Replacement of the EV coolant pump on a 2024 Tesla Cybertruck Dual Motor AWD. This is a PROFESSIONAL-ONLY procedure: the pump is part of Tesla's integrated thermal loop shared with the HV battery and drive units, and Tesla Toolbox software is required to safely depressurize and refill the system. Battery coolant inspection is recommended at 4 years / 50,000 mi.

Warnings

Tools required

Parts

• EV coolant pump assembly (manufacturer-specified for Cybertruck) × 1 — Tesla OEM Cybertruck EV coolant pump — refer to Service Manual for current part number
• Coolant pump O-rings / gaskets (if not pre-installed on new pump) × 1 — OEM seal kit supplied with pump
• Replacement hose clamps (single-use spring or worm-gear, as applicable) × 2 — OEM-equivalent

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 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-specific procedure (NOT 12V — see architecture notes). Confirm LV bus is dead with a 48V-rated multimeter before proceeding.
4. DO NOT touch, cut, or pierce ANY orange cable — these are 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. Connect Tesla Toolbox 3 and place the vehicle in Service Mode. Use Toolbox to command the thermal system into 'Service' / depressurization state for the coolant loop being opened. Do not proceed until Toolbox confirms the loop is depressurized.
7. Allow the vehicle to cool fully — coolant in the integrated loop can exceed 60°C during normal operation and >80°C after fast charging.
8. Lower air suspension to 'Jack Mode' via the touchscreen, then raise the vehicle on a lift rated for the Cybertruck's curb weight. Support at OEM-designated lift points only.
9. Identify the EV coolant pump location and the specific loop it serves (battery, powertrain, or chiller circuit) per the Tesla Service Manual for this VIN before disconnecting any line.

Procedure

1. 1

   Confirm thermal loop depressurization via Toolbox
   With the vehicle in Service Mode, run the Toolbox 'Coolant Service' routine for the relevant loop. Verify on-screen that line pressure has dropped to ambient and that any electrically actuated valves (e.g., the integrated thermal valve assembly) have moved to the service position. Do not open any fitting until Toolbox explicitly confirms safe state.
   ⚠️Skipping this step can spray hot, pressurized coolant onto HV components. Improper handling can damage the HV battery (~$15,000+ to replace) and may cause coolant to contact HV components.
2. 2

   Remove underbody / access panels
   Remove the underbody aero/access panel(s) covering the coolant pump area using the manufacturer-specified fasteners. Set panels aside on a clean surface — do not stack them on stainless body panels.
   ⚠Some underbody panels are structural composites with captive fasteners. Do not over-torque on reinstall.
   Torque spec

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

   Position drain pan and prepare to capture coolant
   Place a clean, dedicated coolant catch pan beneath the pump. The integrated loop holds approximately 10 quarts total; expect to capture 1–3 quarts when isolating just the pump section, more if the full loop drains back. Use only G-48 compatible containers — do not mix with any other coolant.
   ⚠️Coolant from this loop has circulated through the HV battery. Treat any spillage as if it could contact HV components — clean immediately and thoroughly. Improper handling can damage the HV battery (~$15,000+ to replace).
4. 4

   Disconnect electrical connector at the coolant pump
   Release the locking tab on the pump's low-voltage electrical connector and disconnect it. Inspect the connector and pins for coolant intrusion or corrosion. Note: this is a 48V LV connector on Cybertruck — do not test with 12V probes.
   ⚠48V LV system can still produce arc-flash on shorted conductors. Confirm LV battery is disconnected before unlatching.
   Torque spec

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

   Disconnect coolant lines from the pump
   Identify inlet and outlet lines and label them to prevent reversed installation. Loosen hose clamps (or release quick-connect fittings, depending on configuration) and carefully separate the lines from the pump barbs/ports. Allow residual coolant to drain into the pan. Cap or plug open lines immediately to prevent debris ingress.
   ⚠️Opening this line breaks the integrated battery thermal loop. Improper handling can damage the HV battery (~$15,000+ to replace) and may cause coolant to contact HV components. Do not allow coolant to run along wiring harnesses toward the battery pack.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)

   Hose Clamps3 Nm (2 lb-ft)
6. 6

   Remove pump mounting hardware
   Support the pump by hand. Remove the mounting bolts securing the pump to its bracket (or the bracket-to-chassis bolts, as applicable). Lower the pump out of its mounting position.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
7. 7

   Remove the pump from the vehicle
   Maneuver the failed pump out of the chassis cavity, keeping it upright to prevent additional coolant spillage. Inspect the mounting area for cracks, leak staining, or harness damage. Photograph orientation for reference.
   ⚠️Any coolant pooled in the chassis tray must be fully removed before reinstallation. Residual coolant migrating onto HV components can damage the HV battery (~$15,000+ to replace).
8. 8

   Compare and prep the new pump
   Compare the new pump side-by-side with the removed unit: port orientation, connector keying, mounting flange. Transfer any mounting isolators or brackets if not supplied with the new pump. Pre-install fresh O-rings/seals from the OEM kit, lightly lubricated with clean G-48 coolant only — do not use petroleum grease.
9. 9

   Install new pump and torque mounting hardware
   Position the new pump in the bracket. Hand-thread all mounting fasteners before final torque. Torque mounting bolts and any bracket fasteners to the verified specification.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
10. 10

    Reconnect coolant lines
    Remove caps/plugs from the coolant lines. Reconnect inlet and outlet to the correct ports per the labels you applied in Step 5. Use new clamps where the OEM specifies single-use clamps. Torque hose clamps and any threaded coolant fittings to spec. Verify lines are fully seated before tightening.
    ⚠️A reversed or loose connection here can starve the HV battery of coolant flow under load and trigger thermal damage. Improper handling can damage the HV battery (~$15,000+ to replace) and may cause coolant to contact HV components.
    Torque spec

    Coolant Line Fittings15 Nm (11 lb-ft)

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Reconnect electrical connector
    Reconnect the LV connector to the new pump until the locking tab clicks fully home. Torque any connector retention hardware to spec. Verify strain relief and routing match OEM.
    Torque spec

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

    Vacuum-fill and bleed the cooling system via Toolbox
    Connect a vacuum fill tool to the system service port. Pull the system to deep vacuum and verify it holds (a falling vacuum indicates a leak — repair before proceeding). Draw in fresh Tesla G-48 coolant. Then run the Toolbox 'Coolant Fill / Bleed' routine, which sequences the integrated valves and electric pumps to purge air from each branch (battery, powertrain, chiller). Top off as the level stabilizes.
    ⚠️Air pockets in the battery cooling branch can cause localized overheating of HV cells. Do NOT skip the Toolbox-guided bleed. Improper handling can damage the HV battery (~$15,000+ to replace).

Reassembly

1. Reinstall underbody access/aero panels, torquing fasteners to the verified Cover Screws specification.
2. Lower the vehicle and exit Jack Mode via the touchscreen.
3. Reconnect the 48V low-voltage battery using the Cybertruck-specific procedure. Do not attempt to use a 12V jump pack on the 48V system.
4. Exit Service Mode in Toolbox and clear any related DTCs.
5. Allow the vehicle to wake fully and observe pump operation through Toolbox live data.

Verification

• With Toolbox connected, verify the new pump reports correct RPM, current draw, and no DTCs (P0_/P1_ thermal codes or pump-specific fault codes).
• Command the pump through low/medium/high speed via Toolbox and confirm flow (audible pump operation and rising line temperature downstream).
• Inspect every disturbed fitting for leaks after 10 minutes of operation, then again after a 15–20 minute road test.
• Confirm coolant reservoir level is at the 'COLD FULL' mark after the system has fully cooled; top up with G-48 only.
• Verify HV battery and drive unit temperatures during a charging session and under load are within Tesla's normal operating range via Toolbox telemetry.
• Document service: Tesla now recommends battery coolant inspection at 4 years / 50,000 mi — log this service date and mileage for the next inspection interval.
• Confirm steer-by-wire calibration is intact and no steering, suspension, or thermal warnings are present on the driver display before releasing the vehicle.

More procedures for this vehicle