21/05/2024 01:11:19

Handle - Exterior Release - Door - Front - LH - Generation 3.0 (Retrofit)

Correction Code 11451006

  • 2023-10-25: Rearranged installation steps and added extra note.
  • 2023-08-30: Revised title for the hyperlink for the recalibration procedure.
  • 2024-05-21:Updated procedure to make calibration steps before software reinstall.

Special tool(s) required for this procedure:

Part Number Description
1454796-00-A Window switch tool (front)
1080985-10-A Door handle alignment kit

Generation 2.5 Handle Assembly Removal

  1. Shift into Neutral and touch the Park Brake icon on the touchscreen.
  2. Open the door and use a pen or similar object to close the door latch.
    Informational PurposesAn informational icon, calling your attention
    Note
    The latch mechanism is closed after 2 clicks.
  3. Apply masking tape to the outside of the LH front door handle grip.
  4. Make sure the door handle is retracted.
  5. Remove door trim panel (refer to procedure) from the door frame and move it out of the way. If present, do not detach the retention strap.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Support the trim panel to prevent damaging the retention strap or the trim panel tether rivet.
  6. Remove the front window outer belt molding.
  7. Carefully ease the flap seal clear of the inner belt seal for access.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage component(s).
  8. Carefully lift and remove the inner door glass seal.
  9. Connect window master switch to front door harness.
  10. Make sure the door glass is fully raised.
  11. Remove the fasteners (x3) that attach the door controller to the closeout panel (torque 1 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to disconnect the electrical connectors from the door controller.
  12. Tie the door controller aside.
  13. Remove the fasteners (x6 screws and x1 clip) that attach the closeout panel to the door (torque 4 Nm).
  14. Remove and discard the closeout panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    In the following steps, remove any plugs or waterproof tape that covers any of the fasteners.
  15. Release the door handle harness connector clip, and disconnect door handler harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure door handle is retracted before removal.
  16. Remove the nuts (x4) that attach the door handle assembly to the door outer panel (torque 9 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any of the surrounding components.
  17. Fully raise the door glass.
  18. Carefully remove the assembly from the vehicle.
  19. Position the assembly on a soft working surface.
  20. Remove the screws (x4) that attach the door handle assembly rear cover (torque 2 Nm).
  21. Remove the screws (x4) that attach the painted backplate to the handle grip (torque 2 Nm), and then remove the backplate from the assembly.
  22. Remove the exterior door handle from the door handle assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    The door handle of the factory installed Model S door handle assembly is made from metal. Replacement door handles are plastic and slightly smaller than the factory-installed original handle. The door handle must be transferred from the original door handle assembly to the replacement assembly to maintain consistency with the rest of the door handles installed on the vehicle if equipped with factory installed door handles.
  23. Discard the old door handle assembly.

Generation 3.0 Handle Assembly Retrofit

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Always replace plugs or tape removed from the front door shells when servicing or inspecting the door or its components. Additional holes in the door creates more escape paths for air, which decreases the front door pressure sensor's ability detect a side impact, and can negatively affect airbag deployment.
  1. Position the new door handle assembly on a soft working surface.
  2. Remove the screws (x5) that attach the door handle assembly rear cover (torque 2 Nm).
  3. Remove the screws (x4) that attach the backplate to the handle grip (torque 2 Nm) and remove and discard the backplate.
  4. If transferring the metal door handle from original door handle assembly: Remove the plastic door grip from the door handle assembly.
  5. If transferring the metal door handle from original door handle assembly: Install the metal door grip from the original door handle assembly in the replacement door handle assembly.
  6. If transferring the metal door handle from original door handle assembly: Install spacers on the handle fork.
    Informational PurposesAn informational icon, calling your attention
    Note
    When transferring a factory-installed door handle to the replacement door handle assembly, spacers are required to maintain a good fit of the metal door handle to the slightly smaller grip cartridge of the replacement door handle assembly.
    1. Remove the tape covering the adhesive on the spacer for the front-most fork arm.
    2. Place the spacer, with the adhesive side down, on the front-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    3. Remove the tape covering the adhesive on the spacer for the rear-most fork arm.
    4. Place the spacer, with the adhesive side down, on the rear-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    5. Remove the tape covering the adhesive on the second spacer for the rear-most fork arm.
    6. Place the spacer, with the adhesive side down, in the center of the small flat area above the hole on the rearmost fork arm.
  7. Install the painted backplate from the old door handle assembly, and tighten the screws (x4) that attach the backplate to the handle grip (torque 2 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the LED harness is properly routed before tightening the screws.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the handle was not equipped with an LED because it was a base version, install a dummy plug (1118491-00-A) in the empty cavity to prevent water ingress. If a dummy plug is not available, tape can be used to seal the connector cavity instead.
  8. Install the door handle assembly rear cover and tighten the screws (x5) that attach the cover to the assembly (torque 2 Nm).
  9. Apply Threadlocking Adhesive onto the nuts that attach the door handle assembly to the front door assembly.
  10. Position the door handle assembly in the door body, and hand tighten the nuts (x4) that attach the door handle assembly to the door body.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any of the surrounding components.
  11. Remove the masking tape from the outside of the LH front door handle grip.
  12. Use the door handle alignment tool, part number 1080985-00-A (LH alignment tool) or 1080985-01-A (RH alignment tool) to align the door handle.
  13. Tighten the nuts (x4) that attach the door handle assembly to the door outer panel (torque 9 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any of the surrounding components.
  14. Raise the door glass completely.
  15. Use the door handle alignment tool, part number 1080985-00-A (LH alignment tool) or 1080985-01-A (RH alignment tool) to check the alignment the door handle.
    If the alignment has changed, loosen the nuts that attach the door handle assembly to the door body and repeat steps 12 through 15 as necessary until the door handle alignment is correct.
  16. Connect the door handle harness to door handle assembly.
  17. Adjust the exterior edge of the door handle grip to be flush with the outside of the door panel. Tighten or loosen the T40 screw on the rear of the door handle assembly to move the door handle in or out.
  18. Make sure the front and rear of the door handle are flush with the outside of the door panel and the handle fit is consistent with the other door handles on the vehicle.
    1. If the door handle alignment is correct, skip to step 21.
    2. If the door handle appearance is not consistent with the other handles installed on the vehicle, remove the nuts installed in step 13.
    3. To achieve a fit consistent with the other door handles on the vehicle, install or remove shims around the door handle mounting studs on the inboard side of the door panel.
      Informational PurposesAn informational icon, calling your attention
      Note
      To achieve the correct fit, 1 shim (1.5mm thick) on each door handle mounting stud is nominal. If necessary to achieve the correct fit, try combinations of 1 or 2 shims, up to a total of 3.0mm total thickness for all shims on any of the 4 door handle mounting studs.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Failure to properly align the door handle with the outside of the door panel can result in improper fitment, and therefore repeat repair of the door handle.
    4. Repeat step 18 as necessary to achieve the correct fit.
  19. Connect the door handle wiring harness to the door harness.
  20. Attach the door handle wiring harness to the inner door frame with a push clip.
  21. Drill a 25 mm. hole in the closeout panel where indicated.
    Informational PurposesAn informational icon, calling your attention
    Note
    The location for the hole is indicated on the inboard side of the closeout panel.
  22. Install the grommet on the door handle wiring harness, with the larger side of the grommet closer to the inner door frame.
  23. Insert the tabs on the bottom of the door handle module into the retainers on the closeout panel.
  24. Install and tighten the screw (x1) to hold the top of the door handle module to the closeout panel (torque 2 Nm).
  25. If necessary, remove any debris that has fallen inside the door panel.
  26. Carefully reinstall the door glass seal, starting from the rear part of the door, and moving towards the front.
  27. Install the front window outer belt molding.
  28. Route door handle wiring harness through the hole in the closeout panel and seat the sealing grommet.
  29. Connect the window switch tool to the door harness connector.
  30. Raise and lower the window several times and make sure the door handle wiring harness and connectors are not in the path of the window glass as it moves up and down.
  31. Disconnect the window switch tool from the door harness connector.
  32. Disconnect the window switch tool from the door harness connector.
  33. Reinstall any plugs or waterproof tape removed earlier.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Always replace plugs or tape removed from the front door shells when servicing or inspecting the door or its components. Additional holes in the door creates more escape paths for air, which decreases the front door pressure sensor's ability detect a side impact, and can negatively affect airbag deployment.
  34. Install the updated closeout panel and make sure the manual door handle release cable is routed properly.
  35. Tighten the screws (x6) to attach the closeout panel to the door frame (torque 4 Nm).
  36. Install and tighten the screws (x3) that attach the door controller to the closeout panel (torque 2 Nm).
  37. Disconnect and remove master window switch from LH front door harness.
  38. Connect the door handle wiring harness to the door handle module mounted on the closeout panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the locking tab is fully engaged.
  39. Reinstall door tape and patches on inner LH front door.
  40. Remove and discard the old clips from the door trim panel.
  41. Install new clips in the door trim panel (x9).
  42. Gently spread the upper door clips to make sure they hold the door panel securely when installed.
  43. Hold the door trim panel close to the door and connect the door wiring harness to the door panel connector.
  44. Connect the door pocket lamp harness connector.
  45. Connect the door latch release cable to the inner door handle.
  46. Align the door panel with the upper door clips and seat the door panel.
  47. Install the screws (x2) that attach the door panel to the door frame (torque 3 Nm).
  48. Install the bolt that attaches the door panel to the door frame (torque 6 Nm).
  49. Reinstall the door handle insert and the pull cup with the rubber insert.
  50. Release the front door latch.
  51. Shift into Park, and release LH front door latch.
  52. Perform the door exterior release handle recalibration procedure. See Handle - Exterior Release - Door (Recalibrate).
  53. Perform a firmware reinstall. See Firmware Reinstall - Touchscreen.
  54. Verify the operation of all door handles.