HV Battery Cooling System Leak Testing

WARNING: This page is about a different variant/trim than selected.

CAUTION:

Do not allow coolant to come in contact with any high voltage component electrical connections. Engine coolant will create a conductive path and cannot be effectively removed resulting in a loss of isolation and replacement of the contaminated high voltage component.

NOTE:

DO NOT fill the cooling system prior to leak testing. An internal leak can cause excessive coolant leaking into the battery pack, causing a short across the battery and possibly a thermal event. For this reason the system should also not be pressure tested with the system connected to the battery pack. To test the entire system for a leak, a vacuum test should be performed first.

Use the Special Tool # 399-550000, (UView Airlift™ Cooling System Refil Tool) to perform the vacuum test of the system below.

The service area where this procedure is performed should have a minimum shop air requirement of 80 psi (5.5 bar) and should be equipped with an air dryer system.
Choose an appropriate adapter cone that will fit the vehicle's cooling system filler neck.

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Attach the adapter cone (2) to the vacuum gauge (1).

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Make sure the vacuum generator / venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 psi / 5.5 bar) to the vacuum generator / venturi (1).
Position the adaptor cone/vacuum gauge assembly on the filler neck. Make sure that the adapter cone is sealed properly.

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Connect the vacuum generator / venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1).
NOTE:
Do not bump or move the assembly as it may result in loss of vacuum.
Open the vacuum generator / venturi ball valve.
NOTE:
If a strong vacuum is being created in the system, it is normal to observe the hoses collapse.
Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings.
Close the vacuum generator / venturi ball valve.

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Disconnect the vacuum generator / venturi and airline (1) from the adaptor cone/vacuum gauge assembly (2).
Watch the gauge for approximately 20 seconds.
- If the pressure readings do not move, the system has no leaks.
- If the pressure readings move, a leak could be present in the system. Continue to step 12.
Using hose clamp pliers, clamp both hoses as close to the battery pack as possible and repeat the vacuum test.
- If the pressure readings do not move, the battery pack has an internal leak. Replace the battery pack in accordance with the Service Information
- If the pressure readings move, continue to step 13.
Perform the high voltage battery power down procedure. Refer to: HIGH VOLTAGE POWER DOWN .
Disconnect the hoses from the battery pack with the hose clamp pliers still clamped on the hoses.
Some coolant may leak passed the pliers. Aim the hoses into a container to catch any coolant.
Carefully remove the pressure cap. Wipe the inside of filler neck and examine pressure cap sealing surface for nicks, cracks, paint, dirt and residue.
Inspect the outside of the filler neck. If damaged, seating of the pressure cap valve and tester seal could be affected.
Attach the SVT275 Cooling Pressure Tester available from Mopar® Service Equipment, or an equivalent to the pressurized coolant bottle.
Operate tester pump to apply 34 kPa (5 psi) pressure to system. If hoses enlarge excessively or bulges while testing, replace as necessary.
Inspect the system for leaks and repair as necessary.