2026-10-13

Sill Insert (Front Section) (Vehicles Built Through October 15, 2025)

Correction code: Pending NOTE: Unless explicitly stated in the procedure, the above correction code includes all Collision Repair and Service repair work required to perform this procedure, including the linked Collision Repair procedures and linked Service procedures. Do not stack Collision Repair correction codes unless explicitly told to do so. Depending on the damage to the vehicle, additional repairs may be required.

Repair Information

  • There are two versions of this procedure, and the correct procedure to use depends on the vehicle build date, and if the Sill Insert has been repaired previously in the same area.
    If the vehicle was built through October 15, 2025:
    • The original Sill Insert component (Tesla part number 2199514-00-A) has a slightly thicker side wall than the component used in vehicles built after October 15, 2025.
      Note
      The overall width of the Sill Insert is the same in both versions of the component.
    • Additionally, if the complete Sill Insert has been replaced, the new component that was installed may be either version of the component.
    If the vehicle was built after October 15, 2025:
    • The original Sill Insert component (Tesla part number 2199514-00-B) has a slightly thinner side wall than the component used in vehicles built through October 15, 2025.
      Note
      The overall width of the Sill Insert is the same in both versions of the component.
    • Additionally, if the complete Sill Insert has been replaced, the new component that was installed may be either version of the component.
    Warning
    You cannot perform a Sill Insert (Front Section) repair with a mix of Sill Insert component versions. You must create the new component from the same version of the Sill Insert component as is currently on the vehicle. If the service part is not the same version as the component on the vehicle, either order the correct version of the Sill Insert part, or perform the Sill Insert (Complete) procedure.

    Steps have been added in the Repair Procedure section of this procedure to help determine the correct procedure for the vehicle being repaired.

  • Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
  • Properly mount the vehicle on a frame bench when performing this procedure.

Parts List

Quantity Description Image / Notes
1 PANEL - SIDE SILL INSERT (Side 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 Tesla part number 1467695-S0.
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

  1. Remove the necessary portion of the Door Ring Outer to expose the underlying component being replaced.
  2. Cut the original component at the indicated locations.
    • Reference Line/Point
    • Cut Line A = 700 mm
  3. Use calipers to measure the outboard wall of the Sill Insert.
    Note
    To ensure an accurate measurement, make sure the flat surfaces of the caliper jaws are flush against the outboard wall of the Sill Insert.
  4. If the outboard wall of the Sill Insert is 4.5 mm, continue with step 6 of this procedure.
    • Reference Line/Point
  5. If the outboard wall of the Sill Insert is 3.5 mm, do not continue with this procedure. Instead, perform the Sill Insert (Front Section) (Vehicles Built After October 15, 2025) procedure.
    • Reference Line/Point
  6. Remove the original component.
  7. Cut the new Sill Insert as indicated below to make the new component.
    • Reference Line/Point
    • Cut Line B = 395 mm
  8. Remove the weld nut from the Door Ring Inner.
  9. 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.
  10. 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.
  11. 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.
  12. Insert the Cell 1 and Cell 2 Reinforcement Insert Plates and prepare for installation.
  13. Position the Cell 3 Reinforcement Insert Plates and prepare for installation.
    Note
    The Cell 3 Reinforcement Insert Plate created in Step 11 is mounted inside Cell 3.
  14. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  15. Install the new component or components.

    Torque the bolts to 25 Nm.

  16. Install the new component or components.

    Torque the bolt to 31 Nm.

  17. Install the new component or components.
  18. Install the new weld nut on the Door Ring Inner.
    • GMA Weld
  19. 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 HV Disablement Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle HV Disablement 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.
  20. Install the necessary portion of the Door Ring Outer.
  21. Perform any necessary post-repair operations.