C4CH1IF1 - 206 5 DOOR SALOON

REPLACEMENT PART REAR WING (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)

Removal-fitting :

- rear bumper
- tail lamp
- mud shield
- rear door
- door aperture seal
- door lower hinge
- rear seat cushion
- side sill dirt excluder seal

Remove-refit trim :

- part rear floor
- front part of rear wheel arch

Detach the electrical harnesses .

Protect the fuel pipes (right side) .

2 - IDENTIFICATION OF REPLACEMENT PARTS

Rear wing .

Water seal rear bracket .

3 - COMPOSITION

(1) Rear wing .

(2) Assembled rear door striker mounting stiffener .

(3) Roof bar brackets .

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

Rear wing .

Water seal rear bracket .

5 - PREPARATION OF THE NEW PART

Drill 6,5 mm holes for later plug welding .

Drill 6,5 mm holes for later plug welding .

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

Drill 6,5 mm holes for later plug welding .

6 - CUTTING OUT

Cut out by milling out the spot welds .

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

Remove : The water seal rear bracket .

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 .

Remove the component .

7 - SEPARATING

Prepare the mating edges .

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

8 - ADJUSTMENT

Fit :

- the rear wing

Close the door .

Close the tailgate .

Check the clearances .

Open the door .

Open the tailgate .

Mark the cuts .

Remove the rear wing .

Clean up the cut (Final cut) .

Clean up the cut (Final cut) .

Apply supporting structural adhesive .

9 - WELDING

Fit the wing .

MIG stitch weld .

Grind the welds .

Spot weld (Using AB1 equipment) .

MIG plug weld .

Grind the plug welds .

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

MIG plug weld (At B) .

Grind the plug welds .

MIG plug weld .

Grind the plug welds .

Fit : The water seal rear bracket .

Plug weld .

Grind the plug welds .

10 - FINISHING

Lead load .

11 - SEALING

Apply mastic sealant .

Apply mastic sealant .

Apply mastic sealant .

Apply mastic (to be smoothed with a brush) .

12 - PROTECTION

Apply a coat of anti-chip compound .

Apply a coat of anti-chip compound .

Spray liquid wax .