WarningThis vehicle has been designed using the new panel grades HLE - THLE - UHLE - TRIP - 22Mnb5, with tensile strengths between 400 and 1300 MPa (mega Pascal) with 2 - 4 or 6 coatings, depending on the assemblies; the welding parameters of these panels are very different from those used for welding mild steels; it is imperative that the parameters indicated in these methods are strictly observed using the welding equipment (new generation) approved by PEUGEOT which conforms to our specifications; only this equipment is able to carry out a quality repair guaranteeing the level of safety required for this type of operation
WarningThis vehicle has been designed using the mig brazing process technique; when repairing the structure, all the connections concerned must be welded using the same procedure; any other technique is prohibited
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)
Additional operations
Removal-fitting
- Front bumper
- Front headlamp unit
- Engine ECU (on the right-hand side)
- Electric power steering ECU (on the right-hand side - according to equipment)
Detach: the electrical harnesses
Identification of the replacement parts
(1) engine compartment panel support
Cutting out
Cut out the spot welds
- (A) 2 point in 2 thicknesses: 1,47/1,17 mm
- (B) 4 point in 2 thicknesses: 1,47/1,76 mm
- (C) 2 point in 3 thicknesses: 1,47/1,76/1,76 mm
- (D) 1 point in 3 thicknesses: 1,47/1,17/1,17 mm
Cut out the spot weld: (D) 1 point in 3 thicknesses: 1,47/1,17/1,17 mm
Remove: engine compartment panel support
Separating
Prepare the mating edges
Protect the edges of the original and the new part with welding primer
Adjustment
Fit: engine compartment panel support
Check the clearances
Welding
Weld with electric spot welds
| components | A (electrodes: 200 mm) | B (electrodes: 200 mm) |
|---|---|---|
| number of spot welds | 2 | 4 |
| thickness (mm) | 1,47/1,17 | 1,47/1,76 |
| grades | ES - ES | ES - ES |
| trims | G10/10 - G10/10 | G10/10 - G10/10 |
| current (A) | 270 | 270 |
| force (daN) | 10500 | 10500 |
| time (ms) | 450 | 800 |
| components | C (electrodes: 200 mm) | D (electrodes: 200 mm) |
|---|---|---|
| number of spot welds | 2 | 1 |
| thickness (mm) | 1,47/1,76/1,76 | 1,47/1,17/1,17 |
| grades | ES - ES - ES | ES - ES - ES |
| trims | G10/10 - G10/10 - G10/10 | G10/10 - G10/10 - G10/10 |
| current (A) | 270 | 270 |
| force (daN) | 10500 | 10500 |
| time (ms) | 800 | 450 |
Weld with electric spot welds
| components | D (electrodes: 200 mm) |
|---|---|
| number of spot welds | 1 |
| thickness (mm) | 1,47/1,17/1,17 |
| grades | ES - ES - ES |
| trims | G10/10 - G10/10 - G10/10 |
| current (A) | 270 |
| force (daN) | 10500 |
| time (ms) | 450 |