Sill Outer (Complete) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Parts List Quantity Part Number 1 1082281-S0-B (LH) 1082282-S0-B (RH) Sill Outer Assembly 1 1115819-S0-D (LH), 1115820-S0-D (RH) Sill Insert 2 1082361-S0-C 1 Description Image / Notes Sill Insert Mounting Bracket 1095027-S0-B (LH) C-Pillar Reinforcement 1095028-S0-B (RH) The C-Pillar Reinforcement is listed in the Parts Manual as the "C-Pillar Extension". TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Parts List Quantity 2 Part Number Description Image / Notes 1080021-S0-A (LH) Hinge Pillar Assembly 1080022-S0-A (RH) One Hinge Pillar Assembly is needed for replacement and one is needed to make a backing plate. 1 1073673-00-A (LH) Body Side Outer (Complete) 1073674-00-A (RH) 39 rivets needed; order 40 rivets 1454538-00-A High Strength Structural Rivet, 6.5 mm All rivets come in packages of 10; order all rivets in multiples of 10.
Sill Outer (Complete) Parts List Quantity Part Number 17 or 95 rivets needed; order 20 or 100 rivets 1028408-00-A Description Image / Notes Structural Rivet, 6.5 mm Short All rivets come in packages of 10; order all rivets in multiples of 10. 17 rivets are needed if the lower flange of the Sill Outer can be attached to the Sill Inner with resistance spot welds. 95 rivets are needed if the lower flange of the Sill Outer cannot be attached to the Sill Inner with resistance spot welds.
Sill Outer (Complete) Parts List These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Manual. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Repair Information Repair Information This procedure is for the left-hand component; the procedure is identical for the right-hand component. Installation fasteners that replace factory spot welds in steel-to-steel panel interfaces are specified in this procedure where an approved squeeze-type resistance spot welder with the base welding accessories might not be able to reach.
Sill Outer (Complete) 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.
Sill Outer (Complete) Prerequisites 2 Remove the Shotgun Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 1 Identify the component materials in the repair area. Aluminum Mild Steel High-Strength Steel Ultra High-Strength Steel NOTE: Refer to BR-17-10-005, “Model 3 Body Structure Materials and Allowed Operations”, for information about the material each structural component is made from and the operations that are allowed on each type of material. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer. A Mark a cut line in the A-Pillar area 50 mm (2 in) down from the lower edge of the bolt hole shown. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer (continued). B Mark a cut line in the B-Pillar area 60 mm (2-3/8 in) down from the lower edge of the bolt hole shown. C Mark a cut line in the C-Pillar area 110 mm (1-9/16 in) down from the lower edge of the bolt hole shown. Cut Line Cut Line CAUTION: Make sure the cut line is in the area of the steel Wheelhouse Extension and not in the area of the aluminum Wheel Arch.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer (continued). D Cut the Body Side Outer on the cut lines marked in the previous substeps. CAUTION: Do not damage the surrounding components. E Use a drill with a spot weld bit to drill out the spot welds that attach the lower portion of the Body Side Outer. Factory Spot Weld Factory Spot Weld Areas NOTE: The areas highlighted in yellow indicate multiple factory spot welds.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer (continued). E Use a drill with a spot weld bit to drill out the spot welds that attach the lower portion of the Body Side Outer (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer (continued). E Use a drill with a spot weld bit to drill out the spot welds that attach the lower portion of the Body Side Outer (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer (continued). F 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 (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer (continued). G Use a grinding tool to grind through the Wheel Arch flange below the cut made in an earlier substep. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 2 Remove the lower portion of the Body Side Outer (continued). H Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the lower portion of the Body Side Outer. Save the lower portion to use as a template in a later step. 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.
Sill Outer (Complete) Removal 3 Remove the lower portion of the Hinge Pillar. A Use a drill with a spot weld bit to drill out the spot welds that attach the A-Pillar to Shotgun Reinforcement. Factory Spot Weld (x8) NOTE: Factory spot weld locations shown are approximate. Exact spot weld locations and number vary from vehicle to vehicle. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 3 Remove the lower portion of the Hinge Pillar (continued). A Use a drill with a spot weld bit to drill out the spot welds that attach the A-Pillar to Shotgun Reinforcement (continued). B Use a hammer and chisel to remove the A-Pillar to Shotgun Reinforcement. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 3 Remove the lower portion of the Hinge Pillar (continued). C Mark cut lines to remove the lower portion of the Hinge Pillar. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 3 Remove the lower portion of the Hinge Pillar (continued). C Mark cut lines to remove the lower portion of the Hinge Pillar (continued). D Cut the Hinge Pillar on the cut lines marked in the previous substeps. CAUTION: Do not damage the surrounding components. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 3 Remove the lower portion of the Hinge Pillar (continued). E Use a drill with a spot weld bit to drill out the spot welds that attach the lower portion of the Hinge Pillar. Factory Spot Weld Areas NOTE: The areas highlighted in yellow indicate multiple factory spot welds. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 3 Remove the lower portion of the Hinge Pillar (continued). F Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the bulk of the lower portion of the Hinge Pillar. 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.
Sill Outer (Complete) Removal 4 Remove the lower portion of the C-Pillar Extension. A If necessary, trim any portions of the foam baffle that extend below the cut in the C-Pillar area. NOTE: New expanding foam will be added to this area in a later step. B Mark a cut line on the aluminum C-Pillar Extension 150 mm (5-15/16 in) down from the lower edge of the bolt hole shown. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 4 Remove the lower portion of the C-Pillar Extension (continued). B Mark a cut line on the aluminum C-Pillar Extension 150 mm (5-15/16 in) down from the lower edge of the bolt hole shown (continued). C Cut the aluminum C-Pillar Extension on the cut line marked in the previous substep. CAUTION: Take the appropriate steps to minimize the crosscontamination of steel and aluminum components during the repair. CAUTION: Do not damage the surrounding components.
Sill Outer (Complete) Removal 4 Remove the lower portion of the C-Pillar Extension (continued). D 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 (x8) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 4 Remove the lower portion of the C-Pillar Extension (continued). E Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the lower portion of the C-Pillar Extension. Save the lower portion to use as a template in a later step. 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.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly. A Mark cut lines to prepare to cut away the bulk of the original Sill Outer Assembly. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). A Mark cut lines to prepare to cut away the bulk of the original Sill Outer Assembly (continued). B Cut the Sill Outer Assembly on the cut lines marked in the previous substep. CAUTION: Do not damage the surrounding components. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). C Use a drill with a spot weld bit to drill out the spot welds that attach the bulk of the Sill Outer Assembly. Factory Spot Weld Areas NOTE: The areas highlighted in yellow indicate multiple factory spot welds. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). D Use an SPR removal tool or a drill with a high-strength steel bit to remove any remaining pieces of factory self-piercing rivets that were not removed in an earlier step. Factory SPR (x2) NOTE: A belt sander can be used to grind off the heads of the factory SPRs to separate the outer panels before removing the SPRs.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). E Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the bulk of the Sill Outer Assembly (continued). F Mark a cut line on the original Sill Insert. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). G Cut the Sill Insert on the cut line marked in the previous substep. CAUTION: Take the appropriate steps to minimize the crosscontamination of steel and aluminum components during the repair. CAUTION: Do not damage the surrounding components. H Use a hammer to remove the two halves of the Sill Insert. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). I Remove the factory foam dams from the original Sill Insert and set them aside for use during installation at a later step. J Use a drill with a 6.7 mm (17/64 in) bit to drill completely through the factory spot welds shown. Factory Spot Weld NOTE: Flow form rivets will be installed in these locations in a later step. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). J Use a drill with a 6.7 mm (17/64 in) bit to drill completely through the factory spot welds shown (continued). K Use a belt sander to sand down the backside of the spot welds that attach the remaining piece of the Sill Outer Assembly to the B-Pillar Outer. Factory Spot Weld (x21) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). K Use a belt sander to sand down the backside of the spot welds that attach the remaining piece of the Sill Outer Assembly to the B-Pillar Outer (continued). L Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the remaining piece of the middle portion of the Sill Outer Assembly where it meets the B-Pillar Outer.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). L Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the remaining piece of the middle portion of the Sill Outer Assembly where it meets the B-Pillar Outer (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). M Cut back the foam in the C-Pillar Extension area. N Use a drill with a spot weld bit to drill out the spot welds shown. Factory Spot Weld (x7) NOTE: Factory spot weld locations shown are approximate. Exact spot weld locations and number vary from vehicle to vehicle. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). N Use a drill with a spot weld bit to drill out the spot welds shown (continued). O Remove the seam sealer in the area of the factory self-piercing rivets. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). P Use an SPR removal tool or a drill with a high-strength steel bit to remove the factory self-piercing rivets. Factory SPR (x4) NOTE: A belt sander can be used to grind off the heads of the factory SPRs to separate the outer panels before removing the SPRs. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Removal 5 Remove the Sill Outer Assembly (continued). Q Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the remaining piece of the rear portion of the Sill Outer Assembly. 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).
Sill Outer (Complete) Removal 6 Use a disc sander with a medium-abrasive surface conditioning disc to remove any remaining materials from the bond paths. 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. WARNING: Use only sanding wheels and belts that are 80 grit or finer on aluminum components.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation. A Mark alignment lines for the front Sill Insert Mounting Bracket on the new Sill Insert. NOTE: These alignment lines will be used to install the new Sill Insert Mounting Brackets in the correct position in a later substep. B Mark alignment lines for the rear Sill Insert Mounting Bracket on the new Sill Insert.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). C Mark alignment lines on the new Sill Outer Assembly. NOTE: These alignment lines will be used to install the new Sill Insert in the correct position in the next substep. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). D Put the new Sill Insert into the new Sill Outer Assembly, and align it to the lines marked in the previous substep, then clamp the new Sill Insert into position. E Use the lines marked on the Sill Insert in the previous substep to position the new Sill Insert Mounting Brackets between the new Sill Insert and the Sill Outer Assembly.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). F Clamp the new Sill Insert Mounting Brackets into position. G Remove the Sill Insert with Sill Insert Mounting Brackets still securely clamped to it from the Sill Outer. CAUTION: Do not move the Sill Insert Mounting Brackets during removal of the Sill Insert. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). H Mark holes for structural rivets on the front and the rear Sill Insert Mounting Brackets. Structural Rivet, 6.5 mm Short (x2) WARNING: Use the indicated measurements so that rivet holes are placed to prevent the rivets from being installed through internal walls of the Sill Insert.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). J Remove the Sill Insert Mounting Brackets from the Sill Insert. K Use a red Scotch-Brite pad or equivalent to scuff the new Sill Insert in the bond path areas. Steel-to-Aluminum Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). K Use a red Scotch-Brite pad or equivalent to scuff the new Sill Insert in the bond path areas (continued). L Use a red Scotch-Brite pad or equivalent to scuff each of the new Sill Insert Mounting Brackets in the bond path area. Steel-to-Aluminum Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). M Clean all the bond paths on the new Sill Insert and the new Sill Insert Mounting Bracket 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.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). O While the primer layer is still wet, apply a bead of structural adhesive on top of the primer layer on the new Sill Insert. P Position the Sill Insert Mounting Brackets. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). Q Insert the structural rivets. R Install the structural rivets. Structural Rivet, 6.5 mm Short (x4) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 1 Prepare the new Sill Insert for installation (continued). S Wipe off any excess adhesive. T 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation. A Put the new Sill Insert into the new Sill Outer Assembly, and align it to the lines marked in the previous substep. Clamp the new Sill Insert into position. B Mark the outlines of the Sill Insert brackets. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). C Remove the new Sill Insert from the new Sill Outer Assembly. D Mark holes for structural rivets on the new Sill Outer Assembly. Structural Rivet, 6.5 mm Short (x8) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). D Mark holes for structural rivets on the new Sill Outer Assembly (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). E Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets in the Sill Outer Assembly. F Put the new Sill Insert into the new Sill Outer Assembly, and align it to the outlines marked in an earlier substep. Clamp the new Sill Insert into position. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). G Use a drill with a 6.7 mm (17/64 in) bit to drill holes in the new Sill Insert through the holes drilled through the new Sill Outer Assembly in an earlier substep. NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). H Remove the new Sill Insert from the new Sill Outer Assembly. I Use a red Scotch-Brite pad or equivalent to scuff the new Sill Insert and the new Sill Outer Assembly in the bond path areas. Steel-to-Aluminum Bond Path Steel-to-Steel Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). I Use a red Scotch-Brite pad or equivalent to scuff the new Sill Insert and the new Sill Outer Assembly in the bond path areas (continued). J Clean all the bond paths on the new Sill Insert and the new Sill Outer Assembly 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.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). K Spread a thin coating of structural adhesive as a primer layer on the bond paths on the new Sill Insert and the new Sill Outer Assembly. NOTE: Assembly must be performed while the primer layer is still wet. The drying time of the adhesive varies depending on temperature and humidity.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). M Put the new Sill Insert into the new Sill Outer Assembly. N Insert the structural rivets. Structural Rivet, 6.5 mm Short (x8) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). N Insert the structural rivets (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). O Install the structural rivets. P Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 2 Prepare the new Sill Outer for installation (continued). Q Apply urethane adhesive to the factory foam dams that were removed in an earlier step, and install them in the original locations on the new Sill Insert. R 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly. A Use an assistant to put the new Sill Outer Assembly into position, and clamp it into place. NOTE: Make sure to fit the Wheelhouse Extension portion of the new Sill Outer Assembly into the Body Side Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). A Use an assistant to put the new Sill Outer Assembly into position, and clamp it into place (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). B Mark the fastener locations. Structural Rivet, 6.5 mm Short (x5) High Strength Structural Rivet, 6.5 mm (x21) Structural Rivet, 4.8 mm (x9) Installation Spot Weld NOTE: Mark and drill the holes for the bottom row of structural rivets in the B-Pillar Outer at least 15 mm (9/16 in) up from the bottom edge of the B-Pillar Outer.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). B Mark the fastener locations (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). B Mark the fastener locations (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). C Use a drill with a 6.7 mm (17/64 in) bit to drill holes for the 6.5 mm structural rivets. Structural Rivet, 6.5 mm Short (x5) High Strength Structural Rivet, 6.5 mm (x21) NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). C Use a drill with a 6.7 mm (17/64 in) bit to drill holes for the 6.5 mm structural rivets (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). D Use a drill with a 4.8 mm (3/16 in) bit to drill holes for the 4.8 mm structural rivets. Structural Rivet, 4.8 mm (x9) NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). E Mark the surface preparation boundary lines on the new Sill Outer Assembly and on the vehicle. F Remove the new Sill Outer Assembly. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). G Mark the bond path areas on the new component and the vehicle. These areas will be prepared for bonding in the next step. Steel-to-Steel Bond Path Steel-to-Aluminum Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 3 Prepare for installation of the new Sill Outer Assembly (continued). G Mark the bond path areas on the new component and the vehicle. These areas will be prepared for bonding in the next step (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 4 Prepare the surfaces to install the new Sill Outer Assembly. A Use a red Scotch-Brite pad to scuff the Sill Outer Assembly in the bond path areas. B Mark the installation spot weld locations on the new Sill Outer Assembly and on the vehicle. Installation Spot Weld NOTE: If the HV Battery has been removed, mark installation spot weld locations on the lower flange. If the HV Battery has not been removed, these areas will be secured with adhesive only.
Sill Outer (Complete) Replacement 4 Prepare the surfaces to install the new Sill Outer Assembly (continued). B Mark the installation spot weld locations on the new Sill Outer Assembly and on the vehicle (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 4 Prepare the surfaces to install the new Sill Outer Assembly (continued). C Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the new Sill Outer Assembly in the weld areas. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment. CAUTION: Within two hours of removing the e-coat or paint, cover the abraded aluminum areas in the bond path with a thin primer layer of structural adhesive.
Sill Outer (Complete) Replacement 5 Apply structural adhesive to install the new Sill Outer Assembly. A Spread a thin coating of structural adhesive as a primer layer on the bond paths and weld areas on the new Sill Outer Assembly and on the vehicle. NOTE: Assembly must be performed while the primer layer is still wet. The drying time of the adhesive varies depending on temperature and humidity.
Sill Outer (Complete) Replacement 6 Install the new Sill Outer Assembly. A Apply urethane adhesive to the outside of the foam dams on the Sill Insert. B Use an assistant to put the new Sill Outer Assembly into position, and then insert the structural rivets. Structural Rivet, 6.5 mm Short (x5) High Strength Structural Rivet, 6.5 mm (x21) Structural Rivet, 4.8 mm (x9) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 6 Install the new Sill Outer Assembly (continued). B Use an assistant to put the new Sill Outer Assembly into position, and then insert the structural rivets (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 6 Install the new Sill Outer Assembly (continued). B Use an assistant to put the new Sill Outer Assembly into position, and then insert the structural rivets (continued). C Clamp the new Sill Outer into position. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 6 Install the new Sill Outer Assembly (continued). D Install the structural rivets. E Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 6 Install the new Sill Outer Assembly (continued). F Perform resistance spot welding. Installation Spot Weld (x29) 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.
Sill Outer (Complete) Replacement 6 Install the new Sill Outer Assembly (continued). F Perform resistance spot welding (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 6 Install the new Sill Outer Assembly (continued). G Remove any discoloration from the weld areas. H 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).
Sill Outer (Complete) Replacement 6 7 Install the new Sill Outer Assembly (continued). I Prime any bare metal that will not be covered with weld-through primer or structural adhesive in a subsequent repair with a suitable corrosion-resistant epoxy primer. Prepare a backing plate for the installation of the new Hinge Pillar section. A Use a drill with a spot weld bit to drill out the factory spot welds that attach the A-Pillar to Shotgun Reinforcement to the first new Hinge Pillar Assembly.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). A Use a drill with a spot weld bit to drill out the factory spot welds that attach the A-Pillar to Shotgun Reinforcement to the first new Hinge Pillar Assembly (continued). B Use a hammer and chisel to remove the A-Pillar to Shotgun Reinforcement from the new Hinge Pillar Assembly. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). C Cut the first new Hinge Pillar Assembly as shown to create a backing plate. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). D Cut off the flanges from the backing plate, and then cut the backing plate down the middle to create 2 sections. Cut Line NOTE: This allows the backing plate to fit inside the butt joint. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). D Cut off the flanges from the backing plate, and then cut the backing plate down the middle to create 2 sections (continued). E Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the backing plate sections in the areas where the two sections meet. WARNING: Remove the e-coat in a well-ventilated area.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). F G Clean the sections of the backing plate 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.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). H Tack weld the 2 backing plate sections together. 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.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). J Weld the backing plate sections together to create 1 backing plate. 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.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). K Use a grinding tool to grind down the weld on the backing plate. L Put the backing plate into position and clamp it into place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). M Mark the locations for the structural countersunk rivets that will attach the backing plate to the upper portion of the original Hinge Pillar Assembly. Structural Countersunk Rivet, 6.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). M Mark the locations for the structural countersunk rivets that will attach the backing plate to the upper portion of the original Hinge Pillar Assembly (continued). N Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural countersunk rivets. NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes.
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). O 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).
Sill Outer (Complete) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). O 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) (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section. A On the second new Hinge Pillar Assembly, use a drill with a 6.7 mm (17/64 in) bit to drill completely through the factory spot welds that attach the A-Pillar to Shotgun Reinforcement. Factory Spot Weld (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). B Use a hammer and chisel to remove the A-Pillar to Shotgun Reinforcement from the second new Hinge Pillar Assembly. NOTE: Save the A-Pillar to Shotgun Reinforcement for installation in a later step. C Cut the second new Hinge Pillar Assembly on the green dashed line shown. Cut Line NOTE: Leave 2 - 3 mm (3/32 - 1/8 in) of extra material to be trimmed at a later step.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). C Cut the second new Hinge Pillar Assembly on the green dashed line shown (continued). D Put the new Hinge Pillar Assembly section into position and align it to the frame bench jig points. NOTE: If necessary, use a 1 mm (1/16 in) shim to account for the thickness of the Body Side Outer. NOTE: If necessary, trim the new section to achieve suitable gaps.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). D Put the new Hinge Pillar Assembly section into position and align it to the frame bench jig points (continued). E Put the new A-Pillar to Shotgun Reinforcement into position and insert grip screws into the holes that were drilled when the reinforcement was removed in an earlier substep. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). F Clamp the new A-Pillar to Shotgun Reinforcement to the Shotgun Inner. G Mark the remaining fastener locations on the new Hinge Pillar Assembly section. High Strength Structural Rivet, 6.5 mm (x18) Structural Countersunk Rivet, 6.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). G Mark the remaining fastener locations on the new Hinge Pillar Assembly section (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). G Mark the remaining fastener locations on the new Hinge Pillar Assembly section (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). H Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets and countersunk structural rivets. CAUTION: Drill holes for countersunk rivets far enough away from the corners and any other obstructions to provide enough clearance (approximately 18 mm or 11/16 in) for the Microstop countersink cage assembly.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (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) (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). J Mark the surface preparation boundary lines on the new Hinge Pillar section and the vehicle. K Remove the new A-Pillar to Shotgun Reinforcement, the new Hinge Pillar section, and the backing plate. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). L Mark the bond path areas on the new Hinge Pillar Assembly section, the new A-Pillar to Shotgun Reinforcement, the backing plate, and the vehicle. Steel-to-Steel Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 8 Prepare for installation of the new Hinge Pillar section (continued). L Mark the bond path areas on the new Hinge Pillar Assembly section, the new A-Pillar to Shotgun Reinforcement, the backing plate, and the vehicle (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section. A Use the section of the original C-Pillar Extension as a template to mark a cut line on the new C-Pillar Extension. Cut Line NOTE: The section of the original C-Pillar Extension was removed in an earlier step. B Cut the new C-Pillar Extension on the cut line marked in the previous substep. NOTE: Leave 2 - 3 mm (3/32 - 1/8 in) of extra material to be trimmed at a later step.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). C Cut a 40 mm (1-9/16 in) section from the unused portion of the remaining piece of the new C-Pillar Extension to create a backing plate. D Cut off the flanges from the backing plate. Cut Line NOTE: This allows the backing plates to fit inside the butt joint. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). D Cut off the flanges from the backing plate (continued). E Put the backing plate into position and clamp it into place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). F Use a drill with a 4.8 mm (3/16 in) bit to drill holes for countersunk rivets. Countersunk Rivet, 4.8 mm Short (x3) Reference Line/Point CAUTION: Drill holes for countersunk rivets far enough away from the corners and any other obstructions to provide enough clearance (approximately 18 mm or 11/16 in) for the Microstop countersink cage assembly.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). G Put the new C-Pillar Extension section into position and clamp it into place. NOTE: If necessary, trim the new section to achieve suitable gaps. H Mark the fastener locations on the new C-Pillar Extension section. Structural Rivet, 4.8 mm (x5) Countersunk Rivet, 4.8 mm Short (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). H Mark the fastener locations on the new C-Pillar Extension section (continued). I Use a drill with a 4.8 mm (3/16 in) bit to drill holes for structural rivets and countersunk structural rivets. NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). J 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). Countersunk Rivet, 4.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). K Mark the surface preparation boundary lines on the new C-Pillar Extension section and on the vehicle. L Remove the new C-Pillar extension section and the backing plate. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 9 Prepare for installation of the new C-Pillar Extension section (continued). M Mark the bond path areas on the new C-Pillar Extension and the vehicle. Steel-to-Aluminum Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 10 A Prepare the surfaces to install the new Hinge Pillar Assembly section and CPillar Extension section. Use a red Scotch-Brite pad to scuff the new Hinge Pillar Assembly section, the C-Pillar Extension section, and the outside of the backing plates in the bond path areas. NOTE: Make sure to scuff the inside surfaces of the original Hinge Pillar Assembly and the original C-Pillar Extension in the areas that will contact the backing plates.
Sill Outer (Complete) Replacement 10 B Prepare the surfaces to install the new Hinge Pillar Assembly section and CPillar Extension section (continued). Mark the installation spot weld locations on the new Hinge Pillar Assembly section, the A-Pillar to Shotgun Reinforcement, and the vehicle (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 10 C Prepare the surfaces to install the new Hinge Pillar Assembly section and CPillar Extension section (continued). Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat in the weld areas. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment. CAUTION: Take the appropriate steps to minimize the crosscontamination of steel and aluminum components during the repair.
Sill Outer (Complete) Replacement 10 E Prepare the surfaces to install the new Hinge Pillar Assembly section and CPillar Extension section (continued). 11 Apply a suitable corrosion-resistant epoxy primer to any bare metal on the backsides of the backing plates (the sides of the backing plates that will be facing the inside of the vehicle when installed). Apply structural adhesive to install the new Hinge Pillar Assembly section and C-Pillar Extension section.
Sill Outer (Complete) Replacement 11 12 Apply structural adhesive to install the new Hinge Pillar Assembly section and C-Pillar Extension section (continued). B While the primer layer is still wet, apply a bead of structural adhesive on top of the primer layer of the bond path areas on the new Hinge Pillar Assembly section, the new C-Pillar Extension section, and the backing plates. Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). A Put the backing plate for the Hinge Pillar into position and insert the countersunk structural rivets to hold it in place (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). B Put the new Hinge Pillar Assembly section into position, and insert the structural rivets and countersunk structural rivets shown. High Strength Structural Rivet, 6.5 mm (x15) Structural Countersunk Rivet, 6.5 mm (x4) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). B Put the new Hinge Pillar Assembly section into position, and insert the structural rivets and countersunk structural rivets shown (continued). C Install the structural countersunk rivet shown. Structural Countersunk Rivet, 6.5 mm (x1) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). D Put the new A-Pillar to Shotgun Reinforcement into position and insert the structural rivets. High Strength Structural Rivet, 6.5 mm (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). E Align and temporarily secure the new Hinge Pillar section to the frame bench jig points. NOTE: If necessary, use a 1 mm (1/16 in) shim to account for the thickness of the Body Side Outer. F Clamp the new Hinge Pillar section in the areas that do not have fasteners. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). G Install the structural rivets and structural countersunk rivets to install the new Hinge Pillar section and the new A-Pillar to Shotgun Reinforcement. H Put the backing plate for the C-Pillar Extension into position and insert the countersunk rivets to hold it in place. Countersunk Rivet, 4.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). H Put the backing plate for the C-Pillar Extension into position and insert the countersunk rivets to hold it in place (continued). I Put the new C-Pillar Extension section into position and insert the structural rivets and countersunk rivets to hold it in place. Structural Rivet, 4.8 mm (x5) Countersunk Rivet, 4.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). I Put the new C-Pillar Extension section into position and insert the structural rivets and countersunk rivets to hold it in place (continued). J Install the structural rivets and countersunk rivets to install the new C-Pillar Reinforcement section. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). K Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). L Perform resistance spot welding. Installation Spot 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). L Perform resistance spot welding (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 12 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). M Remove any discoloration from the weld areas. N 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).
Sill Outer (Complete) Replacement 12 13 Install the new Hinge Pillar Assembly section and the new C-Pillar Extension section (continued). O Prime any bare metal that will not be covered with weld-through primer or structural adhesive in a subsequent repair with a suitable corrosion-resistant epoxy primer. Prepare the new Body Side Outer section for installation.
Sill Outer (Complete) Replacement 13 Prepare the new Body Side Outer section for installation (continued). B Put the new Body Side Outer section into position and clamp it into place. NOTE: If necessary, trim the new Body Side Outer section to achieve suitable gaps. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 13 Prepare the new Body Side Outer section for installation (continued). C 14 A Remove the new Body Side Outer section. Create and install backing plates for the Body Side Outer butt joints. Cut 40 mm (1-916 in) sections from the remaining pieces of the new Body Side Outer to create backing plates for the 3 butt joints. NOTE: These pieces were cut off of the new Body Side Outer in the previous step.
Sill Outer (Complete) Replacement 14 B Create and install backing plates for the Body Side Outer butt joints (continued). Put each section into position and mark cut lines to remove the unneeded material to create the backing plates shown. Reference Line/Point TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 14 B Create and install backing plates for the Body Side Outer butt joints (continued). Put each section into position and mark cut lines to remove the unneeded material to create the backing plates shown (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 14 C Create and install backing plates for the Body Side Outer butt joints (continued). D Cut the sections on the cut lines marked in the previous substep. Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the outward surface of the backing plates (the sides of the backing plates that will be facing the outside of the vehicle when installed). WARNING: Remove the e-coat in a well-ventilated area.
Sill Outer (Complete) Replacement 14 E Create and install backing plates for the Body Side Outer butt joints (continued). F Wipe the insides of the flanges with isopropyl alcohol (IPA) to remove any cavity wax. Use a drill with an 8 mm (5/16 in) bit to drill holes for plug welds. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 14 G Create and install backing plates for the Body Side Outer butt joints (continued). Use a belt sander with a medium-abrasive belt to remove the paint from the butt joint areas on the vehicle. WARNING: Remove the paint in a well-ventilated area. Wear suitable personal protective equipment. H Use sandpaper or a disc sander with a medium-abrasive surface conditioning disc to remove any remaining epoxy adhesive from the inside surfaces of the flanges.
Sill Outer (Complete) Replacement 14 I Create and install backing plates for the Body Side Outer butt joints (continued). J Apply a suitable corrosion-resistant epoxy primer to any bare metal on the backsides of the backing plates (the sides of the backing plates that will be facing the inside of the vehicle when installed). Put the backing plates into position and clamp them into place. If necessary, trim them to fit.
Sill Outer (Complete) Replacement 14 K Create and install backing plates for the Body Side Outer butt joints (continued). 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.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section. A Put the new Body Side Outer section into position and clamp it into place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). B Temporarily install the door hinge bolts. Bolt, hex-head (x5) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). C Mark the fastener locations on the new component. Structural Countersunk Rivet, 6.5 mm (x2, circled in red) Structural Rivet, 6.5 mm Short (x78) Flow Form Rivet S38 (x6) Installation Spot Weld NOTE: If the Sill Outer was resistance spot welded to the Sill Inner, do not install structural rivets on the lower flange.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). C Mark the fastener locations on the new component (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). D Create holes for flow form rivets. Flow Form Rivet S38 (x6) For more information on installing flow form rivets, refer to BR-18-92-001, "Using Flow Form Rivets". TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). E Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets. Structural Countersunk Rivet, 6.5 mm (x2, circled in red) Structural Rivet, 6.5 mm Short (x78) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). E Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). F 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.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). H Remove the new Body Side Outer section. I Mark the bond path and weld areas on the new component and the vehicle. These areas will be prepared for bonding and welding in the next step. Steel-to-Steel Bond Path GMA Weld TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). I Mark the bond path and weld areas on the new component and the vehicle. These areas will be prepared for bonding and welding in the next step (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 16 A Prepare the surfaces to install the new Body Side Outer Section. B Use a red Scotch-Brite pad to scuff the new Body Side Outer section and the vehicle in the bond path areas. Mark the installation spot weld locations. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 16 C Prepare the surfaces to install the new Body Side Outer Section (continued). Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat in the weld areas. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment. WARNING: Use only sanding wheels and belts that are 80 grit or finer on aluminum components.
Sill Outer (Complete) Replacement 16 D Prepare the surfaces to install the new Body Side Outer Section (continued). 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.
Sill Outer (Complete) Replacement 17 Apply structural adhesive to install the new Body Side Outer section (continued). B While the primer layer is still wet, apply a bead of structural adhesive on top of the primer layer of the bond path areas on the vehicle. C Apply urethane sealant to the foam dam edges. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 A Install the new Body Side Outer section. B Put the new Body Side Outer section into position and clamp it into place. Temporarily install the door hinge bolts. Bolt, hex-head (x5) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 B Install the new Body Side Outer section (continued). C Temporarily install the door hinge bolts (continued). Insert the structural rivets and the structural countersunk rivets. Structural Countersunk Rivet, 6.5 mm (x2, circled in red) Structural Rivet, 6.5 mm Short (x78) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 C Install the new Body Side Outer section (continued). Insert the structural rivets and the structural countersunk rivets (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 C Install the new Body Side Outer section (continued). D Insert the structural rivets and the structural countersunk rivets (continued). Insert the flow form rivets. Flow Form Rivet S38 (x6) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 D Install the new Body Side Outer section (continued). E Insert the flow form rivets (continued). Install the structural rivets and the structural countersunk rivets. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 F Install the new Body Side Outer section (continued). G Install the flow form rivets. If the Sill Outer was attached to the Sill Inner with resistance spot welds: Clamp the lower flange area until the structural adhesive cures. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 H Install the new Body Side Outer section (continued). Use a hammer and dolly to fold over the tabs in the door opening flanges (circled in red in the first image). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 I Install the new Body Side Outer section (continued). J Use a hammer and dolly to fold over the wheel arch flange. Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 K Install the new Body Side Outer section (continued). Perform resistance spot welding. Installation Spot 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Sill Outer (Complete) Replacement 18 K Install the new Body Side Outer section (continued). Perform resistance spot welding (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 K Install the new Body Side Outer section (continued). L Perform resistance spot welding (continued). Remove any discoloration from the weld areas. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 18 M Install the new Body Side Outer section (continued). 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.
Sill Outer (Complete) Replacement 19 B GMA weld the Body Side Outer butt joints (continued). Perform GMA welding in the butt joint areas directly above the backing plates. 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Sill Outer (Complete) Replacement 19 B GMA weld the Body Side Outer butt joints (continued). Perform GMA welding in the butt joint areas directly above the backing plates (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 19 B GMA weld the Body Side Outer butt joints (continued). C Perform GMA welding in the butt joint areas directly above the backing plates (continued). Grind down welds to restore all components to their original dimensions. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 20 A Secure the Body Side Outer butt joint flanges. Pry up the flanges of the original Body Side Outer on both sides of each butt joint weld in preparation to apply structural adhesive. Structural Adhesive TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 20 B Secure the Body Side Outer butt joint flanges (continued). C Apply structural adhesive underneath the flanges that were pried up in the previous substep. Clamp the flanges back into position. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 21 If required, apply a suitable body filler to the joints and finish for paint. 22 Prime any bare metal with a suitable corrosion-resistant epoxy primer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 23 Seal the seams in the factory locations, and as necessary. 24 After refinishing, install expanding foam in area of the C-Pillar where the factory foam was removed in an earlier step. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Complete) Replacement 25 After refinishing, use a 360-degree spray wand of suitable length to apply corrosion-proofing material on the inside of the butt joints to prevent corrosion. 26 Install the new Shotgun Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
