Tesla Model 3: HV Battery Air Leak Test
Pack Enclosure Leak Tester, HV Battery (1026636-00-A)
Pack Kit, Enclosure, Leak Test, HV Battery, Complete (1140501-00-A)
Kit, Encl Leak Test Adapters, HV Battery (1144879-00-A)
Procedure
- Perform the vehicle electrical isolation procedure. See
Vehicle Electrical Isolation Procedure.
- Remove the penthouse HV and penthouse 12V caps.
- Remove the LH rear sill panel trim. See
Trim - Sill Panel - Rear - LH (Remove and Replace).
- Release the clips that attach the low voltage electrical harness to the
charge port to HV battery harness bracket at the penthouse.
- Remove the bolts that attach the charge port to HV battery harness
bracket at the penthouse, and then remove the bracket from the vehicle.
Torque 10 Nm
- Release the clip that attaches the wiring harness to the LH lower
C-pillar.
- Raise the handle to disconnect the wiring harness from the DC input
assembly.
- Install the dummy plug to the DC input assembly.
- Install the dummy plug into the HVC connector.
- Remove and discard the breather from the penthouse probe lid cover.
- Install the leak test adapter plug into the penthouse probe lid cover.
- Remove the mid aero shield panel. See
Panel - Aero Shield - Mid (Remove and Replace).
- Remove and discard the breather from the RH HV battery vent shroud
assembly.
- Install the second leak test adapter plug into the RH shroud assembly.
- Remove and discard the breather from the LH HV battery vent shroud
assembly.
- Install the leak test adapter into the LH shroud assembly.
- Connect the pack enclosure leak tester to the leak test adapter in the
LH HV battery shroud assembly.
- Close both valves on the pack enclosure leak tester, and then connect a
compressed air supply line.
- Fully close the regulator, and then open the inlet valve.
- Set the regulator to 0.15 psi.
- Open the outlet valve, and allow at least 45 seconds for the pressure to
stabilize to 0.15 psi.
- Close the inlet valve, record the starting pressure displayed, and then
start a 60-second timer.
- After 60 seconds record the ending pressure displayed.
- Subtract the ending pressure from the starting pressure, and if:
- The difference is greater than 0.0054 psi, check the hose, adapter, and
plug fittings, close the outlet valve and open the inlet valve, check the
regulator pressure, and then retest from step
21. If the difference is still greater than 0.0054 psi, escalate a
Toolbox session.
- The difference is 0.0054 psi or less, continue the procedure.
- Disconnect the air supply from the pack enclosure leak tester.
- Open the inlet valve, and then disconnect the pack enclosure leak tester
from the leak test adapter in the LH HV battery shroud assembly.
- Remove the leak test adapter from the LH HV battery shroud assembly, and
then install a new breather into the LH shroud assembly.
- Remove the leak test adapter plug from the RH HV battery shroud
assembly, and then install a new breather into the RH shroud assembly.
- Install the mid aero shield panel. See
Panel - Aero Shield - Mid (Remove and Replace).
- Remove the leak test adapter from the penthouse probe lid cover.
- Install a new breather into the penthouse probe lid cover.
- Remove the logic connector cap and dummy plug from the high voltage
controller connector and the DC input assembly.
- Connect the charge port to HV battery wiring harness to the DC input
assembly and lower the handle.
- Fasten the clip that attaches the charge port to HV battery wiring
harness to the LH lower C-pillar.
- Install the charge port to HV battery wiring harness bracket to the
penthouse, and then install the bolts that attach the bracket to the
penthouse.
Torque 10 Nm
- Fasten the clips that attach the low voltage electrical harness to the
charge port to HV battery harness bracket at the penthouse.
- Install the LH rear sill panel trim. See
Trim - Sill Panel - Rear - LH (Remove and Replace).
- Install the penthouse HV and penthouse 12v caps.
- Connect 12 V power. See
12V Power (Disconnect and Connect).
READ NEXT:
SPECIAL TOOLS
Pack Enclosure Leak Tester, HV Battery (1026636-00-A)
Pack Kit, Enclosure, Leak Test, HV Battery, Complete (1140501-00-A)
Kit, Encl Leak Test Adapters, HV Battery (1144879-00-A)
Kit, D
DRAFT
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
SEE MORE:
SPECIAL TOOLS
Cap, Logic Conn, Inv, 3DU (1108272-00-B)
Warning: This procedure disables 12V power, but does not verify that
high voltage power is no longer available to high voltage components (PTC heater,
A/C compressor, inverters, etc). Perform
Vehicle Electrical Isolation Procedure after thi
Remove
Use Toolbox to put the vehicle into Factory Mode.
Invoke diagnostics on the touchscreen.
Inspect the Notifications for either a BMS_a123 or a BMS_W123 alert.
If:
Either alert is present - Contact Service Engineering. Do not perform
this procedure.
Neither alert is present - Continu