14/05/2024 19:43:56

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
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Procedure

  1. Place the vehicle on the 2-post lift.
    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. Run Thermal Fill Drain (Coolant Only) through the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select 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
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Remove fresh air gutter assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  8. Disconnect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
  9. Raise the vehicle to a comfortable working height, and lower the lift onto locks.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.

  10. Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  11. Release LH side hose clip from rear battery skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  12. Release RH side hose clips from rear battery skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  13. Remove lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
  14. Remove upper nut securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
  15. Remove upper bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  16. Remove HV battery rear skid plate enclosure
  17. Position coolant drain container underneath LH rear of HV battery
  18. Disconnect LH coolant hose from rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
  19. Remove fir tree clip securing coolant hose to rear subframe shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  20. Disconnect RDU inverter inlet tube from LH rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
  21. Attach coolant drain hose adapter to PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    Use adapter with 90 degree angle, Make sure locking tab is fully seated
  22. Attach coolant drain hose adapter to coolant hose extension
  23. Attach coolant hose extension to coolant drain hose
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  24. Position coolant drain container underneath RH rear of vehicle
  25. Disconnect rear PT supply hose from rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
  26. Attach coolant pressure tester to PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    This adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
  27. Attach coolant pressure tester to pressure fitting adapter
  28. Connect compressed air to coolant pressure tester
  29. Open regulator valve then slowly adjust regulator to 50 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  30. Open 2nd valve slowly
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  31. Set timer for 1 minutes and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  32. Close regulator valve
  33. Set timer for 1 minutes and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  34. Open regulator valve slowly
  35. Set timer for 1 minutes and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  36. Close regulator valve
  37. Disconnect compressed air from coolant pressure tester
  38. Remove coolant pressure tester from PCS inlet hose coupling
  39. Position coolant drain container underneath LH rear of HV battery
  40. Remove coolant drain adapter with hose from PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  41. Attach coolant pressure tester with hose to PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Make sure the locking tab is fully seated
  42. Position coolant drain container underneath RH rear of vehicle
  43. Attach coolant drain adapter with hose to PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Make sure the locking tab is fully seated
  44. Connect compressed air to coolant pressure tester
  45. Open regulator valve then slowly adjust regulator to 50 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  46. Open 2nd valve slowly
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  47. Set timer for 1 minutes and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  48. Close regulator valve
  49. Set timer for 1 minutes and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  50. Open regulator valve slowly
  51. Set timer for 1 minutes and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  52. Close regulator valve
  53. Disconnect compressed air from coolant pressure tester
  54. Disconnect coolant drain hose adapter from coolant hose extension
  55. Remove coolant drain hose adapter from PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  56. Remove pressure fitting adapter from coolant pressure tester
  57. Remove coolant pressure tester from PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  58. Connect rear PT supply hose to rear of HV battery and plug hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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
  59. Position coolant drain container underneath LH rear of HV battery
  60. Remove plug from HV battery and connect RDU inverter inlet tube
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged
  61. Connect LH coolant hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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
  62. Remove coolant drain container from underneath vehicle
  63. Install fir tree clip securing coolant hose to rear subframe shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  64. Position HV battery rear skid plate enclosure onto HV battery for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance if needed
  65. Install upper bolts securing HV battery rear skid plate enclosure hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, Torque at later step
  66. Install upper nut securing HV battery rear skid plate enclosure hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Torque at later step
  67. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  68. Torque bolts securing HV battery rear skid plate enclosure to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  69. Torque upper nut securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  70. Install RH side hose clips to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  71. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  72. lnstall rear aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts
  73. Install LH and RH clips securing rear aero shield to wheel house liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  74. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  75. Remove coolant bottle cap
  76. Place empty coolant container into front storage area
  77. Fill container with at least 15L of coolant
  78. Place filled coolant container into front storage area
  79. Install refill tool cap onto coolant bottle assembly
  80. Setup vacuum refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  81. Install vacuum refill hose into refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully engaged
  82. Position overflow hose into empty container
  83. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  84. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  85. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  86. Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant
    Informational PurposesAn informational icon, calling your attention
    Note
    This purges trapped air from the hose
  87. Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
  88. Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
  89. Slowly open refill valve to allow coolant to be drawn into system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  90. Once gauge reads zero, close refill valve
  91. Disconnect shop air supply from coolant refill tool
  92. Remove coolant refill hose from coolant container
  93. Remove coolant overflow hose from coolant container
  94. Remove vacuum refill hose from refill cap on coolant bottle
  95. Remove coolant refill tool from vehicle
  96. Remove both coolant containers from inside underhood area
  97. Connect First Responder Loop and LV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
  98. Unlock vehicle gateway
    Informational PurposesAn informational icon, calling your attention
    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
  99. Access Thermal System routines using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Service mode > Thermal
  100. Select "Stop Thermal Fill Drain" through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow routine to complete, ensure routine is successful
  101. Select "Start Coolant Air Purge" using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    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, 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.
  102. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that fluid level is at Max line
  103. Install coolant bottle cap
  104. Install fresh air gutter assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  105. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  106. Raise all windows and close all doors.
  107. Remove the lift arms from below the vehicle.