.
    Note
    Allow 50 seconds fill time. Close the right side regulator valve when the pressure reaches 0.300 psi.
  16. Wait 30 seconds for the pressure to settle.
    • If pressure is below 0.285 psi, check the hose, adapter, plug fittings, and check the pressure regulator, then retest. If pressure is still below 0.285 psi, diagnose enclosure for leaks.
    • If pressure is at 0.285 psi or above, continue to the next step.
  17. Record the value of the starting pressure.
  18. Wait 30 seconds to test pressure.
  19. Record the value of the ending pressure.
  20. Subtract the ending pressure from the starting pressure.
    • If the difference is greater than 0.086 psi, then inspect the tools and retest. If the difference is still greater than 0.051 psi, then diagnose the enclosure for leaks.
    • If difference is 0.086 psi or less, then proceed with the current procedure.
  21. Disconnect the air supply from the regulator tool.
  22. Disconnect the enclosure leak tester from the air splitter.
  23. Remove the air splitter hose from the pyro cover.
  24. Install a new breather plug (1108907-00-B) onto the pyro cover.
  25. Raise the vehicle.
  26. Remove the air splitter hoses (x4) from the thermal vents.
  27. Install new breather plugs (x4) onto the thermal vents.
    Note
    3x tabs per plug, Install new plugs, Press plug evenly, Make sure tabs are fully engaged and plug is flush with vent
  28. 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 (Structural Pack).
    Note
    Make sure that the lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully install the lever and make sure that the locking tab is locked.
  29. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  30. Install the 2nd row seat cushion.
    Note
    1x connector. Slide the rear cushion rearward, then align the foam with the seat rail. Make sure that the cushion is fully seated with a push-pull test.