Lincoln Aviator: High Voltage Battery, Mounting and Cables / General Procedures - High Voltage Battery Leak Test - Plug-In Hybrid Electric Vehicle (PHEV)
Leak detection
NOTE:
This test is meant to be a secondary check after a service
procedure is performed on the high voltage battery when a seal is
disturbed. It is important to follow the workshop manual service
procedure to verify a high voltage battery is sealed correctly.
Special Tool(s) / General Equipment
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VACUTEC® Smoke Machine Fuel EVAP Emissions System Tester (or equivalent)
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Pressure Test Connectors:
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414-011 PHEV-A, BEV-A Battery Pack (Escape/Kuga/Corsair/Mach-E)
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414-012 PHEV-A, BEV-A Battery Pack (Escape/Kuga/Corsair/Mach-E)
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414-013 PHEV-A Battery Pack (Escape/Kuga/Corsair)
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414-010 PHEV-C Battery Pack (Explorer/Aviator)
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414-014 BEV-A Battery Pack (Mach-E)
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414-015 BEV-A Battery Pack (Mach-E)
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All Battery Packs
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To begin the setup, make sure the high voltage
battery is removed from the vehicle and placed in an accessible area
where there is room to walk around the entire pack. The high voltage
battery cover should be installed and sealed according to the workshop
manual procedure.
BEV-A Battery Pack
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Connect the pressure test connectors to the front of the high voltage battery.
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Connect the pressure test connector to the rear of the high voltage battery.
PHEV-A Battery Pack
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Connect the pressure test connectors to the high voltage battery.
PHEV-C Battery Pack
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Connect the pressure test connector to the high voltage battery.
All Battery Packs
NOTE:
PHEV-C battery pack shown, other battery packs similiar.
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NOTICE:
To prevent damage to the vent patch It is
important that the non-adhesive bandage be properly sized so that it
completely covers the vent patch.
Seal the vent patch by placing a large adhesive
bandage directly over the Vent Patch. The patch must be completely be
covered by the bandage. Cover the bandage using duct tape or gorilla
tape.
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NOTE:
Make sure that the VACUTEC® Smoke Machine Fuel EVAP Emissions System Tester is set to Test and not Smoke.
Connect the VACUTEC® Smoke Machine Fuel EVAP
Emissions System Tester to a power source and verify it is powered ON
(green light indicated on the battery symbol) and that it is connected
to shop air. The shop air must be filtered to remove moisture and
contaminates. Place and hold the air outlet hose into the air
pressurization port on the connector. Set the VACUTEC® Smoke Machine
Fuel EVAP Emissions System Tester to TEST.
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Press the Power button on the VACUTEC® Smoke Machine Fuel EVAP Emissions System Tester to begin pressurizing the pack.
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NOTE:
The flow meter bead should drop all the way to
the bottom and stabilize in order to pass the Gross Leak Check. This can
take between 2 to 15 minutes, depending on the pack size. Be aware that
the machine may stop pressurizing before its done, which requires
pressing the power button again.
As the gauge begins to stabilize, watch the bead.
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If the pack has no gross leaks, the bead should
drop all the way to the bottom (0) and stabilize there. This indicates
the Gross Leak Check has passed. Continue to the SNOOP Solution Test.
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If the bead does not drop all the way to the
bottom, there is a gross seal leak and indicates the Gross Leak Check
has failed. The source could be either loose battery pack cover bolt(s),
battery pack seal, vent patch not covered completely, or one of the
custom connectors. Make sure that the connections are secured.
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Apply SNOOP solution to the pressure test
connector(s). If a leak is found the connector may be damaged and
require replacement.
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If the leak cannot be located: For PHEV-C
battery packs, INSTALL a new battery cover gasket and repeat the Gross
Leak Test. If the leak is still present INSTALL new high voltage and low
voltage connector headers one at a time followed by repeating the Gross
Leak Test until the leak can be corrected. For PHEV-A battery packs,
INSTALL a new connector header and wiring harness assembly and high
voltage battery cover. Do not proceed to the SNOOP Solution Test if the Gross Leak test does not pass.
![](images/general_procedures_high_voltage_battery_leak_test_plug_in_hybrid_electric_vehicle_phev_-3029/2324/imagen2_002(384).jpg) |
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NOTE:
SNOOP solution can be difficult to apply in
tight areas with deep wells. Instead of using a manual applicator, it is
recommended to apply with a spray applicator.
Apply SNOOP solution according to the directions below:
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Make sure the pressure test connector is
secured properly before applying SNOOP solution to all areas of the seal
that might be causing the leaks.
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Apply the SNOOP solution around any seal
disturbed by a prior service procedure. The SNOOP solution should not
bubble anywhere around the seal. If the SNOOP solution actively bubbles
at any point, this indicates a leak exists. Repair or install new
components as necessary to repair the leak and repeat the Gross Leak
Test and the SNOOP Solution Test.
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Apply SNOOP solution to the following components:
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Electrical connector headers
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The following is an example of a confirmed leak:
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NOTICE:
If the bandage and tape are not removed from the
vent patch, damage to the high voltage battery can result.
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Once the pack has been confirmed to be sealed,
disconnect the pressure test connector from the high voltage battery.
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Remove the tape and bandage from the vent
patch. Ensure that the vent patch has not been damaged or pulled off the
battery pack. If damage is found INSTALL a new vent patch.
Diagnostic Trouble Code (DTC) Chart
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation)...
Depower
WARNING:
To prevent the risk of high-voltage shock, always follow
precisely all warnings and service instructions, including instructions
to depower the system...
Other information:
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Spherical Cutter
Hot Air Gun
Air Body Saw
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Materials
Name
Specification
Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
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Removal
WARNING:
Electric vehicles damaged by a crash may have compromised
high voltage safety systems and present a potential high voltage
electrical shock hazard...
Truck and utility vehicles can differ from
some other vehicles. Your vehicle could be
higher to allow it to travel over rough terrain
without getting hung up or damaging
underbody components.
The differences that make your vehicle so
versatile also make it handle differently than
an ordinary passenger car...