Lincoln Aviator 2020-2022 Service Manual / Electrical / Battery and Charging System / High Voltage Battery, Mounting and Cables / General Procedures - High Voltage Battery Leak Test - Plug-In Hybrid Electric Vehicle (PHEV)

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


    • VACUTEC® Smoke Machine Fuel EVAP Emissions System Tester (or equivalent)
    • SNOOP Solution
    • Large Adhesive Bandage
    • Tape
    • Shop Air Supply
    • Pressure Test Connectors:
      414-011 PHEV-A, BEV-A Battery Pack (Escape/Kuga/Corsair/Mach-E)
      414-012 PHEV-A, BEV-A Battery Pack (Escape/Kuga/Corsair/Mach-E)
      414-013 PHEV-A Battery Pack (Escape/Kuga/Corsair)
      414-010 PHEV-C Battery Pack (Explorer/Aviator)
      414-014 BEV-A Battery Pack (Mach-E)
      414-015 BEV-A Battery Pack (Mach-E)

All Battery Packs

  1. 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

  1. Connect the pressure test connectors to the front of the high voltage battery.
  1. Connect the pressure test connector to the rear of the high voltage battery.

PHEV-A Battery Pack

  1. Connect the pressure test connectors to the high voltage battery.

PHEV-C Battery Pack

  1. Connect the pressure test connector to the high voltage battery.

All Battery Packs

NOTE: PHEV-C battery pack shown, other battery packs similiar.

  1. 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.
  1. 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.
  1. Press the Power button on the VACUTEC® Smoke Machine Fuel EVAP Emissions System Tester to begin pressurizing the pack.
  1. 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.
    1. 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.
    1. 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.
    1. Apply SNOOP solution to the pressure test connector(s). If a leak is found the connector may be damaged and require replacement.
    1. 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.
  1. 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:
    1. 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.
    1. 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.
  1. Apply SNOOP solution to the following components:
    • Fasteners
    • Gasket sealing surfaces
    • Electrical connector headers
    • Coolant port assembly
    • Weld joints
    • The following is an example of a confirmed leak:
  1. NOTICE: If the bandage and tape are not removed from the vent patch, damage to the high voltage battery can result.


    1. Once the pack has been confirmed to be sealed, disconnect the pressure test connector from the high voltage battery.
    1. 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.

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