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)
Complementary operation(s)
Removal-fitting
- Front door
- Front wing
- Door aperture seal
- Front seat
- Rear seat cushion
- Rear seat backrest
- Rear mud shield
- Wing protector side moulding
- Front mud shield
Remove-refit trim
- Part front and rear floor
- Wing interior
- Inner sill
- Front pillar
- Rear pillar
Release the wiring harnesses
Identification of the replacement parts
Outer sill
Composition
(1): outer sill
(2): sill closer extension
Parts required
Outer sill
Preparation of the new part
Drill at 8mm diameter for later plug welding
Mark cut then out with a 1 mm thick wheel (final cuts)
Cutting out
Mark cut then out with a 1 mm thick wheel (preliminary cut)
Mark cut then out with a 1 mm thick wheel (at A) (preliminary cut)
Cut out by milling out the spot welds (at B)
Cut out by milling out the spot welds
Cut out by milling out the spot welds
Separating
Prepare the mating edges
Protect the edges of the original and the new part with welding primer
Adjustment
Fit
- The front wing
- The front door
- The outer sill
Clearance checks
Remove
- The front wing
- The front door
Mark out the cuts
Mark out the cuts
Remove the exterior longeron
Clean up the cuts (final cuts)
Apply supporting structural adhesive
Welding
MIG stitch weld
Grind the welds
MIG stitch weld (at C)
Grind the welds
MIG plug weld (at D)
Grind the spot welds
Weld with electric spot welds (using equipment AB1)
Weld with electric spot welds (using equipment AB1)
Sealing
Apply a mastic to be smoothed using a brush
Protection
Apply an anti-chip layer
Spray liquid wax