WarningBefore any work on the structure of a vehicle with on board electric energy (electric vehicle/hybrid vehicle), the vehicle must be isolated by an authorised technician
WarningObserve the safety and cleanliness recommendations
WarningObserve the precautions to be taken for the pre-tensioning components
WarningAny repair work carried out on a vehicle with on board electric energy (electric vehicle/hybrid vehicle) must be carried out by an authorised person
WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process
WarningThe number of spot welds necessary for the assembly of a new part must be identical to the number of spot welds fixing the original part
Information
Types of weld bead by electric arc procedure on this component
- MIG brazing with cupro-aluminium rod used with an inert gas
- MAG welding with steel rod and used with active gas
Designations of the high strength steels used in this document
- High strength: high strength steel
- THLE: very high strength steel
- UHLE: ultra high strength steel
NoteUse the products recommended by the manufacturer
Tooling
Operation to be carried out with one of the following systems
- Electronic measurement system
- Mechanical measurement system
- Special head MZ
- Checking jig
| tool | Reference | designation |
|---|---|---|
| [1366-ZZ] | toolkit for testing electric spot welds | |
| [1366] | samples for testing electric spot welds | |
| [1126] | set of spot weld cutters | |
| electric knife kit FEIN -"C1" electric knife -"C2" FEIN offset hub saw blade -"C3" blade no. 103 | ||
| swan's neck drill for cutting out electric spot welds | ||
| hot air blower |
Preliminary operations
Deactivate the pyrotechnic systems
Disconnect the ancillaries battery
WarningEither remove or protect those components which are in the repair zone and risk being damaged by the heat or the dust
Remove (repair side)
- The front wing
- The front door
- The rear door
- The front seat
- The rear seat
- The interior trims
- The seat belts
WarningIf the vehicle has the Stop and Start system; remove-refit the voltage retention device
Release the wiring harnesses
Replace
- The outer sill
- The rear wing
- The a post
- The side member strengthener
- The partition (front pillar) (operation on the left-hand side only)
- The centre pillar lower strengthener
- The rear wing closer (front section)
Location of the replacement part
| reference | designation |
|---|---|
| (1) | inner sill |
| reference | designation |
|---|---|
| (2) | inflating insert |
| (3) | centre pillar lower reinforcement |
| (4) | sill strengthener |
| (5) | inflating insert |
| (6) | rear wing |
| (7) | rear wing closing panel (front section) |
| (8) | outer sill |
| (9) | inflating insert |
| (10) | front pillar |
| (11) | front pillar bottom bulkhead |
| (12) | inflating insert |
Identification of replacement parts
Composition: inner sill
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | inner sill assembly | - | - |
| (1a) | welded earth stud | 6 x 100 | - |
| (1b) | inner sill | 1,17 mm | THLE |
| (1c) | seat belt fixing welded nuts | 10 x 150 | - |
| (1d) | rear jacking point support | 3 mm | high strength |
| (1e) | seat belt mounting strengthener | 3 mm | THLE |
| (1f) | welded bolts | 6 x 100 | - |
| (1g) | front jacking point support | 3 mm | high strength |
Composition: secondary components
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | inflating insert | - | - |
| (3) | centre pillar lower reinforcement | 1,27 mm | THLE |
| (4) | sill strengthener | 1,17 mm | THLE |
| (5) | inflating insert | - | - |
| (6) | rear wing | 0,67 mm | mild steel |
| (7) | rear wing closing panel (front section) | 0,67 mm | mild steel |
| (8) | outer sill | 1,17 mm | high strength |
| (9) | inflating insert | - | - |
| (10) | front pillar | 1,27 mm | high strength |
| (11) | front pillar bottom bulkhead | 1,76 mm | THLE |
| (12) | inflating insert | - | - |
NoteThe front pillar (10) can be partially replaced depending on the circumstances of the repair
| reference | designation |
|---|---|
| (2a) | centre pillar expanding insert |
| (12) | inner sill expanding insert |
| (5) | inflating insert for rear pillar |
| (2b) | centre pillar exterior expanding insert |
| (9) | longeron front closing panel front inflating insert |
WarningTake into account the difference in thickness of the part when setting the welding station
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (13) | seat front crossmember (front) | 1,17 mm | high strength |
| (14) | front seat rear support | 1,47 mm | mild steel |
| (15) | heel panel | 1,17 mm | high strength |
| (16) | rear floor | 0,67 mm | high strength |
| (17) | rear quarter panel inner panel | 0,77 mm | mild steel |
| (18) | rear wheelarch | 0,67 mm | mild steel |
| (19) | side member link / inner sill | 1,17 mm | THLE |
| (20) | front side member | 1,88 mm | high strength |
| (21) | centre pillar inner panel | 0,67 mm | high strength |
| (22) | front floor | 0,57 mm | mild steel |
| (23) | front wing inner panel | 1,17 mm | high strength |
| (24) | chassis member linkage / inner sill | 0,97 mm | THLE |
| (25) | lower bulkhead | 0,77 mm | mild steel |
Preparation of the component
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Mark then drill to diameter 6,5 mm (or 8 mm for the heavy thicknesses) for later plug welding (at "a")
Prepare the mating edges and protect them using a weldable primer (index "C7")
NoteApply the weld-through primer on the internal faces of the panels to be welded
Fit the inflating insert (12) (inner sill)
Seal the inflating insert (12)
Cutting of the part on the body
Mark, then cut out the spot welds
Mark, then cut out the spot welds
Mark, then cut out the spot welds
Mark (at "b"), then cut out the spot weld over 3 thicknesses
Mark, then cut out the spot welds
Remove
- The plugs (26)
- The inner sill (1)
Cleaning and preparation of the body
Prepare the mating edges and protect them using a weldable primer (index "C7")
NoteApply the weld-through primer on the internal faces of the panels to be welded
Prepare the mating edges and protect them using a weldable primer (index "C7")
NoteApply the weld-through primer on the internal faces of the panels to be welded
Prepare the mating edges and protect them using a weldable primer (index "C7")
NoteApply the weld-through primer on the internal faces of the panels to be welded
Adjustment
Position the inner sill (1)
Check the position using one of the approved measurement systems
Holds the part in position
Welding
WarningThe number of spot welds necessary for the assembly of a new part must be identical to the number of spot welds fixing the original part
Weld with MIG / MAG plug welds
Grind the MIG / MAG plug welds
Weld with electric spot welds
Drill (at "c") the inner sill (1), then plug weld
Weld with electric spot welds
Weld with MAG plug welds (at "d")
Weld with electric spot welds
Weld with electric spot welds
NoteThe remaining electric spot welds will be applied when welding the secondary parts
Refit
- The rear wing closer (front section) (7)
- The sill strengthener (4)
- The front left pillar (11) lower partition
- The centre pillar lower strengthener (3)
- The a post (10)
- The rear wing (6)
- The outer sill (8)
Sealing protection
Refit the blanks (26) (at "e")
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index "A1")
Apply a phosphate-print layer to the zones laid bare
Apply index "C4" underseal protection
Painting, then spraying of the index "C5" product into the hollow sections in the repair zone
Additional operations
Refit the electrical harnesses and the components removed
Reinitialisation
Reactivate the pyrotechnic systems
WarningPerform the operations that are required following a reconnection of the ancillaries battery
Reconnect the ancillaries battery