12/09/2024 15:17:36

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 Section Descriptions. If replacing a portion of the Body Side Outer (not the entire Body Side Outer) using a service assembly, follow the guidelines in the Section Descriptions 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 Section Descriptions 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.

Section Descriptions


Body Side Outer Service Assembly and Sectioning
ASY BODY SIDE OUTER Service Assembly	Body Side Outer Sections

General 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 in the section description.
A backing plate may be installed at a butt joint between sections (as described in the individual section description).
Gaps between panels of butt joints should be as small as possible to maximize joint strength.
If specified in the individual section description, GMA weld section butt joints, and seal all open seams after welding.
Note
If a butt joint includes a flange, do not weld on the flange (flanges are secured using only structural adhesive).

Note

Do not cut underlying panels when sectioning the Body Side Outer.


Body Side Outer Sections
A–Pillar Cut Line Reference Line/Point A = 63 mm. B = 236 mm. Note The cut can be made within 20 mm. of the specified cut line.
Create a backing plate 80 mm. wide, and install it as indicated. 2x or Structural Bulb Rivets, 6.5 mm 6x or Countersunk Rivets, 4.8 mm Long Note Apply structural adhesive to the mating surfaces of the backing plate, the vehicle, and the new component or components. Note Fill all gaps with structural adhesive.
Sill (Front) Remove the necessary portions of the HV Battery Support Bracket and Rocker Support Bracket from the Body Side Outer service part. Remove the necessary portions of the HV Battery Support Bracket and Rocker Support Bracket from the vehicle to expose the component being sectioned. Cut Line Reference Line/Point C = 428 mm. D = 92 mm.
Create a backing plate 260 mm. wide, and install it as indicated. Note Apply structural adhesive to the mating surfaces of the backing plate, the vehicle, and the new component or components. Warning When securing the component, structural adhesive should be visible squeezing out along the joints between all mating surfaces, but no structural adhesive should be within 25 mm. of any GMA weld location. Perform GMA welding. GMA Weld Warning Do not weld a panel where it directly contacts underlying structural components. The heat affect zone from welding can weaken the strength of underlying structural components. Use structural adhesive to fill any gaps behind panels and underlying components. Note Fill all gaps with structural adhesive. Install the portions of the HV Battery Support Bracket and Rocker Support Bracket that were removed from the vehicle to expose the component being sectioned.
Sill (Rear) Remove the necessary portions of the HV Battery Support Bracket and Rocker Support Bracket from the Body Side Outer service part. Remove the necessary portions of the HV Battery Support Bracket and Rocker Support Bracket from the vehicle to expose the component being sectioned. Cut Line Reference Line/Point E = 110 mm. F = 200 mm.
Create a backing plate 260 mm. wide, and install it as indicated. Note Apply structural adhesive to the mating surfaces of the backing plate, the vehicle, and the new component or components. Warning When securing the component, structural adhesive should be visible squeezing out along the joints between all mating surfaces, but no structural adhesive should be within 25 mm. of any GMA weld location. Perform GMA welding. GMA Weld Warning Do not weld a panel where it directly contacts underlying structural components. The heat affect zone from welding can weaken the strength of underlying structural components. Use structural adhesive to fill any gaps behind panels and underlying components. Note Fill all gaps with structural adhesive. Install the portions of the HV Battery Support Bracket and Rocker Support Bracket that were removed from the vehicle to expose the component being sectioned.
B–Pillar Cut Line Reference Line/Point G = 64 mm. H = 130 mm. Note The cut can be made within 20 mm. of the specified location.
Create a backing plate 80 mm. wide, and install it as indicated. 4x or Structural Bulb Rivets, 6.5 mm 6x or Countersunk Rivets, 4.8 mm Short Note Apply structural adhesive to the mating surfaces of the backing plate, the vehicle, and the new component or components. Note Fill all gaps with structural adhesive.
C–Pillar Cut Line Reference Line/Point I = 79 mm. J = 79 mm. Note The cut can be made within 20 mm. of the specified location.
Create a backing plate 80 mm. wide, and install it as indicated. Perform GMA welding. GMA Weld or Steel Plug Welds Warning Do not weld a panel where it directly contacts underlying structural components. The heat affect zone from welding can weaken the strength of underlying structural components. Use structural adhesive to fill any gaps behind panels and underlying components. Note Fill all gaps with structural adhesive.
Roof Rail (Front) Cut Line Reference Line/Point K = 174 mm. L = 45 mm.
Create a backing plate 80 mm. wide, and install it as indicated. Note Apply structural adhesive to the mating surfaces of the backing plate, the vehicle, and the new component or components. 6x or Structural Bulb Rivets, 6.5 mm 2x or Countersunk Rivets, 4.8 mm Short Note Fill all gaps with structural adhesive.
Roof Rail (Rear) Cut Line Reference Line/Point M = 48 mm. N = 171 mm.
Create a backing plate 80 mm. wide, and install it as indicated. 6x or Structural Bulb Rivets, 6.5 mm 2x or Countersunk Rivets, 4.8 mm Short Note Apply structural adhesive to the mating surfaces of the backing plate, the vehicle, and the new component or components. Note Fill all gaps with structural adhesive.

Repair Procedure

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

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 to 90 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.
If sectioning only: Perform GMA welding if required by the section(s) being repaired.
or Steel Plug Welds
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 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.

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.
Perform any necessary post-repair operations.