Replacement of EV coolant lines on a 2024 Tesla Cybertruck Cyberbeast Tri Motor. This procedure covers accessible coolant lines outside the HV battery thermal loop and drive unit cooling jackets — work involving the octovalve, heat pump, or HV battery thermal loop is out of scope.

Warnings

Tools required

Parts

• EV coolant line(s) — manufacturer-specified for Cybertruck Tri Motor × 1 — Refer to Tesla EPC for the specific line(s) being replaced
• Hose clamps (replace any disturbed crimp or spring clamps) × 4 — OEM-spec replacement clamps
• O-rings / quick-connect seals (replace any disturbed) × 4 — OEM-spec for fitting size

Fluids

• Tesla Battery/Motor Coolant (G-48) — 10 qt

Preparation

1. Park on level ground, place in P, engage 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 Tesla service procedure (Cybertruck uses 48V LV — NOT 12V). Locate the LV battery per the in-vehicle service mode diagram or Tesla Service Manual.
4. DO NOT touch, cut, or pierce ANY orange cable — these are 800V high-voltage and lethal.
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 coolant system to cool fully — coolant lines can be hot and pressurized after recent driving or charging.
7. Raise the vehicle on a lift rated for Cybertruck weight, using Tesla-specified lift points only. Do NOT lift on the battery enclosure or exoskeleton seams.
8. Identify the specific coolant line(s) to be replaced and confirm they are part of the EV (drive unit / power electronics) loop and not the HV battery thermal loop, octovalve, or heat pump circuit. If unclear, STOP.

Procedure

1. 1

   Remove underbody / aero shielding for access
   Remove the relevant underbody aero shields and any wheel-well liner sections required to access the coolant line routing. Cybertruck uses a mix of plastic fasteners and threaded screws — keep them organized for reassembly.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Place catch pan and identify drain point
   Position a clean catch pan beneath the lowest point of the coolant loop being serviced. Identify the manufacturer-specified drain point or the lowest accessible fitting on the affected loop. Do NOT drain the HV battery thermal loop.
   ⚠Confirm the loop is depressurized before opening any fitting. Even at ambient temperature, EV coolant loops can hold residual pressure from the expansion tank.
3. 3

   Relieve system pressure at the expansion reservoir
   Slowly open the EV coolant expansion reservoir cap to relieve pressure. Use a rag to catch any spray. Leave the cap loose to allow the loop to drain freely.
4. 4

   Drain the affected coolant loop
   Open the lowest fitting or drain on the affected loop and drain into the catch pan. Capture all coolant for proper disposal — Tesla G-48 is ethylene glycol based and toxic to animals.
5. 5

   Document line routing
   Before disturbing any clips or brackets, photograph the existing coolant line routing, clip positions, and clearances from harnesses and orange HV cabling. Correct routing is critical to prevent chafing and to maintain HV cable clearance.
   ⚠️Note the location of any nearby orange HV cabling. Replacement lines must maintain factory clearance from HV cables.
6. 6

   Disconnect coolant line fittings
   Disconnect the coolant line at both ends. Quick-connect fittings require depressing the locking tab evenly; threaded fittings unscrew with a backing wrench on the mating fitting to prevent twisting the component. Cap or plug open fittings to prevent contamination.
   ⚠Never pry on quick-connect collars with a screwdriver — broken collars typically require replacing the entire component, not just the line.
   Torque spec

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

   Release hose clamps where applicable
   For sections retained by hose clamps, slide the clamp back along the hose and work the hose off the barb. If a clamp shows distortion or a hose shows swelling/cracking, replace it.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
8. 8

   Remove line retaining brackets and clips
   Remove bracket bolts and harness-style clips securing the coolant line(s) along the chassis. Set the bracket hardware aside, organized by location.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
9. 9

   Remove the old coolant line
   Carefully extract the line from its routing path. Note any heat shielding, foam wrap, or protective sleeving — these must be transferred to the new line if the replacement does not include them.
   ⚠Do not pull the line past orange HV cabling without supporting both — accidental contact or abrasion of an HV cable jacket is a safety hazard.
10. 10

    Install the new coolant line
    Route the new line exactly per the photos taken in Step 5. Confirm clearance from HV cables, exhaust of any nearby components, and moving suspension/steering parts. Install new O-rings or seals on quick-connect fittings before seating.
11. 11

    Secure brackets, clips, and hose connections
    Reinstall bracket bolts and any sensor brackets to the line. Seat hose ends fully on barbs and position new clamps. Engage all quick-connect fittings until they audibly click and verify by lightly pulling on the fitting.
    Torque spec

    Bracket Bolts20 Nm (15 lb-ft)

    Hose Clamps3 Nm (2 lb-ft)

    Coolant Line Fittings15 Nm (11 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)
12. 12

    Reinstall any disturbed mounting hardware
    If components had to be loosened or shifted (e.g. ancillary brackets) to access the line, reinstall to OEM specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
13. 13

    Vacuum-fill the coolant loop
    Connect a vacuum fill tool to the expansion reservoir. Pull a deep vacuum (per tool instructions) and verify the system holds vacuum for several minutes — this confirms no leaks. Then draw in fresh Tesla G-48 coolant until full. Vacuum filling is required to avoid air pockets in EV coolant loops.
    ⚠Do NOT gravity-fill — air trapped in EV coolant loops can cause pump cavitation and component overheating.
14. 14

    Reinstall underbody shielding
    Reinstall aero shields, wheel-well liners, and any other panels removed for access. Verify all fasteners are present.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reconnect the 48V low-voltage battery per Tesla procedure.
2. Reinstall the expansion reservoir cap to OEM specification.
3. Lower the vehicle to the ground.
4. Wake the vehicle and allow thermal management systems to initialize. Monitor for fault messages on the center display.
5. Run the vehicle through a thermal conditioning cycle (e.g. precondition for charging or cabin heat) to circulate coolant and bleed any residual air.
6. Recheck the expansion reservoir level after the cycle and top up with Tesla G-48 to the cold-fill mark.

Verification

• No coolant or thermal management fault messages on the center display.
• No visible leaks at fittings, clamps, or along the line — inspect after at least one full thermal cycle.
• Expansion reservoir level remains stable at the cold-fill mark after multiple drive/charge cycles (top up if it drops, indicating residual air working out).
• No abnormal coolant pump noise during preconditioning or DC fast charging.
• Confirm clearance between new line and any nearby orange HV cabling is preserved.
• Document the service date — Tesla recommends EV coolant inspection at 4 years / 50,000 mi; the next inspection should be scheduled accordingly.
• Dispose of drained coolant per local hazardous waste regulations — ethylene glycol is toxic.

More procedures for this vehicle