WarningObserve the safety and cleanliness recommendations
WarningObserve the precautions to be taken for the pre-tensioning components
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
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
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
Deactivation: pyrotechnic systems
Disconnect the battery
WarningRemove or protect the components that are in the repair area and that can be damaged by heat or dust
Remove
- The front door
- The rear door
- The outer sill trim
- The front wing
- The front and rear floor sill trims
Release the wiring harnesses
Replace
- The outer sill
- The inflating inserts
Location of the replacement part
| reference | designation |
|---|---|
| (1) | outer sill |
Identification of the replacement parts
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | outer sill | - | mild steel |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Drill (at "a") for later plug welding
NoteApply the weld-through primer on the internal faces of the panels to be welded
Cutting out on body
"A" = 95 mm
"B" = 30 mm
Mark then cut (at "b")
Mark then cut; using the mark (at "c")
Cut out the spot welds
Remove the partial outer sill
Cleaning the body
Prepare the mating edges and protect them using a weldable primer (index "C7")
Adjustment
Position
- The inflating inserts
- The outer sill
- The components for adjusting
- Check the fits and clearances
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
Weld by MAG bead (at "d")
Grind the MAG weld beads
Weld with MAG plug welds (at "e")
Grind the MAG plug welds
Weld with electric spot welds (at "f")
Sealing protection
Apply a phosphate-print layer to the zones laid bare
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
Activation: pyrotechnic systems
WarningPerform the operations to be carried out following reconnection of the battery
Reconnect the battery