WarningObserve the safety and cleanliness recommendations
WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process
Information
The type of weld bead by means of the electric arc process used on this component is the following
MIG / MAG welding
Designations of the high strength steels used in this document
- High strength: high strength steel
- THLE: very high strength steel
Recommended tools
| tool | reference | designation |
|---|---|---|
| [1366-ZZ] | toolkit for testing electric spot welds | |
| [1366-B] | samples for testing electric spot welds | |
| 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
Release the wiring harnesses
Replace the passenger compartment side (complete or part)
Location of the replacement part: sill strengthener
| reference | designation |
|---|---|
| (1) | sill web |
Identification of the replacement part: sill web
Composition: replacement part
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (1) | sill web (assembled) | - | - |
| (1a) | rear pillar lower strengthener | 0,77 | mild steel |
| (1b) | sill partition | 1,76 | mild steel |
| (1c) | sill web | 1,27 | THLE |
| (1d) | rear jacking point | 2,5 | high strength |
Identification of the parts next to the core of the side member
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (1) | sill web (assembled) | - | - |
| 2 | front interior longeron | 1,17 | THLE |
| (3) | side panel | 0,72 | mild steel |
| (4) | front pillar bottom bulkhead | 1,95 | THLE |
| (5) | front wing inner panel | 1,17 | high strength |
| (6) | front pillar strengthener | 1,47 | high strength |
Replacement part preparation: sill web (partial)
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
A = 324 mm
Mark then saw out (at "a") (final cutting)
Remove the side member core (7) (partial)
Preparation: side member core repair sleeves
B = 100 mm
(1) sill web (assembled)
(7) sill web (partial)
(8) side member core repair sleeves
Mark then saw out (at "b")
Remove the repair sleeve from the side member core (8) (partial) (preliminary cut)
(8) side member core repair sleeves (partial)
Mark then saw out (at "c") (final cutting)
Assembly of the repair sleeve onto the partial side member core
(7) sill web (partial)
(8) side member core repair sleeves
D = 50 mm
Position the repair sleeves (8) on the partial side member core (7)
Weld with electric spot welds
Drill to a diameter of 8,5 mm for later MAG plug welding (at "d")
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
E = 324 mm
Mark then cut (at "e")
Cut out the electric spot welds
Remove the side member core (9) (front section)
Cleaning and preparation of the body
Mark out - drill to a diameter of 8,5 mm for later MAG 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
Adjustment
Position: the sleeved partial side member core
Adjust the cuts (if necessary)
Holds the part in position
Welding
MAG weld with beads in succession (at "f")
Weld with MAG plug welds
NoteTo avoid altering the mechanical strength of the side member core, it is recommended not to grind the MAG weld beads that are not directly in contact with the passenger compartment side
Sealing protection
Apply a phosphate-print layer to the zones laid bare
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