- Position lift posts under vehicle lift points.
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- Raise and support vehicle.
NOTE:
Set air suspension to "Jack Mode" if equipped.
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- Loosen RH front wheel.
NOTE:
5x nuts, 21 mm, 175 N.m.
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- Raise vehicle partially and lower onto locks.
- Remove RH front wheel.
NOTE:
5x nuts, 21 mm, 175 N.m.
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- Remove the rear half of the RF Arch Liner.
NOTE:
1x bolt, 10 mm, 4 N.m, 4x clips.
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- Disconnect connector from front trunk harness to hood harness.
NOTE:
1x connector.
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- Disconnect washer fluid level sensor.
NOTE:
1x connector.
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- Disconnect washer pump.
NOTE:
1x connector.
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- Release harness clips from washer bottle.
NOTE:
2x edge clips.
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- Disconnect washer fluid line.
NOTE:
1x hose connection to washer pump, Fluid in reservoir will drain out once hose is disconnected, Place a drain bucket underneath the reservoir to catch the fluid.
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- Release fasteners securing washer bottle to body.
NOTE:
1x bolt, 10 mm, 5 N.m, 2x nuts 10 mm, 5 N.m, 1x clip.
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- Remove washer bottle from vehicle.
NOTE:
Maneuver down and out through wheel well.
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- Disconnect RH side repeater.
NOTE:
2x connectors.
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- Pass harness through opening behind RH shock tower for harness removal.
NOTE:
Pass under HV cables and over top of brake master cylinder following pathway of larger section of front trunk harness along the bulkhead.
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- Raise vehicle fully and lower onto locks.
- Remove clips securing front aero shield to vehicle.
NOTE:
10x push clips.
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- Remove bolts securing front aero shield to vehicle and remove.
NOTE:
12x bolts, 10 mm, 4 N.m.
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- Disconnect the RH fan control module.
NOTE:
1x connector, Module is on the outer side of the RH body beam and can be accessed from underneath the vehicle with front aero shield removed.
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- Disconnect coolant 3 way valve at RH front lower corner of front subframe.
NOTE:
1x connector.
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- Pass leg of harness with fan control module coolant 3 way valve connectors up above the RH body rail for harness removal.
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- Disconnect LH fan control module.
NOTE:
1x connector, Module is on the outer side of the LH body beam and can be accessed from underneath the vehicle with front aero shield removed.
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- Pass leg of harness with fan control module connector up above the LH body rail for harness removal.
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- Remove the bolts securing the bash plate stamping and skid plate to the front subframe skid plate.
NOTE:
2x bolts, 10 mm, 9 N.m.
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- Disconnect battery coolant pump 1.
NOTE:
1x connector.
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- Release all front trunk harness clips for leg of harness running to battery coolant pump 1.
NOTE:
1x fir tree clip, 2x barrel clips.
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- Remove the 12V positive terminal from the bottom of the DCDC.
NOTE:
1x bolt, 13 mm, 13 N.m.
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- Remove the fasteners securing the FJB to rapid splitter HV harness.
NOTE:
4x bolts, T30, 7 N.m, Discard bolts after removal.
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- Release the HV cables from the FJB.
NOTE:
2x cables.
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- Release HV harness clip at bulkhead.
NOTE:
1x clip, This will allow the HV harness to be moved out of the way for the front trunk harness to pass behind the HV harness during removal.
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- Remove fasteners securing bottom of front junction box.
NOTE:
2x bolts, 10 mm, 7 N.m.
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- Disconnect logic connector from front junction box.
NOTE:
1x connector.
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- Remove fastener securing RH side of front junction box.
NOTE:
1x nut, 10 mm, 9 N.m.
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- Pass the logic connector by the HV cables up the bulkhead into the cavity near the RH shock tower for harness removal.
NOTE:
1x harness clip to brake line, Tilt the front junction box away from the bulkhead to make room for the connector.
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Courtesy of TESLA, INC.
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- Disconnect the logic connector from the DCDC converter.
NOTE:
1x connector, Tilt front junction box away from bulkhead to make room for connector to be disconnected.
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- Release the harness and connector edge clip from the bottom of the electric battery heater above the DCDC converter, and disconnect the connector to the electric battery heater.
NOTE:
1x edge clip, 1x connector.
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Courtesy of TESLA, INC.
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- Release the front harness ground connection from the bottom of the E-fuse assembly.
NOTE:
1x patch bolt, T25, 4 N.m, Discard bolt after removal.
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- Pass DCDC logic connector, electric battery heater connector, and E-fuse ground cable up the bulkhead behind front junction box towards the top of the bulkhead for harness removal.
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- Lower vehicle until tires are touching the ground.
- Disconnect light and release switch connectors and remove underhood storage carpet.
NOTE:
2x connectors, Release edge of carpet from underneath underhood storage unit seal.
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- Remove underhood storage unit.
NOTE:
2x bolts, 10 mm, 7 N.m, 2x push clips.
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- Push wiring harness grommet through underhood storage unit and remove.
NOTE:
1x grommet.
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- Remove fuse box cover.
NOTE:
2x clips.
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- Remove 12V supply cable to DCDC.
NOTE:
1x nyloc nut, 13 mm, 12 N.m, 1x clip, Discard nut after removal.
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- Release clips securing 12V battery supply cable to fuse box and strut tower cross beam.
NOTE:
3x clips.
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- Disconnect pyrotechnic fuse connector.
NOTE:
1x connector, Gently lift up orange lock tab to release connector.
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- Remove bolts securing fuse box to body.
NOTE:
2x bolts, 10 mm, 6 N.m.
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- Release fuse box from body.
NOTE:
2x tabs, Slide fuse box to RH side to release tabs and then lift.
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- Disconnect remaining connectors from bottom of fuse box.
NOTE:
3x connectors, Depress locking tabs on sides of flip type connector and flip lever on connector to reseal.
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- Remove front trunk harness ground to left of fuse box.
NOTE:
1x bolt, 13 mm, 15 N.m.
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- Remove fuse box from vehicle.
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- Remove LH shock tower brace.
NOTE:
1x bolt, 13 mm, 30 N.m, 2x bolts, 13 mm, 20 N.m.
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Courtesy of TESLA, INC.
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- Remove RH shock tower brace.
NOTE:
1x bolt, 13 mm, 30 N.m, 2x bolts, 13 mm, 20 N.m.
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Courtesy of TESLA, INC.
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- Remove wiper motor.
NOTE:
3x bolts, 10 mm, 6 N.m, 1x connector.
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- Remove screws securing air suspension reservoir to bracket.
NOTE:
2x screws, T25, 2.5 N.m.
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- Set air suspension reservoir aside for access.
NOTE:
Maneuver below AC line.
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- Reach in behind the LH fender and disconnect the connections at LH Side Repeater.
NOTE:
2x connectors, Access the area by reaching in near the shock tower, the arch liner can be pressed down gently to allow room for reaching into connector locations, the connector release tabs are at the top side top side of the connectors.
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Courtesy of TESLA, INC.
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- Disconnect LH front ride height sensor.
NOTE:
1x connector.
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Courtesy of TESLA, INC.
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- Release clips securing portion of front trunk harness previously disconnected to LH front inner fender area.
NOTE:
2x edge clips.
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- Release harness clip at LH front shock tower.
NOTE:
1x edge clip.
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- Disconnect coolant temp sensor near LH side of bulkhead.
NOTE:
1x connector.
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- Disconnect PT coolant pump 1.
NOTE:
1x connector.
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- Dual Motor Vehicles Only:
Disconnect front drive unit logic connector.
NOTE:
1x connector, Release red lock tab and depress connector lock to disconnect.
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- Release harness ground to the 12V negative battery terminal.
NOTE:
1x nyloc nut, 10 mm, 5 N.m, Discard after removal.
Courtesy of TESLA, INC.
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- Release clip for harness 12V ground at LH shock tower.
NOTE:
1x edge clip.
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- Disconnect high side A/C pressure/temp sensor.
NOTE:
1x connector.
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- Release the front harness ground from the LH front side of the LH Shock Tower.
NOTE:
1x bolt, 13 mm, 15 N.m.
Courtesy of TESLA, INC.
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- Release connector for LH front wheel speed sensor.
NOTE:
1x connector.
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- Disconnect LH headlamp.
NOTE:
1x connector, Take care when removing connector, as release tab must be accessed from the front side of the connector under the outer casing.
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- Release harness clips from studs on LH front body beam.
NOTE:
5x clips.
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- Disconnect battery coolant pump 2.
NOTE:
1x connector.
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- Release connector at front RKE antenna.
NOTE:
1x connector.
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- Release connector at ABS module.
NOTE:
1x flip type connector, Depress the connector lever lock tab and rotate connector lever upwards to release.
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- Disconnect battery chiller and EXV connector.
NOTE:
1x connector, Release red locking tab and depress release tab to disconnect.
Courtesy of TESLA, INC.
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- Release harness fir tree clip near battery chiller.
NOTE:
1x clip.
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- Release connector at air suspension compressor.
NOTE:
1x connector, Release tab is on bottom side of connector.
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- Release harness clip at middle of subframe in front of steering gear.
NOTE:
1x fir tree clip.
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- Feed left leg of front trunk harness out up to LH shock tower.
NOTE:
Take care not to damage components while removing the harness.
Courtesy of TESLA, INC.
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- Disconnect coolant 4 way valve.
NOTE:
1x connector.
- Release harness clip from 4 way valve.
NOTE:
1x clip.
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- Release harness clips from brake lines near LH shock tower.
NOTE:
2x line clips.
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- Release harness clips on LH side under shock tower cross member.
NOTE:
2x fir tree clips.
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- Release brackets holding the brake lines in place near LH body beam.
NOTE:
3x brackets, Only release the upper brake lines, Gently pry bracket off of brake lines and rotate bracket 90 degrees to allow for more movement in brake lines, this will allow more room for harness connections, mainly the ABS controller connector, to pass through opening between brake lines and body beam.
Courtesy of TESLA, INC.
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- Feed harness out under LH side of shock tower cross member to bulkhead then up and over shock tower cross member.
NOTE:
Take care not to damage surrounding components while removing the harness.
Courtesy of TESLA, INC.
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- Disconnect coolant temp sensor near electrical battery heater.
NOTE:
1x connector.
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- Release harness edge clip near harness sealing grommet at Bulkhead.
NOTE:
1x barrel clip.
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- Disconnect PTC heater HV connection at HVJB.
NOTE:
1x connector, Release red lock tab and depress connector release to disconnect.
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- Remove fasteners securing harness carrier bracket to Firewall below TXV.
NOTE:
2x nuts, 10 mm, 5 N.m.
Courtesy of TESLA, INC.
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- Disconnect TXV.
NOTE:
1x connector.
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- Remove bolt securing 12V cable cover to E-fuse assembly and remove cover.
NOTE:
1x patch bolt, 10 mm, 3.5 N.m, Discard bolt after removal.
Courtesy of TESLA, INC.
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Courtesy of TESLA, INC.
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- Remove nut securing E-fuse assembly to electrical battery heater bracket.
NOTE:
1x nut, 10 mm, 7 N.m.
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- Lift up to release E-fuse from tabs at bottom.
NOTE:
2x tabs.
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Courtesy of TESLA, INC.
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- Lift E-fuse assembly up for access to front cover.
NOTE:
Use caution with front drive unit coolant hose.
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- Remove bolts securing E-fuse cover from E-fuse assembly.
NOTE:
3x bolts, T25, 2.7 N.m, Pay attention to bolt locations as 1 is different from the others.
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- Release cover from RH side of E-fuse assembly to expose RH side fasteners.
NOTE:
2x tabs, Release tabs and slide cover off.
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- Remove bolts securing large cables to bottom of E-fuse assembly.
NOTE:
2x patch bolts, T30, 5 N.m, Note location of labeled wires during removal, Discard bolts after removal.
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- Remove screw securing small cable to bottom of E-fuse assembly.
NOTE:
1x screw, PH2, 5 N.m, Note location of labeled wires during removal.
Courtesy of TESLA, INC.
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- Disconnect logic connector from E-fuse assembly.
NOTE:
1x connector, Release red locking tab.
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- Remove screws securing small cables to side of E-fuse assembly.
NOTE:
6x screws, PH2, 4 N.m, Note location of labeled wires during removal.
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- Remove bolt securing 12V power supply cable to E-fuse assembly and remove E-fuse assembly from vehicle.
NOTE:
1x patch bolt, T30, 7 N.m, Discard bolt after removal.
Courtesy of TESLA, INC.
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- Release front harness clips from RH side of Bulkhead near Electromechanical Brake Booster.
NOTE:
2x clips.
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- Release edge clip at brake master cylinder.
NOTE:
1x clip.
- Disconnect logic connector from electromechanical brake booster.
NOTE:
1x locking connector, Release red locking tab, Depress black locking tab, Release lever.
- Disconnect pedal sensor connection.
NOTE:
1x connector.
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- Disconnect brake fluid level sensor.
NOTE:
1x connector.
- Disconnect RH front ride height sensor.
NOTE:
1x connector.
Courtesy of TESLA, INC.
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- Feed first responder loop and ride height sensor connectors out from under the brake master cylinder for harness removal.
Courtesy of TESLA, INC.
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Courtesy of TESLA, INC.
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- Release harness clip on rear inner portion of shock tower below shock tower cross member.
NOTE:
1x clip.
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- Release coolant hose clip at RH shock tower.
NOTE:
1x edge clip, Done to make more room for harness removal.
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- Release harness clip under shock tower cross member at RH side of body.
NOTE:
1x barrel clip.
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- Release chassis ground connections from front side of RH Shock Tower.
NOTE:
3x bolts, 13 mm, 15 N.m.
Courtesy of TESLA, INC.
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- Release harness clips at RH Shock Tower and Body Beam.
NOTE:
6x clips.
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- Disconnect steering gear connectors.
NOTE:
4x connectors, Only release the front trunk harness connectors, It is not necessary to release connectors between the steering rack and controller during front trunk harness replacement, For the larger 2 connectors slide the red locking tab out and then depress release tab to disconnect, For the lower 2 connectors slide out the gray locking tab out and then depress release tab to disconnect.
Courtesy of TESLA, INC.
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- Disconnect RH headlamp.
NOTE:
1x connector, Take care when removing connector, the release tab must be accessed from the front side of the connector under the outer casing.
Courtesy of TESLA, INC.
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- Disconnect RF Wheel Speed Sensor.
NOTE:
1x connector.
Courtesy of TESLA, INC.
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- Disconnect the Front Fascia and FEM connectors from the Front Harness at the connector carrier on the RH Body Beam.
NOTE:
4x connectors.
Courtesy of TESLA, INC.
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- Release fasteners securing FEM and fascia connector carrier to the RH body beam.
NOTE:
2x plastic nuts, 10 mm, 3 N.m.
Courtesy of TESLA, INC.
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- Release harness side FEM and fascia connectors from connector carrier at RH body beam.
NOTE:
4x locking tabs, Release locking tab and slide connector toward rear to release.
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Courtesy of TESLA, INC.
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- Disconnect the air suspension compressor.
NOTE:
1x connector.
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- Disconnect low side A/C pressure/temp sensor.
NOTE:
1x connector.
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- Disconnect air suspension valve block.
NOTE:
1x connector, Take care when removing connector, the release tab must be accessed from the front side of the connector under the outer casing.
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Courtesy of TESLA, INC.
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- Remove fasteners securing the 12V battery bracket to the shock tower cross member and the battery beam.
NOTE:
2x bolts, T30, 5 N.m, 2x bolts, 13 mm, 15 N.m.
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- Remove 12V battery bracket with 12V battery.
NOTE:
The 12V positive cable to E-fuse module is still connected to the battery.
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- Remove fastener securing coolant hose to battery beam.
NOTE:
1x bolt, T30, 5 N.m.
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- Remove fasteners securing coolant reservoir to shock tower cross member.
NOTE:
4x bolts, 10 mm, 6 N.m, This will allow room for reservoir to move to make room during front trunk harness removal.
Courtesy of TESLA, INC.
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- Disconnect coolant reservoir level sensor.
NOTE:
1x connector.
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- Disconnect A/C compressor logic connector.
NOTE:
1x connector.
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- Release edge clip for A/C compressor logic connector.
NOTE:
1x clip.
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- Release ground connection at the A/C compressor mount bracket.
NOTE:
1x bolt, T25, 7 N.m.
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- Remove fasteners securing battery beam to LH and RH body beams.
NOTE:
2x bolts, T30, 3.5 N.m, 2x edge clips.
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- Remove the battery beam.
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- Release A/C line from RH side of A/C compressor.
NOTE:
1x nut, 10 mm, 10 N.m, Remove and discard O-rings.
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Courtesy of TESLA, INC.
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- Release A/C line fasteners below RH side of battery beam.
NOTE:
2x bolts, 10 mm, 8 N.m, Remove and discard O-rings.
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Courtesy of TESLA, INC.
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- Release A/C line bracket on underside of shock tower cross member.
NOTE:
1x nut, 10 mm, 6 N.m.
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- Feed out RH leg of front trunk harness under shock tower cross member and up towards bulkhead.
NOTE:
If necessary move the vehicle up and down on the lift to switch from working from above shock tower cross member, and through the opening in the RH fender well.
Courtesy of TESLA, INC.
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- Disconnect the front trunk harness from the in-cabin fuse box.
NOTE:
1x connector.
Courtesy of TESLA, INC.
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- Remove the front trunk harness ground connection from the in-cabin fuse box.
NOTE:
1x nyloc nut, 10 mm, 6 N.m, Discard after removal.
Courtesy of TESLA, INC.
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- Release the Front Harness Clips from the Bulkhead near the Windshield.
NOTE:
2x edge clips.
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- Release the front trunk harness barrel clips from the studs on the bulkhead.
NOTE:
2x barrel clips.
Courtesy of TESLA, INC.
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- Disconnect the air suspension ECU.
NOTE:
2x connectors.
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- Push the front trunk harness grommet through the bulkhead and feed out harness into the front of the vehicle.
Courtesy of TESLA, INC.
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Courtesy of TESLA, INC.
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- Remove front trunk harness.
NOTE:
Take care not to damage surrounding components while removing harness from vehicle, This is a good time to compare to the new harness provided to ensure parts received are compatible with the vehicle.
Courtesy of TESLA, INC.
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