23/08/2024 13:53:30

Body Side Complete

Repair Information

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	ASY FRONT BODY COMPLETE (Body Side Complete)
3	PLUG	Tesla part number 1870761-00.
46	High Strength Structural Rivet, 6.5 mm
5	Countersunk Rivet, 4.8 mm Short
2	Countersunk Rivet, 4.8 mm Long
1	Flow Form Rivet S08
6	Flow Form Rivet S18
1	Flow Form Rivet S28
1	Flow Form Rivet S48
1	Flow Form Rivet S58
4	Bolt , HF,M12x35,STL[109],ZNFL,PC	Tesla part number 1089657-00.
4	Bolt , HHL,M10x3	Tesla part number 1851387-00.
5	Bolt , HHL,M12x43	Tesla part number 1882229-00.

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

Cut the forward access hole on the original component using the pre-marked center point.

Note
Use a 1 1/8 inch (29 mm.) carbide-tipped hole saw to create the hole.
.
Cut Line
On the original component, verify the location of the center point for the rear-most access hole.
The center point for the rear-most access hole should be located 155 mm to the rear of the indicated hole (measurement A).
Note
If the center point marked on the component is 150 mm, move the center point 5 mm to the rear of the marked center point (measurement B).
Reference Line/Point
- A = 155 mm.
- B = 5 mm.
On the original component, cut the rear access holes.
Cut Line
Note
Use a 1 1/8 inch (29 mm.) carbide-tipped hole saw to create the holes.
On the new service part, cut the forward access hole using the pre-marked center point.

Note
Use a 1 1/8 inch (29 mm.) carbide-tipped hole saw to create the hole.
.
Cut Line
On the new service part, verify the location of the center point for the rear-most access hole.
The center point for the rear-most access hole should be located 155 mm to the rear of the indicated hole (measurement A).
Note
If the center point marked on the component is 150 mm, move the center point 5 mm to the rear of the marked center point (measurement B).
Reference Line/Point
- A = 155 mm.
- B = 5 mm.
On the new service part, cut the rear access holes.
Cut Line
Note
Use a 1 1/8 inch (29 mm.) carbide-tipped hole saw to create the holes.
Remove the original component.

or Factory Spot Welds

or Factory SPRs

or Drill through factory spot welds
Note
When 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.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
or High Strength Structural Rivets, 6.5 mm
- C = 49 mm.
or Countersunk Rivets, 4.8 mm Short

or Countersunk Rivets, 4.8 mm Long

or Flow Form Rivets, S08

or Flow Form Rivets, S18

or Flow Form Rivets, S28

or Flow Form Rivets, S48

or Flow Form Rivets, S58

or Bolts

or Installation Spot Welds
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 as follows:
- HF,M12x35,STL[109],ZNFL,PC bolts, part number 1089657-00: 90 Nm.
- HHL,M10x33 bolts, part number 1851387-00: 90 Nm.
- HHL,M12x435 bolts, part number 1882229-00: 67 Nm.
Perform resistance spot welding.
or Installation Spot Welds
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.

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.
Install the plugs to cover the access holes.

Note
Apply seam sealer to the bottom side of each plug before installation, and remove any visible seam sealer around the outside edge of the plug after installation.
Trim the Rear Rocker Step Reinforcement to allow clearance for the plug that covers the rear access hole.
Note
Remove any visible seam sealer from around the access hole plugs that would be under the foam gasket of the Rear Rocker Step Reinforcement.

Cut Line

Reference Line/Point
- D = 7 mm.
- E = 32 mm.
Perform any necessary post-repair operations.