WarningDepending on the operation to be carried out, observe the instructions for chocking up the vehicle
WarningDeactivate the pneumatic suspension before lifting the vehicle (2 or 4 post lift, workshop jack or customer's jack)
WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process
WarningObserve the elementary rules of hygiene and safety (wear a face mask to protect against fumes and vapour - work in a well ventilated space)
Additional operations
Disconnect the battery
Remove-refit the following components
- Front bumper
- Headlamp
- Front wing
- Front door
- Dashboard (partial)
Detrim-trim the following components
- The bulkhead
- The front floor panel (partly)
Release the wiring harnesses
Protect the interior of the passenger compartment
Information
| reference | designation |
|---|---|
| (1) | front pillar lower strengthener expanding insert |
| (2) | front pillar upper strengthener exterior expanding insert |
Cut-away possibilities on the body side
WarningTo avoid damaging the inflating inserts, the cutting zones close to an inflating insert must be executed with a safety distance of more than 30 mm
Identification of replacement parts
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (1) | front pillar lower strengthener expanding insert | - | - |
| (2) | front pillar assembly | - | - |
| (2a) | body side front part | 0,97 | ADX (*) |
| (2b) | outer sill | 0,97 | ADX (*) |
Replacement part preparation
Mark, then cut (as "a", "b") (final cuts)
Drill 6,5 mm holes for later plug welding
Prepare the mating edges and protect them using a weldable primer
Cutting out
Cut out the spot welds
Mark, then cut (as "c", "d") (temporary cuttings)
Remove: front pillar lower strengthener expanding insert
Bodywork cleaning and preparation
Prepare the mating edges and protect them using a weldable primer
Fit: front pillar lower strengthener expanding insert
Apply a filling adhesive "A2"
Adjustment
Fit the following components
- The front pillar assembly
- Front pillar lower strengthener expanding insert
Check the fit
Adjust the cut lines (final cuts)
Welding
MAG weld with beads in succession (as "f", "g")
Grind the MAG weld beads
Resistance welding parameter (front structure)
Weld with MAG plug welds
Grind the MAG plug welds
Sealing protection
Apply a phosphate-print layer on the zone laid bare
Apply a sealing mastic of type "A1"
Apply an anti-chip protection index "C4" on the panel pre-coated with phosphate print or cataphoresis; identification: anti-chip protection
Paint then spray into the hollow sections, product index C5, in the repair zone
Reinitialisation
Carry out the additional operations
Reconnect the battery
WarningPerform the operations to be carried out following reconnection of the battery