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

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

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

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
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Replace).
Remove fresh air gutter assembly

Note
3x 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 Rear Undertray And Diffuser -Model 3/Y, Rear Aero Shield (Remove and Replace).
Release LH side hose clip from rear battery skid plate enclosure

Note
1x fir tree clip
Release RH side hose clips from rear battery skid plate enclosure

Note
2x fir tree clips
Remove lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
Remove upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
Remove upper bolts securing HV battery rear skid plate enclosure

Note
4x 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

Note
1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
Remove fir tree clip securing coolant hose to rear subframe shear plate

Note
1x fir tree clip
Disconnect RDU inverter inlet tube from LH rear of HV battery

Note
1x 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

Note
Use 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

Note
Use 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

Note
1x 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

Note
This 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

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Open 2nd valve slowly

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Close regulator valve
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Open regulator valve slowly
Set timer for 1 minutes and select start

Note
Once 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

Note
1x spring clip
Attach coolant pressure tester with hose to PCS outlet hose coupling

Note
1x 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

Note
1x 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

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Open 2nd valve slowly

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Close regulator valve
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Open regulator valve slowly
Set timer for 1 minutes and select start

Note
Once 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

Note
1x spring clip
Remove pressure fitting adapter from coolant pressure tester
Remove coolant pressure tester from PCS outlet hose coupling

Note
1x spring clip
Connect rear PT supply hose to rear of HV battery and plug hose

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
Position coolant drain container underneath LH rear of HV battery
Remove plug from HV battery and connect RDU inverter inlet tube

Note
1x 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

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
Remove coolant drain container from underneath vehicle
Install fir tree clip securing coolant hose to rear subframe shear plate

Note
1x fir tree clip
Position HV battery rear skid plate enclosure onto HV battery for installation

Note
Recommend assistance if needed
Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note
4x bolts, 13mm, 35 Nm, Torque at later step
Install upper nut securing HV battery rear skid plate enclosure hand tight

Note
1x nut, 10mm, 13 Nm, Torque at later step
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm
Install RH side hose clips to HV battery rear skid plate enclosure

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
1x clip
lnstall rear aero shield

Note
11x 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

Note
2x clips
Lower vehicle fully

Note
Raise 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

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

Note
Perform push-pull-push test to verify hose is fully engaged
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 coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant

Note
This 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

Note
Make 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

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
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
Access Thermal System routines using the UI

Note
Select Service mode > Thermal
Select "Stop Thermal Fill Drain" through UI

Note
Allow routine to complete, ensure routine is successful
Select "Start Coolant Air Purge" using the UI

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.
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line
Install coolant bottle cap
Install fresh air gutter assembly

Note
3x clips
Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Replace).
Raise all windows and close all doors.
Remove the lift arms from below the vehicle.