WarningBefore any work on the structure of a vehicle with on board electric energy (electric vehicle/hybrid vehicle), the vehicle must be isolated by an authorised technician
WarningObserve the safety and cleanliness recommendations
WarningObserve the precautions to be taken for the pre-tensioning components
WarningAny repair work carried out on a vehicle with on board electric energy (electric vehicle/hybrid vehicle) must be carried out by an authorised person
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
Operation to be carried out with one of the following systems
- Electronic measurement system
- Mechanical measurement system
- Special head MZ
- Checking jig
| tools | 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 headlining
- The B/C post trim
- The floor trim
- The front door
- The rear door
WarningIf the vehicle has the Stop and Start system: remove the central voltage retention device
Release the wiring harnesses
Replace
- The rear inner wing panel (front section)
- The B post lower reinforcement
- Front foot reinforcement
Location: replacement part
| reference | designation |
|---|---|
| (1) | inner sill assembly |
Identification of the replacement part
Composition: inner sill assembly
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | inner sill assembly | - | - |
| (1a) | inner sill | 1,35 mm | high strength |
| (1b) | rear jacking point | 2,5 mm | THLE |
| (1c) | front jacking point | 2 mm | high strength |
| (1d) | A post lower gusset | 2,2 mm | high strength |
| (1e) | seat belt mounting bracket | - | - |
| (1f) | rear jacking point strengthener | 2 mm | high strength |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | inner centre pillar | 0,97 mm | high strength |
| (3) | rear floor extension | 1,47 mm | mild steel |
| (4) | side member assembly | 2,44 mm | mild steel |
| (5) | quarterpanel lower inner panel | 0,67 mm | mild steel |
| (6) | rear wing inner panel front closing panel | 0,87 mm | mild steel |
| (7) | front seat base rear crossmember | 1,37 mm | high strength |
| (8) | front seat base front crossmember | 1,37 mm | high strength |
| (9) | front floor | 0,67 mm | mild steel |
| (10) | bulkhead side crossmember | 2.2 mm | THLE |
| (11) | B post upper reinforcement | 1,47 mm | UHLE |
| (12) | lower bulkhead | 0,77 mm | mild steel |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Mark then drill to Ø 8 mm for later plug spot welding
Remove: the front jacking point (1c)
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
Cutting out: front jacking point
Cut out the spot welds
Remove: the front jacking point
Cutting out: A post lower gusset
Cut out the spot welds
Remove: the front pillar lower gusset
Cutting out: inner sill
Cut out the spot welds
Cut out the spot welds
Level off the MIG weld beads (at "a")
Remove the inner 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
Adjustment
Position
- The inner sill
- The front jacking point
- The components for adjusting
Check the fits and clearances
Check; using one of the approved measurement systems
Remove: the front jacking point
Hold in position: the inner sill
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
Welding: inner sill
Weld with electric spot welds
Weld with electric spot welds (at "b")
Weld with MAG plug welds
Grind the MAG plug welds
Weld by MAG bead (at "c")
Welding: front jacking point
Weld with MAG plug welds
Grind the MAG plug welds
NoteThe remaining electric spot welds will be done during welding of the inner sill strengthener and the outer sill
Sealing protection
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index "A1")
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index "A1")
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