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 front wing
- The front door
- The rear door
- The front seat
- The rear seat
WarningIf the vehicle has the Stop and Start system: remove the central voltage retention device
Release the wiring harnesses
Location of the replacement part
| reference | designation |
|---|---|
| (1) | outer sill |
| (2) | B post strengthener exterior inflating insert |
| (3) | longeron front closing panel front 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 x 100 | - |
Composition: secondary components
| reference | designation |
|---|---|
| (2) | B post strengthener exterior inflating insert |
| (3) | longeron front closing panel front inflating insert |
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 |
|---|---|---|---|
| (4) | centre pillar inner panel | 0,67 mm | high strength |
| (5) | rear wing inner panel front part | 0,67 mm | mild steel |
| (6) | rear wing | 0,67 mm | mild steel |
| (7) | centre pillar | 1,76 mm | THLE |
| (8) | centre pillar lower reinforcement | 1,27 mm | THLE |
| (9) | sill strengthener | 1,17 mm | THLE |
| (10) | inner sill | 1,17 mm | THLE |
| (11) | front pillar | 1,27 mm | THLE |
Preparation of the replacement parts
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Preparation: outer sill
Prepare the mating edges and protect them using a weldable primer (index "C7")
Mark then drill to diameter 6,5 mm (or 8 mm for the heavy thicknesses) for later plug welding
NoteApply the weld-through primer on the internal faces of the panels to be welded
Inflating inserts
Apply filling mastic (index "A1") to the inflating inserts (2), (4)
Cutting of the part on the body
Cutting out: outer sill
Cut out the spot welds
Distance "A" = 165 mm minimum
Mark (at "a") to the dimension "A", then cut
NoteThe rear section of the outer sill must be cut to gain access to the electric spot welds
Cut out the spot welds
Detach the outer sill at the inflating inserts (2), (4): using a hot air gun
Remove the exterior longeron
Inflating inserts
Remove the inflating inserts (2), (4)
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
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
Position the inflating inserts (2), (4)
Seal the expanding inserts (2), (4)
Apply structural adhesive (index "B3")
NoteThe application of structural adhesive (index "B3") is necessary to replace the electric spot welds
Adjustment
Position
- The outer sill (1)
- The components for adjusting
Check the fits and clearances
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 with electric spot welds
Weld with an electric spot weld
Weld with MAG plug welds
Grind the MAG plug welds
Sealing protection
Apply a phosphate-print layer to the zones laid bare
Apply index "C4" underseal protection
| application zone | dimensions | tolerance + | tolerance - |
|---|---|---|---|
| "c" | 25 mm | 5 mm | 0 |
| "d" | 100 mm | 5 mm | 0 |
Apply a phosphate-print layer to the zones laid bare
Apply index "C4" underseal protection
NoteDo not block the drain holes (at "e")
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 a sealing mastic (index "A1")
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