30/05/2024 07:55:07

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

Correction code 10106502 3.18 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.

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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

  1. Measure the gap and flush of LH falcon door according to specification
    Informational PurposesAn informational icon, calling your attention
    Note
    Record that data and use it as a base line when installing the new door
  2. Open LH front door
  3. Lower LH front window
  4. Partially lower LH rear window
  5. Move LH front seat forward
  6. Open LH rear falcon door partially
  7. Remove LH wheel arch cladding
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Carefully release clips and double-sided tape that secure rear wheel arch to rear door assembly
  8. Remove LH rear door cladding
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 1x double sided tape strip, Take care not to damage painted surfaces, Starting at the front of the LH falcon door, release the clips and double sided tape
  9. Remove LH rear outer belt trim
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift and roll outward slowly and evenly starting from front edge, Take care not to bend or damage components
  10. Open LH falcon wing door
  11. Remove LH falcon door lower garnish
    Informational PurposesAn informational icon, calling your attention
    Note
    9x V-clips, Replace any damaged or missing clips, Take care not to damage door trim panel during removal
  12. Remove LH upper falcon door trim
    Informational PurposesAn informational icon, calling your attention
    Note
    17x clips, 1x connector may be present on early production vehicles
  13. Remove LH rear decor trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, 2x connectors
  14. Remove bolts securing LH rear door panel to door
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 10mm, 6 Nm
  15. Remove LH rear door trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    13x clips, 2x connectors
  16. Remove LH rear inner belt seal
  17. Open hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Via center display > Controls > Frunk Open
  18. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums
  19. Power off vehicle via center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls > Safety & Security > Power Off
  20. Disconnect LV battery connector and First Responder Loop
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL
  21. Disconnect 2nd row head air bag connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release orange lock and then disconnect
  22. Remove bolts securing 2nd row head air bag to LH rear door assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 10mm, 7 Nm
  23. Remove LH 2nd row head air bag
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Lift air bag flaps to access clips
  24. Disconnect LH falcon door protection ECU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release black locking tab
  25. Disconnect connectors from LH falcon door module
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  26. Remove bolts securing LH closeout panel to falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    10x bolts, T25, 1.8 Nm
  27. Remove screws securing window motor to LH closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T30, 1.8 Nm
  28. Pull LH closeout panel away from door and lift window motor up to release
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  29. Unclip and feed door release cable through LH closeout panel
  30. Remove clip securing window regulator harness to LH closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  31. Release clips securing lower falcon door harnesses and connectors to LH closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips
  32. Remove bolt securing ground to LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  33. Remove clips securing harness to LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  34. Remove speaker from LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, T25, 4 Nm, 2x datums, 1x connector
  35. Loosen nut securing the front of the window to the regulator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 9 Nm, Nut does not need to be fully removed, If required power the vehicle back on and use the window switch tool to move regulator for nut access
  36. Partially close LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not engage latch
  37. Release clip securing rear of window to regulator and remove glass from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Recommend assistance, Working from the outside of the vehicle, Pull the front of the window towards the rear of the vehicle and then lift the window out from the door, Take caution do not damage any components
  38. Disconnect LH falcon door rear pinch sensor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  39. Remove clip securing LH falcon door rear pinch sensor harness to door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  40. Remove LH falcon door rear pinch sensor fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    7x push clips
  41. Remove LH falcon door rear pinch sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  42. Disconnect LH falcon door front pinch sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  43. Remove LH falcon wing door front pinch sensor fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    7x push clips
  44. Remove LH falcon door front pinch sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet
  45. Remove LH falcon door fixed glass
    Informational PurposesAn informational icon, calling your attention
    Note
    5x patched screws, T25, 3.5 Nm, Discard after removal, Carefully lift up airbag to access the lower screws, Release fixed glass seal from door assembly, Lift fixed glass from bottom edge and pull downwards to release upper edge from between upper cantrail and release seal from door assembly
  46. Remove screws securing LH front falcon door applique
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 3 Nm
  47. Remove LH falcon door applique
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T25, 4.5 Nm
  48. Remove screws securing LH rear upper bright molding to door
    Informational PurposesAn informational icon, calling your attention
    Note
    7x screws, T20, 4 Nm
  49. Disconnect the electrical connector from the LH rear window motor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  50. Remove the upper and lower nuts that secure the regulator to the LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, 10mm, 10Nm
  51. Push the regulator outboard so that the studs no longer protrude through the door shell and push the 2 beams of the regulator together and remove the window motor/regulator assembly from the LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the washers to fall off the studs on the regulator
  52. Disconnect LH ultrasonic sensor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not use pry tool on tripod
  53. Disconnect LH outer door handle carrier connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  54. Release clip from LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  55. Pull back butyl patches to expose LH falcon door outer handle carrier fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    3x butyl patches
  56. Remove LH falcon door outer door handle carrier fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    3x nuts, 10mm, 8 Nm
  57. Remove LH falcon door outer door handle carrier
  58. Disconnect LH falcon door close switch
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  59. Remove LH falcon door close switch
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold on to the connector that’s part of the lit button close switch, while you turn the black prongs surrounding the switch counterclockwise, As the lit button close switch becomes increasingly loose, pull it free from the outside of the door
  60. Disconnect clip from LH lower latch cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  61. Remove LH rear door latch shroud
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  62. Disconnect LH lower latch connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  63. Remove bolts securing LH actuator and pull actuator up to gain access
    Informational PurposesAn informational icon, calling your attention
    Note
    3x nuts, 10mm, 3 Nm
  64. Remove door latch cover from LH door
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T30, 22 Nm, Discard after removal
  65. Remove the latch and cinching actuator assembly from the LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  66. Remove LH rear door lower gap hider
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 4 Nm
  67. Remove LH falcon bump stop bumper
    Informational PurposesAn informational icon, calling your attention
    Note
    Note height before removal, twist in a counterclockwise direction to remove
  68. Remove LH rear door lower harness
    Informational PurposesAn informational icon, calling your attention
    Note
    8x fasteners, 1x plug
  69. Support the rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    May need assist to open
  70. Remove lower falcon door from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door.
  71. Remove the front screws of the cantrail seal
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 3.5 Nm
  72. Remove the rear screws of the cantrail seal
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 3.5 Nm
  73. Remove cantrail seal nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    7x nuts, 8mm, 5 Nm
  74. Remove cantrail seal

Install

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
If using this procedure to install an unpainted part, make sure to apply seam sealer to all seams prior to installing and painting the part. Refer to the Collision Repair manual for more information.
  1. Prepare LH lower falcon door inner panel
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean areas where butyl patches will be applied with IPA, Allow 1 minute to dry
  2. Apply butyl patches to LH lower falcon door inner panel
    Informational PurposesAn informational icon, calling your attention
    Note
    11x butyl patches
  3. Prepare LH lower falcon door outer panel
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean areas where butyl patches will be applied with IPA, Allow 1 minute to dry
  4. Apply butyl patches to LH lower falcon door outer panel
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure butyl patch seals openings to avoid water leaks
  5. Apply support foam to lower outer B-pillar and lower outer C-pillar of LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    Cut to length
  6. Install cantrail seal onto LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    7x nuts, 8mm, 5 Nm, Make sure seal slides behind the nuts, Start from the back and working your way forward
  7. Install screws securing the rear of cantrail seal
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 3.5 Nm
  8. Install screws securing the front of cantrail seal
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 3.5 Nm
  9. Prepare LH lower falcon door inner upper panel
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean area where the seal for the lower NVH extrusion will be applied with IPA, Allow 1 minute to dry
  10. Install lower NVH extrusion seal onto LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply adhesive promoter along installation area, Allow 1 minute for dry time, Remove adhesive cover from seal, Center seal approximately 57 mm from the rear of cantrail seal and 51 mm from the front of cantrail seal
  11. Use IPA wipes or isopropyl alcohol to clean sensor mounting area
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry
  12. Apply adhesion promoter to door skins
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry
  13. Use heat gun and heat up the door skin. If necessary, use the infrared thermometer to check the temperature of door panel to at least 25 degrees C (77 degrees F) evenly
  14. Peel off stickers and Install new holder onto door skin with harness slot in bottom position
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the force gauge to apply a force of 70 N to the top of each of the carrier pads for at least 10 seconds.
  15. Use heat gun and IR temp gun to read temperature of door panel to install Ultrasonic sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    Panel must be 25º C or warmer – use heat gun to warm if necessary
  16. Peel off the adhesive from new sensor, Use heat gun and IR gun to heat sensor prior to application
    Informational PurposesAn informational icon, calling your attention
    Note
    Sensor must be between 40º -50º C prior to installation
  17. Install sensor onto door skin
  18. Use force gauge to press sensor into door and secure
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach the 22 mm tip to the force gauge, Press @ 50N for 10 seconds
  19. Install spacer, spring, and cap to secure sensor
  20. Install LH rear door lower harness
    Informational PurposesAn informational icon, calling your attention
    Note
    8x fasteners, 1x plug
  21. Install LH falcon bump stop bumper
    Informational PurposesAn informational icon, calling your attention
    Note
    Twist in a clockwise direction to install, set height to previously noted level
  22. Install LH rear door lower gap hider
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 4 Nm
  23. Install latch and cinching actuator assembly into the LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  24. Install latch cover onto LH door
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T30, 22 Nm, Install new screw
  25. Install nuts securing cinching actuator assembly onto LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    3x nuts, 10mm, 3 Nm
  26. Connect LH lower latch connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  27. Install LH rear door latch shroud
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  28. Attach clip to LH lower latch cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  29. Install LH falcon door close switch
    Informational PurposesAn informational icon, calling your attention
    Note
    Place it over switch and rotate the black tabs clockwise
  30. Connect LH falcon door close switch
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  31. Install LH falcon door outer door handle carrier
  32. Install nuts securing outer door handle carrier to LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    3x nuts, 10mm, 8 Nm
  33. Secure LH falcon door butyl patches
    Informational PurposesAn informational icon, calling your attention
    Note
    3x butyl patches
  34. Secure LH falcon door outer door handle harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  35. Connect LH outer door handle carrier connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  36. Connect LH ultrasonic sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x clip
  37. Position the regulator inside the rear door panel, push the 2 beams together and ensure the studs protrude through the door shell
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the washers to fall off the studs on the regulator
  38. Install the upper and lower nuts that secure the regulator to the LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, 10mm, 10Nm
  39. Connect the electrical connector from the LH rear window motor
  40. Install screws securing LH rear upper bright molding to door
    Informational PurposesAn informational icon, calling your attention
    Note
    7x screws, T20, 4 Nm
  41. Install LH falcon door applique
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T25, 4.5 Nm
  42. Install screws securing LH front falcon door applique
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 3 Nm
  43. Install LH falcon door fixed glass
    Informational PurposesAn informational icon, calling your attention
    Note
    5x patched screws, T25, 3.5 Nm, Install new patched bolts, Carefully lift up airbag to access the lower screws, Place upper edge of fixed glass assembly in between cantrail seal, Position fixed glass to lineup with the rivnuts, Insert and secure fixed glass seal onto door assembly
  44. Install front pinch sensor to LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet, Route harness into LH falcon door and secure harness grommet
  45. Install push clips securing front pinch sensor to LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    7x push clips
  46. Connect LH front pinch sensor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  47. Install rear pinch sensor to LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet, Route harness into LH falcon door and secure harness grommet
  48. Install push clips securing rear pinch sensor to LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips
  49. Install clip securing rear pinch sensor harness to LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  50. Connect LH rear pinch sensor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  51. Clean LH rear door cladding surface area and prepare for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow IPA to dry for at least 1 minute
  52. Install LH rear door cladding
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Remove backing from double side tape and align clips with body
  53. Install LH wheel arch cladding
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Remove adhesive strip protector from double-sided tape, Align wheel arch onto rear door, Ensure double-sided tape and all clips are fully secured onto rear door
  54. Apply P-80 Emulsion Grease onto seals attached to LH rear door fixed glass for easier installation
  55. Install LH falcon door fixed glass
    Informational PurposesAn informational icon, calling your attention
    Note
    5x patched screws, T25, 3.5 Nm, Install new patched bolts, Carefully lift up airbag to access the lower screws, Place upper edge of fixed glass assembly in between cantrail seal, Position fixed glass to lineup with the rivnuts, Insert and secure fixed glass seal onto door assembly
  56. Install window glass into vehicle and seat it onto the regulator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Recommend assistance, Carefully feed window glass into door and seat it into the rear clip and forward brace
  57. Verify window glass fitment and tighten nut securing the front of the window to the regulator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 9 Nm,
  58. Install LH falcon door speaker
    Informational PurposesAn informational icon, calling your attention
    Note
    4x screws, T25, 4 Nm, 1x connector
  59. Secure window regulator harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  60. Install release cable through the LH closeout panel
  61. Secure LH window motor onto the back of the closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  62. Install screws securing window motor to LH closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T30, 1.8 Nm
  63. Install clips securing harness to falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  64. Install bolt securing ground to LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  65. Install clips securing harnesses and connectors to LH closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips
  66. Connect LH falcon door module
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  67. Connect LH falcon door protection ECU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, securing locking tab
  68. Install LH 2nd row head air bag
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Lift 2nd row head air bag straight up to expose the fir tree clips, Install into LH rear door, Ensure fir clips fully seated
  69. Install bolts securing LH 2nd row head air bag to LH rear door assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 10mm, 7 Nm
  70. Connect LH 2nd row head air bag connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  71. Install LH rear door inner belt seal
  72. Connect First Responder Loop and LV battery connector
    Informational PurposesAn informational icon, calling your attention
    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
  73. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums
  74. Close hood
  75. Install LH rear door trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    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
  76. Install bolts securing LH rear door panel to door
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 10mm, 6 Nm
  77. Install LH rear door decor trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, 2x connectors, Take care not to damage door trim panel
  78. Open LH falcon wing door
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust position as required
  79. Install LH upper falcon door trim
    Informational PurposesAn informational icon, calling your attention
    Note
    17x clips, Align strut cover first, 1x connector may be present on early production vehicles
  80. Install LH falcon door lower garnish
    Informational PurposesAn informational icon, calling your attention
    Note
    9x V-clips, 1x guide tab
  81. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
  82. Measure the gap and flush of LH falcon door according to specification
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust door as necessary
  83. Move LH front seat to original position
  84. Raise both LH side windows
  85. Close LH front door