Adhesives, sealants, and foam products must be used as specified in the repair procedure. Use only Tesla-approved adhesives, sealants, and foam products; refer to Approved Chemicals for a list of currently approved products.

If resistance spot welding is performed in the repair procedure, the welding must be completed before the adhesive cures. Be sure to factor welding time in your calculations.

If any bare metal mating surfaces have been exposed for two hours or longer, abrade the mating surfaces again to remove oxidation, then clean the mating surfaces with isopropyl alcohol (IPA).

Wipe off the remaining isopropyl alcohol with a clean, dry towel immediately after application. Do not let the remaining isopropyl alcohol air dry. Allowing the remaining isopropyl alcohol to air dry can compromise the adhesive bond.

After securing the component, no structural adhesive may be within 25 mm of any GMA weld location (structural adhesive within the GMA weld location can cause weld failure).

Refer to the operating instructions for the approved fastener installation tool for details on how to install the relevant fastener. Use only approved fastener installation tools for structural repairs. Refer to Approved Fasteners and Fastener Tools for Structural Repairs for a list of current approved fastener installation tools.

Use the die indicated in the repair procedure to install each self-piercing rivet. Using an incorrect die might result in premature component separation.

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.

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.

When welding areas where factory spot welds were removed, place an installation spot weld in the same location where the factory spot welds were removed.

Refer to the technical specifications for the structural adhesive being used to determine the amount of heat and/or time for the structural adhesive to reach full design strength.

When force curing adhesive in a repair area near the High Voltage Battery, do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery.

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.

Do not weld a panel where it directly contacts underlying structural components unless directed to do so in the repair procedure. The heat affect zone from welding can weaken the strength of underlying structural components.

Before 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.

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.

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.