Tesla Model S: Carrier - Bumper - Front (Remove and Replace)

Warning: If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.

Removal

1. Recover refrigerant from the vehicle (refer to procedure).
2. Raise and support the vehicle (refer to procedure).
3. Remove the radiator (refer to procedure).
4. Remove the active louver assembly (refer to procedure).
5. Remove the LH headlight (refer to procedure).
6. Remove the RH headlight.
7. Remove the LH horn (refer to procedure).
8. Remove the RH horn.
9. Remove the front antenna (refer to procedure).
10. Remove the LH impact sensor (refer to procedure).
11. Remove the RH impact sensor.
12. Remove the front aero shield (refer to procedure).
13. Remove the bolts (x2) that secure the front bumper carrier to the body (torque 4 Nm).

    Note: LH bolt shown for clarity.

    

14. Remove the bolt that secures the LH staybar to the carrier (torque 11 Nm).

    

15. Remove the nut that secures the air conditioning pipe to the LH condenser (torque 8 Nm).

    

16. Disconnect the pipe and tie aside. Caution: Plug pipe connections to prevent ingress of moisture or dirt. Caution: Remove and discard O-rings. Caution: Lubricate new O-rings with clean refrigerant oil.
17. Remove the nut that secures the inboard air conditioning link pipe (torque 15 Nm).
18. Disconnect the pipe from the condenser and tie aside.

    

19. Disconnect the condenser fan motor connector.
20. Remove the screws (x4) that secure the condenser mounting clamps (torque 3 Nm).

    

21. Release the condenser from the lower mounting and collect the clamps.
22. Release the condenser assembly from the upper mounting and remove from the vehicle.
23. Repeat the previous 9 steps and remove the RH condenser.
24. Remove the following hardware:
    1. the bolt that secures the air suspension compressor bracket to the carrier (red arrow) (torque 6 Nm)
    2. the bolts (x2) that secure the vacuum pump mounting bracket to the front bumper carrier (blue arrows) (torque 6 Nm)

    

25. Remove the following hardware:
    1. the clip that secures the air suspension compressor pump valve to the carrier (blue arrow). Tie the valve aside
    2. the bolt that secures the inboard air conditioning link pipe to the carrier (yellow arrow) (torque 11 Nm). Remove the pipe
    3. the clips (x4) that secure the coolant hose to the carrier (green arrows)
    4. the harness clips (x8) that secure the harness to the carrier (red arrows)

    

26. Remove the following hardware:
    1. the LH and RH ankle catcher end screws (x2) (blue arrows) (torque 11 Nm)
    2. the bolts (x6) that secure the ankle catcher to the crash structure (red arrows) (torque 11 Nm)

    

27. Remove the ankle catcher (refer to procedure).
28. Remove the front bumper carrier.

    

Installation procedure is the reverse of removal.

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