Platter Enclosure Coolant Leak Test

Correction code 1610201016102010
  • 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: 1620 - HV Battery Cooling System

Procedure

  1. Disconnect 12V power. See 12V Power (Disconnect and Connect).
  2. Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  3. Release the lower clips (x3) that attach the lower rear edge of the LH wheel arch liner to the body, to allow access to the coolant hose.
  4. Position the coolant drain under the front LH corner of the HV battery.
  5. Release the clips that attach the battery to chiller hose to the body.
  6. Disconnect the battery to chiller hose at the LH side of the vehicle, plug the female connector of the hose, and allow the battery to drain.
  7. Connect the coolant pressure test adapter to the battery to chiller hose male connector.
  8. Connect the drive unit pressure test fixture to the coolant pressure test adapter.
  9. Close both valves P1 (inlet) and P2 (outlet) on the test fixture, and connect a compressed air supply line.
  10. Fully close the regulator, and then open P1 (inlet valve).
  11. Set the pressure regulator of the test fixture to 26 psi.
  12. Disconnect the HV battery return hose at the LH side of the vehicle, plug the male connector of the hose, and allow the battery to drain.
  13. Connect the coolant drain adapter to the HV battery return hose, and direct the tube to the coolant drain.
  14. Slowly open P2 (outlet valve) to speed the drain, and then close P2 (outlet valve).
  15. Disconnect the coolant drain adapter, and then connect the coolant pressure test adapter plug to the HV battery return hose.
  16. Open P2 (outlet valve) again, and allow at least 45 seconds for the pressure to stabilize to 26 psi.
  17. Close P1 (inlet valve), record the starting pressure displayed, and start a 4 minute timer.
  18. After 4 minutes record the ending pressure displayed.
  19. 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 16. If the difference is still greater than 0.2 psi, escalate a Toolbox session.
    • The difference is less than 0.2 psi, continue the procedure.
  20. Disconnect the air supply from the test fixture.
  21. Open P1 (inlet valve), and disconnect the test fixture from the coolant pressure test adapter.
  22. Remove the coolant pressure test adapter, coolant pressure test adapter plug, and other plugs from the hoses.
  23. Connect the battery to chiller hose, and the HV battery return hose.
  24. Remove the coolant drain from under the vehicle.
  25. Fasten the clips that attach the battery to chiller hose to the body.
  26. Fasten the lower clips (x3) that attach the lower rear edge fo the LH wheel arch liner to the body.
  27. Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  28. Connect 12V power. See 12V Power (Disconnect and Connect).
  29. Perform a vacuum refill the cooling system. See Cooling System (Vacuum Refill).
1Disconnect 12V power. See 12V Power (Disconnect and Connect).
2Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
3Release the lower clips (x3) that attach the lower rear edge of the LH wheel arch liner to the body, to allow access to the coolant hose.
4Position the coolant drain under the front LH corner of the HV battery.
5Release the clips that attach the battery to chiller hose to the body.
6Disconnect the battery to chiller hose at the LH side of the vehicle, plug the female connector of the hose, and allow the battery to drain.
7Connect the coolant pressure test adapter to the battery to chiller hose male connector.
8Connect the drive unit pressure test fixture to the coolant pressure test adapter.
9Close both valves P1 (inlet) and P2 (outlet) on the test fixture, and connect a compressed air supply line.
10Fully close the regulator, and then open P1 (inlet valve).
11Set the pressure regulator of the test fixture to 26 psi.
12Disconnect the HV battery return hose at the LH side of the vehicle, plug the male connector of the hose, and allow the battery to drain.
13Connect the coolant drain adapter to the HV battery return hose, and direct the tube to the coolant drain.
14Slowly open P2 (outlet valve) to speed the drain, and then close P2 (outlet valve).
15Disconnect the coolant drain adapter, and then connect the coolant pressure test adapter plug to the HV battery return hose.
16Open P2 (outlet valve) again, and allow at least 45 seconds for the pressure to stabilize to 26 psi.
17Close P1 (inlet valve), record the starting pressure displayed, and start a 4 minute timer.
18After 4 minutes record the ending pressure displayed.
19Subtract 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 16. If the difference is still greater than 0.2 psi, escalate a Toolbox session.
  • The difference is less than 0.2 psi, continue the procedure.
20Disconnect the air supply from the test fixture.
21Open P1 (inlet valve), and disconnect the test fixture from the coolant pressure test adapter.
22Remove the coolant pressure test adapter, coolant pressure test adapter plug, and other plugs from the hoses.
23Connect the battery to chiller hose, and the HV battery return hose.
24Remove the coolant drain from under the vehicle.
25Fasten the clips that attach the battery to chiller hose to the body.
26Fasten the lower clips (x3) that attach the lower rear edge fo the LH wheel arch liner to the body.
27Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
28Connect 12V power. See 12V Power (Disconnect and Connect).
29Perform a vacuum refill the cooling system. See Cooling System (Vacuum Refill).