WarningObserve the safety and cleanliness recommendations
WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process
Information
Types of weld bead by electric arc procedure on this component
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
Tooling
| tool | reference | designation |
|---|---|---|
| [1366-ZZ] | toolkit for testing electric spot welds | |
| [1366-B] | samples for testing electric spot welds | |
| 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 |
Additional operations
Disconnect the battery
WarningRemove or protect the components that are in the repair area and that can be damaged by heat or dust
Remove
- The front door
- The rear door
- The front wing
- The interior trims
Release the wiring harnesses
Location: replacement part
| reference | designation |
|---|---|
| (1) | outer sill (floor) |
Identification of the replacement part
Composition: outer sill (floor)
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (1) | outer sill (floor) | 0,67 | mild steel |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (2) | inner sill | 1,95 | high strength |
| (3) | front pillar strengthener | 1,76 | high strength |
| (4) | inner sill strengthener | 1,17 | THLE |
| (5) | Stiffener: lower centre pillar | 1,17 | high strength |
Preparation: Replacement Parts
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Mark out then cut (at "a","b","c") in the cutting zones "A","B","C"
Cut-away possibilities on the body side
NoteThe cutting lines "a", "b", "c" are shown as an indication only. the dimensions can change depending on the different sill replacement examples
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
Cutting of the part on the body
Mark out then cut (at "d","e","f") in the cutting zones "D","E","F"
Cut-away possibilities on the body side
NoteThe cutting lines "d", "e", "f" are shown as an indication only. the dimensions can change depending on the different sill replacement examples
Cut out the spot welds (as "g")
Detach the external side member (floor) at the inflating inserts (6), (7), (8), (9); using a hot air gun
Remove the exterior longeron (floor)
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
Inflating inserts
Adjustment
Position
- The outer sill (floor)
- The components for adjusting
Check the fits and clearances
Holds the part in position
Welding
Weld with MAG beads (as "h", "j", "k")
Grind the MAG weld beads
Weld with electric spot welds (as "l")
Sealing protection
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index "A1")
Anti-chip 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
Reconnect the battery
WarningPerform the operations to be carried out following reconnection of the battery