10/12/2024 15:32:21

Cowl Side Assembly

Repair Information

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
Properly mount the vehicle on a frame bench when performing this procedure.

Parts List


Quantity	Description	Image / Notes
1	ASY - COWL SIDE (Cowl Side Assembly)
2	Structural Bulb Rivet, 6.5 mm
13	Rivet, 4.8 mm
26	High Strength Structural 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 Hinge Pillar.
Remove the A-Pillar Outer Reinforcement.
Remove the original component.

or Factory Spot Welds

or Drill through factory spot welds
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.
Prepare for installation.
or Installation Spot Welds

or Structural Bulb Rivets, 6.5 mm

or Rivets, 4.8 mm
or High Strength Structural Rivets, 6.5 mm
- A = 75 mm.
Note
To avoid clash with the Sill Insert, the holes for rivets highlighted in red are created from outside the vehicle, but the rivets are installed from inside the vehicle.
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 foam dam.
Install the new A-Pillar Outer Reinforcement.
Install the Hinge Pillar.
Perform any necessary post-repair operations.