03/10/2024 16:42:57

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	SIDE SILL INSERT (Sill Insert)
1	Bolt , SEMS[FL] - HX - M10-1.5x42 - [109] - G1009 - CMAT	Tesla part number 1516228-00-B.
1	Model 3 Front Sill Insert Section Kit	Kit contents: Cell 1 Reinforcement Insert (x1) Cell 2 Reinforcement Insert (x1) Cell 3 Reinforcement Insert Plates (x2) Bolt HH M8X29 109 G1009 B M (x6) SPAC Nut, M8x2.8-3.5,STL[10] (x6) High Strength Structural Rivet, 6.5 mm (x8) Weld nut, HF,PRJ,M8,[10],TEF (x1)

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.

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
Remove the weld nut from the Door Ring Inner.
Cut the new Sill Insert as indicated below to make the new component.
Cut Line

Reference Line/Point
- B = 395 mm
Use one of the Cell 3 Reinforcement Insert Plates as a template and drill 8 mm holes in the new component and the remaining portion of the Sill Insert.
Enlarge the holes in one of the Cell 3 Reinforcement Insert Plates to 12 mm to allow for SPAC nut installation.

Note
SPAC nuts will be mounted on this Reinforcement Plate, which is installed inside the Sill Insert.
Use structural adhesive to install the SPAC nuts in the enlarged holes of the Cell 3 Reinforcement Insert Plate.

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 Reinforcement Insert Plates 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 Reinforcement Insert Plates to 25 Nm.
Install the new weld nut on the Door Ring Inner.
GMA Weld
Perform GMA welding.
GMA Weld
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 necessary portion of the Door Ring Outer.
Perform any necessary post-repair operations.