2026-11-02

Cooling System (Vacuum Refill)

Correction code 18300400 FRT 0.78 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Equipment:
  • 1050448-00-B Refiller, Cooling System
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.
Warning
Wear appropriate personal protective equipment (PPE) including a full face mask when performing this procedure.
CAUTION
Incorrect use of the Vacuum Refill Tool can result in rupture of the cooling system and possible flooding of High Voltage components.

Procedure

  1. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  2. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  3. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox:(link)
    Note
    Verify the vehicle is in Series via Garage > Vitals > Thermal tab > Coolant loops, Thermal Fluid Fill/Drain.
    Note
    The routine has a 5 hour limit. After 5 hours, the routine must be performed again.
  4. Disconnect the laptop from the vehicle.
    Note
    Do not close Toolbox because the routine will resume later.
  5. Disconnect LV power. See LV Power (Disconnect and Connect).
  6. Remove the coolant bottle cap.
  7. Install the vacuum refill cap onto the coolant bottle assembly.
  8. Put an empty coolant container in the underhood storage unit.
  9. Fill another container with at least 15L of coolant.
  10. Put the filled coolant container onto the coolant cart, and then position the cart as close to the front of the vehicle as possible.
    Note
    Use a fender cover to protect the front of the vehicle.
  11. Setup the coolant refill tool.
    Note
    Verify all valves on the refill tool are in the closed position.
  12. Install the vacuum refill hose into the refill cap on the coolant bottle.
    Note
    Perform a push-pull-push test to verify that the hose is fully installed.
  13. Put the refill hose inside the filled coolant container.
    Note
    Make sure the hose end is fully submerged in coolant.
  14. Position the overflow hose in the empty container.
  15. Connect shop air supply to the coolant refill tool.
    Note
    If not already done, verify that the refill valve is set to off.
  16. Open the shop air supply valve on the vacuum refill tool.
    Note
    Air flow will be present when the valve is open.
  17. Open the air inlet valve to draw a vacuum. Once the gauge stabilizes, close the valve fully.
    Note
    The gauge stabilizes roughly at 60-70 cmHg. Vacuum should not drop after the valves are closed.
  18. Monitor the gauge for 30 seconds to verify vacuum is maintained in the cooling system.
    Note
    If vacuum is not maintained, there may be a leak in the cooling system. Verify no loose connections or fittings on the vacuum refill tool are causing a vacuum leak.
  19. Continue evacuating the cooling system. Open the air inlet valve for 3 minutes, then close the air inlet valve.
  20. Close the shop air supply valve on the refill tool. Air flow noise should stop.
  21. Slowly open the refill valve to allow coolant to be drawn into the cooling system.
    Note
    Make sure the hose end of refill hose is fully submerged during entire process.
  22. Once the gauge reads zero, close the coolant refill valve.
  23. Disconnect the shop air supply from the vacuum refill tool.
  24. Remove the coolant refill hose from the coolant container.
  25. Remove the coolant overflow hose from the coolant container.
  26. Remove the vacuum refill hose from the refill cap on the coolant bottle.
  27. Remove the vacuum refill tool cap.
  28. Remove the coolant refill tool from the vehicle.
  29. Remove the coolant container from the underhood storage unit, move the coolant cart from the front of the vehicle, and then remove the fender cover.
  30. Connect LV power. See LV Power (Disconnect and Connect).
  31. Unlock the vehicle gateway. See Gateway (Unlock).
  32. Touch Thermal > Coolant System > Stop Thermal Fill/Drain, then touch Run. Close once the routine is completed.
  33. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)
    CAUTION
    Make sure the vehicle is not in drive. The test runs for approximately 10 minutes. Putting vehicle into a drive state will stop this routine. Monitor the coolant level and add more coolant as needed.
    Note
    This test is still running despite the stop message.
    Note
    The coolant pumps will be audible during this test.
  34. Check the coolant level and top off as needed.
    Note
    Use a mirror to aid visually.
    Note
    Make sure the coolant fluid level is at the Max line and top off as needed.
  35. Install the coolant bottle cap.
  36. Disable Service Mode. See Service Mode (Enable and Disable).
  37. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  38. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  39. Hold the LH and RH B-pillar upper buttons in the close position to manually calibrate the LH and RH falcon wing doors.