Replacement of the EV coolant pump on a 2024 Model S Long Range AWD. This is a PROFESSIONAL-ONLY procedure that requires Tesla Toolbox software access — the integrated battery/motor/cabin thermal loop must be properly depressurized and refilled with Toolbox to prevent catastrophic HV battery damage.

Warnings

Tools required

Parts

• EV coolant pump (manufacturer-specified for 2024 Model S LR) × 1 — Tesla OEM coolant pump assembly — verify by VIN
• Pump O-ring / sealing gasket (typically supplied with pump) × 1 — OEM seal kit
• Hose clamps (replace if spring-type are fatigued) × 2 — OEM-spec spring or worm clamp

Fluids

• Tesla Battery/Motor Coolant (G-48 / Pentosin G13-equivalent, Tesla-spec only) — 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 12V low-voltage battery in the front trunk (under the nose cowl panel). On 2021+ Plaid variants with 16V lithium under the rear seat, follow that disconnect procedure instead — verify by VIN.
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 and place the vehicle in Service Mode. Use Toolbox to identify the specific coolant pump being replaced (battery loop, powertrain loop, or shared loop) and to depressurize / isolate the appropriate sub-loop before opening any line.
7. Allow the vehicle to cool completely — minimum 1 hour after last drive or charge — before opening any coolant line.
8. Verify correct replacement pump and seals are on hand, and that fresh Tesla-spec coolant is available in sufficient volume (system capacity ~10 qt; have extra for bleeding).
9. Raise vehicle on a Tesla-approved lift using the designated jacking pads. Do not lift on the battery pack or rocker pinch welds without OEM pucks.

Procedure

1. 1

   Confirm loop depressurization via Toolbox
   With the vehicle in Service Mode, command the relevant cooling loop to depressurize via Toolbox. Confirm that loop pressure has bled down before proceeding. Do not skip this step under any circumstance.
   ⚠️Skipping Toolbox depressurization can cause hot, pressurized coolant to spray onto HV components. This can damage the ~$15,000 HV battery and create a shock/fire hazard.
2. 2

   Remove access panels
   Remove the front underbody aero shield and any cowl/access panels needed to reach the coolant pump location. Use plastic trim tools on clip-retained panels and a driver on threaded fasteners. Keep fasteners organized — Tesla mixes fastener types and lengths in adjacent locations.
   Torque spec

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

   Position drain pan and capture coolant
   Position a clean catch pan beneath the pump. Loosen the lowest hose clamp on the pump first to capture coolant gradually. Capture all displaced coolant for proper disposal — Tesla-spec coolant is not to be reused once exposed to air/contaminants.
   ⚠️Even after Toolbox depressurization, residual coolant in the pump and lines can drip onto HV-adjacent components. Improper handling can damage the HV battery (~$15,000+) if coolant migrates into pack penetrations or HV connectors.
4. 4

   Disconnect electrical connector
   Release the locking tab and disconnect the low-voltage electrical connector from the coolant pump. Inspect the connector for coolant intrusion, corrosion, or damaged pins — replace pigtail per OEM guidance if compromised. This connector is low-voltage; orange cabling will not be present at the pump itself, but verify no orange conductors are in the immediate work area before proceeding.
   ⚠If you see ANY orange cable in the work area, stop. The pump itself is LV, but adjacent HV harnesses must not be disturbed.
5. 5

   Disconnect coolant lines from pump
   Loosen the hose clamps and carefully work the hoses off the pump barbs, or unscrew the threaded fittings if equipped. Support the lines so they do not pull on adjacent components. Cap or plug open lines immediately with clean caps to prevent contamination of the loop.
   ⚠️Opening a coolant line on this vehicle breaks the integrated thermal loop. Improper handling can damage the HV battery (~$15,000+ to replace) and may cause coolant to contact HV components. Keep all openings capped and clean.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)

   Coolant Line Fittings15 Nm (11 lb-ft)
6. 6

   Remove pump mounting hardware
   Remove the pump's mounting bolts/bracket fasteners and lift the pump from its bracket. Note orientation and any isolation grommets — these dampen NVH and must be reinstalled or replaced.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

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

   Inspect mounting area and bracket
   Inspect the bracket, isolation grommets, and surrounding hoses for cracking, swelling, or coolant residue. Replace hoses or clamps that show heat damage or weeping. Wipe the mounting surface clean with a lint-free towel.
8. 8

   Install new coolant pump
   Fit new O-ring/seal to the replacement pump per the seal kit instructions (lubricate with fresh Tesla-spec coolant — never with petroleum grease). Set the pump into the bracket in the correct orientation and start all mounting fasteners by hand to avoid cross-threading aluminum.
   ⚠Aluminum threads — start every fastener by hand. Do not use an impact driver on bracket or mounting bolts.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

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

   Reconnect coolant lines
   Reattach hoses to the new pump, ensuring they are seated fully past the barb shoulder. Reposition clamps to original locations and torque. For threaded fittings, install new sealing washers if applicable and torque to spec.
   ⚠️A leaking fitting after refill can dump coolant onto HV components. Improper handling can damage the HV battery (~$15,000+ to replace). Verify each fitting is fully seated and torqued to spec before refilling.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)

   Coolant Line Fittings15 Nm (11 lb-ft)
10. 10

    Reconnect electrical connector
    Re-seat the LV connector until the locking tab clicks. Tug-test to verify full engagement. Route the harness back into its retainers to keep it clear of hot or moving components.
11. 11

    Vacuum-fill the cooling loop
    Using a vacuum/fill tool compatible with the Tesla low-pressure loop, draw the system down to the specified vacuum and hold to verify no leaks. Then fill with fresh Tesla-spec coolant only. Do not pour coolant in via a high-point cap and assume the loop is full — the integrated loop will airlock without proper vacuum fill.
    ⚠️Using non-Tesla-spec coolant or contaminated coolant can damage the HV battery (~$15,000+) and the heat pump/octovalve assembly. Use only G-48 / Tesla-specified fluid.
12. 12

    Run Toolbox bleed/prime routine
    With Toolbox, run the cooling system bleed/prime routine to cycle the pumps and purge air from each branch of the integrated loop. Top off coolant as the level drops during the routine. Repeat until level stabilizes and no air is reported.
    ⚠Skipping the Toolbox-driven bleed will leave air in the battery branch, causing thermal management faults and possible derate or pack damage over time.

Reassembly

1. Reinstall any access panels and the front underbody aero shield, torquing cover screws to spec.
2. Reconnect the 12V (or 16V) low-voltage battery and reinstall the frunk cowl/cover.
3. Exit Service Mode in Toolbox and clear any related DTCs.
4. Wipe down all coolant residue from surrounding components to make future leak inspection meaningful.
5. Dispose of captured coolant per local hazardous fluid regulations.

Verification

• Confirm zero active cooling-system DTCs in Toolbox after the bleed cycle completes.
• With the vehicle awake, monitor pump duty cycle and loop pressures/temperatures via Toolbox at idle and during a Supercharge or DC fast charge session — battery loop should pressurize and circulate without cavitation noise.
• Visually inspect every disturbed fitting after the first heat cycle and again after a short test drive — Tesla-spec coolant leaves a distinctive residue if weeping.
• Verify cabin HVAC heat and A/C still operate normally (the heat pump shares the integrated loop on this platform).
• Recheck coolant level at the reservoir after 24 hours and again after the first full charge cycle; top off only with Tesla-spec coolant.
• Note in service records: Tesla recommends battery coolant inspection every 4 years / 50,000 mi — log this service date for the next interval.

More procedures for this vehicle