Tesla Model 3: Penthouse Coolant Leak Test

DRAFT

Warning:

This procedure was derived from pre-production computer models, and might not reflect the real-world situation. Warnings and cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components.

SPECIAL TOOLS

Drive Unit Pressure Test Fixture (1053600-00-C)

Kit, Coolant Leak Test Adapters, Model 3 (1132185-00-B)

Kit, Coolant Drain & Fill Adapters, M3 (1133843-00-A)

Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-A)

Procedure

1. Disconnect 12V power. See 12V Power (Disconnect and Connect).
2. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
3. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
4. Position a coolant drain under the rear RH side of the HV battery.

5. Disconnect the rear powertrain supply hose from the RH underside of the penthouse, plug the female fitting of the hose, and allow the battery to drain.
6. Connect the coolant pressure test adapter to the HV battery.
7. Connect the drive unit pressure test fixture to the coolant pressure test adapter.
8. Close both valves P1 (inlet) and P2 (outlet) on the test fixture, and connect a compressed air supply line.
9. Fully close the regulator, and then open P1 (inlet valve).
10. Set the pressure regulator of the test fixture to 50 psi.
11. Position the coolant drain under the rear LH side of the HV battery.

12. Disconnect the rear drive unit inverter inlet hose from the LH side of the HV battery, plug the female fitting of the hose, and allow the battery to drain.
13. Connect the coolant drain adapter to the LH side male fitting under the penthouse, and direct the tube to the coolant waste container.
14. If the coolant waste container is a bottle, push a shop towel partially into the bottle neck, to prevent coolant from splashing out.
15. Slowly open P2 (outlet valve) to speed the drain, and then close P2 (outlet valve).
16. Disconnect the coolant drain adapter, and then connect the coolant pressure test adapter plug to the HV battery.
17. Open P2 (outlet valve) again, and allow at least 110 seconds for the pressure to stabilize to 50 psi.
18. Close P1 (inlet valve), record the starting pressure displayed, and start a 4 minute timer.
19. If the penthouse cover was removed as part of another procedure, inspect the coolant input and output tubes and fittings for leaks.
20. After 4 minutes record the ending pressure displayed.
21. Subtract the ending pressure from the starting pressure, and if:

• The difference is greater than 0.35 psi, check the hose, adapter, and plug fittings, close P2 (outlet valve) and open P1 (inlet valve), check the regulator pressure, and then retest from step 17. If the difference is still greater than 0.35 psi, escalate a Toolbox session.
• The difference is less than 0.35 psi, continue the procedure

22. Disconnect the air supply from the test fixture.
23. Open P1 (inlet valve), and disconnect the test fixture from the coolant pressure test adapter.
24. Remove the coolant pressure test adapter and coolant pressure test adapter plug from the HV battery, and the plugs from the hoses.
25. Connect the rear powertrain supply hose to the RH side of the HV battery, and the rear drive unit inverter inlet hose to the LH side of the HV battery.
26. Remove the coolant drain from under the vehicle.
27. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
28. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
29. Connect 12V power. See 12V Power (Disconnect and Connect).
30. Perform a vacuum refill the cooling system. See Cooling System (Vacuum Refill).

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