WarningObserve the safety and cleanliness recommendations
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
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
Additional operations
Disconnect the battery
Remove-refit the following components
- Front mud flaps
- Rear mud guard
- Front wing
- Front door
- Side door
- Sliding side door rail
- Front seat
Strip - retrim the front floor
Release the wiring harnesses
Protect the interior of the passenger compartment
Information
WarningTo prevent damage to the structural inserts, the cutting zones near to a structural insert must leave a safety margin of more than 30 mm
Identification of replacement parts
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | outer longeron assembly, left hand side | - | - |
| (1a) | partial left-hand passenger compartment side | 0.97 mm | ADX (*) |
| (1b) | LH outer longeron | 0.97 mm | ADX (*) |
| (2) | front pillar interior strengthener exterior expanding insert | - | - |
(*) ADX: soft steel
Replacement part preparation
Mark then cut (at "a", "b", "c") (final cut)
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 (at "d", "e", "f") (provisional cut)
When making the cut "d", take care not to cut the front pillar strengthener
Mark then cut (at "g")
Remove the partial exterior chassis member assembly
Cut out the spot weld
Remove the remainder of the exterior chassis member assembly
Remove the front pillar interior strengthener exterior expanding insert (2)
Bodywork cleaning and preparation
Prepare the mating edges and protect them using a weldable primer
Fit the front pillar interior strengthener exterior expanding insert (2)
To respect the following sealing functions
- Acoustic
- Water
- Dust
Seal the expanding inserts
Adjustment
Fit the outer sill assembly
Check the fit
Clean up the cuts (final cuts)
Welding
Weld with electric spot welds (at "h")
Weld with MAG plug welds (at "j")
Grind the MAG plug welds
MAG weld with beads in succession (at "k")
Grind the MAG weld beads
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 a phosphate-print layer to the zones laid bare
Apply an anti-chip layer (index "C4")
Paint then spray into the hollow sections, product index C5, in the repair zone
Reinitialisation
Carry out the additional operations
WarningOperations to be carried out following reconnection of the battery