Tesla Model S: General Fitting Instructions

Component removal

Whenever possible, clean components and surrounding area before removal.

• Cap off openings exposed by component removal.
• Immediately seal fuel, oil or hydraulic lines when apertures are exposed; use plastic caps or plugs to prevent loss of fluid and ingress of dirt.
• Close the open ends of oil ways exposed by component removal with tapered hardwood plugs or conspicuous plastic plugs.
• Immediately after a component is removed, place it in a suitable container; use a separate container for each component and its associated parts.
• Clean bench and provide marking materials, labels and containers before dismantling a component.

Be as clean as possible when dismantling components, particularly brake or Air Conditioning (A/C) system parts. A particle of dirt or a cloth fragment could cause a serious malfunction if trapped in these systems.

• Blow out all tapped holes, crevices, oil ways and fluid passages with an air line. Ensure that any O-rings used for sealing are replaced if disturbed during the process.
• Use marking ink to identify mating parts and ensure correct reassembly. Do not use a centre punch or scriber to mark parts, they could initiate cracks or distortion in marked components.
• Wire together mating parts where necessary to prevent accidental interchange (e.g. roller bearing components).
• Attach labels to all parts which are to be replaced, and to parts requiring further inspection before being passed for reassembly; place these parts in separate containers from those containing parts for rebuild.
• Do not discard a part due for replacement until after comparing it with a new part, to ensure that its correct replacement has been obtained.

Always use the recommended cleaning agent or equivalent. Ensure that adequate ventilation is provided when volatile de-greasing agents are being used. Do not use de-greasing equipment for components containing items which could be damaged by the use of this process.

General inspection

All components should be inspected for wear or damage before being reassembled.

• Never inspect a component for wear or dimensional check unless it is absolutely clean; a slight smear of grease can conceal damage that can lead to failure.
• When a component is to be checked dimensionally against recommended values, use the appropriate measuring equipment (surface plates, micrometers, dial gauges etc.). Ensure the measuring equipment is calibrated and in good serviceable condition.
• Reject a component if its dimensions are outside the specified tolerances, or if it appears to be damaged.
• A part may be refitted if its critical dimension is exactly to its tolerance limit and it appears to be in satisfactory condition.
• If a fastener has misaligned torque markings, re-torque it to the proper value and then mark the fastener with a paint pen.

Oil Seals

Always replace oil seals which have been removed from their working location (whether as an individual component or as part of an assembly). NEVER use a seal which has been improperly stored or handled, such as hung on a hook or nail.

• Carefully examine every seal before fitting to ensure that it is clean and undamaged.
• Ensure the surface on which the new seal is to run is free of burrs or scratches. Replace the component if the original sealing surface cannot be completely restored.
• Protect the seal from any surface which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surface.
• Lubricate the sealing lips with a recommended lubricant before use to prevent damage during initial use. On dual lipped seals, smear the area between the lips with grease.

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