C4BH1AF1 - 206

REPLACEMENT TAIL PANEL ASSEMBLY

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 :

• rear bumper

Removal-fitting :

• tail lamps
• tailgate aperture seal
• boot carpet
• spare wheel
• striker

Remove-refit trim :

• rear panel

Detach :

• the electrical harnesses

2 - IDENTIFICATION OF REPLACEMENT PARTS

Tail panel assembly .

3 - COMPOSITION

(1) Tailgate striker mounting stiffener .

(2) Tail panel inner panel .

(3) Tail panel .

(4) Rear bumper upper support .

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

Tail panel assembly .

5 - CUTTING OUT

Cut out by milling out the spot welds (Symmetrical cuts) .

Cut out by milling out the spot welds .

Remove the component .

6 - SEPARATING

Prepare the mating edges .

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

7 - ADJUSTMENT

Fit :

• the tail panel
• the tailgate

Check the clearances .

8 - WELDING

Spot weld (Using BA1 equipment) .

Spot weld (At A), Using BA1 equipment .

MIG plug weld (At B), Grind the plug welds .

9 - SEALING

Apply mastic sealant .

Apply mastic sealant .

Apply mastic (to be smoothed with a brush) .

10 - PROTECTION

Spray liquid wax .