Installing the Replacement Component

When installing the replacement component:

Once the new component has been installed, complete any necessary Post-Repair Operations.

Install a Foam Dam

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Note
If a factory foam dam was on the vehicle and attached to the component being replaced, it should have been removed from the original component and saved. If a new foam dam is not provided on the replacement component, the original foam dam can be installed on the new component.
  1. Apply a bead of urethane sealant to the contacting edges of the foam dam.
  2. Install the foam dam in the same position on the new component as it was on the original component.

Apply Adhesives

  1. Gather all parts, equipment, and consumables necessary to apply adhesives.
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    Warning
    Adhesives, sealants, and foam products must be used as specified in the repair procedure. Use only Tesla-approved adhesives, sealants, and foam products; refer to Approved Chemicals for a list of currently approved products.
  2. Check the technical specifications of the approved adhesive ensure that you have enough time to perform all the assembly steps in the temperature and humidity conditions you are working in.
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    Note
    If resistance spot welding is performed in the repair procedure, the welding must be completed before the adhesive cures. Be sure to factor welding time in your calculations.
  3. Clean all the mating surfaces on the new component and on the vehicle with isopropyl alcohol (IPA).
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    CAUTION
    If any bare metal mating surfaces have been exposed for two hours or longer, abrade the mating surfaces again to remove oxidation, then clean the mating surfaces with isopropyl alcohol (IPA).
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    Warning
    Wipe off the remaining isopropyl alcohol with a clean, dry towel immediately after application. Do not let the remaining isopropyl alcohol air dry. Allowing the remaining isopropyl alcohol to air dry can compromise the adhesive bond.
  4. Apply the structural adhesive:
    1. Apply a bead of structural adhesive on the vehicle.
    2. Smear the bead of structural adhesive on the vehicle.
    3. Apply a bead of structural adhesive on the replacement component.
    4. Smear the bead of structural adhesive on the replacement component.
    5. Apply a new bead of structural adhesive on top of the already smeared adhesive of either the vehicle or the new component.
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      Note
      Do not apply a new bead of structural adhesive on both the vehicle and the new component.

Secure the New Component

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Note
Complete all necessary preparation steps on the new component and on the vehicle before securing the new component.
  1. Put the new component in position on the vehicle and secure it in place with clamps and/or fixtures.
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    Warning
    When securing the component, structural adhesive should be visible squeezing out along the joints between all mating surfaces, but no structural adhesive should be within 25 mm. of any GMA weld location.
  2. Insert all fasteners (rivets, HUCK BOMs, and nuts or bolts) but do not fully install them at this time.
  3. Clamp all areas that will be secured with self-piercing rivets or welds.
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    CAUTION
    Use only insulated clamps within 200 mm (8 in) of resistance spot weld locations. Do not perform resistance spot welding when there is a shunting (uninsulated) clamp within 200 mm (8 in) of the spot weld location.
  4. Install all blind rivets, flow form rivets, and HUCK BOMs.
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    Note
    Refer to the operating instructions for the approved fastener installation tool for details on how to install the relevant fastener. Use only approved fastener installation tools for structural repairs. Refer to Approved Fasteners and Fastener Tools for Structural Repairs for a list of current approved fastener installation tools.
  5. Tighten each nut and bolt to the torque value specified in the repair procedure.
  6. Install all self-piercing rivets.
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    Warning
    Use the die indicated in the repair procedure to install each self-piercing rivet. Using an incorrect die might result in premature component separation.
  7. Perform resistance spot welding if necessary.
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    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.
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    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.
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    Note
    When welding areas where factory spot welds were removed, place an installation spot weld in the same location where the factory spot welds were removed.
  8. Put panel clamps in place in any areas not secured by fasteners or welds to ensure a good adhesive bond between panels.
  9. Clean off any excess adhesive that squeezed out between the panels as well as any equipment that was contaminated with adhesive during the installation process.
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    Warning
    After securing the component, no structural adhesive may be within 25 mm of any GMA weld location (structural adhesive within the GMA weld location can cause weld failure).
  10. Force cure the structural adhesive or allow enough time for the adhesive to cure at ambient temperature.
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    Note
    Refer to the technical specifications for the structural adhesive being used to determine the amount of heat and/or time for the structural adhesive to reach full design strength.
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    Warning
    When force curing adhesive in a repair area near the High Voltage Battery, do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery.
  11. Perform GMA welding if necessary.
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    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.
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    Warning
    Do not weld a panel where it directly contacts underlying structural components unless directed to do so in the repair procedure. The heat affect zone from welding can weaken the strength of underlying structural components.
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    Warning
    Before GMA welding, make sure that the structural adhesive is dry to the touch. If the structural adhesive is not dry to the touch before GMA welding, the strength of the adhesive bond might be compromised.
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    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.
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    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.

Restore a Hemmed Flange

  1. Fold over the hemmed flange.
  2. Apply seam sealer to the overlap.