WarningObserve the safety and cleanliness recommendations
WarningObserve the precautions to be taken for the pre-tensioning components
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
MAG welding with steel rod and used with active gas
Designations of the high strength steels used in this document
- ADX: soft steel
- HLE: high-strength steel
- THLE: very high-strength steel
- Very high strength: ultra high strength steel
NoteUse the products recommended by the manufacturer
Tooling
| tool | Reference | designation |
|---|---|---|
| [1366-ZZ] | toolkit for testing electric spot welds | |
| [1366] | samples for testing electric spot welds | |
| [1126] | set of spot weld cutters | |
| swan's neck drill for cutting out electric spot welds | ||
| hot air blower |
Preliminary operations
Deactivating the pyrotechnic systems
Disconnect the ancillaries battery
WarningRemove or protect the components that are in the repair area and that can be damaged by heat or dust
Remove
- The front wing
- The front splash shield
- The front door
- The rear door
- The interior trims (side sill)
- The B post trim
- The rear bench seat
- The front seat
Release the wiring harnesses
Location of the replacement part
| reference | designation |
|---|---|
| (1) | outer sill (understructure) |
Identification of the replacement part
Composition: outer sill
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | outer sill | 0,67 mm | ADX |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | front wing inner panel | 1,17 mm | high strength |
| (3) | front pillar inner panel | 1,17 mm | high strength |
| (4) | centre pillar upper strengthener | 1,76 mm | UHLE |
| (5) | centre pillar inner panel | 0,97 mm | HLE |
| (6) | rear wing inner panel (front section) | 0,67 mm | ADX |
| (7) | inner sill | 1,47 mm | high strength |
| (8) | centre pillar lower reinforcement | 1,27 mm | high strength |
| (9) | inner sill strengthener | 0,77 mm | THLE |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Mark, then cut (at "a", "b", "c")
NoteThe cuts "a", "b", "c" are given as a guide and can change according to the different cases for replacement
Mark then pierce to a diameter of 6,5 mm for later plug welding
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 (at "d", "e", "f"), then cut out
NoteThe cuts "d", "e", "f" are given as a guide and can change according to the different cases for replacement
Cut out the spot welds
Cut out the spot welds
Separate the exterior side member at the expanding inserts (at "g"); using a hot air gun
Remove the exterior longeron
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
Apply an index "A1" shimming mastic (at "h", "j")
Adjustment
Position
- The outer sill
- The components for adjusting
Check the fits and clearances
Adjust the cuts (if necessary)
Holds the part in position
Welding
Weld by MAG bead (at "k")
Grind the MAG weld beads
Weld with MAG plug welds
Grind the MAG plug welds
Weld with electric spot welds
Weld with electric spot welds
Sealing protection
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic of type "A1"
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
Put the pyrotechnic systems into service
WarningPerform the operations that are required following a reconnection of the ancillaries battery
Reconnect the ancillaries battery