2024-10-22

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.

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 (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 as needed for the repair being performed.
Note
Sections of the Body Side Outer 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. If replacing sections of the Body Side Outer (not the entire Body Side Outer Assembly), use the relevant portions of each step to determine which parts and fasteners are needed and the steps required to complete the repair.

Parts List


Quantity	Description	Image / Notes
If replacing the entire Body Side Outer: 1	BODY SIDE OUTER COMPLETE (Body Side Outer – Complete)
3	Structural Bulb Rivet, 6.5 mm
8	High Strength Structural Rivet, 6.5 mm
3	Countersunk Rivet, 4.8 mm Long
1	Countersunk Rivet, 4.8 mm Short
1	Flow Form Rivet S08
3	Flow Form Rivet S18
16	Flow Form Rivet S28
84	Flow Form Rivet S38
7	Flow Form Rivet S48
3	Flow Form Rivet S58
7	Bolt	Tesla part number 1621820-00-A.
3	Bolt , M6x18	Tesla part number 1006529-00-A.
2	Bolt , M10x80	Tesla part number 1053943-00-A.
1	Bolt, Torx-head , M8x20	Tesla part number 1014747-00-B.

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, Subassemblies, and Subassembly Sectioning
The BODY SIDE OUTER COMPLETE (shown below) is a single assembly, and can be replaced as a single repair:	Alternatively, instead of replacing the BODY SIDE OUTER COMPLETE, areas of the Body Side Outer Complete can be replaced using the cut lines described in this document.


Body Side Outer Section Descriptions
A–Pillar Section Cut Line Reference Line/Point A = 750 mm. B = 870 mm. Warning Do not cut bolt holes when cutting sections. Note The cut can be made within 350 mm of the specified cut line location to allow sectioning of the Body Side Outer. Note Install a backing plate behind each butt joint if there is sufficient space. Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. or Aluminum Plug Welds Note For these plug welds, drill a 9 mm hole in each of the indicated locations. GMA Weld 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 gaps behind panels and underlying components.
Sill Section Cut Line Reference Line/Point C = 109 mm. D = 109 mm. Warning Do not cut bolt holes when cutting sections. Note The cut can be made within 235 mm of the specified cut line location to allow sectioning of the Body Side Outer. Note Install a backing plate behind each butt joint if there is sufficient space. Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. or Aluminum Plug Welds Note For these plug welds, drill a 9 mm hole in each of the indicated locations. GMA Weld 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 gaps behind panels and underlying components.
B-Pillar Section Cut Line Reference Line/Point E = 24 mm. F = 58 mm. Warning Do not cut bolt holes when cutting sections. Note The cut can be made within 10 mm of the specified cut line location to allow sectioning of the Body Side Outer. Note Install a backing plate behind each butt joint if there is sufficient space. Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. or Aluminum Plug Welds Note For these plug welds, drill a 9 mm hole in each of the indicated locations. GMA Weld 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 gaps behind panels and underlying components.

Repair Procedure

Remove the necessary portion of the A–Pillar Outer to expose the underlying component being repaired.
Remove the original component.

or Factory Spot Welds

or Factory SPRs

or Bolts

or Bolt, Torx-head
Prepare for installation.
or High Strength Structural Rivets, 6.5 mm
- A = 46 mm.
- B = 11 mm.
- C = 35 mm.
- D = 9 mm.
or Structural Bulb Rivets, 6.5 mm

or Countersunk Rivets, 4.8 mm Short

or Countersunk Rivets, 4.8 mm Long

or Flow Form Rivets, S08

or Flow Form Rivets, S18

or Flow Form Rivets, S28
or Flow Form Rivets, S38
- E = 48 mm.
- F = 12 mm.
- G = 8 mm.
- H = 9 mm.
- I = 9 mm.
- J = 8 mm.
- K = 9 mm.
- L = 9 mm.
- M = 13 mm.
- N = 9 mm.
- O = 5 mm.
- P = 9 mm.
or Flow Form Rivets, S48
or Flow Form Rivets, S58
- Q = 15 mm.
- R = 9 mm.
or Flow Form Rivets, S68

or Bolts

or Bolt, Torx-head
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
If replacing a section of the Body Side Outer only: Perform GMA welding on the butt joints between sections.
GMA Weld
or Aluminum Plug Welds

Note
Do not weld a panel where it directly contacts a structural panel underneath. The heat from welding might weaken the strength of the underlying panel. Instead of welding, use structural adhesive to fill gaps between a panel and underlying panels.

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.
Install the new component or components.
Torque the bolts as follows:
- Hex-head M8x27 bolts part number 1621820-00-A: 24 Nm.
- Hex-head M6x18 bolts part number 1006529-00-A: 12 Nm.
- Hex-head M8x27 bolts part number 1053943-00-A: 45 Nm.
- Torx M8x20 bolts part number 1014747-00-B: 24 Nm.
Install the necessary portion of the A–Pillar Outer to cover the underlying component.
Perform any necessary post-repair operations.