C4AH14F1 - 206

REPLACEMENT FRONT CHASSIS LEG ASSEMBLY

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

NOTE : body jig should be used (if necessary) .

1 - COMPLEMENTARY OPERATION(S)

Replacement :

• front half-panel assembly
• bonnet

Removal-fitting :

• alternator mounting (right side)

2 - IDENTIFICATION OF REPLACEMENT PARTS

(1) Front chassis leg assembly .

(2) Front wheel arch gusset .

(3) Chassis leg centre closing panel .

3 - COMPOSITION

(1) Chassis leg link .

(2) Chassis leg link closing panel .

(3) Front wheel arch gusset .

(4) Connector(s) support .

(5) Chassis leg centre closing panel .

(6) Front chassis leg .

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

(1) Front chassis leg assembly .

(2) Front wheel arch gusset .

(3) Part chassis leg centre closing panel .

5 - PREPARATION OF THE NEW PART

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

6 - CUTTING OUT

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

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 parts with welding primer .

8 - ADJUSTMENT

Position :

• front chassis leg assembly
• part chassis leg centre closing panel
• front wheel arch gusset
• front half-panel assembly
• the front wing
• the bonnet
• the front panel
• the front bumper with its frame

Check the clearances .

Open the bonnet .

Check the distance .

Remove :

• the front bumper with its frame
• the front panel
• the front wing
• front half-panel assembly
• front wheel arch gusset

Mark out the cut .

Remove : Part chassis leg centre closing panel .

9 - WELDING

Spot weld (Using AB1 equipment) .

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

Clean up the cut (At B) .

Spot weld (Using AB1 equipment) .

Position : Part chassis leg centre closing panel .

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

MIG stitch weld (At D) .

Grind the welds .

Position : Front wheel arch gusset .

Spot weld (Using AB1 equipment) .

10 - PROTECTION

Spray liquid wax .