Orlando

Headlamp Mount Panel Replacement — Welding

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the battery negative cable. Refer to  Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to  Anti-Corrosion Treatment and Repair : Base .



6. Locate and mark all the necessary factory welds of the headlamp mount panel (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



8. Cut the adhesive (1) with an appropriate tool.



9. Remove the headlamp mount panel (1).

1. Drill 8 mm (5/16 in) for plug welding instead of the adhesive noted from the original panel.
2. Drill 8 mm (5/16 in) for plug welding along the edges of the headlamp mount panel (1) where the spotwelder cannot be applied.
3. Clean and prepare the attaching surfaces for welding.



4. Position the headlamp mount panel (1) on the vehicle.
5. Verify the fit of the headlamp mount panel.
6. Clamp the headlamp mount panel into position.



7. Plug weld the headlight mount panel (1) accordingly.



8. Spot weld the headlight mount panel (1) accordingly.
9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to  Anti-Corrosion Treatment and Repair : Base .
10. Paint the repaired area.
11. Install all related panels and components.
12. Connect the battery negative cable. Refer to  Battery Negative Cable Disconnection and Connection : without Start/Stop System .
13. Enable the SIR system. Refer to SIR Disabling and Enabling .