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
Tooling
| [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 |
Preliminary operations
Deactivation: 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
Release the wiring harnesses
Location: Replacement Parts
| reference | designation |
|---|---|
| (1) | cabin side panel |
Identification of the replacement part
Composition: rear wing
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1a) | cabin side panel | 0,67 mm | mild steel |
| (1b) | door striker fixing support | 1,47 mm | mild steel |
| (1c) | support: sliding side door rail | 0,97 mm | mild steel |
Identification of the parts next to the rear wing
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (2) | cantrail inner panel | 0,67 mm | mild steel |
| (3) | "C" post inner panel | 0,67 mm | mild steel |
| (4) | upper inner panel (side panel) | 0,7 mm | mild steel |
| (5) | stiffener | 1,2 mm | mild steel |
| (6) | drip moulding (cabin side panel) | 1,47 mm | mild steel |
| (7) | rear wheelarch | 0,97 mm | mild steel |
| (8) | inner panel (cabin side panel) | 0,67 mm | mild steel |
| (9) | outer sill | 0,97 mm | mild steel |
| (10) | sill web | 0,77 mm | mild steel |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Draw a line (at "a", "b", "c") in the cutting zones "A", "B", "C" then cut out
NoteThe dimensions "A", "B", "C" are given as an indication only; the dimensions may change in different examples of replacement of part of the passenger compartment side panel
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 index "C7" weld-through primer to the interior surfaces of the panels to be welded
Cutting of the part on the body
Draw a line (at "d", "e", "f") in the cutting zones "D", "E", "F" then cut out
NoteThe dimensions "D", "E", "F" are given as an indication only; the dimensions may change in different examples of replacement of part of the passenger compartment side panel
Cut
- The spotwelds
- Cabin side panel; (at "g") (to make it easier to remove the passenger compartment side part panel)
Cut out the spot welds
Remove
- The cabin side panel (partial)
- The remaining part of the passenger compartment side panel (partial)
Clean and prepare 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
Apply a filling adhesive (index "A1")
Adjustment
Position
- Partial cabin side panel
- The components for adjusting
Check the fits and clearances
Adjust the cuts; if necessary
Holds the part in position
Welding
Weld by MAG bead (as "h", "j", "l")
Using MAG welding equipment, make a weld bead (as "k")
Grind the MAG weld beads
Weld
- By means of electric spot welds
- By means of MAG plug welds (as "m")
Grind the MAG plug 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")
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
Activation: pyrotechnic systems
Reconnect the battery
WarningPerform the operations to be carried out following reconnection of the battery