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
- MIG brazing with cupro-aluminium rod used with an inert gas
- 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
- Very high strength: 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 | |
| [1126] | set of spot weld cutters | |
| [FEIN-400E] | electric knife kit FEIN C1 electric knife C2 offset hub saw blade C3 blade no. 103 | |
| swan's neck drill for cutting out electric spot welds | ||
| hot air blower |
Preliminary operations
Deactivate the pyrotechnic systems
Disconnect the ancillaries battery
WarningEither remove or protect those components which are in the repair zone and risk being damaged by the heat or the dust
Remove
- The front bumper
- Headlamp (repair side)
- The front panel upper crossmember
- The front panel support plate
WarningIf the vehicle has the Stop and Start system; remove-refit the voltage retention device
Release the wiring harnesses
Location of the replacement part
Recover the front panel support plate (1) and the 2 bolts (3)
| reference | designation |
|---|---|
| (1) | front block half-panel stiffener assembly |
| (2) | support plate on front panel |
| (3) | bolts |
Identification of the replacement part
Composition: front block half-panel stiffener assembly
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (1a) | front block half-panel stiffener | 1,95 mm | THLE |
| (1b) | welded nut | 8 x 125 | - |
Composition: support plate on front panel
| reference | designation |
|---|---|
| (2) | support plate on front panel (assembled) |
| (2a) | support plate on front panel |
| (2b) | welded nut 8 X 125 |
| (2c) | welded nut 6 X 100 |
WarningTake into account the difference in thickness of the part when setting the welding station
Identification of the parts adjacent to the replacement part
| reference | designation | thickness | nature/classification |
|---|---|---|---|
| (4) | front panel support | 1,17 mm | mild steel |
Preparation: front block half-panel stiffener
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
Assemble the front block half-panel stiffener (1) and the front panel support plate assembly (2) using the bolts (3)
Cutting the front block half-panel stiffener
Cut out the spot welds
Remove the front block half-panel stiffener (1)
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
Adjustment
Position
- The front half panel strengthener (1)
- The front panel support plate (2)
- The front panel upper crossmember (5)
Retain the front half panel strengthener (1) in position
Remove
- The front panel upper crossmember (5)
- The front panel support plate (2)
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
Sealing protection
Apply a phosphate-print layer to the zones laid bare
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 that are required following a reconnection of the ancillaries battery
Reconnect the ancillaries battery