Tesla Model S Owners & Service Manuals

Tesla Model S: Remove Components For Access

Note: If possible, use the "From Below" procedure to remove and install the front drive unit (refer to procedure).

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1054160-00-A Support Jack, Front DU
Tesla 1056360-00-A Service Cover, Steering Rackg
Tesla 1054946-00-A Fluid Transfer Pan
Tesla 1056542-01-A Special 15mm Ratchet Wrench
Tesla 1056566-00-A Locating Shim Set, Front Motor
Bosch 682-Q3MEC2T 2 Ton Foldable Engine Crane
Tesla 1056361-00-A Oberg Tilt-Lift
Tesla 1057312-00-A Axle Extractor
Tesla 1051629-00-A Cap, Connection, Rosenberger, H4Z001-000/52
Remove Components For Access
  1. Remove the front wheels (refer to procedure).
  2. Release the fasteners that secure the lower arch liners. Fold the arch liner forward to access the rear of the wheelwell.
  3. Lower the vehicle.
  4. Remove the 12V battery bracket beam (refer to procedure).
  5. Release the 2 fir tree clips that secure the 12V positive harness to the front crossmember.

    Remove Components For Access

  6. Move the 12V positive harness to the RH side of the vehicle to keep it out of the working area.

    Remove Components For Access

  7. Release the 4 bolts that secure the coolant reservoir to the front crossmember (torque 6 Nm). Do not remove the reservoir at this time.

    Remove Components For Access

Caution: At this point in the procedure, there are still 2 coolant hoses and 1 harness attached to the reservoir.
  1. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.

    Remove Components For Access

  2. Ensure that the cap on the reservoir is properly secured, then pull the reservoir forward into the underhood area.

    Note: The reservoir hose is routed behind the drive unit hose. Note the routing of the hoses and ensure that they are routed correctly during reinstallation.

    Remove Components For Access

  3. Gently pull down on the 2 coolant hoses to release the clips (x4) that secure them to the front crossmember.

    Remove Components For Access

  4. Release the clip that secures the coolant reservoir hose to the A/C line.

    Remove Components For Access

  5. On the LH side of the 3-way fitting, clamp the coolant hose that leads to the differential housing. Remove the hose from the front drive unit and and plug the nipple.

    Remove Components For Access Remove Components For Access

  6. Move the coolant reservoir to the LH side of the vehicle and secure it out of the working area.

    Caution: The reservoir is still secured to 2 coolant hoses.

    Remove Components For Access

  7. On the LH side of the drive unit, clamp the coolant hose. Remove the hose and plug the nipple. Tip: Use flexible hose clamp pliers to release the locking ring.
  8. Move the clamped drive unit coolant hose to the RH side of the vehicle so that it is out of the working area.

    Remove Components For Access

  9. Release the clip that secures the LH A/C line to the compressor HV harness.

    Remove Components For Access

  10. Release the 2 nuts that secure the A/C lines to the compressor. Plug both holes and cap both lines.
  11. Disconnect the compressor LV harness.

    Remove Components For Access

  12. Release the ground strap from the A/C compressor bracket (torque 7 Nm).

    Remove Components For Access

  13. Release the edge clip that secures the LV harnesses to the compressor bracket.

    Remove Components For Access

  14. Release the fir tree clip that secures the LV harnesses to the top of the front drive unit.

    Remove Components For Access

  15. Wrap the LV harnesses around the RH hood strut so that they are out of the working area.
  16. Have an assistant support the compressor. Release the 3 bolts that secure the A/C compressor bracket to the front drive unit (torque 10 Nm).

    Caution: Do not spill any oil when removing the compressor.

    Remove Components For Access

  17. Move the compressor and bracket to the RH side of the vehicle and secure them outside of the working area.

    Remove Components For Access

  18. Raise the vehicle.
Note: Perform the next 3 steps on both sides of the vehicle.
  1. Release the nut that secures the sway bar end links to the sway bar (torque 70 Nm).

    Remove Components For Access

  2. Release the wheel speed sensor harness from the brackets on the knuckle and the body.

    Remove Components For Access

  3. Release the bolt that secures the upper control arm to the knuckle (torque 60 Nm).

    Remove Components For Access

  4. Temporarily lower the vehicle and remove the RH halfshaft from the jackshaft. Tip: Use a deadblow hammer to separate the halfshaft.

    Remove Components For Access

  5. Raise the vehicle to access the RH wheelwell.
  6. At the rear base of the RH wheelwell, release and drain the coolant hose that leads to coolant pump 4.

    Note: This is necessary because the coolant hose and pump are removed with the drive unit.

    Hose highlighted in red

    Hose highlighted in red

  7. Release any clips that secure the coolant hose to the body.
  8. Lower the vehicle to provide easier access to the underhood area.
  9. Working from the underhood area, release the 2 bolts that secure the bracket for coolant pump 4.

    Note: These bolts appear similar to other fasteners used in this procedure, but are slightly shorter. Ensure that the correct bolts are used during reinstallation.

    Remove Components For Access  

  10. Release the straps that secure the lower RH section of the acoustic cover around the front drive unit. Remove only the lower RH section of the cover to access the drain plug.
  11. Set the fluid transfer pan into position beneath the drain plug. Ensure that the pan is level, then route the drain hose between the subframe and aeroshield so that it will drain into an oil drain pan.

    Remove Components For Access

  12. Remove the drain plug (torque 28 Nm).
  13. Release the 2 bolts that secure each fuse box to the front crossmember (torque 5 Nm). Move both fuse boxes behind the front crossmember.
  14. Release the bolt that secures the bracket for coolant pump 3 (torque 6.5 Nm). Move the bracket behind the front crossmember.

    Remove Components For Access

  15. Release the 4 screws that secure the HV cables to the front drive unit (torque 7 Nm).

    Caution: During reinstallation, carefully inspect the connector seals. If any are damaged, replace them.

    Caution: Apply P-80 emulsion to the connector seals on the HV cables before securing the HV cables during reinstallation.

    Caution: Do not apply P-80 emulsion to the HV terminals.

    Remove Components For Access

  16. Disconnect the motor logic connector.
  17. On the LH side of the underhood area, release the bracket from the body that secures the 4-way valve.
  18. Hand-tighten the drain plug and remove the fluid transfer pan.

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