2026-08-09

Ancillary Bay Coolant Leak Test (Model Y L) (Inspection)

Correction code 16201200 FRT 1.20 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-03-18: Released new procedure.
Equipment:
  • 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

Procedure

  1. Raise and support the vehicle.
  2. Open the LH front door and lower the LH front window.
  3. Start the thermal fill/drain routine.
    1. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
    2. Unlock the vehicle gateway. See Gateway (Unlock).
    3. Tap the Service Mode "wrench" at the bottom of the touchscreen UI, and then tap Thermal > Actions > Start Thermal Fill/Drain, and select Run to start the routine.
      Note
      This routine has a 5-hour limit. After 5 hours, this routine must be performed again.
    Note
    The EPB Selection field can also be selected as Left/Right as needed.
  4. Disconnect the LV power. See LV Power (Disconnect and Connect) (Modify).
  5. Remove the air intake duct. See Duct - Air Intake (Remove and Replace).
  6. Remove the rear HV battery skid plate. See Skid Plate - Rear (Remove and Replace).
  7. Place the coolant drain container underneath the LH rear of the vehicle.
  8. Disconnect the LH coolant hose from the rear of the HV battery by releasing the spring clip, then plug both the hose and passthrough with 2 plugs.
    Note
    Remove the special tool plugs if returning the battery to Reman.
  9. Disconnect the RDU inverter inlet hose from the PCS2 Lite outlet hose coupling at the LH rear of the HV battery by releasing the spring clip, then plug both the hose and coupling with 2 plugs once disconnected.
    Note
    • Coolant loss greater than 1 L will require vacuum fill.
    • Remove the special tool plugs if returning the battery to Reman.
  10. Connect the 90-degree coolant drain and fill adapter to the PCS2 Lite outlet hose coupling at the LH rear of the HV battery, ensuring the locking clip is fully seated and the valve is open (inline with the adapter).
  11. Connect the coolant hose extension to the coolant drain and fill adapter by pressing the hose end onto the adapter until it clicks into place.
  12. Connect the coolant hose extension to the coolant drain hose.
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  13. Place the coolant drain container underneath the RH rear of the HV battery.
  14. Disconnect the rear powertrain supply hose from the PCS2 Lite inlet hose coupling at the RH rear of the HV battery by releasing the spring clip, then plug both the hose and coupling with 2 plugs once disconnected.
    Note
    • Coolant loss greater than 1 L will require vacuum fill.
    • Remove the special tool plugs if returning the battery to Reman.
  15. Connect the coolant leak test adapter to the PCS2 Lite inlet hose coupling at the RH rear of the HV battery, remove the rubber plug from the coupler if installed, and ensure the locking clip is fully seated.
  16. Connect the coolant leak test fixture hose to the leak test adapter.
    Note
    Hand-tighten the hose connection; no tool is required for tightening.
  17. Remove the coolant drain container from underneath the vehicle.
  18. Connect compressed air to the coolant pressure tester, ensuring all valves on the pressure regulator are closed.
  19. Open the RH regulator valve and slowly adjust the regulator to 50 psi.
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  20. Open the LH regulator valve slowly.
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  21. Wait at least 2 minutes for the coolant to completely drain.
  22. Close the RH regulator valve.
  23. Disconnect compressed air from the coolant pressure tester.
  24. Open the inlet valve on the leak test fixture to discharge air from the coolant system.
  25. Disconnect the coolant leak test adapter from the PCS2 Lite inlet hose coupling by releasing the spring clip at the RH rear of the HV battery, while keeping the leak test fixture inlet hose connected to the adapter.
  26. Disconnect the coolant drain and fill adapter from the PCS2 Lite outlet hose coupling by releasing the spring clip at the LH rear of the HV battery, while keeping the extension hose attached to the adapter.
  27. Connect the coolant leak test adapter with the coolant leak test fixture hose to the PCS2 Lite outlet hose coupling by securing the spring clip at the LH rear of the HV battery, ensuring the locking tab is fully seated.
  28. Connect the coolant drain and fill adapter with the extension hose to the PCS2 Lite inlet hose coupling by securing the spring clip at the RH rear of the HV battery, ensuring the locking tab is fully seated.
  29. Connect compressed air to the coolant pressure tester, ensuring all valves on the pressure regulator are closed.
  30. Open the RH regulator valve and slowly adjust the regulator to 50 psi.
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  31. Open the LH regulator valve slowly.
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  32. Wait at least 2 minutes for the coolant to completely drain.
  33. Close the RH regulator valve.
  34. Disconnect compressed air from the coolant pressure tester.
  35. Disconnect the coolant hose extension from the coolant drain hose by pressing the gray button to release the hose fitting.
  36. Disconnect the coolant hose extension from the coolant drain and fill adapter by pressing the gray button to release the hose fitting.
  37. Disconnect the coolant drain hose adapter from the PCS2 Lite inlet hose coupling by releasing the spring clip, and install a plug on the inlet hose coupling once disconnected.
    Note
    Remove the special tool plugs if returning the battery to Reman.
  38. Disconnect the coolant leak test fixture hose from the leak test adapter.
  39. Disconnect the coolant leak test adapter from the PCS2 Lite outlet hose coupling using by releasing the spring clip, and install a plug on the outlet hose coupling once disconnected.
    Note
    Remove the special tool plugs if returning the battery to Reman.
  40. 54-66
  41. Remove the plug from the PCS2 Lite inlet hose coupling, then install the 90-degree coolant leak test adapter with NPT plug and secure the spring clip, ensuring the locking clip is fully seated.
  42. Remove the plug from the PCS2 Lite outlet hose coupling, then install the coolant leak test adapter and secure the spring clip, ensuring the locking clip is fully seated.
  43. Connect the coolant leak test fixture hose to the leak test adapter.
  44. Connect compressed air to the coolant pressure tester, ensuring all valves on the pressure regulator are closed.
  45. Open the RH regulator valve and slowly adjust the regulator to 50 psi.
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  46. Open the LH regulator valve slowly.
    Note
    Use caution as coolant may spill, and ensure you wear safety glasses.
  47. Wait for 110 seconds to allow the pressure to stabilize within the system, close the RH regulator valve, and record the starting pressure.
  48. Start a 240-second timer; after 240 seconds, record the ending pressure.
  49. Subtract the ending pressure from the starting pressure, and if:
    • The difference is greater than 0.5 psi, check the hose, adapter, and plug fittings, close the outlet valve and open the inlet valve, check the regulator pressure, and then retest. If the difference is still greater than 0.5 psi, escalate a Toolbox session.
    • The difference is 0.5 psi or less, continue the procedure.
  50. Disconnect the coolant leak test fixture hose from the leak test adapter.
  51. Remove the coolant leak test adapter from the PCS2 Lite outlet hose coupling by releasing the spring clip.
  52. Remove the coolant leak test adapter from the PCS2 Lite inlet hose coupling by releasing the spring clip.
  53. Remove the plug from the RDU inverter inlet hose, and connect the hose to the PCS2 Lite outlet hose coupling at the LH rear of the HV battery by securing the spring clip.
    Note
    • Perform a push-pull-push test to ensure that the hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  54. Connect the LH coolant hose to the rear of the HV battery by removing the plugs (x2) and securing the spring clip.
    Note
    • Perform a push-pull-push test to ensure that the hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  55. Remove the plug from the rear powertrain supply hose, and connect the hose to the PCS2 Lite inlet hose coupling at the RH rear of the HV battery by releasing the spring clip.
    Note
    • Perform a push-pull-push test to ensure that the hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  56. Install the rear HV battery skid plate. See Skid Plate - Rear (Remove and Replace).
  57. Perform a vacuum refill of the cooling system. See Cooling System - Vacuum Refill (Test/Adjust).
  58. Connect the LV power. See LV Power (Disconnect and Connect) (Modify).
  59. Stop the thermal fill/drain routine.
    1. Unlock the vehicle gateway. See Gateway (Unlock).
    2. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Stop Thermal Fill Drain, and then allow the routine to complete.
    3. Select Thermal > Coolant System > Coolant Purge Start, click Run, and then allow the routine to complete.
      Note
      • The routine will last for a while after the stop message displays. The coolant pumps are audible.
      • The test lasts for approximately 10 mins. Do not start another routine during this time.
      • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
      • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
      • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  60. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    Note
    Ensure that the coolant level is at the "Max" line.
  61. Exit Service Mode. See Service Mode.
  62. Install the air intake duct. See Duct - Air Intake (Remove and Replace).
  63. Raise the LH front window and close the LH front door.
  64. Remove the vehicle from the lift.