09/09/2022 15:16:39

Door Assembly - Rear Upper - LH (Remove and Replace)

Correction code 10106702 2.52 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.

Measure the gap and flush of LH falcon door according to specification

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Record that data and use it as a base line when installing the new door
Open LH front door
Lower both LH side windows
Move LH front seat forward
Open LH falcon wing door
Remove LH falcon door lower garnish

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9x V-clips, Replace any damaged or missing clips, Take care not to damage door trim panel during removal
Remove LH upper falcon door trim

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17x clips, 1x connector may be present on early production vehicles
Remove LH falcon rear upper bracket

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5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
Remove LH falcon front upper bracket

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5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip
Remove LH upper outer falcon door middle trim

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7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
Remove LH upper gap hider trim

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4x clips
Lower LH falcon door

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May need to assist the door to close
Remove LH falcon door upper glass

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10x nuts, 10mm, 6 Nm, Recommend assistance
Remove LH rear decor trim panel

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7x clips, 2x connectors
Remove bolts securing LH rear door panel to door

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8x bolts, 10mm, 6 Nm
Remove LH rear door trim panel

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13x clips, 2x connectors
Open LH falcon wing door
Support the rear door

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May need assist to open
Open hood

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Via center display > Controls > Frunk Open
Remove rear underhood apron

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11x clips, 2x datums
Power off vehicle via center display

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

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2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL
Release clips securing harness connectors to closeout panel

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3x clips
Disconnect connectors for upper harness

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2x locking connectors, 1x connector
Remove bolt securing ground to LH lower falcon door

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1x bolt, 10mm, 10 Nm
Remove clips securing harness to LH lower falcon door

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5x clips
Mark the position of the lower falcon door to the upper falcon door assembly
Remove the lower falcon door from vehicle

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4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door.
Disconnect both front and rear falcon door strut connectors

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4x connectors
Remove the upper falcon door harness clips and route the harness to back of the falcon door

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7x clips,Protect the spine applique
Remove the front primary strut from upper falcon door

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1x C-clip, 1x harness clip
Remove the rear primary strut from upper falcon door

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1x C-clip, 1x harness clip
Pull the upper falcon door lower to mark the hinges

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The upper door is still spring loaded, Recommend assistance if necessary, Caution: the upper falcon door hinges are spring loaded and will retract to the open position.
Remove the LH upper falcon door from vehicle

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4x 13mm bolts, 24Nm, Loosen bolts in closed position, Remove bolts in open position, Recommend assistance if necessary
Lay LH rear door upper harness on top of vehicle

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Use fender cover to protect spine and roof glass
Remove front secondary strut with bracket from upper falcon door

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1x C-clips, 2x harness clips, 3x bolts, 10mm, 12 Nm
Remove rear secondary strut with bracket from upper falcon door

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1x C-clips, 2x harness clips, 3x bolts, 10mm, 12 Nm
Remove front secondary hinge assembly with clamp bracket

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3x bolts, E18, 32 Nm, Recommend assistance
Remove rear secondary hinge assembly with clamp bracket

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3x bolts, E18, 32 Nm, Recommend assistance
Remove LH front upper falcon door bump stop assembly

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2x bolts, 10mm, 8 Nm, 1x screw, T30, 5 Nm
Remove LH rear upper falcon door bump stop assembly

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2x bolts, 10mm, 8Nm, 1x screw, T30, 5 Nm
Use IPA clean NVH seal area of the new upper falcon door

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Allow 1 minute drying time
Apply adhesive promoter to NVH seal area of the new upper falcon door

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Allow 1 minute drying time
Install new upper falcon door NVH seal to new upper falcon door

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Use roller to press the seal in place
Install LH front upper falcon door bump stop assembly

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2x bolts, 10mm, 8Nm, 1x screw, T30, 5 Nm
Install LH rear upper falcon door bump stop assembly

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2x bolts, 10mm, 8 Nm, 1x screw, T30, 5 Nm
Install the rear secondary hinge assembly with bracket

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3x bolts, E18, 32 Nm
Install the front secondary hinge assembly with bracket

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3x bolts, E18, 32 Nm
Install rear secondary strut with bracket from upper falcon door

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1x C-clips,2x harness clips, 3x bolts, 10mm, 12 Nm
Install front secondary strut with bracket from upper falcon door

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1x C-clips,2x harness clips, 2x bolts, 10mm, 12 Nm
Install the LH upper falcon door and hand tighten bolts

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4x bolts, 13mm, 24 Nm, Recommend assistance if necessary
Pull the upper falcon door lower and make sure the upper falcon door is aligned and centered before tightening

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4x bolts, 13mm, 24 Nm, Use a rubber hammer to position upper falcon door to previous marked location, Use caution as the falcon door hinges are spring loaded and will want to retract to falcon door open position, Recommend assistance
Install the rear primary strut to upper falcon door

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1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
Install the front primary strut to upper falcon door

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1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
Install the upper falcon door harness

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7x clips, Replace any broken clips
Connect both front and rear falcon door strut connectors

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4x connectors
Install the lower falcon door to vehicle

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4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door, Ensure the lower falcon door hinges align with marked position before tightening bolts
Install clips securing harness to falcon door

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4x clips
Install bolt securing ground to LH rear door

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1x bolt, 10mm, 10 Nm
Connect three connectors for upper harness

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2x locking connectors, 1x connector
Connect First Responder Loop and LV battery connector

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2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated
Install rear underhood apron

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11x clips, 2x datums
Close hood
Remove door support stand
Calibrate the rear doors.

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If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
Check the gap and flush of LH falcon door according to specification

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Adjust as needed
Adjust door as close to specification as possible if necessary

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Adjust the lower falcon door hinges, the upper corner of the lower falcon door should be adjust a bit under flush at this time, the struts should push it out once installed. Recommend assistance, 6x bolts, E18, 32 Nm, 4x bolts, 13mm, 24 Nm
Install LH falcon door upper glass

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10x nuts, 10mm, 6 Nm, Recommend assistance
Open LH falcon wing door

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Adjust position as required
Install LH rear door trim panel

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2x connectors, 13x clips, Install door trim starting from top and make sure the door trim tab is fitted correctly on the inner belt seal
Install bolts securing LH rear door panel to door

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8x bolts, 10mm, 6 Nm
Install LH rear door decor trim panel

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7x clips, 2x connectors, Take care not to damage door trim panel
Install LH upper gap hider trim

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4x clips
Install LH upper outer falcon door middle trim

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7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
Install LH falcon front upper bracket

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5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
Install LH falcon rear upper bracket

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5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
Install LH upper falcon door trim

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17x clips, Align strut cover first, 1x connector may be present on early production vehicles
Install LH falcon door lower garnish

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9x V-clips, 1x guide tab
Move LH front seat to original position
Raise both LH side windows
Close LH front door