Tesla Model S Repair & Service Manual 2012-2016
Tesla Model S Repair & Service Manual 2012-2016
MAKE: Tesla
MODEL: Model S
YEAR: 2012 2013 2014 2015 2016
Wiring_diagram
Theory_of_Operation_Guides
Service_manual
Complete repair service manual with electrical wiring diagrams for 2012-2016 Tesla Model S, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
2012-2016 Tesla Model S workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
...
• Introduction
◦ How To Use This Manual
◦ Repairs and Replacements
◦ Warranty Service Regions
◦ Abbreviations and Symbols
• Best Practice
◦ Electrical Precautions
◦ General Precautions
◦ Environmental Precautions
◦ General Fitting Instructions
◦ Oil Seals
◦ Locking Devices
◦ Flexible Pipes and Hoses
◦ Wheels and Tires
◦ Air Bag and Supplementary Restraint System (SRS) Precautions
◦ SRS Component Replacement Policy
◦ Air Conditioning System Precautions
• Charging
◦ General
◦ Charging Precautions
• Technical Data
◦ Motor
◦ Steering
◦ Suspension
◦ Wheel Alignment
◦ Brakes
◦ Wheels
◦ Tire Pressures
◦ Electrical
◦ Fuse Locations
◦ Exterior Dimensions
◦ Weights
• Identification Numbers
◦ Vehicle Identification Number (VIN)
◦ Drive unit number
◦ Manufacturing certification label
◦ Vehicle paint codes
◦ Serial Number
• Tesla Special Tools
◦ Reason for Special Tools
◦ Badge and Spoiler Tools
◦ Battery Cooling System Tools
◦ Bosch-Supplied Tools
◦ Electronic Devices
◦ Hardware
◦ Large Tools
◦ Safety
◦ Templates
◦ Wire Harnesses
◦ Small Hand Tools
• Lifting and Jacking
◦ Raising and supporting the vehicle
• Fluids and Capacities
◦ Fluids
◦ Fluid Capacities
• Special Tools - HV Battery Alignment Rods
• Links to front matter
• Sensor - Air Quality (Remove and Replace)
• 00 INSPECTION AND SERVICE
◦ Annual Service
• 10 BODY
◦ Jack Mode Activation
◦ Raise Vehicle - 2 Post Lift
◦ Raise Vehicle - 4 Post Lift
◦ Fascia Assembly - Front (Remove and Install)
◦ Fascia Assembly - Front (Remove and Replace)
◦ Bumper Assembly - Front (Remove and Replace)
◦ Ankle Catcher Assembly (Remove and Replace)
◦ Applique - Fascia - Front - 1st Generation (Remove and Replace)
◦ Applique - Fascia - Front - 2nd Generation (Remove and Install)
◦ Applique - Fascia - Front - 2nd Generation (Remove and Replace)
◦ Grill - Fascia - Front (Remove and Replace)
◦ Chin Spoiler Assembly (Remove and Replace)
◦ Fascia Assembly - Rear (Remove and Install)
◦ Fascia Assembly - Rear (Remove and Replace)
◦ Bumper Assembly - Rear (Remove and Replace)
◦ Diffuser Trim - Rear (Remove and Replace)
◦ Carrier - Bumper - Front (Remove and Replace)
◦ Strut - Shock Tower to Bulkhead - LH (Remove and Replace)
◦ Windshield Assembly (Remove and Replace)
◦ Sensor - Light/Rain (Remove and Replace)
◦ Fixed Glass - Front Door - LH (Remove and Replace)
◦ Body Glass - Rear Quarter - LH (Remove and Replace)
◦ Liftgate Glass (Remove and Install)
◦ Liftgate Glass (Remove and Replace)
◦ Liftgate Glass - Defrost Element (Remove and Replace)
• 11 CLOSURES
◦ Hood Assembly (Remove and Install)
◦ Hinge - Hood - LH (Remove and Replace)
◦ Cable - Latch - Hood (RWD) (Remove and Replace)
◦ Cable - Latch - Hood - LH (Dual Motor) (Remove and Replace)
◦ Actuator - Latch - Hood - LH (Dual Motor) (Remove and Replace)
◦ Gas Strut - Hood - LH (Remove and Replace)
◦ Striker - Hood (Remove and Replace)
◦ Latch - Hood - Primary (RWD) (Remove and Replace)
◦ Latch - Hood - Secondary (RWD) (Remove and Replace)
◦ Latch - Hood (Dual Motor) (Remove and Replace)
◦ Acoustic Panel - Hood (Remove and Replace)
◦ Liftgate Assembly (Remove and Install)
◦ Power Strut - Liftgate (Remove and Replace)
◦ Strut - Liftgate (Remove and Replace)
◦ Latch - Liftgate (Remove and Replace)
◦ Striker - Liftgate (Remove and Replace)
◦ Actuator - Cinching (Remove and Replace)
◦ Cable - Cinching (Remove and Replace)
◦ Exterior Release Switch - Liftgate (Remove and Replace)
◦ Door Assembly - Front - LH (Remove and Replace)
◦ Latch - Door - Front - LH (Remove and Replace)
◦ Latch - Door - Rear - LH (Remove and Replace)
◦ Striker - Door - Front - LH (Remove and Replace)
◦ Striker - Door - Rear - LH (Remove and Replace)
◦ Handle - Interior Release - Door - Front - LH (Remove and Replace)
◦ Handle - Interior Release - Door - Rear - LH (Remove and Replace)
◦ Cable - Interior Release - Front - LH (Remove and Replace)
◦ Handle - Exterior Release - Door - Front - LH (Remove and Replace)
◦ Handle - Exterior Release - Door - Rear - LH (Remove and Replace)
◦ Grip - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ Grip - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ Back Plate - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ Back Plate - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ LED - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ LED - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ Motor - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ Motor - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ PCB - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ PCB - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ Press Sensor - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ Press Sensor - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ Position Sensor - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ Position Sensor - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ Fork and Control Link - Door - Exterior Handle - Front - LH (Remove and Replace)
◦ Fork and Control Link - Door - Exterior Handle - Rear - LH (Remove and Replace)
◦ Position Switch Harness - Door Handle (Remove and Replace)
◦ Door Glass - LH - Front - Adjust
◦ Door Glass - LH - Front (Remove and Replace)
◦ Door Glass - LH - Rear - Adjust
◦ Door Glass - LH - Rear (Remove and Replace)
◦ Door Glass - RH - Rear - Adjust
◦ Window Guide Rail - Front - LH (Remove and Replace)
◦ Window Guide Rail - Rear - LH (Remove and Replace)
◦ Window Motor/Regulator Assembly - Front - LH (Remove and Replace)
◦ Window Motor/Regulator Assembly - Rear - LH (Remove and Replace)
◦ Seal - Body - Side - Rear - Secondary - LH (Remove and Replace)
◦ Seal - Body - Side - Front - Primary - LH (Remove and Replace)
◦ Seal - Body - Side - Rear - Primary - LH (Remove and Replace)
◦ Seal - Door - Front - A Pillar - Margin - LH (Remove and Replace)
◦ Seal - Door- Front - Rocker - LH (Remove and Replace)
◦ Seal - Door - Front - LH (Remove and Replace)
◦ Seal - Door - Rear - C Pillar - Margin - LH (Remove and Replace)
◦ Seal - Rear Door - LH (Remove and Replace)
◦ Seal - Hood (Remove and Replace)
◦ Seal - Liftgate (Remove and Replace)
◦ Seal - Door Front Outer Belt - LH (Remove and Replace)
◦ Seal - Door Front Inner Belt - LH (Remove and Replace)
◦ Seal - Belt - Door Inner - Rear - LH (Remove and Replace)
◦ Seal - Door Rear Outer Belt - LH (Remove and Replace)
◦ Seal - Sliding Glass - Panoramic Roof (Remove and Replace)
• 12 EXTERIOR FITTINGS
◦ Wheel Arch Liner - Upper - Front - LH (Remove and Replace)
◦ Wheel Arch Liner - Rear - LH (Remove and Replace)
◦ Wheel Arch Liner - Lower - Front - LH (Remove and Replace)
◦ Panel - Aero Shield - Front (Remove and Replace)
◦ Panel - Aero Shield - Mid (Remove and Replace)
◦ Panel - Diffuser Tray - Rear (Remove and Replace)
◦ Rails - Diffuser Tray Rear - LH (Remove and Replace)
◦ Rear Lettering (Remove and Replace)
◦ Applique - Liftgate (Remove and Replace)
◦ Badge - Ludicrous Speed (Retrofit)
◦ Bracket - License Plate - Front (Retrofit)
◦ Door Mirror Assembly - LH (Remove and Replace)
◦ Glass - Door Mirror - LH (Remove and Replace)
◦ 'B' Post Trim Panel - LH (Remove and Replace)
◦ Brightwork - Body side - LH (Remove and Replace)
◦ Rocker Panel - LH (Remove and Replace)
◦ Pad - Lifting - Each (Remove and Replace)
◦ Panel - Cowl Screen (Remove and Replace)
◦ Assembly - Underhood Apron - Front (Remove and Replace)
◦ Underhood Apron - Center - Rear (Remove and Replace)
◦ Underhood Apron - LH (Remove and Replace)
• 13 SEATS
◦ Motor - Seat Tilt - Driver's Seat (Remove and Replace)
◦ Motor - Seat Height - Driver's Seat (Remove and Replace)
◦ Assembly - Lumbar Support - Back Rest - Driver's Seat (Remove and Replace)
◦ Motor - Recliner - Back Rest - Driver Seat (Remove and Replace)
◦ Switch - Seat Height Adjust - Driver's Seat (Remove and Replace)
◦ Switch - Back Rest and Cushion Adjust - Driver's Seat (Remove and Replace)
◦ Seat Assembly - Driver's (Remove and Install)
◦ Seat Cushion - Lower - 2nd Row (Remove and Install)
◦ Seat Cushion - Lower - 2nd Row - Executive - LH (Remove and Replace)
◦ Back Rest Assembly - Seat - 2nd Row - LH (Remove and Install)
◦ Back Rest Assembly - Seat - 2nd Row - RH (Remove and Install)
◦ Back Rest Assembly - 2nd Row - Executive (Remove and Replace)
◦ Assembly - Back Rest - Driver's Seat (Remove and Replace)
◦ Frame - Seat Base - 2nd Row Cushion (Remove and Replace)
◦ Frame - Seat Base - 2nd Row - Executive (Remove and Replace)
◦ Frame - Seat Back - 2nd Row Seat - LH (Remove and Replace)
◦ Frame - Seat Back - 2nd Row Seat - RH (Remove and Replace)
◦ Base Assembly - Front Passenger's Seat (Remove and Replace)
◦ Bolster - Side - Seat - 2nd Row - LH (Remove and Replace)
◦ Striker - Seat back - 2nd Row Seat - LH (Remove and Replace)
◦ Pivot Lock - Seat back - 2nd Row Seat - LH (Remove and Replace)
◦ Pivot Lock - Seat back - 2nd Row Seat - RH (Remove and Replace)
◦ Pivot Sleeve - Seat back - 2nd Row Seat - LH (Remove and Replace)
◦ Seat Assembly - 3rd Row (Remove and Replace)
◦ Cover - Outer Side - Driver's Seat (Remove and Install)
◦ Cover - Outer Side - Driver's Seat (Remove and Replace)
◦ Cover - Back Rest - Driver's Seat (Remove and Install)
◦ Trim - Cushion - Driver's Seat (Remove and Replace)
◦ Trim - Cushion - Front Passenger's Seat (Remove and Replace)
◦ Foam - Cushion - Driver's Seat (Remove and Replace)
◦ Foam - Cushion - Front Passenger's Seat (Remove and Replace)
◦ Trim and Foam Assembly - Driver's Seat (Remove and Install)
◦ Trim and Foam Assembly - Front Passenger's Seat (Remove and Install)
◦ Latch - Seat Back - 2nd Row Seat - LH (Remove and Replace)
◦ Cover - Seat back - 2nd Row Seat - RH (Remove and Replace)
• 14 INSTRUMENT PANELS AND PEDALS
◦ Switch - Brake Light (Remove and Replace)
◦ Brake Pedal (Remove and Replace)
◦ Accelerator Assembly (Remove and Replace)
◦ Glove Box (Remove and Replace)
◦ Glove Box - Latch Release (Remove and Replace)
◦ Glove Box - Damper (Remove and Replace)
◦ IP Carrier (Remove and Replace)
◦ Cross Car Beam (Remove and Replace)
◦ Assembly - Frame - Instrument Cluster (Remove and Replace)
◦ Trim - Touch Screen Surround (Remove and Replace)
◦ Face Level Vent - Driver's - Outer (Remove and Replace)
◦ Face Level Vent - Driver's - Inner (Remove and Replace)
◦ Face Level Vent - Front Passenger's - Outer (Remove and Replace)
◦ Face Level Vent - Front Passenger's - Inner (Remove and Replace)
◦ Assembly - Bin - Storage Center Compartment (Remove and Replace)
◦ Assembly - Instrument Panel Lower - RH (Remove and Replace)
◦ Assembly - Instrument Panel Side Cover - LH (Remove and Replace)
◦ Panel - A Pillar Trim - Middle - LH (Remove and Replace)
◦ Assembly - Finisher - Instrument Panel - LH (Remove and Replace)
◦ Assembly - Finisher - Instrument Panel - RH (Remove and Replace)
◦ Assembly - Mesh Grille - Defrost (Remove and Replace)
◦ Assembly - Top Pad - Instrument Panel (Remove and Install)
◦ Assembly - Top Pad - Instrument Panel (Remove and Replace)
◦ Trim - Dash - Driver's Side - Lower (Remove and Replace)
◦ Trim - Dash - Driver's Side - Inner to Bezel (Remove and Replace)
◦ Assembly - Cover - Footwell - LH (Remove and Replace)
◦ Assembly - Cover - Footwell - RH (Remove and Replace)
◦ Assembly - Cover - Footwell - LH (RHD) (Remove and Replace)
◦ Assembly - Cover - Footwell - RH (RHD) (Remove and Replace)
• 15 INTERIOR TRIM
◦ Rear View Mirror - 1st Generation (Remove and Replace)
◦ Rear View Mirror - 2nd Generation (Remove and Replace)
◦ Sun Visor - Driver's (Remove and Replace)
◦ Assembly - Mirror - Sun Visor - LH (Remove and Replace)
◦ Trim - Rear View Mirror (Remove and Replace)
◦ Finisher - Liftgate - Rear Window - Upper (Remove and Replace)
◦ Finisher - Liftgate - Rear Window - Lower (Remove and Replace)
◦ Finisher - Liftgate - Rear Window - Side - LH (Remove and Replace)
◦ Panel - Door Trim - LH - Front (Remove and Install)
◦ Panel - Door Trim - Front - LH (Remove and Replace)
◦ Panel - Door Trim - LH - Rear (Remove and Install)
◦ Panel - Door Trim - LH - Rear (Remove and Replace)
◦ Trim - Sill Panel - LH (Remove and Replace)
◦ Trim - 'A' Post - LH (Remove and Install)
◦ Trim - 'A' Post - LH (Remove and Replace)
◦ Trim - 'B' Post - Upper - LH (Remove and Install)
◦ Trim - 'B' Post - Upper - LH (Remove and Replace)
◦ Trim - 'B' Post - Lower - LH (Remove and Install)
◦ Trim - 'C' Post Upper - LH (Remove and Replace)
◦ Trim - 'C' Post Rear - LH (Remove and Replace)
◦ Trim - Sill Panel - LH - Rear (Remove and Replace)
◦ Footrest - Driver's (Remove and Replace)
◦ Assembly - Closeout Extension - LH - Center Console (Remove and Replace)
◦ Cup Holder (Remove and Replace)
◦ Trim - Center Console - Rear (Remove and Replace)
◦ Assembly - Panel - Wrapped - LH (Remove and Replace)
◦ Vent - Center Console (Remove and Replace)
◦ Center Console Assembly (Remove and Replace)
◦ Drop In Center Console Assembly (Remove and Replace)
◦ 2nd Row Center Console Assembly (Remove and Replace)
◦ Center Console - 2nd Row - Executive (Remove and Replace)
◦ Finisher - Floor - Center Console (Remove and Replace)
◦ Headlining (Remove and Install)
◦ Headlining (Remove and Replace)
◦ Headliner - Panoramic Roof (Remove and Install)
◦ Headlining - Panoramic Roof (Remove and Replace)
◦ Underhood Storage Unit (RWD) (Remove and Install)
◦ Underhood Storage Unit (Dual Motor) (Remove and Replace)
◦ Underhood Storage Extension Box (Remove and Install)
◦ Assembly - Hood Latch Cover (Remove and Replace)
◦ Lamp - Underhood Storage Area (Remove and Replace)
◦ Trim - Rear Trunk - Side - LH (Remove and Replace)
◦ Trim - Rear Trunk - Side - RH (Remove and Replace)
◦ Trim - Rear Trunk - Floor (Remove and Replace)
◦ Carpet - Underhood Storage (Remove and Install)
◦ Carpet - Underhood Storage (Dual Motor) (Remove and Install)
◦ Carpet - Interior Complete (Remove and Replace)
• 16 BATTERY SYSTEM
◦ HV Battery Assembly (Remove and Install)
◦ HV Battery Assembly (Remove and Replace)
◦ HV Battery Blanket (Remove and Replace)
◦ HV Battery Charge/Discharge - 3rd Generation Tool (Out of Vehicle)
◦ HV Battery Charge/Discharge - 4th Generation Tool (Out of Vehicle)
◦ HV Battery Coolant - Drain and Refill
• 17 ELECTRICAL
◦ Vehicle Electrical Isolation Procedure
◦ Disconnect 12V Power (RWD)
◦ Disconnect 12V Power (Dual Motor)
◦ Battery - Auxiliary - 12V (RWD) (Remove and Replace)
◦ Battery - Auxiliary - 12V (RHD) (Remove and Replace)
◦ Battery - Auxiliary - 12V (Dual Motor) (Remove and Replace)
◦ 12V Positive Jump Post (Remove and Replace)
◦ Fusebox - Battery (RHD) (Remove and Replace)
◦ 12V Battery Bracket Beam (Remove and Replace)
◦ Harness - Instrument Panel (Remove and Replace)
◦ Harness - Body Front Left (Remove and Replace)
◦ Module - Condenser Fan Control - LH (Remove and Replace)
◦ Module - Door Controller (Remove and Replace)
◦ Module - Liftgate Control (Remove and Replace)
◦ Module - Park Assist (Remove and Replace)
◦ Module - Electric Park Brake - EPB (Remove and Replace)
◦ Module - Sunroof Controller (Remove and Replace)
◦ Module - Sunroof Controller (RHD) (Remove and Replace)
◦ Module - Air Suspension - ECU (Remove and Replace)
◦ Module - Air Suspension - ECU (Remove and Install)
◦ Module - Air Suspension - ECU (RHD) (Remove and Replace)
◦ Module - Air Suspension - ECU (RHD) (Remove and Install)
◦ Module - Passive Safety Restraint - PSRCM (Remove and Replace)
◦ Module - Body Controller - BCM (Remove and Replace)
◦ Module - Body Controller - BCM (RHD) (Remove and Replace)
◦ Module - Body Controller - BCM (Dual Motor) (RHD) (Remove and Replace)
◦ Module - Memory Seat (Remove and Replace)
◦ Module - Steering Column Control (Remove and Replace)
◦ Module - Thermal Controller (Remove and Replace)
◦ Module - HVAC Controller - RCCM (Remove and Replace)
◦ Module - Seat Heater - Driver's Seat (Remove and Replace)
◦ Module - TPMS - Baolong (Remove and Replace)
◦ Module - TPMS - Continental (Remove and Replace)
◦ Module - HomeLink Transmitter (Remove and Replace)
◦ Sensor - Parking Distance - Front - Each (Remove and Replace)
◦ Sensor - Parking Distance - Rear - Each (Remove and Replace)
◦ Sensor - Radar - Front (Remove and Replace)
◦ Calibration - Front Radar Sensor
◦ Receiver - Remote Keyless Entry (RKE) - Immobilizer (Remove and Replace)
◦ Casing - Transmitter - Remote Keyless Entry (RKE)
◦ Transmitter - Remote Keyless Entry (RKE) - Programming
◦ LF Antenna - Bumper Carrier (Remove and Replace)
◦ LF Antenna - RH - A Post (Remove and Replace)
◦ LF Antenna - Dash - Front - LH (Remove and Replace)
◦ LF Antenna - Center - Heelboard (Remove and Replace)
◦ LF Antenna - Center - Rear (Remove and Replace)
◦ Column Switch - Wash/Wipe (Remove and Replace)
◦ Column Switch - Cruise Control (Remove and Replace)
◦ Column Switch - Tilt/Telescope (Remove and Replace)
◦ Switch - Hazard Warning (Remove and Replace)
◦ Switch - Glove Box (Remove and Replace)
◦ Power Socket 12V - Center Console - Rear (Remove and Replace)
◦ Switch Pack - Driver's (Remove and Replace)
◦ Switch - Window Lift - Front Passenger's (Remove and Replace)
◦ Switch - Window Lift - LH - Rear (Remove and Replace)
◦ Switches - Steering Wheel (Remove and Replace)
◦ Front Reading (Dome) Lights (Remove and Replace)
◦ Rear Reading (Dome) Lights (Remove and Replace)
◦ Headlight - Adjust - North America
◦ Headlight - Adjust - Europe
◦ Headlight Assembly - LH (Remove and Replace)
◦ Tail Light Assembly (Non-Motorized Charge Port) - LH (Remove and Replace)
◦ Tail Light Assembly (Motorized Charge Port) - LH (Remove and Replace)
◦ Lamp - Brake - High Mounted (Remove and Replace)
◦ Light - License Plate (Remove and Replace)
◦ Light - Fog/Reverse - Rear - LH (Remove and Replace)
◦ Lamp - Side Repeater - Front - LH (Remove and Replace)
◦ Lamp - Reflex - Rear - LH (Remove and Replace)
◦ Lamps - Fog - Front - Adjust
◦ Lamp - Fog - Front - LH (Remove and Replace)
◦ Horn - 1st Generation (Remove and Replace)
◦ Horn - 2nd Generation (Remove and Replace)
◦ Wiper Motor Assembly (Remove and Replace)
◦ Pump - Windshield Washer Reservoir (Remove and Replace)
◦ Reservoir - Windshield Washer (Remove and Replace)
◦ Nozzle - Windshield Washer Jet (Remove and Replace)
◦ Sensor - Level - Windshield Washer Reservoir (Remove and Replace)
◦ Wiper Blades - Pair (Remove and Replace)
◦ Wiper Arms - Pair (Remove and Replace)
◦ Wiper Blades - Adjust
• 18 THERMAL MANAGEMENT
◦ Filter - Particulate (Remove and Replace)
◦ HVAC Assembly (Remove and Replace)
◦ Actuator - Inlet (Remove and Replace)
◦ Actuator - Driver's Temperature (Remove and Replace)
◦ Actuator - Mode (Remove and Replace)
◦ Actuator - Front Passenger's Temperature (Remove and Replace)
◦ Actuator - Defrost (Remove and Replace)
◦ Motor - Fan assembly - HVAC (Remove and Replace)
◦ Hose - HVAC - Drain (Remove and Replace)
◦ Hose - Front HVAC - Drain (Dual Motor) (Remove and Replace)
◦ Heater - PTC (Remove and Replace)
◦ Heater - PTC (Dual Motor) (Remove and Replace)
◦ Heater - PTC (Dual Motor) (RHD) (Remove and Replace)
◦ A/C Refrigerant Recovery and Recharge (Remove and Replace)
◦ AC Refrigerant Leak Detection
◦ Condenser - Gas Cool (Remove and Replace)
◦ Condenser - Sub-cool (Remove and Replace)
◦ Fan - Condenser - LH (Remove and Replace)
◦ Fan - Condenser - RH (Remove and Replace)
◦ Receiver Dryer and Desiccant (Remove and Replace)
◦ Compressor - 1st Generation (Remove and Replace)
◦ Compressor - 2nd Generation (Remove and Replace)
◦ Compressor (Dual Motor) (Remove and Replace)
◦ Compressor (Dual Motor) (RHD) (Remove and Replace)
◦ Mounting - Air Conditioning Compressor (Remove and Replace)
◦ Pipe - High Pressure - Sub-Cool Condenser to Chiller (Remove and Replace)
◦ Pipe - High Pressure - Charge Port (Remove and Replace)
◦ Pipe - High Pressure - Compressor to Condenser (Remove and Replace)
◦ Pipe - High Pressure - Compressor to Condenser (Dual Motor) (Remove and Replace)
◦ Pipe - Low Pressure - Charge Port (Remove and Replace)
◦ Pipe - High Pressure - Charge Port (Dual Motor) (Remove and Replace)
◦ Pipe - High Pressure - Gas Cool to Sub-Cool Condenser (Remove and Replace)
◦ Pipe - Low Pressure - Chiller (Remove and Replace)
◦ TXV Valve - Evaporator (Remove and Replace)
◦ TXV Valve - Chiller (Remove and Replace)
◦ Pressure Transducer - High Pressure (Remove and Replace)
◦ Pressure Transducer - Low Pressure (Remove and Replace)
◦ Battery Chiller and TXV Assembly (Remove and Replace)
◦ Cooling System - Partial Refill and Bleed
◦ Cooling System - Drain and Refill
◦ Coolant System - Check and Fill
◦ Cooling System - Vacuum Refill
◦ Radiator (Remove and Replace)
◦ Reservoir Assembly - Coolant (Remove and Replace)
◦ Reservoir Assembly - Coolant (Dual Motor) (Remove and Replace)
◦ Reservoir Cap - Coolant (Remove and Replace)
◦ 3 Way Coolant Valve - Chiller Bypass (Remove and Replace)
◦ 3 Way Coolant Valve - Radiator Bypass (Remove and Replace)
◦ 4 Way Coolant Valve - Series/Parallel (Remove and Replace)
◦ Coolant Heater - Electric - Battery - 1st Generation (Remove and Replace)
◦ Coolant Heater - Electric - Battery - 2nd Generation (Remove and Replace)
◦ Coolant Heater - Electric - Battery (Dual Motor) (Remove and Replace)
◦ Battery Coolant Pump 1 (Remove and Replace)
◦ Battery Coolant Pump 2 (Remove and Replace)
◦ Powertrain Coolant Pump 1 (RWD) (Remove and Replace)
◦ Powertrain Coolant Pump 1 (Dual Motor) (Remove and Replace)
◦ Powertrain Coolant Pump 2 (Remove and Replace)
◦ Active Louver - Center (Remove and Replace)
◦ Duct - Condenser LH (Remove and Replace)
◦ Motor - Active Louver - Front Fascia (Remove and Replace)
◦ Vent - Motorized - Front Fascia - LH (Remove and Replace)
• 20 SAFETY AND RESTRAINT
◦ Air bag - Driver's (Remove and Replace)
◦ Knee Air bag - Driver's (Remove and Replace)
◦ Air bag - Front Passenger's (Remove and Replace)
◦ Knee Air Bag - Front Passenger's (Remove and Replace)
◦ Curtain Air bag - Driver's (Remove and Replace)
◦ Side Air bag - Driver's (Remove and Replace)
◦ Seat Belt Assembly - 1st Row - LH (Remove and Replace)
◦ Buckle Assembly - 1st Row - LH (Remove and Replace)
◦ Seat Belt Assembly - 2nd Row - LH (Remove and Replace)
◦ Buckle Assembly - 2nd Row - LH (Remove and Replace)
◦ Seat Belt Assembly - 2nd Row - Center (Remove and Replace)
◦ Seat Belt Assembly - 3rd Row - LH (Remove and Replace)
◦ Buckle Assembly - 3rd Row - LH (Remove and Replace)
◦ Pre-Tensioner - Outboard Lap - 1st Row - LH (Remove and Replace)
◦ Pyrotechnic Fuse (Remove and Replace)
◦ Sensor - Intrusion - Door - Front (Remove and Replace)
◦ Sensor - Impact - Front (Remove and Replace)
◦ Sensor - Impact - B Pillar (Remove and Replace)
◦ Sensor - Impact - C Pillar (Remove and Replace)
◦ Switch - Reminder - Seat Belt - Driver's Seat (Remove and Replace)
◦ Sensor - Occupant Classification - Front Passenger's Seat (Remove and Replace)
◦ Sensor - Occupant Classification - Front Passenger’s Seat - Calibration
◦ Sensor - Pedestrian Protection (Remove and Replace)
◦ Actuator - Pedestrian Protection - LH (Remove and Replace)
• 21 INFOTAINMENT
◦ Instrument Cluster (Remove and Replace)
◦ Media Control Unit - Touch Screen (Remove and Replace)
◦ Media Control Unit - Touch Screen (Remove and Install)
◦ SIM Card - With SIM Extender (Remove and Replace)
◦ SD Card - Media Control Unit (Remove and Replace)
◦ Camera - Forward Facing (Remove and Replace)
◦ Camera - Rear Facing (Remove and Replace)
◦ Drive Cycle Calibration - Forward Facing Camera
◦ Target Calibration - Forward Facing Camera
◦ Speaker - Front Door Premium Audio - LH/RH (Remove and Replace)
◦ Speaker - Rear Door All, Front Door Base Audio (Remove and Replace)
◦ Subwoofer Assembly (Remove and Replace)
◦ Tweeter - 'A' Post - LH (Remove and Replace)
◦ Speaker - Rear - LH/RH (Remove and Replace)
◦ Premium Boost Amplifier (Remove and Replace)
◦ Tuner - AM - FM (Remove and Replace)
◦ Antenna Amplifier - AM/FM and RKE (Remove and Replace)
◦ Antenna Amplifier - FM2/Satellite/DAB (Remove and Replace)
◦ Antenna - RF Filter - RH (Remove and Replace)
◦ Antenna - AM/FM/RKE (Remove and Replace)
◦ Antenna - FM2 and Defrost Grid (Remove and Replace)
◦ Antenna - DAB (Remove and Replace)
◦ Antenna - Satellite Radio - Liftgate-Mounted (Remove and Replace)
◦ Antenna - Satellite Radio - Roof-Mounted (Remove and Replace)
◦ Microphone - Bluetooth (Remove and Replace)
◦ Antenna - GPS (Remove and Replace)
◦ Antenna - WiFi (Remove and Replace)
◦ Antenna - GSM - LH (Remove and Replace)
• 24 ROOF
◦ Calibration - Panoramic Roof Assembly
◦ Sliding Glass - Panoramic Roof Assembly (Remove and Replace)
◦ Fixed Glass - Panoramic Roof Assembly (Remove and Replace)
◦ Frame - Panoramic Roof Assembly (Remove and Replace)
◦ Side Applique - 1st Generation - LH (Remove and Replace)
◦ Side Applique - 2nd Generation - LH (Remove and Replace)
◦ Front Applique - 1st Generation (Remove and Replace)
◦ Panoramic Roof Drive Cable - LH (Remove and Replace)
◦ Wind Deflector Arm - LH (Remove and Replace)
◦ Wind Deflector (Remove and Replace)
◦ Motor - Sunroof - LH (Remove and Replace)
◦ Motor - Sunroof - RH (Remove and Replace)
• 30 CHASSIS
◦ Subframe Assembly - Rear (Remove and Install)
◦ Subframe Assembly - Rear (Remove and Replace)
◦ Subframe Assembly - Front (Remove and Install)
◦ Subframe Assembly - Front (Remove and Replace)
◦ Skidplate - Front (Remove and Replace)
◦ Skidplate - Rear (Remove and Replace)
◦ Skid Bar - Front Subframe (Remove and Replace)
◦ Bash Plate - Front - Stamping (Remove and Replace)
◦ Bash Plate - Front - Extrusion (Remove and Replace)
• 31 SUSPENSION
◦ Four Wheel Alignment Check
◦ Four Wheel Alignment - Check and Adjust
◦ Ride Height - Adjust
◦ Suspension - Front - Check Torque
◦ Knuckle - Suspension - Front - LH (Remove and Replace)
◦ Hub - Front - LH (Remove and Replace)
◦ Link - Sway Bar - Front - LH (Remove and Replace)
◦ Sway Bar - Front (RWD) (Remove and Replace)
◦ Sway Bar - Front (Dual Motor) (Remove and Replace)
◦ Control Arm - Upper - Front - LH (Remove and Replace)
◦ Control Arm - Upper - Front - RH (Remove and Replace)
◦ Link - Lower - Fore - LH (Remove and Replace)
◦ Link - Lower - Aft - LH (Remove and Replace)
◦ Suspension - Rear - Check Torque
◦ Knuckle - Suspension - Rear - LH (Remove and Replace)
◦ Hub - Rear - LH (Remove and Replace)
◦ Control Arm Assembly - Rear - Lower - LH (Remove and Replace)
◦ Link - Suspension - Rear - Upper - LH (Remove and Replace)
◦ Toe Link Assembly - Rear - LH (Remove and Replace)
◦ Sway Bar - Rear (Remove and Replace)
◦ Drop Link - Sway Bar - Rear - LH (Remove and Replace)
◦ Integral Link - Rear - LH (Remove and Replace)
◦ Air Spring Module - Front - LH (Remove and Replace)
◦ Air Spring Module - Rear - LH (Remove and Replace)
◦ Air Suspension - Pressurize/Depressurize - One Air Spring
◦ Air Suspension - Depressurize - Full System
◦ Air Suspension - Pressurize - Full System
◦ Compressor - Air Suspension (Remove and Replace)
◦ Sensor - Ambient Air Temperature - Compressor (Remove and Replace)
◦ Solenoid - Air Suspension (Remove and Replace)
◦ Reservoir - Air Suspension (Remove and Replace)
◦ Sensor - Ride Height - Front - LH (Remove and Replace)
◦ Sensor - Ride Height - Rear - LH (Remove and Replace)
◦ Air Line - Air Suspension - Valve Block to LH Front Air Spring (Remove and Replace)
◦ Air Suspension - Primary Lines Assembly (Remove and Replace)
◦ Air Line - Air Suspension - Reservoir to Compressor (Remove and Replace)
◦ Air Line - Air Suspension - Compressor to Valve Block (Remove and Replace)
◦ Air Line - Air Suspension - Valve Block Exhaust (Remove and Replace)
◦ Spring and Damper Assembly - Front - LH (Remove and Replace)
◦ Spring and Damper Assembly - Rear - LH (Remove and Replace)
◦ Spring and; Damper Assembly - Rear - RH (Remove and Replace)
• 32 STEERING
◦ Steering Rack (RWD) (Remove and Replace)
◦ Steering Rack (Dual Motor) (Remove and Replace)
◦ Tie Rod End - LH (Remove and Replace)
◦ Seal - Steering Rack (Remove and Replace)
◦ Shaft - Steering Column - Intermediate Lower (Remove and Replace)
◦ Shaft - Steering Column - Intermediate Lower (Dual Motor) (Remove and Replace)
◦ Shaft - Steering Column - Intermediate Upper (Remove and Replace)
◦ Shaft - Steering Column - Intermediate Upper (Dual Motor) (Remove and Replace)
◦ Steering Wheel (Remove and Replace)
◦ Steering Column (Remove and Replace)
• 33 BRAKES
◦ Brake Rotor - Front - LH (Remove and Replace)
◦ Brake Rotor - Rear - LH (Remove and Replace)
◦ Brake Caliper - Front - LH (Remove and Replace)
◦ Brake Caliper - Rear - LH (Remove and Replace)
◦ Brake Pads - Front - Set (Remove and Replace)
◦ Brake Pads - Rear - Set (Remove and Replace)
◦ Brake Pads - Burnishing
◦ Shield - Dust - Brake - Front - LH (Remove and Replace)
◦ Shield - Dust - Brake - Rear - LH (Remove and Replace)
◦ Shield - Dust - Brake - Front - 2nd Generation (Retrofit)
◦ Master Cylinder and Reservoir Assembly (Remove and Install)
◦ Master Cylinder (Remove and Replace)
◦ Brake Hose - Flexible - Front - LH (Remove and Replace)
◦ Brake Hose - Flexible - Rear - LH (Remove and Replace)
◦ Bleed Procedure - One Caliper (Remove and Replace)
◦ Bleed Procedure - System (Remove and Replace)
◦ Vacuum Brake Booster Assembly (Remove and Replace)
◦ Electromechanical Brake Booster Assembly (Remove and Replace)
◦ Vacuum Pump (Remove and Replace)
◦ Bracket - Vacuum Pump (Remove and Replace)
◦ Reservoir - Master Cylinder (Remove and Replace)
◦ Brake Lines - Booster to ABS (Dual Motor) (RHD) (Remove and Replace)
◦ Rear Park Brake Caliper Release
◦ Park Brake Caliper - Release - Harness Tool - Through Calipers
◦ Park Brake Caliper - Release - Harness Tool - Through ECU
◦ Brake Caliper - Rear - Park Brake - LH (Remove and Replace)
◦ Brake Pads - Park Brake - Set (Remove and Replace)
◦ Brake Pads - Park Brake - Burnishing
◦ ABS Modulator Assembly (Remove and Replace)
◦ Sensor - Wheel Speed - ABS - Front - LH (Remove and Replace)
◦ Sensor - Wheel Speed - ABS - Rear - LH (Remove and Replace)
◦ Brake Sensor Cluster - ESC (Remove and Replace)
• 34 WHEELS AND TIRES
◦ Tire - Front - LH
◦ Tire - Front - LH - Rebalance
◦ Tire Rotation
◦ Wheel (Remove and Install)
◦ Wheels - Axle Set (Remove and Install)
◦ Wheels - Vehicle - Set (Remove and Install)
◦ Wheel Sensor - TPMS (Remove and Replace)
◦ TPMS Sensor - ID Learn Procedure - Baolong
◦ TPMS Sensor - ID Learn Procedure - Continental
◦ TPMS - Set Thresholds
• 39 FRONT DRIVE UNIT
◦ Front Drive Unit (From Above) (Remove and Install)
◦ Front Drive Unit (From Above) (Remove and Replace)
◦ Front Drive Unit (From Below) (Remove and Install)
◦ Front Drive Unit (From Below) (Remove and Replace)
◦ Mount - Front Drive Unit - RH (Remove and Replace)
◦ Mount - Front Drive Unit - LH (Remove and Replace)
◦ Mount - Front Drive Unit - LH (Adjust)
◦ Gearbox Fluid - Front (Remove and Replace)
◦ Driveshaft Assembly - Front - LH (Remove and Replace)
◦ Driveshaft Assembly - Front - RH (Remove and Replace)
◦ Jackshaft Assembly - Front (Remove and Replace)
• 40 REAR DRIVE UNIT
◦ Drive Unit - Rear - Large (Remove and Replace)
◦ Drive Unit - Rear - Large (Remove and Install)
◦ Drive Unit - Rear - Small (Remove and Install)
◦ Drive Unit - Rear - Small (Remove and Replace)
◦ Mount - Motor - Side (Remove and Replace)
◦ Bushing - Drive Unit - Front (Remove and Replace)
◦ Bushing - Drive Unit - Rear (Remove and Replace)
◦ Sensor - Motor - Speed (Remove and Replace)
◦ Gearbox Fluid - Large Rear Drive Unit (Remove and Replace)
◦ Gearbox Fluid - Small Rear Drive Unit (Remove and Replace)
◦ Oil Seal - Differential to Driveshaft Assembly - LH (Remove and Replace)
◦ Driveshaft Assembly - LH (Remove and Replace)
• 44 HIGH VOLTAGE SYSTEM
◦ Charge Port - Single Phase - Non-Motorized (Remove and Replace)
◦ Charge Port - Single Phase - Motorized (Remove and Replace)
◦ Charge Port - 3 Phase (Remove and Replace)
◦ Charge Port - Single Phase - Non-Motorized - Manual Release of Cable
◦ Charge Port - 3 Phase - Manual Release of Cable
◦ Door - Charge Port - Non-Motorized (Remove and Replace)
◦ Door - Charge Port - Single Phase - Motorized (Remove and Replace)
◦ Slave Charger - LH - 1st Generation (Remove and Replace)
◦ Slave Charger - LH - 2nd Generation (Remove and Replace)
◦ Master Charger - RH - 1st Generation (Remove and Replace)
◦ Master Charger - RH - 2nd Generation (Remove and Replace)
◦ DCDC Converter - 1st Generation (Remove and Replace)
◦ DCDC Converter - 2nd Generation (Remove and Replace)
◦ DCDC Converter (Dual Motor) (Remove and Replace)
◦ Forward Junction Box - 2nd Generation (Remove and Replace)
◦ Forward Junction Box - 2nd Generation - 20 Amp Fuse (RWD) (Remove and Replace)
◦ Forward Junction Box - 2nd Generation - 40 Amp Fuse (RWD) (Remove and Replace)
◦ Forward Junction Box (Dual Motor) (Remove and Replace)
◦ HV Junction Box - 1st Generation (Remove and Replace)
◦ HV Junction Box - Cover - 1st Generation (Remove and Replace)
◦ HV Junction Box - 2nd Generation (Remove and Replace)
◦ HV Junction Box - Cover - 2nd Generation (Remove and Replace)
◦ HV Junction Box - Reed Switch - 1st Generation (Remove and Replace)
◦ HV Rapid Mate Vehicle Side (Remove and Replace)
◦ HV Harness - HVJB to Charge Port - 2nd Generation
◦ HV Harness - Front Drive Unit to HVJB
◦ HV Harness - Rear Drive Unit to HVJB
• 50 EXTERNAL CHARGING CONNECTORS
◦ Handle and Cable Assembly - 40A Wall Connector (Remove and Replace)
◦ Handle and Cable Assembly - 80A Wall Connector (Remove and Replace)
◦ 200A Fuses - Wall Connector (Remove and Replace)
◦ Firmware Update - CHAdeMO Charging Adapter
...
Theory of Operation Guides
Click one of the below links to open the associated document:
1 Drive Unit
2 ABS
3 Electric Park Brake
4 Air Suspension
5 Electric Power Steering
6 Thermal Management
7 Restraint System
8 Panoramic Sunroof
9 Charging
10 Tire Pressure Monitoring System
11 Electrical
...
Model S Electrical Information
Below are the available Circuit Diagrams and Connector Reference guides for the Model S.
Circuit Diagrams
Left-Hand Drive, Rear Wheel Drive
Start of Production through May 31, 2013
May 31, 2013 through January 6, 2014
January 6, 2014 through May 19, 2014 (without HVAC ionizer)
January 28, 2014 through July 11, 2014 (with HVAC ionizer)
July 11, 2014 through October 28, 2014
October 28, 2014 through Current Production
Left-Hand Drive, Dual Motor
All LHD Dual Motor
Right-Hand Drive, Rear Wheel Drive
Start of Production through July 9, 2014
July 9, 2014 through October 28, 2014
October 28, 2014 through Current Production
Connector References
Left-Hand Drive, Rear Wheel Drive
Start of Production through May 31, 2013
May 31, 2013 through January 6, 2014
January 6, 2014 through May 19, 2014 (without HVAC ionizer)
January 28, 2014 through July 11, 2014 (with HVAC ionizer)
July 11, 2014 through October 28, 2014
October 28, 2014 through Current Production
Left-Hand Drive, Dual Motor
All LHD Dual Motor
Right-Hand Drive, Rear Wheel Drive
Start of Production through July 9, 2014
July 9, 2014 through October 28, 2014
October 28, 2014 through Current Production
...
Tesla Model S Repair & Service Manual 2012-2016
