2026-08-27

高压电池仓漏气测试（结构化电池组）

校正代码 16100420 0.55 注意：除非本程序中另有明确规定，否则上述校正代码和 FRT 反映的是执行本程序（包括关联程序）所需的所有工作。除非明确要求，否则请勿堆叠校正代码。 注意：请参阅平均维修工时，深入了解 FRT 及其创建方式。 注意：请参阅人员保护，确保在执行以下程序时穿戴适当的个人防护装备 (PPE)。注意：请参阅人体工程学注意事项查看安全健康的作业规程。

  • 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.
    注
    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 总成 - 过滤器 - HEPA 空调滤清器（拆卸和更换）
  6. Move LH front seat forward
  7. Move RH front seat forward
  8. Remove the rear aero shield. See 面板 - 流线型护板 - 后部（拆卸和更换）.
  9. Disconnect LV power. See 12V/低压电源（断开和连接）
  10. Perform the vehicle HV disablement procedure. See 车辆高压禁用程序 （结构化电池组）
  11. Lower the vehicle until the tires are touching the floor.
  12. Remove the LH lower C-pillar trim. See 饰板 - C 柱 - 下 - 左侧（拆卸和更换）.
  13. Remove the 2nd row 60 seat back assembly from the vehicle. See 座椅靠背 - 第二排 - 左侧（拆卸和更换）.
  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.
    注
    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.
    注
    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.
    注
    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.
    注
    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 电阻表（零点调节）.
  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.
    注
    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.
    注
    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 座椅靠背 - 第二排 - 左侧（拆卸和更换）.
  46. Install the LH lower C-pillar trim. See 饰板 - C 柱 - 下 - 左侧（拆卸和更换）.
  47. Raise the vehicle.
  48. Connect the RDU HV harness connector to the HV battery.
    注
    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 面板 - 流线型护板 - 后部（拆卸和更换）.
  50. Install the push clips (x2) at the left and right wheel house liner to the rear aero shield.
  51. Connect LV power. See 12V/低压电源（断开和连接）.
  52. Install the HEPA filter assembly. See 总成 - 过滤器 - HEPA 空调滤清器（拆卸和更换）.
  53. Attach the washer tank neck onto the washer tank.
    注
    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.
    注
    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.