Body Side Outer Assembly TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Repair Criteria Body Side Outer Assembly, Subassemblies, and Subassembly Sectioning The Body Side Outer Assembly (shown below) is a single assembly, and can be replaced as a single repair: Alternatively, instead of replacing the complete Body Side Outer Assembly, areas of the Body Side Outer can be replaced using either: • Portions of the complete Body Side Outer Assembly using the cut lines described in this document.
Body Side Outer Assembly Repair Criteria Using this Document This document contains two major parts: 1 The Body Side Outer Section Descriptions provides information on where and how to section the Body Side Outer Assembly (or subassemblies) as necessary to replace damaged areas of the Body Side Outer panel, or to gain access to underlying parts of the vehicle structure.
Body Side Outer Assembly Body Side Outer Section Descriptions 1 Upper A-Pillar section. Cut Line Reference Line/Point 2 Lower A-Pillar section. Cut Line Reference Line/Point NOTE: The rear cut line is where the A-Pillar Body Side Outer and the BPillar Body Side Outer service assemblies meet. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Body Side Outer Section Descriptions 3 Lower Sill Forward section. Cut Line Reference Line/Point NOTE: The cut line is where the A-Pillar Body Side Outer and the BPillar Body Side Outer service assemblies meet. 4 Lower B-Pillar section. Cut Line Reference Line/Point NOTE: The rear cut line is where the B-Pillar Body Side Outer and the Rear Quarter Outer service assemblies meet. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Body Side Outer Section Descriptions 5 Roof Rail Forward section. Cut Line Reference Line/Point NOTE: The forward cut line is measured from the center of the stamped tab shown. NOTE: The rear cut line is where the A-Pillar Body Side Outer and the BPillar Body Side Outer service assemblies meet. 6 Roof Rail Middle section.
Body Side Outer Assembly Body Side Outer Section Descriptions 7 B-Pillar Upper section. Cut Line Reference Line/Point NOTE: The cut line for the B-pillar Upper section is measured on the roof rail from the rear edge of the Rear Roof Header. NOTE: The rear cut line on the roof rail is where the B-Pillar Body Side Outer and the Rear Quarter Outer service assemblies meet. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Body Side Outer Section Descriptions 8 Roof Rail Rear section. Cut Line Reference Line/Point NOTE: The forward cut line of the roof rail rear section is measured from the edge of the Rear Roof Header shown in this image. NOTE: The forward cut line of the Roof Rail Rear section is where the BPillar Body Side Outer and Rear Quarter Outer service assemblies meet. 9 Roof Rail Rear Quarter section.
Body Side Outer Assembly Body Side Outer Section Descriptions 10 Quarter section. Cut Line Reference Line/Point NOTE: The lower cut line of the Quarter section is measured from the bottom edge of the lower bolt hole for the Rear Door Striker CAUTION: Do not cut the steel Body Side Outer panel directly over the underlying aluminum Rear Wheelhouse Reinforcement panel or the Rear Wheel Arch Assembly underneath (both shown here in red).
Body Side Outer Assembly Body Side Outer Section Descriptions 11 Quarter Lower section. Cut Line Reference Line/Point CAUTION: Do not cut the steel Body Side Outer panel directly over the underlying aluminum Rear Wheel Arch Assembly underneath (shown here in red). NOTE: The front cut line on the sill in the rear door opening is where the B-Pillar Body Side Outer and Rear Quarter Outer service assemblies meet. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.
Body Side Outer Assembly Parts List Quantity 1 Part Number Description Image / Notes 1504887-S0-A (LH) M3 ASY, BODY SIDE OUTER 1504888-S0-A (RH) NOTE: A pre-cut sub assembly may be used if sectioning the Body Side Outer. 17 rivets needed; order 20 rivets. 1028719-00-A Structural Rivet, 4.8 mm All rivets come in packages of 10; order all rivets in multiples of 10. 71 rivets needed; order 80 rivets 1028408-00-A Structural Rivet, 6.
Body Side Outer Assembly Parts List Quantity Part Number 1 rivet needed; order 10 rivets 1069331-00-A Description Image / Notes Flow Form Rivet S38 All rivets come in packages of 10; order all rivets in multiples of 10. NOTE: Only required if Cantrail Extension Inner is being replaced.
Body Side Outer Assembly Repair Information Repair Information This procedure is for the left-hand component; the procedure is identical for the right-hand component. NOTE: Any individual section or any combination of sections of the Body Side Outer Assembly can be replaced so long as the referenced cut lines from the Body Side Outer Section Descriptions portion of this document are used.
Body Side Outer Assembly Prerequisites 1 Disconnect 12V and high voltage power (refer to the appropriate section in BR-17-17-004, "Disconnecting 12V and High Voltage Power on Model 3"). WARNING: Before disconnecting the 12V power supply, make sure that all windows are at least slightly open. Attempting to open a door with a fully-closed window when the 12V power supply is disconnected could result in door glass shatter.
Body Side Outer Assembly Removal 1 Remove the original component. A • If replacing the complete Body Side Outer Assembly, go to Step B and continue with the removal. • If repairing a section of the Body Side Outer: Mark and cut the Body Side Outer at the section cut line locations described in the Body Side Outer Section Descriptions. CAUTION: Cut outer panel only. NOTE: When performing section repairs, not all steps in this document are required.
Body Side Outer Assembly Removal 1 Remove the original component (continued). B Remove and discard the bolts. C Use a drill with a spot weld bit to drill out the factory spot welds. Use a belt sander to sand down any factory spot welds that cannot be reached with a drill. Factory Spot Weld Areas Bolt, hex-head (x2) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Removal 1 Remove the original component (continued). C Use a drill with a spot weld bit to drill out the factory spot welds. Use a belt sander to sand down any factory spot welds that cannot be reached with a drill (continued). D Use a drill with a 4.8 mm bit to drill completely through the spot welds shown. Factory Spot Weld NOTE: 4.8 mm countersunk rivets will be installed in these locations in a later step.
Body Side Outer Assembly Removal 1 Remove the original component (continued). E Use an SPR removal tool or a drill with a high-strength steel bit to remove the factory self-piercing rivets. Use a belt sander for any factory self-piercing rivets that cannot be removed with an SPR removal tool or a drill. Factory SPR (x30) NOTE: Factory SPR locations shown are approximate. Exact rivet locations and number may vary from vehicle to vehicle.
Body Side Outer Assembly Removal 1 Remove the original component (continued). G Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the original component. WARNING: Do not heat any adhesive joints of components that are not being removed. Heating adhesive joints weakens the adhesive bond and could compromise vehicle crash integrity. WARNING: Do not heat the adhesive joints above 100°C (212°F).
Body Side Outer Assembly Removal 2 Use a disc sander with a medium-abrasive surface conditioning disc to remove any remaining materials from the mating surfaces. Use a belt sander with a medium-abrasive belt for any areas that cannot be reached with a disc sander. Vacuum any adhesive dust. WARNING: Remove the epoxy adhesive in a well-ventilated area. Wear suitable personal protective equipment. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 1 Prepare for installation. A If repairing a section of the Body Side Outer, use the remnants of the original component as a template to mark and cut the new component. B Put the new component into position and secure it in place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 1 Prepare for installation (continued). C If repairing a section of the Body Side Outer, trim the new component at the butt joint locations to achieve suitable gaps. D Temporarily install the bolts but do not torque them at this time. Bolt, hex-head (x2) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 1 Prepare for installation (continued). E Mark the fastener locations on the new component. Structural Rivet, 4.8 mm (x17) Countersunk Rivet, 4.8 mm Short (x5) Flow Form Rivet S08 (x5) Flow Form Rivet S18 (x16) Flow Form Rivet S38 (x1) Installation Spot Weld (x126) NOTE: The S38 Flow Form Rivet only required if the Cantrail Extension Inner has been replaced. NOTE: If only the Bodyside Outer was removed, the spot welds obstructed by the Dashboard may be omitted.
Body Side Outer Assembly Replacement 1 Prepare for installation (continued). F Mark the fastener locations on the new component. Structural Countersunk Rivet, 6.5 mm (x2) Structural Rivet, 6.5 mm Short (x71) Installation Spot Weld (x3) NOTE: The 6.5mm Structural Countersunk Rivets only required if the Front Hinge Pillar (Section) has been replaced. NOTE: 6.
Body Side Outer Assembly Replacement 1 Prepare for installation (continued). G Use a drill with a 6.7 mm bit to drill holes for 6.5 mm structural rivets. Structural Countersunk Rivet, 6.5 mm (x2) Structural Rivet, 6.5 mm Short (x71) CAUTION: Do not drill holes for rivets in the areas that would interfere with installation of the plastic rocker trim (indicated here by red arrows). NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes.
Body Side Outer Assembly Replacement 1 Prepare for installation (continued). I Use a drill with the Microstop countersink cage assembly and the appropriate-sized countersink bit to countersink the holes for countersunk rivets (Microstop Countersink Kit, Tesla p/n 1133101-00A). NOTE: If the depth adjustment for the Microstop countersink cage assembly has not already been set, do the procedure in the Microstop Countersink Kit tool instructions to adjust the tool.
Body Side Outer Assembly Replacement 1 Prepare for installation (continued). K Mark boundary lines along all mating surfaces between the new components and the vehicle for surface preparation. L Remove the new component. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 2 If repairing a section of the Body Side Outer, create and install backing plates. A Cut 40 mm wide sections from the remaining pieces of the original or the new component to create backing plates similar to the one shown here in red for the section locations. B Trim the flanges from the backing plates as necessary to allow them to fit inside the butt joints.
Body Side Outer Assembly Replacement 2 If repairing a section of the Body Side Outer, create and install backing plates (continued). C Put the backing plates in position and test fit the new component on the vehicle to ensure the plates do not affect component fitment. D Use a drill with an 8 mm bit to drill holes for plug welds that will secure the backing plates. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 2 If repairing a section of the Body Side Outer, create and install backing plates (continued). E Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat or paint from the outside surface of the backing plates and the weld areas on the vehicle. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment. NOTE: The lower sill area may contain cavity wax and require cleaning with isopropyl alcohol.
Body Side Outer Assembly Replacement 2 If repairing a section of the Body Side Outer, create and install backing plates (continued). G Plug weld the backing plates. 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Body Side Outer Assembly Replacement 3 Prepare the surfaces. A Use a red Scotch-Brite pad or equivalent to scuff the e-coat on the mating surfaces of the new component. B Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat from the weld areas of the new components and the vehicle. Use a belt sander with a medium-abrasive belt for any areas that cannot be reached with a disc sander.
Body Side Outer Assembly Replacement 3 Prepare the surfaces (continued). C Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat from the weld areas of the new components and the vehicle. Use a belt sander with a medium-abrasive belt for any areas that cannot be reached with a disc sander. Installation Spot Weld (x115) WARNING: Do not remove e-coat in areas where steel and aluminum make direct contact. WARNING: Remove the e-coat in a well-ventilated area.
Body Side Outer Assembly Replacement 3 Prepare the surfaces (continued). D Clean all the bond paths and weld areas on the new component or components and on the vehicle with isopropyl alcohol (IPA). WARNING: 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. 4 Apply structural adhesive.
Body Side Outer Assembly Replacement 4 Apply structural adhesive (continued). A Spread a thin coating of structural adhesive as a primer layer on the mating surfaces of the vehicle, the backing plate, and the new component (continued). WARNING: Do not apply structural adhesive within 25 mm of the GMA weld locations. Applying structural adhesive within 25 mm of the GMA weld locations can cause weld failure.
Body Side Outer Assembly Replacement 5 Install the new component. A Apply a bead of urethane sealant to the foam dam edges. B Put the new component into position and secure it in place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 5 Install the new component (continued). C Temporarily install the bolts but do not torque them at this time. Bolt, hex-head (x2) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 5 Install the new component (continued). D Insert the structural, countersunk, and flow form rivets. Structural Rivet, 4.8 mm (x17) Countersunk Rivet, 4.8 mm Short (x5) Structural Countersunk Rivet, 6.5 mm (x2) Structural Rivet, 6.5 mm Short (x71) Flow Form Rivet S08 (x5) Flow Form Rivet S18 (x16) Flow Form Rivet S38 (x1) NOTE: The 6.5mm Structural Countersunk Rivets only required if the Front Hinge Pillar (Section) has been replaced. NOTE: 6.
Body Side Outer Assembly Replacement 5 Install the new component (continued). D Insert the structural, countersunk, and flow form rivets (continued). E Clamp all bonded areas that are not secured with a fastener. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 5 Install the new component (continued). F Install the structural, countersunk, and flow form rivets. G Torque the bolts to 24 Nm. Bolt, hex-head (x2) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 5 Install the new component (continued). H Perform resistance spot welding. Installation Spot Weld (x129) 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Body Side Outer Assembly Replacement 5 Install the new component (continued). H Perform resistance spot welding (continued). I Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Body Side Outer Assembly Replacement 5 Install the new component (continued). J Bake the structural adhesive so that the bonded panels reach a temperature of 60°C–80°C (140°F–176°F) for at least 30 minutes to achieve full strength. WARNING: 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.
Body Side Outer Assembly Replacement 6 If repairing a section of the Body Side Outer, GMA weld the butt joints (continued). A Perform GMA welding (continued). WARNING: Do not weld the panel where it directly contacts the high strength panels underneath. The heat from welding might weaken the strength of the underlying high strength steel structure.
Body Side Outer Assembly Replacement 6 7 If repairing a section of the Body Side Outer, GMA weld the butt joints (continued). B Use a grinding tool to grind down the welds until they are flush with the panel. Seal the seams in the factory locations, and as necessary. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
