Inverter Coolant Leak Test

Correction code 4020201040202010

DRAFT

from-cad
Warning:

This procedure was derived from pre-production computer models, and might not reflect the real-world situation. Warnings and cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components.

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  • 1053600-00-C Drive Unit Pressure Test Fixture
  • 1132185-00-B Kit, Coolant Leak Test Adapters, Model 3
  • 1133843-00-AKit, Coolant Drain & Fill Adapters, M3
  • 1135762-00-AKit, Svc Plug, Cooling Hose, Model 3

SPECIAL TOOLS

Drive Unit Pressure Test Fixture (1053600-00-C)
Kit, Coolant Leak Test Adapters, Model 3 (1132185-00-B)
Kit, Coolant Drain & Fill Adapters, M3 (1133843-00-A)
Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-A)
Parent topic: 4020 - Rear Drive Inverter

Procedure

  1. Disconnect 12V power. See 12V Power (Disconnect and Connect).
  2. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  3. Position a coolant drain under the inverter.
  4. Disconnect the coolant outlet hose at the top of the inverter.
  5. Plug the female fitting of the hose, and connect the coolant pressure test adapter to the inverter.
  6. Connect the drive unit pressure test fixture to the coolant pressure test adapter.
  7. Close both valves P1 (inlet) and P2 (outlet) on the test fixture, and connect a compressed air supply line.
  8. Fully close the regulator, and then open P1 (inlet valve).
  9. Set the pressure regulator of the test fixture to 26 psi.
  10. Disconnect the coolant inlet hose at the bottom of the inverter, plug the female fitting of the hose, and allow the inverter to drain.
  11. Connect the coolant drain adapter to the bottom of the inverter, and direct the tube to the coolant drain.
  12. Slowly open P2 (outlet valve) to speed the drain, and then close P2 (outlet valve).
  13. Disconnect the coolant drain adapter, and then connect the coolant pressure test adapter plug to the inverter.
  14. Open P2 (outlet valve) again, and allow at least 45 seconds for the pressure to stabilize to 26 psi.
  15. Close P1 (inlet valve), record the starting pressure displayed, and start a 4 minute timer.
  16. After 4 minutes record the ending pressure displayed.
  17. Subtract the ending pressure from the starting pressure, and if:
    • The difference greater than 0.2 psi, check the hose, adapter, and plug fittings, close P2 (outlet valve) and open P1 (inlet valve), check the regulator pressure, and then retest from step 14. If the difference is still greater than 0.2 psi, escalate a Toolbox session.
    • The difference is 0.2 psi or less, continue the procedure.
  18. Disconnect the air supply from the test fixture.
  19. Open P1 (inlet valve), and disconnect the test fixture from the coolant pressure test adapter.
  20. Remove the coolant pressure test adapter and coolant pressure test adapter plug from the inverter, and the plugs from the hoses.
  21. Connect the hoses to the inverter.
    Caution:
    Perform a push-pull test to verify that the hose is fully seated.
  22. Remove the coolant drain from under the vehicle.
  23. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  24. Connect 12V power. See 12V Power (Disconnect and Connect).
  25. Perform a vacuum refill the cooling system. See Cooling System (Vacuum Refill).
1Disconnect 12V power. See 12V Power (Disconnect and Connect).
2Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
3Position a coolant drain under the inverter.
4Disconnect the coolant outlet hose at the top of the inverter.
5Plug the female fitting of the hose, and connect the coolant pressure test adapter to the inverter.
6Connect the drive unit pressure test fixture to the coolant pressure test adapter.
7Close both valves P1 (inlet) and P2 (outlet) on the test fixture, and connect a compressed air supply line.
8Fully close the regulator, and then open P1 (inlet valve).
9Set the pressure regulator of the test fixture to 26 psi.
10Disconnect the coolant inlet hose at the bottom of the inverter, plug the female fitting of the hose, and allow the inverter to drain.
11Connect the coolant drain adapter to the bottom of the inverter, and direct the tube to the coolant drain.
12Slowly open P2 (outlet valve) to speed the drain, and then close P2 (outlet valve).
13Disconnect the coolant drain adapter, and then connect the coolant pressure test adapter plug to the inverter.
14Open P2 (outlet valve) again, and allow at least 45 seconds for the pressure to stabilize to 26 psi.
15Close P1 (inlet valve), record the starting pressure displayed, and start a 4 minute timer.
16After 4 minutes record the ending pressure displayed.
17Subtract the ending pressure from the starting pressure, and if:
  • The difference greater than 0.2 psi, check the hose, adapter, and plug fittings, close P2 (outlet valve) and open P1 (inlet valve), check the regulator pressure, and then retest from step 14. If the difference is still greater than 0.2 psi, escalate a Toolbox session.
  • The difference is 0.2 psi or less, continue the procedure.
18Disconnect the air supply from the test fixture.
19Open P1 (inlet valve), and disconnect the test fixture from the coolant pressure test adapter.
20Remove the coolant pressure test adapter and coolant pressure test adapter plug from the inverter, and the plugs from the hoses.
21Connect the hoses to the inverter.
Caution:
Perform a push-pull test to verify that the hose is fully seated.
22Remove the coolant drain from under the vehicle.
23Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
24Connect 12V power. See 12V Power (Disconnect and Connect).
25Perform a vacuum refill the cooling system. See Cooling System (Vacuum Refill).