30/05/2024 07:23:52

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

Correction code 10106702

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.

Removal

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

Note
Record that data and use it as a base line when installing the new door
Open LH front door
Lower LH front window
Lower LH rear window fully
Move LH front seat forward
Open LH falcon door
Remove LH falcon door lower garnish

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

Note
17x clips, 1x connector may be present on early production vehicles
Remove LH upper outer falcon door rear trim

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

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

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

Note
4x clips
Lower LH falcon door

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

Note
10x nuts, 10mm, 6 Nm, Recommend assistance
Remove decorative trim panel

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8x clips, Push down 2 metal clips and slide rearward to release the trim
Remove door panel bolts

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

Note
13x clips, 1x connector
Open LH rear door
Support the rear door

Note
May need assist to open
Open hood

Note
Via center display > Controls > Front Trunk
Power down vehicle using MCU

Note
Via Controls > Safety > ''Power off"
Remove underhood aprons

Note
4x aprons
Remove frunk carpet

Note
2x connectors
Remove underhood storage unit

Note
10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
Remove HEPA filter

Note
Lift up from bottom and pull out
Disconnect 12V negative terminal and First Responder Loop

Note
1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
Release clips securing harness connectors to closeout panel

Note
3x clips
Remove the ground strap from lower falcon door and disconnect door harness from close out panel harness

Note
1x bolt, 10mm, 9 Nm, 3 connectors
Remove lower falcon door harness clips

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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

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

Note
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

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

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

Note
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

Note
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

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

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

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

Note
3x bolts, EP 16, 32Nm, Recommend assistance if necessary
Remove the rear secondary hinge assembly with clamp bracket

Note
3x bolts, EP 16, 32Nm, Recommend assistance if necessary
Remove LH front upper falcon door bumpstop assembly

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

Note
2x bolts, 10mm, 8Nm, 1x screw, T30, 5Nm

Installation

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.

Use IPA clean NVH seal area of the new upper falcon door

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

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

Note
Use roller to press the seal in place
Install LH front upper falcon door bumpstop assembly

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

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

Note
3x bolts, EP 16, 32 Nm
Install the front secondary hinge assembly with bracket

Note
3x bolts, EP 16, 32 Nm
Install the rear secondary strut with bracket from the upper falcon door

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

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

Note
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

Note
4x bolts, 13mm, 24 Nm, Use a rubber hammer to tap on the upper falcon door to center it, Recommend assistance,Caution: the upper falcon door hinges are spring loaded and it want to retract to falcon door open position.
Install the rear primary strut to upper falcon door

Note
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

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

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

Note
4x connectors, 2 clips
Install the lower falcon door to vehicle

Note
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 lower falcon door harness clips

Note
5x clips
Install the ground strap from lower falcon door and connect door harness to close out panel harness

Note
1x bolt, 10mm, 9 Nm, 3 connectors
Secure clips securing harness connectors to closeout panel

Note
3x clips
Connect first responder loop and then 12V negative terminal

Note
1x connector, 1x nut, 10mm, 5 Nm
Remove door support stand
Calibrate falcon doors using MCU

Note
Required after 12V and FRL disconnect
Close LH rear door and window
Check the gap and flush of LH falcon door according to specification

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

Note
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, 32Nm, 4x bolts, 13mm, 24 Nm
Install LH falcon door upper glass

Note
10x nuts, 10mm, 6 Nm, Recommend assistance
Open LH rear door
Install LH upper gap hider trim

Note
4x clips
Install LH upper outer falcon door middle trim

Note
7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
Install LH upper outer falcon door front trim

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

Note
5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
Replace LH rear door trim panel clips

Note
13x clips
Install LH rear door trim panel

Note
13x clips, 1x connector
Install bolts securing LH rear door trim panel to door

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

Note
8x clips
Install LH upper falcon door trim

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

Note
9x V-clips, 1x guide tab
Close LH Falcon door
Install HEPA filter housing
Install underhood storage unit

Note
10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
Install frunk carpet

Note
2x connectors
Install under hood aprons

Note
4x aprons
Close hood
Move LH front seat to original position
Raise LH rear window
Raise LH front window
Close LH front door