WarningThis vehicle has been designed using the new panel grades HLE - THLE - UHLE - TRIP - 22Mnb5, with tensile strengths between 400 and 1300 MPa (mega Pascal) with 2 - 4 or 6 coatings, depending on the assemblies; the welding parameters of these panels are very different from those used for welding mild steels; it is imperative that the parameters indicated in these methods are strictly observed using the welding equipment (new generation) approved by PEUGEOT which conforms to our specifications; only this equipment is able to carry out a quality repair guaranteeing the level of safety required for this type of operation
WarningThis vehicle has been designed using the mig brazing process technique; when repairing the structure, all the connections concerned must be welded using the same procedure; any other technique is prohibited
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
Replacement: outer sill
Removal-fitting
- Door aperture seal
- Front seat
Remove-refit trim
- Part a post
- Part front floor
- Partial B-pillar
Identification of the replacement parts
(1) passenger compartment side, lower part
Preparation of the new part
Mark then drill 5 holes of Ø 6,5 mm in accordance with the given dimensions for subsequent welding with plug welds
Cutting out
Cut out the spot welds
- (A) 1 point in 2 thicknesses: 0,67/1,76 (mm)
- (B) 1 point in 3 thicknesses: 0,67/1,76/1,80 (mm)
- (C) 17 point in 3 thicknesses: 0,67/1,76/2,00 (mm)
- (D) 1 point in 2 thicknesses: 0,67/1,80 (mm)
- (E) 1 point in 2 thicknesses: 0,67/1,76 (mm)
- (F) 2 point in 3 thicknesses: 0,67/1,76 (mm)
- (G) 4 point in 3 thicknesses: 0,67/1,17/2,00 (mm)
- (H) 2 point in 2 thicknesses: 0,67/1,17 (mm)
- (I) 5 point in 3 thicknesses: 0,67/1,17/1,47 (mm)
- (J) 1 point in 3 thicknesses: 0,67/1,17/1,76 (mm)
- (K) 2 point in 3 thicknesses: 0,67/1,76/1,47 (mm)
- (L) 2 point in 2 thicknesses: 0,67/1,76 (mm)
(M) mark then cut (provisional cuts)
Remove: passenger compartment side, lower part
Separating
Prepare the mating edges
Protect the edges of the original and the new part with welding primer
Adjustment
Fit
- Passenger compartment side, lower part
- Outer sill
- Front wing
- Sliding door bottom rail
- Sliding door
Check the fits and clearances
Use the approved checking and measuring equipment
Remove
- Front wing
- Sliding door
- Sliding door bottom rail
- Outer sill
Mark the final cuts
Remove: passenger compartment side, lower part
Retouch the final cuts
Apply supporting structural adhesive (A3)
Fit: passenger compartment side, lower part
Welding
The weld spot (A) is to be made with: the outer sill
MIG plug weld: (E) 1 point in 2 thicknesses: 0,67/1,76 mm
Grind the plug welds
Weld with electric spot welds
| components | B (electrodes: 120 mm) | C - D - F (electrodes: 120 mm) |
|---|---|---|
| number of spot welds | 1 | 20 |
| thickness (mm) | 0,67/1,76/1,80 | 0,67/1,76/2,00 |
| grades | ES - P260 - HR45 | ES, - P260 - HR45 |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| power (A) | 11300 | 11300 |
| force (daN) | 450 | 450 |
| time (ms) | 800 | 800 |
| components | G - H (electrodes: 120 mm) | I (electrodes: 120 mm) |
|---|---|---|
| number of spot welds | 6 | 5 |
| thickness (mm) | 0,67/1,17/2,00 | 0,67/1,17/1,47 |
| grades | ES - E390D - HR45 | ES - E390D - ES |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| power (A) | 11300 | 11300 |
| force (daN) | 350 | 350 |
| time (ms) | 450 | 450 |
| components | J (electrodes: 120 mm) | K - L (electrodes: 120 mm) |
|---|---|---|
| number of spot welds | 1 | 4 |
| thickness (mm) | 0,67/1,17/1,76 | 0,67/1,76/1,47 |
| grades | ES - E390D - P260 | ES - P260 - ES |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| power (A) | 11300 | 11300 |
| force (daN) | 350 | 450 |
| time (ms) | 450 | 800 |
MIG stitch weld (as (M))
Grind the welds (as (M))
Sealing
Apply a mastic to be smoothed using a brush (A1)
Protection
Inject polyurethane foam for hollow sections into the insert support (C6)
Apply an anti-chip layer (C4)
Spray liquid wax into the box sections (C5)