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
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
- UHLE: 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 | |
| - | swan's neck drill for cutting out electric spot welds | |
| - | hot air blower |
Preliminary operations
Deactivate the 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 side door aperture seals
- The front bumper
- The fuel flap
- The rear bumper
- The interior trims
- The front wing
- The boot lid
- The windscreen
- The rear screen
Release the wiring harnesses
Replace
- The cabin side front strengthener (combustion engine version) or the cabin side front strengthener (hybrid version)
- The roof or the roof (sunroof)
Location of the replacement part
| reference | designation |
|---|---|
| (1) | side panel (complete) |
| (2) | plug: understructure |
| (3) | plug: front pillar |
| (4) | inflating insert: cabin side closing panel |
Identification of the replacement part
Composition: side panel (complete)
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | side panel (complete) | - | - |
| (1a) | side panel | 0,67 mm | mild steel |
| (1b) | rear wing gutter | 0,77 mm | high strength |
| (1c) | rear boot balancer spring mounting | 1,47 mm | high strength |
| (1d) | rear light housing | 0,87 mm | mild steel |
| (1e) | rear wing lower closing panel | 0,77 mm | high strength |
| (1f) | Stiffener (rear jacking point) | 1,95 mm | mild steel |
| (1g) | front wing rear support | 0,67 mm | mild steel |
| (1h) | windscreen pillar closure panel | 0,67 mm | mild steel |
| (1j) | rear door striker fastening stiffener | 2 mm | high strength |
| (1k) | extension (rear wing lower closing panel) | 1,95 mm | mild steel |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (5) | door pillar stiffener | 1,17 mm | high strength |
| (6) | Roof metal panel | 1,07 mm | high strength |
| (7) | windscreen pillar stiffener | 1,17 mm | very high strength |
| (8a) | roof arch strengthener (front section) | 0,97 mm | high strength |
| (8b) | roof arch strengthener (rear section) | 1,17 mm | high strength |
| (9) | roof bow cantrail | 1,07 mm | high strength |
| (10) | rear quarter panel inner panel | 0,67 mm | mild steel |
| (11) | rear wheelarch | 0,97 mm | high strength |
| (12) | rear interior longeron | 0,97 mm | mild steel |
| (13) | rear jacking point | 2,5 mm | high strength |
| (14) | sill strengthener | 0,97 mm | THLE |
| (15) | upper B-post liner | 0,97 mm | high strength |
| (16) | lower B-post liner | 1,27 mm | high strength |
| (17) | centre pillar lower reinforcement | 1,8 mm | high strength |
| (18) | centre pillar upper strengthener | 1,8 mm | very high strength |
| (19) | windscreen pillar inner panel | 0,97 mm | high strength |
| (20) | front interior longeron | 1,17 mm | THLE |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Cut out the spot welds
Remove the boot aperture (21)
Mark then drill to Ø 6,5 mm for later plug spot welding
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
Cutting of the part on the body
Cut out the spot welds
Cut out the spot welds
Cut out the spot welds
Cut out the spot welds
Separate the passenger compartment side (complete) at the expanding inserts (4), (22), (23), (24), (25), (26), (27); using the hot air blower
Remove the passenger compartment side (complete)
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
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
Seal the expanding inserts (22), (23), (24), (25), (26), (27)
Apply some bedding sealant (index: "A1") (at "a")
Apply a seal (index "A1") around the outer expanding insert (4)
Clip the expanding insert (4) onto the passenger compartment side (complete)
Adjustment
Position
- The passenger compartment side (complete)
- 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 MAG plug welds (at "b")
Grind the MAG plug welds
Weld with electric spot welds
Weld with electric spot welds
Weld with MAG plug welds
Grind the MAG plug welds
Sealing protection
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index: "A1")
NoteIf there is poor sealing at the expanding insert (27), inject some polyurethane foam (index: "C6") (at "c")
Apply a sealing mastic (index "A1") around the plugs (2), (3)
Clip the plugs (2), (3) onto the passenger compartment side
WarningDo not block the drain holds with the stone chip protection (at "d")
Apply underseal protection (index: "C4")
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 to be carried out following reconnection of the battery
Reconnect the battery