Battery cooling system service on the 2024 Cybertruck involves draining, flushing, and refilling the low-voltage/accessory cooling loop with Tesla G-48 coolant. This procedure addresses ONLY the accessible accessory/radiator coolant loop — any work involving the HV battery thermal loop, octovalve, or heat pump requires Tesla Toolbox and HV training.

Warnings

Tools required

Parts

• Coolant hose clamps (replace if spring-type are fatigued) × 4 — OEM-spec spring or worm clamp as removed
• Underbody panel fasteners (often single-use plastic) × 10 — manufacturer-specified clip

Fluids

• Tesla Battery/Motor Coolant (G-48 specification, pre-mixed) — 10 qt

Preparation

1. Park on level ground, place in P, and engage the parking brake.
2. Exit ALL doors with the key fob away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Disconnect the 48V low-voltage battery per Cybertruck service procedure (NOT a 12V battery — terminals, fusing, and disconnect order differ). Refer to the Tesla Service Manual for the 48V isolation sequence.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal at 800V on this platform.
5. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
6. Allow the vehicle to cool for at least 1 hour before opening any coolant circuit — pressurized coolant can scald.
7. Place the air suspension into Jack/Service Mode via the touchscreen before lifting; failure to do so can damage the air struts or trigger fault codes.
8. Raise the vehicle on a lift or jack stands rated for the Cybertruck's curb weight; use the manufacturer-specified lift points.
9. Have at least 12 quarts of containment ready — actual drained volume varies by how much remains in the heat exchangers.

Procedure

1. 1

   Confirm scope of service
   Verify the job is limited to the accessible accessory/radiator cooling loop (front radiator, expansion/degas bottle, accessible hoses, low-voltage electronics cooling). If the work order requires servicing the HV battery thermal loop, octovalve, heat pump, or any orange-cabled component, STOP — that work requires Tesla Toolbox and HV-certified personnel.
   ⚠️Do not loosen any coolant fitting that routes directly into the HV battery pack or octovalve assembly.
2. 2

   Remove front underbody aero panel
   Remove the front underbody/aero shield to access the radiator drain area and lower coolant hoses. Note clip locations; many fasteners are single-use plastic and should be replaced.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Depressurize and open the coolant reservoir
   Confirm system is cool. Slowly rotate the coolant reservoir cap to its first detent to vent residual pressure, then remove fully. Inspect cap seal and reservoir for contamination, oil sheen, or discoloration — any of these indicate cross-contamination and require deeper diagnosis before refilling.
4. 4

   Drain the accessible coolant loop
   Position the drain pan beneath the lowest point of the accessible loop (typically the lower radiator hose connection on Cybertruck). Loosen the lower hose clamp and carefully separate the hose to drain. If a dedicated drain plug is present on the radiator, use it instead. Capture all fluid for disposal. Do NOT open any fitting that connects to the HV battery thermal circuit.
   ⚠Coolant remaining in upper hoses and heat exchangers may continue to weep for several minutes. Keep pan in place.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)
5. 5

   Inspect hoses, clamps, and reservoir
   With the system drained, inspect all accessible coolant hoses for swelling, hardening, chafing, or weeping. Inspect spring clamps for fatigue. Replace any suspect hoses or clamps with OEM-spec parts. Inspect the degas/expansion bottle for cracks at the seams and around mounting tabs.
6. 6

   Reconnect lower hose / drain point
   Reinstall the lower hose with a new or verified clamp, or reinstall the radiator drain plug with a fresh seal if equipped. Ensure clamp orientation matches removal.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)
7. 7

   Vacuum-fill the cooling system
   Connect a coolant vacuum-fill tool to the reservoir. Pull the system down to manufacturer-specified vacuum (typically ~25 inHg) and verify it holds — a failure to hold vacuum indicates a leak that must be found before filling. With vacuum confirmed, draw in pre-mixed Tesla G-48 coolant until the reservoir reaches the COLD FILL line. Total system capacity for the accessible loop is approximately 10 quarts; do not overfill.
8. 8

   Install reservoir cap and prepare for bleed
   Install the reservoir cap to the first sealed position. Reconnect the 48V low-voltage battery following the manufacturer-specified reconnection sequence.
9. 9

   Run the bleed/circulation routine
   With doors closed and key fob present, power the vehicle ON (do not drive). Run the HVAC and cooling system through a circulation cycle per Tesla service procedure to purge air from the accessory loop. Tesla's full service bleed routine requires Toolbox; without it, run multiple heat/cool cycles and monitor reservoir level, topping off as air is expelled. If air cannot be fully purged without Toolbox, escalate to a Tesla-certified shop.
10. 10

    Top off and verify level
    After the system has cycled and stabilized at operating temperature then cooled, top off the reservoir to the COLD FILL mark with G-48. Verify cap seals correctly.
11. 11

    Reinstall underbody panel
    Reinstall the front underbody aero panel using new clips where required.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Confirm all hose clamps are seated and oriented as found.
2. Confirm reservoir cap is fully seated and locked.
3. Confirm 48V low-voltage battery terminals are torqued to OEM specification — refer to Tesla Service Manual (do not apply generic 12V values).
4. Reinstall any removed trim or covers and verify all single-use clips were replaced.
5. Exit Jack/Service Mode and lower the vehicle; allow air suspension to re-level before driving.

Verification

• With the vehicle at operating temperature, verify no coolant warning, low-coolant alert, or thermal fault appears on the touchscreen.
• After a full heat-cool cycle (drive followed by 1+ hour cool-down), recheck the reservoir at COLD FILL — a drop indicates remaining trapped air or a leak.
• Inspect under the vehicle for drips at the lower hose, drain plug, and reservoir base after the first drive.
• Confirm cabin HVAC heat and AC both function normally — abnormal performance can indicate the wrong loop was serviced or air remains in the system.
• Document the service date and odometer reading. Tesla's current guidance is battery coolant inspection at 4 years / 50,000 mi — schedule the next inspection accordingly.
• If the vehicle logs any thermal-management DTCs after service, have the system bled and verified using Tesla Toolbox at a certified shop — the consumer-accessible bleed is not a substitute for the factory routine.

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