WarningThis vehicle has been designed using the mig brazing process technique; when repairing the structure, all the connections concerned must be welded using the same procedure; any other technique is prohibited
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)
Additional operations
Removing - refitting
- Dashboard
- Front door
- Front wing
- Windscreen
- Door aperture seal
- Seal (windscreen aperture)
- Bonnet
- Seal support (screen pillar)
Remove-refit trim
- Windscreen pillar
- Windscreen aperture
Identification of the replacement parts
Windscreen pillar
Preparation of the new part
Mark out then drill 6,5 mm holes for later plug welding
Cutting out
Cut: the securing points
- (a) 8 point in 2 thicknesses 1,17/1,47 (mm)
- (b) 1 point in 2 thicknesses 1,17/1,47 (mm)
- (c) 4 point in 3 thicknesses 1,17/1,47/0,67 (mm)
- (d) 3 point in 2 thicknesses 1,17/0,67 (mm)
- (e) 8 point in 3 thicknesses 1,17/1,47/0,67 (mm)
- (f) 1 point in 3 thicknesses 1,17/1,17/1,47 (mm)
Cut: the securing points
- (g) 1 point in 3 thicknesses 1,17/1,17/1,47 (mm)
- (h) 8 point in 3 thicknesses 1,17/1,47/0,67 (mm)
- (i) 3 point in 2 thicknesses 1,17/0,67 (mm)
- (j) 4 point in 3 thicknesses 1,17/1,47/0,67 (mm)
- (k) 1 point in 2 thicknesses 1,17/1,47 (mm)
- (l) 3 point in 2 thicknesses 1,17/1,47 (mm)
Cut the element following the dimension indicated
Separating
Prepare the mating edges
Protect the edges of the original and the new part with welding primer
Remove the remaining edge following (m)
Adjustment
Fit
- Windscreen pillar
- Front door
Check the fits and clearances
Welding
MIG plug weld
- (a) 8 point in 2 thicknesses 1,17/1,47 (mm)
- (f) 1 point in 3 thicknesses 1,17/1,17/1,47 (mm)
Weld with electric spot welds
| components | number of spot welds | thickness (mm) | thickness (mm) | thickness (mm) | current (kA) | force (daN) |
|---|---|---|---|---|---|---|
| (b) | 1 | 1,17 | 1,47 | - | 12 | 300 |
| (c) | 4 | 1,17 | 1,47 | 0,67 | 13,2 | 300 |
| (d) | 3 | 1,17 | 0,67 | - | 11 | 210 |
| (e) | 8 | 1,17 | 1,47 | 0,67 | 13,2 | 300 |
MIG plug weld: (g) 1 point in 3 thicknesses 1,17/1,17/1,47 (mm)
Weld with electric spot welds
| components | number of spot welds | thickness (mm) | thickness (mm) | thickness (mm) | current (kA) | force (daN) |
|---|---|---|---|---|---|---|
| (h) | 8 | 1,17 | 1,47 | 0,67 | 13,2 | 300 |
| (i) | 3 | 1,17 | 0,67 | - | 11 | 210 |
| (j) | 4 | 1,17 | 1,47 | 0,67 | 3,2 | 300 |
| (k) | 1 | 1,17 | 0,67 | - | 11 | 210 |
| (l) | 3 | 1,17 | 1,47 | - | 12 | 300 |
Weld a cupro-soldering bead in accordance with (n)
Grind the weld: at (n)
Sealing
Apply a mastic to be smoothed using a brush (A1)
Protection
Inject polyurethane foam for hollow sections into the insert support (C6)
Fit the windscreen pillar seal support using the holes drilled in the windscreen aperture as a reference
Spray liquid wax (C5)