How to

Pressure testing a KIA battery pack

Share Resource:

Resource Highlights

High-voltage battery packs – it’s not all about the electrics. You’ve got to make sure they’re completely airtight to avoid moisture seeping in and the resulting long-term damage this poses.

Watch as Delphi expert, Matt, demonstrates how to seal the pack, test your equipment, and pressurise the system before checking for any leaks. You’ll learn how to:

Prepare the battery and work area for safe testing
Seal off vents and connectors to prevent false readings
Prove your equipment before connecting to the battery
Run a pressure test
Interpret results to confirm the battery is leak-free

Batteries How to Distributors Shop Owners Technicians 1 min read

Why does an HV battery need to be airtight?

Air leaks can introduce moisture and contaminants into the battery pack, which may lead to corrosion or electrical faults. Ensuring the pack is sealed is critical for long-term reliability.

How do I prepare the battery for a pressure test?

Before testing, ensure the area is safe and voltage absence is confirmed. Then, seal all vents and connector openings (tape works fine) to avoid false pressure drops.

What is the purpose of proving the equipment first?

Before connecting to the battery, the pressure kit should be tested in isolation to make sure it holds pressure and isn’t leaking itself!

What pressure should I use to test the battery pack?

For this KIA pack, the target is around 20 millibar, and shouldn’t exceed 25 millibar. After pressurising, leave the system for a few minutes and check for a steady, unchanged reading.

What if the pressure reading drops?

A drop in pressure indicates the battery pack may have an air leak. The pack should not be refitted until the leak is located and resolved.

SIGN UP TO FIND MORE

Fill up your details to hear more from our experts and get the latest updates from Delphi.

First Name*

Surname*

I have read and accept the Terms of Use and Privacy Policy

I agree to receive personalised marketing emails.

I would like to be kept up to date with promotions/marketing/features/events.

You can change your mind at any time by clicking the unsubscribe link in the footer of any newsletter email you receive from us, or by contacting us at [email protected]