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Home >> Tesla >> 2019 >> Model S Performance >> Repair and Diagnosis (Single Page) >> Accessories & Equipment >> Interior/Illumination Lights >> Electrical System -- Model S >> Harnesses >> Harnesses - Main Lower Dash and Front Trunk (RHD) (Dual Motor) - Remove And Replace >> Install Front Trunk Harness

Install Front Trunk Harness

  1. Place new front trunk harness into the front of the vehicle.
    G15033731Courtesy 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.
    G15033732Courtesy of TESLA, INC.
    G15033733Courtesy 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.
    G15033734Courtesy of TESLA, INC.
    G15033735Courtesy of TESLA, INC.
  4. Make connections at the Air Suspension Control Module.
    NOTE: 2x connectors.
    G15033736Courtesy of TESLA, INC.
  5. Secure the Front Harness Ground connection at the In-Cabin Fuse Box.
    NOTE: 1x nut, 10 mm, 6 N.m.
    G15033737Courtesy of TESLA, INC.
  6. Connect the Front Harness connector at the In-Cabin Fuse Box.
    NOTE: 1x connector.
    G15033738Courtesy 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.
    G15033739Courtesy of TESLA, INC.
    G15033740Courtesy 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.
    G15033741Courtesy of TESLA, INC.
    G15033742Courtesy 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.
    G15033743Courtesy 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.
    G15033744Courtesy of TESLA, INC.
    G15033745Courtesy of TESLA, INC.
  12. Secure harness clips near Brake Booster.
    NOTE: 2x clips.
    G15033746Courtesy of TESLA, INC.
  13. Secure harness clips at Bulkhead to right of Brake Booster and on body seam in fender well.
    NOTE: 2x clips.
    G15033747Courtesy of TESLA, INC.
  14. Route FJB logic connector down bulkhead along FJB HV cables.
    NOTE: 1x connector.
    G15033748Courtesy of TESLA, INC.
    G15033749Courtesy 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.
    G15033750Courtesy 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.
    G15033751Courtesy 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.
    G15033752Courtesy 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.
    G15033753Courtesy of TESLA, INC.
    G15033754Courtesy 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.
    G15033755Courtesy 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.
    G15033756Courtesy of TESLA, INC.
  22. Install the FEM Connector Carrier to the RH Body Beam.
    NOTE: 2x nuts, 10 mm, plastic, 3 N.m.
    G15033757Courtesy 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.
    G15033758Courtesy of TESLA, INC.
  24. Connect front Fascia and FEM connectors to Front Harness at connector carrier on RH Body Beam.
    NOTE: 4x connectors.
    G15033759Courtesy of TESLA, INC.
  25. Connect RH front wheel speed sensor.
    NOTE: 1x connector.
    G15033760Courtesy of TESLA, INC.
  26. Connect RH headlamp.
    NOTE: 1x connector.
    G15033761Courtesy 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.
    G15033762Courtesy of TESLA, INC.
  28. Secure front harness clips to RH body beam.
    NOTE: 4x barrel clips.
    G15033763Courtesy 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.
    G15033764Courtesy of TESLA, INC.
  31. Secure A/C line bracket to shock tower cross member.
    NOTE: 1x nut, 10 mm, 6 N.m.
    G15033765Courtesy 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.
    G15033766Courtesy 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.
    G15033767Courtesy of TESLA, INC.
    G15033768Courtesy 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.
    G15033769Courtesy of TESLA, INC.
    G15033770Courtesy 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.
    G15033771Courtesy 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.
    G15033772Courtesy of TESLA, INC.
  38. Install 12V battery beam.
    NOTE: 2x bolts, T30, 3.5 N.m, 1x edge clip.
    G15033773Courtesy of TESLA, INC.
  39. Install the harness edge clip to the Battery Beam at RH end.
    NOTE: 1x clip.
    G15033774Courtesy of TESLA, INC.
  40. Secure coolant reservoir hose to 12V battery beam.
    NOTE: 1x bolt, T30, 5 N.m.
    G15033775Courtesy 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.
    G15033776Courtesy of TESLA, INC.
  43. Secure 12V power supply cable to E-fuse assembly.
    NOTE: 1x patch bolt, T30, 7 N.m, Use new bolt.
    G15033777Courtesy 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.
    G15033778Courtesy of TESLA, INC.
  45. Connect logic connector to E-fuse assembly.
    NOTE: 1x connector, Secure red locking tab.
    G15033779Courtesy 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).
    G15033780Courtesy 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).
    G15033781Courtesy 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.
    G15033782Courtesy of TESLA, INC.
    G15033783Courtesy of TESLA, INC.
  49. Install bolts securing E-fuse cover onto E-fuse assembly.
    NOTE: 3x screws, T25, 2.7 N.m.
    G15033784Courtesy of TESLA, INC.
  50. Position E-fuse onto bracket.
    NOTE: 2x tabs, Route the 12V+ cable from E-fuse down to DCDC for installation.
    G15033785Courtesy of TESLA, INC.
    G15033786Courtesy of TESLA, INC.
  51. Install nut securing E-fuse assembly to electrical battery heater bracket.
    NOTE: 1x nut, 10 mm, 7 N.m.
    G15033787Courtesy 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.
    G15033788Courtesy of TESLA, INC.
  53. Connect TXV.
    NOTE: 1x connector.
    G15033789Courtesy of TESLA, INC.
  54. Secure harness clip to RH side of sealing grommet at Bulkhead.
    NOTE: 1x barrel clip.
    G15033790Courtesy of TESLA, INC.
  55. Connect coolant temp sensor to LH side of electrical battery heater.
    NOTE: 1x connector.
    G15033791Courtesy 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.
    G15033792Courtesy of TESLA, INC.
    G15033793Courtesy of TESLA, INC.
    G15033794Courtesy of TESLA, INC.
    G15033795Courtesy of TESLA, INC.
    G15033796Courtesy 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.
    G15033797Courtesy of TESLA, INC.
  58. Route leg of harness for LH side repeater and ride height sensor behind LH wheelhouse liner.
    NOTE: 3x edge clips.
    G15033798Courtesy of TESLA, INC.
  59. Secure connections to LH Side Repeater.
    NOTE: 2x connectors.
    G15033799Courtesy of TESLA, INC.
  60. Connect LH front ride height sensor.
    NOTE: 1x connector.
    G15033800Courtesy of TESLA, INC.
    G15033801Courtesy of TESLA, INC.
  61. Connect coolant temp sensor near LH front wheelhouse liner and bulkhead.
    NOTE: 1x connector.
    G15033802Courtesy of TESLA, INC.
  62. Dual Motor Vehicles Only:  Connect front drive unit logic connector.
    NOTE: 1x connector.
    G15033803Courtesy of TESLA, INC.
  63. Connect PT coolant pump 1.
    G15033804Courtesy of TESLA, INC.
  64. Secure front harness clips at LH inner shock tower.
    NOTE: 2x fir tree clips.
    G15033805Courtesy 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.
    G15033806Courtesy of TESLA, INC.
    G15033807Courtesy of TESLA, INC.
  66. Route and secure the harness ground at the LH Shock Tower.
    NOTE: 1x bolt, 13 mm, 15 N.m.
    G15033808Courtesy of TESLA, INC.
    G15033809Courtesy of TESLA, INC.
  67. Connect high side A/C pressure/temp sensor.
    NOTE: 1x connector.
    G15033810Courtesy 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.
    G15033811Courtesy of TESLA, INC.
  69. Secure harness clips at LH body beam.
    G15033812Courtesy of TESLA, INC.
  70. Route harness leg for LH fan controller on outside of LH body beam.
    G15033813Courtesy of TESLA, INC.
  71. Connect LH front wheel speed sensor.
    NOTE: 1x connector.
    G15033814Courtesy of TESLA, INC.
  72. Connect LH headlamp.
    NOTE: 1x connector.
    G15033815Courtesy of TESLA, INC.
  73. Route harness leg near ABS pump and make connection to battery coolant pump 2.
    NOTE: 1x connector, 1x line clip.
    G15033816Courtesy of TESLA, INC.
  74. Connect ABS module connector.
    NOTE: 1x connector, Engage connector and flip latch to fully engage and lock connection.
    G15033817Courtesy 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.
    G15033818Courtesy of TESLA, INC.
  76. Connect Steering Gear.
    NOTE: 1x connector, Be sure to engage grey locking tab after making connection.
    G15033819Courtesy of TESLA, INC.
  77. Connect air suspension compressor.
    NOTE: 1x connector.
    G15033820Courtesy of TESLA, INC.
  78. Connect battery chiller and EXV.
    NOTE: 1x connector, Be sure to engage red locking tab after making connection.
    G15033821Courtesy of TESLA, INC.
  79. Connect RKE antenna.
    NOTE: 1x connector.
    G15033822Courtesy 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.
    G15033823Courtesy of TESLA, INC.
  82. Connect lower battery coolant heater connection and secure to bracket.
    NOTE: 1x connector, 1x clip.
    G15033824Courtesy of TESLA, INC.
  83. Connect DCDC logic connector.
    NOTE: 1x connector.
    G15033825Courtesy of TESLA, INC.
  84. Route and install 12V positive terminal to DCDC.
    NOTE: 1x bolt, 13 mm, 13 N.m.
    G15033826Courtesy of TESLA, INC.
  85. Install HV cables to FJB.
    NOTE: 4x bolts, T30, 7 N.m.
    G15033827Courtesy 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.
    G15033828Courtesy of TESLA, INC.
    G15033829Courtesy of TESLA, INC.
  87. Secure FJB HV harness clip at bulkhead.
    NOTE: 1x clip.
    G15033830Courtesy of TESLA, INC.
  88. Connect FJB logic connector.
    NOTE: 1x connector.
    G15033831Courtesy of TESLA, INC.
  89. Secure harness for battery coolant pump 1 connector.
    NOTE: 2x barrel clips, 1x fir tree clip.
    G15033832Courtesy of TESLA, INC.
    G15033833Courtesy of TESLA, INC.
  90. Connect battery coolant pump 1.
    NOTE: 1x connector.
    G15033834Courtesy 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.
    G15033835Courtesy of TESLA, INC.
  92. Connect LH fan control module and secure harness.
    NOTE: 1x connector, 1x clip.
    G15033836Courtesy of TESLA, INC.
  93. Connect RH fan control module and secure harness.
    NOTE: 1x connector, 1x clip.
    G15033837Courtesy of TESLA, INC.
  94. Connect coolant 3 way valve.
    NOTE: 1x connector.
    G15033838Courtesy 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.
    G15033839Courtesy of TESLA, INC.
  96. Install clips securing front aero shield to vehicle.
    NOTE: 10x push clips.
    G15033840Courtesy of TESLA, INC.
  97. Install and tighten bolts securing front aero shield to vehicle.
    NOTE: 12x bolts, 10 mm, 3 N.m.
    G15033841Courtesy of TESLA, INC.
  98. Lower vehicle to comfortable working height.
  99. Connect RH side repeater.
    NOTE: 2x connectors.
    G15033842Courtesy of TESLA, INC.
  100. Place washer bottle for installation.
    G15033843Courtesy 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.
    G15033844Courtesy of TESLA, INC.
    G15033845Courtesy of TESLA, INC.
    G15033846Courtesy of TESLA, INC.
  102. Secure washer fluid line to pump.
    NOTE: 1x hose.
    G15033847Courtesy of TESLA, INC.
  103. Secure harness clips to washer bottle.
    NOTE: 2x edge clips.
    G15033848Courtesy of TESLA, INC.
  104. Connect washer fluid pump.
    NOTE: 1x connector.
    G15033849Courtesy of TESLA, INC.
  105. Connect washer fluid level sensor.
    NOTE: 1x connector.
    G15033850Courtesy of TESLA, INC.
  106. Connect front trunk harness to hood harness.
    NOTE: 1x connector.
    G15033851Courtesy 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.
    G15033852Courtesy of TESLA, INC.
  108. Install RH front wheel.
    NOTE: 5x nuts, 21 mm, 175 N.m.
    G15033853Courtesy 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.
    G15033854Courtesy of TESLA, INC.
    G15033855Courtesy of TESLA, INC.
  111. Top off windshield washer fluid.
    G15033856Courtesy of TESLA, INC.
  112. Connect PTC heater HV Cable at FJB.
    NOTE: 1x connector.
    G15033857Courtesy 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.
    G15033858Courtesy of TESLA, INC.
  114. Place air suspension reservoir into position.
    G15033859Courtesy of TESLA, INC.
  115. Loosely install air suspension reservoir brackets.
    NOTE: 2x screws, T25, 2.5 N.m.
    G15033860Courtesy of TESLA, INC.
  116. Install wiper motor.
    NOTE: 3x bolts, 10 mm, 6 N.m, 1x connector.
    G15033861Courtesy of TESLA, INC.
    G15033862Courtesy 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.
    G15033863Courtesy of TESLA, INC.
    G15033864Courtesy of TESLA, INC.
    G15033865Courtesy of TESLA, INC.
  119. Install RH shock tower brace.
    NOTE: 2x bolts, 13 mm, 20 N.m, 1x bolt, 13 mm, 30 N.m.
    G15033866Courtesy of TESLA, INC.
    G15033867Courtesy of TESLA, INC.
  120. Place fuse box into vehicle and reconnect harness connectors.
    NOTE: 3x connectors.
    G15033868Courtesy of TESLA, INC.
  121. Position fuse box onto body.
    NOTE: 2x tabs.
    G15033869Courtesy 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.
    G15033870Courtesy of TESLA, INC.
  123. Install bolts securing fuse box to body.
    NOTE: 2x bolts, 10 mm, 6 N.m.
    G15033871Courtesy of TESLA, INC.
  124. Reconnect pyrotechnic fuse connector.
    NOTE: 1x connector, Be sure to secure locking clip.
    G15033872Courtesy of TESLA, INC.
  125. Secure clips holding 12V battery supply cable to fuse box and strut tower beam.
    NOTE: 3x clips.
    G15033873Courtesy of TESLA, INC.
  126. Reinstall fuse box cover.
    NOTE: 2x clips.
    G15033874Courtesy of TESLA, INC.
  127. Secure front trunk harness ground at shock tower cross member.
    NOTE: 1x bolt, 13 mm, 15 N.m.
    G15033875Courtesy 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.
    G15033876Courtesy of TESLA, INC.
  129. Install underhood storage unit.
    NOTE: Install harness and grommet.
    G15033877Courtesy of TESLA, INC.
  130. Install bolts and clips securing underhood storage unit.
    NOTE: 2x bolts, 10 mm, 7 N.m, 2x push clips.
    G15033878Courtesy 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.
    G15033879Courtesy of TESLA, INC.
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