2024-12-10

Mount Block - Roof Rack (Remove and Replace)

Correction code 24300012 1.80 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

2024-12-10: Added new caution about Pre-Installation Glass Inspection service requirements.

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.

CAUTION

For Europe only: Only technicians who have been trained in working with diisocyanates and have completed all required certification courses are permitted to perform procedures using urethane and other products containing diisocyanates. Proper personal protective equipment (PPE) must be worn when working with products containing diisocyanates.

CAUTION

New glass components (windshield, roof, door, and fixed glass) must be inspected before installation to meet Tesla’s internal standards of quality. Perform the inspection described in Pre-Installation Glass Inspection before beginning this procedure.

Remove LH mid A-pillar trim

Note
1x clip, 2x tabs
Remove LH IP end cap

Note
4x clips
Remove LH upper A-pillar trim

Note
2x tethered clips, 1x clip, 1x connector, Pull inside of the upper portion of upper A-pillar, Depress 2x tabs to remove each tether from body side, Disconnect tweeter, Then pull upper A-pillar upward to remove
Remove LH sun visor bracket cover

Note
4x clips, Extending the sun visor may allow for extra working room
Remove LH sun visor fastener

Note
1x screw, T25, 3.5 Nm, Extending the sun visor may allow for extra working room
Remove LH sun visor from headliner area

Note
Fold sun visor to the closed and folded down position but do not latch in place
Disconnect LH sun visor connector

Note
1x connector
Open RH front door
Remove RH mid A-pillar trim

Note
1x clip, 2x tabs
Remove RH IP end cap

Note
4x clips
Remove RH upper A-pillar trim

Note
2x tethered clips, 1x clip, 1x connector, Pull inside of the upper portion of upper A-pillar, Depress 2x tabs to remove each tether from body side, Disconnect tweeter, Then pull upper A-pillar upward to remove
Remove RH sun visor bracket cover

Note
4x clips, Extending the sun visor may allow for extra working room
Remove RH sun visor fastener

Note
1x screw, T25, 3.5 Nm, Extending the sun visor may allow for extra working room
Remove RH sun visor from headliner area
Disconnect RH sun visor connector

Note
1x connector
Release rear view mirror lower cover

Note
4x tabs, Press inward on the sides of the cover and pull the bottom edge downward to release
Disconnect rear view mirror connector

Note
1x connector
Remove rear view mirror

Note
Rotate mirror to release
Remove upper rear view mirror cover

Note
4x clips, 3x connectors, Carefully pull down on upper rear view mirror cover to release from clips
Move LH front seat forward
Open LH rear door
Release LH front seat belt

Note
Turn release mechanism counter clockwise, turn back clockwise after releasing
Partially release LH lower B-pillar

Note
6x clips, Release from upper trim and body
Remove LH upper B-pillar

Note
7x clips, Release clips and route seatbelt through B-pillar, Be cautious not to separate the upper B-pillar, There are plastic welds near the center of trim holding upper and lower portion together
Push open LH coat hook
Pry open LH coat hook screw cover

Note
2x tabs
Remove LH coat hook screw

Note
1x screw, T25, 2.5 Nm
Move RH front seat forward
Open RH rear door
Release RH front seat belt

Note
Turn release mechanism counter clockwise, turn back clockwise after releasing
Partially release RH lower B-pillar

Note
6x clips, Release from upper trim and body
Remove RH upper B-pillar

Note
7x clips, Release clips and route seatbelt through B-pillar, Be cautious not to separate the upper B-pillar, There are plastic welds near the center of trim holding upper and lower portion together
Push open RH coat hook
Pry open RH coat hook screw cover

Note
2x tabs
Remove RH coat hook screw

Note
1x screw, T25, 2.5 Nm
Open liftgate
Remove parcel shelf
Remove LH side bolster trim

Note
1x clip, 1x tab, Start by releasing upper portion
Fold the 60 seat in down position

Note
Release seat from either button at backrest or from trunk switch, If seat cushion is not present, protect the seat as required
Separate LH lower C-pillar trim from LH mid C-pillar trim

Note
4x clips, 1x datum
Remove LH mid C-pillar trim

Note
3x clips
Release LH upper C-pillar trim and move aside

Note
7x clips
Remove RH side bolster trim

Note
1x clip, 1x tab, Start by releasing upper portion
Fold the 40 seat in down position

Note
If seat cushion is not present, protect the seat as required
Separate RH lower C-pillar trim from RH mid C-pillar trim

Note
4x clips, 1x datum
Remove RH mid C-pillar trim

Note
3x clips
Release RH upper C-pillar trim and move aside

Note
7x clips
Remove bolts securing rear of headliner to body

Note
2x bolts, 10mm, 3 Nm, Bolt located on LH & RH side of headliner
Release headliner from body

Note
18x clips, 2x hooks, Headliner will be supported by 8x tethers when released, Push upward and inward to release hooks on the coat hook assemblies from the body
Close liftgate
Apply tape to the vehicle exterior

Note
Cover the side rails and front corners of the liftgate
Measure and record gaps from fixed roof glass to windshield, body sides, and liftgate glass

Note
Measurements will be used during installation of new glass
Open liftgate
Apply masking tape to protect the headliner
Cut length of square wire to use with T-handles

Note
Make sure there's adequate wire
Insert tool through roof glass urethane at rear corner
Attach square wire and pull tool back through into vehicle
Insert square wire into one T-handle
Attach second T-handle
Using T-handles, cut urethane securing roof glass to body

Note
Recommend assistance, Use caution near XM antenna, roof rack blocks, and bolts for brackets near B-pillars
Secure suction cups to roof glass at each corner

Note
4x suction cup tools, Recommend assistance
Remove fixed roof glass from vehicle

Note
Recommend assistance, discard per local regulations
Remove old urethane from body

Note
Ensure residual urethane is 1 mm or less in thickness
Remove datums and any other debris from body
Wipe body with IPA to clean surface

Note
Allow 1 minute dry time
Replace any body plugs or tape that were damaged during removal or cleaning
Inspect XM antenna to make sure it is secure and the foam is not damaged

Note
If damaged, please replace as needed.
Release tether clips from body

Note
6x tether clips, This will assist with headliner installation later, A good tool to release these clips is available for purchase via eProcurment in the Grainger punchout catalog, Item #2ZPP2 - GearWrench Push Pin Pliers
Remove caps from front roof rack mount fasteners

Note
2x caps
Remove fasteners securing front roof rack mount

Note
2x nuts, 10mm, 6.3 Nm, Headliner support bracket will come loose with the fasteners
Remove front roof rack mount

Note
2x studs, May need to free mount from urethane
Install new gaskets to front roof rack mount block

Note
2x gaskets
Install front roof rack mount

Note
2x studs, Orient arrow pointing outward
Install fasteners securing front roof rack mount and headliner bracket

Note
2x nuts, 10mm, 6.3 Nm, Support headliner bracket while installing fasteners
Install caps to front roof rack mount fasteners

Note
2x caps
Attach suction cups to new roof glass
Position new roof glass onto vehicle for dry fit

Note
Recommend assistance
Make sure gaps are all within acceptable limits

Note
If glass is too high, it may be necessary to trim or remove net pads
Remove roof glass and set it upside-down onto stand

Note
Recommend assistance
Remove protective tape from vehicle body
Clean glass mating surfaces with isopropyl alcohol

Note
Allow 1 minute dry time
Apply primer to body on urethane path and any areas that were damaged during removal

Note
If vehicle is equipped with roof rack anchors, primer should go around the inside of the roof bracket. If vehicle is not equipped with roof rack brackets, primer outside the roof rack bracket mounting holes. Allow primer to dry for at least 1 minute
Prepare caulking gun and urethane

Note
Opening must be 8mm wide and 14mm tall
Apply urethane to body

Note
If equipped with roof rack anchors urethane should go around the inside of the roof rack anchor, if not urethane should go on the outside of the anchor mounting holes.
Place new roof glass onto vehicle but do not set yet

Note
Recommend assistance. Align datum at rear of glass to body
Position new seal at front of glass beneath windshield seal

Note
A trim tool can be used to properly seat the roof glass seal under the windshield seal
Press glass onto body once in position

Note
Use sandbags for the front if needed
Verify clearances with liftgate glass, windshield, and body sides are within CVIS specification

Note
Adjust if necessary
Remove suction cups from roof glass
Remove protective tape from headliner
Secure tether clips to headliner

Note
Listen for audible click when seated properly
Secure headliner to body

Note
18x clips, 2x hooks, Push coat hook upward and outward to secure hooks to the body flange at the top of the coat hook assembly
Install bolts securing rear of headliner to body

Note
2x bolts, 10mm, 3 Nm, Bolt located on LH & RH side of headliner
Install RH upper C-pillar trim

Note
7x clips, Replace any damaged clips
Install RH mid C-pillar trim

Note
3x clips, Replace any damaged clips
Secure RH lower C-pillar trim onto RH mid C-pillar trim

Note
4x clips
Fold the 40 seat into vertical position

Note
Remove seat cushion protection
Install RH side bolster trim

Note
1x clip, 1x tab, Replace clip if damaged, Hook bottom portion and then secure the top
Install LH upper C-pillar trim

Note
7x clips, Replace any damaged clips
Install LH mid C-pillar trim

Note
3x clips, Replace any damaged clips
Secure LH lower C-pillar trim onto LH mid C-pillar trim

Note
4x clips
Install LH side bolster trim

Note
1x clip, 1x tab, Replace clip if damaged, Hook bottom portion and then secure the top
Install parcel shelf
Close liftgate
Install RH coat hook screw

Note
1x screw, T25, 2.5 Nm
Close RH coat hook screw cover

Note
2x tabs
Push RH coat hook closed
Install LH coat hook screw

Note
1x screw, T25, 2.5 Nm
Close LH coat hook screw cover

Note
2x tabs
Push LH coat hook closed
Install RH upper B-pillar

Note
7x clips, Route seatbelt through B-pillar, Replace any damaged or missing clips
Reinstall top portion of RH lower B-pillar

Note
6x clips, Replace any damaged or missing clips
Secure RH front seat belt
Move RH front seat to original position
Close RH rear door
Install LH upper B-pillar

Note
7x clips, Route seatbelt through B-pillar, Replace any damaged or missing clips
Reinstall top portion of LH lower B-pillar

Note
6x clips, Replace any damaged or missing clips
Secure LH front seat belt
Fold the 60 seat into vertical position

Note
Remove seat cushion protection
Close LH rear door
Move LH front seat to original position
Install upper rear view mirror cover

Note
4x clips, 3x connectors, Ensure the rear view mirror harness is routed so that it hangs freely on the outside and is not pinched between the cover and glare shield assembly
Install rear view mirror

Note
Install the rear view mirror by turning mirror counter clockwise until mirror is secured
Connect rear view mirror connector

Note
1x connector, Connect rear view mirror connector and tuck harness slack along the arm
Connect RH sunvisor connector

Note
1x connector
Install RH sun visor into headliner area

Note
Fold sun visor to the closed and folded down position, but do not latch in place
Install RH sun visor fastener

Note
1x screw, T25, 3.5 Nm
Install RH sun visor bracket cover

Note
4x clips
Install RH upper A-pillar trim

Note
2x tethered clips, 1x clip, 1x connector, Slide bottom of trim along IP and speaker grill, attach each tether to body side, Set clips starting at the bottom and work up, Pull seal over trim
Install RH IP end cap

Note
4x clips
Install RH mid A-pillar trim

Note
1x clip, 2x tabs, Verify weather seal is seated properly
Close RH front door
Connect LH sun visor connector

Note
1x connector
Install LH sun visor into headliner area
Install LH sun visor fastener

Note
1x screw, T25, 3.5 Nm
Install LH sun visor bracket cover

Note
4x clips
Install LH upper A-pillar trim

Note
2x tethered clips, 1x clip, 1x connector, Slide bottom of trim along IP and speaker grill, attach each tether to body side, Set clips starting at the bottom and work up, Pull seal over trim
Install LH IP end cap

Note
4x clips
Install LH mid A-pillar trim

Note
1x clip, 2x tabs, Verify weather seal is seated properly
Install tether onto rear view mirror lower cover

Note
2x tabs, Guide tabs through anchor on rear view mirror lower cover
Install rear view mirror lower cover

Note
4x tabs, Install the tabs closest to the rearview mirror assembly and push the cover up to secure

Model S Service Manual

Mount Block - Roof Rack (Remove and Replace)

Figure 1

Figure 2

Figure 3