C4CH19F1 - 206 3 DOOR SALOON

REPLACEMENT OUTER SILL (3 DOOR)

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

IMPERATIVE : observe elementary health and safety rules (wearing of filter mask for organic fumes - work in a ventilated area) .

1 - COMPLEMENTARY OPERATION(S)

Removal-fitting :

- front door
- front wing
- door aperture seal
- front seat
- rear seat cushion
- rear seat backrest
- rear mud shield
- wing protector side moulding
- front mud shield

Remove-refit trim :

- part front and rear floor
- wing interior
- inner sill
- front pillar
- rear pillar

Detach the electrical harnesses .

2 - IDENTIFICATION OF REPLACEMENT PARTS

Outer sill .

3 - COMPOSITION

(1) : Outer sill .

(2) : Sill closer extension .

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

Outer sill .

5 - PREPARATION OF THE NEW PART

Drill to 8 mm for later plug welding .

Mark then cut out with a 1 mm thick wheel (Final cuts) .

6 - CUTTING OUT

Mark then cut out with a 1 mm thick wheel (preliminary cut) .

Mark then cut out with a 1 mm thick wheel (At A) (preliminary cut) .

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

Cut out by milling out the spot welds .

Cut out by milling out the spot welds .

7 - SEPARATING

Prepare the mating edges .

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

8 - ADJUSTMENT

Fit :

- the front wing
- the front door
- the outer sill

Clearance check .

Remove :

- the front wing
- the front door

Mark the cuts .

Mark the cuts .

Remove the outer sill panel .

Clean up the cuts (Final cuts) .

Apply supporting structural adhesive .

9 - WELDING

MIG stitch weld .

Grind the welds .

MIG stitch weld (At C) .

Grind the welds .

MIG plug weld (At D) .

Grind the spot welds .

SPOT WELD (Using AB1 equipment) .

SPOT WELD (Using AB1 equipment) .

10 - SEALING

Apply mastic (to be smoothed with a brush) .

11 - PROTECTION

Apply a coat of anti-chip compound .

Spray liquid wax .