28/08/2024 13:49:12

Body Side Outer (Generation 2 Rear Node and Generation 1 B–Pillar)

Repair Information

Any individual section or any combination of sections of the Body Side Outer can be replaced so long as the referenced cut lines from the Body Side Outer Section Descriptions portion of this document are used.
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.

Verify This is the Correct Procedure

There are several variations of the Body Side Outer procedure. Use this procedure only if the vehicle has both:

Generation 2 Rear Node: This Rear Node was installed on vehicles built on or after November 5, 2014.
Refer to Model S Rear Node Versions for information on identifying the generation of the Rear Node in the vehicle.
Generation 1 B–Pillar: This B–Pillar was installed on Model S vehicles built before October 12, 2016.
Refer to Model S B–Pillar Generation Identification for information on identifying the generation of the B–Pillar in the vehicle.

After confirming which generation of Rear Node and B–Pillar are in the vehicle, select the corresponding procedure:


Rear Node	B–Pillar	Correct Procedure
Generation 1	Generation 1	Body Side Outer (Generation 1 Rear Node and Generation 1 B–Pillar)
Generation 2	Generation 1	Body Side Outer (Generation 2 Rear Node and Generation 1 B–Pillar) (this procedure)
Generation 2	Generation 2	Body Side Outer (Generation 2 Rear Node and Generation 2 B–Pillar)

Using this Document

This document contains two major parts:

Body Side Outer Section Descriptions provide information on where and how to section the Body Side Outer Assembly (or subassemblies) as necessary to replace damaged areas of the Body Side Outer panel, or to gain access to underlying parts of the vehicle structure. Use the section descriptions to determine where to successfully section the Body Side Outer Assembly as needed for the repair being performed.
Note
Sections of the Body Side Outer Assembly can be replaced individually or in any combination of sections so long as the referenced cut locations identified in this document are used.
Note
Measurements from bolt hole locations are from the center of the referenced holes unless stated differently in the section description.
The Removal and Replacement portions of this document contain the information necessary to replace the entire Body Side Outer Assembly. If replacing sections of the Body Side Outer Assembly (not the entire Body Side Outer), use the relevant portions of each step to determine which parts and fasteners are needed and the necessary steps to complete the repair.

Parts List


Quantity	Description	Image / Notes
1	ASSY - BODY SIDE OTR COMP (Body Side Outer Complete)	Note A pre-cut subassembly may be used if sectioning the Body Side Outer. See Body Side Outer Section Descriptions for more information.
1	High Strength Structural Rivet, 6.5 mm
11	Structural Bulb Rivet, 6.5 mm
10	Structural Rivet, 6.5 mm Medium
4	Countersunk Rivet, 4.8 mm Long
2	Countersunk Rivet, 4.8 mm Short
4	High Strength Structural Flange Rivet, 6.5 mm
8	Structural Flange Rivet
35	Flow Form Rivet S08
19	Flow Form Rivet S18
32	Flow Form Rivet S28
23	Flow Form Rivet S38
104	Flow Form Rivet S48
13	Flow Form Rivet S58
2	Flow Form Rivet S68
2	Bolt, Panhead Flange , M8 x 1.25 x 16 PAN FLANGE HEAD	Tesla part number 1008833-01-A.
4	Bolt, hex-head	Tesla part number 1057210-00-A.
6	Nut , M8-1.25,HF,Steel	Tesla part number 1006628-01-A.
1	BUTYL PATCH 300X150X2	Tesla part number 1004969-00-A.

Note

Rivet quantities listed above are for the complete repair. If repairing a section (or sections), the quantity of parts and fasteners will be different.

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.

Body Side Outer Section Descriptions


Body Side Outer Service Assemblies and Sections
The Body Side Outer Complete is a single component, and can be replaced as a single repair. Alternatively, instead of replacing the complete Body Side Outer, areas of the Body Side Outer can be replaced using: Sections of the Body Side Outer Complete Assembly using the cut lines described in this document. Pre-made service subassemblies (shown below). Sections of subassemblies using the cut lines described in this document. Warning When cutting sections, do not cut bolt holes. Note Install a backing plate behind each butt joint if there is sufficient space and use structural adhesive to fill any gaps behind panels and underlying components.
Assembly or Subasembly	Sections
ASSY - BODY SIDE OTR COMP

ASSY - PNL-BODY SIDE OTR

ASSY - BODY SIDE OTR A-PILLAR

ASSY - BODY SIDE OTR B-PILLAR

ASSY - BODY SIDE OTR C-PILLAR


Body Side Outer Section
Hinge Pillar Cut Line Reference Line/Point A = 60 mm. B = 148 mm. Note The cut can be made within 60 mm. of the specified location to allow sectioning of the Door Ring Outer. GMA Weld or Aluminum Plug Welds
A–Pillar Cut Line Reference Line/Point C = 69 mm. D = 72 mm. Note The cut can be made within 369 mm. of the specified location to allow sectioning of the Door Ring Outer. GMA Weld or Aluminum Plug Welds
Front Sill Cut Line Reference Line/Point E = 126 mm. F = 126 mm. Note The cut can be made within 270 mm. of the specified location to allow sectioning of the Door Ring Outer. GMA Weld or Aluminum Plug Welds
B–Pillar Cut Line Reference Line/Point G = 229 mm. H = 182 mm. Note The cut can be made within 76 mm. of the specified location. GMA Weld or Aluminum Plug Welds Warning Do not weld a panel where it directly contacts underlying structural components. The heat affect zone from welding can weaken the strength of underlying structural components. Use structural adhesive to fill any gaps behind panels and underlying components.
Rear Roof Rail Cut Line Reference Line/Point I = 97 mm. J = 40 mm. Note The cut can be made up to 200 mm. forward or up to 280 mm. to the rear of the specified location to allow sectioning of the Door Ring Outer. GMA Weld or Aluminum Plug Welds
Rear Sill Cut Line Reference Line/Point K = 125 mm. L = 120 mm. Note The cut can be made within 70 mm. of the specified location to allow sectioning of the Door Ring Outer. GMA Weld or Aluminum Plug Welds
Dogleg Cut Line Reference Line/Point M = 280 mm. N = 425 mm. Note The procedure must be performed before this section can be replaced. Note The cut can be made within 70 mm. of the specified location. GMA Weld or Aluminum Plug Welds
Rear Quarter Cut Line Reference Line/Point O = 30 mm. P = 25 mm. Q = 110 mm. GMA Weld or Aluminum Plug Welds

Repair Procedure

Remove the component that covers the Front Header Assembly:
Depending on the vehicle build date, the component that covers the Front Header Assembly may be any of the following:
- Roof Assembly (refer to procedure)
- Roof Glass (refer to procedure)
- Panoramic Roof Assembly frame (refer to procedure)
Remove the original component.

or Factory Spot Welds

or Factory SPRs

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.

or Factory Structural Rivets

Factory Pin and Collar
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.

or High Strength Structural Rivets, 6.5 mm
or Structural Bulb Rivets, 6.5 mm
- A = 10 mm.
- B = 57 mm.
or Countersunk Rivets, 4.8 mm Short
or Countersunk Rivets, 4.8 mm Long
- C = 14 mm.
- D = 51 mm.
or Structural Rivets, 6.5 mm Medium

or High Strength Structural Flange Rivet, 6.5 mm

or Structural Flange Rivets, 6.5 mm

or Flow Form Rivets, S08

or Flow Form Rivets, S18

or Flow Form Rivets, S28

or Flow Form Rivets, S38

or Flow Form Rivets, S48

or Flow Form Rivets, S58

or Flow Form Rivets, S68

Bolt, Panhead Flange
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 25 Nm.
If performing a section repair only: Perform GMA welding on the butt joints.
GMA Weld
or Aluminum Plug Welds

Warning
Do not weld a panel where it directly contacts an underlying structural component. The heat from welding might weaken the strength of the structural component.

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
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.

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.

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.
If a camera is not to be installed, install a butyl patch.
Trim the butyl patch to fit within the gasket of the B–Pillar applique.
Note
The following measurements are approximate.
E = 60 mm.
F = 125 mm.
G = 80 mm.
Install the component that was removed to provide access to the Front Header Assembly:
- Roof Assembly (refer to procedure)
- Roof Glass (refer to procedure)
- Panoramic Roof Assembly frame (refer to procedure)
Enlarge the existing holes in the the B-Pillar and the B-Pillar Seal Carriers to 10 mm.
Install the B-Pillar Seal Carriers.

or Bolts, hex-head

Nut

Torque the bolts to 10 Nm.
Perform any necessary post-repair operations.