This section provides general information which helps technicians identify hazardous operations during service and prevent personal injury and component damage.

When the repair involves environmental protection, ergonomics, and health protection, follow the detailed guidance in: Environmental Precautions, Ergonomic Precautions and General Precautions.

Always wear safety glasses and safety toe shoes when in a service or collision shop. All repair and operating instructions should be reviewed and understood before working on Tesla vehicles, associated components, or associated repair equipment.

Consumable parts specified in the service procedure (such as nyloc nuts, patchbolts, clips, and seals) must be replaced as instructed and must not be reused.

This document serves as general safety guidance. It does not replace specific repair steps, Tech Notes, training courses, or equipment operator manuals. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.

Qualification and PPE

• Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.
• Always wear High Voltage (HV) gloves and safety glasses when handling any High Voltage component, including test equipment. Before each use, test gloves using an authorized glove tester and verify that the testing date on the gloves has not expired. Both HV gloves must pass testing before repair. If either glove does not pass the air check, discard the pair. Continue to wear the HV gloves until instructed to remove them.
• Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
• If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
• ESD wrist straps should never be worn when working with High Voltage (HV) components.
• Always have an electrical safety hook in the area when working with HV components. Electrical safety hooks are used to remove an injured person from a live High Voltage circuit without risking additional injury.

Vehicle HV Disablement and Isolation

• Assume that High Voltage is present at all times when working on a Tesla vehicle, associated High Voltage components, or associated High Voltage test equipment until proven otherwise. Be aware that energy states can change during testing, so err on the side of caution. Never disconnect or cut an orange High Voltage power cable or HV component unless the HV system has been disabled.
• Use a High Voltage digital multimeter to check for the presence of High Voltage on both sides of the connector every time a High Voltage connector is disconnected. Make sure that the multimeter and leads are capable of handling at least 500V DC before performing a procedure that involves High Voltage. In certain regions, a Voltage Absence Tester (VAT) is required for this procedure, and the use of a multimeter is not allowed. Always adhere to local or regional tooling regulations.
• After disabling the vehicle, power is maintained for 1 minute in the High Voltage electrical system. Wait the specified time before measuring or operating.
• Set up a work warning isolation area according to the service task, and post conspicuous warning signs such as “Do Not Enter” and “High Voltage Hazard.”
• When removing or installing modules, contactors, relays, fuses, busbars, or other parts inside the battery enclosure, no part of the technician’s body shall contact the battery enclosure or any exposed parts inside the HV battery. Protect all exposed high-voltage and low-voltage metal terminals that appear during the work.
• For HV battery storage precautions, disposal procedures, and high-voltage circuits, etc., see Electrical Precautions.

• The Supplementary Restraint System (SRS) includes airbags, pretensioners, and other safety-related components. The SRS contains components which could be potentially hazardous to the technician if not serviced and handled correctly.
• Always follow these precautions and the relevant Service Manual procedures when servicing airbags and other SRS components. Only trained professionals should service the SRS.
• In the event of an airbag or seatbelt pretensioner deployment, certain airbag and seatbelt components must be replaced, and other components must be inspected for damage. Refer to Airbag and Supplementary Restraint System (SRS) Component Replacement Policy for a specific list of items that must be inspected and replaced.
• Never install used SRS components from another vehicle, or attempt to repair an SRS component. Use only new, genuine Tesla replacement parts. Never use SRS components that lack clear identification labels. Never use an Restraint Control Module (RCM) that has been dropped. Never apply electrical power to an SRS component unless instructed to do so as part of an approved test procedure. Always use new fasteners when replacing SRS components. Make sure that the fasteners are tightened to the specified torque. Make sure that SRS components are not contaminated with oil, grease, detergent, or water.
• Make sure 12V/LV power has been disconnected for at least 1 minute before disconnecting the electrical harness from Supplementary Restraint System (SRS) components, such as RCM, sensors, airbags, etc. Disconnect the 12V/LV battery and the First Responder Loop. Failure to do so can result in unintended safety system behaviors. For more information on SRS precautions, see Airbag and Supplementary Restraint System (SRS) Precautions.
• Do not supply power to the RCM until all other SRS components are connected. Make sure that the RCM is installed correctly. There must not be any gap between the RCM and the body. An incorrectly mounted RCM might cause the SRS system to malfunction.
• Do not use a multimeter or other general purpose test equipment on SRS components. Only use the recommended diagnostic equipment to diagnose SRS system faults.
• The airbag should always be handled by the igniter; the igniter should never be left dangling. The RCM is a particularly shock sensitive device.
• Always replace any plugs or tape removed from the front door shells when replacing a front door pressure sensor. Additional holes in the door create more escape paths for air, which decreases the sensor's ability to detect a side impact, and can negatively affect airbag deployment. The side impact airbag deployment depends on the door sensor's ability to detect a side impact from air pressure. Make sure that there are no uncovered holes in the door shells. Additionally, always reinstall plugs or tape when servicing or inspecting the doors and their components.
• Only personnel who have undergone the appropriate training should undertake deployment of airbag and seatbelt pretensioner modules. Only use approved deployment equipment, and only deploy airbags and pretensioner components in a well-ventilated designated area. Make sure components are not damaged or ruptured before deployment.
• Store the airbag module with the deployment side facing up. This will prevent it from being propelled if accidentally deployed, which might cause injury.
• Supplementary restraint system (SRS) components can be hazardous if not handled properly. For handling, storage, deployment, and disposal, see Airbag and Supplementary Restraint System (SRS) Precautions.

• Thermal management components operate under very tight specifications and can malfunction if Service procedures are not carefully followed. DO NOT rely on past experience with other thermal management systems; read through the Service Manual and do not deviate from the instructions.
• Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For EMEA, in addition to any local A/C or F-gas certification, Tesla technicians are required to complete the Air Conditioning Safety Essentials training before working on Thermal Management and A/C systems. Only personnel familiar with both vehicle A/C systems and the A/C machine are permitted to service the systems. Always read and understand the A/C machine operator’s manual before operating the A/C machine.
• Replacement of the A/C desiccant bag must follow the Service Manual steps. After recovering the A/C refrigerant, carefully depress both Schrader valves to level out any pressure difference between the A/C system pressure and the actual ambient atmospheric pressure. Wear appropriate personal protective equipment (PPE) including a face shield when performing desiccant-related repair to protect against foreign objects flying out under pressure.
• Refrigerants R134a and R1234yf are hazardous liquids and, if handled incorrectly, can cause serious injury. Suitable Personal Protective Equipment (PPE), consisting of face protection, safety glasses, face shield, heat-proof gloves, chemical resistant gloves, rubber boots, and apron or waterproof overalls, must be worn when performing recovery or recharge on the air conditioning system.
• Only use Tesla-specified refrigerant in the vehicle A/C system and the A/C machine. Do not mix refrigerant types within a vehicle A/C system or in the same container. Mixing refrigerants can severely damage the A/C machine and the vehicle A/C system. If oil must be added to the A/C system, use the appropriate oil specified in the Service Manual. Select the refrigerant oil type according to the compressor type. Do not mix different types of A/C system oil. See Fluids and Capacities for A/C oil specifications.
• Do not allow refrigerant oil to come in contact with any surfaces of the vehicle as it might cause damage to the paint, trim, or finish of the vehicle.
• Do not use compressed air to pressure test or leak test the A/C machine or the vehicle A/C system. Some mixtures of air and refrigerant are combustible at elevated pressures. These mixtures are potentially dangerous and might result in fire or explosion, causing personal injury or property damage. Be aware of fire hazards. Do not use the A/C machine in the vicinity of spilled or open containers of flammable liquid.
• Do not breathe refrigerant and lubricant vapor or mist. Exposure might cause personal injury, especially to the eyes, nose, throat, and lungs. Perform service and repairs in a well-ventilated area. If accidental discharge occurs, ventilate the work area before returning to work. Additional health and safety information is available from the equipment, refrigerant, and lubricant manufacturers. Refer to manufacturer's instruction manuals and Material Safety Data Sheets.
• For more information. See Air Conditioning System Precautions.

• Do not close the door with the window fully raised, as upper bright trim will be damaged.
• Do not begin cutting the windshield without first setting the drill clutch to 1. Failure to set the drill clutch to 1 may result in serious injury. Wear appropriate eye and hand protection while cutting the glass assembly. For additional precautions, refer to the windshield and roof glass repair and replacement guide.
• Seat base edges are sharp and can cause personal injury. Wear cut resistant gloves when removing the seat from the vehicle, and while performing procedures that involve work on or near the seat base.
• To avoid damaging the hood, ensure that the hood is fully closed before activating the windshield wipers.
• Brake fluid dissolves paint. Have clean towels and plenty of water standing by to wash spilled brake fluid off painted surfaces. Dispose of used brake fluid in accordance with local environmental regulations.
• Following repair procedures, apply protective tape around the working area as needed to prevent paint scratches and part damage.

• Technicians must be trained and familiar with the construction, performance, and safe operating procedures of the tools they use.
• Wear appropriate personal protective equipment (PPE). Use tools only for their intended purpose.
• Inspect tools before use. Do not use tools that are damaged, deformed, or cracked. Never use equipment that is defective or not working as expected based on the equipment operator’s manual.
• Do not modify tools or remove safety guards if equipped.
• Inspect and service equipment at the required maintenance intervals.
• Keep tools dry and clean so that they do not slip in use.
• Store tools properly when not in use.

Lifting Equipment (Two-Post Lift, Four-Post Lift, Floor Jack)

• Perform a visual check of the floor jack according to the equipment operator's manual before using the lifting equipment.
• Do not attach the charging cable to the charge port while the vehicle is on the lift.
• Place the lifting arm pads only under the vehicle’s specified lift points. When the floor jack is used, to avoid damage, NEVER support the vehicle from diagonal points (for example, LH front and RH rear) at the same time.
• Make sure that no part of the vehicle is in danger of contacting the ceiling, tool boxes, or other items in the service area when the vehicle is raised.
• Raise the vehicle slightly, and check the following:
  • Make sure all 4 pads are in the correct position.
  • Check the balance of the vehicle.
  • Make sure that the four arms are properly locked and cannot rotate.
• Do not work on an incorrectly supported vehicle.
• While the lift is in operation, the technician must remain at the operating position and continuously monitor the lift. After raising to the necessary service height, the safety locks must be properly engaged.
• If an electric jack or pneumatic jack is used, stay away from the vehicle prior to raising it to avoid injuries.
• Before lowering, make sure no one is under the vehicle and that the area is clear of obstructions.

Tire Changer

• Always read and understand the tire equipment operator’s manual and on-screen instructions before operating the wheel balancer or tire changer.
• Always make sure to properly secure the wheel and exercise caution around all moving parts and pinch points, including the indent rollers. Additionally, secure all loose items such as hair, jewelry, and clothing, so that they will not catch on moving parts.
• Wear appropriate personal protective equipment (PPE) including cut-resistant gloves and safety glasses when performing this procedure.
• The machine must be operated by no more than one person at a time. Other persons must maintain a safe distance from the equipment while in use to avoid accidental contact.
• Before use, confirm that the motor control pedal returns to the rest position, that the inflation pedal inflates as expected, and that the tire lift pedal operates normally.
• Never place hands in the gap between the bead hook and the wheel at any time during tire-changer operation.
• Make sure the tire machine arm does not contact the TPMS sensor.

Wheel Balancer

• Always read and understand the tire equipment operator’s manual and on-screen instructions before operating the wheel balancer or tire changer.
• Always make sure to properly secure the wheel and exercise caution around all moving parts and pinch points, including the indent rollers. Additionally, secure all loose items such as hair, jewelry, and clothing, so that they will not catch on moving parts.
• The machine must be operated by no more than one person at a time. Other persons must maintain a safe distance of at least three feet from equipment while in use.

Hand Tools / Power Tools / Pneumatic Tools

• Hand tools: Screwdriver bits must be in good condition. The insulation on electrically insulated screwdrivers must not be damaged, and the metal shaft underneath must not be exposed.
• Power tools: Power tools must have complete insulation and grounding or double insulation. Before use, inspect the cable for damage and confirm that the plug is intact. Do not pull the tool by the cable or use the cable as a lifting rope. Do not use power tools in wet conditions or with wet hands unless the tool is rated for that use. Disconnect power before changing accessories or making adjustments. Grinding wheels and cutting discs must be intact and speed-matched; do not exceed rated speed.
• Pneumatic tools: Hose fittings must be secure and clamps intact. Never point these tools at anyone. Operators must never rest the muzzle against themselves or others. When using an impact wrench, watch for reaction torque and keep the body clear of the rotation path. Eye protection must be worn at all times when operating pneumatic tools. Hearing protection is also required because of noise hazards. Head and face protection is recommended to prevent injury from flying debris. Wear proper PPE including eye protection if using shop air to blow out debris. To avoid personal injury, eye protection must be worn while using compressed air.

LV Maintainer

• Use only LV maintainer specified by Tesla and select an appropriate type of LV maintainer. Inspect before use, and make sure the external power supply is still within its service life.
• Do not charge a LV maintainer unattended for an extended period.

Cutting Tools

• Cutting tools must have the blade facing a safe direction; close or sheath them when not in use. Always wear cut-resistant gloves when using cutting tools. When using cutting tools, protect surrounding parts. Do not damage harnesses or interior trim.

S-Hooks

• Hang S-hooks only from a secure support point. Do not hang them from locations that can vibrate or slip. After hanging, apply light tension to confirm that the hook will not come off.

Pry Tools

• Use a pry tool of the correct size and work from a stable fulcrum.
• Do not pry with excessive force.
• As needed, apply protective tape around the work area to prevent component damage.

Other

• When handling large or heavy parts, it's recommended to use lifting equipment or obtain assistance from another person.