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
Removal-fitting
- Front wing
- The side sliding door
- Sliding door bottom rail
Identification of the replacement parts
(1) outer sill
Preparation of the new part
Mark then drill 25 holes to Ø 6,5 mm for later plug welding
Cutting out
Cut out the spot welds
- (A) 16 point in 2 thicknesses: 0,67 / 0,67 mm
- (B) 1 point in 3 thicknesses: 0,67 / 0,67 / 0,77 mm
- (C) 1 point in 3 thicknesses: 0,67 / 0,67 / 1,76 mm
- (D) 3 point in 2 thicknesses: 0,67 / 1,76 mm
- (E) 12 point in 3 thicknesses: 0,67 / 1,76 / 2,00 mm
- (F) 1 point in 3 thicknesses: 0,67 / 1,76 / 1,17 mm
- (G) 3 point in 3 thicknesses: 0,67 / 1,17 / 2,00 mm
- (H) 11 point in 3 thicknesses: 0,67 / 1,17 / 1,47 mm
- (I) 1 point in 2 thicknesses: 0,67 / 1,47 mm
(J) cut: the outer sill
Remove the exterior longeron
Cut: 4 point in 2 thicknesses: 0,67 / 0,67 mm
Remove the rest of the part (outer sill)
Separating
Prepare the mating edges
Protect the edges of the original and the new part with welding primer
Adjustment
Apply supporting structural adhesive (A3)
Fit
- The outer sill
- The front wing
- Sliding door bottom rail
- The sliding door
Check the fits and clearances
Remove
- The front wing
- The sliding door
- Sliding door bottom rail
Welding
MIG plug weld
- (A) 16 point in 2 thicknesses: 0,67 / 0,67 mm
- (B) 1 point in 3 thicknesses: 0,67 / 0,67 / 0,77 mm
- (C) 1 point in 3 thicknesses: 0,67 / 0,67 / 1,76 mm
- (D) 3 point in 2 thicknesses: 0,67 / 1,76 mm
- (F) 1 point in 3 thicknesses: 0,67 / 1,76 / 1,17 mm
- (K) 4 point in 2 thicknesses: 0,67 / 0,67 mm
Grind the plug welds
Weld with electric spot welds
| components | E (electrodes: 120 mm) | G (electrodes: 120 mm) |
|---|---|---|
| number of spot welds | 12 | 3 |
| thickness (mm) | 0,67 / 1,76 / 2,00 | 0,67 / 1,17 / 2,00 |
| grades | ES - P260 - HR45 | ES - E390D - HR45 |
| trims | G10/10 - g10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| force (daN) | 450 | 350 |
| power (A) | 11300 | 11300 |
| time (ms) | 800 | 450 |
| components | H (electrodes: 120 mm) | I (electrodes: 120 mm) |
|---|---|---|
| number of spot welds | 11 | 1 |
| thickness (mm) | 0,67 / 1,17 / 1,47 | 0,67 / 1,47 |
| grades | ES - E390D - ES | ES - ES |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 |
| force (daN) | 350 | 350 |
| power (A) | 11300 | 11300 |
| time (ms) | 450 | 450 |
Sealing
As (L): apply a mastic to be smoothed using a brush (A1)
As (M): apply a finishing compound (A4)
Protection
Apply an anti-chip layer (C4) (according to the procedure: anti-chip protection identification)
Spray liquid wax into the box sections (C5)