WarningThis vehicle has been designed using the new panel grades HLE - THLE - UHLE - TRIP - 22Mnb5, with tensile strengths between 400 and 1300 MPa (mega Pascal) with 2 - 4 or 6 coatings, depending on the assemblies; the welding parameters of these panels are very different from those used for welding mild steels; it is imperative that the parameters indicated in these methods are strictly observed using the welding equipment (new generation) approved by PEUGEOT which conforms to our specifications; only this equipment is able to carry out a quality repair guaranteeing the level of safety required for this type of operation
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
Replacement: front door
Replacement: rear door
Removal-fitting
- Front seat
- Rear seat cushion
- Front door seal
- Rear door seal
Remove-refit trim
- Centre pillar
- Front floor - rear (partially)
Release the wiring harnesses
Identification of the replacement parts
(1) side panel (centre structure)
Part needed for the repair
(2) outer expanding insert (centre pillar stiffener)
Preparation of the new part
Mark, then cut
Cutting out
Mark, then cut: provisional cut (at (A))
Cut out the spot welds
- (B) 3 point in 3 thicknesses 0,72/1,17/1,17
- (C) 2 point in 2 thicknesses 0,72/2,00
- (D) 6 point in 3 thicknesses 0,72/2,00/1,47
- (E) 10 point in 3 thicknesses 0,72/2,00/1,47
- (F) 1 point in 2 thicknesses 0,72/2,00
- (G) 5 point in 3 thicknesses 0,72/1,17/1,17
- (H) 1 point in 3 thicknesses 0,72/2,00/1,17
- (I) 3 point in 3 thicknesses 0,72/1,17/1,17
- (J) 3 point in 3 thicknesses 0,72/2,00/1,17
- (K) 3 point in 3 thicknesses 0,72/1,17/1,17
- (L) 3 point in 3 thicknesses 0,72/2,00/1,17
- (M) 6 point in 3 thicknesses 0,72/1,17/1,17
Cut out the spot welds
- (N) 13 point in 3 thicknesses 0,72/2,00/1,47
- (O) 17 point in 3 thicknesses 0,72/2,00/1,47
Separating
Prepare the mating edges
Protect the edges of the original and the new part with welding primer
Adjustment
Fit: outer expanding insert (centre pillar stiffener)
Mark the final cuts
Remove: side panel (centre structure)
Clean up the cuts
Fit
- Side panel (centre structure)
- The front door
- The rear door
Check the fits and clearances
Check the fits and clearances
Remove
- The front door
- The rear door
Use the approved checking and measuring equipment
Welding
MIG stitch weld (at (A))
Grind the welds
Weld with electric spot welds
| components | B (electrodes 120 mm) | C (electrodes 120 mm) |
|---|---|---|
| number of spot welds | 3 | 2 |
| thickness | 0,72 - 1,17 - 1,17 | 0,72 - 2,00 |
| grades | ES - DP600 - E390D | ES - HR45 |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 |
| force (daN) | 380 | 350 |
| amperages (A) | 11300 | 11300 |
| time (ms) | 450 | 450 |
| components | D (electrodes 120 mm) | E (electrodes 120 mm) |
|---|---|---|
| number of spot welds | 6 | 10 |
| thickness | 0,72 - 2,00 - 1,47 | 0,72 - 2,00 - 1,47 |
| grades | ES - HR45 - E390D | ES - HR45 - E390D |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| force (daN) | 450 | 450 |
| amperages (A) | 11300 | 11300 |
| time (ms) | 800 | 800 |
| components | F (electrodes 120 mm) | G (electrodes 120 mm) |
|---|---|---|
| number of spot welds | 1 | 5 |
| thickness | 0,72 - 2,00 | 0,72 - 1,17 - 1,17 |
| grades | ES - HR45 | ES - DP600 - E390D |
| trims | G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| force (daN) | 350 | 350 |
| amperages (A) | 11300 | 11300 |
| time (ms) | 450 | 450 |
| components | H (electrodes 120 mm) | I (electrodes 120 mm) |
|---|---|---|
| number of spot welds | 1 | 3 |
| thickness | 0,72 - 2,00 - 1,17 | 0,72 - 1,17 - 1,17 |
| grades | ES - HR45 - E390D | ES - DP600 - E390D |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| force (daN) | 350 | 350 |
| amperages (A) | 11300 | 11300 |
| time (ms) | 450 | 450 |
| components | J (electrodes 120 mm) | K (electrodes 120 mm) |
|---|---|---|
| number of spot welds | 3 | 3 |
| thickness | 0,72 - 2,00 - 1,17 | 0,72 - 1,17 - 1,17 |
| grades | ES - HR45 - E390D | ES - DP600 - E390D |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| force (daN) | 350 | 350 |
| amperages (A) | 11300 | 11300 |
| time (ms) | 450 | 450 |
| components | L (electrodes 120 mm) | M (electrodes 120 mm) |
|---|---|---|
| number of spot welds | 3 | 6 |
| thickness | 0,72 - 2,00 - 1,17 | 0,72 - 1,17 - 1,17 |
| grades | ES - HR45 - E390D | ES - DP600 - E390D |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| force (daN) | 350 | 350 |
| amperages (A) | 11300 | 11300 |
| time (ms) | 450 | 450 |
Weld with electric spot welds
| components | N (electrodes 120 mm) | O (electrodes 120 mm) |
|---|---|---|
| number of spot welds | 13 | 17 |
| thickness | 0,72 - 2,00 - 1,47 | 0,72 - 2,00 - 1,47 |
| grades | ES - HR45 - E390D | ES - HR45 - E390D |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| force (daN) | 450 | 450 |
| amperages (A) | 11300 | 11300 |
| time (ms) | 800 | 800 |
Sealing
Apply a mastic to be smoothed using a brush (A1)
Protection
Inject polyurethane foam for hollow sections into the insert support (C6)
Spray liquid wax into the box sections (C5)
Apply an anti-chip layer (C4)