03/07/2024 16:00:52

Sill Outer (Complete)

Parts List

Quantity Description Image / Notes
1 ASSY - Sill Outer (Sill Outer Assembly)
1 Sill Insert
2 Sill Insert Mounting Bracket
16 High Strength Structural Rivet, 6.5 mm
2 Structural Bulb Rivet, 6.5 mm
4 Rivet, 4.8 mm
6 Structural Rivet, 6.5 mm Short
1 Flow Form Rivet S08
1 Flow Form Rivet S18
3 Flow Form Rivet S38

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 necessary portion of the Body Side Outer Assembly to expose the underlying component being replaced.
  2. Remove the Hinge Pillar (Section).
  3. Remove the lower section of the C–Pillar Reinforcement.
  4. Remove the original component.
    Cut Line

    or Factory SPRs

    or Factory Structural Rivets

    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.
  5. Remove the Sill Insert.
  6. From the back side of the Sill Outer, separate the spot welds at the bottom flange of the B–Pillar Outer (the area circled in red).
    or Factory Spot Welds
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not drill through or damage the bottom flange of the B–Pillar Outer.
  7. Mark the center line for the installation for the Sill Insert Mounting Brackets on the new Sill Insert as shown below.
    • A = 260 mm
    • B = 221 mm
    Informational PurposesAn informational icon, calling your attention
    Note
    The measurements are from the end of the Sill Insert to the center of the Sill Insert Mounting Bracket.
  8. Clamp the new Sill Insert to the new Sill Outer in the locations indicated.
    • C = 173 mm
    • D = 51 mm
  9. Position the Sill Insert Mounting Brackets between the Sill Insert and the Sill Outer along the center line drawn in an earlier step, and adjust the brackets so that they make contact with the Sill Outer.
  10. Prepare to install the Sill Insert Mounting Brackets.

    or Structural Rivets, 6.5 mm Short

  11. Apply structural adhesive to the mating surfaces of the Sill Insert Mounting Brackets and the Sill Insert.
  12. Install the Sill Insert Mounting Brackets on the Sill Insert.
  13. Prepare to install the new Sill Insert in the new Sill Outer.

    or Structural Rivets, 6.5 mm Short

  14. Apply structural adhesive to the mating surfaces on Sill Insert Mounting Brackets, the Sill Insert, and the Sill Outer.
  15. Install the Sill Insert in the new Sill Outer Assembly.
  16. Prepare to install the new Sill Outer Assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    A red X indicates a location where a factory-installed fastener is not being replaced.

    or Installation Spot Welds

    or Rivets, 4.8 mm
    • E = 10 mm
    • F = 74 mm
    or High Strength Structural Rivets, 6.5 mm
    Informational PurposesAn informational icon, calling your attention
    Note
    The upper row of rivets securing the bottom of the B–Pillar should match the factory spot weld locations.
    • G = 15 mm
    Informational PurposesAn informational icon, calling your attention
    Note
    The center of all rivets in the bottom row of structural rivets must be at the indicated height from the lower edge of the new component, as shown below.

    or Structural Rivets, 6.5 mm Short

    or Structural Bulb Rivets, 6.5 mm

    or Flow Form Rivets, S08

    or Flow Form Rivets, S18

    GMA Weld

  17. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  18. Install the new component or components.
  19. Perform resistance spot welding.
    or Installation Spot 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.
  20. 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.
  21. Install the lower section of the C–Pillar Reinforcement.
  22. Install the Hinge Pillar (Section).
  23. Install the portion of the Body Side Outer Assembly that was removed to expose the component being replaced.
  24. Install the fasteners as indicated.
    or Flow Form Rivets, S38
  25. Perform any necessary post-repair operations.