11/10/2024 16:57:19

Body Side Outer Assembly

Repair Information

  • Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
  • This procedure can be completed without using a frame bench.
  • The Body Side Outer Assembly can be:
    • Replaced in a single repair as a single complete component, using the M3 ASY, BODY SIDE OUTER service part and the instructions in the Repair Procedure section of this document.
    • Repaired using any of the pre-cut service assemblies shown in Service Assemblies. If replacing a portion of the Body Side Outer (not the entire Body Side Outer Assembly) using a service assembly, use only the relevant portions of each step in the Repair Procedure to determine which parts and fasteners are needed and the steps required to complete the repair.
    • Repaired in sections that are larger or smaller than the service assemblies. Any individual section or any combination of sections of the Body Side Outer Assembly can be replaced so long as the guidelines from the Sectioning Guidelines are followed.

Parts List

Quantity Description Image / Notes
1 M3 ASY, BODY SIDE OUTER
Informational PurposesAn informational icon, calling your attention
Note
A pre-cut sub assembly may be used if sectioning the Body Side Outer.
1 PLUG,ROUND,25MM,TPV,BLK
Tesla part number 1077461-00-A.
Informational PurposesAn informational icon, calling your attention
Note
Required only if repairing the Quarter section on vehicles built before 5-October-20.
10 Structural Bulb Rivet, 6.5 mm
2 Countersunk Rivet, 4.8 mm Short
1 Countersunk Rivet, 4.8 mm Long
2 Structural Countersunk Rivet, 6.5 mm
11 Flow Form Rivet S18
1 Flow Form Rivet S28
2 Bolt , SEMS,[FL],HX,M8X23.5,[109],G1009,PTC Tesla part number 1063260-00-C.
1 Rivnut,M6x1,4.0mm GRP,STL,ZnNi Tesla part number 1038174-00-A.
Informational PurposesAn informational icon, calling your attention
Note
Required only if repairing the Quarter section and the vehicle has a Rivnut to attach the ground wire to the Charge Port Housing Assembly.
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.

Service Assemblies

Aside from the M3 ASY, BODY SIDE OUTER, shown in the Parts List, the following service assemblies are available.
Body Side Outer Service Assemblies
ASY, A PLR BODY SIDE OTRASY, B PLR BODY SIDE OTRASY, REAR QUARTER OUTER ASSY

Sectioning Guidelines

General sectioning guidelines:
  • If a section repair requires the removal or installation of additional panels or assemblies, perform the necessary procedures using the specific repair procedure for each panel or assembly.
  • It is allowable to cut through a clearance hole or a non functional hole (exterior trim hole), as described below.
  • Do not cut within 25 mm. of the center of a bolt hole.
  • Sections do not require fasteners at butt joints unless specifically indicated.
  • A backing plate may be installed at a butt joint between sections (as described in create and install backing plates).
  • Gaps between panels of butt joints should be as small as possible to maximize joint strength.
  • GMA weld section butt joints.
  • Seal all open seams after welding.
  • If a butt joint includes a flange, do not weld on the flange (flanges are secured using only structural adhesive).

Informational PurposesAn informational icon, calling your attention
Note
Do not cut underlying panels when sectioning the Body Side Outer.

The images below show the Body Side Outer (complete). The colored areas indicate if sectioning is allowed. Compare the damaged area of the vehicle's Body Side Outer to the images below, then use the repair criteria corresponding to the color of the highlighted area to find the criteria to use to determine if the damaged area of the component can be sectioned.

Body Side Outer Sectioning
Informational PurposesAn informational icon, calling your attention
Note
Sectioning of Service Assemblies is identical to the corresponding area of the Body Side Outer (complete).
Informational PurposesAn informational icon, calling your attention
Note
If sectioning in this area, do not weld the butt joint in the indicated area; instead, fill the seam with strucrutal adhesive.

Based on the colors used in the image above, the allowed repairs are as follows:

Table 1. Allowed Sectioning
Area Color Arear Repairability
Green areas: Sectioning is allowed in these areas.
Yellow areas: Sectioning is allowed in these areas.
Informational PurposesAn informational icon, calling your attention
Note
Sectioning in these areas requires the component be returned to its original geometry for proper function.

Areas shown in yellow may:

  • Allow water ingress, so use special care to make sure that seals fit correctly in all repaired areas.
    Informational PurposesAn informational icon, calling your attention
    Note
    Once the repair is complete, make sure that all seals fit properly and make sure that water does not ingress in the repair area.
  • Be where other components mount to the Body Side Outer. Use special care to make sure that openings in the body Side Outer are the same size as the original openings, and ensure that mounting areas allow components fit properly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Once the repair is complete, make sure that mounted compnents are flush with the Body Side Outer surface and that the components fit correctly in all repaired areas.
Red areas: Sectioning is not allowed.

Repair Procedure

  1. If replacing a section of the Body Side Outer: Mark the Body Side Outer at the section cut line locations as described in the Sectioning Guidelines.
  2. Remove the original component.
    or Factory Spot Welds
    or Drill through factory spot welds
    Informational PurposesAn informational icon, calling your attention
    Note
    When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.

    or Factory SPRs

    or Bolts

  3. Separate the Wheel Arch flange.
  4. Prepare for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    If replacing a section of the Body Side Outer (not the entire Body Side Outer Assembly), use the relevant portions of each step to determine which parts and fasteners are needed and the steps required to complete the repair.
    Informational PurposesAn informational icon, calling your attention
    Note
    A red X indicates a location where a factory-installed fastener is not being replaced.

    or Countersunk Rivets, 4.8 mm Short

    or Countersunk Rivets, 4.8 mm Long

    or Structural Bulb Rivets, 6.5 mm
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the rivet circled in red connects all underlaying panels.

    or Structural Countersunk Rivets, 6.5 mm

    or Flow Form Rivets, S18

    or Flow Form Rivets, S28

    Bolt

    or Installation Spot Welds

    or Steel Plug Welds

  5. If replacing the Quarter section of the Body Side Outer of a vehicle built before 5-October-20, use the underlying panel for reference to mark and cut 2 holes in the locations outlined in green (shown below).
  6. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  7. Install the new component or components.
    Torque the bolts to 35 Nm.
    Informational PurposesAn informational icon, calling your attention
    Note
    The Body Side Outer lower flange is secured using structural adhesive only.
  8. Perform resistance spot welding.
    or Installation Spot Welds

    or Steel Plug Welds

    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
    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.
  9. If replacing a section of the Body Side Outer, perform GMA welding on the butt joints.
    GMA Weld
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not weld the panel where it directly contacts the high strength panels underneath. The heat from welding might weaken the strength of the underlying high strength steel structure.
    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
    Warning
    Before GMA welding, make sure that the structural adhesive is dry to the touch. If the structural adhesive is not dry to the touch before GMA welding, the strength of the adhesive bond might be compromised.
    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.
  10. Fold over the Wheel Arch flange.
  11. If replacing the Quarter section of the Body Side Outer of a vehicle built before 5-October-20, perform GMA welding to close the hole outlined in red.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not weld the panel where it directly contacts the high strength panels underneath. The heat from welding might weaken the strength of the underlying high strength steel structure.
    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
    Warning
    Before GMA welding, make sure that the structural adhesive is dry to the touch. If the structural adhesive is not dry to the touch before GMA welding, the strength of the adhesive bond might be compromised.
    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.
  12. If replacing the Quarter section of the Body Side Outer of a vehicle built before 5-October-20, install the pass through plug in the existing hole as shown.
  13. If replacing the Quarter section and the original Charge Port Housing had a ground wire or harness attachment point, drill a hole in the new Charge Port Housing for a Rivnut or a retainer clip.

    Rivnut

    Refer to the Charge Port Housing procedure for information about the size and location of the hole.

  14. Perform any necessary post-repair operations.