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
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
- THLE: very high strength steel
NoteUse the products recommended by the manufacturer
Tooling
Operation to be carried out with one of the following systems
| tools | Reference | designation |
|---|---|---|
| [1366-ZZ] | toolkit for testing electric spot welds | |
| [1366] | samples for testing electric spot welds | |
| [1126] | set of spot weld cutters | |
| electric knife kit FEIN -"C1" electric knife -"C2" FEIN offset hub saw blade -"C3" blade no. 103 | ||
| 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 (repair side)
- The front wing
- The front seat
- The front door
- The lower hinge (front door)
WarningIf the vehicle has the Stop and Start system: remove the central voltage retention device
Detach the electrical harnesses and the mats and carpets
Location: replacement part
| reference | designation |
|---|---|
| (1) | outer sill (front section) (assembled) |
Identification of the replacement part
(2) outer sill assembly (new part)
NoteThe outer sill (front section) (1) is extracted from the outer sill assembly (2)
Composition: outer sill assembly
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2a) | outer sill | 0.67 mm | mild steel |
| (2b) | front wing lower rear bracket | 1.17 mm | mild steel |
WarningTake into account the difference in thickness of the part when setting the welding station
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (3) | inner sill | 1.37 mm | high strength |
| (4) | sill strengthener | 0.77 mm | high strength |
| (5) | door pillar stiffener | 1.17 mm | high strength |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Preparation: outer sill (front section)
Distance "A" = 665 mm
Mark (at "a") to the dimension "A", then cut
NoteThe dimension "A" is given as a guide and can change depending on the different cases for replacement of the outer sill (front section) (1)
Outer sill (front section)
Debur the cuts made
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: outer sill (front section)
Distance "B" = "A" - 15 mm
Mark at "b" then cut
Mark (at "c") in the line of the fixing holes for the front door lower hinge, then cut
NoteThe cutting line "b" is given as a guide. the dimension can alter depending on the different cases for replacing the outer sill (front section) (1)
Cut out the spot welds
Remove: the outer sill (front section) (1)
Position: the outer sill (front section) (1) (new part)
Retain the outer sill (front section) (1) in position, using the fixing holes for the front door lower hinge (at "e")
Mark out (at "d")
Remove the exterior longeron (front section) (1)
Cutting out: cutting drop
Cut (at "d")
Cut out the spot welds
Remove: the drop (5)
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")
Seal the expanding or structural inserts
Adjustment
Position
- The outer sill (front section) (1)
- The components for adjusting
Check the fits and clearances
Adjust the cuts (if necessary)
Retain the outer sill (front section) (1) in position, using the fixing holes for the front door lower hinge (at "e")
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 "f", "g")
Grind the MAG weld beads
Weld with electric spot welds
NoteThe remaining spot welds will be made when welding the external side member
Sealing protection
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic of type "A1"
NoteDo not block the drain holes (at "h")
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