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Installation Manual

Tesla Model S


Refresh front Fascia
Troubleshooting Guide

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We've compiled the following guide to address some of the common concerns that customers have encountered during installation of our Refresh Front Fascia System for Model S. For any questions not covered in this guide, please contact us:
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topic: FASCIA MAKING CONTACT / NOT FITTING OVER CRASH BEAM

One recurring question we've received from several installers is whether we have any tips on how to make the initial fitting process go smoothly; particularly, how to prevent the Fascia from snagging on other components.

  • It is crucial, when installing the Refresh Fascia (or any bumper cover for any car), that the process should not be attempted by one person alone. By utilizing two people, each person can equally support the weight of the Fascia, plus the installed lamps, grilles and associated trim pieces, which helps to prevent snags, as well as permit a gentle spreading of the ends of the Fascia to fit around the headlamps and Front End Module (FIGURE-1).
  • One of the common points where the Fascia snags is along the rearmost edge of the under panel section. We recommend gently pulling downward on it, causing it to spread over the lower supports and other chassis components (FIGURE-2).
  • Another common issue we've seen is improper mounting of the wiring sub-harness for the front bumper components, resulting in major snags during installation. We recommend replicating the OEM layout as closely as possible (FIGURE-3 + FIGURE-4 + FIGURE-5). Pay close attention to the center section near the hood latch and center parking sensors (if equipped), as this is the area that can often get caught during fitting (FIGURE-4).

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FIGURE-1

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FIGURE-2

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FIGURE-3

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FIGURE-4

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FIGURE-5


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topic: Fascia to front fender fitment

Some installers have encountered some difficulty with fitting of the upper sections of the Fascia to the plastic retainers and front fenders. We found the cause of most difficulties to be related to how the tabs are oriented during installation. We recommend the following:

  • Do not modify the slots on the tops of the tabs in any way!!! Doing so can completely remove the ability for the tabs to properly engage the tabs on the black plastic retaining blocks attached to the fender.
  • We've previously encountered issues with the Fascia seating properly due to bent / damaged tabs on the black plastic mounting blocks, so please check this first!
  • Pressing in the upper sections of the Fascia should begin at frontmost portion of the tab (FIGURE-6).  Once the tabs begin to "clip-in," continue until the tab is completed seated (FIGURE-7). Once this alignment has been achieved, install the factory Torx screw to lock the position into place *****DO NOT OVERTIGHTEN THE SCREW, DOING SO COULD PERMANENTLY DAMAGE THE FASCIA*****

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FIGURE-6

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FIGURE-7

 
 
 

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topic: Fascia to headlight fitment

We've seen scenarios in which the factory Model S bumper as well as damaged or mishandled Unplugged Performance Refresh bumpers have uneven fitment underneath the headlights. the Model X, and Model 3 resolves this issue by having attachment points underneath the headlight areas, however unfortunately the Model Sdoes not have attachment points in that area. To assist body shops with adjusting fitment of factory bumpers and Unplugged Peformance bumpers we developed a supplemental mounting and support system for underneath the headlights. We do not advise this for a new fascia installation as it is not needed for correct fitment. However when there are cases of trouble with fitment underneath the headlights this system can be utilized. Common cases we have seen that justify using this system include: vehicles that have been in accidents or have poor panel gaps from the factory, vehicles which have had the bumpers torn off or heavily worn, vehicles which have distorted bumper shape due to mishandling, etc. 

*For Unplugged Performance authorized shops we can provide the drill template and the rapid prototyped headlight mounting bracket system shown. Additional costs may apply for parts and postage.


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topic: AUTO PILOT SENSOR OBSTRUCTION

While we haven't seen this issue occur more than once or twice, as it's of extreme importance, we wanted to make sure we addressed potential obstruction of Auto Pilot radar sensor. 

The Auto Pilot's lower radar sensor is extremely sensitive to any sort of obstruction; if the sensor becomes blocked, the Auto Pilot system will stop functioning. As a result, it's very important that special attention is paid to proper alignment of the lower grille.  

During fitting of the Fascia, ensure that cutout section of the OEM grille is properly positioned around the AP sensor (FIGURE-8). Specifically, make sure to orient the opening in the same location as with the factory bumper cover installed (we recommend taking a photo prior to installation to use as a reference). Be sure not to accidentally displace the OEM rubber gasket that surrounds the AP radar sensor (FIGURE-9).


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FIGURE-8

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FIGURE-9


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topic: Fascia + V-stripe tab orientation

We've received a few questions from installers regarding the orientation of the tabs for the Fascia, as well as the V-Stripe panel. Specifically, how the tabs are supposed to overlap prior to the bolts being installed.

After installing the V-Stripe onto the Fascia, the tabs of the Fascia should be folded over the V-Stripe's tabs (FIGURE-10). 

NOTE: Ensure use of the 30mm long M6 flanged hex-head bolts supplied with the Fascia (THE OEM BOLTS ARE NOT COMPATIBLE).

 


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FIGURE-10


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