25/03/2024 17:24:54

Harness - Main Front (Structural Pack) (Remove and Replace)

Correction code 17100742 4.08 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 wearing proper PPE when performing the below procedure.

2024-03-22: Added a Note to make sure the first responder loop is disconnected prior to the installation of the new main front harness.
2023-08-28: Updated EPB Service Mode reference.

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.

Open both front doors and lower both front windows.
Move both front seats backward.
Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
Open hood
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Remove rear apron

Note
14x clips
Remove access panel

Note
3x clips, 1x connector
Remove fasteners securing the frunk assembly

Note
5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to reservoir neck
Remove frunk assembly from vehicle

Note
6x clips, Replace any clips if broken or missing
Release washer hose from washer tank neck

Note
3x anchors
Remove washer tank neck from washer tank

Note
1x O-ring, Pull straight out
Remove HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly
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, Allow 2 minutes for all electrical circuits to fully discharge
Remove fasteners securing the LV battery

Note
3x bolts, 8mm, 6 Nm Early production vehicle may have3x bolts, M6, 10mm, 10 Nm
Remove LV battery from vehicle

Note
Raise up LV battery vertically from the vehicle
Release positive jump post

Note
1x cover, 1x bolt, E5, 8 Nm, Remove positive jump post cover to access jump post bolt
Remove fresh air intake duct

Note
1x bolt, 10mm, 4 Nm, 2x clips, 1x pin, Remove bolt, Gently pry pin out from thermal beam, then remove from bulkhead studs
Remove LH wiper arm nut cover

Note
1x cover
Remove the nut securing the LH wiper arm to wiper module

Note
1x nut, 15mm, 25 Nm
Disconnect washer hose from LH wiper arm to Y-tube fitting and release washer hose clip

Note
1x clip, 1x hose
Remove the LH wiper arm and hose assembly from vehicle
Remove RH wiper arm nut cover

Note
1x cover
Remove the nut securing the RH wiper arm to wiper module

Note
1x nut, 15mm, 25 Nm
Disconnect washer hose from RH wiper arm to Y-tube fitting and release washer hose clip

Note
1x clip, 1x hose
Remove the RH wiper arm and hose assembly from vehicle
Disconnect washer hose from washer pump to Y-tube fitting and release washer hose clip

Note
1x clip, 1x hose
Remove cowl screen retaining clips

Note
2x push clips
Release the cowl clips at the center bracket

Note
2x retaining clips
Remove cowl screen from vehicle

Note
2x clips, Release the corners of the cowl by pulling away from the body then lift the cowl off of the windshield
Remove the bolts securing wiper module

Note
2x bolts, 10mm, 7 Nm
Remove wiper module from anchor bracket

Note
1x rubber anchor, Carefully pull wiper assembly forward to disengage rubber anchor from under windshield bracket
Disconnect wiper module harness

Note
1x connector, Rotate wiper assembly to expose under side
Remove wiper module from vehicle
Disconnect washer pump harness clip

Note
1x fir clip
Remove bolts securing washer tank

Note
1x bolt, 10mm, 3 Nm, 1x nut, 10mm, 3 Nm
Unplug washer tank level sensor

Note
1x connector, Move washer tank forward and raise to access connector
Disconnect washer tank pump connector

Note
1x connector
Remove washer assembly

Note
Drain washer fluid once removed
Release 12V positive cable clip from front controller

Note
1x clip
Release main harness front controller ground cable

Note
1x bolt, 10mm, 8.5 Nm
Disconnect the supermanifold harness from the front controller

Note
1x connector
Remove bolts securing front controller shield assembly and remove from vehicle

Note
2x bolts, 10mm, 8.5 Nm
Disconnect remaining connectors on front controller

Note
5x connectors, Release locking tabs first if equipped
Release harness guide from front controller

Note
2x patch bolts, 8mm, 6 Nm, 1x temp set clip, Discard bolts after removal, Remove bolts first, then pivot harness guide slightly forward and up to remove temp set clip from front harness
Remove bolts securing front controller

Note
3x bolts, 10mm, 10 Nm
Remove the front controller from vehicle

Note
Push harness connectors down to provide space, Gently pry bottom of controller out of BIW temp set holes, Then swing controller forward and up to release from top temp set
Place absorbent material below car computer coolant hose connection points to collect any spilled coolant
Remove car computer coolant plugs from new car computer

Note
2x coolant plugs
Release coolant hoses from car computer

Note
2x spring clips
Install coolant plugs into coolant outlets of car computer that is being removed from vehicle
Install plugs to car computer coolant hoses

Note
2x plugs, Do not need to engage spring clips
Remove nuts securing car computer to bulkhead

Note
6x nyloc nuts, 7.1 Nm, Discard nuts after removal
Remove LH IP end cap

Note
3x clips
Remove LH mid A-pillar assembly

Note
1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
Remove LH air wave bezel cap from main decor assembly

Note
2x clips
Remove clip securing LH lower A-pillar trim

Note
1x push clip
Remove LH lower A-pillar trim

Note
6x clips, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release trim panel
Remove LH front floormat
Remove LH console side panel carpet

Note
11x clips, 2x guide pins, Use trim tool starting at top edge to release upper clips, then pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
Remove screw and clips securing LH footwell cover

Note
2x push clips, 1x screw, T20, 2.5 Nm
Remove connectors from LH footwell cover and remove from vehicle

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector
Release clips securing LH cabin carpet to cabin support

Note
2x push clips, 1x vertical clip, Insert clip pry tool outboard of clip and rotate to the right to release one side of clip, Move clip pry tool inboard of clip and rotate to left to fully release carpet clip from cabin support
Fold LH front cabin carpet rearward

Note
1x clip, Release seat harness clip and route harness away, Fold back LH cabin carpet back, Maneuver under brake and accelerator pedals
Disconnect front harness white connector X909 from LH body harness and separate from left body controller

Note
1x connector, 1x clip
Release harness from LH controller

Note
1x clip
Disconnect J1 power connector

Note
1x connector, Release lock then remove
Disconnect J6 frunk connector

Note
1x connector
Push the LH side of the front harness through the bulkhead

Note
Ensure that the LH harness is drawn without resistance
Remove RH IP end cap

Note
3x clips
Remove RH mid A-pillar assembly

Note
1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
Remove clip securing RH lower A-pillar trim

Note
1x push clip
Remove RH lower A-pillar trim

Note
6x clips, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release trim panel
Move RH front seat backward
Remove RH front floormat
Remove main decor assembly

Note
2x screws, T20, 2.3 Nm, 15x clips, 1x center clip, Replace securing clips as needed
Remove clips securing RH footwell assembly

Note
4x push clips, Clip count may vary depending on region
Disconnect RH footwell assembly connectors and remove from vehicle

Note
2x connectors
Disconnect glove box USB cable from car computer

Note
1x connector, Depress latch on top of USB cable to release internal latches, then release from car computer. Connector count may vary depending from config
Remove screws securing glove box assembly to IP carrier

Note
6x screws, T20, 2.3 Nm
Disconnect glove box assembly connectors

Note
3x connectors
Remove the glove box from IP carrier

Note
3x clips
Remove RH console side panel carpet

Note
12x clips, 2x locating pins, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
Release clips securing RH cabin carpet to cabin support

Note
2x clips
Fold RH front cabin carpet rearward

Note
1x clip, Release seat harness clip and route harness away, Fold back RH cabin carpet back
Remove the passenger footwell air duct

Note
1x push clip
Remove the RH IP air wave duct

Note
2x push clips
Release ground strap from car computer

Note
1x bolt, T25, 4 Nm, Bolt located, Discard bolt after removal
Disconnect connectors on front side of car computer

Note
4x connectors, If equipped, release locking tab, then remove connector body
Release harness connectors on LH side of car computer

Note
7x connectors, If equipped, release locking tab, then remove connector body
Release harness guide clip

Note
1x clip, Pinch release tabs with needle nose pliers
Slide car computer inward to allow access to connectors and harness clips

Note
With right hand on top of computer and left hand under computer, use right hand to help push airbag up and towards the rear of the vehicle to provide clearance for visor.
Remove visor from car computer

Note
4xclips Pull tab on left side of computer away from computer and lift visor up and way.
Release harness clips from top of car computer

Note
2x harness clips
Release connectors from RH side of car computer and remove from vehicle

Note
8x connectors, If equipped, release locking tab, then remove connector body
Disconnect J6 frunk connector

Note
1x connector
Disconnect J1 power connector

Note
1x connector, Release lock then remove
Release black connector from right body controller and disconnect

Note
1x connector, 1x clip
Disconnect 12V connector from vehicle

Note
1x connector
Release DCDC cable from RH controller

Note
1x clip
Push the RH side of the front harness through the bulkhead

Note
Ensure that the RH harness is drawn without resistance
Disconnect harness connector for windshield heater from underhood area and release clip

Note
1x connector, 1x clip
Secure the windshield harness out of the way to avoid damage

Note
Secure using tape
Remove wheel chocks and push vehicle onto lift

Note
Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, Replace wheel chocks once vehicle in correct position
Remove LH front wheel cap

Note
1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
Remove RH front wheel cap

Note
1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
Loosen LH front wheel

Note
5x nuts, 21mm, 175 Nm
Loosen RH front wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle partially and lower lift onto locks

Note
Set vehicle to a comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove LH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH front wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove front aero shield

Note
12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
Release LH front wheel liner from HV battery

Note
1x rocker bolt, 10mm, 12 Nm, 2x aero shield bolts, 10mm, 6 Nm
Release RH front wheel liner from HV battery

Note
1x rocker bolt, 10mm, 12 Nm, 2x aero shield bolts, 10mm, 6 Nm
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Remove LH front fender garnish

Note
11x clips,1x push clip, 3x tabs, Release from center of garnish and work your way outward towards both ends, Be cautious not to bend front tabs going into front fascia
Remove clips securing LH front wheel liner to vehicle

Note
10x push clips, 5x metal clips, Use prytool to get cutters under metal clip, Metal clips located behind rotor
Remove LH front wheel liner

Note
5x studs
Disconnect the front harness connectors for the LH side repeater and camera

Note
2x connectors
Remove the front harness clip for the LH side repeater and camera harness

Note
1x clip
Disconnect LH Front wheel speed sensor connector

Note
1x clip, 1x connector, Release locking tab
Disconnect LH FEM harness connector

Note
1x connector, Disengage locking tab
Disconnect connector to cooling fan module

Note
1x connector,
Disconnect connectors from horn assembly

Note
2x connectors, Take note of original routing
Remove the front harness for the cooling fan module harness

Note
1x clip
Disconnect LH headlamp connector

Note
1x connector, Pull tab to disengage lock mechanism, Pull again to release connector, Do not press down on tab
Disconnect the HVIL connector

Note
1x locking connector, Do not push down on red tab, Pull red tab to disengage lock, Pull tab again to release connector
Cut LV battery ground cable
Release LV battery ground cable from body

Note
1x bolt, 10mm, 10 Nm, 1x fir tree
Locate and disconnect the LH front shotgun crash accelerometer

Note
1x connector, Release locking tab and pull tab outward to release connector
Remove the front harness ground terminals at LH front shock tower

Note
3x bolt, 10mm, 8 Nm,1x connector discard the self tapping tri-lobular bolts
Disconnect HCU connector

Note
1x connector, Release red locking tab, Press black release tab and rotate lever upward to remove
Release connection for the front subframe harness

Note
1x locking connector, Release red locking tab, Disengage connection and release
Remove the LH harness bracket from vehicle

Note
2x tabs
Remove AC compressor ground strap

Note
1x bolt, 10mm, 7 Nm, Fastener may vary depending on production
Disconnect the steering gear assembly connectors

Note
2x connectors, Two stage connectors, Slide red locking tab to unlock, then depress the connector release to disconnect
Disconnect logic connectors from steering gear assembly

Note
2x locking connectors, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Release front harness clip on LH side of front subframe

Note
1x clip
Disconnect brake fluid level sensor

Note
1x connector, Slide locking tab away from connector to fully release
Disconnect iBooster assembly harness from brake booster assembly

Note
2x connectors, Slide locking tab away from connector to fully release
Release clips securing front harness to LH side of body

Note
9x clips
Remove RH front fender garnish

Note
11x clips,1x push clip, 3x tabs, Release from center of garnish and work your way outward towards both ends, Be cautious not to bend front tabs going into front fascia
Remove clips securing RH front wheel liner to vehicle

Note
10x push clips, 5x metal clips, Use prytool to get cutters under metal clip, Metal clips located behind rotor
Remove RH front wheel liner

Note
5x studs
Release connection for the front fascia

Note
1x locking connector, Release red locking tab and disengage connector
Release harness clip and connector to pedestrian warning speaker

Note
1x locking connector, 1x clip, Pull tab to disengage lock, Pull again release from connector, Speaker is located behind RH wheel liner
Disconnect RH FEM harness connector

Note
1x connector, Disengage locking tab
Disconnect the RH front wheel speed sensor connector

Note
1x connector, Release locking tab
Remove the front harness clip for the RH front wheel speed sensor harness

Note
2x clips
Disconnect the front harness connectors for the RH side repeater and camera

Note
2x connectors
Remove the front harness clip for the RH side repeater and camera harness

Note
1x clip
Disconnect RH headlamp connector

Note
1x connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Locate and disconnect the RH front shotgun crash accelerometer

Note
1x connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Remove the front harness ground terminals at RH front shock tower

Note
1x bolt, 10mm, 8 Nm,1x connector discard the self tapping tri-lobular bolts
Remove the front harness clip around RH front frame rail area

Note
8x clips
Remove the front harness from vehicle

Note
Recommend assistance
Release main harness front controller ground cable

Note
1x zip tie, Prior to cutting tape mark position of main harness front controller ground cable to main harness for overlay step, Remove main harness front controller ground cable from main harness bundle with seam cutting tool, Remove excess electrical tape
Tape zip ties to front main harness

Note
4x zip ties, Fold zip ties in "U" shape and tape to harness, Do not zip ties, this will be done at a later step
Tape front main harness

Note
Tape front main harness and ground cable separately, Do not tape main harness front controller ground cable back to bundle
Install edge clip to main harness

Note
1x Zip tie edge clip
Position the front harness to vehicle for installation.

Note
Make sure the first responder loop is disconnected prior to the installation of the new main front harness.

Note
Make sure to route RH branch underneath A/C compressor HV harness, Recommend assistance
Route the front harness around the HVAC plenum duct area and push the RH side of the harness into passenger side compartment

Note
Route harness underneath A/C HV harness, Make sure to install grommet in proper orientation
Route the front harness around the brake booster area and push the LH side of the harness into driver side compartment

Note
Make sure to install grommet in proper orientation
Install clips securing front harness to LH side of body

Note
9x clips
Install the LH harness bracket to the vehicle

Note
2x tabs
Install front harness clip on LH side of front subframe

Note
1x clip
Connect logic connectors to steering gear assembly

Note
2x connectors, Engage locking tab
Connect the steering gear assembly connectors

Note
2x locking connectors, Engage locking tab
Secure connection for the front subframe harness

Note
1x locking connector, Red locking tab, Connect from front of bracket and lock from opposite side of bracket
Connect HCU connector

Note
1x connector, Seat connection and rotate lever downward, Secure red locking tab
Install AC compressor ground strap

Note
1x bolt, 10mm, 7 Nm, Fastener may vary depending on production
Install the front harness ground terminals to LH front shock tower

Note
3x bolts, 10mm, 8 Nm, 1x connector
Connect iBooster assembly harness to brake booster assembly

Note
2x connectors, Secure locking tab by sliding towards connector once installed
Connect brake fluid level sensor

Note
1x connector, Secure locking tab by sliding towards connector once installed
Connect the HVIL connector

Note
1x locking connector, Engage locking tab
Connect the front shotgun crash accelerometer

Note
1x connector, 2 stage connection, Verify connection is fully secured
Connect LH headlamp

Note
1x connector, 1x locking tab
Install the front harness clip for the LH side repeater and camera harness

Note
1x clip
Connect electrical harness to LH side repeater

Note
2x connectors, Ensure lock on camera connection is secure
Connect LH FEM harness connector

Note
1x connector, Engage locking tab
Install connector to cooling fan module

Note
1x connector
Install the front harness clip for the cooling fan module harness

Note
1x clip
Connect horn assembly connectors

Note
2x connectors
Connect LH Front wheel speed sensor connector

Note
1x clip, 1x connector, Engage locking tab
Install LH front wheel liner

Note
5x studs, Tuck liner behind aero shield
Install clips securing LH front wheel liner to vehicle

Note
10x push clips, 5x metal clips, Use socket to press metal clip evenly, Metal clips located behind rotor
Install LH front fender garnish

Note
12x clips, 3x tabs, Start at rear and maneuver into rocker panel, Be cautious not to bend front tabs going into front fascia
Install the front harness clip around RH front frame rail area

Note
8x clips
Install the front harness ground terminals to RH front shock tower

Note
2x bolts, 10mm, 8 Nm, 1x connector
Install RH headlamp connector

Note
1x connector
Install RH front shotgun crash accelerometer

Note
1x connector
Connect RH FEM harness connector

Note
1x connector, Engage locking tab
Secure connection and clip for pedestrian warning speaker

Note
1x connector, 1x clip, Engage locking tab
Secure connection for the front fascia

Note
1x locking connector, Secure connection and fully engage red locking tab
Connect the front harness connectors for the RH side repeater and camera

Note
2x connectors
Install the front harness clip for the RH side repeater and camera harness

Note
1x clip
Connect the RH front wheel speed sensor connector

Note
1x connector
Install the front harness clip for the RH front wheel speed sensor harness

Note
2x clips
Install RH front wheel liner

Note
5x studs, Tuck liner behind aero shield
Install clips securing RH front wheel liner to vehicle

Note
10x push clips, 5x metal clips, Use socket to press metal clip evenly, Metal clips located behind rotor
Install RH front fender garnish

Note
11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
Removed the tape from the windshield heater harness and windshield
Connect the windshield heater harness and install clip

Note
1x connector, 1x clip
Maneuver front controller into position

Note
Slide over temp set hook first, then into bottom bracket temp set holes
Secure front controller

Note
3x bolts, 10mm, 10 Nm
Install harness guide to front controller

Note
2x patch bolts, 8mm, 6 Nm, 1x temp set clip, Install new bolts, Pivot harness guide upwards and back to install temp set clip to front harness, then install bolts
Connect front controller harness connectors

Note
5x connectors, Fully seat connector, then engage locking tabs if equipped
Install front controller protection shield

Note
2x bolts, 10mm, 8.5 Nm
Connect the supermanifold harness to the front controller

Note
1x connector
Overlay main harness front controller ground cable to main harness

Note
4x zip ties, route Main harness controller ground cable over main harness and secure with zip ties
Install main harness front controller ground cable to front controller

Note
1x bolt, 10mm, 8.5 Nm
Secure 12V positive cable to front controller

Note
1x clip
connect washer tank pump connector

Note
1x connector
Connect washer tank level sensor

Note
1x connector
Install washer tank assembly

Note
Align retaining stud at firewall with washer tank upper bracket
Install washer tank retaining nut and bolt

Note
1x bolt, 10mm, 3 Nm, 1x nut, 10mm, 3 Nm
Connect washer pump harness clip

Note
1x fir clip
Position wiper module to vehicle and connect harness

Note
1x connector, Secure electrical connector with wiper assembly upside down, Rotate assembly rearward ensuring harness clearance
Install wiper module to anchor bracket

Note
1x rubber anchor, Carefully push wiper assembly rearward to fully engage rubber anchor to under windshield bracket
Install the bolts securing wiper module

Note
2x bolts, 10mm, 7 Nm
Install cowl screen assembly

Note
2x clips, Press the corners of the cowl into the body
Install the cowl clips at the center bracket

Note
2x retaining clips
Install cowl screen retaining clips

Note
2x clips
Connect washer hose from washer pump to Y-tube fitting and secure washer hose clip

Note
1x clip, 1x hose
Install the RH wiper arm and hose assembly onto vehicle
Install the nut securing the RH wiper arm to wiper module

Note
1x nut, 15mm, 25 Nm, Make sure the wiper tip is aligned between the two indicators at corner of windshield
Install RH wiper arm nut cover

Note
1x cover
Connect washer hose from RH wiper arm to Y-tube fitting and secure washer hose clips

Note
1x clip, 1x hose
Install the LH wiper arm and hose assembly onto vehicle
Install the nut securing the LH wiper arm to wiper module

Note
1x nut, 15mm, 25 Nm, Make sure the wiper tip is aligned between the two indicators at windshield
Install LH wiper arm nut cover

Note
1x cover
Connect washer hose from LH wiper arm to Y-tube fitting and secure washer hose clip

Note
1x clip, 1x hose
Position LV battery into vehicle

Note
Lower vertically LV battery into the vehicle
Install fasteners securing LV battery

Note
3x bolts, 8mm, 6 Nm. Early production vehicle may have3x bolts, M6, 10mm, 10 Nm
Install positive jump post

Note
1x bolt, E5, 8 Nm, Place cover over stud once torqued
Install LV battery ground cable to body

Note
1x fir tree, 1x bolt, 10mm, 10 Nm
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Apply Loctite 222 onto aero shield bolts and secure LH front wheel liner onto HV battery

Note
1x rocker bolt, 10mm, 12 Nm, 2x aero shield bolts, 10mm, 6 Nm
Apply Loctite 222 onto aero shield bolts and secure RH front wheel liner onto HV battery

Note
1x rocker bolt, 10mm, 12 Nm, 2x aero shield bolts, 10mm, 6 Nm
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle

Note
12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
Lower vehicle partially and set onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Install LH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque LH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH front wheel

Note
5x nuts, 21mm, 175 Nm
Install LH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install RH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle
Push vehicle away from lift

Note
Recommend assistance, Place wheel chocks to keep vehicle from moving, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
Connect 12V connector to vehicle

Note
1x connector
Secure DCDC cable to RH controller

Note
1x clip
Connect black connector and secure to right body controller

Note
1x connector, 1x clip
Connect J1 power connector

Note
1x connector, Fully seat connector then engage lock
Connect J6 frunk connector

Note
1x connector
Place car computer into vehicle and connect RH side connectors

Note
8x connectors, If equipped, fully seat connector, then engage locking tab
Secure harness to top of car computer

Note
2x harness clips
Install visor on car computer

Note
4x clips, Align coolant pipe clips over coolant pipes and lower visor until all clips are secured.
Slide car computer into position on bulkhead

Note
Use caution during installation due to minimal clearance between shroud and passenger airbag connectors and harness
Secure harness guide clip

Note
1x harness clip
Connect LH side connectors

Note
7x connectors, If equipped, fully seat connector, then engage locking tab
Connect connectors on the front side of car computer

Note
4x connectors, If equipped, fully seat connector, then engage locking tab
Secure ground cable to car computer

Note
1x bolt, T25, 4 Nm, Bolt located, Discard bolt after removal
Install nuts securing car computer to the bulkhead

Note
5x nyloc nuts, 13mm, 7.1 Nm, Install new nyloc nuts
Verify there are no coolant plugs in the car computer coolant necks
Remove plugs from car computer coolant hoses

Note
2x plugs, Engage spring clips after removal
Secure hoses to car computer coolant inlet/outlet

Note
2x spring clips, Perform push-pull-push test to ensure the hoses are fully seated
Remove absorbent material from below car computer coolant hose connection points
Remove coolant bottle cap
Fill coolant bottle to base of neck as indicated
Fold RH front main cabin carpet back to original position

Note
1x clip, Secure seat harness clip and route harness, Fold RH cabin carpet back
Install clips securing RH cabin carpet to cabin support

Note
2x push clips, Secure clips and verify fitment of carpet
Connect glove box assembly connectors

Note
3x connectors, Puddle lamp harness routing prevent blocking movement of pawls
Install the new glove box into IP carrier

Note
3x clips
Install screws securing glove box assembly to IP carrier

Note
6x screws, T20, 2.3 Nm
Connect glove box USB cable to car computer

Note
1x connector, Connector count may vary depending from config
Connect the RH footwell assembly connectors

Note
2x connectors
Install clips securing RH footwell assembly

Note
4x push clips
Install main decor assembly

Note
15x clips, 1x center clip
Install RH lower A-pillar trim

Note
6x clips, 2x locating pins, Align front locating pin first
Install clip securing RH lower A-pillar trim

Note
1x clip
Install RH mid A-pillar assembly

Note
1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Make sure the seal seat on top of the trim
Install RH air wave bezel cap to main decor assembly

Note
2x clips
Install RH IP end cap

Note
3x clips
Install RH front floor mat
Connect J6 frunk connector

Note
1x connector
Connect J1 power connector

Note
1x connector, Fully seat connector then engage lock
Secure harness to LH controller
Connect front harness white connector X909 to LH body harness and clip to LH body controller

Note
1x connector, 1x clip
Fold LH front cabin carpet back to original position

Note
1x clip, Secure seat harness clip and route harness, Fold LH cabin carpet back, Maneuver under brake and accelerator pedals
Install clips securing LH cabin carpet to cabin support

Note
2x push clips, 1x vertical clip, Secure vertical clip into place first, Verify fitment of carpet
Install connectors to LH footwell cover and position for installation

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector
Install screw and clips securing LH footwell cover

Note
1x screw, T20, 2.5 Nm, 2x push clips
Install LH console side panel carpet

Note
11x clips, 2x locating pins, Position side panel and align the front into front locator, then the rear locator, Push side panel towards console to install
Install LH lower A-pillar trim

Note
6x clips, 2 locating pins, Align front locating pin first
Install clip securing LH lower A-pillar trim

Note
1x push clip
Install LH mid A-pillar assembly

Note
1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim
Install LH air wave bezel cap to main decor assembly

Note
2x clips
Install LH front floormat
Install HEPA duct

Note
1x bolt, 10mm, 4 Nm, 1x datum, 2x ears, Secure ears onto bulkhead studs then secure datum
Connect first responder loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Connect to vehicle using Toolbox 3.0

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
Select ‘
TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
Thermal ➜ Coolant System ➜ Coolant Purge Start
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
’, click ‘Run’, and allow routine to complete
Note
Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Install coolant bottle cap
Install HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
Install washer tank neck to washer tank

Note
1x O-ring
Install washer hose to washer tank neck

Note
3x anchors
Install frunk assembly to vehicle

Note
6x clips, Replace any clips if broken or missing
Install fasteners securing the frunk assembly

Note
5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to washer bottle neck
Install access panel

Note
3x clips, 1x connector
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Move RH front seat to original position
Raise RH front window
Close RH front door
Move LH front seat to original position
Raise LH front window
Close LH front door

Model Y Service Manual

Harness - Main Front (Structural Pack) (Remove and Replace)

Figure 1

Figure 2

Figure 3