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 |
Note A pre-cut sub
assembly may be used if sectioning the Body Side
Outer. |
8 | 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 | |
3 | Flow Form Rivet S08 | |
12 | Flow Form Rivet S18 |
Service Assemblies
Body Side Outer Service Assemblies | ||
---|---|---|
ASY, A PLR BODY SIDE OTR | ASY, B PLR BODY SIDE OTR | ASY, REAR QUARTER OUTER ASSY |
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).
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 | |
---|---|
Note Sectioning
of Service Assemblies is identical to the corresponding area
of the Body Side Outer (complete). |
|
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:
Area Color | Arear Repairability |
---|---|
Green areas: | Sectioning is allowed in these areas. |
Yellow areas: | Sectioning is allowed in these areas. Note Sectioning in
these areas requires the component be returned to its
original geometry for proper function. Areas shown in yellow may:
|
Red areas: | Sectioning is not allowed. |
Repair Procedure
- If replacing a section of the Body Side Outer: Mark the Body Side Outer at the section cut line locations described in the Sectioning Guidelines.
-
Remove the original component.
or Factory Spot Weldsor Drill through factory spot weldsNoteWhen drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.or BoltsNoteRetain these bolts for use in installing the new component.
- Separate the Wheel Arch flange.
-
Prepare for installation.
NoteA 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
- Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
-
Install the new component or components.
Torque the bolts to 35 Nm.NoteThe Body Side Outer lower flange is secured using structural adhesive only.
-
Perform resistance spot
welding.
or Installation Spot WeldsWarningFailure 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.CAUTIONDo 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.
- Fold over the Wheel Arch flange.
- Perform any necessary post-repair operations.