C4CH1EF1 - 206 5 DOOR SALOON

REPLACEMENT OUTER SILL (5-DOOR)

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

1 - COMPLEMENTARY OPERATION(S)

Removal-fitting :

• mud shield : front
• mud shield : rear
• front wing
• front door
• rear door
• bottom hinge : front door
• bottom hinge : rear door
• door aperture seal (front rear)
• front seat
• rear seat cushion
• bonnet opening control
• side sill dirt excluder seal

Remove-refit trim :

• centre pillar
• part front floor
• part rear floor
• rear wheel arch (front section)

Detach the electrical harnesses .

Protect the fuel pipes (On the right-hand side) .

2 - IDENTIFICATION OF REPLACEMENT PARTS

Outer sill assembly .

3 - COMPOSITION

(1) Sill closer extension .

(4) Outer sill .

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

Outer sill assembly .

5 - PREPARATION OF THE NEW PART

Mark out then drill 8 mm holes for later plug welding .

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) .

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

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 .

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 part with welding primer .

8 - ADJUSTMENT

Fit :

• outer sill
• front door
• rear door
• front wing

Check the clearances .

Remove :

• front wing
• front door
• rear door

Mark the cuts .

Remove : Outer sill .

Clean up the cut (Final cut) .

Clean up the cut (Final cut) .

Clean up the cut (Final cut) .

9 - WELDING

Position the outer sill panel .

MIG stitch weld (At A) .

Grind the welds .

Spot weld at (B) (Using AB1 equipment) .

MIG stitch weld (At C) .

MIG plug weld (At D) .

Grind the welds and the weld spots .

MIG stitch weld .

Grind the welds .

Spot weld (Using AB1 equipment) .

Spot weld (Using AB1 equipment) .

10 - FINISHING

Lead load .

11 - SEALING

Apply mastic to the interior and smooth it with a brush .

12 - PROTECTION

Apply a coat of anti-chip compound .

Spray liquid wax .