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 | |
| 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 rear door
- The rear seat
- The rear mud guard
WarningIf the vehicle has the Stop and Start system; remove-refit the voltage retention device
Release the wiring harnesses
Location: replacement part
| reference | designation |
|---|---|
| (1) | outer sill |
Identification of parts
Outer sill
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | outer sill | 1,17 mm | high strength |
WarningTake into account the difference in thickness of the part when setting the welding station
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | inner sill | 1,17 mm | THLE |
| (3) | rear wing inner panel front part | 0,67 mm | mild steel |
| (4) | rear wing | 0,67 mm | mild steel |
| (5) | sill strengthener | 1,17 mm | THLE |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Cut: outer sill (rear section)
"A" = 600 mm
Mark at "a" in the cutting zone "A", then cut
NoteThe dimension "A" is given as a guide and can change depending on the different cases for replacement of the outer sill (rear section)
Reserve the dimension "B"
| reference | designation |
|---|---|
| (6) | outer sill (rear section) |
| (7) | cutting drop |
Throw away the cut-off (7)
Preparation of the sill (rear section)
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
Cutting of the sill rear section on the bodywork
"C" = "B" - 25 mm
Mark at "b" then cut
Cut out the spot welds
"D" = 165 mm
Mark (at "c"), then cut out
NoteThe rear section of the outer sill must be cut to gain access to the electric spot welds
Cut out the spot welds
Remove the exterior longeron (rear section)
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 the outer sill (6) (rear section)
Mark out (at "d")
Remove the exterior longeron (6) (rear section)
Cut (at "d")
Throw away the cut-off (8)
Adjust the cuts (if necessary)
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
Apply structural adhesive (index "B3")
NoteThe application of structural adhesive (index "B3") is necessary to replace the electric spot welds
Position the outer sill (6) (rear section)
Weld by MAG bead
Grind the bead of MAG weld
Weld with MAG plug welds
Grind the MAG plug welds
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 a phosphate-print layer to the zones laid bare
Apply index "C4" underseal protection
Apply a phosphate-print layer to the zones laid bare
Apply index "C4" underseal protection
| application zone | dimensions | tolerance + | tolerance - |
|---|---|---|---|
| "E" | 25 mm | 5 mm | 0 |
| "F" | 100 mm | 5 mm | 0 |
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
Reactivate the pyrotechnic systems
WarningPerform the operations that are required following a reconnection of the ancillaries battery
Reconnect the ancillaries battery