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 | |
| 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 |
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 front door aperture seal
- The rear door aperture seal
- The interior trims
Release the wiring harnesses
Location: Replacement Parts
| reference | designation |
|---|---|
| (1) | outer sill (understructure) |
| (2) | body sill plug |
Identification of replacement parts
Composition: outer sill (understructure)
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | outer sill (understructure) | - | - |
| (1a) | outer sill (understructure) | 0,67 mm | mild steel |
| (1b) | jacking point strengthener | 1,95 mm | mild steel |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (3) | door pillar stiffener | 1,17 mm | high strength |
| (4) | Roof metal panel | 1,07 mm | high strength |
| (5) | Centre column upper stiffener | 1,8 mm | UHLE |
| (6) | lower B-post liner | 1,27 mm | high strength |
| (7) | centre pillar lower reinforcement | 1,8 mm | high strength |
| (8) | front interior longeron | 1,17 mm | THLE |
| (9) | rear interior longeron | 0,97 mm | mild steel |
| (10) | rear jacking point | 2,5 mm | high strength |
| (11) | sill strengthener | 0,97 mm | THLE |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Mark out then cut (at "a", "b", "c") in the cutting zones "A", "B", "C"
Mark out then cut (at "a", "b", "c") in the cutting zones "A", "B", "C"
NoteThe cutting lines "a", "b", "c" are given as a guide. the dimensions can change depending on the different sill replacement examples
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
Mark out then cut (at "d", "e", "f") in the cutting zones "D", "E", "F"
Mark out then cut (at "d", "e", "f") in the cutting zones "D", "E", "F"
NoteThe cutting lines "d", "e", "f" are given as a guide. the dimensions can change depending on the different sill replacement examples
Cut out the spot welds
Remove the exterior longeron (understructure)
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
Seal the expanding inserts (12), (13), (14), (15)
Seal the expanding inserts (12), (13), (14), (15)
Apply a gap-filling adhesive "A1" to the rear wheel arch (at "g")
Adjustment
Position
- The outer sill (understructure)
- The components for adjusting
Check: the fits and clearances
Check: the fits and clearances
Adjust the cuts (if necessary)
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 by MAG bead (at "h", "j", "k")
Grind the MAG weld beads
Weld with electric spot welds
Sealing protection
Apply seals around the plugs (2) (index: "A1")
Clip in the plugs (2)
Apply a phosphate-print layer to the zones laid bare
WarningDo not block the drain holds with the stone chip protection (at "l")
Apply index "C4" underseal protection
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