Replacement: partial windscreen pillar — Front pillar — Side structure

Replacement: partial windscreen pillar Citroen Berlingo I facelift

WarningThis method only applies to vehicles which have a reinforced structure

WarningObserve the elementary rules of hygiene and safety (wear a face mask to protect against fumes and vapour - work in a well ventilated space)

WarningAll of the stripped surfaces must be protected by means of the approved electrolytic rezincing process reference C8

Identification

Replacement: partial windscreen pillar — c5fp0w8d

Figure 1

Vehicles which have a reinforced structure can be identified by the presence of a shim located under the dashboard on the passenger side, at the top of the mat

Additional operations

Remove - refit

Front door
Front wing
Dashboard
Windscreen

Release

The electrical harnesses
The aerial cable

Identification of the replacement parts

Figure 2

Windscreen pillar

Preparation of new parts

Figure 3

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

Replacement: partial windscreen pillar — c4cp1b2d

Figure 4

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

Replacement: partial windscreen pillar — c4cp1b3d

Figure 5

Mark then saw out (cutting zones at "a")

Final cut

Prepare the mating edges and protect them using a weldable primer C7

Cutting out

Replacement: partial windscreen pillar — c4cp1b4d

Figure 6

Mark then cut (provisional cut at "a")

Cut out by milling out the spot welds

(at "b") 4 spot welds in 3 thicknesses of 0.77/1.47/0.77 mm
(at "c") 6 spot welds in 3 thicknesses of 0.77/1.47/1.17 mm
(at "d") 6 spot welds in 3 thicknesses of 0.77/1.17/1.17 mm
(at "e") 3 spot welds in 3 thicknesses of 0.77/1.17/1.17 mm

Replacement: partial windscreen pillar — c4cp1b5d

Figure 7

Cut out by milling out the spot welds

(at "b") 4 spot welds in 3 thicknesses of 0.77/1.47/0.77 mm
(at "c") 1 spot weld in 3 thicknesses of 0.77/1.47/1.17 mm
(at "d") 1 spot weld in 3 thicknesses of 0.77/1.17/1.17 mm
(at "f") 1 spot weld in 3 thicknesses of 0.77/1.17/0.77 mm
(at "g") 5 spot welds in 2 thicknesses of 0.77/1.17 mm
(at "h") 1 spot weld in 3 thicknesses of 0.77/1.17/1.17 mm
(at "j") 2 spot welds in 3 thicknesses of 0.77/1.47/1.17 mm

Remove the partial windscreen pillar

Separating

Replacement: partial windscreen pillar — c4cp1b6d

Figure 8

Prepare the mating edges and protect them using a weldable primer C7

Adjustment

Replacement: partial windscreen pillar — c4cp1b7d

Figure 9

Mark the final cut

Remove the partial windscreen pillar

Clean up the cut

Fit

The partial windscreen pillar
The front door
The windscreen

Check the clearances

Remove

The windscreen
The front door

Welding

Replacement: partial windscreen pillar — c4cp1b8d

Figure 10

Weld using successive beads (MIG or MAG), (at "a")

Grind the weld

Weld with electric spot welds

(at "b") 4 spot welds in 3 thicknesses of 0.77/1.47/0.77 mm
(at "c") 6 spot welds in 3 thicknesses of 0.77/1.47/1.17 mm
(at "d") 6 spot welds in 3 thicknesses of 0.77/1.17/1.17 mm
(at "e") 1 spot weld in 3 thicknesses of 0.77/1.17/1.17 mm

Weld with MAG plug welds (at "k") 2 spot welds in 3 thicknesses of 0.77/1.17/1.17 mm

Grind the plug welds

Replacement: partial windscreen pillar — c4cp1b9d

Figure 11

Weld with electric spot welds

(at "b") 4 spot welds in 3 thicknesses of 0.77/1.47/0.77 mm
(at "c") 1 spot weld in 3 thicknesses of 0.77/1.47/1.17 mm
(at "d") 1 spot weld in 3 thicknesses of 0.77/1.17/1.17 mm
(at "f") 1 spot weld in 3 thicknesses of 0.77/1.17/0.77 mm
(at "g") 1 spot weld in 2 thicknesses of 0.77/1.17 mm

Weld with MAG plug welds

(at "h") 1 spot weld in 3 thicknesses of 0.77/1.17/1.17 mm
(at "j") 2 spot welds in 3 thicknesses of 0.77/1.47/1.17 mm
(at "l") 4 spot welds in 2 thicknesses of 0.77/1.17 mm

Grind the plug welds

Protection

Spray liquid wax C5