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Home >> Tesla >> 2017 >> Model S P100D >> Repair and Diagnosis >> Electrical >> Charging Systems >> Electrical System -- Model S >> Harnesses >> Harness - Trunk - Front - Remove and Replace >> Removal

Harness - Trunk - Front - Remove and Replace: Removal

  1. Open all doors and lower the windows.
  2. Prepare the LH seat assembly for removal later in this procedure. See Seat Assembly - 1st Row - LH - Remove and Install , steps 1 through 8
  3. Repeat the previous step for the RH seat assembly.
  4. Recover the refrigerant. See A/C Refrigerant Recovery And Recharge - Remove And Replace .
  5. Enable tow mode through the touchscreen.
  6. Disconnect 12V power. See Disconnect 12V Power .
  7. Remove the cowl screen panel. See Panel - Cowl Screen (Remove And Replace) .
  8. Remove the wiper motor. See WIPER MOTOR ASSEMBLY (REMOVE AND REPLACE) .
  9. Remove the LH shock tower brace. See Shock Tower Brace - LH (Remove And Replace) .
  10. Remove the RH shock tower brace.
  11. Remove the screws (x2) that attach the air suspension reservoir to the brackets, and then remove the brackets from the vehicle.
    G00653815Courtesy of TESLA, INC.
  12. Maneuver the air suspension reservoir below the AC line and then set the reservoir aside for access.
    G00653816Courtesy of TESLA, INC.
  13. Remove the bolts (x2) that attach the TXV to the evaporator.
    NOTE: Discard o-rings and replace during installation.
    G00653817Courtesy of TESLA, INC.
  14. Disconnect the A/C lines and the TXV from the HVAC unit.
    NOTE: Gently pull the lines away from the bulkhead/HVAC box. Make sure to retain the O-rings at the TXV.
    G00653818Courtesy of TESLA, INC.
  15. Disconnect the LH seat harness connectors (x3), and then remove the LH seat from the vehicle.
  16. Disconnect the RH seat harness connectors (x2), and then remove the RH seat from the vehicle.
  17. Remove the center console. See Center Console Assembly (Remove And Replace) .
  18. Remove the instrument panel top pad assembly. See Assembly - Top Pad - Instrument Panel - Remove And Install .
  19. Remove the RH instrument panel finisher assembly. See Assembly - Finisher - Instrument Panel - RH - Remove And Replace .
  20. Remove the instrument cluster frame assembly. See Assembly - Frame - Instrument Cluster - Remove And Replace .
  21. Remove the LH inner instrument panel finisher assembly with vent. See Face Level Vent - Driver's - Inner - Remove And Replace .
  22. Remove the LH instrument panel outer finisher assembly. See Assembly - Finisher - Instrument Panel - LH - Remove And Replace .
  23. Remove the steering column. See Steering Column - Remove And Replace .
  24. Remove the instrument cluster. See Instrument Cluster - Remove And Replace .
  25. Remove the media control unit. See Media Control Unit - Remove And Install .
  26. Remove the IP carrier. See IP Carrier - Remove And Replace .
  27. Disconnect the headliner harness connectors (x3) at the LH A-pillar and release the harness from the vehicle.
    G00653819Courtesy of TESLA, INC.
  28. Remove the cross car beam harness connectors (x7) at the LH lower A-pillar.
    NOTE: Only release connectors that run to the harness on the cross car beam.
    G00653820Courtesy of TESLA, INC.
    G00653821Courtesy of TESLA, INC.
  29. Disconnect the cross car beam harness connectors (x7) at the RH lower A-pillar.
    NOTE: Only release connectors that run to the harness on the cross car beam.
    G00653822Courtesy of TESLA, INC.
    G00653823Courtesy of TESLA, INC.
  30. Remove the cross car beam. See Cross Car Beam (Remove And Replace) .
    G00653824Courtesy of TESLA, INC.
    G00653825Courtesy of TESLA, INC.
    G00653826Courtesy of TESLA, INC.
  31. Remove the LH and RH lower B-pillar trim. See Trim - B-Pillar - Lower - LH - Remove And Install .
  32. Remove 2nd row cushion seat base frame. See Frame - Seat Base - 2nd Row Cushion - Remove And Replace .
  33. Remove the main carpet from the vehicle. See Carpet - Interior Complete - Remove And Replace .
  34. Remove the HVAC assembly. See HVAC Assembly - Remove And Replace .
  35. Remove the connectors (x3) connecting the lower dash harness to the front trunk harness.
    G00653827Courtesy of TESLA, INC.
  36. Disconnect adaptive air suspension ECU connectors (x3).
    G00653828Courtesy of TESLA, INC.
  37. Lift up the harness connectors, and then remove the air suspension ECU from the vehicle.
    G00653829Courtesy of TESLA, INC.
  38. Disconnect the harness connectors (x3) from the connector carrier at the lower RH A-pillar.
    G00653830Courtesy of TESLA, INC.
    G00653831Courtesy of TESLA, INC.
  39. Remove the female side connectors (x4) from the RH A-pillar connector carrier bracket.
    NOTE: Use the flat head screw driver to carefully lift-up the locking tab securing the female side connector in the carrier connector bracket.
    G00653832Courtesy of TESLA, INC.
    G00653833Courtesy of TESLA, INC.
  40. Disconnect the front trunk harness from the in-cabin fuse box.
    G00653834Courtesy of TESLA, INC.
  41. Remove the front trunk harness ground connection from the in-cabin fuse box.
    G00653835Courtesy of TESLA, INC.
  42. Release the front trunk harness barrel clips (x2) from the studs on the bulkhead.
    NOTE: 2x barrel clips
    G00653836Courtesy of TESLA, INC.
  43. Push the front trunk harness grommet through the bulkhead and feed out harness into the front of the vehicle.
    G00653837Courtesy of TESLA, INC.
    G00653838Courtesy of TESLA, INC.
  44. Disconnect the main harness connector from the RH A-pillar cabin fuse box.
    NOTE: Only remove the single connector that leads to the main front trunk harness.
    G00653839Courtesy of TESLA, INC.
  45. Prepare the vehicle for lifting, but do not raise it at this time. See Raise Vehicle - 2 Post Lift .
    NOTE: Make sure to enable "Jack Mode" before lifting the vehicle.
  46. Remove the LH and RH front wheels. See Wheel - Remove And Install .
  47. Remove the nut and clips (x5) that attach the rear half of the RH front wheelhouse liner to the body.
    G00653840Courtesy of TESLA, INC.
    G00653841Courtesy of TESLA, INC.
  48. Fold over the RH front wheelhouse liner and put it in between the brake rotor and the front fascia.
    G00653842Courtesy of TESLA, INC.
  49. Disconnect the RH side repeater camera connectors (x2).
    G00653843Courtesy of TESLA, INC.
  50. Remove the nut and clips (x5) that attach the rear half of LH front wheelhouse liner to the body.
    G00653844Courtesy of TESLA, INC.
    G00653845Courtesy of TESLA, INC.
    G00653846Courtesy of TESLA, INC.
  51. Fold over the LH front wheelhouse liner and put it in between the brake rotor and the front fascia.
    G00653847Courtesy of TESLA, INC.
  52. Disconnect the connector from the front trunk harness to the hood harness.
    G00653848Courtesy of TESLA, INC.
  53. Remove the windshield washer reservoir. See Reservoir - Windshield Washer - Remove And Replace .
  54. Disconnect the LH side repeater camera connectors (x2).
    G00653849Courtesy of TESLA, INC.
  55. Pass the harness through the opening behind the RH shock tower for harness removal.
    NOTE: Pass the harness under the HV cables and over the top of the brake master cylinder following the pathway of the larger section of the front trunk harness along the bulkhead.
    G00653850Courtesy of TESLA, INC.
  56. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove And Replace)
  57. Remove the HV battery. See HV Battery (RWD/AWD) - Remove And Install .
  58. Remove all items from pockets and ensure that you do not wear any metal items.
  59. Put on HV insulating gloves and leather over gloves.
  60. Verify that there is no high voltage present at the HV rapid mate.
    NOTE: Measure B+ to Ground, B- to Ground, B+ to B-. If voltage is greater than 10V, pack contactors are not open or welded. Stop work and reach out to Service Engineering.
    G00653851Courtesy of TESLA, INC.
  61. Install HV and LV Rapid Mate covers.
    G00653852Courtesy of TESLA, INC.
  62. Remove HV insulating gloves.
  63. Remove the front aero shield panel. See Panel - Aero Shield - Front - Remove And Replace .
  64. Disconnect the RH fan control module connector.
    NOTE: The module is located on the outer side of the RH body beam and can be accessed from underneath the vehicle with the front aero shield removed.
    G00653853Courtesy of TESLA, INC.
  65. Disconnect the coolant 3-way valve at the RH front lower corner of the front subframe.
    G00653854Courtesy of TESLA, INC.
  66. Pass the leg of the harness with the fan control module coolant 3-way valve connectors up, above the RH body rail, for harness removal.
    G00653855Courtesy of TESLA, INC.
  67. Disconnect the LH fan control module.
    NOTE: The module is located on the outer side of the LH body beam and can be accessed from underneath the vehicle with the front aero shield removed.
    G00653856Courtesy of TESLA, INC.
  68. Pass the leg of the harness with the fan control module connector up, above the LH body rail, for harness removal.
    G00653857Courtesy of TESLA, INC.
  69. Disconnect the battery coolant pump 1 connector.
    G00653858Courtesy of TESLA, INC.
  70. Release the front trunk harness clips (x3) for the leg of the harness that runs to battery coolant pump 1.
    G00653859Courtesy of TESLA, INC.
    G00653860Courtesy of TESLA, INC.
  71. Remove the bolt that attaches the 12V positive terminal to the bottom of the DCDC.
    G00653861Courtesy of TESLA, INC.
  72. Remove the bolts (x4) that attach the FJB to rapid splitter HV harness.
    G00653862Courtesy of TESLA, INC.
  73. Release the 2 HV cables from the FJB.
    G00653863Courtesy of TESLA, INC.
  74. Release the HV harness clip at the bulkhead.
    NOTE: This allows the HV harness to be moved out of the way for the front trunk harness to pass behind it during removal.
    G00653864Courtesy of TESLA, INC.
  75. Remove the bolts (x2) that attach the bottom of front junction box to the vehicle.
    G00653865Courtesy of TESLA, INC.
  76. Disconnect the logic connector from the front junction box.
    G00653866Courtesy of TESLA, INC.
  77. Remove the nut that attaches the RH side of front junction box to the vehicle.
    G00653867Courtesy of TESLA, INC.
  78. Pass the logic connector by the HV cables up the bulkhead into the cavity near the RH shock tower for harness removal.
    NOTE: Tilt the front junction box away from the bulkhead to make room for the connector
    G00653868Courtesy of TESLA, INC.
    G00653869Courtesy of TESLA, INC.
  79. Disconnect the logic connector from the DCDC converter.
    NOTE: Tilt the front junction box away from the bulkhead to make room for the connector to be disconnected.
    G00653870Courtesy of TESLA, INC.
  80. Disconnect the battery heater connector from the FJB.
    G00653871Courtesy of TESLA, INC.
    G00653872Courtesy of TESLA, INC.
    G00653873Courtesy of TESLA, INC.
  81. Pass the DCDC logic connector, the electric battery heater connector, and the E-fuse ground cable up the bulkhead behind the front junction box towards the top of the bulkhead for harness removal.
    G00653874Courtesy of TESLA, INC.
    G00653875Courtesy of TESLA, INC.
  82. Lower the vehicle for access to the underhood area.
  83. Disconnect the LH shotgun accelerometer sensor connector.
    G00653876Courtesy of TESLA, INC.
  84. Disconnect the RH shotgun accelerometer sensor connector.
    G00653877Courtesy of TESLA, INC.
  85. Remove the underhood storage unit. See Underhood Storage Unit - Remove And Install .
  86. Remove the underhood fuse box. See Fusebox - Underhood - 2nd Generation - Remove And Replace .
  87. Remove the bolt that attaches the front trunk harness ground at the left of the fuse box location.
  88. Disconnect the LH front ride height sensor connector.
    G00653878Courtesy of TESLA, INC.
  89. Release the clips that attach the portion of the front trunk harness that was previously disconnected from the LH front inner fender area.
    G00653879Courtesy of TESLA, INC.
  90. Release the harness clip at the LH front shock tower.
    G00653880Courtesy of TESLA, INC.
  91. Disconnect the coolant temperature sensor connector near the LH side of the bulkhead.
    G00653881Courtesy of TESLA, INC.
  92. Disconnect the PT coolant pump 1 connector.
    G00653882Courtesy of TESLA, INC.
  93. Disconnect the front drive unit logic connector.
    G00653883Courtesy of TESLA, INC.
  94. Remove and discard the nut that attaches the harness ground to the 12V negative battery terminal.
    G00653884Courtesy of TESLA, INC.
  95. Release the clip that attaches the 12V ground harness to the LH shock tower.
    G00653885Courtesy of TESLA, INC.
  96. Disconnect the high side A/C PT sensor connector.
    G00653886Courtesy of TESLA, INC.
  97. Remove the front trunk harness ground bolts (x3) and release the shotgun accelerometer harness clip from the front side of the LH shock tower.
    G00653887Courtesy of TESLA, INC.
  98. Disconnect the connector for the LH front wheel speed sensor.
    G00653888Courtesy of TESLA, INC.
  99. Disconnect the LH connector to damper harness.
    G00653889Courtesy of TESLA, INC.
  100. Disconnect the LH headlamp connector.
    NOTE: Take care when removing connector, as the release tab must be accessed from the front side of the connector under the outer casing.
    G00653890Courtesy of TESLA, INC.
  101. Disconnect the LH front harness connector of the front end module harness.
    G00653891Courtesy of TESLA, INC.
  102. Release the harness clips (x5) from the studs on the LH front body beam.
    G00653892Courtesy of TESLA, INC.
  103. Disconnect the battery coolant pump 2 connector.
    G00653893Courtesy of TESLA, INC.
  104. Release the connector of the front remote keyless entry antenna.
    G00653894Courtesy of TESLA, INC.
  105. Release the ABS module connector.
    NOTE: Depress the connector lever lock tab and rotate the connector lever upwards to release.
    G00653895Courtesy of TESLA, INC.
  106. Disconnect the battery chiller and EXV connector.
    G00653896Courtesy of TESLA, INC.
  107. Release the harness fir tree clip near the battery chiller.
    G00653897Courtesy of TESLA, INC.
  108. Disconnect the connector at the air suspension compressor.
    G00653898Courtesy of TESLA, INC.
  109. Release the harness clip at the middle of subframe, in front of the steering gear.
    G00653899Courtesy of TESLA, INC.
  110. Feed the left leg of the front trunk harness out up to the LH shock tower.
    G00653900Courtesy of TESLA, INC.
  111. Disconnect the coolant 4-way valve connector.
    G00653900Courtesy of TESLA, INC.
    G00653902Courtesy of TESLA, INC.
  112. Release the harness clip from the 4 way-valve.
    G00653903Courtesy of TESLA, INC.
  113. Release the harness clips from the brake lines near the LH shock tower.
    G00653904Courtesy of TESLA, INC.
  114. Release the harness clips on the LH side under the shock tower cross member.
    G00653905Courtesy of TESLA, INC.
  115. Release the brackets (x3) that hold the brake lines in place near LH body beam
    NOTE: Only release the upper brake lines. Gently pry the bracket off of the brake lines and rotate the bracket 90 degrees to allow for more movement in the brake lines. This will allow more room for harness connections, mainly the ABS module connector, to pass through the opening between the brake lines and the body beam.
    G00653906Courtesy of TESLA, INC.
  116. Feed the harness out under the LH side of the shock tower cross member to the bulkhead, then up and over shock tower cross member.
    G00653907Courtesy of TESLA, INC.
  117. Remove the nuts (x3) that attach the harness carrier bracket to the bulkhead below the TXV.
    G00653908Courtesy of TESLA, INC.
    G00653909Courtesy of TESLA, INC.
  118. Disconnect the TXV connector.
    G00653910Courtesy of TESLA, INC.
  119. Remove the bolt that attaches the 12V cable cover to the E-fuse assembly, and then remove the cover.
    NOTE: Discard bolt after removal
    G00653911Courtesy of TESLA, INC.
    G00653912Courtesy of TESLA, INC.
  120. Remove the bolt that attaches the 12V power supply cable to the E-fuse assembly.
    NOTE: Discard the bolt after removal.
    G00653913Courtesy of TESLA, INC.
  121. Remove the nut that attaches the E-fuse assembly to the electrical battery heater bracket.
    G00653914Courtesy of TESLA, INC.
  122. Lift the bracket up to release the E-fuse from the tabs at the bottom.
    G00653915Courtesy of TESLA, INC.
    G00653916Courtesy of TESLA, INC.
  123. Remove the bolt that attaches the DCDC positive cable to the E-fuse assembly.
    NOTE: Discard the bolt after removal.
    G00653917Courtesy of TESLA, INC.
  124. Lift the E-fuse assembly up for access to the front cover.
    NOTE: Use caution with the front drive unit coolant hose.
    G00653918Courtesy of TESLA, INC.
  125. Remove the bolts (x3) that attach the E-fuse cover to thee E-fuse assembly.
    NOTE: Pay attention to bolt locations as 1 bolt is different from the others.
    G00653919Courtesy of TESLA, INC.
  126. Remove the bolts (x2) that attach the large cables to the bottom of the E-fuse assembly.
    NOTE: Note the location of the labeled wires during removal. Discard bolts after removal.
    G00653920Courtesy of TESLA, INC.
  127. Remove the screw that attaches the small cable to the bottom of the E-fuse assembly.
    NOTE: Note the location of the labeled wire during removal.
    G00653921Courtesy of TESLA, INC.
  128. Disconnect the logic connector from the E-fuse assembly.
    G00653922Courtesy of TESLA, INC.
  129. Release the cover from the RH side of the E-fuse assembly to expose the RH side fasteners.
    NOTE: Release the 2 tabs and slide the cover off.
    G00653923Courtesy of TESLA, INC.
  130. Remove the screws (x6) that attach the small cables to the side of the E-fuse assembly.
    NOTE: Note the location of the labeled wires during removal.
    G00653924Courtesy of TESLA, INC.
  131. Remove the bolt that attaches the ground cable to the E-fuse assembly.
    NOTE: Discard bolt after removal.
    G00653925Courtesy of TESLA, INC.
  132. Release the front trunk harness clip from the RH side of the bulkhead near the electromechanical brake booster.
    G00653926Courtesy of TESLA, INC.
  133. Release the edge clip at the brake master cylinder, and then disconnect the pedal sensor connector.
    G00653927Courtesy of TESLA, INC.
  134. Disconnect the logic connector from the electromechanical brake booster.
    G00653928Courtesy of TESLA, INC.
  135. Disconnect brake fluid level sensor and release the edge clip.
    G00653929Courtesy of TESLA, INC.
    G00653930Courtesy of TESLA, INC.
  136. Disconnect the RH front ride height sensor connector.
    G00653931Courtesy of TESLA, INC.
  137. Release the harness clip on the rear inner portion of the shock tower below the shock tower cross member.
    NOTE: 1x clip
    G00653932Courtesy of TESLA, INC.
  138. Release the coolant hose clip at the RH shock tower.
    NOTE: This is done to make more room for harness removal.
    G00653933Courtesy of TESLA, INC.
  139. Release the harness clip under the shock tower cross member at the RH side of the body.
    G00653934Courtesy of TESLA, INC.
  140. Disconnect the RH connector to the damper harness.
    G00653935Courtesy of TESLA, INC.
  141. Remove the chassis ground bolt, shotgun accelerometer harness clip, and wheel speed sensor connector from the front side of the RH shock tower.
    G00653936Courtesy of TESLA, INC.
  142. Release the harness clips (x4) at the RH shock tower and body beam.
    G00653937Courtesy of TESLA, INC.
  143. Disconnect the steering gear connectors (x4).
    NOTE: Only release the front trunk harness connectors, It is not necessary to release the connectors between the steering rack and controller during front trunk harness replacement.
    G00653939Courtesy of TESLA, INC.
  144. Disconnect the RH headlamp connector.
    NOTE: Take care when removing connector, the release tab must be accessed from the front side of the connector under the outer casing.
    G00653939Courtesy of TESLA, INC.
  145. Disconnect front fascia and front end module (FEM) connectors (x3) from the front trunk harness at the connector carrier on the RH body beam.
    G00653940Courtesy of TESLA, INC.
  146. Release the plastic nuts that attach the FEM and fascia connector carrier to the RH body beam.
    G00653941Courtesy of TESLA, INC.
  147. Disconnect the low side A/C PT sensor connector.
    G00653942Courtesy of TESLA, INC.
  148. Disconnect the air suspension valve block connector.
    NOTE: Take care when removing connector: the release tab must be accessed from the front side of the connector under the outer casing
    G00653943Courtesy of TESLA, INC.
    G00653944Courtesy of TESLA, INC.
    G00653945Courtesy of TESLA, INC.
  149. Remove the bolts (x4) that attach the 12V battery bracket to the shock tower cross member and the battery beam.
    G00653946Courtesy of TESLA, INC.
  150. Remove the 12V battery bracket with 12V battery from the vehicle.
    NOTE: The 12V positive cable to the E-fuse module remains connected to the battery.
    G00653947Courtesy of TESLA, INC.
  151. Remove the bolt that attaches the coolant hose to the battery beam.
    G00653948Courtesy of TESLA, INC.
  152. Remove the bolts (x4) that attach the coolant reservoir to the shock tower cross member.
    NOTE: This will allow room for the reservoir to move to make room during front trunk harness removal.
    G00653949Courtesy of TESLA, INC.
  153. Disconnect the coolant reservoir level sensor connector.
    G00653950Courtesy of TESLA, INC.
  154. Disconnect the A/C compressor logic connector.
    G00653951Courtesy of TESLA, INC.
  155. Release the edge clip for the A/C compressor logic connector.
    G00653952Courtesy of TESLA, INC.
  156. Remove the bolt that attaches the ground connection to the A/C compressor mount bracket.
    G00653953Courtesy of TESLA, INC.
  157. Remove the bolts (x2) and clips (x2) that attach the battery beam to LH and RH body beams.
    G00653954Courtesy of TESLA, INC.
  158. Remove the battery beam from the vehicle.
    G00653955Courtesy of TESLA, INC.
  159. Release the A/C line from the RH side of the A/C compressor.
    NOTE: Discard O-ring(s).
    G00653956Courtesy of TESLA, INC.
    G00653957Courtesy of TESLA, INC.
  160. Release the bolts (x2) that attach the A/C line below the RH side of the battery beam.
    NOTE: Discard O-ring(s).
    G00653958Courtesy of TESLA, INC.
    G00653959Courtesy of TESLA, INC.
  161. Release the A/C line bracket at the underside of the RH shock tower.
    G00653960Courtesy of TESLA, INC.
  162. Feed out the RH leg of the front trunk harness under the shock tower cross member and up towards the 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.
    G00653961Courtesy of TESLA, INC.
  163. Remove the front trunk harness.
    NOTE: This is a good time to compare the removed harness to the new harness provided to ensure parts received are compatible with the vehicle.
    G00653962Courtesy of TESLA, INC.
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