03/07/2024 15:59:24

Cowl Top

Repair Information

  • Use this procedure to replace any combination of the sections of the Cowl Top Assembly shown below. Remove and install the appropriate fasteners depending on the sections being replaced.
  • 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.

Using this Document

This document contains two major parts:
  1. Cowl Top Section Descriptions provide information on where and how to section the Cowl Top Assembly as necessary to replace damaged areas of the Cowl Top Assembly, or to gain access to underlying parts of the vehicle structure. Use the section descriptions to determine where to successfully section the Cowl Top Assembly as needed for the repair being performed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Sections of the Cowl Top Assembly can be replaced individually or in any combination of sections so long as the referenced cut locations identified in this document are used.
    Informational PurposesAn informational icon, calling your attention
    Note
    Measurements from bolt hole locations are from the center of the referenced holes unless stated differently in the section description.
  2. The Repair Procedure portion of this document contains the information necessary to replace the entire Cowl Top Assembly. If replacing sections of the Cowl Top Assembly (not the entire Cowl Top Assembly), use the relevant portions of each step to determine which parts and fasteners are needed and the steps required to complete the repair.

Parts List

Quantity Description Image / Notes
1 for complete replacement or 2 for section repair ASSY - COWL TOP (Cowl Top Assembly)
2 Rivet, 4.8 mm
2 High Strength Structural Rivet, 6.5 mm
3 Countersunk Rivet, 4.8 mm Short
8 Structural Bulb Rivet, 6.5 mm

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.

Cowl Top Section Descriptions

Cowl Top Assembly and Sectioning
The Cowl Top Assembly (shown below) is a single assembly, and can be replaced as a single repair: Alternatively, instead of replacing the complete Cowl Top Assembly, areas of the Cowl Top can be replaced using portions of the complete Cowl Top Assembly service part using the cut lines described in this document.

Cowl Top (Complete)

Cowl Top (Sections)
Cowl Top Section Descriptions

Cut Line

Reference Line/Point

  • A = 84 mm.
  • B = 66 mm.
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Warning
Do not cut bolt holes when cutting sections.
Informational PurposesAn informational icon, calling your attention
Note
Install a backing plate behind each butt joint.

Repair Procedure

  1. 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.
  2. For vehicles manufactured after January 6, 2019 only: Remove the spot welds shown below.
    or Factory Spot Welds
  3. For section repairs only: Cut the new Cowl Top service part as indicated in the Cowl Top Section Descriptions to create the new component.
  4. Prepare for installation.

    or Structural Bulb Rivets, 6.5 mm

    or Rivets, 4.8 mm

    or Countersunk Rivets, 4.8 mm Short

    or Installation Spot Welds

  5. For vehicles manufactured after January 6, 2019 only: Install the indicated fasteners.

    or High Strength Structural Rivets, 6.5 mm

  6. For section repairs only: Create and install a backing plate.
  7. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  8. Install the new component or components.
  9. Perform resistance spot welding.
    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.
  10. For section repairs only: 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.
  11. Perform any necessary post-repair operations.