C4CH0TF1 - 206 5 DOOR SALOON

REPLACEMENT CENTRE PILLAR (5-DOOR)

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 :

• front door
• rear door

Removal-fitting :

• front seat
• front seat belt
• rear seat cushion
• door aperture seal (front; rear)

Remove-refit trim :

• centre pillar
• roof
• part front and rear floor

Detach the electrical harnesses .

2 - IDENTIFICATION OF REPLACEMENT PARTS

Body side front part .

Roof bow cantrail .

(1) Centre post stiffener assembly .

(2) Centre pillar inner panel .

3 - COMPOSITION

Body side front part .

Roof bow cantrail .

(1) Centre pillar stiffener .

(2) Centre pillar inner panel .

(3) Tapping plate retainer .

(4) Tapping plate .

(5) Welded nut .

(6) Welded pin .

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

Part passenger compartment front section .

Part roof bow inner panel .

(1) Centre pillar stiffener .

(2) Centre pillar inner panel .

5 - PREPARATION OF NEW PARTS

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

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

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

Drill 6,5 mm holes for later plug welding .

Drill to 6,5 diameter for later plug welding .

Drill 6,5 mm holes for later plug welding .

6 - CUTTING OUT

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

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

Cut out by milling out the spot welds .

Mark then cut the centre pillar assembly using a 1 mm thick grinding wheel (Provisional cut) .

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

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

Cut out by milling out the spot welds .

Cut with a 1 mm thick wheel .

Remove the component .

Cut out by milling out the spot welds .

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

Position :

• centre pillar inner panel
• centre pillar stiffener
• part passenger compartment front section
• cantrail inner panel
• front door
• rear door

Check the clearances .

Remove :

• the front door
• the rear door

Check the clearance : X = 1360 ± 1 mm .

Mark out the cut .

Mark the cuts .

Mark out the cut .

Remove :

• cantrail inner panel
• part passenger compartment front section
• centre pillar stiffener
• centre pillar inner panel

Clean up the cut (Final cut) .

Clean up the cut (Final cut) .

Clean up the cuts (Final cuts) .

9 - WELDING

Fit the centre pillar inner panel .

Spot weld (Using AB1 equipment) .

Position the centre pillar stiffener .

MIG stitch weld .

MIG plug weld (At A) .

Grind the plug welds .

Spot weld (At B) .

(Using AB1 equipment) .

MIG plug weld (At C) .

Grind the plug welds .

Spot weld (At D) .

(Using AB1 equipment) .

MIG stitch weld (At E) .

Grind the welds .

MIG plug weld (At F) .

Grind the plug welds .

MIG stitch weld (At G) .

Grind the welds .

Spot weld (At H) .

(Using AB1 equipment) .

Spot weld (Using AB1 equipment) .

10 - FINISHING

Lead load .

Lead load .

11 - SEALING

Apply mastic (to be smoothed with a brush) .

12 - PROTECTION

Apply a coat of anti-chip compound .

Spray liquid wax .

Spray liquid wax .