2025-06-11

Hose Bundle - Coolant - HV Battery (Long Range) (Remove and Install)

Correction code NEW NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Warning

Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.

2025-05-05: Released new procedure.

This procedure requires Refrigerant evacuation and recharge, please add specific evacuation and recharge correction code as needed
Set up AC machine

Note
Touch time only, Connect to power, Turn power switch on
Raise and support vehicle

Note
Set air suspension to "Jack Mode"
Open LH front door

Note
Push LH B-pillar door trigger to release
Lower LH front window
Open RH front door

Note
Push RH B-pillar door trigger to release
Lower RH front window
Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox: (link)
Unlock vehicle gateway

Note
After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information
Navigate to Refrigerant System through UI

Note
Select Service Mode > Thermal > Refrigerant System
Select "Start Thermal Fill Drain (Coolant and Refrigerant)" through UI

Note
Allow routine to complete, ensure routine is successful
Open powered front trunk

Note
Via exterior switch or UI
Power down vehicle via UI

Note
Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Remove rear underhood apron

Note
9x clips
Disconnect FRL connector then disconnect MV battery connector

Note
2x connectors, Release locking tab then disconnect FRL connector, Slide eCPA to left then lift lever to release MV battery connector, Early production trucks may have black FRL connector, Release eCPA by pushing down to unlock and slide red locking tab, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove lower valence fasteners

Note
2x clips, 2x covers, 6x bolts, 10mm, 6 Nm, Release covers to expose bolts
Remove front aero shield

Note
11x bolts, 10mm, 6 Nm
Disconnect CFM connectors

Note
2x connectors, 2x clips
Remove fore crossmember fasteners

Note
2x bolts, 18mm, 90 Nm
Place coolant catcher below RH front of vehicle
Disconnect battery coolant supply and return hoses

Note
2x edge clips, 2x spring clips, Use caution with pick near HV harness, Release edge clips from casting, Plug Hoses, Position coolant drain as needed
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Remove caps from low side and high side AC ports

Note
2x caps
Connect A/C hoses to ports

Note
Pull back frunk wall if installed to access low side port
Perform refrigerant system recovery

Note
Note or print the amount of refrigerant and oil recovered, If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart https://toolbox.teslamotors.com/articles/353700
Remove frunk assembly

Note
6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Remove bolt covers from frunk floor, Remove washer fluid cap by gently prying upwards, Rotate bumpstops counter clockwise to release, the 25mm socket from PT Sensor kit can be used, Avoid straining emergency frunk release connector
Remove front center applique

Note
8x tabs, 1x connector, Release upper 4 tabs by pushing down then gently pull away, Release frunk release trigger connector
Remove front fascia fasteners

Note
2x covers, 6x bolts, 10mm, 4 Nm, Remove tow hook covers to expose bolts
Release clips securing front portion of the LH front wheel house liner

Note
4x clips
Remove front fascia LH side fastener

Note
1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
Release clips securing front portion of the RH front wheel house liner

Note
4x clips
Remove front fascia RH side fastener and connectors

Note
1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Pull red locking tab to release, Do not push down on locking tab
Remove front lower fascia assembly

Note
Place on suitable protective surface
Disconnect the powertrain bypass hose, radiator outlet hose, radiator inlet hose from the Supermanifold

Note
3x spring clips, This will drain the coolant reservoir
Disconnect radiator to manifold hose from radiator and plug connections

Note
1x spring clip, Remove from vehicle, Plug hoses
Disconnect manifold to radiator hose from radiator and plug connections

Note
1x spring clips, Plug hoses
Release harness from CFM

Note
1x grommet, 2x connectors, 5x harness clips, Pull red locking tab to disengage louver connector, Release temperature sensor then disconnect, Release grommet and pull harness through from frunk area
Remove upper CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Remove fore crossmember

Note
Lift CFM up as required for additional clearance, Use of a dead blow hammer can aid removal
Remove CFM

Note
Recommend assistance, Remove from below impact beam, Ensure harness is not pinched during removal
Disconnect supermanifold harness

Note
1x connector
Remove bolts securing supermanifold

Note
2x bolts, 15mm, 33 Nm, Break free then remove by hand to avoid tool jamming, Support manifold from underneath, Lower Supermanifold until resting on HVAC case
Disconnect battery supply hose, powertrain supply hose, and battery return hose from supermanifold

Note
3x spring clip, 2x connectors, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector, Pull supermanifold forward to access clips and connectors
Remove LH mid A-pillar trim

Note
1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip
Remove LH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
Remove footwell cover

Note
3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether
Remove RH mid A-pillar trim

Note
1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip
Remove RH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
Remove Mid IP panel

Note
19x clips
Remove lower IP panel

Note
4x patch bolts, 10mm, 7 Nm, 4x screws, T20, 2 Nm, 15x panel clips, 1x push clip, 4x connectors, Discard patch bolts after removal, Release LH/RH knee air bag harness from the main IP harness buddy clips, Remove blue tape to allow service slack & prevent stress to knee air bag connectors, Release connector locking tabs, Release OBD port from lower IP
Remove RH EPP clip

Note
1x clip, Pull back for access to car computer
Disconnect glovebox USB connector

Note
1x connector, Release locking tab
Remove glovebox

Note
1x connectors, 1x clip, 5x screws, T20, 2 Nm, 2x datums
Place absorbant mats under car computer

Note
Ensure coolant will not spill onto electrical components
Disconnect car computer coolant hoses

Note
2x spring clips, Remove lower hose first then upper hose, Plug hoses, Use a coolant jug to catch as much coolant as possible, Tuck hoses out of way once plugged
Remove car computer hose grommet from bulkhead

Note
Push grommet outwards into frunk area, Pull hoses through to frunk area
Remove AC hoses from vehicle
Remove nut securing Penta HVAC line assembly to the Supermanifold plate

Note
1x nut, 13mm, 36 Nm
Remove AC line from Supermanifold

Note
1x bolt, 13mm, 22 Nm, 1x bolt, 10mm, 8 Nm, Remove bolt at supermanifold then mounting bracket bolt near LV battery, Remove AC line assembly from supermanifold, Ensure no washers remain on supermanifold
Remove the Supermanifold from the vehicle

Note
Recommend assistance, Rotate the Supermanifold counter clockwise under the Megabeam, Support from underneath and at reservoir
Remove coolant hose bundle

Note
1x breather fitting, 2x clips, Release breather from front drive unit, Release clips then remove coolant hose bundle, Pull HV battery coolant hoses upwards from behind front drive unit, Manipulate as required, Vehicle shown further disassembled for clarity
Install coolant hose bundle

Note
1x breather fitting, 2x clips, Manipulate hoses as required to place in position, Secure edge clips to HVAC case, Secure front drive unit breather, Vehicle shown further disassembled for clarity
Replace the seal washers to the Penta HVAC line on the AC manifold side

Note
5x seal washers, Lube seal washers with RB100EV POE oil
Install the Supermanifold to the vehicle

Note
Recommend assistance, Rotate the Supermanifold counter clockwise under the Megabeam, Support from underneath and at reservoir, Align penta HVAC line
Secure chiller to battery hose, powertrain supply hose, chiller to battery hose to supermanifold

Note
3x spring clip, 2x connectors, Engage locking tabs, Ensure all hoses are fully engaged with a push-pull-push test
Install pentaline to Supermanifold

Note
1x nut, 13mm, 36 Nm, Ensure good alignment of pipes before tightening nut
Install bolts securing supermanifold

Note
2x bolts, 15mm, 33 Nm, Start by hand
Install CFM

Note
Install from bottom, Assistance recommend Manipulate as required, Ensure harness is not pinched during install
Install fore crossmember

Note
Install fasteners at a later step, Lift CFM upwards as required for clearance, Tap into position with dead blow hammer if required
Install upper CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Secure harness to CFM

Note
1x grommet, 2x connector, 1x harness clip, Secure grommet then connect temperature sensor, Engage locking tab on louver connector
Connect radiator inlet coolant hose

Note
1x spring clips,Ensure hose is fully engaged with a push-pull-push test
Connect radiator to manifold hose to radiator

Note
1x spring clip, Ensure hose is fully engaged with a push-pull-push test
Secure powertrain bypass hose, radiator outlet hose, and radiator inlet hose to Supermanifold

Note
3x spring clips, Ensure all hoses are fully engaged with a push-pull-push test
Connect supermanifold electrical connector

Note
1x connector
Replace seal washers for supermanifold to compressor AC line on supermanifold side

Note
2x seal washers, Lube seal washers with RB100EV POE oil
Install AC manifold line assembly to Supermanifold

Note
1x bolt, 13mm, 22 Nm, 1x bolt, 10mm, 8 Nm, Install manifold to Supermanifold then secure bracket near LV battery
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Connect battery supply and return coolant hoses

Note
2x edge clips, 2x spring clips, Remove plugs, Secure edge clips to casting, Perform a push-pull-push test to ensure hose is engaged
Connect CFM connectors

Note
2x connectors, Engage locking tab
Install fore crossmember fasteners

Note
2x bolts, 18mm, 90 Nm, Shift crossmember as required to align bolt holes
Install front aero shield

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
Install lower valence fasteners

Note
2x clips, 2x covers, 6x bolts, 10mm, 6 Nm, Secure covers
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Reconnect AC hoses to vehicle
Perform system vacuum and refrigerant refill

Note
Select 20 mins of Vacuum, Recharge refrigerant to car's specs, add oil quantity as needed, select both HP and LP for charging
Remove AC hoses from vehicle
Remove coolant bottle cap
Install vacuum refill cap onto coolant bottle assembly
Place empty coolant container into front storage area

Note
If frunk is not installed take caution, CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia
Fill container with at least 15L of coolant
Place filled coolant container onto coolant drain & fill cart

Note
Do not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle
Setup coolant refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose to refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully installed
Position overflow hose into empty container
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Slowly open the refill valve to allow coolant to be drawn into the system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once the gauge reads zero, close the coolant refill valve
Remove shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove vacuum refill cap from coolant bottle assembly
Remove coolant refill tool from vehicle

Note
Move coolant drain & fill cart away from vehicle
Remove coolant container from inside underhood area
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install front lower fascia assembly

Note
Ensure no harnesses are pinched
Install RH fascia fastener and connectors

Note
1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Engage locking tab
Secure RH wheel liner

Note
4x clips
Install LH fascia fastener

Note
1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
Secure LH wheel liner

Note
4x clips
Install front fascia fasteners and covers

Note
2x covers, 6x bolts, 10mm, 4 Nm, Install tow hook covers
Install front center applique

Note
8x tabs, 1x connector, Ensure all tabs engage, Secure frunk release trigger connector
Connect FRL connector then connect MV battery connector

Note
2x connectors, Connect FRL connector then secure locking tab, Position lever to secure MV battery connector then slide eCPA to right, Early production trucks may have black FRL connector, If power cycling vehicle then ensure at least 60 seconds has passed since powering down
Access thermal system routines using the UI

Note
Select quick controls > Service mode > Thermal > Actions
Run ODIN routine
PROC_EGGRIGHT3_X_THERMAL-FILL-DRAIN-STOP
via Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Thermal Fill/Drainvia Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Perform Heat Pump Commissioning through UI

Note
Select Thermal > Sensors and Valves > Run Heat Pump Commissioning, click Run, close once routine is passed
Install caps onto AC ports

Note
2x caps
Select "Start Coolant Air Purge" using the UI

Note
Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install coolant bottle cap
Perform Thermal Performance through the UI

Note
Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow https://toolbox.teslamotors.com/articles/206000
Install frunk assembly

Note
6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Install bolt covers to frunk floor, Install washer fluid cap, Install bumpstops by aligning tabs then turning clockwise, Ensure emergency frunk release functions
Install rear underhood apron

Note
9x clips, Adjust windshield seal as required
Close powered front trunk

Note
Via exterior switch or UI
Raise RH front window
Close RH front door
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
Raise LH front window
Close LH front door
This procedure requires Refrigerant evacuation and recharge, please add specific evacuation and recharge correction code as needed

Note
18200102,18033302,18033305,18200122**Always use this Step ID**

Cybertruck Service Manual

Hose Bundle - Coolant - HV Battery (Long Range) (Remove and Install)

Figure 1

Figure 2

Figure 3