Replacement of the EV coolant pump on the 2024 Tesla Roadster Tri Motor. This is a PROFESSIONAL-ONLY procedure — the pump is part of Tesla's integrated battery/motor thermal loop and requires Tesla Toolbox to safely depressurize the system. Note: Tesla now recommends battery coolant inspection at 4 years / 50,000 mi.

Warnings

Tools required

Parts

• EV coolant pump assembly (manufacturer-specified for Roadster Tri Motor) × 1 — Refer to Tesla Service Manual / EPC for this VIN — do not substitute
• Coolant hose clamps (single-use spring or worm-gear, as applicable) × 4 — OEM-equivalent, sized to OEM hose ID
• Pump O-ring / gasket kit × 1 — Supplied with pump or OEM seal kit

Fluids

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

Preparation

1. Park on level ground, place in P (or neutral with wheel chocks on manual-equipped early units), 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, even on this non-HV job.
3. Disconnect the 12V low-voltage battery per the manufacturer-specified procedure for this vehicle. See architecture notes — Roadster low-voltage battery location differs from other Teslas.
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 coolant service / depressurization routine for the battery thermal loop. Do not proceed until Toolbox confirms the loop is depressurized.
7. Allow the vehicle to cool fully — coolant in the loop can be hot and pressurized even after Toolbox depressurization if the vehicle was recently driven or charged.
8. Raise the vehicle on a lift or properly rated jack stands at the manufacturer-specified lift points. The Roadster's Lotus-derived chassis has specific lift points — using incorrect points can damage the bonded aluminum tub.
9. Stage a coolant catch pan and absorbent pads beneath the pump location.

Procedure

1. 1

   Verify thermal loop is depressurized
   Confirm via Tesla Toolbox that the battery cooling loop is fully depressurized and that no active thermal management cycle is running. Do not proceed otherwise.
   ⚠️Opening a pressurized battery thermal loop can spray coolant onto HV components. Damage to the HV battery (~$15,000+ to replace) and HV exposure are possible. Toolbox confirmation is mandatory.
2. 2

   Remove access panels / underbody covers
   Remove the underbody aero panels and any access covers required to reach the EV coolant pump. Note fastener locations — Roadster underbody panels use a mix of bonded inserts and threaded fasteners; do not force.
   ⚠Aluminum chassis: do not pry against structural panels. Support panels as fasteners are removed to avoid bending.
   Torque spec

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

   Drain the coolant loop
   Position the catch pan beneath the manufacturer-specified drain point. Open the drain per the Tesla Service Manual procedure and allow full drainage. Capacity is approximately 10 qt total system; expect a partial volume from the pump circuit.
   ⚠️This step opens the integrated thermal loop. Improper handling can allow coolant to contact HV battery components — catastrophic damage (~$15,000+) and HV hazard possible. Contain all spillage.
   ⚠Tesla coolant is ethylene-glycol based — toxic to humans and animals. Capture and dispose of per local regulations.
4. 4

   Locate and identify the EV coolant pump
   Identify the EV coolant pump for the circuit being serviced. The Tri Motor Roadster has multiple coolant circuits; verify you are servicing the correct pump per the work order and Toolbox diagnostic data before disconnecting anything.
   ℹ️If the pump location, mounting, or connector style does not match the service documentation you are working from, STOP. Roadster-specific service info is rare and assumptions are dangerous.
5. 5

   Disconnect the pump electrical connector
   Release the locking tab and disconnect the low-voltage electrical connector from the pump. If the connector uses a retaining bolt, remove it.
   ⚠Confirm the connector is low-voltage (typically black). If you see ANY orange cabling at this location, STOP — this is not the correct component for a non-HV-trained tech.
   Torque spec

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

   Clamp coolant hoses and disconnect
   Apply hose pinch-off clamps upstream and downstream of the pump to minimize residual coolant loss. Loosen the hose clamps and carefully work the hoses off the pump barbs. Plug open hose ends immediately to prevent contamination.
   ⚠️Breaking the coolant loop here exposes the integrated thermal system. Coolant contacting HV battery components or busbars can damage the HV battery (~$15,000+) and create a shock hazard. Capture every drop.
   ⚠Do not pry hoses off with metal tools — damage to the pump barb causes leaks. Use plastic hose-removal tools.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)

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

   Remove pump mounting hardware
   Support the pump and remove the mounting bolts and any associated bracket bolts. Lower the pump from its mount.
   ⚠Aluminum mounting points are easily stripped. Loosen evenly and avoid side-loading the bolts.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
8. 8

   Inspect mount and hoses
   Inspect the pump bracket, isolation grommets, and hose ends for cracking, swelling, or contamination. Replace any hose with a damaged sealing surface — do not reuse marginal components on a battery thermal circuit.
   ℹ️Hose failure on this loop puts coolant on HV components. Err on the side of replacement.
9. 9

   Install new pump
   Transfer any reusable brackets, install new O-rings/seals from the kit, and position the new pump. Hand-thread mounting bolts before final torque to avoid cross-threading aluminum.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

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

    Reconnect coolant hoses
    Install new hose clamps in the same orientation. Seat hoses fully on the barbs before tightening. For threaded coolant fittings (if equipped), torque to spec.
    ⚠️A loose hose clamp on the battery thermal loop can dump coolant onto the HV battery in service — potential ~$15,000+ damage and HV exposure. Verify each clamp is fully seated and torqued.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

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

    Reconnect electrical connector
    Reconnect the low-voltage connector and verify the locking tab clicks fully home. If a retainer bolt is used, torque to spec.
    Torque spec

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

    Vacuum-fill and refill coolant
    Using a vacuum-fill tool, evacuate the loop to confirm leak-tightness, then fill with Tesla-spec G-48 battery/motor coolant. System capacity is approximately 10 qt total — fill the serviced circuit per the Tesla Service Manual.
    ⚠Do NOT substitute non-G-48 coolant. Wrong chemistry can damage the HV battery cold plate and the cooling loop materials.
13. 13

    Run Toolbox bleed routine
    With Toolbox connected, run the coolant fill / air-bleed routine. The integrated loop cannot be reliably bled by hand — Toolbox cycles the pumps and valves in the correct sequence.
    ⚠️Skipping the Toolbox bleed routine can leave air in the battery cold plate, causing local overheating and potential HV battery damage.

Reassembly

1. Reinstall any removed underbody aero panels and access covers, torquing fasteners to specification.
2. Lower the vehicle to the ground.
3. Reconnect the 12V low-voltage battery.
4. Wake the vehicle and allow systems to fully boot.
5. Top off coolant reservoir to the correct cold-fill level after the Toolbox bleed completes.
6. Clean any spilled coolant from underbody and dispose of waste fluid per local regulations.

Verification

• Use Tesla Toolbox to read pump RPM/PWM duty and current draw across all thermal modes — verify the new pump operates within spec.
• Confirm no DTCs related to the thermal loop, pump, or battery cooling remain active after a full drive cycle.
• Inspect all disturbed hose connections and the pump body for leaks after a heat-soak cycle (charge or short drive, then re-inspect).
• Verify HV battery temperature management responds correctly: monitor pack temperature delta during a Supercharger session or sustained driving — abnormal temperature rise indicates trapped air or pump under-performance.
• Record service mileage and date. Tesla recommends battery coolant inspection at 4 years / 50,000 mi — log next inspection due.

More procedures for this vehicle