2024-08-08

Ancillary Bay Coolant Leak Test (Inspection)

Correction code 16200200 FRT 0.90 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. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Procedure

  1. Place the vehicle on the 2-post lift.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Ensure the vehicle is not charging.
  2. Open all doors and lower all windows.
  3. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  4. Unlock the vehicle gateway. See Gateway Unlock.
  5. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Fill/Drain, click Run, and allow the routine to complete.
  6. Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  7. Remove the rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
  8. Position a coolant drain container underneath the LH rear of the HV battery.
  9. Disconnect the LH coolant hose from the rear of HV battery, and plug the ends of fittings as soon as possible to avoid coolant loss.
  10. Remove the fir tree clip that attach the coolant hose to the rear subframe shear plate.
  11. Disconnect the rear drive unit inverter inlet tube from the LH rear of HV battery, and plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  12. Attach the 90-degree coolant drain hose adapter to the PCS outlet hose coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab is fully seated.
  13. Attach the coolant drain hose adapter to the coolant hose extension.
  14. Attach the coolant hose extension to the coolant drain hose.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The coolant may spill. Make sure to wear safety glasses.
  15. Position the coolant drain container underneath the RH rear of vehicle.
  16. Disconnect the rear PT supply hose from the rear of HV battery, and plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  17. Attach the coolant pressure tester to the PCS inlet hose coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab is fully seated.
  18. Attach the coolant pressure tester to the pressure fitting adapter.
  19. Connect the compressed air to the coolant pressure tester.
  20. Open the regulator valve, then slowly adjust the regulator to 50 psi.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The coolant may spill. Make sure to wear safety glasses.
  21. Open the 2nd valve slowly.
  22. Set the timer to 1 minute and select Start, and then select Stop Reset once the timer is complete.
  23. Close the regulator valve.
  24. Set the timer to 1 minute and select Start, and then select Stop Reset once the timer is complete.
  25. Open the regulator valve slowly.
  26. Set the timer to 1 minute and select Start, and then select Stop Reset once the timer is complete.
  27. Close the regulator valve.
  28. Disconnect the compressed air from the coolant pressure tester.
  29. Remove the coolant pressure tester from the PCS inlet hose coupling.
  30. Position the coolant drain container underneath the LH rear of HV battery.
  31. Remove the coolant drain adapter with hose from the PCS outlet hose coupling.
  32. Attach the coolant pressure tester with hose to the PCS outlet hose coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab is fully seated.
  33. Position the coolant drain container underneath the RH rear of vehicle.
  34. Attach the coolant drain adapter with hose to the PCS inlet hose coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab is fully seated.
  35. Connect the compressed air to the coolant pressure tester.
  36. Open the regulator valve, then slowly adjust the regulator to 50 psi.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The coolant may spill. Make sure to wear safety glasses.
  37. Open the 2nd valve slowly.
  38. Set the timer to 1 minute and select Start, and then select Stop Reset once the timer is complete.
  39. Close the regulator valve.
  40. Set the timer to 1 minute and select Start, and then select Stop Reset once the timer is complete.
  41. Open the regulator valve slowly.
  42. Set the timer to 1 minute and select Start, and then select Stop Reset once the timer is complete.
  43. Close the regulator valve.
  44. Disconnect the coolant drain hose adapter from the coolant hose extension.
  45. Remove the coolant drain hose adapter from the PCS inlet hose coupling.
  46. Remove the plugs on the ends of fittings, and then install the coolant pressure test plug adapter to the PCS inlet hose coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab is fully seated.
  47. Slowly open the valve on the pressure regulator, and allow the pressure to reach specification.
  48. Close the valve and wait for 2 minutes to let the pressure settle, and then record the reading.
  49. Perform the coolant pressure leak test.
  50. Wait for another 4 minutes and record the reading.
    Informational PurposesAn informational icon, calling your attention
    Note
    The delta should be no more than 0.35 psi. If the pressure test fails, check if the coolant hose is fully seated.
  51. Disconnect the compressed air from the coolant pressure tester.
  52. Open the P1 valve to release the system pressure.
  53. Remove the coolant pressure test plug adapter from the PCS inlet hose coupling.
  54. Remove the pressure fitting adapter from the coolant pressure tester.
  55. Remove the coolant pressure tester from the PCS outlet hose coupling.
  56. Remove the plugs on the ends of fittings, and then connect the rear PT supply hose to the rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  57. Position the coolant drain container underneath the LH rear of HV battery.
  58. Remove the plugs on the ends of fittings, and then connect the rear drive unit inverter inlet tube to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
  59. Remove the plugs on the ends of fittings, and then connect the LH coolant hose to the rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  60. Remove the coolant drain container from underneath vehicle.
  61. Install the fir tree clip that attaches the coolant hose to the rear subframe shear plate.
  62. Install the rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
  63. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  64. Remove the lift arms from below the vehicle.