Non-SRS Wiring Repairs: Tesla - UPDATE

What is a non-SRS wiring repair? It is the repairing of an electrical component that is not part of the supplemental restraints system circuit (usually identified by yellow wire looms). As technology increases on vehicles, so does the number of components that utilize electricity. Many of the sensors and modules are becoming smarter and more sensitive. If the wire is too long, the wrong gauge, or spliced in the wrong location, it can cause malfunctions in the components that it’s powering. Many OEMs have different restrictions and guidelines for repairing wiring that does not control SRS components. On the other hand, there are OEMs that don’t allow wiring repairs at all, so full harness replacement is the only option.

Information pertaining to non-SRS wiring harness repairs can be found in vehicle-specific Collision Repair Procedures ➤ General Repair Guidelines ➤ Electrical Harness Repair Guidelines. Information on what wires may be repaired, who may perform the repairs, supplies needed, splice procedures, and warnings and cautions before starting a repair is located in this area.

Tesla acknowledges:

"Repairing a damaged electrical harness can save significant time and material costs compared to replacing the harness."

Information for identifying which wires are repairable and who may perform the repairs is also found in the Electrical Harness Repair Guidelines document.

Tesla states:

  • "Warning Only trained technicians are allowed to repair electrical connectors. Performing a repair of an electrical connector without proper training could result in injury to the technician and damage to the electrical components."
  • "...If the repair cannot be completed to factory-level quality, replace the harness."
  • "Any wire marked with a + sign on the wire in the circuit diagram; this indicates a safety-critical circuit... These circuits are repairable by a body shop if they Do Not have a + sign on the wire in the circuit diagram."
  • "High-Voltage (HV) circuits are not repairable. Replace the entire wiring harness if there is damage to any of these wires:

Required supplies are located within this document. Tesla offers part numbers for harness repair kits, crimp barrels, heat shrink tube, solder, electrical tape, cable ties, crimp tool, and soldering iron.

Per Tesla only a Tesla Service Center, Regional Technical Specialist, or Field Technical Specialist is allowed to repair the following:

  • Safety-related chassis circuits
    • Stability control
    • ABS
    • Parking brake
  • Powertrain circuits
    • Accelerator or brake pedal signal
    • Wheel speed sensors
    • Motor encoder
  • Advanced driver assistance systems (ADAS) such as:
    • Park assist sensors
    • Radar assembly
    • Cameras (forward-facing, rearview, B-pillar, or side repeater)
  • SRS circuits such as airbag and seat belt
  • Airbag sensor and seat sensor
  • High-Voltage Interlock Loop (HVIL)
  • Wiring for any CAN or LIN Bus
  • Coaxial cables
  • Any wire sizes not listed in the Supplies area
  • Wires that have damage within 100 mm of a connector
  • Terminals
  • Any wire marked with a + sign on the wire in the circuit diagram

Tesla offers the ability to repair many electrical system wiring harnesses. All repairs must be performed by a trained technician. Some repairs can only be performed by specific Tesla designated technicians or facilities. It is important to read and follow OEM procedures to be certain what electrical wiring repairs can be carried out to help achieve a complete, safe, and quality repair.

For additional Tesla information, check out the Tesla OEM Information page.

Additional I-CAR Collision Repair News you may find helpful:
Non-SRS Wiring Repairs
Tesla Restraints Wiring: UPDATE
Where Do I Find Other Types Of Information In Tesla?

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