Tesla Model S: Frame - Panoramic Roof Assembly (Remove and Replace) - Removal

Warning: To avoid personal injury, wear cut-resistant gloves when performing this operation.

Special tools required for this procedure:

1. Remove the panoramic roof sliding glass (refer to procedure).
2. Remove the LH side applique:
   • 1st Generation Side Applique: Refer to procedure.
   • 2nd Generation Side Applique: Refer to procedure.
3. Remove the RH side applique.
4. Remove the panoramic roof fixed glass (refer to procedure).
5. Remove the front applique:
   • 1st Generation Front Applique: Refer to procedure.
   • 2nd Generation Front Applique: Refer to procedure.
6. Remove the LH footwell cover:
   • LHD vehicles: Refer to procedure.
   • RHD vehicles: Refer to procedure.
7. Remove the RH footwell cover:
   • LHD vehicles: Refer to procedure.
   • RHD vehicles: Refer to procedure.
8. Loosen the sunroof motors:
   1. If the vehicle is equipped with premium audio, remove the bolts (x3) that secure the premium boost amplifier module bracket to the front cross car beam (torque 6 Nm).
   2. Loosen the screws (x3) that secure the LH sunroof motor to the dash frame (torque 5 Nm) and pull the LH sunroof motor away from the motor block to release the cable.

      

   3. Remove the glove box assembly (refer to procedure).
   4. Loosen the screws (x3) that secure the RH sunroof motor to the A-pillar (torque 5 Nm) and pull the RH sunroof motor away from the motor block to release the cable.

      

9. Lower the headliner and support it on the seats (refer to procedure).
10. Remove both rear drive links and cables: Note: Perform this step on both sides of the vehicle.
    1. Remove the drive cable stop screw.

       

    2. If necessary, remove the grey foam block (highlighted in green) at the rear of the drive cable channel.

       

    3. Remove the rear links.
    4. Remove the drive cables from the guide tubes. Note: The cables tend to get hung up at the point in the drive channel where the stop screw was located.
11. Release the front drain tubes (x2) from the roof assembly.

    

12. Release the rear drain tubes (x2) from the roof assembly.

    

13. Disconnect the pinch sensor electrical connector located on the RH side between the A-pillar and B-pillar.

    

14. Disconnect 12V power.
    • Rear wheel drive (RWD): Refer to procedure.
    • Dual Motor: Refer to procedure.

15. Unplug the electrical connector for the curtain airbag canister and remove the rear bolt that secures the curtain airbag canister (torque 10 Nm) so that the cannister can be moved away from the work area.

    

16. Remove the caps from the roof rack anchor nuts and then remove the roof rack anchor nuts (x4, 2 per anchor) (torque 11 Nm). Remove the roof rack anchors (x2). Note: Cut away any adhesive that is holding in the anchors as necessary.
17. Remove the butyl patches and the threaded inserts (x2) from the roof frame.

    

18. Repeat steps 15-18 on the other side of the vehicle
19. Starting at the center of the front section of the roof frame and moving toward the sides, use a hydroblade tool to carefully cut through the adhesive.

    Caution: Take care not to damage the copper guides.

    Note: Lubricate the blade with water during this step, or spray the blade and the work area with glass cleaner.

    Note: The center portion of the frame overlaps above the side portions.

    

    

     

    1	Locations the center portion overlaps above the side portion

20. Cut an appropriate length of square wire and insert the wire into the square wire cutting tool.
21. Push the tool through the adhesive at the roof rack bracket cutaway. Pull the wire through and remove the tool.
22. Connect the T-handles to the wire.

    Note: The remainder of the removal procedure requires an assistant.

    

23. Cut through the adhesive at the rear section of the roof frame with the cutting tool and then cut through the adhesive at the side sections. Use a flat tool to guide the wire underneath the frame as it changes direction or level.

    Warning: To avoid personal injury, eye protection must be worn when performing this operation.

    Warning: Only use cleaning agents and solvents in a well-ventilated area.

    Caution: The technician inside the vehicle should use a flashlight and a wedge tool to guide the wire, making sure not to apply too much downward pressure on the wire. Too much pressure might result in the wire cutting through the pinch weld.

    Caution: Take care not to damage component(s).

    

    Note: In several locations, the body and roof frame dip slightly and there is minimal clearance between the frame and the body, which can make it difficult to get the wire to pass though those points. Use a flat tool to help guide the wire between the body and the roof frame.

    Note: On 1st generation panoramic roofs, the wire might get stuck on a speed nut in front of the middle header. Use a flat tool to help guide the wire between the body and the roof frame.

    Note: On each side of the frame two metal rivets protrude from the bottom of the roof frame. These rivets can be hard to cut through. Use a wedge tool to hold the cutting wire firmly against the body to guide it underneath the riveted area. Alternatively, use a flat metal tool to cut some of the adhesive near the rivets to provide a path for the wire.

    Note: At the center of the rear section, a locator post protrudes downward from the roof frame. Pry up the roof frame to guide the wire under the datum peg. Alternatively, hold the bottom of the locator post while cutting it, and remove it. Do not allow the locator post to fall into the roof channel.

    

    1	Locations where frame dips slightly
    2	Locations where frame dips slightly and has 2 metal rivets
    3	Location of locator post

    

24. Remove the panoramic roof frame from the vehicle.

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