Author: BenjaminNelson via YouTube
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I pressure test the 2013 Tesla Model S battery pack to make sure it’s water-proof. When it doesn’t pass testing, I troubleshoot WHY!
Please click SHOW MORE!
00:00 Pressure Testing overview
03:39 Pinched O-Rings
07:54 Failed Test
08:10 New Air Pump
09:43 Spraying for Leaks
10:34 Front Leak
12:01 Front Leak Fix
12:35 Breather Installation
13:17 Front underside breather
13:50 Reinstall Side Rail Covers
14:25 What’s Next!
Pressure-testing makes sure that the battery is waterproof.
The test is supposed to be done at LESS than 0.2 PSI (Above that, the umbrella valves open.) Tesla calls for using a special pressure regulator which can get down to that low of a pressure. Since I didn’t have that, I just used my Ryobi tire pump. After that, I found that an aquarium air pump actually worked a little better, since it’s ever lower pressure and flow.
It turned out that I had MULTIPLE leaks!
A few of the new umbrella valves that I installed had their o-rings pinched! Very obvious once I found them.
There were also several bolts/screws which leaked. I believe that’s because I had somebody else working with me when we installed the screws. I didn’t double-check the work, and it looked like a couple screws weren’t torqued-down. Adding a little more sealant and re-torquing the screws fixed that.
The last leak was the hardest to find. It turned out that a screw stripped out the threads of the aluminum case of the battery. I drilled out the hole slightly larger and installed a helicoil to replace the threads. Then I added additional sealant and torqued the screw down.
After all that, the pack passed the pressure test and I could install the gore breathers and the side rail covers.
Sikaflex Sealant: https://amzn.to/4na3Y7I
Manometer: https://amzn.to/4gxu6qI
M5 Helicoil kit: https://amzn.to/48m0f2b
Brass Schrader Valves: https://amzn.to/4mDy0zL
1"/26mm Silicone plugs: https://amzn.to/4poqpay
Link to step by step Tesla Battery Repair instructions: https://sites.google.com/view/teslahvbattery/home
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