LEMON Manuals: Even more car manuals for everyone
Home >> Tesla >> 2019 >> Model S Performance >> Repair and Diagnosis (Single Page) >> Accessories & Equipment >> Exterior Lights >> Electrical System -- Model S >> Harnesses >> Harnesses - Main Lower Dash and Front Trunk (RHD) (RWD) - Remove And Replace >> Install Front Trunk Harness

Install Front Trunk Harness

  1. Place new front trunk harness into the front of the vehicle.
    G15034659Courtesy of TESLA, INC.
  2. Route cabin portion of front trunk harness through opening in bulkhead and seat sealing grommet.
    NOTE: The sealing grommet is marked for orientation, Ensure the arrow is pointing up.
    G00624062Courtesy of TESLA, INC.
    G00624063Courtesy of TESLA, INC.
  3. Remove the plastic cover in the in cabin portion of the Front Harness, then route and secure harness clips to RH side of the Bulkhead.
    NOTE: 6x clips.
    G00624064Courtesy of TESLA, INC.
    G00624065Courtesy of TESLA, INC.
  4. Make connections at the Air Suspension Control Module.
    NOTE: 2x connectors.
    G00624066Courtesy of TESLA, INC.
  5. Secure the Front Harness Ground connection at the In-Cabin Fuse Box.
    NOTE: 1x nut, 10 mm, 6 N.m.
    G00624067Courtesy of TESLA, INC.
  6. Connect the Front Harness connector at the In-Cabin Fuse Box.
    NOTE: 1x connector.
    G00624068Courtesy of TESLA, INC.
  7. Un-bundle RH portion of new front trunk harness and route against bulkhead down RH side behind HV cables that run to the FJB.
    G00624069Courtesy of TESLA, INC.
    G00624070Courtesy of TESLA, INC.
  8. Raise vehicle partially and lower onto locks.
  9. Remove the connector carrier for FEM connections from the new harness.
    NOTE: this will aid in creating room for routing the harness up to the RH Body Beam.
    G00624071Courtesy of TESLA, INC.
    G00624072Courtesy of TESLA, INC.
  10. Apply tape to the secure connector lock for the Fuse Box connector from the RH leg of the harness.
    NOTE: The connector will need to be passed through a tight between the A/C lines and taping the lock in place will assist in the later step.
    G00624073Courtesy of TESLA, INC.
  11. Route right side of front trunk harness under shock tower cross member and out towards front of RH body beam.
    NOTE: Working from right front fender well, pass the harness through the opening under shock tower cross member, If needed raise or lower the vehicle on the lift to work from above and in the fender well to ease in routing harness.
    G00624074Courtesy of TESLA, INC.
    G00624075Courtesy of TESLA, INC.
  12. Secure harness clips near Brake Booster.
    NOTE: 2x clips.
    G00624076Courtesy of TESLA, INC.
  13. Secure harness clips at Bulkhead to right of Brake Booster and on body seam in fender well.
    NOTE: 2x clips.
    G00624077Courtesy of TESLA, INC.
  14. Route FJB logic connector down bulkhead along FJB HV cables.
    NOTE: 1x connector.
    G00624078Courtesy of TESLA, INC.
    G00624079Courtesy of TESLA, INC.
  15. Lower vehicle to comfortable working height.
  16. Route fuse box and ground connectors through opening in A/C lines.
    NOTE: 2x connectors.
    G00624080Courtesy of TESLA, INC.
  17. Secure clips at inner RH shock tower.
    NOTE: 1x fir tree clip towards rear of inner shock tower, 1x barrel clip towards the middle.
    G00624081Courtesy of TESLA, INC.
  18. Route 2 harness legs for steering gear and secure to coolant hose below.
    NOTE: 2x clips, These legs of the harness sit on top and are secured to the coolant lines with large circle clips on the bottom.
    G00624082Courtesy of TESLA, INC.
  19. Route leg of harness with connectors for headlamp, coolant 3 way valve, fan controller, and wheel speed sensor to RH outer side of RH body beam.
    NOTE: 4x connectors, Coolant 3 way valve and RH fan controller connectors are routed down to the underside of vehicle while the others remain above body beam for installation.
    G00624083Courtesy of TESLA, INC.
    G00624084Courtesy of TESLA, INC.
  20. Locate the RH harness ground connections from the separate harness legs and route towards grounding points on RH Shock Tower.
    NOTE: 3x cables.
    G00624085Courtesy of TESLA, INC.
  21. Install the Front Harness FEM connectors to the harness connector carrier.
    NOTE: 4x connectors, See Image for Connector orientation to carrier.
    G00624086Courtesy of TESLA, INC.
  22. Install the FEM Connector Carrier to the RH Body Beam.
    NOTE: 2x nuts, 10 mm, plastic, 3 N.m.
    G00624087Courtesy of TESLA, INC.
  23. Route harness and connect the air suspension compressor, valve block, and low side A/C pressure sensor.
    NOTE: 3x connectors, 1x line clip, Take care not to mix up the 2 air suspension connectors, Power supply is a slightly larger 2 wire connector and is connected near the subframe while the logic connector is directly at the air compressor.
    G00624088Courtesy of TESLA, INC.
  24. Connect front Fascia and FEM connectors to Front Harness at connector carrier on RH Body Beam.
    NOTE: 4x connectors.
    G00624089Courtesy of TESLA, INC.
  25. Connect RH front wheel speed sensor.
    NOTE: 1x connector.
    G00624090Courtesy of TESLA, INC.
  26. Connect RH headlamp.
    NOTE: 1x connector.
    G00624091Courtesy of TESLA, INC.
  27. Make RH harness leg connections at the Steering Gear.
    NOTE: 3x connectors, Ensure connector locking tabs are engaged after making connections.
    G00624092Courtesy of TESLA, INC.
  28. Secure front harness clips to RH body beam.
    NOTE: 4x barrel clips.
    G00624093Courtesy of TESLA, INC.
  29. Install the 3 ground fasteners at the RH Shock Tower.
    NOTE: 3x bolts, 13 mm, 15 N.m, 1x edge clip.
  30. Connect A/C lines by RH shock tower.
    NOTE: 2x bolts, 10 mm, 8 N.m, Install new O-rings prior to connecting lines.
    G00624094Courtesy of TESLA, INC.
  31. Secure A/C line bracket to shock tower cross member.
    NOTE: 1x nut, 10 mm, 6 N.m.
    G00624095Courtesy of TESLA, INC.
  32. Secure A/C line to RH side of A/C compressor.
    NOTE: 1x nut, 10 mm, 10 N.m, Install new O-ring prior to connecting lines.
    G00624096Courtesy of TESLA, INC.
  33. Route harness leg to ride height sensor and FRL and make connections.
    NOTE: 1x connector, 2x edge clips, Connect RH ride height sensor, harness edge clip, and secure FRL edge clip, The new harness should come with a new FRL attached, remove and discard the old FRL.
    G00624097Courtesy of TESLA, INC.
    G00624098Courtesy of TESLA, INC.
  34. Route the harness leg and make connections at the Brake Booster, Fluid Reservoir, and Master Cylinder.
    NOTE: 3x connectors, 1x edge clip.
  35. Route harness leg and make ground connection at the AC compressor.
    NOTE: 1x bolt, T25, 7 N.m.
    G00624099Courtesy of TESLA, INC.
    G00624100Courtesy of TESLA, INC.
  36. Secure main section of front trunk harness to RH side of bulkhead.
    NOTE: 1x clip, 2x nuts, 10 mm, 5 N.m.
    G00624101Courtesy of TESLA, INC.
  37. Re-position coolant bottle and install the fasteners securing the coolant bottle to the shock tower cross member.
    NOTE: 4x bolts, 10 mm, 6 N.m.
    G00624102Courtesy of TESLA, INC.
  38. Install 12V battery beam.
    NOTE: 2x bolts, T30, 3.5 N.m, 1x edge clip.
    G00624103Courtesy of TESLA, INC.
  39. Install the harness edge clip to the Battery Beam at RH end.
    NOTE: 1x clip.
    G00624104Courtesy of TESLA, INC.
  40. Secure coolant reservoir hose to 12V battery beam.
    NOTE: 1x bolt, T30, 5 N.m.
    G00624105Courtesy of TESLA, INC.
  41. Place 12V battery with bracket onto the battery beam and shock tower cross member for installation.
    NOTE: The 12V positive cable to the E-fuse module is still connected to the battery and can be placed for installation together.
  42. Install fasteners securing battery bracket to battery beam and shock tower cross member.
    NOTE: 2x bolts, T30, 5 N.m, 2x bolts, 13 mm, 15 N.m.
    G00624106Courtesy of TESLA, INC.
  43. Secure 12V power supply cable to E-fuse assembly.
    NOTE: 1x patch bolt, T30, 7 N.m, Use new bolt.
    G00624107Courtesy of TESLA, INC.
  44. Install screws securing small cables to side of E-fuse assembly.
    NOTE: 6x screws, PH2, 4 N.m, Make sure to install wires in proper positions as noted during removal.
    G00624108Courtesy of TESLA, INC.
  45. Connect logic connector to E-fuse assembly.
    NOTE: 1x connector, Secure red locking tab.
    G00624109Courtesy of TESLA, INC.
  46. Install screw securing small cable to front of E-fuse assembly.
    NOTE: 1x screw, PH2, 5 N.m, Make sure to install wire in proper position as noted during removal (H).
    G00624110Courtesy of TESLA, INC.
  47. Install bolts securing large cables to front of E-fuse assembly.
    NOTE: 2x patch bolts, T30, 5 N.m, Make sure to install wires in proper positions as noted during removal, Install new patch bolts (G, J).
    G00624111Courtesy of TESLA, INC.
  48. Install cover onto RH side of E-fuse assembly.
    NOTE: Align cover with cable cutouts and fully engage until audible click is heard, Image on left shows where to align cover with cables.
    G00624112Courtesy of TESLA, INC.
    G00624113Courtesy of TESLA, INC.
  49. Install bolts securing E-fuse cover onto E-fuse assembly.
    NOTE: 3x screws, T25, 2.7 N.m.
    G00624114Courtesy of TESLA, INC.
  50. Position E-fuse onto bracket.
    NOTE: 2x tabs, Route the 12V+ cable from E-fuse down to DCDC for installation.
    G00624115Courtesy of TESLA, INC.
    G00624116Courtesy of TESLA, INC.
  51. Install nut securing E-fuse assembly to electrical battery heater bracket.
    NOTE: 1x nut, 10 mm, 7 N.m.
    G00624117Courtesy of TESLA, INC.
  52. Route leg of harness for connections to electric battery heater, DCDC, and E-fuse ground down behind the bulkhead for installation.
    NOTE: 3x connectors, To be secured from underneath the vehicle later on.
    G00624118Courtesy of TESLA, INC.
  53. Connect TXV.
    NOTE: 1x connector.
    G00624119Courtesy of TESLA, INC.
  54. Secure harness clip to RH side of sealing grommet at Bulkhead.
    NOTE: 1x barrel clip.
    G00624120Courtesy of TESLA, INC.
  55. Connect coolant temp sensor to LH side of electrical battery heater.
    NOTE: 1x connector.
    G00624121Courtesy of TESLA, INC.
  56. Un-bundle the LH portion of the Front Harness and feed under LH side of the Shock Tower Cross Member and along the LH Body Beam.
    NOTE: Starting from the Bulkhead with the largest connector which is for the ABS control unit, route the harness under the coolant lines then along the inner side of the LH Shock Tower under the Shock Tower Support Cross Member then down the LH Body Beam, Be sure to route harness behind brake lines below Battery Beam, The connector for the ABS Control unit is the largest, recommend passing this connector through the opening between the brake lines and LH Body Beam first while routing harness, then continuing with the more forward sections of the harness until the harness fir tree clips can be seen near their locating holes under the Shock Tower Cross Member.
    G00624122Courtesy of TESLA, INC.
    G00624123Courtesy of TESLA, INC.
    G00624124Courtesy of TESLA, INC.
    G00624125Courtesy of TESLA, INC.
    G00624126Courtesy of TESLA, INC.
  57. Secure main LH section of front trunk harness to body below 2 coolant lines to the left of sealing grommet.
    NOTE: 1x barrel clip, Body stud where harness clip secures is NOT on bulkhead, it is on the rear section of the body beam and points straight up.
    G00624127Courtesy of TESLA, INC.
  58. Route leg of harness for LH side repeater and ride height sensor behind LH wheelhouse liner.
    NOTE: 3x edge clips.
    G00624128Courtesy of TESLA, INC.
  59. Secure connections to LH Side Repeater.
    NOTE: 2x connectors.
    G00624129Courtesy of TESLA, INC.
  60. Connect LH front ride height sensor.
    NOTE: 1x connector.
    G00624130Courtesy of TESLA, INC.
    G00624131Courtesy of TESLA, INC.
  61. Connect coolant temp sensor near LH front wheelhouse liner and bulkhead.
    NOTE: 1x connector.
    G00624132Courtesy of TESLA, INC.
  62. Dual Motor Vehicles Only:  Connect front drive unit logic connector.
    NOTE: 1x connector.
    G00624133Courtesy of TESLA, INC.
  63. Connect PT coolant pump 1.
    G00624134Courtesy of TESLA, INC.
  64. Secure front harness clips at LH inner shock tower.
    NOTE: 2x fir tree clips.
    G00624135Courtesy of TESLA, INC.
  65. Route and secure harness leg for coolant 4 way valve below battery beam and connect.
    NOTE: 1x connector, 1x fir tree clip, 2x line clips.
    G00624136Courtesy of TESLA, INC.
    G00624137Courtesy of TESLA, INC.
  66. Route and secure the harness ground at the LH Shock Tower.
    NOTE: 1x bolt, 13 mm, 15 N.m.
    G00624138Courtesy of TESLA, INC.
    G00624139Courtesy of TESLA, INC.
  67. Connect high side A/C pressure/temp sensor.
    NOTE: 1x connector.
    G00624140Courtesy of TESLA, INC.
  68. Secure brake line brackets on LH body beam.
    NOTE: 3x brackets, Rotate brackets into position and gently press brake lines into guide channels.
    G00624141Courtesy of TESLA, INC.
  69. Secure harness clips at LH body beam.
    G00624142Courtesy of TESLA, INC.
  70. Route harness leg for LH fan controller on outside of LH body beam.
    G00624143Courtesy of TESLA, INC.
  71. Connect LH front wheel speed sensor.
    NOTE: 1x connector.
    G00624144Courtesy of TESLA, INC.
  72. Connect LH headlamp.
    NOTE: 1x connector.
    G00624145Courtesy of TESLA, INC.
  73. Route harness leg near ABS pump and make connection to battery coolant pump 2.
    NOTE: 1x connector, 1x line clip.
    G00624146Courtesy of TESLA, INC.
  74. Connect ABS module connector.
    NOTE: 1x connector, Engage connector and flip latch to fully engage and lock connection.
    G00624147Courtesy of TESLA, INC.
  75. Route and secure harness leg for steering gear, air compressor, heat exchanger, and RKE antenna.
    NOTE: 1x line clip, 1x square fir tree clip, 1x fir tree clip.
    G00624148Courtesy of TESLA, INC.
  76. Connect Steering Gear.
    NOTE: 1x connector, Be sure to engage grey locking tab after making connection.
    G00624149Courtesy of TESLA, INC.
  77. Connect air suspension compressor.
    NOTE: 1x connector.
    G00624150Courtesy of TESLA, INC.
  78. Connect battery chiller and EXV.
    NOTE: 1x connector, Be sure to engage red locking tab after making connection.
    G00624151Courtesy of TESLA, INC.
  79. Connect RKE antenna.
    NOTE: 1x connector.
    G00624152Courtesy of TESLA, INC.
  80. Raise vehicle to comfortable working height.
  81. Route and secure the E-fuse harness ground at the bottom of the E-fuse Assembly.
    NOTE: 1x bolt, T25, 4 N.m, Install new patch bolt.
    G00624153Courtesy of TESLA, INC.
  82. Connect lower battery coolant heater connection and secure to bracket.
    NOTE: 1x connector, 1x clip.
    G00624154Courtesy of TESLA, INC.
  83. Connect DCDC logic connector.
    NOTE: 1x connector.
    G00624155Courtesy of TESLA, INC.
  84. Route and install 12V positive terminal to DCDC.
    NOTE: 1x bolt, 13 mm, 13 N.m.
    G00624156Courtesy of TESLA, INC.
  85. Install HV cables to FJB.
    NOTE: 4x bolts, T30, 7 N.m.
    G00624157Courtesy of TESLA, INC.
  86. Install fasteners securing FJB to bulkhead.
    NOTE: 2x bolts, 10 mm, 7 N.m, 1x nut, 10 mm, 9 N.m.
    G00624158Courtesy of TESLA, INC.
    G00624159Courtesy of TESLA, INC.
  87. Secure FJB HV harness clip at bulkhead.
    NOTE: 1x clip.
    G00624160Courtesy of TESLA, INC.
  88. Connect FJB logic connector.
    NOTE: 1x connector.
    G00624161Courtesy of TESLA, INC.
  89. Secure harness for battery coolant pump 1 connector.
    NOTE: 2x barrel clips, 1x fir tree clip.
    G00624162Courtesy of TESLA, INC.
    G00624163Courtesy of TESLA, INC.
  90. Connect battery coolant pump 1.
    NOTE: 1x connector.
    G00624164Courtesy of TESLA, INC.
  91. Install the bolts securing the Bash Plate Stamping and Skid Plate to the front Subframe.
    NOTE: 2x bolts, 10 mm, 9 N.m.
    G00624165Courtesy of TESLA, INC.
  92. Connect LH fan control module and secure harness.
    NOTE: 1x connector, 1x clip.
    G00624166Courtesy of TESLA, INC.
  93. Connect RH fan control module and secure harness.
    NOTE: 1x connector, 1x clip.
    G00624167Courtesy of TESLA, INC.
  94. Connect coolant 3 way valve.
    NOTE: 1x connector.
    G00624168Courtesy of TESLA, INC.
  95. Install front aero shield into position and hand tighten center bolts.
    NOTE: 2x bolts, 10 mm, 3 N.m, Make sure the front of the aero shield is inserted into tabs on fascia.
    G00624169Courtesy of TESLA, INC.
  96. Install clips securing front aero shield to vehicle.
    NOTE: 10x push clips.
    G00624170Courtesy of TESLA, INC.
  97. Install and tighten bolts securing front aero shield to vehicle.
    NOTE: 12x bolts, 10 mm, 3 N.m.
    G00624171Courtesy of TESLA, INC.
  98. Lower vehicle to comfortable working height.
  99. Connect RH side repeater.
    NOTE: 2x connectors.
    G00624172Courtesy of TESLA, INC.
  100. Place washer bottle for installation.
    G00624173Courtesy of TESLA, INC.
  101. Install fasteners securing washer bottle to body.
    NOTE: 1x bolts, 10 mm, 5 N.m, 2x nuts, 10 mm, 5 N.m, 1x clip.
    G00624174Courtesy of TESLA, INC.
    G00624175Courtesy of TESLA, INC.
    G00624176Courtesy of TESLA, INC.
  102. Secure washer fluid line to pump.
    NOTE: 1x hose.
    G00624177Courtesy of TESLA, INC.
  103. Secure harness clips to washer bottle.
    NOTE: 2x edge clips.
    G00624178Courtesy of TESLA, INC.
  104. Connect washer fluid pump.
    NOTE: 1x connector.
    G00624179Courtesy of TESLA, INC.
  105. Connect washer fluid level sensor.
    NOTE: 1x connector.
    G00624180Courtesy of TESLA, INC.
  106. Connect front trunk harness to hood harness.
    NOTE: 1x connector.
    G00624181Courtesy of TESLA, INC.
  107. Secure rear portion of RH front wheelhouse liner to vehicle.
    NOTE: 1x nut, 10 mm, 4 N.m, 5x push clips.
    G00624182Courtesy of TESLA, INC.
  108. Install RH front wheel.
    NOTE: 5x nuts, 21 mm, 175 N.m.
    G00624183Courtesy of TESLA, INC.
  109. Lower vehicle until tires are touching the ground.
  110. Torque the RH Lug Nuts to specification.
    NOTE: 5x lug nuts, 21 mm, 175 N.m. Wheel lugs should always be torqued in a star pattern and then double checked after all 5 lug nuts have been torqued. Install lug nut covers if equipped.
    G00624184Courtesy of TESLA, INC.
    G00624185Courtesy of TESLA, INC.
  111. Top off windshield washer fluid.
    G00624186Courtesy of TESLA, INC.
  112. Connect PTC heater HV Cable at FJB.
    NOTE: 1x connector.
    G00624187Courtesy of TESLA, INC.
  113. Install 12V cable cover to E-fuse assembly and secure.
    NOTE: 1x patch bolt, T30, 3.5 N.m, Use new bolt.
    G00624188Courtesy of TESLA, INC.
  114. Place air suspension reservoir into position.
    G00624189Courtesy of TESLA, INC.
  115. Loosely install air suspension reservoir brackets.
    NOTE: 2x screws, T25, 2.5 N.m.
    G00624190Courtesy of TESLA, INC.
  116. Install wiper motor.
    NOTE: 3x bolts, 10 mm, 6 N.m, 1x connector.
    G00624191Courtesy of TESLA, INC.
    G00624192Courtesy of TESLA, INC.
  117. Secure air suspension reservoir brackets.
    NOTE: 2x screws, T25, 2.5 N.m.
  118. Install LH shock tower brace.
    NOTE: 1x bolt, 13 mm, 30 N.m, 2x bolts, 13 mm, 20 N.m.
    G00624193Courtesy of TESLA, INC.
    G00624194Courtesy of TESLA, INC.
    G00624195Courtesy of TESLA, INC.
  119. Install RH shock tower brace.
    NOTE: 2x bolts, 13 mm, 20 N.m, 1x bolt, 13 mm, 30 N.m.
    G00624196Courtesy of TESLA, INC.
    G00624197Courtesy of TESLA, INC.
  120. Place fuse box into vehicle and reconnect harness connectors.
    NOTE: 3x connectors.
    G00624198Courtesy of TESLA, INC.
  121. Position fuse box onto body.
    NOTE: 2x tabs.
    G00624199Courtesy of TESLA, INC.
  122. Install new nut securing 12V supply cable to DCDC.
    NOTE: 1x nyloc nut, 13 mm, 12 N.m, Install new nyloc nut.
    G00624200Courtesy of TESLA, INC.
  123. Install bolts securing fuse box to body.
    NOTE: 2x bolts, 10 mm, 6 N.m.
    G00624201Courtesy of TESLA, INC.
  124. Reconnect pyrotechnic fuse connector.
    NOTE: 1x connector, Be sure to secure locking clip.
    G00624202Courtesy of TESLA, INC.
  125. Secure clips holding 12V battery supply cable to fuse box and strut tower beam.
    NOTE: 3x clips.
    G00624203Courtesy of TESLA, INC.
  126. Reinstall fuse box cover.
    NOTE: 2x clips.
    G00624204Courtesy of TESLA, INC.
  127. Secure front trunk harness ground at shock tower cross member.
    NOTE: 1x bolt, 13 mm, 15 N.m.
    G00624205Courtesy of TESLA, INC.
  128. Secure front trunk harness ground to 12V negative terminal clamp.
    NOTE: 1x edge clip, 1x nyloc nut, 10 mm, 5 N.m, Install new nut.
    G00624206Courtesy of TESLA, INC.
  129. Install underhood storage unit.
    NOTE: Install harness and grommet.
    G00624207Courtesy of TESLA, INC.
  130. Install bolts and clips securing underhood storage unit.
    NOTE: 2x bolts, 10 mm, 7 N.m, 2x push clips.
    G00624208Courtesy of TESLA, INC.
  131. Install underhood storage carpet and reconnect light and release switch connectors.
    NOTE: 2x connectors, Secure edges of carpet underneath underhood storage unit seal.
    G00624209Courtesy of TESLA, INC.
scientia non olet · About LEMON Manuals