Sill Outer (Front Section) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Parts List Quantity Part Number Description Image / Notes 1 1082281-S0-A (LH) Sill Outer Assembly 1082282-S0-A (RH) 2 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) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Parts List Quantity Part Number 23 rivets or 62 rivets needed; order 30 rivets or 70 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. 23 rivets are needed if the lower flange of the new Sill Outer front section can be attached to the Sill Inner with resistance spot welds.
Sill Outer (Front Section) Repair Information Repair Information This procedure is for the left-hand component; the procedure is identical for the right-hand component. The items listed in the "Prerequisites" section of this document include only the last structural component that needs to be removed before starting the repair and any other prerequisites that are not obvious.
Sill Outer (Front Section) 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 (Front Section) Prerequisites 2 Remove the Shotgun Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) 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 (Front Section) Removal 2 Remove the lower portion of the Body Side Outer in the A-Pillar area. A Mark a cut line in the A-Pillar area 50 mm (2 in) down from the lower edge of the bolt hole shown. B Mark a cut line on the lower portion of the Body Side Outer 260 mm (10-1/4 in) from the forward edge of the door hinge bolt shown. Cut Line Reference Line/Point Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Removal 2 Remove the lower portion of the Body Side Outer in the A-Pillar area (continued). C Cut the Body Side Outer on the cut lines marked in the previous substeps. CAUTION: Do not damage the surrounding components. D 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 (x2) Factory Spot Weld Areas NOTE: The areas highlighted in yellow indicate multiple factory spot welds.
Sill Outer (Front Section) Removal 2 Remove the lower portion of the Body Side Outer in the A-Pillar area (continued). D 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 (Front Section) Removal 2 Remove the lower portion of the Body Side Outer in the A-Pillar area (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 Body Side Outer in the A-Pillar area. 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.
Sill Outer (Front Section) 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 (Front Section) 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 (Front Section) Removal 3 Remove the lower portion of the Hinge Pillar (continued). C Mark the cut lines shown to remove the bulk of 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 (Front Section) Removal 3 Remove the lower portion of the Hinge Pillar (continued). C Mark the cut lines shown to remove the bulk of the lower portion of the Hinge Pillar (continued). D Cut the original Hinge Pillar 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 (Front Section) 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 (Front Section) 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 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.com.
Sill Outer (Front Section) Removal 4 Remove the front section of the original Sill Outer. A Cut the Sill Outer 50 mm (2 in) from the front edge of the B-Pillar Outer. Cut Line Reference Line/Point 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 (Front Section) Removal 4 Remove the front section of the original Sill Outer (continued). B Use a drill with a 6.7 mm (17/64 in) bit to drill completely through the spot welds shown. Factory Spot Weld (x2) 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 (Front Section) Removal 4 Remove the front section of the original Sill Outer (continued). C Use a drill with a spot weld bit to drill out the remaining 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 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 (Front Section) Removal 4 Remove the front section of the original Sill Outer (continued). D Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the front section of the Sill Outer. 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. NOTE: Save the front section to be used as a template in a later step.
Sill Outer (Front Section) Removal 5 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 1 Prepare the new Sill Outer front section. A Mark a cut line 942 mm (37-1/16 in) from the front edge of the new Sill Outer. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 1 Prepare the new Sill Outer front section (continued). B Cut the new Sill Outer on the cut line marked in the previous substep. C Put the new section into position and clamp it into place. If necessary, trim the new section to fit. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 2 Create a reinforcement plate for the new Sill Outer front section. A Cut an 80 mm (3-18 in) section from the remaining piece of the new Sill Outer. Cut Line NOTE: Measure 80 mm (3-18 in) forward from the forward edge of the dimple shown (circled in red) on the remaining piece of the Sill Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 2 Create a reinforcement plate for the new Sill Outer front section (continued). A Cut an 80 mm (3-18 in) section from the remaining piece of the new Sill Outer (continued). B Cut off the flanges from the reinforcement plate. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section. A Put the reinforcement plate into position, centered over the butt joint between the original Sill Outer and the new Sill Outer front section, and clamp it into place. B On the original front section of the Sill Outer that was removed in an earlier step, cut a template that includes the holes made when drilling completely through 2 of the factory spot welds in an earlier step.
Sill Outer (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section (continued). C Clamp the template into position on the new Sill Outer front section. D Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets through the holes in the template, and then remove the template. 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 (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section (continued). D Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets through the holes in the template, and then remove the template (continued). E Mark the remaining fastener locations on the new Sill Outer (front section) and the reinforcement plate. Structural Rivet, 6.
Sill Outer (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section (continued). E Mark the remaining fastener locations on the new Sill Outer (front section) and the reinforcement plate (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section (continued). F Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets. 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 (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section (continued). G Mark the surface preparation boundary lines on the vehicle and the new front section. H Remove the reinforcement plate and the new front section. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section (continued). I Mark the bond path areas on the reinforcement plate, the new front section, and the vehicle. 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 (Front Section) Replacement 3 Prepare for installation of the new Sill Outer front section (continued). I Mark the bond path areas on the reinforcement plate, the new front section, and the vehicle (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 4 Prepare the surfaces to install the new Sill Outer front section. A Use a red Scotch-Brite pad or equivalent to scuff the reinforcement plate, the new front section, and the vehicle in the bond path areas. B Mark the installation spot weld locations.
Sill Outer (Front Section) Replacement 4 Prepare the surfaces to install the new Sill Outer front section (continued). B Mark the installation spot weld locations (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 4 Prepare the surfaces to install the new Sill Outer front section (continued). C Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the vehicle, the new Sill Outer front section, and the reinforcement in the weld areas. Use a belt sander with a medium-abrasive belt for any areas that cannot be reached with a disc sander. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment.
Sill Outer (Front Section) Replacement 5 Apply structural adhesive to install the new Sill Outer front section. A Spread a thin coating of structural adhesive as a primer layer on the bond paths on the new Sill Outer front section, the reinforcement, 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 (Front Section) Replacement 6 Install the new Sill Outer front section. A Put the new Sill Outer front section into position and insert the structural rivets shown to hold it into place. Structural Rivet, 6.5 mm Short (x9) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 6 Install the new Sill Outer front section (continued). B Put the reinforcement into position and insert the structural rivets to hold it into place. Structural Rivet, 6.5 mm Short (x14) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 6 Install the new Sill Outer front section (continued). C Clamp the new Sill Outer front section into position. D Install the structural rivets. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 6 Install the new Sill Outer front section (continued). E Brush structural adhesive into the seams between the reinforcement and the Sill Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 6 Install the new Sill Outer front section (continued). F Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 6 Install the new Sill Outer front section (continued). G 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 (Front Section) Replacement 6 Install the new Sill Outer front section (continued). G Perform resistance spot welding (continued). H Clamp all areas not secured with fasteners or spot welds. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 6 Install the new Sill Outer front section (continued). I Remove any discoloration from the weld areas. J 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 6 Install the new Sill Outer front section (continued). K 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 (Front Section) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). A On the first new Hinge Pillar Assembly, use a drill with a spot weld bit to drill out the factory 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 from the first new Hinge Pillar Assembly.
Sill Outer (Front Section) 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 (Front Section) 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 (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.
Sill Outer (Front Section) 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). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). E Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat from the sections in the areas where the sections meet. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment. F Clean the sections of the backing plate with isopropyl alcohol (IPA).
Sill Outer (Front Section) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). G Put the backing plate sections into position and clamp them into place. NOTE: If necessary, trim the backing plate sections to achieve the proper fit. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) 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 (Front Section) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). J GMA weld the 2 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 (Front Section) 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 (Front Section) 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 (Front Section) 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 (Front Section) Replacement 7 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). N Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural countersunk rivets (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 (Front Section) 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 (Front Section) 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 (Front Section) 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 (Front Section) 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). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) 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. 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 8 Prepare for installation of the new Hinge Pillar section (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. F Clamp the new A-Pillar to Shotgun Reinforcement to the Shotgun Inner. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) 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. High Strength Structural Rivet, 6.5 mm (x15) Structural Countersunk Rivet, 6.5 mm (x4) Installation Spot Weld NOTE: Mark and drill the holes for the bottom row of structural countersunk rivets at least 15 mm (9/16 in) up from the bottom edge of the new section.
Sill Outer (Front Section) 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 (Front Section) 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). H Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets and countersunk structural rivets.
Sill Outer (Front Section) 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 (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). Structural Countersunk Rivet, 6.
Sill Outer (Front Section) 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 (Front Section) 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 (Front Section) 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 (Front Section) 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 (Front Section) Replacement 9 Prepare the surfaces to install the new Hinge Pillar Assembly section. A Use a red Scotch-Brite pad to scuff the new Hinge Pillar Assembly section, the A-Pillar to Shotgun Reinforcement, the vehicle, and the outside of the backing plate in the bond path areas. NOTE: Make sure to scuff the inside surfaces of the original Hinge Pillar Assembly on the vehicle in the areas that will contact the backing plates.
Sill Outer (Front Section) Replacement 9 Prepare the surfaces to install the new Hinge Pillar Assembly section (continued). B 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 (Front Section) Replacement 9 Prepare the surfaces to install the new Hinge Pillar Assembly section (continued). C 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 (Front Section) Replacement 9 Prepare the surfaces to install the new Hinge Pillar Assembly section (continued). E 10 A Apply a suitable corrosion-resistant epoxy primer to any bare metal on the backside of the backing plate (the sides of the backing plate that will be facing the inside of the vehicle when installed). Apply structural adhesive to install the new Hinge Pillar Assembly section.
Sill Outer (Front Section) Replacement 10 B Apply structural adhesive to install the new Hinge Pillar Assembly section (continued). 11 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 section and on the backing plate. Install the new Hinge Pillar Assembly section. A Put the backing plate for the Hinge Pillar into position and insert the countersunk structural rivets to hold it in place.
Sill Outer (Front Section) Replacement 11 Install the new Hinge Pillar Assembly 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 (Front Section) Replacement 11 Install the new Hinge Pillar Assembly 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 (Front Section) Replacement 11 Install the new Hinge Pillar Assembly 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 (Front Section) Replacement 11 Install the new Hinge Pillar Assembly 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 (Front Section) Replacement 11 Install the new Hinge Pillar Assembly 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 (Front Section) Replacement 11 Install the new Hinge Pillar Assembly section (continued). F Clamp the new Hinge Pillar section in the areas that do not have fasteners (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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 11 Install the new Hinge Pillar Assembly section (continued). H Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 11 Install the new Hinge Pillar Assembly section (continued). I Perform resistance spot welding to install the new Hinge Pillar Assembly section and A-Pillar to Shotgun Reinforcement. 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.
Sill Outer (Front Section) Replacement 11 Install the new Hinge Pillar Assembly section (continued). I Perform resistance spot welding to install the new Hinge Pillar Assembly section and A-Pillar to Shotgun Reinforcement (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 11 Install the new Hinge Pillar Assembly section (continued). J Remove any discoloration from the weld areas. K 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 (Front Section) Replacement 12 13 Prime any bare metal that will not be covered with weld-through primer or structural adhesive in a subsequent repair with a suitable corrosionresistant epoxy primer. Prepare the new Body Side Outer section for installation. A Clamp the remaining piece of the original Body Side Outer to the new Body Side Outer, and use it as a template to mark cut lines at each butt joint. Remove the template.
Sill Outer (Front Section) Replacement 13 Prepare the new Body Side Outer section for installation (continued). B Cut the new Body Side Outer on the cut lines 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. C Put the new Body Side Outer section into position and check for suitable gaps. If necessary, trim the new Body Side Outer section. Remove the new Body Side Outer section.
Sill Outer (Front Section) Replacement 14 A Create and install backing plates for the Body Side Outer butt joints. Cut 40 mm (1-916 in) sections from the remaining piece of the new A-Pillar Body Side Outer to create backing plates for the 2 butt joints. NOTE: This piece was cut off of the new Body Side Outer in an earlier step. B Trim the excess material from each section to match the backing plates shown. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.
Sill Outer (Front Section) Replacement 14 B Create and install backing plates for the Body Side Outer butt joints (continued). C Trim the excess material from each section to match the backing plates shown (continued). 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 (Front Section) Replacement 14 D 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. E Wipe the insides of the flanges with isopropyl alcohol (IPA) to remove any cavity wax.
Sill Outer (Front Section) Replacement 14 F Create and install backing plates for the Body Side Outer butt joints (continued). G Use a drill with an 8 mm (5/16 in) bit to drill holes for plug welds. 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. WARNING: Remove the epoxy adhesive in a well-ventilated area. Wear suitable personal protective equipment.
Sill Outer (Front Section) Replacement 14 H Create and install backing plates for the Body Side Outer butt joints (continued). Apply a suitable weld-through 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). CAUTION: Only use zinc weld-through primers. Other primers might cause corrosion and compromise the integrity of the repair. I Put the backing plates into position and clamp them into place.
Sill Outer (Front Section) Replacement 14 J 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 (Front Section) 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. 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 (Front Section) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). B Temporarily install the door hinge bolts (continued). C Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets and structural countersunk rivets. Structural Rivet, 6.5 mm Short (x39) Structural Countersunk Rivet, 6.5 mm (x2) NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes.
Sill Outer (Front Section) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). C Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets and structural countersunk rivets (continued). D 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). Structural Countersunk Rivet, 6.
Sill Outer (Front Section) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). E Mark the installation spot weld locations on the new Body Side Outer section. Installation Spot Weld TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). F Mark the surface preparation boundary lines on the new Body Side Outer section and on the vehicle. G Remove the new Body Side Outer section. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). H 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 (Front Section) Replacement 15 Prepare for the installation of the new Body Side Outer section (continued). H 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 (Front Section) 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 on the new section and on the vehicle. Installation Spot Weld TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 16 B Prepare the surfaces to install the new Body Side Outer Section (continued). Mark the installation spot weld locations on the new section and on the vehicle (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 16 B Prepare the surfaces to install the new Body Side Outer Section (continued). C Mark the installation spot weld locations on the new section and on the vehicle (continued). Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat in the GMA weld areas and the installation spot weld locations. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment.
Sill Outer (Front Section) 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 (Front Section) Replacement 17 Apply structural adhesive to install the new Body Side Outer section (continued). B 18 A 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. Install the new Body Side Outer section. 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 (Front Section) Replacement 18 B Install the new Body Side Outer section (continued). 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 (Front Section) Replacement 18 C Install the new Body Side Outer section (continued). Insert the structural rivets and structural countersunk rivets. Structural Rivet, 6.5 mm Short (x39) Structural Countersunk Rivet, 6.5 mm (x2) D Install the structural rivets and structural countersunk rivets. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 18 E 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 (Front Section) Replacement 18 E Install the new Body Side Outer section (continued). F 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 (Front Section) Replacement 18 G Install the new Body Side Outer section (continued). Clamp all bond path areas that are not secured with welds or fasteners. NOTE: If the Sill Outer front section was attached to the Sill Inner with resistance spot welds, make sure to clamp the lower flange area. H Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 18 I 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 (Front Section) Replacement 19 A GMA weld the Body Side Outer butt joints. 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 (Front Section) Replacement 19 A GMA weld the Body Side Outer butt joints (continued). B 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 (Front Section) Replacement 20 A Secure the butt joint flanges. B 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 Apply structural adhesive underneath the flanges that were pried up in the previous substep. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 20 C Secure the butt joint flanges (continued). 21 Clamp the flanges back into position. If required, apply a suitable body filler to the joints and finish for paint. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Sill Outer (Front Section) Replacement 22 Prime any bare metal with a suitable corrosion-resistant epoxy primer. 23 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.
Sill Outer (Front Section) Replacement 24 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. 25 Install the new Shotgun Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
