Ancillary Bay Coolant (Drain and Refill)
Correction code 16202000 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 LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 1053600-00-D Drive Unit Pressure Test Fixture
- 1135762-00-A Coolant Hose Plug Kit
- 1065131-00-A Battery Coolant Drain Kit
- 1080568-00-A Fluid Catcher
Procedure
-
Place the vehicle on the
2-post lift.
Tip: Ensure the vehicle is not charging.
- Open all doors and lower all windows.
- Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
- Unlock the vehicle gateway. See Gateway Unlock.
-
Run Thermal Fill Drain
(Coolant Only) through the UI
NoteSelect Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
-
Remove fresh air gutter
assembly
Note3x clips
- Disconnect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
-
Raise the vehicle to a
comfortable working height, and lower the lift onto locks.
CAUTION
Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.
Make sure that the doors are clear of surrounding objects.
- Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
-
Release LH side hose clip
from rear battery skid plate enclosure
Note1x fir tree clip
-
Release RH side hose clips
from rear battery skid plate enclosure
Note2x fir tree clips
-
Remove lower bolts securing
HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
-
Remove upper nut securing HV
battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
-
Remove upper bolts securing
HV battery rear skid plate enclosure
Note4x bolts, 13mm, 35 Nm
-
Remove HV battery rear skid
plate enclosure
-
Position coolant drain
container underneath LH rear of HV battery
-
Disconnect LH coolant hose
from rear of HV battery
Note1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
-
Remove fir tree clip
securing coolant hose to rear subframe shear plate
Note1x fir tree clip
-
Disconnect RDU inverter
inlet tube from LH rear of HV battery
Note1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
-
Attach coolant drain hose
adapter to PCS outlet hose coupling
NoteUse adapter with 90 degree angle, Make sure locking tab is fully seated
-
Attach coolant drain hose
adapter to coolant hose extension
-
Attach coolant hose
extension to coolant drain hose
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Position coolant drain
container underneath RH rear of vehicle
-
Disconnect rear PT supply
hose from rear of HV battery
Note1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
-
Attach coolant pressure
tester to PCS inlet hose coupling
NoteThis adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
-
Attach coolant pressure
tester to pressure fitting adapter
-
Connect compressed air to
coolant pressure tester
-
Open regulator valve then
slowly adjust regulator to 50 psi
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Open 2nd valve slowly
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Set timer for 1 minutes and
select start
NoteOnce timer is complete, select Stop Reset
-
Close regulator valve
-
Set timer for 1 minutes and
select start
NoteOnce timer is complete, select Stop Reset
-
Open regulator valve
slowly
-
Set timer for 1 minutes and
select start
NoteOnce timer is complete, select Stop Reset
-
Close regulator valve
-
Disconnect compressed air
from coolant pressure tester
-
Remove coolant pressure
tester from PCS inlet hose coupling
-
Position coolant drain
container underneath LH rear of HV battery
-
Remove coolant drain adapter
with hose from PCS outlet hose coupling
Note1x spring clip
-
Attach coolant pressure
tester with hose to PCS outlet hose coupling
Note1x spring clip, Make sure the locking tab is fully seated
-
Position coolant drain
container underneath RH rear of vehicle
-
Attach coolant drain adapter
with hose to PCS inlet hose coupling
Note1x spring clip, Make sure the locking tab is fully seated
-
Connect compressed air to
coolant pressure tester
-
Open regulator valve then
slowly adjust regulator to 50 psi
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Open 2nd valve slowly
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Set timer for 1 minutes and
select start
NoteOnce timer is complete, select Stop Reset
-
Close regulator valve
-
Set timer for 1 minutes and
select start
NoteOnce timer is complete, select Stop Reset
-
Open regulator valve
slowly
-
Set timer for 1 minutes and
select start
NoteOnce timer is complete, select Stop Reset
-
Close regulator valve
-
Disconnect compressed air
from coolant pressure tester
-
Disconnect coolant drain
hose adapter from coolant hose extension
-
Remove coolant drain hose
adapter from PCS inlet hose coupling
Note1x spring clip
-
Remove pressure fitting
adapter from coolant pressure tester
-
Remove coolant pressure
tester from PCS outlet hose coupling
Note1x spring clip
-
Connect rear PT supply hose
to rear of HV battery and plug hose
Note1x spring clip, 1x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair
-
Position coolant drain
container underneath LH rear of HV battery
-
Remove plug from HV battery
and connect RDU inverter inlet tube
Note1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged
-
Connect LH coolant hose to
rear of HV battery
Note1x spring clip, 2x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair
- Remove coolant drain container from underneath vehicle
-
Install fir tree clip
securing coolant hose to rear subframe shear plate
Note1x fir tree clip
-
Position HV battery rear
skid plate enclosure onto HV battery for installation
NoteRecommend assistance if needed
-
Install upper bolts securing
HV battery rear skid plate enclosure hand tight
Note4x bolts, 13mm, 35 Nm, Torque at later step
-
Install upper nut securing
HV battery rear skid plate enclosure hand tight
Note1x nut, 10mm, 13 Nm, Torque at later step
-
Install lower bolts securing
HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
-
Torque bolts securing HV
battery rear skid plate enclosure to vehicle
Note4x bolts, 13mm, 35 Nm
-
Torque upper nut securing HV
battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm
-
Install RH side hose clips
to HV battery rear skid plate enclosure
Note2x fir tree clips
-
Install LH side hose clip to
HV battery rear skid plate enclosure
Note1x clip
-
lnstall rear aero
shield
Note11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts
-
Install LH and RH clips
securing rear aero shield to wheel house liner
Note2x clips
-
Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Remove coolant bottle
cap
-
Place empty coolant
container into front storage area
-
Fill container with at least
15L of coolant
-
Place filled coolant
container into front storage area
-
Install refill tool cap onto
coolant bottle assembly
-
Setup vacuum refill
tool
NoteVerify all valves on refill tool are in the closed position, See image for clarity
-
Install vacuum refill hose
into refill cap on coolant bottle
NotePerform push-pull-push test to verify hose is fully engaged
-
Position overflow hose into
empty container
-
Place refill hose inside
filled coolant container
NoteMake sure hose end is fully submerged into coolant
-
Connect shop air supply to
coolant refill tool
NoteIf not already done, Verify refill valve is set to off
-
Open air inlet valve to draw
a vacuum, Once gauge stabilizes, Fully close valve
NoteGauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
-
Slowly open coolant refill
valve to allow coolant to be drawn into coolant refill hose, Close valve
when hose is full of coolant
NoteThis purges trapped air from the hose
- Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
- Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
-
Slowly open refill valve to
allow coolant to be drawn into system
NoteMake sure hose end of refill hose is fully submerged during entire process
-
Once gauge reads zero, close
refill valve
-
Disconnect shop air supply
from coolant refill tool
-
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 coolant refill tool
from vehicle
-
Remove both coolant
containers from inside underhood area
-
Connect First Responder Loop
and LV battery
Note2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
-
Unlock vehicle gateway
NoteAfter 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
-
Access Thermal System
routines using the UI
NoteSelect Service mode > Thermal
-
Select "Stop Thermal Fill
Drain" through UI
NoteAllow routine to complete, ensure routine is successful
-
Select "Start Coolant Air
Purge" using the UI
NoteWait 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, 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
NoteEnsure that fluid level is at Max line
-
Install coolant bottle
cap
-
Install fresh air gutter
assembly
Note3x clips
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Raise all windows and close all doors.
- Remove the lift arms from below the vehicle.