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
Release the wiring harnesses
Protect the interior of the passenger compartment
Replace the outer sill assembly
Identification of replacement parts
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (1) | sill web assembly | - | - |
| (1a) | sill web | 1,17 | ADX (*) |
| (1b) | sliding door lower rail upper half-casing | 1,47 | ADX (*) |
| (1c) | sliding door lower rail lower half-casing | 1,47 | ADX (*) |
| (1d) | rear jack rest | 2,15 | HLE (*) |
| (1e) | sliding door exterior half-casing support | 0,77 | ADX (*) |
| (1f) | sliding door rail half-casing strengthener | 1,47 | ADX (*) |
| (1g) | front jack rest | 1,76 | ADX (*) |
(*) ADX: mild steel - (*) HLE: high strength steel
Preparation of the replacement parts
Drill 10 mm holes for later plug welding (at "a", "b")
NoteRemove the front jack rest (1g)
Prepare the mating edges and protect them using a weldable primer
Cutting out
Cut out the spot welds
Remove the sill assembly core
Bodywork cleaning and preparation
Prepare the mating edges and protect them using a weldable primer
Adjustment
Clip the inserts (2), (3)
Fit the outer sill assembly
Check the fit
Remove the outer sill assembly
Welding
Weld with electric spot welds
Weld with MAG plug welds (at "c")
Protection
Apply a phosphate-print layer to the zones laid bare
Spray liquid wax into the hollow sections (index C5)
Reinitialisation
Carry out the additional operations
Operations to be carried out following reconnection of the battery