C4BH2CF1 - 206

REPLACEMENT REAR WHEEL ARCH ASSEMBLY (5-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)

Replacement :

- rear wing

Detach :

- the electrical harnesses

2 - IDENTIFICATION OF REPLACEMENT PARTS

Rear wheel arch assembly .

3 - COMPOSITION

(1) Rear wing inner panel .

(2) Strut support .

(3) Rear seat belt fastening stiffener .

(4) Jacking stiffener .

(5) Rear back rest striker fixing plate .

(6) Rear seat belt reel securing plate .

(7) Rear wheel arch (Rear section) .

(8) Rear wheel arch .

(9) Rear bumper bracket .

(10) Rear wheel arch stiffener .

(11) "C" post inner panel .

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

Rear wheel arch assembly .

5 - PREPARATION OF THE NEW PART

Drill 6,5 mm holes for later plug welding .

Drill 6,5 mm holes for later plug welding .

6 - 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 .

Cut out by milling out the spot welds .

7 - SEPARATING

Prepare the mating edges .

Prepare the mating edges .

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

8 - ADJUSTMENT

Fit :

- the rear wheel arch assembly
- the rear wing
- the door
- the tailgate

Check the clearances .

Remove :

- the tailgate
- the door
- the rear wing

9 - WELDING

Spot weld at (At A) Using AB1 equipment .

MIG plug weld (At B) .

Grind the plug welds .

MIG plug weld .

Grind the plug welds .

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

MIG plug weld (At D) .

Spot weld (Using DA1 equipment) .

10 - SEALING

Apply mastic (to be smoothed with a brush) .

11 - PROTECTION

Apply a coat of anti-chip compound .