Cooling System (Drain and Refill)

Correction code 1830010018300100
Parent topic: 1830 - Cooling System

Remove

  1. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  4. Disconnect 12V power. See 12V Power (Disconnect and Connect).
  5. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  6. Release the push clips that attach the lower rear edge of the LH and RH wheel liners to the vehicle for access to the coolant hose.
    LH side shown, RH similar
  7. Pull the LH and RH wheel liners back, and then attach the liners to the subframe with bungee straps.
  8. Position the coolant drain container underneath the RH front side of the HV battery.
  9. Release the spring clip to disconnect the powertrain return hose at the RH side of the vehicle, and then plug the female side of the hose.
  10. Attach a powertrain drain fitting adapter to the male side of the powertrain return hose, and then attach a hose extension to the adapter.
  11. Attach the hose extension to the coolant cart drain hose.
  12. Release the spring clip to disconnect the rear powertrain supply hose at the RH side of the vehicle, and then plug the male side of the hose.
  13. Attach a powertrain flush fitting adapter to the female side of the rear powertrain supply hose.
  14. Attach the powertrain flush fitting adapter to the coolant pressure tester on the coolant cart, and then preset the pressure regulator valve.
  15. Attach a compressed air line to the coolant pressure tester.
    Note: Make sure the valve on the pressure regulator is closed.
  16. Open the valve on the powertrain drain fitting adapter.
  17. Slowly open the valve on the pressure regulator and allow coolant to drain out of the powertrain return hose.
  18. Close the valve on the pressure regulator when no more coolant is draining from the powertrain return hose.
  19. Remove the powertrain flush fitting adapter from the female side of the powertrain supply hose.
  20. Remove the powertrain drain fitting adapter from the male side of the powertrain return hose.
  21. Remove the plugs and attach the spring clips (x2) to reconnect both powertrain coolant hoses.
  22. Remove the powertrain drain fitting adapter from the cart drain hose, and then remove the powertrain flush fitting adapter from the cart pressure hose.
  23. Position the coolant drain container underneath the LH front side of the HV battery.
  24. Release the spring clip to disconnect the HV battery return hose at the LH side of the vehicle, and then plug the male side of the hose.
  25. Attach the battery drain fitting adapter to the female side of the HV battery return hose, and then attach the battery drain fitting adapter to the coolant cart drain hose.
  26. Release the spring clip to disconnect the HV battery supply hose, and then plug female side of the hose.
  27. Release the clips that attach the chiller hose to the body.
  28. Attach a battery flush fitting adapter to the male side of the HV battery supply hose.
  29. Attach the battery flush fitting adapter to the coolant cart pressure hose.
  30. Open the valve on the battery drain fitting adapter.
  31. Slowly open the valve on the pressure regulator and allow coolant to drain out of the HV battery return hose.
  32. Close the valve on the pressure regulator when no more coolant is draining from the HV battery return hose.
  33. Disconnect the compressed air line from the coolant pressure tester.
  34. Remove the battery drain fitting adapter from the female side of the HV battery return hose.
  35. Remove the battery flush fitting adapter from the male side of the HV battery supply hose.
  36. Remove the plug and reconnect the HV battery to battery chiller hoses.
  37. Remove the plug and reconnect the HV battery return hose.
  38. Install the clips that attach the battery chiller hose to the body.
  39. Remove the coolant drain container from underneath the vehicle.
  40. Remove the battery drain fitting adapter from the cart drain hose, and then remove the battery flush fitting adapter from the cart pressure hose.
1Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
2Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
3Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
4Disconnect 12V power. See 12V Power (Disconnect and Connect).
5Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
LH side shown, RH similar
6Release the push clips that attach the lower rear edge of the LH and RH wheel liners to the vehicle for access to the coolant hose.
7Pull the LH and RH wheel liners back, and then attach the liners to the subframe with bungee straps.
8Position the coolant drain container underneath the RH front side of the HV battery.
9Release the spring clip to disconnect the powertrain return hose at the RH side of the vehicle, and then plug the female side of the hose.
10Attach a powertrain drain fitting adapter to the male side of the powertrain return hose, and then attach a hose extension to the adapter.
11Attach the hose extension to the coolant cart drain hose.
12Release the spring clip to disconnect the rear powertrain supply hose at the RH side of the vehicle, and then plug the male side of the hose.
13Attach a powertrain flush fitting adapter to the female side of the rear powertrain supply hose.
14Attach the powertrain flush fitting adapter to the coolant pressure tester on the coolant cart, and then preset the pressure regulator valve.
15Attach a compressed air line to the coolant pressure tester.
Note: Make sure the valve on the pressure regulator is closed.
16Open the valve on the powertrain drain fitting adapter.
17Slowly open the valve on the pressure regulator and allow coolant to drain out of the powertrain return hose.
18Close the valve on the pressure regulator when no more coolant is draining from the powertrain return hose.
19Remove the powertrain flush fitting adapter from the female side of the powertrain supply hose.
20Remove the powertrain drain fitting adapter from the male side of the powertrain return hose.
21Remove the plugs and attach the spring clips (x2) to reconnect both powertrain coolant hoses.
22Remove the powertrain drain fitting adapter from the cart drain hose, and then remove the powertrain flush fitting adapter from the cart pressure hose.
23Position the coolant drain container underneath the LH front side of the HV battery.
24Release the spring clip to disconnect the HV battery return hose at the LH side of the vehicle, and then plug the male side of the hose.
25Attach the battery drain fitting adapter to the female side of the HV battery return hose, and then attach the battery drain fitting adapter to the coolant cart drain hose.
26Release the spring clip to disconnect the HV battery supply hose, and then plug female side of the hose.
27Release the clips that attach the chiller hose to the body.
28Attach a battery flush fitting adapter to the male side of the HV battery supply hose.
29Attach the battery flush fitting adapter to the coolant cart pressure hose.
30Open the valve on the battery drain fitting adapter.
31Slowly open the valve on the pressure regulator and allow coolant to drain out of the HV battery return hose.
32Close the valve on the pressure regulator when no more coolant is draining from the HV battery return hose.
33Disconnect the compressed air line from the coolant pressure tester.
34Remove the battery drain fitting adapter from the female side of the HV battery return hose.
35Remove the battery flush fitting adapter from the male side of the HV battery supply hose.
36Remove the plug and reconnect the HV battery to battery chiller hoses.
37Remove the plug and reconnect the HV battery return hose.
38Install the clips that attach the battery chiller hose to the body.
39Remove the coolant drain container from underneath the vehicle.
40Remove the battery drain fitting adapter from the cart drain hose, and then remove the battery flush fitting adapter from the cart pressure hose.

Procedure

  1. Release the bungee straps and install the push clips that attach the lower rear edge of the LH and RH front wheel liners to the vehicle.
    LH side shown, RH similar
  2. Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  3. Connect 12V power. See 12V Power (Disconnect and Connect).
  4. Connect a laptop with Toolbox to the vehicle.
  5. Type "thermal" into the search field.
    Note: Make sure "Actions" is selected if not already.
  6. Click the play button next to "PROC_VCFRONT_X_THERMAL-FILL-DRAIN", and then select Run.
  7. Remove the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
  8. Remove the cap from the superbottle reservoir.
  9. Fill a container with at least 15 L of coolant, and then place the container into the front storage area.
  10. Fully submerge the coolant refill hose into the coolant container.
  11. Attach the vacuum refill tool to the superbottle.
    Note: Use a cone shaped adapter to ensure vacuum will be pulled from the lower chamber.
  12. Make sure the coolant refill valve and the air inlet valve are both closed.
  13. Place the end of the overflow hose into an empty container.
  14. Connect shop air supply to the vacuum refill tool and set the minimum pressure to 5.5 bar (80 PSI).
  15. Open the air inlet valve for 10 seconds to allow the vacuum tool to evacuate the cooling system and create a vacuum.
  16. Slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose. Close the valve when the hose is full of coolant.
    Note: This purges trapped air from the hose.
  17. Monitor the gauge for 30 seconds to verify a vacuum is maintained in the cooling system.
  18. Reopen the air inlet valve for 3 minutes to evacuate the cooling system, and then close the valve.
  19. Slowly open the coolant refill valve to allow coolant to be drawn in the cooling system. When the gauge stops moving, close the coolant refill valve.
    Note: Make sure the end of the coolant refill hose is fully submerged during the entire process.
  20. Lift the coolant refill tool from the reservoir and hold above the coolant container to allow excess coolant to drain.
  21. Disconnect the shop air supply from the coolant refill tool.
  22. Remove both coolant containers from the front storage area.
  23. Type "vcfront" into the search field.
  24. Click the play button next to "TEST-RESET_VCFRONT", and then select Run.
  25. Click the play button next to "TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE", and then select Run.
    Note: Make sure that the drive rails are off. Turning on the drive rail will stop the routine.
    Note: The test lasts approximately 10 minutes.
    Note: Test will vary speeds from 3,500 to 6,500 RPM, viewable under the PT Thermal tab.
    Note: If speeds hover at around 7,000 RPM, the pumps are air locked. Go to step 9 and perform the vacuum fill again.
  26. Inspect coolant level and top off if necessary.
LH side shown, RH similar
1Release the bungee straps and install the push clips that attach the lower rear edge of the LH and RH front wheel liners to the vehicle.
2Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
3Connect 12V power. See 12V Power (Disconnect and Connect).
4Connect a laptop with Toolbox to the vehicle.
5Type "thermal" into the search field.
Note: Make sure "Actions" is selected if not already.
6Click the play button next to "PROC_VCFRONT_X_THERMAL-FILL-DRAIN", and then select Run.
7Remove the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
8Remove the cap from the superbottle reservoir.
9Fill a container with at least 15 L of coolant, and then place the container into the front storage area.
10Fully submerge the coolant refill hose into the coolant container.
11Attach the vacuum refill tool to the superbottle.
Note: Use a cone shaped adapter to ensure vacuum will be pulled from the lower chamber.
12Make sure the coolant refill valve and the air inlet valve are both closed.
13Place the end of the overflow hose into an empty container.
14Connect shop air supply to the vacuum refill tool and set the minimum pressure to 5.5 bar (80 PSI).
15Open the air inlet valve for 10 seconds to allow the vacuum tool to evacuate the cooling system and create a vacuum.
16Slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose. Close the valve when the hose is full of coolant.
Note: This purges trapped air from the hose.
17Monitor the gauge for 30 seconds to verify a vacuum is maintained in the cooling system.
18Reopen the air inlet valve for 3 minutes to evacuate the cooling system, and then close the valve.
19Slowly open the coolant refill valve to allow coolant to be drawn in the cooling system. When the gauge stops moving, close the coolant refill valve.
Note: Make sure the end of the coolant refill hose is fully submerged during the entire process.
20Lift the coolant refill tool from the reservoir and hold above the coolant container to allow excess coolant to drain.
21Disconnect the shop air supply from the coolant refill tool.
22Remove both coolant containers from the front storage area.
23Type "vcfront" into the search field.
24Click the play button next to "TEST-RESET_VCFRONT", and then select Run.
25Click the play button next to "TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE", and then select Run.
Note: Make sure that the drive rails are off. Turning on the drive rail will stop the routine.
Note: The test lasts approximately 10 minutes.
Note: Test will vary speeds from 3,500 to 6,500 RPM, viewable under the PT Thermal tab.
Note: If speeds hover at around 7,000 RPM, the pumps are air locked. Go to step 9 and perform the vacuum fill again.
26Inspect coolant level and top off if necessary.

Install

  1. Install the cap on the superbottle reservoir.
  2. Install the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
  3. Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  4. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
1Install the cap on the superbottle reservoir.
2Install the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
3Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
4Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
5Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).