WarningObserve the safety and cleanliness recommendations
WarningObserve the precautions to be taken for the pre-tensioning components
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
NoteUse the products recommended by the manufacturer
Tooling
| tools | Reference | designation |
|---|---|---|
| [1366-ZZ] | toolkit for testing electric spot welds | |
| [1366] | samples for testing electric spot welds | |
| [1126] | set of spot weld cutters | |
| swan's neck drill for cutting out electric spot welds | ||
| hot air blower |
Preliminary operations
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 rear bumper
- The rear lamp
- The boot trims
- The seat
Release the wiring harnesses
Replace: the roof
Location: replacement part
| reference | designation |
|---|---|
| (1) | cabin side panel |
Identification of the replacement part
Identification: replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1) | cabin side panel | 0,67 mm | mild steel |
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | cantrail inner panel | 1,17 mm | mild steel |
| (3) | upper stiffener: cabin side panel | 0,68 mm | mild steel |
| (4) | lower stiffener: cabin side panel | 0,68 mm | mild steel |
| (5) | roof bow extension | 0,70 mm | mild steel |
| (6) | rear pillar upper bracket | 0,87 mm | mild steel |
| (7) | hinged door pillar | 0,97 mm | mild steel |
| (8) | rear wing gutter | 1,47 mm | mild steel |
| (9) | cabin side panel inner panel extension | 0,67 mm | mild steel |
| (10) | cabin side panel inner panel | 0,67 mm | mild steel |
| (11) | outer sill | 0,97 mm | mild steel |
| (12) | sill web | 0,77 mm | mild steel |
| (13) | centre pillar | 2 mm | high strength |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
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
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")
Apply 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
"A", "B", "C" = 20 mm
Mark then cut (at "a", "b", "c"); using a saw
Cut out the spot welds
Detach: the cabin side panel (at "e"); using a hot air gun
Cut out the spot welds (at "d") (if necessary)
Remove: the cabin side panel (partial)
Cut out the spot welds
Cut out the spot welds (at "f") over 2 thicknesses
Remove the remaining parts of the passenger compartment side panel
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
Adjustment
Position
- The cabin side panel
- The components for adjusting
Check the fits and clearances
Apply a setting adhesive
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 "f")
Grind the MAG plug welds
Weld with electric spot welds (at "g")
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")
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index: "A1")
Refit: the roof
Apply a phosphate-print layer to the zones laid bare
Apply a sealing mastic (index: "A1")
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
Reconnect the battery