Component Tests and General Diagnostics

Rechargeable Energy Storage System Smoke Test

Special Tools

* EL-50812 - Volt Battery Smoke Test Leak Adapters

* GE 41413-A - Evaporative Emissions System Tester (EEST)

For equivalent regional tools, refer to Special Tools Tools and Equipment.

1. Remove the rechargeable energy storage system (RESS) from the vehicle. Refer to Drive Motor Battery Replacement and Shipping Preparation (Volt) Procedures.





Caution: Refer to Fastener Caution Fastener Caution.

Note: Adapters for connectors X6 and X7 have to be positioned downward approximately 45 degrees, then pushed upward to lock in place.

2. Install the EL-50812 - Volt battery smoke test leak adapters to all of the RESS electrical connectors (X1 through X7).
Tighten the fastener to 9 Nm (80 lb in).

3. Reinstall the S15 manual service disconnect lever or seal the drive motor generator battery high voltage manual disconnect connector, using duct tape.




4. Create a small hole through the duct tape and vent patch (2) to allow a full soak of the smoke into the RESS.

Note: It is not recommended to use the tester in an outside repair bay area because wind and sunlight may affect temperature and your ability to see the smoke.

5. Turn OFF any fans that may cause air movement around or near the RESS.




6. Install the tester hose (1) to the RESS adapter

Note: Completely unwind the smoke hose from the bracket for optimal tester performance.

7. Turn the nitrogen/smoke valve on the control panel to smoke.

Note: The remote switch operates in a push ON, push OFF fashion.

8. Press and release the remote switch to activate the tester and inject smoke into the RESS.




9. Soak/Fill the RESS with smoke for TWO MINUTES until smoke is observed from the hole in vent (2).

10. Once smoke in observed from the hole, press and release the remote switch to deactivate the tester to relieve the pressure within the RESS.

11. Seal the hole in vent (2) with duct tape.

Note: For optimal visual smoke performance, deactivate the smoke flow and allow the system pressure to drop. Allowing the smoke to exit through small holes at a low flow rate greatly enhances visibility.

12. Introduce smoke into the RESS for THREE MINUTES. Using a high-intensity white light, look for any visible smoke emitting anywhere from the RESS.

13. Press and release the remote switch to deactivate the tester.

14. Repair any visible leaks by retightening the fasteners or by resealing any areas using butyl sealant.

15. Retest the RESS, to ensure repair has been completed.

16. Remove the duct tape from rear vent (2).

17. Open the nitrogen tank valve and turn the nitrogen/smoke valve on the control panel to Nitrogen.

18. Press and release the remote switch to activate the tester and inject nitrogen into the RESS for FIVE MINUTES, verify no smoke is coming from the vent.

19. Remove all old vents from the RESS.

20. Install NEW Gore patches (P/N 20791600), replacing the old vents.

21. Disconnect the tester and remove the adapters from the RESS.

22. Remove the S15 manual service disconnect lever or the duct tape used to seal the S15 manual service disconnect connector.

23. Install the rechargeable energy storage system (RESS) in the vehicle. Refer to Drive Motor Battery Replacement and Shipping Preparation (Volt) Procedures.