C4AH13F1 - 206

REPLACEMENT FRONT PILLAR

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 :

• door
• front wing

Removal-fitting :

• windscreen
• bonnet hinge bar
• windscreen wiper motor
• connectors
• fascia
• door aperture seal
• front seats
• bonnet

Remove-refit trim :

• part front floor
• front pillar
• screen pillar

Detach :

• the electrical harnesses

2 - IDENTIFICATION OF REPLACEMENT PARTS

Body side front part .

Assembled front pillar stiffener .

Passenger compartment side front stiffener .

Water seal bracket .

Windscreen finisher side bracket .

3 - COMPOSITION

(1) Body side front part .

(2) Water seal bracket .

(3) Windscreen finisher side bracket .

(4) Door stop yoke stiffener .

(5) Door stop yoke closing panel .

(6) Front wing fixing bracket .

(7) Sill closer extension .

(8) Front pillar hinge upper stiffener .

(9) Spacer (Front pillar) .

(10) Front pillar hinge lower stiffener .

(11) Door pillar stiffener .

(12) Tapping plate .

(13) Base (Front pillar hinge upper stiffener) .

(14) Tapping plate .

(15) Base (Front pillar hinge lower stiffener) .

(16) Passenger compartment side front stiffener .

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

Body side front part .

Assembled front pillar stiffener .

Passenger compartment side front stiffener .

Water seal bracket .

Windscreen finisher side bracket .

5 - PREPARATION OF NEW PARTS

Drill to 6.5 mm diameter for later plug welding .

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

Drill to 6.5 mm diameter for later plug welding .

Drill to 6.5 mm diameter for later plug welding .

Drill to 6.5 mm diameter 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 .

Remove the component .

Cut out by milling out the spot welds .

Cut out by milling out the spot welds .

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

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

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

Remove the component .

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 parts with welding primer .

8 - ADJUSTMENT

Fit :

• assembled front pillar stiffener
• body side front part
• passenger compartment side front stiffener
• water seal bracket
• windscreen finisher side bracket
• the front wing
• the front door
• the bonnet

Check the clearances .

Check the clearance : X = 1395 ± 1 mm .

Remove :

• the front wing
• the bonnet
• the front door

Mark out the cut .

Mark out the cut .

Clean up the cut (Final cut) .

Clean up the cut (Final cut) .

9 - WELDING

MIG plug weld (At A) .

SPOT WELD (At B), Using AB1 equipment .

MIG plug weld (At C) .

Grind the plug welds .

SPOT WELD (At D), Using AB1 equipment .

SPOT WELD, Using AB1 equipment .

MIG stitch weld (At E) .

Grind the welds .

SPOT WELD (At F), Using AB1 equipment .

MIG stitch weld .

Grind the welds .

MIG plug weld (At G) .

Grind the plug welds .

SPOT WELD (At H), Using AB1 equipment .

SPOT WELD, Using AB1 equipment .

Fit the windscreen finisher side bracket .

Check the dimension .

Check the dimension .

MIG plug weld .

Grind the plug welds .

Fit the water seal bracket .

Check the dimension .

Align the round holes in relation to the rectangular holes to position the drip moulding correctly .

MIG plug weld .

Grind the plug welds .

10 - FINISHING

Lead load .

11 - SEALING

Apply mastic (to be smoothed with a brush) .

12 - PROTECTION

Apply a coat of anti-chip compound .

Spray liquid wax .