Cooling System - Drain and Refill

FRT No: 18300100
Caution: Use the specified coolant only. In this manual, refer to General Information > Capacities, Fluids, and Lubricants > Fluids .

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1008787-00-A Battery Cooling System Pressure Tester
Bosch 697-0700-4 Coolant System Tester (Pump and One Adapter)
Note: Only the coolant reservoir adapter is used for this procedure.
Tesla 1050448-00-A Universal Cool Sys Refiller Matco MCR102U

Drain

  1. Prepare the vehicle for lifting, but do not raise the vehicle at this time.
  2. Use Toolbox to prepare the vehicle for draining and refilling coolant:
    1. Connect a laptop with Toolbox 2.0 or higher to the vehicle.
    2. Oen the "Fluid Drain and Fill" panel.
    3. Check the "Coolant Panel" check box.
    4. In the "Routine" dropdown menu, select Fluid Drain/Fill.
    5. Press the Start/Play button.

Note: Before continuing this procedure, inspect the "Thermal" mode readout on the touchscreen and ensure that the powertrain and battery systems are in "series" mode"

  1. Remove the HEPA filter duct (refer to procedure).
  2. Disconnect 12V power (refer to procedure).
  3. Remove the front aeroshield (refer to procedure).
  4. Disconnect the low voltage harness from battery coolant pump 1.

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  5. Slide the coolant pump off of the subframe bracket.
  6. Release the barrel clip on the inlet coolant hose from the top of the subframe.
  7. Place a coolant catcher beneath the coolant pump.
  8. Clamp the outlet coolant hose. Release the inlet cooling hose from the pump and allow the coolant to drain into the coolant catcher.
    Tip: Move the inlet hose behind the subframe crossmember.

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  9. As coolant continues to drain, lower the vehicle.
  10. Install the reservoir adapter into the reservoir.
  11. Insert the rubber hose on the pressure tester into the rubber grommet in the coolant reservoir adapter. Push the hose into the grommet until it is secure.

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    1 Pressure tester
    2 Coolant reservoir adapter
  12. Make sure the valve on the Battery Cooling System Pressure Tester is closed (the handle is perpendicular to the valve).

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  13. Connect the Battery Cooling System Pressure Tester to a compressed air line.
  14. Set the pressure regulator on the Battery Cooling System Pressure Tester to 5 psi (0.34 Bar).
    Caution: Do not exceed 5 psi (0.34 Bar) or damage to the battery might result.
  15. Slowly open the valve on the pressure tester. When enough coolant has been removed so that the flow has been reduced to a slow drip, close the regulator.
  16. Raise the vehicle.
  17. Clamp the inlet coolant hose.
  18. Release the clamp on the outlet coolant hose. Allow coolant to drain from the pump into the coolant cacher.

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    1 Pressure tester
    2 Coolant reservoir adapter
  19. As coolant continues to drain, lower the vehicle.
  20. Set the pressure regulator on the Battery Cooling System Pressure Tester to 5 psi (0.34 Bar).
    Caution: Do not exceed 5 psi (0.34 Bar) or damage to the battery might result.
  21. Slowly open the valve on the pressure tester. When enough coolant has been removed so that the flow from the pump has been reduced to a slow drip, close the regulator.
  22. Raise the vehicle.
  23. Secure the hoses to the pump, then reinstall the pump onto the subframe bracket.
  24. Reconnect the low voltage harness to the coolant pump.

Note: Do not reinstall the front aeroshield at this time.

  1. Lower the vehicle.
  2. Remove the pressure tester from the vehicle.

Vacuum Fill

  1. Ensure that the coolant reservoir adapter is securely installed, then connect the vacuum refill tool.
  2. Ensure that the coolant refill valve and the air inlet valve are closed.

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    1 Coolant refill hose
    2 Coolant refill valve
    3 Air inlet valve
    4 Shop air supply
    5 Overflow hose
  3. Connect shop air supply with a minimum pressure of 5.5 bar (80 PSI) to the vacuum refill tool.
  4. Place the end of the overflow hose in a suitable container to collect any coolant that is drawn out of the system when the vacuum is applied.
  5. Open the air inlet valve.
    Note: A hissing noise is normal.
  6. Allow the tool to evacuate the system until the needle on the vacuum gauge reaches the green range or the needle stops moving.
    Note: It is normal for some cooling hoses to collapse due to the vacuum in the system.
  7. Close the air inlet valve and monitor the gauge for approximately 30 seconds to verify that a vacuum is maintained in the cooling system.
    Note: If the gauge reading drops, there is a leak in the system that must be fixed before refilling with coolant.
  8. Position a container of coolant at, or as close as possible to, the height of the coolant reservoir.
    Note: Ensure that there is sufficient coolant to refill the entire system. In this manual, refer to General Information > Capacities, Fluids, and Lubricants > Fluid Capacities.
    Caution: Use the specified coolant only. In this manual, refer to General Information > Capacities, Fluids, and Lubricants > Fluids.
  9. Place the end of the coolant refill hose into the coolant container. Ensure that the end is fully submerged.
    Tip: If the container is especially deep, the end of the hose might float in the coolant. Use a weight, hanger, or other tool to keep the end of the hose submerged in the coolant.
  10. Very slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose. Close the valve when the hose is full of coolant. This purges trapped air from the hose.
  11. Reopen the air inlet valve. Close the valve when the vacuum gauge needle stops rising.
  12. Slowly open the coolant refill valve to allow coolant to be drawn into the system.
    Caution: Ensure that the end of the coolant refill hose remains submerged to prevent air from being drawn into the system. Immediately close the coolant refill valve if air enters the coolant refill hose.
  13. Once the gauge stops moving, close the coolant refill valve.
  14. Remove the vacuum refill tool:
    1. Leave the coolant refill hose in the container.
    2. Lift the tool from the reservoir.
    3. Holding the tool above the container, open the coolant refill valve to drain the coolant from the refill hose into the container.
  15. Start the cooling system bleed procedure (refer to procedure).
    Tip: It is not necessary to run the complete (15 minute) bleed routine. The bleed routine can be stopped once the coolant level has stabilized.
  16. After the bleed procedure is complete, reinstall the front aeroshield.