WarningObserve the safety and cleanliness recommendations
WarningObserve the precautions to be taken for the pre-tensioning components
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
Information
Types of weld bead by electric arc procedure on this component
MAG welding with steel rod and used with active gas
NoteUse the products recommended by the manufacturer
Tooling
| tool | Reference | designation |
|---|---|---|
| [1366-ZZ] | toolkit for testing electric spot welds | |
| [1366] | samples for testing electric spot welds | |
| swan's neck drill for cutting out electric spot welds |
Preliminary operations
Deactivation: pyrotechnic systems
Disconnect the battery
WarningRemove or protect the components that are in the repair area and that can be damaged by heat or dust
Remove
- The front splash shield
- The rear mud guard
- The front wing
- The front door
- Rear door
- Bottom hinge: front door
- Bottom hinge: rear door
- Front/rear door inlet seal
- Front seat
- Rear seat cushion
- Bonnet opening control
- Side sill dirt excluder seal
Remove the trim
- Centre pillar
- Part front floor
- Part rear floor
- Rear wheelarch (front structure)
Release the wiring harnesses
Protect the fuel pipes (on the right-hand side)
Identification of the replacement part
Outer sill assembly
Composition: replacement part
(1) outer sill
(2) sill closer extension
Preparation: replacement part
Mark then drill to Ø 8 mm for later plug spot welding
Mark then cut by means of a 1 mm grinder (final cut)
Cutting of the part on the body
Mark then cut by means of a 1 mm grinder (provisional cut)
Mark then cut by means of a 1 mm grinder (provisional cut)
Mark then cut by means of a 1 mm grinder (provisional cut)
Cut out the spot welds
Cut out the spot welds
Cut out the spot welds
Cut out the spot welds
Remove: the outer sill
Cleaning and preparation of the body
Prepare the mating edges and protect them using a weldable primer (index "C7")
NoteApply the weld-through primer on the internal faces of the panels to be welded
Adjustment
Position
- Outer sill
- Front door
- Rear door
- Front wing
Check the fits and clearances
Holds the part in position
Remove
- Front wing
- Front door
- Rear door
Mark out the cuts
Remove: outer sill
Clean up the cut (final cut)
Clean up the cut (final cut)
Clean up the cut (final cut)
Welding
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
Position: the outer sill
Weld with MAG beads (at "A")
Grind the MAG weld beads
Weld with electric spot welds (at "B")
Weld by MAG bead (at "C")
Weld with MAG plug welds (at "D")
Grind the MAG spot welds as well as the bead
Weld by MAG bead
Grind the bead of MAG weld
Weld with electric spot welds
Weld with electric spot welds
Sealing protection
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index "A1")
Apply an anti-chip layer (indice "C4")
Painting, then spraying of the index "C5" product into the hollow sections in the repair zone
Additional operations
Refit the electrical harnesses and the components removed
Reinitialisation
Activation: pyrotechnic systems
Reconnect the battery
WarningPerform the operations to be carried out following reconnection of the battery