C4AH17F1 - 206

REPLACEMENT FRONT WHEEL ARCH ASSEMBLY

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

IMPERATIVE : body jig should be used .

1 - COMPLEMENTARY OPERATION(S)

Replacement :

- assembled centre chassis leg rear section

Removal - refitting :

- fascia
- screen wiper mechanism (left side)
- windscreen

Remove-refit trim :

- bulkhead

Detach :

- electrical harnesses

2 - IDENTIFICATION OF REPLACEMENT PARTS

(1) Front wheel arch assembly .

(2) Front wing inner panel .

(3) Passenger compartment side front stiffener .

3 - COMPOSITION

(1) Front suspension support .

(2) Front wheel arch .

(3) Front wheel arch gusset .

(4) Front wing inner panel .

(5) Passenger compartment side front stiffener .

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

(1) Front wheel arch assembly .

(2) Part front wing inner panel .

(3) Passenger compartment side front stiffener .

5 - PREPARATION OF THE NEW PART

Drill 6,5 mm holes for later plug welding .

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

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 .

Remove the component .

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

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

Remove the component .

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

Position :

- the wheel arch assembly
- the part front wing inner panel
- the front wing
- the bonnet

Check the clearances .

Remove :

- the bonnet
- the front wing

Mark out the cut .

Remove :

- the part front wing inner panel

Clean up the cut (Final cut) .

9 - WELDING

MIG plug weld .

Grind the plug welds .

MIG plug weld .

Grind the plug welds .

MIG stitch weld .

Position : The part front wing inner panel .

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

MIG stitch weld (At D) .

Grind the welds .

Fit the passenger compartment side front stiffener .

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

MIG plug weld (At F) .

Grind the plug welds .

10 - SEALING

Apply mastic (to be smoothed with a brush) .

Apply mastic (to be smoothed with a brush) .

Apply mastic sealant .

11 - PROTECTION

Apply a coat of anti-chip compound .

Spray liquid wax .