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
Operation to be carried out with one of the following systems
- Electronic measurement system
- Mechanical measurement system
- Special head MZ
- Checking jig
| 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 ancillaries 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 rear door
- The front door aperture seal
- The rear door aperture seal
- The front left seat
- The rear bench seat
- The interior trims
Release the wiring harnesses
Replace the passenger compartment side
Location: Replacement Parts
| reference | designation |
|---|---|
| (1) | inner sill (complete) |
| (2) | rear inner longeron expanding foam insert |
Identification of replacement parts
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | inner sill assembly | - | - |
| (1a) | front interior longeron | 1,17 mm | THLE |
| (1b) | seatbelt reel fixing mounting | 2,5 mm | THLE |
| (1c) | rear interior longeron | 0,97 mm | mild steel |
| (1d) | rear jacking point | 2,5 mm | high strength |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (3) | Roof metal panel | 1,07 mm | high strength |
| (4) | front floor front part | 0,67 mm | mild steel |
| (5) | front floor, rear part | 0,62 mm | mild steel |
| (6) | flanged cross member | 0,87 mm | high strength |
| (7) | rear floor, front part | 0,67 mm | mild steel |
| (8) | rear wheelarch | 0,97 mm | high strength |
| (9) | front side member | 1,8 mm | high strength |
| (10) | front side member closing panel | 1,47 mm | THLE |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Clip the expanding insert (2) on the inner sill (1)
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 MIG weld seam
Cut out the spot welds
Cut out the spot welds
Remove the inner longeron (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
Adjustment
Position
- The inner sill (complete)
- The components for adjusting
Check; using one of the approved measurement systems
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 electric spot welds
MIG stitch weld
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
Seal the expanding inserts
Additional operations
Refit the electrical harnesses and the components removed
Reinitialisation
Reactivate the pyrotechnic systems
WarningPerform the operations that are required following a reconnection of the ancillaries battery
Reconnect the ancillaries battery