Replacement of EV coolant lines on a 2024 Tesla Cybertruck Dual Motor AWD. This procedure covers accessible low-voltage coolant plumbing only — NOT the HV battery thermal loop, octovalve, or drive unit cooling jackets, which require Tesla Toolbox and HV training.

Warnings

Tools required

Parts

• Replacement EV coolant line(s) × 1 — Tesla Cybertruck OEM coolant hose — match by routing location
• Hose clamps (spring or worm-gear, as OEM) × 4 — Match OEM clamp style and size
• O-rings / quick-connect seals × 2 — OEM coolant fitting seal kit

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. NOTE: This is a 48V system, not 12V — use the correct procedure and PPE.
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. Enable Service Mode / Jack Mode on the touchscreen to disable air suspension self-leveling before lifting.
7. Allow the coolant system to cool completely (minimum 1 hour after last drive) — coolant is hot and pressurized when warm.
8. Identify the specific coolant line(s) being replaced and confirm they are part of the accessible low-voltage / accessory cooling circuit, NOT the HV battery thermal loop. If unclear, STOP.
9. Stage a catch pan capable of holding the full system capacity (~10 qt).

Procedure

1. 1

   Raise and support the vehicle
   With Service Mode active, lift the Cybertruck at the manufacturer-specified jack points and support on rated jack stands. Confirm the vehicle is stable before going underneath. Remove wheels only if access requires it.
   ⚠Use only Tesla-approved lift points. The exoskeleton and battery enclosure are not lift-rated everywhere.
2. 2

   Remove underbody covers and access panels
   Remove the relevant underbody aero/skid panels and any front trunk (frunk) trim required to expose the coolant lines. Catalog fasteners by location. Inspect for orange cabling routed alongside — if present, do not disturb.
   Torque spec

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

   Identify and photograph the coolant routing
   Photograph the existing coolant line routing, clamp positions, retainers, and any heat shielding before disassembly. The Cybertruck's coolant plumbing is densely packaged; correct re-routing is essential to avoid chafing against the exoskeleton or harnesses.
4. 4

   Drain the coolant circuit
   Locate the lowest accessible drain point on the affected circuit and drain into the catch pan. If no drain plug exists on this circuit, draining will occur as the line is disconnected — position the catch pan accordingly. Capture all fluid for proper disposal.
   ⚠Tesla G-48 coolant is toxic to animals. Contain all spills.
5. 5

   Disconnect any sensors on the coolant line
   If the line has an inline temperature or pressure sensor, disconnect the electrical connector and remove the sensor or sensor bracket as required. Cap the sensor port to prevent contamination.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)

   Connector Bolts7 Nm (5 lb-ft)
6. 6

   Release coolant line fittings
   For quick-connect fittings, use the correct release tool to depress the locking tabs and separate. For threaded fittings, loosen carefully — back up the mating fitting with a second wrench to avoid twisting downstream lines. For clamped hoses, release the clamp and work the hose free without prying against adjacent components.
   ⚠Never force a quick-connect — broken locking tabs require replacement of the mating component.
7. 7

   Unbolt line retaining brackets
   Remove the bracket bolts and any P-clips or routing clamps securing the coolant line to the frame, exoskeleton subframe, or accessory mounts. Keep hardware organized by location.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Remove the old coolant line
   Carefully extract the old line from the vehicle, paying attention to its path around harnesses, suspension components, and HV cabling. Do NOT pull lines past orange cables or HV components.
   ⚠️If the line is routed alongside an orange HV cable, STOP. Do not disturb HV cabling.
9. 9

   Compare old and new lines
   Lay the new line next to the old. Verify length, bend geometry, fitting orientation, and any integrated brackets or sensors match. A mismatched line indicates an incorrect part — do not install.
10. 10

    Install the new coolant line
    Lubricate new O-rings with clean coolant before installation. Route the new line exactly as the original, ensuring no contact with the exoskeleton, suspension components, or HV cabling. Seat all quick-connects fully — listen for the audible click and tug-test each connection.
    ⚠A partially seated quick-connect will leak under pressure and may fail without warning.
    Torque spec

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

    Reinstall brackets, clamps, and sensors
    Reinstall all retaining brackets, P-clips, hose clamps, and any inline sensors. Torque each to the manufacturer-specified value. Reconnect sensor electrical connectors and verify they are fully latched.
    Torque spec

    Bracket Bolts20 Nm (15 lb-ft)

    Mounting Bolts27 Nm (20 lb-ft)

    Hose Clamps3 Nm (2 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)

    Connector Bolts7 Nm (5 lb-ft)
12. 12

    Vacuum-fill the cooling system
    Using a vacuum fill tool, draw the system down to the tool manufacturer's specified vacuum and hold to verify no leaks. Then draw in fresh Tesla G-48 coolant. Vacuum filling is required to avoid air pockets in the Cybertruck's complex coolant routing.
    ⚠Use only Tesla-specified G-48 coolant. Mixing coolant types will damage seals and degrade thermal performance.
13. 13

    Top off and inspect for leaks
    Top off the reservoir to the cold-fill mark. Reconnect the 48V low-voltage battery using correct sequence. Exit Service Mode. Run the vehicle's coolant pump cycle (per touchscreen service menu if available) and inspect every fitting for weeping or seepage.

Reassembly

1. Reinstall underbody aero/skid panels and torque cover screws.
2. Reinstall any frunk trim or access panels removed.
3. Reinstall wheels if removed and torque lug nuts to OEM specification — refer to Tesla Service Manual.
4. Lower the vehicle from jack stands.
5. Exit Service Mode via the touchscreen and allow air suspension to re-level.
6. Dispose of used coolant at a certified recycling facility.

Verification

• Start the vehicle and monitor the touchscreen for any thermal system, coolant level, or low-voltage warnings.
• Drive the vehicle through a normal warm-up cycle and re-inspect every fitting and clamp for leaks once at operating temperature.
• Recheck coolant reservoir level after the first drive cycle and again after 24 hours — top off as needed with G-48.
• Verify no DTCs are stored. If diagnostic access is unavailable to the user, have a Tesla-certified shop scan the vehicle.
• Record the service date and mileage. Tesla recommends a battery coolant inspection at 4 years / 50,000 mi — log this for future reference.

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