21/03/2023 19:41:20

Side Sill Insert (Front Section)

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.

Parts List


Quantity	Description	Image / Notes
1	MY SIDE SILL INSERT SVC E-COATED (Sill Insert)
1	Bolt	Tesla part number 1516228-00-B.
1	Model 3 Front Sill Insert Section Kit	Kit contents: M3 Cell 1 Connector, part number 1467691-00-A (x1) M3 Cell 2 Connector, part number 1467693-00-A (x1) M3 Cell 3 Connector Strap, part number 1467694-00-A (x2) Bolt HF M8x1.25x20 [10.9], part number 2007113 (x6) SPAC Nut, M8x2.8-3.5,STL[10], part number 1071915-00-A (x6) High Strength Structural Rivet, 6.5 mm , part number 1454538-00-A (x8) Weld nut, HF,PRJ,M8,[10],TEF, part number 1077796-00-B (x1)

When ordering parts, refer to the Parts Manual 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 Manual to find a specific part for the vehicle.

Repair Procedure

Remove the necessary portion of the Door Ring Outer.
Cut the original component at the indicated locations.
Cut Line

Reference Line/Point
- A = 700 mm
Remove the original component.

or Bolts

Note
Remove the foam dam from the Sill Insert section being removed and save it for installation in a later step.
Cut the new Sill Insert as indicated below to make the new component.
Cut Line

Reference Line/Point
- B = 398 mm
Use one of the Cell 3 Connector Straps as a template and drill 8 mm holes in the new component and the remaining portion of the Sill Insert.

Note
If necessary, remove the weld nut from the Door Ring Inner below the repair area to allow clearance for the drill.
Enlarge the holes in one of the Cell 3 Connector Strap to 12 mm to allow for SPAC nut installation.
Use structural adhesive to install the SPAC nuts in the enlarged holes of the Cell 3 Connector Strap.

Note
Refer to Install the new component or components for instructions on installing the SPAC nuts on the connector strap.

Note
After the adhesive is cured, inspect the threads of the SPAC nuts on the Cell 3 Connector Strap and use a thread chaser to remove any dried adhesive.
Insert the Cell 1 and Cell 2 connectors and prepare for installation.

or High Strength Structural Rivets, 6.5 mm

or Bolts
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.

Torque the front bolt on the new Sill Insert section to 60 Nm.

Torque the bolts for the Cell 3 Connector Strap to 25 Nm.

Note
If it was necessary to remove the weld nut from the Door Ring Inner, weld on a new weld nut.
Install the foam dam that was removed in an earlier step.
Install the necessary portion of the Door Ring Outer.