WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process
WarningObserve the elementary rules of hygiene and safety (wear a face mask to protect against fumes and vapour - work in a well ventilated space)
WarningRemove or protect the parts in the repair area which could be damaged by the heat or dust
Additional operations
WarningOperation to be carried out on an alignment bench
Removing - refitting
- Front wing
- Front wing strengthener
- Half front suspension (on side of operation)
Disconnect the battery
Release the wiring harnesses
Location of the replacement part
(1) suspension mounting
Identification of the replacement part
Identification
(1) suspension mounting
Identification: adjacent parts
| reference | designation | thickness (mm) | nature/classification |
|---|---|---|---|
| (1) | suspension mounting | 2,00 | E 220 BH / high strength (*) |
| (2) | scuttle closing panel | 0,70 | ES / mild steel |
| (3) | front wing inner panel | 0,80 | DP 600 / THLE (**) |
| (4) | front wheel arch | 1,60 | E 220 BH / high strength (*) |
| (5) | wheel arch bracket | 2,00 | E 340 F / high strength (*) |
Replacement part preparation
WarningWhen cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection
Prepare the mating edges
Drill 6 holes of Ø 6,5 for MAG plug welding (as "a")
Protect the surfaces of the panels using an index "C7" weld-through primer
NoteIllustration: on the left-hand side; apply the index "C7" weld-through primer to the interior surfaces of the panels to be welded
Separating
Unclip: the 7 electric spot welds (as "b")
Unclip: the 7 electric spot welds (as "c")
Unclip: the 6 electric spot welds (as "d")
Unclip: the 6 electric spot welds (as "e")
Bodywork cleaning and preparation
Prepare the mating edges
Protect the surfaces of the panels using an index "C7" weld-through primer
NoteApply the index "C7" weld-through primer to the interior surfaces of the panels to be welded
Fitting - adjustment - welding: replacement part
Fit and adjust: the suspension mounting
Clamp: the suspension mounting
Weld with MAG plug welds (6 points)
Grind the MAG plug welds
Reweld with MAG plug spot welds (14 points)
Grind the MAG plug welds
Weld with MAG plug welds (6 points)
Grind the MAG plug welds
Sealing
Apply a sealing mastic: index "A4"
Protection
Apply a phosphate-print layer to the zones laid bare
Paint then spray into the hollow sections, product index C5, in the repair zone
Apply an anti-chip layer
Reinitialisation
Carry out the additional operations
Reconnect the battery