17/06/2022 13:25:36

Harness - HVAC Assembly (Remove and Replace)

Correction code 17104102 2.40 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.

Remove

Remove the center console assembly. See Center Console Assembly - 1st Row (Remove and Install).
Remove LH IP end cap.

Note
7x clips, 1x datum, Ensure clip at IP carrier is released fully before removal.
Remove LH mid A-pillar trim.

Note
2x clips, 3x datums, Release clips from upper A-pillar and IP sub assembly, Lift mid A-pillar trim out of lower A-pillar trim.
Remove IP LH mid panel.

Note
6x tabs.
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.
Remove LH sunvisor bezel.

Note
6x clips, 5x tabs, Release clips, then slide bezel towards front of vehicle to release.
Remove bolts securing LH upper A-pillar to body.

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Discard nut after removal.
Remove LH upper A-pillar from vehicle.

Note
1x connector, 2x datums, 6x clips, Release clips and rotate pillar inboard to access connector, Release datums upward out of IP sub assembly.
Adjust steering column fully rearward and fully down.

Note
Via UI > Controls > Steering , Use left steering wheel scroll wheel to adjust steering column.
Open hood.

Note
Via center display > Controls > Frunk Open.
Power off vehicle via center display.

Note
Controls > Safety & Security > Power Off.
Remove rear underhood apron.

Note
11x clips, 2x datums.
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, Release red lock tab on FRL.
Remove RH IP end cap.

Note
3x clips.
Remove RH mid A-pillar trim.

Note
2x clips, 3x datums, Release clips from upper A-pillar and IP sub assembly, Lift mid A-pillar trim out of lower A-pillar trim.
Remove RH front door sill trim panel.

Note
8x clips, 3x datums.
Remove RH lower A-pillar trim.

Note
1x bolt, T25, 5 Nm, 2x clips, 1x datum.
Fold RH front cabin carpet aside for access.
Release harness from RH footrest panel.

Note
1x clip.
Release RH footrest panel.

Note
2x bolts, 10mm, 5 Nm, 2x nut, 10mm, 5 Nm.
Remove RH footrest panel.

Note
Fold RH primary support carpet up, Rotate RH footrest panel out of vehicle.
Remove RH sunvisor bezel.

Note
6x clips, 1x tab, Release clips, then slide bezel towards front of vehicle to release.
Remove bolts securing RH upper A-pillar to body.

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Discard nut after removal.
Remove RH upper A-pillar from vehicle.

Note
1x connector, 2x datums, Rotate pillar inboard to access connector, Release datums upward out of IP sub assembly.
Release IP service panel.

Note
2x tabs, 4x datums, Release top tabs and slide rearward.
Release diagnostic and CAN harnesses from IP service panel.

Note
2x clips.
Remove IP service panel.

Note
1x connector.
Remove center display bracket bolts.

Note
2x bolts, 10mm, 11.5 Nm.
Remove center display shroud.

Note
3x tabs, Slide display outwards until shroud fully clears IP and support, Release the bottom tabs and pull upward.
Release center display coax and power connectors.

Note
2x connectors, 1x clip, Slide display rearward outwards from IP bracket and support during connector release.
Remove center display.

Note
Slide rearward, Place on soft clean surface.
Remove IP closeout panel.

Note
4x tabs.
Remove IP RH mid Panel.

Note
14x tabs, 2 datums.
Remove IP Decor.

Note
21x clips, 6x datums, 4x connectors, Release each IP decor connector clip from IP carrier then disconnect from IP harness.
Remove fasteners securing RH knee air bag assembly to vehicle.

Note
2x bolts, 10mm, 8 Nm, 1x clip.
Remove the RH knee air bag assembly from vehicle.

Note
2x connectors, 1x clip, 6x tabs, Release 2x locking tab on airbag connector.
Release glove box.

Note
5x screws, T20, 3 Nm.
Release glove box connectors.

Note
3x connectors.
Remove USB outlet.

Note
2x screws, T20, 3 Nm, 1x clip.
Remove glove box.
Release passenger IP air duct temperature sensor connector.

Note
1x connector.
Remove passenger IP air duct.

Note
2x push-pull rivets.
Remove IP carrier cross beam screws.

Note
2x bolts, 10mm, 3 Nm.
Release passenger IP airbag connectors.

Note
3x connectors, Pull down spring loaded locks simultaneously to release airbag connectors.
Release RH lower instrument panel.

Note
3x screws, T20, 3 Nm.
Release center lower instrument panel.

Note
6x screws, T20, 3 Nm.
Release LH lower instrument panel.

Note
3x screws, T20, 3 Nm.
Release instrument cluster harness.

Note
1x connector, 1x clip.
Release IP trim harness.

Note
1x connector, 1x clip.
Position lower instrument panel assembly away from IP sub-assembly.

Note
6x datums, Move top edge as far rearward as possible without excessive stress on assembly.
Release IP ground harness.

Note
1x clip, 1x bolt, 10mm, 9 Nm, Note routing behind center display RH bracket.
Remove IP sub-assembly.

Note
Slide IP sub-assembly rearward, Lift assembly up from IP carrier, Ensure airwave vents and passenger air bag are clear of lower IP assembly, Remove assembly out through RH front door, Recommend assistance as needed.
Remove driver IP air vent duct.

Note
2x rivets, 1x connector, Slide outboard and up out of HVAC unit assembly.
Remove driver floor jumper left foot duct.

Note
2x push clips.
Release spring clip securing driver air bag assembly to steering wheel and pull driver air bag assembly away from steering wheel.

Note
2x spring clips, 2x datums, Press the spring simultaneously from two access holes to release, Access holes located at 4 and 8 o’clock position, Do not insert tool too far as air bag connector could be damaged.
Disconnect driver air bag connector and remove driver air bag assembly.

Note
1x connector.
Disconnect steering wheel connector.

Note
1x connector.
Remove bolt that secures the steering wheel to the column.

Note
1x patch bolt, 10mm allen, 80 Nm, Discard after removal.
Remove steering wheel.

Note
Note that the steering wheel is splined to the column.
Pull upward to release steering column upper shroud from lower shroud.

Note
6x clips, 4x datums.
Remove lower shroud to steering column.

Note
2x screws, T20, 1.5 Nm, 1x clip, 1x datum, Slide lower shroud rearward to release datum.
Remove lower instrument panel assembly.

Note
3x screws, T20, 3 Nm, 8x tabs, Remaining screws located at bottom of assembly, Release assembly and carefully guide over upper steering column.
Remove driver floor jumper duct.

Note
1x tab, Release from HVAC housing then release at top from driver left foot floor jumper duct.
Release LH floor HVAC actuator and LH floor duct temp sensor connectors.

Note
2x connectors.
Release LH panel HVAC actuator and defrost duct temp sensor connectors.

Note
2x connectors, 1x tab, Release HVAC harness from housing.
Release 1st row bypass HVAC actuator connector.

Note
1x connector 2x tabs, Release HVAC harness from housing.
Release HVAC blower motor connector.

Note
1x connector, 2x clips.
Maneuver LH HVAC harness under IP support.

Note
1x clip.
Release intake HVAC actuator.

Note
1x connector.
Release connector at RH panel HVAC actuator.

Note
1x connector.
Release RH panel HVAC actuator.

Note
2x screws, T20, 2.3 Nm, 1x datum, Hold actuator arm while removing actuator, Note actuator arm keyed angle upon removal.
Remove screws securing defrost HVAC Actuator and remove from HVAC assembly.

Note
2x screws, T20, 2.3 Nm.
Disconnect Defrost HVAC Actuator connector and remove actuator from vehicle.

Note
1x connector.
Release RH floor HVAC actuator and RH floor duct temp sensor.

Note
2x connectors.
Release evaporator thermistor connector.

Note
1x connector.
Release 2nd row bypass, console, 2nd row floor HVAC actuators, & 2nd row floor duct temp sensor.

Note
4x connectors.
Release center branch of HVAC harness from housing.

Note
6x tabs.
Release RH branch of HVAC harness from housing.

Note
4x clips.
Release HVAC blower x059 connector and HVAC case x058 connector from right controller.

Note
1x clip, 2x connectors.
Remove HVAC harness from vehicle.

Note
Maneuver center HVAC harness between RH floor duct and housing.

Install

Install HVAC harness to vehicle.

Note
Maneuver center HVAC harness between RH floor duct and housing.
Secure RH branch of HVAC harness to housing.

Note
4x clips.
Secure HVAC blower x059 connector and HVAC case x058 connector to right controller.

Note
1x clip, 2x connectors.
Secure RH floor HVAC actuator and RH floor duct temp sensor.

Note
2x connectors.
Secure evaporator thermistor connector.

Note
1x connector.
Secure 2nd row bypass, console, 2nd row floor HVAC actuators, & 2nd row floor duct temp sensor.

Note
4x connectors.
Secure center branch of HVAC harness to housing.

Note
6x tabs.
Connect defrost HVAC Actuator connector.

Note
1x connector.
Install defrost HVAC Actuator to HVAC assembly.

Note
2x screws, T20, 2.3 Nm, Actuator is keyed to HVAC assembly, Ensure alignment before installing screws.
Secure RH panel HVAC actuator.

Note
2x screws, T20, 2.3 Nm, 1x datum, Note actuator arm keyed angle upon installation matches actuator.
Secure connector at RH panel HVAC actuator.

Note
1x connector.
Secure intake HVAC actuator.

Note
1x connector.
Maneuver LH HVAC harness under IP support.

Note
1x clip.
Secure HVAC blower motor connector.

Note
1x connector, 2x clips.
Secure 1st row bypass HVAC actuator connector.

Note
1x connector 2x tabs, Secure HVAC harness to housing.
Secure LH panel HVAC actuator and defrost duct temp sensor connectors.

Note
2x connectors, 1x tab, Secure HVAC harness to housing.
Secure LH floor HVAC actuator and LH floor duct temp sensor connectors.

Note
2x connectors.
Install driver floor jumper duct.

Note
1x tab, Secure at top to driver left foot floor jumper duct then install to HVAC housing.
Secure lower instrument panel assembly.

Note
3x screws, T20, 3 Nm, 8x tabs, Secure only the screws located at bottom of assembly, Remainder of screws are secured at a later step.
Install lower shroud to steering column.

Note
2x screws, T20, 1.5 Nm, 1x clip, 1x datum, Slide lower shroud forward to engage datum.
Align the clips and datums then press downward to install upper shroud onto lower shroud.

Note
6x clips, 4x datums.
Install driver floor jumper left foot duct.

Note
2x push clips.
Install driver IP air vent duct.

Note
2x rivets, 1x connector, Slide inboard and into HVAC unit assembly.
Install IP sub-assembly.

Note
4x datums, Slide IP sub-assembly into vehicle, Ensure passenger air bag and driver vent assembly have clearance past lower IP assembly, Engage IP sub-assembly datums into dash slots, Recommend assistance.
Secure IP ground harness.

Note
1x clip, 1x bolt, 10mm, 3.5 Nm, Note routing behind center display RH bracket.
Secure IP trim harness.

Note
1x connector, 1x clip.
Secure instrument cluster harness.

Note
1x connector.
Position lower instrument panel assembly into IP sub-assembly.
Secure LH lower instrument panel.

Note
3x screws, T20, 3 Nm.
Secure center lower instrument panel.

Note
6x screws, T20, 3 Nm.
Secure RH lower instrument panel.

Note
3x screws, T20, 3 Nm.
Install IP Decor.

Note
21x clips, 6x datums, 4x connectors, Connect ambient bright harness, Secure each IP decor connector clip to IP carrier, Secure IP decor to lower instrument panel.
Install IP carrier cross beam bolts.

Note
2x bolts, 10mm, 3 Nm.
Secure passenger IP airbag connectors.

Note
3x connectors.
Install passenger IP air duct.

Note
2x push-pull rivets.
Secure passenger IP air duct temperature sensor connector.

Note
1x connector.
Install RH footrest panel.

Note
Rotate RH footrest panel into vehicle, Fold RH primary support carpet down.
Secure RH footrest panel.

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

Note
1x clip.
Fold RH main carpet back into place.
Secure USB outlet.

Note
2x screws, T20, 2 Nm, 1x clip, Ensure USB socket flush in glove box.
Secure glove box connectors.

Note
3x connectors, Route harness through glove box datums.
Install glove box.

Note
5x screws, T20, 3 Nm.
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 bolts, 10mm, 8 Nm, 1x clip.
Install RH lower A-pillar trim.

Note
1x bolt, T25, 5 Nm, 2x clips, 1x datum.
Install RH front door sill trim panel.

Note
8x clips, 3x datums.
Install RH upper A-pillar to vehicle.

Note
1x connector, 2x datums, Secure RH upper A-pillar harness, Align datums into IP sub assembly, Rotate upper A-pillar panel into position.
Install bolts securing RH upper A-pillar to body.

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut.
Install RH sunvisor bezel.

Note
6x clips, 1x tab, Insert tab and slide bezel towards rear of vehicle, then secure clips.
Install RH mid A-pillar trim.

Note
2x clips, 3x datums, Verify weather seal is seated properly.
Install RH IP end cap.

Note
3x clips.
Install IP RH mid Panel.

Note
14x tabs, 2 datums.
Install IP closeout panel.

Note
4x tabs.
Route display harness behind LH display bracket .
Secure center display coax and power connectors.

Note
2x connectors, 1x clip, Ensure strain relief clip is secure to linkage arm, Replace clip if damaged.
Install center display shroud.

Note
3x tabs, Slide display downward until shroud tabs fully engages.
Secure center display to IP carrier.

Note
2x bolts, 10mm, 11.5 Nm, Slide center display into IP carrier, Start RH bolt first.
Secure IP service panel connector.

Note
1x connector.
Secure diagnostic and CAN harnesses to IP service panel.

Note
2x clips.
Install IP service panel.

Note
2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP.
Install LH upper A-pillar to vehicle.

Note
1x connector, 2x datums, 6x clips, Secure LH upper A-pillar harness, Align datums into IP sub assembly, Rotate upper A-pillar panel into position engaging clips fully.
Install bolts securing LH upper A-pillar to body.

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut.
Install LH sunvisor bezel.

Note
6x clips, 5x tabs, Insert tabs and slide bezel towards rear of vehicle, then secure clips.
Install IP LH mid panel.

Note
6x tabs.
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.
Install LH mid A-pillar trim.

Note
2x clips, 3x datums, Insert mid A-pillar trim into lower A-pillar trim, Secure clips into upper A-pillar and IP sub assembly, Verify weather seal is seated properly.
Install LH IP end cap.

Note
7x clips, 1x datum.
Install steering wheel.

Note
Note that the steering wheel is splined to the column and can only be installed in the correct position.
Install bolt securing steering wheel to steering column.

Note
1x patch bolt, 10mm allen, 80 Nm, Install new patch bolt.
Secure steering wheel connector.

Note
1x connector.
Secure driver air bag connector.

Note
1x connector.
Secure driver air bag assembly to steering wheel and verify it is fully engaged.

Note
2x datums, 2x spring clip.
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 upper locking tab when fully seated.
Install rear underhood apron.

Note
11x clips, 2x datums.
Close hood.
Install the center console assembly. See Center Console Assembly - 1st Row (Remove and Install).
Adjust steering column back to original position.

Note
Via UI>Controls>Steering , Use left steering wheel scroll wheel to adjust steering column.
Calibrate RH falcon wing door.

Note
Hold the upper B-pillar button in the down position to manually calibrate.
Close RH front door.
Calibrate LH falcon wing door.

Note
Hold the upper B-pillar button in the down position to manually calibrate.