Follow the guidelines below when repairing the electrical harness of a Tesla vehicle:

1. High Voltage (HV) circuits are not repairable. Replace the entire wiring harness if there is damage to any of these wires.
2. Wires or circuits within the ancillary bay are not repairable: Replace the affected wiring harness if there is damage to any of these wires.
3. Coaxial cables are not repairable: Replace the affected cable if it has been damaged.
4. Wires marked with a ++ sign in the circuit diagram:

   For example:

   

   Wires marked with a ++ sign in the circuit diagram cannot:

   • Have deviations
   • Have continuity checked manually
   • Be repinned
   • Be spliced
   • Be reworked
   Note

   In some models, ++ circuits may also be identified with a yellow stripe or may be twisted with another wire that has a yellow stripe.
5. The items listed below are repairable only by a trained technician.
   Warning

   Only trained technicians are allowed to repair high voltage or safety-related circuits. Performing a repair of high voltage or safety-related circuits without proper training could result in injury to the technician or damage to the electrical components.

   Contact Tesla Collision Repair for guidance if repairs are needed on of the following:

   • Safety-related chassis circuits, such as stability control, ABS, or parking brake.
   • Powertrain circuits, such as accelerator pedal signal, brake pedal signal, wheel speed sensors and motor encoder.
   • Driver Assistance safety circuits, such as parking sensors, radar assembly, cameras (forward-facing, rear-view, b-pillar, or side repeater).
   • Supplemental restraint system (SRS) circuits, such as airbag and seatbelt.
   • Airbag sensor and seat sensor.
   • High Voltage Interlock Loop (HVIL).
   • Wiring for any CAN or LIN Bus.
   • Any wire sizes not listed in the Supplies section of this document.
   • Wires that have damage within 100 mm of a connector.
   • Terminals.
   • Any wire marked with a + sign on the wire in the circuit diagram. For example:

     

     Note

     A + sign on the pin name in the circuit diagram indicates positive power. These circuits are repairable if they do not have a + sign on the wire in the circuit diagram.

     

   CAUTION

   Do not perform a repair if the wire damage is within 100 mm of a connector.
6. If more than 1 wire in a harness needs to be repaired, plan the locations of the repairs and mark each wire with the approximate location of the splice. Avoid placing the splices next to each other to minimize the increase in harness diameter. Stagger the splices as much as possible.

   

7. Do not perform a splice repair in any area that has movement, such as the liftgate, door, or moving part of a seat harness. Replace the affected wiring harness instead.
   CAUTION

   Do not perform a splice repair in any area that has movement, such as the liftgate, door, or moving part of a seat harness. Replace the affected wiring harness instead.
8. When doing a repair to an electrical harness, contact Tesla Collision Repair as described in Contacting Tesla Collision Repair with the information listed below:
   1. Subject: [Vehicle Identification Number (VIN)] Electrical Harness Repair.
   2. Body of the e-mail:
      • Description from the circuit diagram For example, “WPR01-A RD 1.50 FLRY”

        

      • The circuit that is being repaired. For example, “Windshield wiper motor power from left controller to X2208.”.
      • Type of repair (single splice, double splice, number of wires affected).
      • If known, how the damage was caused.
      • Photographs of the damaged area. Include photos before, during and after the repair. Make sure that a photo that shows the original routing of the wire is included.

Using a single splice to repair a wire shortens the length of the wire segment. A wire can be repaired with a single splice in the following circumstances (if any of these do not apply, refer to Repair Using a Double Splice):

• The damage is to 1 wire in 1 location.
• The length of the damage is less than 10 mm.
• The harness is long and loose enough to be unaffected by the shortening caused by this repair.
• The repair will not put excess strain on the wire where it enters the connector or harness transition.

For the Single Splice Repair procedure steps, refer to the Single Splice Repair Procedure.

A wire should be repaired with 2 splices in either of the following circumstances:

• Damage to 1 wire in 1 location that affects more than 10 mm of the wire.
• Damage to 1 wire in more than 1 location, to be repaired by adding a new section of wire.

For the Double Splice Repair procedure steps, refer to the Double Splice Repair Procedure.

Repairs can be performed using the tools and supplies from the harness repair kit (1061177-00-B) and the soldering iron and heat tool kit (1060908-00-A for North America and APAC or 1060908-01-A for EMEA). Equivalent tools and supplies may be sourced locally, so long as they meet the same specifications as the Tesla-supplied tools and supplies.

• Crimp tool: 1060842-00-A
• Replacement soldering tip: 1061312-00-A
• Wire cutting and stripping pliers: 1060844-00-A
• Solder (lead-free, no-clean flux, 96.5% Tin, 3% Silver, 0.5% Copper, .031 in diameter): 1061316-00-A
• Electrical tape (yellow): 1061317-00-A
• Harness tape (black): 1053847-00-A
• Cable ties: 1061321-00-A
• Crimp barrels: Refer to table below
• Heat shrink tube: Refer to table below

Purchase the necessary primary wire from a local supplier. Refer to the above table for the proper size. The wire must meet the following specifications, unless otherwise specified on the harness wire label:

• Copper
• Stranded
• 60V
• Thin-wall PVC insulation (SAE TWP type or equivalent)