Replacement of the EV coolant pump on a 2024 Model Y Performance AWD. This is a PROFESSIONAL-ONLY procedure — the pump shares Tesla's integrated battery/motor/cabin thermal loop, and Tesla Toolbox software is required to safely depressurize and refill the system. Battery coolant should also be inspected per Tesla's 4-year / 50,000 mi guidance.

Warnings

Tools required

Parts

• EV coolant pump assembly (manufacturer-specified for 2024 Model Y Performance) × 1 — Tesla OEM coolant pump — confirm exact part by VIN
• Coolant hose O-rings / quick-connect seals (as required by pump variant) × 1 — OEM seal kit
• Replacement hose clamps (if spring-clamp style is reused-once) × 2 — OEM equivalent

Fluids

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

Preparation

1. Park on level ground, place in P, and engage the parking brake.
2. Exit all doors with the key fob carried away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize before opening any panels.
3. Disconnect the 12V low-voltage battery (located under/behind the rear seat area on Model Y — verify location for this specific build). Cap the negative terminal.
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 run the appropriate Service Mode routine to depressurize and isolate the battery/powertrain coolant loop. Do NOT proceed if the loop cannot be confirmed depressurized.
7. Allow the vehicle to cool — coolant in the powertrain loop can be hot even with the car 'off'.
8. Raise the vehicle on a lift rated for EV curb weight (~4,400 lb) using Tesla-specified lift pad locations to avoid crushing the HV pack.
9. Identify the specific coolant pump being replaced (powertrain vs. battery loop pump) from Toolbox documentation before removing any line.

Procedure

1. 1

   Confirm system isolation via Toolbox
   With Tesla Toolbox connected, execute the service routine to vent and isolate the appropriate coolant circuit. Confirm pressure has bled down before loosening any fitting. Do not skip this step — the loop can be pressurized even with the car powered off.
   ⚠️Opening a pressurized line that feeds the HV battery cold plate can spray coolant onto HV components. Improper handling here can damage the HV pack (~$15,000+) and create a shock hazard.
2. 2

   Remove access panels / underbody covers
   Remove the relevant underbody aero panel(s) and any wheel-well liner needed to expose the coolant pump. Use plastic trim tools on clipped fasteners and a socket on the threaded fasteners. Keep fasteners organized — Tesla uses several lengths in the same area.
   Torque spec

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

   Locate and document the coolant pump
   Photograph the pump, hose routing, clamp orientation, and electrical connector position before disturbing anything. Note which hose feeds which port — reversed installation can cause flow direction faults logged by the BMS/PCS.
4. 4

   Drain coolant from the affected circuit
   Position a clean catch pan beneath the lowest point of the circuit. Following the drain procedure called out in Toolbox, open the manufacturer-specified drain point and capture the coolant. Used Tesla G-48 coolant should be disposed of per local hazardous-waste rules.
   ⚠️This circuit is shared with the HV battery. Any coolant left in the system that is contaminated, mixed, or topped off with the wrong fluid can damage the HV pack (~$15,000+ to replace).
5. 5

   Disconnect the pump electrical connector
   Release the locking tab on the low-voltage connector at the pump and set the harness aside. Inspect the connector for coolant intrusion or corrosion — a leaking pump often wets this connector first.
6. 6

   Disconnect coolant lines from the pump
   Using hose-clamp pliers (for spring clamps) or a small driver (for worm clamps), release the clamps and slide them back on the hoses. Carefully work each hose off the pump barbs. Catch residual coolant in the pan. If the pump uses quick-connect fittings, depress the retaining tabs evenly and pull straight — do not pry.
   ⚠️Opening this line breaks the integrated thermal loop. Coolant dripping onto HV connectors, the pack vent, or busbars can damage the HV battery (~$15,000+) and is a shock hazard. Cover nearby HV components with plastic before disconnecting.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)

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

   Remove pump mounting hardware
   Support the pump with one hand and remove the bracket bolts / mounting bolts securing it to the chassis or subframe bracket. Lower the pump out of the vehicle. Inspect the mount isolators (rubber grommets) — replace if cracked or oil-soaked.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)

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

   Compare old and new pump
   Place the old and new pumps side-by-side. Verify port orientation, connector keying, mounting pattern, and any integrated sensor matches. Transfer mount isolators or brackets only if the new pump did not ship with them.
9. 9

   Install new pump
   Position the new pump in its bracket and install the mounting hardware finger-tight first to allow alignment, then torque to specification. Confirm the pump body is not contacting any harness or chassis member that could transmit vibration noise.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

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

    Reconnect coolant lines
    Install new O-rings/seals where applicable. Push hoses fully onto the pump barbs (or seat quick-connects until you hear/feel the lock click and verify with a pull test). Position hose clamps in their original locations and torque per spec. For threaded coolant fittings, torque to spec — do not over-tighten aluminum fittings.
    ⚠️An improperly seated hose or clamp can leak into the HV battery pack area. A coolant leak onto the HV pack can cause battery damage (~$15,000+) and create a shock/fire hazard. Verify each connection twice.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

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

    Reconnect electrical connector
    Plug the low-voltage connector back into the pump until the lock tab fully engages. Route the harness back into its original clips so it does not contact the pump body or hot components.
12. 12

    Vacuum-fill and refill coolant
    Connect a vacuum-fill machine to the manufacturer-specified service port. Pull the system to vacuum, hold to verify no leaks, then draw in fresh Tesla G-48 coolant. Refill capacity for the full powertrain/battery system is approximately 10 qt — actual amount drawn depends on which circuit was opened.
    ⚠️Air pockets left in the battery cooling circuit can cause localized overheating of the HV pack and permanent damage (~$15,000+). The system MUST be vacuum-filled — gravity fill is not acceptable on this loop.
13. 13

    Run Toolbox bleed / pump prime routine
    With Toolbox, execute the coolant fill/bleed routine for the affected circuit. This cycles the pumps and valves to purge air. Top off the reservoir to the cold-fill line as the routine consumes additional coolant. Repeat the bleed cycle until no further air is purged and the level stabilizes.

Reassembly

1. Reinstall any sensor or bracket hardware that was removed for access, torquing to specification.
2. Reinstall underbody aero panels and wheel-well liners; verify all clips are seated to maintain aero performance and range.
3. Reconnect the 12V low-voltage battery (negative last). Allow the vehicle to complete its wake-up sequence before starting tests.
4. Clean any spilled coolant from the underbody and HV pack vicinity with lint-free towels — do not use compressed air toward HV connectors.

Verification

• With Toolbox, read coolant pump RPM and current draw — values should match the expected range for the circuit and show no fault codes.
• Verify no DTCs related to BMS coolant flow, PCS coolant flow, or thermal management are present after a full drive cycle.
• Run the vehicle through a heat-soak / charge cycle (e.g., a DC fast-charge session or a sustained highway drive) and recheck for leaks at the pump, hoses, and clamp points.
• Confirm reservoir level is still at the cold-fill line after the system has cycled and cooled.
• Document the service date and mileage for the owner — Tesla recommends battery coolant inspection every 4 years / 50,000 mi.
• If brake fluid (2-year interval), cabin filter (2-year interval), or tire rotation (every 6,250 mi) are also due, advise the owner while the vehicle is in service.

More procedures for this vehicle