Penthouse Coolant (Drain and Refill)

Correction code 1620200016202000
  • 1053600-00-C Drive Unit Pressure Test Fixture
  • 1132185-00-B Kit, Coolant Leak Test Adapters, Model 3
  • 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • GSN-TL-000564 Kit, Battery Coolant Drain and Fill

SPECIAL TOOLS

Drive Unit Pressure Test Fixture (1053600-00-C)
Kit, Coolant Leak Test Adapters, Model 3 (1132185-00-B)
Kit, Coolant Drain & Fill Adapters, M3 (1133843-00-A)
Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-A)
Kit, Battery Coolant Drain and Fill (GSN-TL-000564)

Drain

  1. Disconnect 12V power. See 12V Power (Disconnect and Connect).
  2. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  3. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  4. Position a coolant drain under the rear RH side of the HV battery.
  5. Disconnect the rear powertrain supply hose from the RH underside of the penthouse, plug the female fitting of the hose, and allow the battery to drain.
  6. Connect the coolant pressure test adapter to the RH side male fitting under the penthouse.
  7. Connect the hose from the drive unit pressure test fixture to the coolant pressure test adapter.
  8. Close both valves P1 (inlet) and P2 (outlet) on the test fixture, and connect a compressed air supply line.
  9. Fully close the regulator, and then open P1 (inlet valve).
  10. Set the pressure regulator of the test fixture to 50 psi.
  11. Position the coolant drain under the rear LH side of the HV battery.
  12. Disconnect the rear drive unit inverter inlet hose from the LH underside of the penthouse, plug the female fitting of the hose, and allow the battery to drain.
  13. Connect the coolant drain adapter to the LH side male fitting under the penthouse, and direct the tube to the coolant waste container.
  14. If the coolant waste container is a bottle, push a shop towel partially into the bottle neck, to prevent coolant from splashing out.
  15. Slowly open P2 (outlet valve) to speed the drain.
  16. Wait at least 2 minutes for the coolant to fully drain.
  17. Close P2 (outlet valve) when no more coolant is expelled.
  18. Move the coolant drain under the rear RH side of the HV battery.
  19. Interchange the coolant pressure test adapter and the coolant drain adapter on the male fittings under the penthouse, and direct the tube to the coolant waste container.
  20. Slowly open P2 (outlet valve) to speed the drain.
  21. Wait at least 2 minutes for the coolant to fully drain.
  22. Close P2 (outlet valve) when no more coolant is expelled.
    Caution:
    Though not visible, there is still residual coolant in the power conversion system thermal block and input and output tubes. When servicing the power conversion system and input and output tubes, make sure not to spill any coolant, and to immediately wipe up any coolant that has spilled.
  23. Disconnect the air supply from the test fixture.
  24. Remove the coolant pressure test adapter and coolant drain adapter from the HV battery.
  25. Perform the service procedures that required the penthouse coolant to be drained.
  26. After the components have been replaced, refill the coolant. See Refill.
1Disconnect 12V power. See 12V Power (Disconnect and Connect).
2Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
3Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
4Position a coolant drain under the rear RH side of the HV battery.
5Disconnect the rear powertrain supply hose from the RH underside of the penthouse, plug the female fitting of the hose, and allow the battery to drain.
6Connect the coolant pressure test adapter to the RH side male fitting under the penthouse.
7Connect the hose from the drive unit pressure test fixture to the coolant pressure test adapter.
8Close both valves P1 (inlet) and P2 (outlet) on the test fixture, and connect a compressed air supply line.
9Fully close the regulator, and then open P1 (inlet valve).
10Set the pressure regulator of the test fixture to 50 psi.
11Position the coolant drain under the rear LH side of the HV battery.
12Disconnect the rear drive unit inverter inlet hose from the LH underside of the penthouse, plug the female fitting of the hose, and allow the battery to drain.
13Connect the coolant drain adapter to the LH side male fitting under the penthouse, and direct the tube to the coolant waste container.
14If the coolant waste container is a bottle, push a shop towel partially into the bottle neck, to prevent coolant from splashing out.
15Slowly open P2 (outlet valve) to speed the drain.
16Wait at least 2 minutes for the coolant to fully drain.
17Close P2 (outlet valve) when no more coolant is expelled.
18Move the coolant drain under the rear RH side of the HV battery.
19Interchange the coolant pressure test adapter and the coolant drain adapter on the male fittings under the penthouse, and direct the tube to the coolant waste container.
20Slowly open P2 (outlet valve) to speed the drain.
21Wait at least 2 minutes for the coolant to fully drain.
22Close P2 (outlet valve) when no more coolant is expelled.
Caution:
Though not visible, there is still residual coolant in the power conversion system thermal block and input and output tubes. When servicing the power conversion system and input and output tubes, make sure not to spill any coolant, and to immediately wipe up any coolant that has spilled.
23Disconnect the air supply from the test fixture.
24Remove the coolant pressure test adapter and coolant drain adapter from the HV battery.
25Perform the service procedures that required the penthouse coolant to be drained.
26After the components have been replaced, refill the coolant. See Refill.

Refill

  1. Perform a penthouse coolant leak test. See Penthouse Coolant Leak Test.
  2. Remove the plugs from the hoses.
  3. Connect the rear powertrain supply hose to the RH side of the HV battery, and the rear drive unit inverter inlet hose to the LH side of the HV battery.
  4. Move the coolant drain to under the motor.
  5. Release the clip that attaches the coolant inlet hose to the heat exchanger.
  6. Release the clip and disconnect the coolant inlet hose from the heat exchanger upper fitting.
  7. Attach a coolant fill tube to the coolant inlet hose fitting.
  8. Pump coolant into the hose until back pressure is felt or coolant overflows.
  9. Attach the coolant fill tube to the heat exchanger upper fitting.
  10. Pump coolant into the heat exchanger until back pressure is felt or coolant overflows.
  11. Reconnect the coolant inlet hose to the heat exchanger upper fitting and fasten the clip.
  12. Fasten the clip that attaches the coolant inlet hose to the heat exchanger.
  13. If the penthouse cover was removed as part of another procedure, inspect the coolant input and output tubes and fittings for leaks.
  14. Remove the coolant drain from under the vehicle.
  15. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  16. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  17. Connect 12V power. See 12V Power (Disconnect and Connect).
  18. Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).
1Perform a penthouse coolant leak test. See Penthouse Coolant Leak Test.
2Remove the plugs from the hoses.
3Connect the rear powertrain supply hose to the RH side of the HV battery, and the rear drive unit inverter inlet hose to the LH side of the HV battery.
4Move the coolant drain to under the motor.
5Release the clip that attaches the coolant inlet hose to the heat exchanger.
6Release the clip and disconnect the coolant inlet hose from the heat exchanger upper fitting.
7Attach a coolant fill tube to the coolant inlet hose fitting.
8Pump coolant into the hose until back pressure is felt or coolant overflows.
9Attach the coolant fill tube to the heat exchanger upper fitting.
10Pump coolant into the heat exchanger until back pressure is felt or coolant overflows.
11Reconnect the coolant inlet hose to the heat exchanger upper fitting and fasten the clip.
12Fasten the clip that attaches the coolant inlet hose to the heat exchanger.
13If the penthouse cover was removed as part of another procedure, inspect the coolant input and output tubes and fittings for leaks.
14Remove the coolant drain from under the vehicle.
15Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
16Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
17Connect 12V power. See 12V Power (Disconnect and Connect).
18Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).