Hinge Pillar (Section) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) 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 1073679-S0-A (LH) A-Pillar Body Side Outer 1073680-S0-A (RH) 18 rivets needed; order 20 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.
Hinge Pillar (Section) Parts List Quantity Part Number 1 — Description Image / Notes Structural Adhesive WARNING: Use only Tesla-approved structural adhesive; refer to BR-15-92-008, "Approved Structural Adhesive and Urethane Sealants" for a list of current approved structural adhesives. Refer to BR-17-92-002, "Obtaining Adhesives, Coolant, and Other Chemicals" for information on how to obtain approved structural adhesive. 1 — Weld-Through Primer Source locally; not available from Tesla.
Hinge Pillar (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. Refer to the estimating system being used for a complete list of the prerequisites that must be performed before starting the repair.
Hinge Pillar (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.
Hinge Pillar (Section) Prerequisites 2 Remove the Shotgun Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Removal 1 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. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Removal 1 Remove the lower portion of the Body Side Outer in the A-Pillar area (continued). B Mark a cut line on the lower portion of the Body Side Outer, depending on the extent of the damage to the Body Side Outer. • The largest section of the Body Side Outer that can be removed is cutting 590 mm (23-1/4 in) from the forward edge of the door hinge bolt shown.
Hinge Pillar (Section) Removal 1 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.
Hinge Pillar (Section) Removal 1 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.
Hinge Pillar (Section) Removal 1 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. Heating adhesive joints weakens the adhesive bond and could compromise vehicle crash integrity.
Hinge Pillar (Section) Removal 1 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 (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Removal 2 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.
Hinge Pillar (Section) Removal 2 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.
Hinge Pillar (Section) Removal 2 Remove the lower portion of the Hinge Pillar (continued). C Mark a cut line 70 mm (2-3/4 in) down from the lower edge of the A-Pillar Outer Reinforcement. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Removal 2 Remove the lower portion of the Hinge Pillar (continued). D Cut the original Hinge Pillar on the cut line marked in the previous substep. 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 Hinge Pillar. Factory Spot Weld Areas NOTE: The areas highlighted in yellow indicate multiple factory spot welds.
Hinge Pillar (Section) Removal 2 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 (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.
Hinge Pillar (Section) Removal 2 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 (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Removal 3 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.
Hinge Pillar (Section) Replacement 1 Prepare a backing plate for the installation of the new Hinge Pillar section. 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. Factory Spot Weld (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 1 Prepare a backing plate for the installation of the new Hinge Pillar section (continued). B Use a hammer and chisel to remove the A-Pillar to Shotgun Reinforcement from the first new Hinge Pillar Assembly. 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.
Hinge Pillar (Section) Replacement 1 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.
Hinge Pillar (Section) Replacement 1 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.
Hinge Pillar (Section) Replacement 1 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).
Hinge Pillar (Section) Replacement 1 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.
Hinge Pillar (Section) Replacement 1 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.
Hinge Pillar (Section) Replacement 1 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.
Hinge Pillar (Section) Replacement 1 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.
Hinge Pillar (Section) Replacement 1 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, 6.5 mm (x3) CAUTION: Make sure to locate the forward-most hole inboard enough so that it does not conflict with the fasteners used to install the A-Pillar to Shotgun Reinforcement in a later step.
Hinge Pillar (Section) Replacement 1 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.
Hinge Pillar (Section) Replacement 1 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).
Hinge Pillar (Section) Replacement 1 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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 (x15) Structural Countersunk Rivet, 6.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 2 Prepare for installation of the new Hinge Pillar section (continued). K Remove the new A-Pillar to Shotgun Reinforcement, the new Hinge Pillar section, and the backing plate (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.
Hinge Pillar (Section) Replacement 2 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.
Hinge Pillar (Section) Replacement 3 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.
Hinge Pillar (Section) Replacement 3 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.
Hinge Pillar (Section) Replacement 3 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.
Hinge Pillar (Section) Replacement 3 4 Prepare the surfaces to install the new Hinge Pillar Assembly section (continued). E Apply a suitable weld-through 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.
Hinge Pillar (Section) Replacement 4 5 Apply structural adhesive to install the new Hinge Pillar Assembly 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 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.
Hinge Pillar (Section) Replacement 5 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.
Hinge Pillar (Section) Replacement 5 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.
Hinge Pillar (Section) Replacement 5 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.
Hinge Pillar (Section) Replacement 5 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.
Hinge Pillar (Section) Replacement 5 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 and the A-Pillar to Shotgun Reinforcement in the areas that do not have fasteners. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.
Hinge Pillar (Section) Replacement 5 Install the new Hinge Pillar Assembly 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 Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 5 Install the new Hinge Pillar Assembly section (continued). I 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.
Hinge Pillar (Section) Replacement 5 Install the new Hinge Pillar Assembly section (continued). I Perform resistance spot welding (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 5 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).
Hinge Pillar (Section) Replacement 6 7 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 A-Pillar Body Side Outer section for installation. A Clamp the remaining piece of the original Body Side Outer to the new A-Pillar Body Side Outer, and use it as a template to mark cut lines at each butt joint. Remove the template.
Hinge Pillar (Section) Replacement 7 Prepare the new A-Pillar Body Side Outer section for installation (continued). B Cut the new A-Pillar 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.
Hinge Pillar (Section) Replacement 8 Create and install backing plates for the Body Side Outer butt joints. A 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.
Hinge Pillar (Section) Replacement 8 Create and install backing plates for the Body Side Outer butt joints (continued). B Trim the excess material from each section to match the backing plates shown (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 8 Create and install backing plates for the Body Side Outer butt joints (continued). B Trim the excess material from each section to match the backing plates shown (continued). C 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.
Hinge Pillar (Section) Replacement 8 Create and install backing plates for the Body Side Outer butt joints (continued). D Use a belt sander with a medium-abrasive belt to remove the paint from the butt joint weld areas on the vehicle. GMA Weld WARNING: Remove the paint 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.
Hinge Pillar (Section) Replacement 8 Create and install backing plates for the Body Side Outer butt joints (continued). E Wipe the insides of the flanges with isopropyl alcohol (IPA) to remove any cavity wax. F 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.
Hinge Pillar (Section) Replacement 8 Create and install backing plates for the Body Side Outer butt joints (continued). G 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. NOTE: Pry up the flanges where necessary to gain access to the adhesive.
Hinge Pillar (Section) Replacement 8 Create and install backing plates for the Body Side Outer butt joints (continued). I Put the backing plates into position and clamp them into place. If necessary, trim them to fit. J 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.
Hinge Pillar (Section) Replacement 8 9 Create and install backing plates for the Body Side Outer butt joints (continued). K Use a grinding tool to grind down the plug welds until they are flush with the panel. 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.
Hinge Pillar (Section) Replacement 9 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.
Hinge Pillar (Section) Replacement 9 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 countersunk rivets. Structural Countersunk Rivet, 6.5 mm (x2) 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.
Hinge Pillar (Section) Replacement 9 Prepare for the installation of the new Body Side Outer section (continued). E Mark the installation spot weld locations on the new section. Installation Spot Weld TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 9 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, and then remove the new Body Side Outer section. G 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.
Hinge Pillar (Section) Replacement 9 Prepare for the installation of the new Body Side Outer section (continued). G 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.
Hinge Pillar (Section) Replacement 9 Prepare for the installation of the new Body Side Outer section (continued). G 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.
Hinge Pillar (Section) Replacement 10 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.
Hinge Pillar (Section) Replacement 10 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 and installation spot weld areas. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment.
Hinge Pillar (Section) Replacement 10 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.
Hinge Pillar (Section) Replacement 11 12 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 on the new component. Install 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.
Hinge Pillar (Section) Replacement 12 Install 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.
Hinge Pillar (Section) Replacement 12 Install the new Body Side Outer section (continued). C Insert the structural countersunk rivets. D Install the structural countersunk rivets. Structural Countersunk Rivet, 6.5 mm (x2) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 12 Install the new Body Side Outer section (continued). E 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.
Hinge Pillar (Section) Replacement 12 Install the new Body Side Outer section (continued). F Clamp all bond path areas that are not secured with welds or fasteners. G Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 12 Install the new Body Side Outer section (continued). 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). 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.
Hinge Pillar (Section) Replacement 13 GMA weld the butt joints. A 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.
Hinge Pillar (Section) Replacement 13 GMA weld the butt joints (continued). A Perform GMA welding in the butt joint areas directly above the backing plates (continued). B 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.
Hinge Pillar (Section) Replacement 14 A Secure the butt joint flanges. Pry up the flanges of the original Body Side Outer on both sides of each butt joint weld and apply structural adhesive underneath the flanges. Structural Adhesive B Clamp the flanges back into position. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 15 If required, apply a suitable body filler to the joints and finish for paint. 16 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.
Hinge Pillar (Section) Replacement 17 Seal the seams in the factory locations, and as necessary. 18 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Hinge Pillar (Section) Replacement 19 Install the new Shotgun Outer. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
