C4BH2GF1 - 206 3 DOOR SALOON

REPLACEMENT PART REAR WING (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 :

- rear battery unit
- rear bumper
- tail lamp
- quarter light
- rear seat belt
- front seat belt
- door striker
- door aperture seal
- tailgate aperture seal
- quarter light seal
- rear mud shield (according to specification)
- wing protector side moulding
- fuel filler neck (right side)

Remove-refit trim :

- wing inner panel
- inner sill
- rear pillar

Detach the electrical harnesses .

Protect the fuel pipes (right side) .

2 - IDENTIFICATION OF REPLACEMENT PARTS

Rear wing .

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

Rear wing .

4 - PREPARATION OF THE NEW PART

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

Drill 6,5 mm holes for later plug welding .

Drill 6,5 mm holes for later plug welding .

Drill 6,5 mm holes for later plug welding .

Drill 6,5 mm holes for later plug welding .

5 - CUTTING OUT

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

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

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 .

Cut out by milling out the spot welds .

6 - SEPARATING

Prepare the mating edges .

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

7 - ADJUSTMENT

Fit :

- the rear wing
- the luggage compartment lid

Close the door and check the clearances .

Open the door .

Mark the cuts .

Remove :

- the luggage compartment lid
- the rear wing

Clean up the cuts (At A) ,(Final cut) .

Apply supporting structural adhesive (At B) .

8 - WELDING

Fit the wing .

MIG stitch weld .

Grind the welds .

MIG plug weld (At C) .

Grind the plug welds .

Spot weld (Using AB1 equipment) .

MIG plug weld (At D) .

Grind the plug welds .

Spot weld (At E) ,(Using AB1 equipment) .

MIG plug weld .

Grind the plug welds .

Spot weld (At F) ,(Using AB1 equipment) .

MIG plug weld (At G) .

Grind the plug welds .

MIG plug weld .

Grind the plug welds .

9 - FINISHING

Lead load .

10 - SEALING

Apply mastic sealant .

Apply mastic sealant .

Apply mastic sealant .

Apply mastic (to be smoothed with a brush) .

11 - PROTECTION

Apply a coat of anti-chip compound .

Apply a coat of anti-chip compound .

Spray liquid wax .