30/09/2024 12:30:41

Sill Insert (Front Section)

Parts List

Quantity Description Image / Notes
1 SIDE SILL INSERT (Side Sill Insert)
1 BRACKET-SILL INSERT MOUNT SERVICE (Sill Insert Mounting Bracket)
1 Weld nut Tesla part number 1078311-00-A.
1 Model 3 Front Sill Insert Section Kit
Kit contents:
  • Cell 1 Reinforcement Insert (x1)
  • Cell 2 Reinforcement Insert (x1)
  • Cell 3 Reinforcement Insert Plates (x2)
  • Bolt (x6)
  • SPAC Nut, M8x2.8-3.5,STL[10] (x6)
  • High Strength Structural Rivet, 6.5 mm (x8)
  • Weld nut, HF,PRJ,M8,[10],TEF (x1)

When ordering parts, refer to the Parts Catalog and enter the VIN of the vehicle being repaired to find the correct parts (and the part numbers) for the vehicle. Alternatively, use the search function in the Parts Catalog to find a specific part for the vehicle.

Repair Procedure

  1. Remove the Sill Outer (Front Section).
  2. Cut the original component at the indicated locations.

    Cut Line

    Reference Line/Point

    • A = 186 mm

  3. Remove the original component.
  4. Cut the new component in the indicated location.

    Cut Line

    Reference Line/Point

    • B = 645 mm
    • C = 738 mm
  5. Mark the mounting position for the Sill Insert Mounting Bracket on the Sill Insert section in the indicated location.

    Reference Line/Point

    • D = 12 mm
    • E = 167 mm
    • F = 260 mm
  6. Mark the rivet locations on the Sill Insert Mounting Bracket using the measurements provided.

    High Strength Structural Rivet, 6.5 mm

    Reference Line/Point

    • G = 66 mm
    • H = 23 mm
  7. Apply structural adhesive to the mating surfaces on the Sill Insert Mounting Bracket and the new Sill Insert.
  8. Install the Sill Insert Mounting Bracket on the new Sill Insert.
  9. Remove the weld nuts from the Sill Inner.
  10. Drill 8 mm holes for bolts in the Sill Insert section.
    Informational PurposesAn informational icon, calling your attention
    Note
    Using the existing holes in the outer Cell 3 reinforcement plate as guides, drill 8 mm holes for bolts through the Sill Insert portion still in the vehicle.
  11. Enlarge the holes in one of the Cell 3 Reinforcement Insert Plates to 12 mm to allow for SPAC nut installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    SPAC nuts will be mounted on this Reinforcement Plate, which is installed inside the Sill Insert.
  12. Use structural adhesive to install the SPAC nuts in the enlarged holes of the Cell 3 Reinforcement Insert Plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Install the new component or components for instructions on installing the SPAC nuts on the inner reinforcement plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    After the adhesive is cured, inspect the threads of the SPAC nuts on the inner Cell 3 Reinforcement Insert Plate and use a thread chaser to remove any dried adhesive.
  13. Prepare for installation.
    • I = 114 mm

    Reference Line/Point

    Bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    Using the existing holes in the outer Cell 3 reinforcement plate as guides, drill 8 mm holes for bolts through the Sill Insert portion still in the vehicle (do not damage the SPAC nuts on the inner Cell 3 reinforcement plate).

    High Strength Structural Rivet, 6.5 mm

  14. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  15. Install the new component or components.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque the bolts to 25 Nm.
  16. Install the new weld nuts.
    GMA Weld
  17. Perform GMA welding.
    GMA Weld
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    To maintain vehicle crash integrity, use only approved welding wire and an approved GMA welder to perform GMA welding on Tesla vehicles. Refer to Approved Gas Metal Arc (GMA) Welders and Welding Wire for information on approved GMA welders and welding wire.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not weld on a Tesla vehicle before performing the Vehicle Electrical Isolation Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle Electrical Isolation Procedure). Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components.
    Informational PurposesAn informational icon, calling your attention
    Note
    Before GMA welding, a test weld using material of the same gauge and type should be performed to make sure that the welding equipment settings produce a satisfactory joint.
  18. Install the new Sill Outer (Front Section).
  19. Perform any necessary post-repair operations.