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
| 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 door
- The rear door
- The B/C post trim
WarningIf the vehicle has the Stop and Start system: remove the central voltage retention device
Release the wiring harnesses
Location: replacement part
| reference | designation |
|---|---|
| (1) | outer sill |
Identification of the replacement part
Composition: outer sill
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | outer sill | 0,67 mm | mild steel |
Composition: B post inflating insert
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | B post inflating insert | - | - |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (3) | front wing inner panel | 1,37 mm | high strength |
| (4) | A post lower gusset | 2,2 mm | high strength |
| (5) | B post upper reinforcement | 1,47 mm | UHLE |
| (6) | inner centre pillar | 0,97 mm | high strength |
| (7) | quarterpanel lower inner panel | 0,67 mm | mild steel |
| (8) | rear wing inner panel front closing panel | 0,87 mm | mild steel |
| (9) | inner sill | 1,35 mm | high strength |
| (10) | centre pillar lower strengthener | 1,27 mm | high strength |
| (11) | 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
NoteThe cutting lines must be perpendicular to the edge
Mark at "a" in the cutting zone "A", then cut
Mark at "b" in the cutting zone "B", then cut
Mark at "c" in the cutting zone "C", then cut
NoteThe dimensions "A", "B", "C" 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
Cutting of the part on the body
NoteThe cutting lines must be perpendicular to the edge
Mark (at "d") in the cutting zone "D" then cut
Mark (at "e") in the cutting zone "E" then cut
Distance "F" = 425 mm
Mark at "f" in the cutting zone "F", then cut
NoteThe dimensions "D", "E", "F" are given as a guide and may change according to different examples of replacement of the outer sill
Cut out the spot welds
Detach the outer sill panel at the inflating insert (2); using a hot air gun
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
Position the expanding or structural inserts
Seal the expanding or structural inserts
Adjustment
Position
- The outer sill
- The components for adjusting
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", "h", "j")
Grind the MAG weld beads
Weld with electric spot welds
Sealing protection
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