C4AH15F1 - 206

REPLACEMENT FRONT HALF-PANEL ASSEMBLY

WARNING : all the scoured areas must be protected by the approved electrolytic re-zincing process .

1 - COMPLEMENTARY OPERATION(S)

Replacement :

• grille
• headlight

Removal-fitting :

• front wing
• bumpers
• bumper frame
• front panel
• the ECU with its bracket (right side)
• canister (right side)
• screen-wash reservoir (right-hand side)
• air cleaner (left side)

Detach :

• the fuse box (left side)
• the electrical harnesses
• ABS hydraulic block (left side)
• bonnet opening cable (left side)

2 - SPECIAL FEATURES

For adjustment of the half-panel, use the relevant positioning jigs .

3 - IDENTIFICATION OF REPLACEMENT PARTS

(1) Front half-panel assembly .

4 - COMPOSITION

(1) Headlamp panel assembly .

(2) Front bumper front bracket .

(3) Front bumper rear bracket .

(4) Front half-panel stiffener .

(5) Front panel bracket .

5 - PART(S) REQUIRED TO CARRY OUT THE OPERATION

(1) Front half-panel assembly .

6 - SPECIAL TOOLS

[1] Jig for positioning the left front half-panel (-).1117 B .

[2] Jig for positioning the right front half-panel (-).1117 C .

7 - CUTTING OUT

Cut out by milling out the spot welds .

Cut out by milling out the spot welds .

Cut out by milling out the spot welds (At A) .

Cut out by grinding the spot welds using a grinding wheel 6 mm thick (At B) .

Remove the component .

8 - SEPARATING

Prepare the mating edges .

Protect the edges of the original and the new part with welding primer .

9 - ADJUSTMENT

Position :

• front half-panel assembly
• the front wing

Position the assembled front half-panel using tool [1] .

Close the bonnet .

Check the clearances .

Open the bonnet .

Check the distance .

10 - WELDING

Spot weld (Using AB1 equipment) .

Remove the tool [2] .

Spot weld (At C) (Using AB1 equipment) .

MIG plug weld (At D) .

Grind the plug welds .

11 - PROTECTION

Spray liquid wax .