09/09/2022 15:16:12

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.

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 LH front window
Partially lower LH rear window
Move LH front seat forward
Open LH rear falcon door partially
Remove LH wheel arch cladding

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4x clips, Carefully release clips and double-sided tape that secure rear wheel arch to rear door assembly
Remove LH rear door cladding

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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
Remove LH rear outer belt trim

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Lift and roll outward slowly and evenly starting from front edge, Take care not to bend or damage components
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 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
Remove LH rear inner belt seal
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
Disconnect 2nd row head air bag connector

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1x connector, Release orange lock and then disconnect
Remove bolts securing 2nd row head air bag to LH rear door assembly

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6x bolts, 10mm, 7 Nm
Remove LH 2nd row head air bag

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4x clips, Lift air bag flaps to access clips
Disconnect LH falcon door protection ECU

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1x connector, Release black locking tab
Disconnect connectors from LH falcon door module

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2x connectors
Remove bolts securing LH closeout panel to falcon door

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10x bolts, T25, 1.8 Nm
Remove screws securing window motor to LH closeout panel

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3x screws, T30, 1.8 Nm
Pull LH closeout panel away from door and lift window motor up to release

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2x tabs
Unclip and feed door release cable through LH closeout panel
Remove clip securing window regulator harness to LH closeout panel

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1x clip
Release clips securing lower falcon door harnesses and connectors to LH closeout panel

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7x clips
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
Remove speaker from LH rear door

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4x bolts, T25, 4 Nm, 2x datums, 1x connector
Loosen nut securing the front of the window to the regulator

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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
Partially close LH rear door

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Do not engage latch
Release clip securing rear of window to regulator and remove glass from vehicle

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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
Disconnect LH falcon door rear pinch sensor connector

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1x connector
Remove clip securing LH falcon door rear pinch sensor harness to door

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1x clip
Remove LH falcon door rear pinch sensor fasteners

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7x push clips
Remove LH falcon door rear pinch sensor

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1x grommet
Disconnect LH falcon door front pinch sensor

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1x connector
Remove LH falcon wing door front pinch sensor fasteners

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7x push clips
Remove LH falcon door front pinch sensor

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1x grommet
Remove LH falcon door fixed glass

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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
Remove screws securing LH front falcon door applique

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2x screws, T25, 3 Nm
Remove LH falcon door applique

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2x bolts, T25, 4.5 Nm
Remove screws securing LH rear upper bright molding to door

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7x screws, T20, 4 Nm
Disconnect the electrical connector from the LH rear window motor

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1x connector
Remove the upper and lower nuts that secure the regulator to the LH rear door

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4x nuts, 10mm, 10Nm
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

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Do not allow the washers to fall off the studs on the regulator
Disconnect LH ultrasonic sensor connector

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1x connector, Do not use pry tool on tripod
Disconnect LH outer door handle carrier connector

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1x connector
Release clip from LH falcon door

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1x clip
Pull back butyl patches to expose LH falcon door outer handle carrier fasteners

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3x butyl patches
Remove LH falcon door outer door handle carrier fasteners

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3x nuts, 10mm, 8 Nm
Remove LH falcon door outer door handle carrier
Disconnect LH falcon door close switch

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1x connector
Remove LH falcon door close switch

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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
Disconnect clip from LH lower latch cover

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1x clip
Remove LH rear door latch shroud

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2x tabs
Disconnect LH lower latch connector

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1x connector
Remove bolts securing LH actuator and pull actuator up to gain access

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3x nuts, 10mm, 3 Nm
Remove door latch cover from LH door

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2x screws, T30, 22 Nm, Discard after removal
Remove the latch and cinching actuator assembly from the LH falcon door

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2x connectors
Remove LH rear door lower gap hider

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2x screws, T25, 4 Nm
Remove LH falcon bump stop bumper

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Note height before removal, twist in a counterclockwise direction to remove
Remove LH rear door lower harness

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8x fasteners, 1x plug
Support the rear door

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May need assist to open
Remove lower falcon door from vehicle

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4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door.
Remove the front screws of the cantrail seal

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2x screws, T25, 3.5 Nm
Remove the rear screws of the cantrail seal

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2x screws, T25, 3.5 Nm
Remove cantrail seal nuts

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7x nuts, 8mm, 5 Nm
Remove cantrail seal
Prepare LH lower falcon door inner panel

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Clean areas where butyl patches will be applied with IPA, Allow 1 minute to dry
Apply butyl patches to LH lower falcon door inner panel

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11x butyl patches
Prepare LH lower falcon door outer panel

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Clean areas where butyl patches will be applied with IPA, Allow 1 minute to dry
Apply butyl patches to LH lower falcon door outer panel

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Ensure butyl patch seals openings to avoid water leaks
Apply support foam to lower outer B-pillar and lower outer C-pillar of LH lower falcon door

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Cut to length
Install cantrail seal onto LH lower falcon door

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7x nuts, 8mm, 5 Nm, Make sure seal slides behind the nuts, Start from the back and working your way forward
Install screws securing the rear of cantrail seal

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2x screws, T25, 3.5 Nm
Install screws securing the front of cantrail seal

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2x screws, T25, 3.5 Nm
Prepare LH lower falcon door inner upper panel

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Clean area where the seal for the lower NVH extrusion will be applied with IPA, Allow 1 minute to dry
Install lower NVH extrusion seal onto LH lower falcon door

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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
Use IPA wipes or isopropyl alcohol to clean sensor mounting area

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Allow 1 minute to dry
Apply adhesion promoter to door skins

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Allow 1 minute to dry
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
Peel off stickers and Install new holder onto door skin with harness slot in bottom position

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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.
Use heat gun and IR temp gun to read temperature of door panel to install Ultrasonic sensor

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Panel must be 25º C or warmer – use heat gun to warm if necessary
Peel off the adhesive from new sensor, Use heat gun and IR gun to heat sensor prior to application

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Sensor must be between 40º -50º C prior to installation
Install sensor onto door skin
Use force gauge to press sensor into door and secure

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Attach the 22 mm tip to the force gauge, Press @ 50N for 10 seconds
Install spacer, spring, and cap to secure sensor
Install LH rear door lower harness

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8x fasteners, 1x plug
Install LH falcon bump stop bumper

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Twist in a clockwise direction to install, set height to previously noted level
Install LH rear door lower gap hider

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2x screws, T25, 4 Nm
Install latch and cinching actuator assembly into the LH falcon door

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2x connectors
Install latch cover onto LH door

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2x screws, T30, 22 Nm, Install new screw
Install nuts securing cinching actuator assembly onto LH rear door

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3x nuts, 10mm, 3 Nm
Connect LH lower latch connector

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1x connector
Install LH rear door latch shroud

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2x tabs
Attach clip to LH lower latch cover

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1x clip
Install LH falcon door close switch

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Place it over switch and rotate the black tabs clockwise
Connect LH falcon door close switch

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1x connector
Install LH falcon door outer door handle carrier
Install nuts securing outer door handle carrier to LH falcon door

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3x nuts, 10mm, 8 Nm
Secure LH falcon door butyl patches

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3x butyl patches
Secure LH falcon door outer door handle harness clip

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1x clip
Connect LH outer door handle carrier connector

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1x connector
Connect LH ultrasonic sensor

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1x connector, 1x clip
Position the regulator inside the rear door panel, push the 2 beams together and ensure the studs protrude through the door shell

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Do not allow the washers to fall off the studs on the regulator
Install the upper and lower nuts that secure the regulator to the LH rear door

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4x nuts, 10mm, 10Nm
Connect the electrical connector from the LH rear window motor
Install screws securing LH rear upper bright molding to door

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7x screws, T20, 4 Nm
Install LH falcon door applique

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2x bolts, T25, 4.5 Nm
Install screws securing LH front falcon door applique

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2x screws, T25, 3 Nm
Install LH falcon door fixed glass

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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
Install front pinch sensor to LH falcon door

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1x grommet, Route harness into LH falcon door and secure harness grommet
Install push clips securing front pinch sensor to LH falcon door

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7x push clips
Connect LH front pinch sensor connector

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1x connector
Install rear pinch sensor to LH falcon door

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1x grommet, Route harness into LH falcon door and secure harness grommet
Install push clips securing rear pinch sensor to LH falcon door

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7x clips
Install clip securing rear pinch sensor harness to LH falcon door

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1x clip
Connect LH rear pinch sensor connector

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1x connector
Clean LH rear door cladding surface area and prepare for installation

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Allow IPA to dry for at least 1 minute
Install LH rear door cladding

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4x clips, Remove backing from double side tape and align clips with body
Install LH wheel arch cladding

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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
Apply P-80 Emulsion Grease onto seals attached to LH rear door fixed glass for easier installation
Install LH falcon door fixed glass

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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
Install window glass into vehicle and seat it onto the regulator

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1x clip, Recommend assistance, Carefully feed window glass into door and seat it into the rear clip and forward brace
Verify window glass fitment and tighten nut securing the front of the window to the regulator

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1x nut, 10mm, 9 Nm,
Install LH falcon door speaker

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4x screws, T25, 4 Nm, 1x connector
Secure window regulator harness

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1x clip
Install release cable through the LH closeout panel
Secure LH window motor onto the back of the closeout panel

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2x tabs
Install screws securing window motor to LH closeout panel

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3x screws, T30, 1.8 Nm
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
Install clips securing harnesses and connectors to LH closeout panel

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7x clips
Connect LH falcon door module

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2x connectors
Connect LH falcon door protection ECU

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1x connector, securing locking tab
Install LH 2nd row head air bag

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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
Install bolts securing LH 2nd row head air bag to LH rear door assembly

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6x bolts, 10mm, 7 Nm
Connect LH 2nd row head air bag connector

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1x connector, Engage locking tab
Install LH rear door inner belt seal
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
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
Open LH falcon wing door

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Adjust position as required
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
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.
Measure the gap and flush of LH falcon door according to specification

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Adjust door as necessary
Move LH front seat to original position
Raise both LH side windows
Close LH front door