12/09/2024 15:07:02

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.
  • Properly mount the vehicle on a frame bench when performing this procedure.
  • The Body Side Outer Assembly can be:
    • Replaced in a single repair as a single complete component, using the service part and the instructions in the Repair Procedure section of this document.
    • Repaired using the service assembly shown in #TASK_HKS_YZG_GXB. If replacing a portion of the Body Side Outer (not the entire Body Side Outer) using a service assembly, follow the guidelines in the #TASK_HKS_YZG_GXB and 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 smaller than the service assembly. Any individual section or any combination of sections of the Body Side Outer Assembly can be replaced so long as the guidelines from the #TASK_HKS_YZG_GXB are followed.

Parts List

Quantity Description Image / Notes
1

or

2 (if sectioning)		 ASY BODY SIDE OUTER (Body Side Outer)
16 High Strength Structural Rivet, 6.5 mm
1 Countersunk Rivet, 4.8 mm Short
2 Countersunk Rivet, 4.8 mm Long
1 Flow Form Rivet S08
4 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.

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 original component.

    or Factory Spot Welds

    or Factory SPRs

    or Drill through factory spot welds
    Informational PurposesAn informational icon, calling your attention
    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

  2. Prepare for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    A red X indicates a location where a factory-installed fastener is not being replaced.

    or High Strength Structural Rivets, 6.5 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

  3. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  4. Install the new component or components.

    Torque the bolts to 90 Nm.

  5. Perform resistance spot welding.
    or Installation Spot Welds
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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 IconA warning icon, calling your attention to a possibly risky situation
    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.
  6. Perform any necessary post-repair operations.