2025-03-12

Ancillary Bay Coolant Leak Test (Inspection)

Correction code 16200200 FRT 0.80 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 Precautionsfor safe and healthy working practices.

  • 1053600-00-C Drive Unit Pressure Test Fixture
  • 1132185-00-B Kit, Coolant Leak Test Adapters, Model 3
  • 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • GSN-TL-000564 Kit, Battery Coolant Drain and Fill

Procedure

  1. If the power conversion system is being installed, and if the ancillary bay coolant drain has already been performed, begin the ancillary bay coolant leak test at step #TASK_Z5N_YBP_GCB__GUID-0FC64F61-527E-4B70-A8AA-D7112DCD020B.
  2. Disconnect LV power. See LV Power (Modify).
  3. Remove the mid aero shield panel. See Aero Shield - Rear (Remove and Replace).
  4. Remove the rear HV battery skid plate. See Skid Plate - Rear (Remove and Replace).
  5. Position a coolant drain under the rear RH side of the HV battery.
  6. Release the clip, disconnect the rear powertrain supply hose from the RH underside of the ancillary bay, plug the female fitting of the hose, and allow the battery to drain.
  7. Connect the coolant pressure test adapter to the male fitting on the RH underside of the ancillary bay.
  8. On the drive unit pressure test fixture, turn both valve P2 (outlet) and valve P1 (inlet) clockwise to close.
  9. Turn the pressure regulator knob counter-clockwise many turns so that it is loose, to close.
  10. Connect the supply air hose to the right side of the drive unit pressure test fixture.
  11. Turn valve P1 (inlet) counter-clockwise to open.
  12. Power on the pressure gauge, and then turn the pressure regulator knob clockwise to set the pressure to 50 PSI.
    Informational PurposesAn informational icon, calling your attention
    Note
    If 50 PSI is not attainable, 48 PSI or 49 PSI is sufficient.
  13. Connect and hand-tighten the outlet air hose to the left side of the drive unit pressure test fixture.
  14. Connect and hand-tighten the outlet air hose from the drive unit pressure test fixture to the coolant pressure test adapter.
  15. Position the coolant drain under the rear LH side of the HV battery.
  16. Release the clip, disconnect the rear drive unit inverter inlet hose from the male fitting on the LH underside of the ancillary bay, plug the female fitting of the hose, and allow the battery to drain.
  17. Connect the 90 degree coolant drain adapter to the male fitting on the LH underside of the ancillary bay.
  18. Connect the coolant drain hose to the 90 degree coolant drain adapter, and route the end of the hose to the coolant waste container.
  19. If the coolant waste container is a bottle, push a shop towel partially into the bottle neck, to prevent coolant from splashing out.
  20. Set the timer for 2 minutes.
  21. Slowly turn valve P2 (outlet) counter-clockwise to open and start the timer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Monitor the coolant drain and mitigate any splashing.
  22. When the timer completes, turn valve P2 (outlet) clockwise to close.
  23. Press the grey button to disconnect the coolant drain hose from the 90 degree coolant drain adapter.
  24. Release the clip to disconnect the 90 degree coolant drain adapter from the male fitting on the LH underside of the ancillary bay.
  25. Release the clip to disconnect the coolant pressure adapter and outlet air hose together from the male fitting on the RH underside of the ancillary bay.
  26. Fasten the clip, and then connect the 180 degree coolant drain adapter to the male fitting on the RH underside of the ancillary bay.
  27. Connect the coolant drain hose to the coolant drain adapter.
  28. Fasten the clip, and then connect the coolant pressure adapter and outlet air hose together to the male fitting on the LH underside of the ancillary bay.
  29. Set the timer for 2 minutes.
  30. Slowly turn valve P2 (outlet) counter-clockwise to open and start the timer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Monitor the coolant drain and mitigate any splashing.
  31. When the timer completes, turn valve P2 (outlet) clockwise to close.
  32. Release the clip to disconnect the coolant pressure adapter and outlet air hose together from the male fitting on the LH underside of the ancillary bay.
  33. Press the grey button to disconnect the coolant drain hose from the 180 degree coolant drain adapter.
  34. Release the clip to disconnect the 180 degree coolant drain adapter from the male fitting on the RH underside of the ancillary bay.
  35. Fasten the clip, and then connect the coolant pressure adapter and outlet air hose together to the male fitting on the RH underside of the ancillary bay.
  36. Connect the coolant plug adapter to the male fitting on the LH underside of the ancillary bay.
  37. Adjust the pressure regulator knob for 50 PSI.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clockwise increases pressure, counter-clockwise decreases pressure.
    Informational PurposesAn informational icon, calling your attention
    Note
    If 50 PSI is not attainable, 48 PSI or 49 PSI is sufficient.
  38. Slowly turn valve P2 (outlet) counter-clockwise to open and allow the pressure to stabilize.
  39. Set the timer for 4 minutes.
  40. Record the starting pressure displayed.
  41. Turn valve P1 (inlet) clockwise to close, and then start the timer.
  42. When the timer completes, record the ending pressure displayed.
  43. Subtract the ending pressure from the starting pressure.
  44. Check the hoses, the adapters, and plug fittings.
  45. Turn valve P2 (outlet) clockwise to close and turn valve P1 (inlet) counter-clockwise to open.
  46. Repeat step #TASK_Z5N_YBP_GCB__GUID-D138C7EB-1DA2-45BB-8661-A97676448E54 through step #TASK_Z5N_YBP_GCB__GUID-6A842015-A7E5-44A0-AF67-A05FF040E3C8.
    • If the difference is still greater than 0.35 PSI, escalate to Service Engineering.
    • If the different is 0.35 PSI or less, continue to the next step.
  47. Disconnect the supply air hose from the right side of the drive unit pressure test fixture.
  48. Turn valve P1 (inlet) counter-clockwise to open, and allow the air to bleed of f.
  49. Loosen and disconnect the outlet air hose from the left side of the drive unit pressure test fixture.
  50. Loosen and disconnect the outlet air hose from the coolant pressure adapter.
  51. Release the clip to disconnect the coolant pressure adapter from the male fitting on the RH underside of the ancillary bay.
  52. Release the clip, and then disconnect the coolant plug adapter from the male fitting on the LH underside of the ancillary bay.
  53. Position the coolant drain under the rear RH side of the HV battery.
  54. Remove the plug from the rear powertrain supply hose, connect the hose to the male fitting on the RH underside of the ancillary bay, fasten the clip, and then perform a Push-Pull-Push test of the fitting.
  55. Position the coolant drain under the rear LH side of the HV battery.
  56. Remove the plug from the rear drive unit inverter inlet hose, connect the hose to the male fitting on the LH underside of the ancillary bay, fasten the clip, and then perform a Push-Pull-Push test of the fitting.
  57. Remove the coolant drain from under the vehicle.
  58. Install the rear HV battery skid plate. See Skid Plate - Rear (Remove and Replace).
  59. Install the mid aero shield panel. See Aero Shield - Rear (Remove and Replace).
  60. If the ancillary bay coolant leak test was requested by another service procedure, return to that procedure.
  61. Connect LV power. See #GUID-E11A35CC-1803-41C5-87F0-D7868FA3E51F.
  62. Perform a vacuum refill the cooling system. See Cooling System - Vacuum Refill (Test/Adjust).