Replacement of EV coolant lines on a 2024 Model X Long Range. This job involves the low-voltage coolant circuit plumbing only — if work crosses into the battery thermal loop, octovalve, or superbottle, stop and refer to a Tesla-certified technician.

Warnings

Tools required

Parts

• EV coolant line(s) — manufacturer-specified for 2024 Model X × 1 — Refer to Tesla EPC for the specific line(s) being replaced
• Coolant line O-rings / seals (as applicable to fittings being opened) × 1 — OEM replacement seal kit
• Spring/worm hose clamps (if originals are single-use crimp style) × 2 — OEM spec replacement clamps
• Underbody fastener clips (commonly damaged on removal) × 1 — OEM body clip assortment

Fluids

• Tesla Battery/Motor Coolant (G-48 compatible) — 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 12V low-voltage battery in the frunk (similar position to Model S). Follow the in-vehicle low-voltage disconnect procedure if equipped.
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. Before lifting: enable Jack Mode on the touchscreen to lock air suspension height (do this before disconnecting 12V).
7. Allow the vehicle to cool for at least 1 hour after driving — coolant can be hot and pressurized.
8. Position the vehicle on a lift using only Tesla-approved lift pad locations. Never lift on the battery pack.
9. Identify the specific coolant line(s) being replaced and confirm they are part of the LV/auxiliary coolant plumbing, not the HV battery thermal loop.
10. Have replacement lines, seals, clamps, and fresh G-48-spec Tesla coolant on hand before opening the system.

Procedure

1. 1

   Remove underbody aero panels and access covers
   Remove the relevant aero shields and access covers to expose the coolant routing. Note clip locations and bag fasteners by location. Replace any clips that crack on removal.
   Torque spec

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

   Relieve cooling system pressure
   With the system fully cooled, slowly open the coolant reservoir cap to relieve any residual pressure, then re-seat loosely. Place absorbent mat under the work area.
   ⚠Hot coolant under pressure can cause severe burns. Confirm cold-to-touch before opening.
3. 3

   Drain coolant from the affected circuit
   Position the drain pan beneath the lowest accessible drain point on the circuit being serviced. Open the drain or loosen the lowest line fitting to drain into the pan. Capture all fluid for proper disposal.
   ℹ️If draining produces less than expected volume, the line may share a circuit with the HV pack — STOP and reassess.
4. 4

   Photograph and label line routing
   Before disconnecting anything, photograph each fitting, clip, and routing path. Tesla coolant lines often share visually similar quick-disconnect fittings — mislabeling causes incorrect routing on reinstall.
5. 5

   Disconnect coolant line fittings
   Using the appropriate quick-disconnect release tool, depress the locking tabs and separate fittings. For threaded fittings, loosen with a backing wrench to avoid twisting the mating port. For hose-clamp connections, slide clamps back and gently rotate the hose to break the seal.
   ⚠Do not pry on plastic fittings — they fracture easily. Use only the proper release tool.
6. 6

   Remove line retaining brackets and clips
   Unbolt any intermediate retaining brackets that secure the coolant line to the chassis or subframe. Note bracket orientation. Remove plastic push-clips carefully.
   Torque spec

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

   Remove sensor(s) from old line if transferring
   If the old line carries a temperature or pressure sensor that will be reused, unplug the connector and unbolt the sensor. Inspect the sensor O-ring and replace if deformed.
   Torque spec

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

   Extract the old coolant line
   Carefully route the old line out of the vehicle, taking note of any heat shields, harness loops, or routing channels. Do not force the line past harnesses — release retaining clips first.
   ⚠Avoid contacting orange HV cabling or HV connectors during extraction. If the line routes near HV components, route the new line identically without disturbing HV harnesses.
9. 9

   Install the new coolant line
   Compare the new line to the old one for length, bend pattern, and fitting orientation. Route the new line along the documented path, seating it into all retaining channels and heat shields. Install new O-rings/seals at every opened fitting.
10. 10

    Reinstall retaining brackets and sensors
    Reinstall intermediate brackets and any transferred sensors. Reconnect sensor electrical connectors and confirm latch engagement.
    Torque spec

    Bracket Bolts20 Nm (15 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Reconnect coolant fittings
    Reconnect quick-disconnect fittings until you hear and feel the locking tab click — then tug-test each connection. Tighten threaded coolant fittings and reposition hose clamps over the bead on the mating port.
    ⚠An unseated quick-disconnect can pass a tug test under no pressure but separate under system pressure. Verify the locking ring is fully forward.
    Torque spec

    Coolant Line Fittings15 Nm (11 lb-ft)

    Hose Clamps3 Nm (2 lb-ft)
12. 12

    Refill and vacuum-bleed the coolant system
    Using a vacuum fill tool, draw the cooling circuit down to vacuum and verify it holds (no leak-down). Then fill with Tesla-spec G-48 coolant to the correct reservoir level. The system holds approximately 10 quarts total — only the affected sub-circuit volume is needed for a partial replacement.
    ℹ️If vacuum does not hold, a fitting is not seated. Do not proceed to running the vehicle.

Reassembly

1. Reinstall any heat shields disturbed during line routing.
2. Reinstall underbody aero panels and access covers, replacing any damaged clips.
3. Torque cover screws to specification.
4. Reconnect the 12V low-voltage battery in the frunk, negative terminal last.
5. Close the frunk and exit Jack Mode via the touchscreen once the vehicle is back on the ground.
6. Allow the air suspension to self-level before driving.

Verification

• With the vehicle powered on (foot off brake, in P), monitor the touchscreen Service menu for any coolant-related faults or low-coolant warnings.
• Inspect every opened fitting for weeping or drips after 5 minutes of system pressurization.
• Drive the vehicle through a full thermal cycle — including a charging session if possible — and re-inspect for leaks while warm.
• Recheck the coolant reservoir level after the first drive cycle and top up to the correct mark with G-48-spec Tesla coolant if needed.
• Tesla now recommends battery coolant inspection at 4 years / 50,000 miles — log this service date in your records and schedule the next inspection accordingly.
• Verify no Falcon door, suspension, or thermal management alerts are present on the touchscreen before returning the vehicle to service.

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