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
Replacement
- Short roof
- Tail panel
Remove-refit the following components
- The side sliding door
- Lower rail of the sliding side door
- Sliding side door guide rail
- Sliding side door seal
- Rear quarter window
- Rear bumper
- Rear bumper crossmember
- Tail lamp
- Rear hinged door
- Hinged rear door fixings
- Hinged rear door seal
- Fuel filler flap
- Bench seat row 2
- Bench seat row 3
Detrim-trim the following components
- The rear pillar
- The rear wing
- The sliding side door aperture
- The roof rear section
- The rear floor
Release the wiring harnesses
Protect the interior of the passenger compartment
Information
Follow the instructions indicated in the methods below
- Cut-away possibilities: side panel
- Identification of the expanding inserts - sealing foam
Identification of replacement parts
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (1) | glazed passenger compartment side panel assembly | - | - |
| (1a) | rear glazed passenger compartment side panel | 0,77 | ADX (*) |
| (1b) | drip moulding upper gusset | 1,95 | ADX (*) |
| (1c) | hinged rear door upper hinge strengthener | 2,44 | ADX (*) |
| (1d) | left-hand pillar drip moulding | 1,76 | ADX (*) |
| (1e) | hinged rear door lower hinge strengthener | 2,44 | ADX (*) |
| (1f) | rear bumper side bracket | 1,17 | ADX (*) |
| (1g) | rear wing panel lower closing panel | 0,77 | ADX (*) |
| (1h) | outer sill | 0,97 | ADX (*) |
| (1j) | sliding side door central rail housing | 0,97 | ADX (*) |
| (1k) | sliding side door striker fixing support | 1,47 | ADX (*) |
| (1l) | side panel rear section | 0,97 | ADX (*) |
(*) ADX: mild steel
Replacement part preparation
Mark then cut (final cuts)
Mark then drill to Ø 6,5 mm for later plug welding (at "a")
Prepare the mating edges and protect them using a weldable primer
Cutting out
Cut out the spot welds
Mark then cut (temporary cuttings)
Cut out the spot welds
Cut out the spot welds
Mark then cut at "b" to make cutting of the spot welds easier
Remove the glazed passenger compartment side panel assembly
Cut out the spot welds
Remove the remaining part of the glazed passenger compartment side panel assembly
Bodywork cleaning and preparation
Prepare the mating edges and protect them using a weldable primer
Apply a filling adhesive A2
To respect the following sealing functions (at "c", "d")
- Acoustic
- Water
- Dust
Check the sealing of the inflating inserts
Adjustment
Fit the glazed passenger compartment side panel assembly
Check the fit
Retouch the lines of the cuts (final cuts)
Welding
MAG weld with beads in succession (at "e", "f")
Grind the MAG weld beads
Weld with electric spot welds
Weld with electric spot welds
Weld with electric spot welds (at "g")
Weld with MAG plug welds (at "h")
Grind the MAG plug welds
Weld with electric spot welds (access is in the direction of the arrow)
Sealing protection
Apply a phosphate-print layer on the zone laid bare
Apply index "C4" underseal protection
Paint then spray into the hollow sections, product index C5, in the repair zone
Reinitialisation
Carry out the additional operations
WarningPerform the operations to be carried out following reconnection of the battery