06/11/2024 04:55:29

Harness - Main Front (Remove and Replace)

Correction code 17100702 7.20 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 proper PPE is worn when performing the below procedure.

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.

Note

This procedure is for the Original version of this part. An updated/region-specific Global Refresh version of this part is available for newer vehicles and that procedure is here: Harness - Main Front (EMEA) (Remove and Replace).

Remove

Connect A/C machine to power and switch on

Note
Touch time only, Machine will run various background tasks, Wait until Main Menu comes up before continuing
Skip the following panels when prompted

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Use selections indicated in pictures
Perform hose flush

Note
Touch time only, Connect couplers to machine, Open couplers by turning clockwise, Using Main Menu > Next > Menu > Flush hoses > Verify hose connection, Machine will chime once process is complete
Open LH front door
Lower LH and RH front windows
Using center display, place wipers into "Service Mode"

Note
via Controls > Service > Wiper Service Mode
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-REFRIGERANTvia Toolbox: (link)

Note
Select "x" at the top right of the window to close once complete, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours EXV's will close and routine must be performed again, Verify EXV positions are open via Garage > Vitals > HP > Refrigerant Loop EXV, Verify LCC, CC Left, Evap, CC Right, Chiller are all at ~100%. Recirc is at ~20%, LCC Solenoid is OPENED
Remove the underhood storage unit. See .
Remove caps from low side and high side AC ports

Note
2x caps
Connect hoses to vehicle and perform A/C recovery

Note
Connect couplers to vehicle, Note the amount of refrigerant and oil recovered, mark oil drain bottle oil level (use a piece of tape marking the fluid level), Open couplers by turning clockwise, Using Main Menu > Recover > Verify hose connection, Machine will chime once process is complete, Vehicle may be left unattended, Note or print the amount of refrigerant and oil recovered, Refrigerant recovered should be ~2.24 lb (1.02 kg), Oil recovered should be ~0.3 oz (8.87 mL), If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart https://toolbox.teslamotors.com/articles/353700
Raise and support vehicle

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
Remove LH front wheel cap

Note
Lift every other spoke at a time until cap is released from rim
Remove RH front wheel cap

Note
Lift every other spoke at a time until cap is released from rim
Loosen RH front wheel

Note
5x nuts, 21mm, 175 Nm
Loosen LH front wheel

Note
5x nuts, 21mm, 175 Nm
Move LH front seat backward
Remove LH mid A-pillar trim

Note
1x clip, 2x tabs
Remove LH lower A-pillar trim

Note
7x clips
Remove LH footwell cover

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1x connector, 2x magnets
Remove LH front floor mat
Remove LH console side carpet

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11x clips
Release LH HEPA assembly lower dash bolt

Note
1x bolt, 10mm, 7Nm
Open RH front door
Move RH front seat backward
Remove RH mid A-pillar trim

Note
1x clip, 2x tabs
Remove RH lower A-pillar trim

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7x clips
Remove RH footwell cover

Note
3x magnets, 1x connector
Remove RH front floor mat
Remove RH console side carpet

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11x clips
Fold RH front cabin carpet aside for access
Release harness from RH footrest panel

Note
1x clip
Remove RH footrest panel

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2x bolts, 10mm, 5 Nm, 1x nut, 10mm, 5 Nm
Release RH HEPA assembly lower dash bolt

Note
1x bolt, 10mm, 7Nm
Release LH wiper arm hose nozzle

Note
1x hose
Remove LH wiper arm nut cover

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1x cover
Remove LH wiper arm nut and release assembly

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1x nut, 15mm, 26 Nm
Release RH wiper arm hose nozzle

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1x hose
Remove RH wiper arm nut cover

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1x cover
Remove RH wiper arm nut and release assembly

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1x nut, 15mm, 26 Nm
Release washer hose nozzle by LH shock tower cover

Note
1x hose, 3x clips
Remove LH shock tower cover

Note
3x push clips, 1x fir tree clip
Remove RH shock tower cover

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3x push clips, 1x fir tree clip
Remove wiper cowl screen panel

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4x push clips, 2x end tabs
Remove fasteners securing LH V-brace and remove assembly

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3x bolts, 10mm, 18 Nm, 1x nut, 10mm, 9 Nm
Remove fasteners securing RH V-brace and remove assembly

Note
3x bolts, 10mm, 18 Nm, 1x nut, 10mm, 9 Nm
Using center display, place wipers into "Service Mode"

Note
via Controls > Service > Wiper Service Mode
Power off vehicle from center display

Note
Via Controls > Safety & Security > Power Off
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection
Remove wiper module

Note
3x bolts, 10mm, 8 Nm, 1x connector, Rotate module forward and up to access connector, Observe LH wiper arm pivot during removal to avoid damage to windshield
Release clip securing the supermanifold to battery pump supply hose from LV battery

Note
1x clip
Remove fasteners securing the LV battery and move aside

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3x bolts, 10mm, 9 Nm, 2x datums, Take note of datums and carefully move assembly aside
Disconnect air quality sensor harness

Note
1x connector
Remove HEPA filter assembly cover

Note
2x tabs, 2x datums, 2x slots, , Be cautious and do not damage the mounting clips, Maneuver cover forward and up in front of V-brace cross member
Remove HEPA filter

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2x clips, Release clips, Pivot filter forward and out of housing
Release V-brace crossmember

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2x nuts, 10mm, 18 Nm
Remove HEPA housing assembly

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2x nuts, 10mm, 7 Nm, Rotate V-brace cross member forward to create access to HEPA assembly retaining nuts, Maneuver assembly forward and up out of vehicle
Remove fasteners securing LH knee air bag assembly to vehicle

Note
2x patch bolts, E10, 8 Nm, Discard after removal
Remove the LH knee air bag assembly from vehicle

Note
3x connectors, 1x clip, 6x tabs, Release 2x locking tab on airbag connector
Fold LH front cabin carpet aside for access
Remove frunk harness ground from LH footwell area

Note
1x nut, 10mm, 8 Nm
Disconnect J14 X036 Power connector

Note
1x connector, Release lock then remove
Disconnect J9 X037 Frunk connector

Note
1x connector
Remove fasteners securing RH knee air bag assembly to vehicle

Note
2x patch bolts, E10, 8 Nm, Discard after removal
Remove RH knee air bag assembly from vehicle

Note
2x connectors, 6x tabs, 1x clip, Release 2x locking tab on airbag connector
Install coolant hose clamps to coldplate hoses

Note
2x hoses, Place coolant absorbent material around the car computer
Release coolant hoses from car computer coldplate assembly

Note
2x spring locks, Install coolant plugs at both hoses and car computer
Remove car computer supply hoses through the bulkhead

Note
Remove coolant hose clamps from car computer supply hose, Ensure plugs are secure and leak free, Guide hoses between HVAC assembly and bulkhead
Disconnect brown fakra connection from car computer

Note
1x connector, X836
Disconnect frunk connectors on RH side of car computer

Note
5x connectors
Release connectors at RH side of AP motherboard

Note
3x connectors, Release locks on connectors before removal
Release frunk harness from RH footwell area

Note
2x clips
Remove frunk harness ground from RH footwell area

Note
1x nut, 10mm, 8 Nm
Disconnect J14 X056 Power connector

Note
1x connector, Release lock then remove
Disconnect harness connectors

Note
2x connectors, Release lock then remove
Release harness connector clips from RH controller

Note
2x clips
Disconnect J9 X050 Frunk connector

Note
1x connector,
Release electrical connections from TASC 2.0 ECU

Note
3x connectors
Disconnect steering gear assembly connectors

Note
2x connectors, Two-stage connectors, Slide red locking tab to unlock then depress connector release to disconnect
Remove AC hoses from vehicle
Remove Penta HVAC line from HVAC assembly

Note
2x bolts, 13mm, 22 Nm
Raise vehicle partially and lower onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove RH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove LH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove LH front wheel liner

Note
13x clips, 2x fan clips
Remove LH front jounce hose bracket from body

Note
1x bolt, 10mm, 8 Nm
Disconnect LH front repeater

Note
2x connectors
Release LH repeater harness from body

Note
1x clip
Disconnect LH front ride height sensor

Note
1x connector
Disconnect ground junction connector (G500)

Note
1x connector, Release red locking tab, Depress black tab and rotate lever to release
Disconnect LH front accelerator sensor

Note
1x connector, Release red locking tab
Disconnect LH cooling fan module connector

Note
1x connector, Disconnect this after coolant hoses are plugged to avoid coolant damaging connector
Release horn high tone connection

Note
1x locking connector, Release red locking tab
Release horn low tone connection

Note
1x locking connector, Release red locking tab
Disconnect frunk harness from washer system

Note
2x Connectors, 3x Fir tree Clips, Disconnect connectors then remove the Fir Tree clips
Remove the RH front wheel liner

Note
13x clips, Release clips, Remove from vehicle
Remove RH front jounce bracket from body

Note
1x bolt, 10mm, 8 Nm
Disconnect RH front repeater

Note
2x connectors
Release RH repeater harness from body

Note
1x clip
Disconnect RH front ride height sensor

Note
1x connector
Disconnect ground junction connector (G500)

Note
1x connector, Release red locking tab, Depress black tab and rotate lever to release
Disconnect RH cooling fan module connector

Note
1x connector, Disconnect this after coolant hoses are plugged to avoid coolant damaging connector
Release frunk harness from RH wheel well area

Note
1x clip
Release air compressor connections

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2x connectors
Release air suspension valve block connector

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1x connector
Release clips securing electrical harness to air compressor bracket

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2x clips
Disconnect RH front accelerator

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1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect front fascia harness

Note
2x connectors, Pull red tab to disengage lock then disconnect, Located behind RH wheel arch liner
Release frunk harness from front end carrier

Note
3x clips
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove clips securing front aero shield to valence and HV battery

Note
3x push clips
Remove bolts securing front aero shield and remove from vehicle

Note
9x bolts, 10mm, 6 Nm
Disconnect EPAS CAN connectors

Note
2x connectors, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
Release frunk harness from subframe

Note
3x clips, Route harness away from subframe
Remove bolts securing front skid plate to body sill

Note
2x bolts, 15mm, 30 Nm
Remove bolts securing front skid plate to body casting

Note
2x bolts, 15mm, 60 Nm
Remove bolts securing front skid plate to front subframe and remove skid plate

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm
Disconnect logic connector to HV battery

Note
1x connector, Pull red locking tab outwards and release connection
Disconnect power connector to HV battery

Note
1x connector, Pull red locking tab outwards and release connection
Release frunk harness from HV battery and body

Note
2x clips
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Disconnect RH headlamp connector

Note
1x connector
Disconnect FEM harness from RH side

Note
1x connector, Release locking tab
Release frunk harness from top RH side of front end carrier and crash rail

Note
2x clips
Release frunk harness from RH crash rail

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2x clips
Disconnect RH front damper harness from frunk harness

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1x connector
Release damper harness connector from RH crash rail

Note
1x clip
Disconnect black connector on RH side of radiator along crash rail

Note
1x connector, Release locking tab
Remove bolt securing RH side ground to RH side crash rail

Note
1x bolt, 10mm, 8 Nm
Disconnect RH front wheel speed sensor from frunk harness

Note
1x connector, 1x clip
Release frunk harness from frunk side of RH side crash rail

Note
2x clips
Release upper connections on the front controller

Note
2x locking connectors, Push in locking tabs and lift levers to release
Release LH middle connection on the front controller

Note
1x locking connector, Push in locking tab and lift lever to release
Release RH middle connections on the front controller

Note
2x locking connectors, Slide locking mechanism outwards to release
Release lower connections on the front controller

Note
2x locking connectors, Slide red locking tab outwards to release
Remove bolt securing front controller ground cable

Note
1x bolt, 10mm, 10 Nm
Remove bolts securing front controller

Note
3x bolts, 10mm, 10 Nm
Remove front controller from vehicle and release ground cable from multi system beam

Note
2x locating tabs, 1x ground cable
Release three way valve connection

Note
1x locking connector, Disengage red locking tab and slide tab outwards to release connection
Remove clips securing air suspension rear bundle to RH side of frunk harness

Note
2x clips
Release RH front brake pipe from clips

Note
5x clips, Do not bend pipe
Release battery coolant temp sensor connection

Note
1x locking connector, Disengage red locking tab and slide tab outwards to release connection
Remove clip securing battery supply hose to RH side of frunk harness

Note
1x clip
Release battery supply hose from battery coolant pump

Note
1x hose clip, 2x plugs, Plug both ends
Release battery coolant pump connection

Note
1x connector, Disengage red locking tab and slide tab outwards to release connection
Release frunk harness from RH front of body

Note
3x clips
Release frunk harness from RH side of bulkhead

Note
2x clips
Release grommet from RH side of bulkhead

Note
1x grommet
Maneuver frunk harness branch through RH side of bulkhead

Note
Move aside for clearance
Release branch routed to HV battery from below beam

Note
1x clip, Follow hose downward to RH side body beam, Place clip prytool between clip and beam, Work clip out from bottom of beam, May need to slightly tap tool handle with hammer being cautious not to damage coolant hose
Release frunk body harness from FDU harness

Note
1x locking connector, Release locking tab
Release clip securing frunk body harness to FDU LV harness bracket

Note
1x clip
Release frunk harness from FDU assembly

Note
1x clip
Disconnect LH front headlamp

Note
1x connector
Disconnect frunk harness from LH side FEM harness connection

Note
1x connector, Release red locking tab
Release frunk harness from top LH side of front end carrier

Note
2x clips
Disconnect frunk harness from LH side crash rail

Note
1x connector, Release locking tab
Release LH front damper harness connection

Note
1x connector
Disconnect LH front wheel speed sensor from frunk harness

Note
1x connector, 3x clips
Remove frunk harness ground from LH crash rail

Note
1x bolt, 10mm, 8 Nm
Release frunk harness from LH side crash rail

Note
4x clips
Release battery controller ground cable

Note
1x bolt, 10mm, 9 Nm
Release harness clip from battery controller

Note
1x fir tree clip
Remove fasteners securing battery controller and tilt controller for access

Note
1x bolt, 10mm, 10 Nm, 1x nut, 10mm, 10 Nm
Release top J4 connection from battery controller

Note
1x locking connector, Slide mechanism outwards to release
Release middle J5 connection from battery controller

Note
1x locking connector, Push in locking tab and lift lever to release
Release side J3 connection from battery controller

Note
1x locking connector, Slide mechanism outwards to release
Release middle J2 connection from battery controller

Note
1x locking connector, Slide red locking tab outwards and release
Release side J1 connection from battery controller

Note
1x locking connector, Slide red locking tab outwards and release
Release harness clip from battery controller

Note
1x clip
Remove battery controller from vehicle
Release LV harness from multi system beam

Note
1x bolt, 10mm, 8 Nm, 2x clips
Disconnect brake fluid level sensor

Note
1x connector
Disconnect brake booster ECU connector

Note
1x connector, Release red locking tab, then depress black tab and rotate lever to release
Disconnect the hydraulic control unit

Note
1x connector, Release red locking tab and rotate lever upward to remove
Release grommet from LH side of bulkhead

Note
1x grommet
Maneuver frunk harness branch through LH side of bulkhead

Note
Move aside for clearance
Release frunk harness guide from bulkhead

Note
2x clips
Release AC compressor HV harness clip from body

Note
1x clip
Disconnect AC compressor logic connector

Note
1x locking electrical connector, Do not push down on red tab, Pull to disengage lock, Pull again to release connector
Remove retaining clip securing AC compressor logic harness to AC compressor HV harness bracket

Note
1x fir tree clip
Remove AC compressor ground strap

Note
1x bolt, T25, 7 Nm
Release clip securing the coolant hose to the AC compressor bracket

Note
1x fir tree clip
Release PT coolant pump connection

Note
1x connector, Disengage red locking tab and slide tab outwards to release connection
Remove PT coolant pump from AC compressor bracket

Note
Slide pump assembly away from compressor off lower bracket
Release compressor bracket from multi-system beam

Note
2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while removing the fasteners, Carefully remove the AC compressor and AC compressor bracket towards the front of the vehicle and under the multi-system beam, Be cautious around the coolant hose and supermanifold harness, Place fender cover on fan housing and gently place AC compressor assembly down
Remove FDU ground strap from body stud

Note
1x bolt, 12mm, 15 Nm, Remove strap assembly
Release frunk harness guide from LH side crash rail

Note
2x clips
Support supermanifold using bungee cords

Note
This is needed for frunk harness removal at later step, Be cautious to avoid damage to surrounding components
Remove bolts securing the supermanifold to the multi-system beam

Note
2x bolts, 15 mm, 31 Nm, Recommend assistance, Support from underneath and at reservoir
Release multi-system beam

Note
4x bolts, 15mm, 60 Nm
Place a folded rag underneath RH and LH side of the multi-system beam

Note
Lift multi-system beam up only the amount required to clear the reservoir fill neck between top of supermanifold and bottom of beam, Recommend assistance if needed
Remove coolant bottle cap
Remove frunk harness from vehicle

Note
Recommend assistance, Feed harness between multi-system beam and super manifold, Maneuver harness to clear surrounding components, Move Bungee's around harness to allow clearance as needed

Install

Install frunk harness into position

Note
Feed harness between multi-system beam and super manifold, Maneuver harness to clear surrounding components, Move Bungee's around harness to allow clearance as needed, Move each branch into place for installation
Maneuver frunk harness branch through LH side of bulkhead

Note
1x grommet
Install frunk harness into LH side of bulkhead

Note
1x grommet
Maneuver frunk harness branch through RH side of bulkhead

Note
Position for installation
Secure frunk harness grommet into RH side of bulkhead

Note
1x grommet
Route frunk harness towards HV battery and secure clip below beam

Note
1x clip
Secure frunk harness onto RH side of crash rail

Note
3x clips
Install frunk harness onto LH side crash rail

Note
2x clips
Remove shop rags from underneath RH and LH side of the multi-system beam
Secure multi-system beam

Note
4x bolts, 15mm, 60 Nm, Position beam and start bolts by hand
Install bolts securing the Supermanifold to the multi-system beam

Note
2x bolts, 15 mm, 31 Nm, Recommend assistance, Support from underneath and at reservoir, Hand start bolts to Supermanifold
Remove bungee cords supporting supermanifold assembly
Install FDU ground strap to body stud

Note
1x bolt, 12mm, 15 Nm, Position strap for install
Install bolts securing AC compressor bracket to multi system beam

Note
2x bolts, 15mm, 31 Nm, Recommend assistance, Carefully support the AC compressor assembly and secure assembly, Prevent damage to any components, Remove any bungee cords
Secure AC compressor HV harness clip onto body

Note
1x clip
Install AC compressor ground strap

Note
1x bolt, T25, 7 Nm
Secure PT coolant pump onto AC compressor bracket

Note
Slide pump assembly onto compressor lower bracket
Install clip securing the coolant hose to the AC compressor bracket

Note
1x fir tree clip
Secure PT coolant pump connection

Note
1x connector, Secure connector and full engage red locking tab
Install frunk harness onto LH side crash rail

Note
4x clips
Install frunk harness ground onto LH crash rail

Note
1x bolt, 10mm, 8 Nm
Connect LH front wheel speed sensor to frunk harness

Note
1x connector, 3x clips
Secure LH front damper harness connection

Note
1x connector
Connect frunk harness onto LH side crash rail

Note
1x connector, Engage locking tab
Secure frunk harness onto top of LH side of front end carrier

Note
2x clips
Connect frunk harness to LH side FEM harness connection

Note
1x connector, Secure red locking tab
Connect LH headlamp connector

Note
1x connector
Connect the hydraulic control unit

Note
1x connector, Seat connection and rotate lever downward, then secure locking tab
Connect brake booster ECU connector

Note
1x connector, Align connector and rotate lever to fully seat, Secure red locking tab
Install LV harness onto multi system beam

Note
1x bolt, 10mm, 8 Nm, 2x clips
Position battery controller into vehicle
Secure harness clip onto battery controller

Note
1x clip
Secure side J1 connection onto battery controller

Note
1x locking connector, Engage red locking tab
Secure middle J2 connection onto battery controller

Note
1x locking connector, Engage red locking tab
Secure side J3 connection onto battery controller

Note
1x locking connector, Verify yellow locking tab is fully opened, Seat connector and mechanism will begin to engage
Secure middle J5 connection onto battery controller

Note
1x locking connector, Verify lever is fully opened, Seat connector and lever will being to engage
Secure top J4 connection onto battery controller

Note
1x locking connector, Verify yellow locking tab is fully opened, Seat connector and mechanism will begin to engage
Secure harness clip onto battery controller

Note
1x clip
Secure battery controller ground cable

Note
1x bolt, 10mm or E10 5-lobe, 9 Nm
Position battery controller forward and install fasteners

Note
1x bolt, 10mm, 10 Nm, 1x nut 10mm, 10 Nm
Secure frunk harness onto FDU

Note
1x clip
Install clip securing frunk body harness to FDU LV harness bracket

Note
1x clip
Secure frunk body harness onto FDU harness

Note
1x connector, Engage red locking tab
Install frunk harness guide onto bulkhead

Note
3x clips
Secure RH front brake pipe onto clips

Note
5x clips, Do not bend pipe
Secure frunk harness onto RH side of bulkhead

Note
2x clips
Install clips securing air suspension rear bundle to RH side of frunk harness

Note
2x clips
Secure car computer supply hoses to the bulkhead

Note
Guide hoses between HVAC assembly and bulkhead, Ensure grommet is fully seated into bulkhead
Secure battery coolant pump connection

Note
1x connector, Secure connector and full engage red locking tab
Secure battery coolant pump to bracket

Note
1x clip, Slide pump on to bracket and secure lower coolant hose to bracket
Install clip securing battery supply hose to frunk harness

Note
1x clip
Secure battery coolant temp sensor connection

Note
1x locking connector, Secure connector and fully engage red locking tab
Secure three way valve connection

Note
1x locking connector, Secure connector and fully engage red locking tab
Position front controller for installation and position ground cable

Note
2x locating tabs, 1x ground cable
Install bolts securing front controller

Note
3x bolts, 10mm, 10 Nm. Start with the side bolt
Install bolt securing front controller ground cable

Note
1x bolts, 10mm, 10 Nm
Secure lower connections on the front controller

Note
2x locking connectors, Engage red locking tab
Secure RH middle connections on front controller

Note
2x locking connectors, Verify yellow locking tabs are fully opened, Seat connectors and mechanism will begin to engage
Secure LH middle connection for front controller

Note
1x locking connector, Verify lever is fully opened, Seat connector and lever will being to engage
Secure upper connections for the front controller

Note
2x locking connectors, Verify levers are fully opened, Seat connectors and levers will begin to engage
Install frunk harness onto RH side crash rail

Note
2x clips
Connect RH front wheel speed sensor to frunk harness

Note
1x connector, 3x clips
Install bolt securing RH side ground to RH side crash rail

Note
1x bolt, 10mm, 8 Nm
Connect black connector on RS of radiator along crash rail

Note
1x connector, Engage locking tab
Secure damper harness connector onto RH crash rail

Note
1x clip
Connect RH front damper harness

Note
1x connector
Secure frunk harness onto RH crash rail

Note
2x clips
Secure frunk harness onto top RH side of front end carrier and crash rail

Note
2x clips
Connect frunk harness to RH side FEM harness connection

Note
1x connector, Engage red locking tab
Connect RH headlamp connector

Note
1x connector
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Secure frunk harness onto HV battery and body

Note
2x clips
Secure power connector to HV battery

Note
1x connector, Engage red locking tab
Secure logic connector to HV battery

Note
1x connector, Engage red locking tab
Position front skid plate for installation and thread in all bolts

Note
4x bolts, 15mm, 70 Nm, 2x bolts, 15mm, 60 Nm, 2x bolts, 15mm, 30 Nm, 2x bolts, 10mm, 10 Nm, Torque at later step
Torque bolts securing front skid plate to body casting

Note
2x bolts, 15mm, 60 Nm
Torque bolts securing front skid plate to body sill

Note
2x bolts, 15mm, 30 Nm
Secure frunk harness onto subframe

Note
3x clips
Connect EPAS CAN connectors

Note
2x connectors, Engage locking tab
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle

Note
9x bolts, 10mm, 6 Nm
Install clips securing front aero shield to valence and HV battery

Note
3x push clips
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Secure frunk harness onto front end carrier

Note
3x clips
Connect front fascia harness

Note
2x connectors, Engage locking tab, Located behind RH wheel arch liner
Connect RH front accelerator

Note
1x connector, Engage locking tab
Install clips securing electrical harness to air compressor bracket

Note
2x clips
Secure air suspension valve block connector

Note
1x connector
Secure air compressor connections

Note
2x connectors
Secure frunk harness onto RH wheel well area

Note
1x clip
Install RH cooling fan module connector

Note
1x connector
Connect ground junction connector (G500)

Note
1x connector, Secure red locking tab
Connect RH front ride height sensor

Note
1x connector
Secure RH repeater harness to body

Note
1x clip
Connect RH front repeater

Note
2x connectors, Support repeater from exterior to prevent damage to retaining clips
Install RH front jounce bracket to body

Note
1x bolt, 10mm, 8 Nm
Install RH front wheel liner

Note
13x clips
Connect frunk harness to washer system

Note
2x Connectors, 3x Fir tree Clips
Secure horn low tone connection

Note
1x locking connector, Verify fully seated and engage red locking tab
Secure horn high tone connection

Note
1x locking connector, Verify fully seated and engage red locking tab
Install LH cooling fan module connector

Note
1x connector
Connect LH front accelerator sensor

Note
1x connector, Engage red locking tab
Connect ground junction connector (G500)

Note
1x connector, Secure red locking tab
Connect LH front ride height sensor

Note
1x connector
Secure LH repeater harness to body

Note
1x clip
Connect LH front repeater

Note
2x connectors, Support repeater from exterior to prevent damage to retaining clips
Install LH front jounce hose bracket to body

Note
1x bolt, 10mm, 8 Nm
Install LH front wheel liner

Note
13x clips
Install LH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Install Penta HVAC line from HVAC assembly

Note
2x bolts, 13mm, 22 Nm
Reconnect AC hoses to vehicle
Perform AC vacuum and run leak test

Note
Set vacuum time to 15 minutes and leak test to ON, Machine will chime once process is complete, Vehicle may be left unattended, Verify leak test passed before continuing
Install HEPA housing assembly

Note
2x nuts, 10mm, 7 Nm, Maneuver assembly down and under cross member, Rotate V-brace crossmember bracket back to install position
Secure V-brace crossmember

Note
2x nuts, 10mm, 18 Nm
Install HEPA filter

Note
3x datums, 2x clips, Align 3 datums into bottom of housing, Confirm air flow direction, Ensure clips lock and secure filter into housing
Install HEPA filter assembly cover

Note
2x tabs, 2x datums, 2x slots, Maneuver cover down and under V-brace cross member, Fully engage seal and locking tabs
Connect air quality sensor harness

Note
1x connector
Install fasteners securing LV battery to multi-system beam

Note
3x bolts, 10mm, 9 Nm, 2x datums, Shift into position and install fasteners
Install clip securing the supermanifold to battery pump supply hose onto LV battery

Note
1x clip
Install wiper module

Note
3x bolts, 10mm, 8 Nm, 1x connector, Secure electrical connector first, Rotate module rearward and under windshield, Observe LH wiper arm pivot during install to avoid damage to windshield
Connect steering gear assembly connectors

Note
2x connectors, Two-stage connectors, Ensure locking tab is engaged after an audible click is heard when connecting
Secure coolant hoses to car computer coldplate assembly

Note
2x spring locks, Remove coolant plugs and absorbent material, Ensure spring locks engage and perform pull-push-pull test on each hose coupling
Secure electrical connections to TASC 2.0 ECU

Note
3x connectors
Connect J9 X050 Frunk connector

Note
1x connector
Secure harness connector clips onto RH controller

Note
2x clips
Connect harness connectors

Note
2x connectors, Fully seat connector then engage lock
Connect J14 X056 Power connector

Note
1x connector, Fully seat connector then engage lock
Install bolt securing frunk harness ground near RH footwell area

Note
1x bolt, 10mm, 8 Nm
Secure frunk harness onto RH footwell area

Note
2x clips
Install connectors at RH side of AP motherboard

Note
3x connectors
Connect frunk connectors on RH side of car computer

Note
5x connectors
Connect brown fakra connection onto car computer

Note
1x connector, X836
Secure RH HEPA assembly lower dash bolt

Note
1x bolt, 10mm, 7Nm
Install RH footrest panel

Note
2x bolts, 10mm, 5 Nm, 1x nut, 10mm, 5 Nm
Secure harness to RH footrest panel

Note
1x clip
Fold RH main carpet back into place
Install RH console side carpet

Note
11x clips
Install RH front floor mat
Install RH footwell cover

Note
3x magnets, 1x connectors
Install RH lower A-pillar trim

Note
7x clips, Verify weather seal is seated properly
Install RH mid A-pillar trim

Note
1x clip, 2x tabs, Verify weather seal is seated properly
Fold RH main carpet back into place
Install RH knee air bag assembly into vehicle

Note
2x connectors, 6x tabs, 1x clip, Hook tabs before fully seating, Use caution not to damage the connector/harness, Support the knee air bag while connecting the connector
Install fasteners securing RH knee air bag assembly to vehicle

Note
2x patch bolts, E10, 8 Nm, Install new fasteners
Connect J9 X037 Frunk connector

Note
1x connector
Connect J14 X036 Power connector

Note
1x connector, Fully seat connector then engage lock
Install frunk harness ground onto LH footwell area

Note
1x bolt, 10mm, 8 Nm
Secure LH HEPA assembly lower dash bolt

Note
1x bolt, 10mm, 7Nm
Fold LH main carpet back into place
Install LH front floor mat
Install LH footwell cover

Note
1x connector, 2x magnets
Install LH lower A-pillar trim

Note
7x clips, Verify weather seal is seated properly
Install LH console side carpet

Note
11x clips
Install LH mid A-pillar trim

Note
1x clip, 2x tabs, Verify weather seal is seated properly
Install the LH knee air bag assembly into vehicle

Note
1x clip, 3x connectors, 6x tabs, Hook tabs before fully seating, Use caution not to damage the connector/harness, Support the knee air bag while connecting the connectors
Install fasteners securing LH knee air bag assembly to vehicle

Note
2x patch bolts, E10, 8 Nm, Install new fasteners
Select "refrigerant charge" on AC machine

Note
Select the arrows under "refrigerant charge", Enter refrigerant amount of 1.02 kg (1020 g)
Connect First Responder Loop and LV battery connector

Note
2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Using center display, remove wipers from "Service Mode"
Install fasteners securing LH V-brace and secure

Note
3x bolts, 10mm, 18 Nm, 1x nut, 10mm, 9 Nm
Install fasteners securing RH V-brace and secure

Note
3x bolts, 10mm, 18 Nm, 1x nut, 10mm, 9 Nm
Install wiper cowl screen panel

Note
4x push clips, 2x end tabs
Install wiper cowl screen panel

Note
4x push clips, 2x end tabs
Install RH wiper arm assembly and secure nut

Note
1x nut, 15mm, 26 Nm, Line up wiper to reference mark on windshield
Install RH wiper arm nut cover
Secure RH wiper arm washer nozzle

Note
1x hose, Hose is routed below the arm
Install LH wiper arm assembly and secure nut

Note
1x nut, 15mm, 26 Nm, Line up wiper to reference mark on windshield
Install LH wiper arm nut cover
Secure LH wiper arm washer nozzle

Note
1x hose, Hose is routed below the arm
Secure washer hose nozzle by LH shock tower cover

Note
1x hose, 3x clips
Install LH shock tower cover

Note
3x push clip, 1x fir tree clip
Install RH shock tower cover

Note
3x push clip, 1x fir tree clip
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Move RH front seat to original position
Close RH front door
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAIN
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Note
Select ‘X’ at top right of window to close once complete
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGvia Toolbox: (link)via Service Mode: Thermal ➜ Refrigerant System ➜ Run Heat Pump Commissioningvia Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Heatpump commissioning

Note
If this routine is not run after entering Thermal Drain/Fill mode, the AC compressor operation will be blocked, Select ‘X’ at top right of window to close once complete
Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine

Note
Disconnect high side coupler from vehicle, Turn AC on, Temp setting LO, Panel mode on, Fresh air mode on, Blower speed set to 10, Verify Hose Equalize settings, Verify discharge pressure does not exceed 26 bar and suction pressure is not below 1.15 bar,
Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine

Note
Remove low side coupler from vehicle, Turn vehicle off, Verify Hose Equalize settings, Machine will chime once process is complete
Install caps onto AC ports

Note
2x caps
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
Thermal ➜ Coolant System ➜ Coolant Purge Start
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE
via Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
Note
Select ‘X’ at top right of window to close once complete
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install coolant bottle cap
Install the underhood storage unit. See .
Torque LH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH front wheel

Note
5x nuts, 21mm, 175 Nm
Install RH front wheel cap

Note
Align valve stem with cap
Install LH front wheel cap

Note
Align valve stem with cap
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Move LH front seat to original position
Raise LH and RH front windows
Close LH front door

Model S Service Manual

Harness - Main Front (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3