WarningBefore any work on the structure of a vehicle with on board electric energy (electric vehicle/hybrid vehicle), the vehicle must be isolated by an authorised technician
WarningObserve the safety and cleanliness recommendations
WarningObserve the precautions to be taken for the pre-tensioning components
WarningAny repair work carried out on a vehicle with on board electric energy (electric vehicle/hybrid vehicle) must be carried out by an authorised person
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
- MIG brazing with cupro-aluminium rod used with an inert gas
- MAG welding with steel rod and used with active gas
Designations of the high strength steels used in this document
- High strength: high strength steel
- THLE: very high strength steel
- Very high strength: ultra high strength steel
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 | |
| [1126] | set of spot weld cutters | |
| [FEIN-400E] | electric knife kit FEIN C1 electric knife C2 FEIN offset hub saw blade C3 blade no. 103 | |
| swan's neck drill for cutting out electric spot welds | ||
| hot air blower |
Preliminary operations
Deactivate the pyrotechnic systems
Disconnect the ancillaries battery
WarningEither remove or protect those components which are in the repair zone and risk being damaged by the heat or the dust
Remove
- The front bumper
- The front wing (repair side)
- The front seat (repair side)
WarningIf the vehicle has the Stop and Start system remove-refit the voltage retention device
Detach the electrical harnesses and the mats and carpets
Location of the replacement part
| reference | designation |
|---|---|
| (1) | outer sill |
| (2) | sill front closing panel inflating insert |
Identification of replacement parts
Composition: outer sill
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1a) | outer sill | 1,17 mm | high strength |
| (1b) | crimped nuts | 6 x100 | - |
WarningTake into account the difference in thickness of the part when setting the welding station
Composition: sill front closing panel inflating insert
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | sill front closing panel inflating insert | - | - |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (3) | inner sill | 1,17 mm | THLE |
| (4) | sill strengthener | 1,17 mm | THLE |
| (5) | front pillar | 1,27 mm | high strength |
Preparation of the replacement parts
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Preparation: outer sill (front section)
"A" = 730 mm
NoteThe outer sill (front section) (6) is extracted from the outer sill assembly (1)
Mark (at "a") in the cutting zone "A" then cut
NoteThe cutting line "a" is shown as an indication only; it may differ depending on the different circumstances of repair
Prepare the mating edges of all the new components and protect them with a weldable primer (index "C7")
NoteApply the weld-through primer on the internal faces of the panels to be welded
Mark then drill to diameter 6,5 mm (or 8 mm for the heavy thicknesses) for later plug welding (at "b")
Inflating insert (sill front closing panel)
Apply an index "A1" shimming mastic
Cutting of the part on the body
Distance "B" = cutting line "a"
Mark (at "c") to the dimension "B", then cut
Cut out the spot welds
Detach the outer sill panel (6) at the inflating insert (2) (longeron front closer); using a hot air gun
Remove the exterior longeron (6) (front section)
Remove the inflating insert (2)
Cleaning and preparation of the body
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
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 the inflating insert (longeron front closer) (2)
Position
- The outer sill (front section) (6)
- The components for adjusting
Check the fits and clearances
Adjust the cuts (if necessary)
Holds the part in position
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
Weld by MAG seam weld (at "d")
Grind the bead of MAG weld (at "d")
Weld with MAG plug welds (at "e")
Grind the plug welds (at "e")
Weld with electric spot welds
Sealing protection
Apply index "C4" underseal protection
NoteDo not block the drain holes (at "f")
Apply index "C4" underseal protection
Apply a phosphate-print layer to the zones laid bare
Apply index "C4" underseal protection
| zone | dimensions | tolerance |
|---|---|---|
| "g" | 110 mm | + 5 mm |
| "h" | 25 mm | + 5 mm |
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
Deactivate the pyrotechnic systems
WarningPerform the operations that are required following a reconnection of the ancillaries battery
Reconnect the ancillaries battery