2024-12-04

A–Pillar Outer

Using this Document

This document contains two major parts:
  1. A–Pillar Outer Section Descriptions provide information on where and how to section the A–Pillar Outer as necessary to replace damaged areas of the A–Pillar Outer, or to gain access to underlying parts of the vehicle structure. Use the section descriptions to determine where to successfully section the A–Pillar Outer as needed for the repair being performed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Sections of the A–Pillar Outer can be replaced individually or in any combination of sections so long as the referenced cut locations identified in this document are used.
    Informational PurposesAn informational icon, calling your attention
    Note
    Measurements from bolt hole locations are from the center of the referenced holes unless stated differently in the section description.
  2. The Removal and Replacement portions of this document contain the information necessary to replace the entire A–Pillar Outer. If replacing a section of the A–Pillar Outer (not the entire A–Pillar Outer), 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 complete A–Pillar Outer: 1

If replacing a section of the A–Pillar Outer: 2

 ASY-A PILLAR OTR (A–Pillar Outer)
2 Countersunk Rivet, 4.8 mm Short
5 Rivet, 4.8 mm
4 Flow Form Rivet S28
13 Flow Form Rivet S38

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.

A–Pillar Outer Section Descriptions

A–Pillar Outer Sectioning

The A–Pillar Outer (shown below) can be replaced as a single repair.

Alternatively, instead of replacing the complete A–Pillar Outer, the upper or lower areas of the A–Pillar Outer can be replaced using portions of the complete A–Pillar Outer service part using the cut lines described in this document.

 

A–Pillar Outer Section Descriptions

Section Cut Line

Cut Line

Reference Line/Point

  • A = 95 mm.
  • B = 94 mm.
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Note
The cut can be made within 245 mm. of the specified cut line location.
GMA Weld

Repair Procedure

  1. If replacing a section of the A–Pillar Outer: Mark the A–Pillar Outer at the section cut line location described in the A–Pillar Outer Section Descriptions.
  2. If replacing a section of the A–Pillar Outer: Cut the A–Pillar Outer service part at the section cut line location described in the A–Pillar Outer Section Descriptions.
  3. Remove the original component.
    Informational PurposesAn informational icon, calling your attention
    Note
    If replacing a section of the A–Pillar Outer: Remove only the A–Pillar section and the fasteners in the section being replaced.

    or Factory Spot Welds

    or Factory SPRs

  4. If replacing a section of the A–Pillar Outer: Create and install a backing plate.
  5. Prepare for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    A red X indicates a location where a factory-installed fastener is not being replaced.
    or Flow Form Rivets, S38
    • A = 9 mm.

    or Countersunk Rivets, 4.8 mm Short

    or Rivets, 4.8 mm
    • B = 60 mm.

    or Flow Form Rivets, S28

  6. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  7. Install the new component or components.
  8. If replacing a section of the A–Pillar Outer: Perform GMA welding.
    Informational PurposesAn informational icon, calling your attention
    Note
    Weld the butt joint between A–Pillar sections.

    GMA Weld

    Warning IconA warning icon, calling your attention to a possibly risky situation
    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 IconA warning icon, calling your attention to a possibly risky situation
    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 IconA warning icon, calling your attention to a possibly risky situation
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
  9. Perform any necessary post-repair operations.