01/08/2024 10:54:08

Tonneau - Lower Assembly, Tonneau (Remove and Install)

Correction code 1120122012 1120122011 FRT 2.58 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

2024-08-07: Update sail applique steps to discard old applique and clean area before installing new applique.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Warning

Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.

Open all 4 doors

Note
Push pillar door triggers to release
Lower all 4 windows
Move LH front seat forward
Move RH front seat forward
Open tonneau cover

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Press forward arrow on LH bed rail
Open tailgate

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Press button to release
Open powered front trunk

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Via exterior switch or UI
Power down vehicle via UI

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Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Remove rear underhood apron

Note
9x clips
Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release

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2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
Remove front header trim

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19x clips, 1x magnet, 1x connector, 1x harness clip
Remove LH mid A-pillar trim

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2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
Remove LH IP quarter panel

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3x clips, 5x tabs, 2x datums
Remove LH upper A-pillar panel

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8x clips, 1x tether clip, 1x harness clip, 1x connector, 1x bolt, 10mm, 6 Nm, Pull inwards to release, Depress tabs on either side of tether clip to release
Remove rear header trim

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12x clips, 3x datums
Remove LH lower C-pillar trim

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3x clips, 7x tabs, 4x datums, Starting at door sill pull upward then forward to release, Leave trim attached to seat belt
Open LH coat hook

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Press to release
Release LH coat hook bolt cover

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2x tabs
Remove LH coat hook bolt

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1x bolt, T20, 2.5 Nm
Remove LH cantrail trim panel

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5x clips, 1x connector, 3x bolts, T30, 6 Nm, Release clips then allow cantrail to hang from tethers for access to fasteners
Disconnect headliner harness from LH rear maplight

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1x connector
Remove LH cantrail trim panel

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5x clips, 1x connector, 3x bolts, T30, 6 Nm, Release clips then allow cantrail to hang from tethers for access to fasteners
Remove LH 2nd row shoulder cover

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7x clips, 1x datum
Remove 2nd row seatback LH outboard bolster

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5x clips, 2x datums, Release from bottom
Remove LH C-pillar upper trim

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5x clips, 3x tabs
Partially release RH lower C-pillar trim

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1x clip, 1x datum
Remove RH mid A-pillar trim

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2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
Remove RH upper A-pillar panel

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8x clips, 1x harness clip, 1x connector, 1x bolt, 10mm, 6 Nm, Pull inwards to release
Push open RH coat hook

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Press to release
Remove RH coat hook bolt cover

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2x tabs
Remove RH coat hook bolt

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1x bolt, T20, 2.5 Nm
Remove RH cantrail trim panel

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5x clips, 1x connector, 3x bolts, T30, 6 Nm, Release clips then allow cantrail to hang from tethers for access to fasteners
Release RH 2nd row shoulder cover

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7x clips, 1x datum
Remove 2nd row RH outboard seatback bolster

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4x clips, 2x datums
Remove RH Upper C-pillar

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5x clips, 3x tabs
Remove interior fasteners securing lower tonneau assembly

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2x bolts, 13mm, 20 Nm
Remove fastener covers from bed floor assembly

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6x covers
Remove bed floor assembly

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10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
Open bed cargo tub lid
Remove cargo tub struts from cargo lid

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2x strut clips
Remove bed cargo tub lid

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4x bolts, 10mm, 5 Nm, Recommend assistance
Remove LH sail applique

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9x clips, 6x double-sided tape strips, 1x connector, 1x harness clip, Lift rear edge first to remove connector and harness clip, Remove double-sided tape from applique and bed side, Remove any remaining adhesive with IPA wipes, Discard sail applique after removal
Remove LH tonneau water management seal

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1x clip, Pull away from rail to release from groove
Remove LH upper bed side wall assembly

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8x clips, Start from rear, Lift tonneau seal as required. Pull from the bottom downwards.
Remove LH bed closeout panel

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6x clips, 1x tab, Release LH tailgate cable by disengaging lock spring from bolt and sliding cable eyelet off to allow removal of bed closeout panel from vehicle
Remove LH lower bed side wall

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1x bolt, 15mm, 46 Nm, 2x bolts, T45, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Release locking tabs, Disconnect bed outlet connectors from bed side wall and ground strap, 1x bolt, 10mm, 10 Nm, 2x connectors, Release locking tabs, Slide lock to release, Recommend assistance
Remove LH tonneau rail

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9x bolts, 10mm, 9 Nm, Lift upwards and slide rearwards to relase
Remove RH sail applique

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9x clips, 6x double-sided tape strips, Remove double-sided tape from applique and bed side, Remove any remaining adhesive with IPA wipes, Discard sail applique after removal
Remove RH tonneau rail seal

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1x clip, Pull away from rail to release from groove
Remove RH upper bed side wall assembly

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8x clips, 1x connector. Pull downwards
Remove RH bed closeout panel

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6x clips, 1x tab, Release RH tailgate cable by disengaging lock spring from bolt and sliding cable eyelet off in order to remove bed closeout panel from vehicle
Remove RH bed side wall

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1x bolt, 15mm, 46 Nm, 2x bolts, T40, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Release locking tabs
Remove RH tonneau rail

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9x bolts, 10mm, 9 Nm, Lift upwards and slide rearwards to relase
Remove false wall

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2x bolts, 15mm, 45 Nm. Recommended to use assistance to prevent scratching bed liner
Remove tonneau applique

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2x bolts, T30, 9 Nm, Remove bolts then firmly pull upward from rear edge of applique to release rear of applique, Depress locking tab on forward mounting points to release
Remove LH backlight applique assembly

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2x clips, 1x adhesive strip, Cut adhesive then pry inward to release
Remove RH backlight applique assembly

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2x clips, 1x adhesive strip, Cut adhesive then pry inward to release
Remove LH tonneau motor

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1x connector, 2x bolts, 10mm, 11 Nm
Remove RH tonneau motor

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1x connector, 2x bolts, 10mm, 11 Nm
Remove false wall brackets

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4x nuts, 13mm, 30 Nm
Remove lower tonneau brackets

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4x nuts, 13mm, 30 Nm, 2x bolts, 13mm, 30 Nm
Remove lower tonneau assembly fasteners

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2x nuts, 10mm, 6 Nm, 2x bolts, 10mm, 6 Nm, 2x bolts, 13mm, 20 Nm
Remove lower tonneau assembly

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Assistance required, Lift straight upwards then raise one side of assembly over bed wall to pivot
Install lower tonneau assembly

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Assistance required, Lower into position, Ensure no harnesses or airlines get caught in lower brackets
Install lower tonneau assembly fasteners

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2x nuts, 10mm, 6 Nm, 2x bolts, 10mm, 6 Nm, 2x bolts, 13mm, 20 Nm
Install lower tonneau brackets

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4x nuts, 13mm, 30 Nm, 2x bolts, 13mm, 30 Nm
Install false wall brackets

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4x nuts, 13mm, 30 Nm
Install RH tonneau motor

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1x connector, 2x bolts, 10mm, 11 Nm
Install LH tonneau motor

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1x connector, 2x bolts, 10mm, 11 Nm
Instal LH backlight applique assembly

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2x clips, Replace any missing or damaged clips, Install new double sided adhesive
Instal RH backlight applique assembly

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2x clips, Replace any missing or damaged clips, Install new double sided adhesive
Install tonneau applique

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2x bolts, T30, 9 Nm, Position over mounting points then apply downward pressure to engage front and rear attachment points, Install bolts, Ensure seal is not caught outboard of applique, Use trim tool to adjust seal position as required
Install false wall

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2x bolts, 15mm, 45 Nm. Recommended to use assistance to prevent scratching bed liner
Install RH tonneau rail

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9x bolts, 10mm, 9 Nm, Maneuver rail into position
Install RH bed side wall

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1x bolt, 15mm, 46 Nm, 2x bolts, T40, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Recommend assistance
Install RH bed closeout panel

Note
6x clips, 1x tab, Release RH tailgate cable to install bed closeout panel from vehicle
Install RH upper bed side wall assembly

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8x clips, Replace any missing or damaged clips, Lift tonneau seal as required
Install RH tonneaue rail seal

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1x clip
Clean RH tonneau rail surface

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Remove any adhesive tape remaining, Use a cordless drill with eraser wheel attachment for ease adhesive residue removal, Wipe surface with IPA wipes, Allow IPA to dry for 1 minute
Install RH sail applique

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9x clips, 6x double-sided tape strips, 1x push nut, Install new RH sail applique, Do not remove forward section of double-sided tape backing until push nut is installed, Position applique, Partially lift applique to install push nut securing applique onto body, Secure rear of applique, Wet out urethane adhesive sections with roller
Install LH tonneau rail

Note
9x bolts, 10mm, 9 Nm, Maneuver rail into position
Install LH lower bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, 13mm, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Secure locking tabs, Connect bed outlet connectors onto bed side wall and ground strap, 1x bolt, 10mm, 10 Nm, 2x connectors, Secure locking tabs, Slide lock to secure, Recommend assistance
Install LH bed closeout panel

Note
6x clips, 1x tab, Secure LH tailgate cable once closeout installed
Install LH upper bed side wall assembly

Note
8x clips, Replace any missing or damaged clips, Lift tonneau seal as required
Install LH tonneau water management seal

Note
1x clip, Push seal into rail groove
Clean LH tonneau rail surface

Note
Remove any adhesive tape remaining, Use a cordless drill with eraser wheel attachment for ease adhesive residue removal, Wipe surface with IPA wipes, Allow IPA to dry for 1 minute
Install LH sail applique

Note
"9x clips, 6x double-sided tape strips, 1x connector, 1x harness clip, 1x push nut, Install new LH sail applique, Do not remove forward section of double-sided tape backing until push nut is installed, Position applique, Partially lift applique to install push nut securing applique onto body, Connect and secure switch harness then secure rear of applique, Wet out urethane adhesive sections with roller
Install bed cargo tub lid

Note
4x bolts, 10mm, 6 Nm, Snug bolts, Torque will be done at later step, Position bed cargo tub lid onto vehicle, Install bolts securing bed cargo tub lid onto hinges, Recommend assistance
Install cargo tub struts onto cargo lid

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2x strut clips
Close bed cargo tub lid
Install bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
Install fastener covers onto bed floor assembly

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6x covers
Install interior fasteners securing lower tonneau assembly

Note
2x bolts, 13mm, 20 Nm
Install RH Upper C-pillar

Note
5x clips, 3x tabs
Install 2nd row RH outboard seatback bolster

Note
4x clips, 2x datumns
Install RH 2nd row shoulder cover

Note
7x clips, 1x datum
Secure RH cantrail panel

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5x clips, 1x connector, 3x bolts, T30, 6 Nm, Secure tethers then secure clips
Install RH coat hook bolt

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1x bolt, T20, 2.5 Nm
Install RH coat hook bolt cover

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2x tabs
Close RH coat hook

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Press to secure
Secure RH lower C-pillar trim

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1x clip, 1x datum
Install RH upper A-pillar panel

Note
8x clips, 1x tether clip, 1x edge clip, 1x connector, 1x bolt, 10mm, 6 Nm, Ensure tethers are correctly oriented, Replace any missing or damaged clips
Install RH mid A-pillar trim

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2x clips, 2x tabs,
Install LH C-pillar upper panel

Note
5x clips, 3x tabs
Install 2nd row seatback LH outboard bolster

Note
5x clips, 2x datums, Replace any missing or damaged clips
Install LH 2nd row shoulder cover

Note
7x clips, 1x datum
Install LH cantrail panel

Note
5x clips, 1x connector, 3x bolts, T30, 6 Nm, Secure tethers then secure clips
Install LH coat hook bolt

Note
1x bolt, T20, 2.5 Nm
Secure LH coat hook bolt cover

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2x tabs
Close LH coat hook

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Press to secure
Secure LH lower C-pillar trim

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1x clip, 1x datum
Install LH upper A-pillar panel

Note
8x clips, 1x tether clip, 1x edge clip, 1x connector, 1x bolt, 10mm, 6 Nm, Ensure tethers are correctly oriented, Replace any missing or damaged clips
Install LH mid A-pillar trim

Note
2x clips, 2x tabs, Replace any missing or damaged clips
Install rear header trim

Note
12x clips, 3x datums, Replace any missing or damaged clips
Install front header trim

Note
19x clips, 1x magnet, 1x connector, 1x harness clip
Close tonneau cover
Close tailgate
Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement

Note
2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection, If power cycling vehicle ensure at least 60 seconds has passed since powering down
Install rear underhood apron

Note
9x clips, Adjust windshield seal as required
Close powered front trunk

Note
Via exterior switch or UI
Connect to vehicle using Toolbox 3.0

Note
Vehicle OBD II connection is integrated into drivers lower IP cover, Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)
Select "Actions" tab and search for "Tonneau"
Select "Tonneau Cover Calibration", click "Run", and allow routine to complete

Note
Select "X" at top right of window to close once complete
Disconnect Toolbox 3 from vehicle and remove laptop
Move LH front seat to original position
Move RH front seat to original position
Raise all 4 windows

Note
Verify switch is operating as expected
Close all 4 doors