C4BH2DF1 - 206

REPLACEMENT PART REAR FLOOR

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 :

• tail panel assembly
• tailgate

Removal-fitting :

• spare wheel
• spare wheel carrier
• rear silencer
• heat shield
• seat backrest
• the centre seat belt
• the seat belt stalks
• fuel tank

Tilt and protect the seat cushions .

Remove-refit trim :

• side panels (3-door)
• rear floor

Detach the electrical harnesses .

2 - IDENTIFICATION OF REPLACEMENT PARTS

Rear floor .

3 - COMPOSITION

(1) Rear floor .

(2) Rear bumper lower bracket (On the left-hand side) .

(3) Rear bumper lower bracket (On the right-hand side) .

(4) Rear seat fixing stiffeners .

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

Part rear floor .

5 - PREPARATION OF THE NEW PART

Drill 6,5 mm holes for later plug welding .

Mark out then drill 6,5 mm holes for later plug welding .

Mark out then drill 6,5 mm holes for later plug welding .

Drill 6,5 mm holes for later plug welding .

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

Drill 6,5 mm holes for later plug welding .

6 - CUTTING OUT

Cut out by milling out the spot welds .

Symmetrical cuts .

Cut out by milling out the spot welds .

Cut out by milling out the spot welds .

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

Symmetrical cuts .

Remove the component .

7 - SEPARATING

Prepare the mating edges .

Prepare the mating edges .

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

8 - ADJUSTMENT

Fit :

• the part rear floor

Check the clearances .

9 - WELDING

MIG plug weld .

Grind the plug welds .

Symmetrical welding .

Spot weld (Using FA1 equipment) .

MIG plug weld (At C) .

Grind the plug welds .

Spot weld (At D) ,(Using FA1 equipment) .

MIG seam weld .

10 - SEALING

Apply mastic (to be smoothed with a brush) .

11 - PROTECTION

Apply a coat of anti-chip compound .

Spray liquid wax .