03/07/2024 16:07:20

Body Side Outer

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 can be:
- Replaced in a single repair as a single complete component, using the Body Side Outer Complete service part and the instructions in the Repair Procedure section of this document.
- Repaired using any of the pre-cut service assemblies shown in Body Side Outer 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	BODY SIDE OUTER COMPLETE (Body Side Outer Complete)
2	Countersunk Rivet, 4.8 mm Short
7	Structural Bulb Rivet, 6.5 mm
2	Structural Countersunk Rivet, 6.5 mm
2	High Strength Structural Rivet, 6.5 mm
3	Flow Form Rivet S08
5	Flow Form Rivet S18
9	Flow Form Rivet S28
15	Flow Form Rivet S38
8	Flow Form Rivet S48
7	Bolt , M8x27	Tesla part number 1621820-00-A.

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 Service Assemblies


Body Side Outer Service Assemblies
ASSY - BODY SIDE OTR COMP	ASSY - PNL-BODY SIDE OTR

ASSY - BODY SIDE OTR A-PILLAR	ASSY - BODY SIDE OTR C-PILLAR

Sectioning Guidelines

General sectioning guidelines:

When sectioning in the area where the C-Pillar meets the Rear Quarter:
- Cut as described below:
  Cut Line
  Reference Line/Point
  - A = 30 mm.
  - B = 25 mm.
  - C = 110 mm.
- Create and install a backing plate under the butt joint:
  GMA Weld
  or Aluminum Plug Welds
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).

Note

Do not cut underlying panels when sectioning the Body Side Outer.


Body Side Outer Sectioning

Note Sectioning of Body Side Outer Service Assemblies is identical to the corresponding area of the Body Side Outer (complete).

Based on the colors used in the image above, the allowed repairs are as follows:

Table 1. Allowed Sectioning
Area Color	Arear Repairability
Green areas:	Sectioning is allowed in these areas. Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. Note Seal all open seams after welding.
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: Allow water ingress, so use special care to make sure that seals fit correctly in all repaired areas. Note Once the repair is complete, make sure that all seals fit properly and make sure that water does not ingress in the repair area. Be where other components mount to the Body Side Outer. Use special care to make sure that openings in the Body Side Outer are the same size as the original openings, and ensure that mounting areas allow components fit properly. Note Once the repair is complete, make sure that mounted compnents are flush with the Body Side Outer surface and that the components fit correctly in all repaired areas. Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. Note Seal all open seams after welding.
Red areas:	Sectioning is not allowed.

Repair Procedure

If repairing the Dog Leg Section section of the Body Side Outer: Remove the Quarter Outer Skin (Vehicles Built Through February 17, 2022).
Remove the Rear Header Upper.
Separate the rear wheel arch flange.

Note
If repairing only a section of the Body Side Outer, separate only the necessary portion of the hemmed flange.
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.

or Factory SPRs

or Bolts
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.

or Structural Bulb Rivets, 6.5 mm

or Countersunk Rivets, 4.8 mm Short

or Structural Countersunk Rivets, 6.5 mm
or High Strength Structural Rivets, 6.5 mm
- A = 13 mm.
- B = 9 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 Bolts
If repairing a section of the Body Side Outer: If space is available under the butt joints between sections, create and install a backing plate under each butt joint.
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 24 Nm.
If replacing a section of the Body Side Outer, perform GMA welding on the butt joints.

GMA Weld

or Aluminum Plug Welds

Warning
Do not weld the panel where it directly contacts the high strength panels underneath. The heat from welding might weaken the strength of the underlying high strength steel structure.

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.

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.

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.
Install the Rear Header Upper.
If repairing the Dog Leg Section section of the Body Side Outer: Install the Quarter Outer Skin (Vehicles Built Through February 17, 2022).
Fold over the wheel arch flange.
Perform any necessary post-repair operations.