WarningA qualified technician must make the vehicle safe prior to any operation on a hybrid vehicle
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
- 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
| 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
Deactivate the pyrotechnic systems
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 seat
- The rear bench seat
- The rear bench seat back
- The B/C post trim
- The front door
- The rear door
- The headlining
WarningIf the vehicle has the Stop and Start system: remove the central voltage retention device
Release the wiring harnesses
Replace the roof
Location: replacement part
| reference | designation |
|---|---|
| (1) | ‘B’ post |
Identification of replacement parts
Composition: front ring (side panel)
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | front ring (side panel) | 0,67 mm | mild steel |
Composition: lower cap (‘B’ post)
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | lower cap (‘B’ post) | - | - |
Composition: inflating insert (‘B’ post)
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (3) | inflating insert (‘B’ post) | - | - |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (4) | inner centre pillar | 0,97 mm | high strength |
| (5) | cantrail inner panel | 0,97 mm | high strength |
| (6) | B post upper reinforcement | 1,47 mm | UHLE |
| (7) | centre pillar lower strengthener | 1,27 mm | high strength |
| (8) | inner sill | 1,35 mm | high strength |
| (9) | roof arch core | 0,77 mm / 1,27 mm | UHLE / UHLE |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Distance A = 800 mm
Distance B = 900 mm
Mark at "a" in the cutting zone "A", then cut
Mark at "b" in the cutting zone "B", then cut
NoteThe dimensions "A", "B" are given as an indication only and may change depending on the different circumstances of replacement of the centre pillar
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
Distance C = 240 mm
Distance D = 330 mm
Mark (at "c") in the cutting zone "C" then cut
Mark (at "d") in the cutting zone "D" then cut
NoteThe cutting lines C, D are given as a guide. the dimensions may change depending on the different circumstances of replacement of the centre pillar
Distance E = 320 mm
Distance F = 200 mm
Mark (at "e") in the cutting zone "E" then cut
Mark (at "f") in the cutting zone "F" then cut
NoteThe cutting lines E, F are given as a guide. the dimensions may change depending on the different circumstances of replacement of the centre pillar
Cut out the spot welds
Detach the centre pillar at the inflating inserts (3); using a hot air gun
Remove: the centre pillar
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
Position the inflating insert (3)
Seal the inflating insert (3)
Adjustment
Position: the centre pillar
Position the components used for adjustment
Check the fits and clearances
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")
Grind the MAG weld beads
Weld by MAG bead (at "h")
Grind the MAG weld beads
Weld with electric spot welds
Sealing protection
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 to be carried out following reconnection of the battery
Reconnect the battery