03/07/2024 16:00:53

Sill Outer (Front Section)

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.

Parts List


Quantity	Description	Image / Notes
2	M3 ASY - SIDE SILL OUTER (Sill Outer Assembly)
20	Structural Rivet, 6.5 mm Short
3	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.

Repair Procedure

Remove the necessary portion of the Body Side Outer Assembly to expose the underlying component being replaced.
Remove the Hinge Pillar (Section).
Cut the original component at the indicated locations.
Cut Line

Reference Line/Point
- A = 50 mm
Remove the original component.

or Factory Spot Welds
Cut the new component in the indicated location.
Cut Line

Reference Line/Point
- B = 942 mm
Create an 80 mm wide reinforcement plate from the second new Sill Outer.
Prepare for installation.

Note
A red X indicates a location where a factory-installed fastener is not being replaced.

Note
For each rivet being installed, drill a 6.7 mm hole through both the Sill Outer and the top part of the Sill Insert. These holes provide clearance for the rivets used in the Sill Outer section.

or Structural Bulb Rivets, 6.5 mm

or Structural Rivets, 6.5 mm Short

or Installation Spot Welds
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.
Perform resistance spot welding.

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.

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.
Install the Hinge Pillar (Section).
Install the portion of the Body Side Outer Assembly that was removed to expose the component being replaced.

Note
The Body Side Outer lower flange is secured to the Sill Outer using structural adhesive only.
Perform any necessary post-repair operations.