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
- High strength: high strength steel
- THLE: very high strength steel
- UHLE: 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
Disconnect the battery
Deactivating the pyrotechnic systems
WarningRemove or protect the components that are in the repair area and that can be damaged by heat or dust
Remove
- The body sill plugs (1)
- The front door
- The rear door
- The cover
- The front wing
- The interior trims
Detach
- The front door seal
- The rear door seal
WarningIf the vehicle is fitted with the Stop and Start system, discharge the power accumulator
Release the wiring harnesses
Location: replacement part
| reference | designation |
|---|---|
| (2) | outer sill |
Identification of the replacement part
Composition: outer sill assembly
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | outer sill assembly | - | - |
| (2a) | outer sill | 0,67 mm | mild steel |
| (2b) | longeron front closer | 0,67 mm | mild steel |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (3) | front pillar lower gusset | 2,2 mm | THLE |
| (4) | inner sill | 2,5 mm | high strength |
| (5) | rear side member | 2,44 mm / 1,76 mm | mild steel / high strength |
| (6) | rear wing inner panel front section | 0,67 mm | mild steel |
| (7) | centre pillar lower reinforcement | 1,17 mm | high strength |
| (8) | door pillar stiffener | 1,27 mm | high strength |
| (9) | inner sill inner panel | 0,77 mm | THLE |
Preparation: replacement part
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
"A" = 62 mm
Mark at "a" in the cutting zone "A", then cut
"B" = 83 mm
Mark at "b" in the cutting zone "B", then cut
NoteThe dimensions "A", "B" are given as a guide and may change according to different examples of replacement of the outer sill
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
"C" = 70 mm
Mark (at "c") in the cutting zone "C" then cut
NoteThe dimension "C" is given as a guide and can change depending on the different cases for replacement of the outer sill
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
"D" = 52 mm
Mark (at "d") in the cutting zone "D" then cut
"E" = 73 mm
Mark (at "e") in the cutting zone "E" then cut
NoteThe dimensions "D", "E" are given as a guide and may change according to different examples of replacement of the outer sill
"F" = 255 mm
Mark (at "f") in the cutting zone "F" then cut
NoteThe dimension "F" is given as a guide and can change depending on the different cases for replacement of the outer sill
Cut out the spot welds
Separate the exterior side member at the expanding inserts; using the hot air blower
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
Apply a setting adhesive (index "A1")
Adjustment
Position
- The outer sill
- The components for adjusting
Check the fits and clearances
Check the position; using one of the approved measurement systems
Adjust the cuts (if necessary)
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 by MAG bead (at "g", "h")
Grind the MAG weld beads
Weld by MAG bead (at "j")
Grind the MAG weld beads
Weld by MAG bead (at "k")
Grind the MAG plug welds
Weld with electric spot welds
Sealing protection
Apply stone chip protection
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index "A1")
Apply a sealing mastic (index "A1")
Painting, then spraying of the index "C5" product into the hollow sections in the repair zone
Additional operations
Refit
- The body sill plugs (1)
- The electrical harnesses and the removed components
Reinitialisation
Carry out the additional operations
Put the pyrotechnic systems into service
WarningPerform the operations to be carried out following reconnection of the battery
Reconnect the battery