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Testing a KIA HV battery cooling system – think beyond State of Health

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Battery State of Health gets all the attention, but what about the cooling system?

In this video, Matt, our Delphi expert, takes you through the steps on how to pressure test the cooling system on a KIA high-voltage battery pack, even when the battery is out of the vehicle.

The video will walk you through how to:

Prepare the work area safely and confirm voltage nascence
Set up a custom header tank system
Use a standard pressure test kit
Apply the right test pressure (around 0.5 bar)
Interpret results to determine if the system is leak-free

Batteries How to Distributors Shop Owners Technicians 1 min read

Why should I test the HV battery cooling system?

The cooling system is critical to battery performance and safety. A leak can lead to overheating or damage, even if the battery’s State of Health looks fine. Pressure testing confirms the system’s integrity before refitting the pack.

How do I test a battery’s cooling system when it’s outside the vehicle?

Since a standard setup won’t work off the vehicle, you’ll need to build a custom header tank to pressurize the system. The video demonstrates how to create this workaround using basic tools and adapters.

What pressure should I test the system at?

If you don’t have manufacturer specifications, aim for around 0.5 bar. After pressurizing, leave the system for a few minutes to confirm it’s holding pressure and to verify no leaks.

What if the pressure drops during the test?

A drop in pressure means there’s likely a leak in the cooling system. You’ll need to open the battery pack and investigate further before reinstalling it into the vehicle.

Can EV batteries use different cooling systems?

Yes. The KIA in this video uses a liquid coolant, but you can also use air conditioning refrigerant instead.

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