WarningObserve the elementary rules of hygiene and safety (wear a face mask to protect against fumes and vapour - work in a well ventilated space)
WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process
Complementary operation(s)
Removal-fitting
- Front door
- Rear door
- Front wing
- Door aperture seal (before - rear)
- Side sill dirt excluder seal
- Rear seat cushion
- Rear seat backrest
- Rear mud shield
Remove-refit trim
- Part front and rear floor
- Front pillar
- Centre pillar
Release the wiring harnesses
Identification of the replacement parts
Outer sill
Composition
(1) sill front closing panel
(2) outer sill
Parts required
Outer sill
Preparation of the new part
Mark out then drill 6,5 mm holes for later plug welding
Cutting out
Mark cut then out with a 1 mm thick wheel
(provisional cut)
Mark cut then out with a 1 mm thick wheel
(provisional cut)
Mark cut then out with a 1 mm thick wheel
(provisional cut)
Cut out by milling out the spot welds
Cut out by milling out the spot welds
Cut out by milling out the spot welds (at A)
Cut with a 6 mm thick wheel (at B)
Remove the component
Separating
Prepare the mating edges
Protect the edges of the original and the new parts with welding primer
Adjustment
Fit
- Outer sill
- Front door
- Rear door
- Front wing
Check the clearances
Remove
- Front wing
- Front door
- Rear door
Mark out the cuts
Remove the exterior longeron
Clean up the cuts (at C)
Apply supporting structural adhesive (at D)
Welding
Fit the exterior longeron
MIG stitch weld
Grind the welds
MIG plug weld
Grind the plug welds
MIG plug weld (at E)
Grind the plug welds
Weld with electric spot welds (at F)
Using equipment AB1
Weld with electric spot welds
Using equipment AB1
Finish
Lead load
Sealing
Apply a mastic to be smoothed using a brush
Protection
Apply an anti-chip layer
Spray liquid wax