2020-03-02

Position Switch Harness - Door Handle (Remove and Replace)

Correction Code 11457502

Informational PurposesAn informational icon, calling your attention
Note
This procedure is valid for all 2nd generation door handles.

Special tool required for this procedure:

Supplier Part Number Description
Tesla 1080559-10-A WIHA TORQUE VARIO (TORQUE SCREWDRIVER .1 - .6 NM)

Removal

  1. Remove the exterior door handle assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to remove the door grip from the assembly.
  2. Remove and discard the door handle cover.
  3. Cut the cable ties that secure the wires to the door handle.
  4. Disconnect the electrical connectors (x2).
  5. Remove and discard the screws (x4) that secure the motor (torque 0.3 Nm). Remove the motor from the handle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rear door handles only have 3 screws.
  6. Remove the adjustment screw from the door handle.
  7. Remove and discard the screws (x2) that secure the door handle module (torque 0.3 Nm).
  8. Move the module out of the way, then release the screw that secures the rear microswitch (torque 0.3 Nm).
  9. Release the screw that secures the front microswitch (0.3 Nm).
  10. Remove the microswitch harness from the door handle.

Installation

  1. Install the microswitch harness.
  2. Reinstall all components other than the door backing. Leave the harnesses loose.
    Informational PurposesAn informational icon, calling your attention
    Note
    If performing this procedure on a rear door handle, do not install the lower rear screw for the motor bracket.
  3. Route the harnesses under the tabs as shown:
    1 Microswitch harness
    2 Microswitch and motor harnesses
    3 Microswitch, motor, and pressure harnesses
  4. Route the LED harness along the front of the handle and secure the connector.
  5. Move the primary door harness towards the bottom of the handle and out of the working area.
  6. Route the motor harness:
    • Front door handle: Route the harness so that it forms a loop above the door module.
    • Rear door handle: Route the motor harness so that it forms 2 loops below the door module.
  7. Connect the microswitch harness to the connector on the primary harness.
  8. Push the harnesses onto the module and hold them in place. Loop the microswitch harness so that the taped section is routed over the plastic extrusion.
  9. Use a cable tie to secure the taped section of harness to the plastic extrusion. Discard any excess tie.
  10. Use a cable tie to secure the microswitch, motor, and pressure harnesses together as shown. Discard any excess tie.
  11. Use a cable tie to secure the microswitch, motor, and pressure harnesses together as shown. Discard any excess cable tie.
  12. Form a drip loop in the primary door harness, then use a cable tie to secure the primary door harness connector to the door handle as shown. Discard any excess tie.
  13. Use a cable tie to secure the pressure switch to the door handle as shown. Discard any excess cable tie.
  14. Install a new back seal on the door handle assembly:
    1. Align the stud towers on the door handle assembly with the holes in the back seal.
    2. Press the back seal firmly to properly set the butyl seal between the back seal and the door handle assembly.
      Informational PurposesAn informational icon, calling your attention
      TIp
      Use a suitable tool to apply pressure along the perimeter of the back seal to make sure proper seating of the butyl seal on the door handle assembly.
    3. Put a push nut on top of each stud. Use a deep 5 mm socket to press the push nut over the stud.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not use excessive force to drive the push nut into the stud.
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure that the push nut is firmly set into the stud without a gap between the back seal and the door handle assembly.
    4. Repeat steps a-c on the rest of the studs (total of 4 push nuts/studs per front door handle and 3 push nuts/studs per rear door handle).
    5. Use a cable tie to secure the back seal to the door handle assembly.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      To avoid damage to the back seal, do not overtighten the cable tie.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      To avoid damage to the door handle electrical harness, make sure proper routing of all wires.
      Front door handle Rear door handle
    6. Remove any excess tie.
  15. Reinstall the door handle.