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 Assembly
can be:
- Replaced in a single repair as a single complete component, using the ASY- BODY SIDE OUTER service part and the instructions in the Repair Procedure section of this document.
- Repaired using any of the pre-cut service assemblies shown in 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 | ASSEMBLY - BODY SIDE OUTER COMPLETE (Body Side Outer Assembly) |
Note A pre-cut
sub assembly may be used if sectioning the Body Side Outer.
See Service Assemblies for more information. |
1 | High Strength Structural Rivet, 6.5 mm | |
1 | Countersunk Rivet, 4.8 mm Short | |
2 | Structural Bulb Rivet, 6.5 mm | |
10 | Flow Form Rivet S18 | |
4 | Flow Form Rivet S28 | |
4 | Flow Form Rivet S38 | |
4 | Bolt | Tesla part number 1063260-00-C. |
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.
Service Assemblies
Body Side Outer Service Assemblies | |
---|---|
A B PLR BODY SIDE OTR | REAR QUARTER OUTER ASY |
Sectioning Guidelines
- 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).
The images below show the Body Side Outer (complete). The colored areas indicate if sectioning is allowed. Compare the damaged area of the vehicle's Body Side Outer to the images below, then use the repair criteria corresponding to the color of the highlighted area to find the criteria to use to determine if the damaged area of the component can be sectioned.
Body Side Outer Sectioning | |
---|---|
Note Sectioning
of 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:
Area Color | Arear Repairability |
---|---|
Green areas: | Sectioning is allowed in these areas. |
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 include areas that:
|
Red areas: | Sectioning is not allowed. |
Repair Procedure
- If repairing the Upper A-Pillar section or the Rear Roof Rail section of the Body Side Outer: Remove the Roof Rack Bracket.
- If repairing the Hinge Pillar section of the Body Side Outer: Remove the Shotgun Outer.
- If replacing a section of the Body Side Outer: Mark the Body Side Outer at the section cut line locations described in the Sectioning Guidelines.
-
Remove the original component.
or Drill through factory spot weldsNoteWhen drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
or Bolts
-
Prepare for installation.
NoteIf only the Body Side Outer was removed, the spot welds obstructed by the Dashboard may be omitted.NoteIn the images below, a red X indicates a location where a factory-installed fastener is not being replaced. Secure these locations using structural adhesive only.
or High Strength Structural Rivets, 6.5 mm
or Structural Bulb Rivets, 6.5 mm
or Countersunk Rivets, 4.8 mm Short
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 bolts to 38 Nm.NoteThe Body Side Outer lower flange is secured using structural adhesive only.
-
Perform resistance spot
welding.
WarningFailure 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.CAUTIONDo 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.
-
Perform GMA welding.
or Steel Plug WeldsWarningFailure 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.WarningTo 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.CAUTIONDo 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.NoteBefore 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.
-
If replacing a section of
the Body Side Outer,
perform GMA welding on the butt joints.
WarningDo 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.WarningFailure 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.WarningTo 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.WarningBefore 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.CAUTIONDo 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.NoteBefore 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.
- If repairing the Hinge Pillar section of the Body Side Outer: Install the Shotgun Outer.
- If repairing the Upper A-Pillar section or the Rear Roof Rail section of the Body Side Outer: Replace the Roof Rack Bracket.