C4AH16F1 - 206

REPLACEMENT ASSEMBLED CENTRE CHASSIS LEG REAR SECTION

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 :

• front half-panel assembly
• bonnet
• front wing

Removal - refitting :

• power train assembly
• brake servo (left side)

2 - SPECIAL FEATURES

For marking out the chassis leg rear cut, use the appropriate jigs .

3 - IDENTIFICATION OF REPLACEMENT PARTS

(1) Chassis leg centre closing panel .

(2) Assembled centre chassis leg rear section .

4 - COMPOSITION

(1) Chassis leg link .

(2) Chassis leg link closing panel .

(3) Connector(s) support .

(4) Engine sub-frame front mounting support .

(5) Centre chassis leg cut .

(6) Chassis leg front partition .

(7) Chassis leg centre closing panel .

(8) Front chassis leg .

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

(1) Chassis leg centre closing panel .

(2) Assembled centre chassis leg rear section .

6 - SPECIAL TOOLS

[1] Template for rear cut (Centre chassis leg), Reference (-).1117 A .

7 - PREPARATION OF THE NEW PART

Drill to 8 mm for later plug welding .

Drill to 8 mm for later plug welding .

8 - CUTTING OUT

Mark out using the tool [1] .

Cut with a 1 mm thick wheel (Final 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 .

Cut out by milling out the spot welds .

Remove the component .

9 - SEPARATING

Prepare the mating edges .

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

10 - WELDING

Fit the centre chassis leg .

Spot weld (Using BA1 equipment) .

Spot weld (Using BA1 equipment) .

MIG stitch weld (At A) .

MIG plug weld (At B) .

Grind the welds and the plug welds .

MIG plug weld (At C) .

MIG stitch weld (At D) .

Grind the welds and the plug welds .

Fit the chassis leg centre closing panel .

MIG stitch weld (At E) .

MIG plug weld (At F) .

Grind the welds and the plug welds .

Spot weld (At G) (Using BA1 equipment) .

11 - SEALING

Apply mastic (to be smoothed with a brush) .

Apply mastic (to be smoothed with a brush) .

12 - PROTECTION

Apply a coat of anti-chip compound .

Spray liquid wax .