All language subtitles for How.Its.Made.Dream.Cars.S04E04.1080p.DSCP.WEB-DL.AAC2.0.H.264-NTb

Narrator: TODAY
ON "HOW IT'S MADE: DREAM CARS,"

THE PEUGEOT RCZ R.

SMALL, STYLISH,
AND SUPERCHARGED.

-- Captions by VITAC --
www.vitac.com

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

♪♪

IN HéRIMONCOURT FRANCE IN 1810,

THE PEUGEOT FAMILY
CONVERTED THEIR GRAIN MILL

INTO A STEEL MILL.

AT FIRST, THEY SPECIALIZED IN
MAKING STEEL FOR SAW BLADES,

COFFEE GRINDERS,
AND DRESSMAKING.

LATER, THEY BRANCHED OUT INTO
BICYCLES AND AUTOMOBILES.

IN 1891, THE PEUGEOT TYPE 3

BECAME THE FIRST
SERIES-MANUFACTURED CAR

IN THE WORLD.

IN 2013, THE PEUGEOT 208 T16
BROKE THE PIKE'S PEAK RECORD.

IN 1993, THE 905 MADE HISTORY

BY SWEEPING THE FIRST THREE
POSITIONS AT LE MANS.

IN 2007, PEUGEOT INTRODUCED
A CONCEPT CAR, THE RCZ.

IN 2014, PEUGEOT SPORT,
A SPECIALIZED DIVISION,

DEVELOPED THE
SUPERCHARGED RCZ R.

THE RCZ R IS ONE OF PEUGEOT'S
MOST POWERFUL PRODUCTION CARS.

IT'S FRONT-MOUNTED ENGINE

IS A TURBOCHARGED
FOUR-CYLINDER POWERHOUSE

THAT CAN GENERATE
270 HORSEPOWER,

MAKING IT THE MOST POWERFUL
1.6-LITER ENGINE IN THE WORLD

FOR A PRODUCTION VEHICLE.

♪♪

AT THE MAGNA STEYR MANUFACTURING
FACILITIES IN GRAZ, AUSTRIA,

A TECHNICIAN TRANSFERS
THE FRONT COMPARTMENT

TO THE START OF THE MAIN
UNDERBODY ASSEMBLY LINE.

HE BRINGS THE REAR
COMPARTMENT INTO POSITION.

AT THIS STAGE, THE MANUFACTURERS

GIVE THE CAR ITS UNIQUE I.D.
NUMBER.

MAGNA ASSEMBLES THE RCZ R

IN A FLOOR WITH OTHER
VERSIONS OF THE RCZ LINE,

INCLUDING THE RCZ GT.

THE BODY-ASSEMBLY PROCESS FOR
THE RCZ R IS 98% AUTOMATED.

HERE, ROBOTS SPOT-WELD
THE STEEL COMPONENTS

OF THE CAR'S SIDE
PANELS TOGETHER.

THE RCZ R CAR BODY HAS
215 DIFFERENT PARTS,

WITH 3,451 WELD POINTS.

A ROBOT PICKS UP THE SIDE PANEL

SO A SECOND MACHINE CAN
APPLY A BEAD OF SEALER.

THE ROBOTS TRANSFER THE SIDE
PANELS TO SPECIALIZED FIXTURES.

THE FIXTURES RAISE THE
BODY SIDES INTO POSITION

SO ROBOTS CAN WELD
THE SIDES IN PLACE.

THE SPOT-WELDING
ROBOTS GO TO WORK,

FIRMLY ATTACHING ALL OF
THE COMPONENTS TOGETHER.

IN ADDITION TO SPOT-WELDING,

THE ROBOTS WELD 183 BOLTS
ONTO THE CAR BODY.

THIS FACILITY CAN BUILD 112
CARS EVERY TWO SHIFTS.

THE BODY IS BEGINNING
TO LOOK LIKE A CAR.

TWO TECHNICIANS
ADD A STEEL ROOF.

THIS PANEL FORMS PART OF THE
CAR'S DOUBLE-BUBBLE ROOF SHAPE,

AND IMMEDIATELY
IDENTIFIES IT AS AN RCZ.

THE TECHNICIANS ATTACH THE
ROOF WITH SPOT-WELDERS.

THE DOUBLE-BUBBLE
ROOF RECALLS THE WORK

OF THE FAMOUS CAR
DESIGNER UGO ZAGATO,

WHO DEVELOPED THE
FEATURE IN THE 1950s

TO PROVIDE HEAD
ROOM FOR OCCUPANTS

WEARING RACING HELMETS.

A TEAM MEMBER USES A
SPECIALIZED FIXTURE

TO HELP HIM ATTACH A CAR
DOOR TO THE RCZ R BODY.

TECHNICIANS CAN
ONLY MOUNT THE HOOD

ONCE THE REST OF
THE BODY IS BUILT.

THAT'S BECAUSE THE
HOOD IS ALUMINUM,

WHILE THE REST OF
THE CAR IS STEEL.

IF ANY STEEL FLECKS HIT THE
HOOD DURING THE BUILD PHASE,

THEY WILL CORRODE AND
MARK THE ALUMINUM.

THE RCZ R BODY TAKES
A FOUR-MINUTE SOAK

IN A BATH CHARGED TO 300 VOLTS.

THIS GIVES IT AN ELECTRIC
COATING THAT PROVIDES

AN IMPORTANT LAYER OF CORROSION
PROTECTION ON THE INSIDE

AND OUTSIDE OF THE VEHICLE.

TWO PAINT SPECIALISTS
EQUIPPED WITH PROTECTIVE GEAR

APPLY THE BASE COAT TO THE
INSIDE SURFACES OF THE CAR.

THE AIR IN THIS BOOTH IS HEATED
TO 72 DEGREES FAHRENHEIT.

IT'S FILTERED TO MINIMIZE
AIRBORNE PARTICLES,

AND MAINTAINED AT 65% HUMIDITY

TO OPTIMIZE THE WATERBORNE
PAINT'S ADHERENCE

TO THE CAR'S SURFACE.

ROBOTS APPLY A BASE
COAT TO THE EXTERIOR.

THE ELECTROSTATICALLY-CHARGED
PAINT DROPLETS

SPRAY FROM NOZZLES TURNING AT
50,000 REVOLUTIONS PER MINUTE.

IN JUST FOUR MINUTES, THE
ROBOTS FINISH COATING THE CAR.

FROM HERE, THE CAR BODY
TRAVELS TO A FLASH OVEN,

WHICH BURNS THE WATER
OUT OF THE BASE COAT

BEFORE THE CLEAR COAT GOES ON.

♪♪

Narrator: AT THE HEART OF THE RCZ
R IS ITS 1.6-LITER POWERHOUSE.

IT PACKS 270 HORSEPOWER,

AND A MAXIMUM TORQUE
OF 244 FOOT-POUNDS

BETWEEN 1,900 AND 5,500 RPMs.

♪♪

PEUGEOT BUILDS ITS RCZ R ENGINES

IN THE SMALL TOWN OF
HéRIMONCOURT IN EASTERN FRANCE.

THE COMPANY HAS OWNED AND
OPERATED THE FACTORY SINCE 1824.

A TECHNICIAN
LUBRICATES THE BORES

TO PREPARE FOR INSTALLATION
OF THE PISTONS.

HE COLLECTS THE PISTON, ENSURES
IT HAS ALL OF ITS COMPONENTS,

THEN SLIDES IT INTO A DEVICE

THAT COMPRESSES
THE PISTON RINGS.

A YELLOW NETTING IS ADDED
TO PREVENT THE PISTON

FROM DAMAGING THE BORE.

HE INSTALLS ALL FOUR CYLINDERS,

THEN CRANKS THE ENGINE
BLOCK 180 DEGREES.

HE THEN QUICKLY LOOSENS

AND REMOVES A SERIES
OF LARGE BOLTS.

THIS ALLOWS HIM TO LIFT
OFF THE CRANKCASE COVER.

ONE BY ONE, HE CAREFULLY
INSTALLS THE CRANKCASE BEARINGS.

HE UNSCREWS AND REMOVES
THE PISTON-ROD CAPS.

THEN HE BRINGS THE
CRANKSHAFT TO THE BLOCK

AND LOWERS IT INTO PLACE
USING A LIFT-ASSIST DEVICE.

HE REPLACES THE PISTON-ROD
CAPS OVER THE CRANKSHAFT,

THEN TIGHTENS THEM BY HAND
TO HOLD THEM IN PLACE.

A SPECIALIZED TIGHTENING
DEVICE GIVES THE BOLTS

THE PRECISE TORQUE
PRESCRIBED THE ENGINEERS.

THE TECHNICIAN REPOSITIONS
THE CRANKCASE COVER.

THE COVER HAS A BEAD OF
SILICONE AROUND ITS PERIMETER

TO HELP SEAL THE JOINT.

HE AGAIN USES A PRE-PROGRAMMED
DEVICE TO TIGHTEN THE BOLTS

ON THE CRANKCASE TO THE
ENGINEERS' SPECIFIED TORQUE.

A COVER GOES OVER THE
OIL-PUMP SPROCKET AND CHAIN.

A TECHNICIAN LOWERS THE
OIL PUMP'S PLASTIC COVER

INTO POSITION, BOLTING
IT SECURELY IN PLACE

WITH A TORQUE-CONTROLLED
POWER DRIVER.

HE CAREFULLY POSITIONS
THE CYLINDER HEAD GASKET

OVER THE BORES,

THEN BRINGS THE CYLINDER
HEAD TO THE CYLINDER BLOCK.

HE USES A GUIDE DOWEL TO
ENSURE PROPER ALIGNMENT.

HE ATTACHES THE CYLINDER HEAD
SECURELY TO THE ENGINE BLOCK.

A TORQUE-CONTROL DEVICE
LINKED TO A MONITOR

DIGITALLY GUIDES HIM

THROUGH THE PRESCRIBED
FASTENING PATTERN.

THE CYLINDER HEAD HAS
ALL OF ITS COMPONENTS

PRE-INSTALLED, INCLUDING
THE VALVES, PUSH RODS,

ROCKER ARMS, AND TWO CAMSHAFTS.

A PLASTIC GUIDE HELPS HIM
AS HE LOWERS AND INSTALLS

THE TIMING CHAIN AND SPROCKET.

HE INSERTS THE CAMSHAFT
SPROCKET NEXT TO IT,

ALIGNS THE GEAR TEETH, LOOPS THE
TIMING CHAIN OVER THEM BOTH,

AND TEMPORARILY SECURES THEM
WITH A HANDHELD RATCHET DRIVER.

HE THEN INSTALLS THE CRANKSHAFT
HUB INTO ITS POSITION.

HE CAN NOW PLACE THE COVER
OVER THE CYLINDER HEAD

AND BOLT IT IN PLACE.

THE COMPOSITE PLASTIC COVER

CONTRIBUTES TO THE CAR'S
LOW OVERALL WEIGHT.

THE SAME IS TRUE FOR
THE EXHAUST MANIFOLD.

THE CAR'S CURB WEIGHT
IS JUST 2,820 POUNDS.

FINALLY, THE TECHNICIAN MOUNTS

THE ENGINE'S TWIN-SCROLL
TURBOCHARGER

TO THE CYLINDER HEAD.

IT'S TIME TO FIRE UP THE ENGINE
AND CHECK ITS FUNCTIONALITY.

AN INSPECTOR STARTS THE ENGINE

AND CHECKS FOR ANY
SIGNS OF LEAKS.

THE SYSTEM NOTIFIES HIM

IF IT DETECTS ANY FLAWS IN
THE ENGINE'S PERFORMANCE.

A POSITIONING TOOL
HELPS A TECHNICIAN

ATTACH THE FLYWHEEL
TO THE CRANKSHAFT.

HE INSTALLS THE CLUTCH MECHANISM

WITH THE HELP OF A
COMPRESSION TOOL,

AND SCREWS THE ASSEMBLY IN PLACE

FOLLOWING A PRESCRIBED
TORQUING SEQUENCE.

AN INSPECTOR
EXAMINES THE ENGINE,

CHECKING THE VISIBILITY
AND CORRECTNESS

OF THE SERIAL NUMBER,
THE FLUID LEVELS,

AND ELECTRICAL CONNECTIONS.

TO GENERATE 270 HORSEPOWER
FROM A FOUR-CYLINDER ENGINE,

PEUGEOT OPTIMIZES EVERY DETAIL,

RESULTING IN A SPORTS
CAR JUST AS CAPABLE

OF COMPETING ON RACE CIRCUITS

AS IT IS OF MAKING
THE DAILY COMMUTE.

♪♪

Narrator: THE POWER TRAIN MAY
BE ANCHORED BY ITS ENGINE,

BUT THE SIX-SPEED
MANUAL TRANSMISSION,

MacPHERSON STRUT
FRONT SUSPENSION,

AND VENTILATED DISC BRAKES

ALL CONTRIBUTE TO THE RCZ
R's REMARKABLE COMBINATION

OF PERFORMANCE AND EFFICIENCY.

MAGNA IS A CANADIAN-BASED
AUTOMOTIVE MANUFACTURER

WITH FACILITIES ALL
OVER THE WORLD.

ASSEMBLY OF THE RCZ
R TAKES PLACE HERE

AT THE MAGNA FACILITY
IN GRAZ, AUSTRIA.

A TECHNICIAN LOWERS THE ENGINE

ONTO THE
POWER-TRAIN-ASSEMBLY PALLET.

A TEAM MEMBER PLUGS
THE RIGHT HALF SHAFT

INTO THE TRANSMISSION.

HE ATTACHES THE BRAKE
DISC AND TRAILING ARM

BEFORE CONNECTING THE TIE ROD.

A TECHNICIAN ON THE LEFT SIDE OF
THE TRANSMISSION DOES THE SAME.

FOR THE RCZ R, PEUGEOT
REWORKED THE SUSPENSION,

TUNING THE DAMPERS AND
STIFFENING THE SPRINGS

TO CREATE A MORE
RIGID RIDE QUALITY.

HE SLIDES A PORTION OF THE
EXHAUST SYSTEM INTO POSITION.

IT WILL LATER BE ATTACHED
TO THE CATALYTIC CONVERTER.

A TEAM MEMBER USES A LIFT ASSIST
TO TRANSFER THE REAR AXLE

AND BRAKE SUBASSEMBLY TO THE
PALLET, WHERE HE LOWERS IT.

TEAM MEMBERS TRANSPORT THE REST
OF THE CAR'S EXHAUST SYSTEM

TO THE POWER-TRAIN
PALLET FOR INSTALLATION.

PEUGEOT HAS TUNED THE SYSTEM
TO CREATE AN EXHAUST NOTE

THAT'S SATISFYING FOR DRIVERS.

THE NOTE IS AGGRESSIVE, BUT
CONFORMS TO SOUND REGULATIONS.

A BOX FULL OF PEUGEOT'S
FAMED BRAND INSIGNIA

WARMS UNDER A HEAT LAMP.

THIS ENSURES THEIR
ADHESIVE BACKINGS

WILL ATTACH FIRMLY TO
THE CAR'S SURFACE.

BACK IN 1847, THE
PEUGEOT BROTHERS

CHOSE THE IMAGE OF A
LION TO ILLUSTRATE

THAT THEIR SAW BLADES
WERE AS STRONG, SUPPLE,

AND SWIFT AS THE BIG CAT ITSELF.

THEIR FIRST EMBLEM SHOWED A LION
WALKING ON TOP OF AN ARROW.

THE STANDING LION WAS
ADOPTED IN THE 1970s.

THE "R" SYMBOL
STANDS FOR RACING.

THE TECHNICIAN BRINGS THE
BRAKE-AND-CLUTCH PEDAL SYSTEM

TO THE CAR AND INSTALLS IT.

SHE FINGER-TIGHTENS THE
PEDALS TO HOLD THEM IN PLACE.

THE FINAL TORQUE COMES LATER.

THE RCZ R IS MANUAL ONLY,

BUT AN AUTOMATIC
TRANSMISSION IS AVAILABLE

FOR SOME OTHER
VERSIONS OF THE RCZ.

TEAM MEMBERS USE A SPECIALIZED
LIFT-ASSIST DEVICE

TO SLIDE THE
PRE-ASSEMBLED DASHBOARD

INSIDE THE CAR'S COCKPIT.

THE LEATHER AND ALCANTARA
UPHOLSTERED DASHBOARD

FEATURES RED OVERSTITCHING.

THE OVERSTITCHING IS
A SIGNATURE FEATURE,

IDENTIFYING THE CAR AS AN RCZ R

RATHER THAN THE
LESS POWERFUL RCZ.

AN OVERHEAD CONVEYOR SYSTEM
POSITIONS THE CAR BODY

FOR ITS MARRIAGE
WITH THE CHASSIS.

THE MARRIAGE IS
COMPLETELY AUTOMATED.

LASERS PRECISELY ALIGN
THE TWO SUBASSEMBLIES

SO THAT THEY JOIN PERFECTLY.

TEAM MEMBERS THEN
VERIFY ALIGNMENT

AND COMPLETE THE
ATTACHMENT OPERATION.

A TECHNICIAN USES
AN EXTENSION DEVICE

TO BOLT THE CHASSIS TO THE BODY.

THE AUTOMATED CONNECTION
TAKES JUST 20 SECONDS.

THE TEAM MEMBERS NEED
JUST 20 MORE SECONDS

TO COMPLETE THE BOLTING PROCESS.

THE WHOLE PROCESS TAKES
LESS THAN A MINUTE.

A TECHNICIAN MOUNTS THE
RCZ R COOLING SYSTEM.

THIS INCLUDES THE RADIATOR

AND THE INTERCOOLER
FOR THE TURBOCHARGER.

THE RADIATOR WAS DESIGNED
TO KEEP THE ENGINE COOL

UNDER EXTREME HEAT CONDITIONS,
LIKE THOSE FOUND IN AUSTRALIA.

LIKE ALL TURBOCHARGED ENGINES,

THE RCZ R REQUIRES
AN INTERCOOLER

TO INCREASE EFFICIENCY.

THE FRONT END OF THE RCZ
R IS NEARLY FINISHED,

BUT THERE'S STILL A
LOT OF WORK REQUIRED

TO COMPLETE THE ASSEMBLY.

♪♪

Narrator: TO BRING
A PEUGEOT RCZ R

TO THE POINT AT WHICH IT'S
READY FOR ITS TEST-DRIVE,

TEAM MEMBERS AT
MAGNA MUST COMPLETE

THE ASSEMBLY PROCESS USING AN
OPTIMIZED PRODUCTION LINE,

TECHNICAL EXPERTISE, AND
STATE-OF-THE-ART EQUIPMENT.

TECHNICIANS INSTALL
THE REAR BUMPER.

IT'S MADE OF LIGHTWEIGHT
COMPOSITE MATERIALS.

COMPOSITES CAN BE
MOLDED TO ANY SHAPE,

ARE CHEAP TO PRODUCE, AND
EASY TO SWAP OUT IF DAMAGED.

THE RCZ R BUMPER
FITS NEATLY AROUND

THE CAR'S STAINLESS-STEEL
TAIL PIPES.

THE REAR WINDOW CONTINUES
THE DOUBLE-BUBBLE CURVES

THAT BEGIN ON THE ROOF.

PRODUCING GLASS IN THIS
SHAPE AT A REASONABLE PRICE

WAS ONE OF THE MOST
TECHNICALLY-DIFFICULT ASPECTS

OF THE DEVELOPMENT PHASE.

THIS MAY BE WHY THE RCZ MODELS
ARE THE ONLY PRODUCTION CARS

IN THE WORLD WITH BUBBLED GLASS.

THE MATTE ALUMINUM ROOF ARCHES
FORM ANOTHER SIGNATURE ELEMENT

OF THE RCZ R's LOOK.

A TEAM MEMBER CARRIES THE
LIGHTWEIGHT COMPONENT

TO THE CAR AND ADHERES
IT FIRMLY IN PLACE

BEFORE STRIPPING OFF
A PROTECTIVE LAYER

OF PLASTIC FILM.

THE L.E.D. BRAKE LIGHTS
SNAP INTO POSITION.

THEY'RE CONTINUOUS WITH THE
CURVE OF THE REAR FENDER

TO MAXIMIZE AERODYNAMIC
EFFICIENCY

AND CONFORM TO THE
CAR'S GRACEFUL LINES.

TEAM MEMBERS INSTALL

THE LIGHTWEIGHT
COMPOSITE FRONT BUMPER

WITH THE PEUGEOT
NAME, LION BADGE,

AND SIGNATURE GRILLE DESIGN.

A TECHNICIAN USES A LIFT ASSIST
TO MOUNT A WHEEL ON ITS BASE

IN AN AUTOMATED PROCESS.

THE 19-INCH WHEELS SIT ON RIMS

DESIGNED TO HOUSE AND OPTIMIZE
THE BRAKE-COOLING SYSTEM.

TEAM MEMBERS THEN BRING
TWO MACHINES TO THE CAR

TO COMPLETE A FULLY-AUTOMATED
LUG-TORQUING PROCESS.

THE MACHINES ENSURE THE LUGS
ARE SIMULTANEOUSLY TIGHTENED

TO THE PRESCRIBED PARAMETERS.

AFTER THE PAINT JOB AND BEFORE
THE ASSEMBLY PROCESS BEGINS,

THE MANUFACTURERS
REMOVE THE DOORS

AND FINISH THEM IN A
SEPARATE SUBASSEMBLY AREA.

THIS PROTECTS THE DOORS FROM
DAMAGE DURING ASSEMBLY.

IT ALSO MAKES IT
EASIER FOR TECHNICIANS

TO MOVE IN AND OUT OF THE
VEHICLE AS THEY WORK.

HERE, TECHNICIANS
REUNITE THE DOORS

WITH THEIR ORIGINAL CAR BODY.

THE VEHICLES MOVE THROUGH
A QUALITY-CONTROL AREA

EQUIPPED WITH SIDE LIGHTS.

AN INSPECTOR USES A SOFT
CLOTH TO WIPE THE BODY

IN SEARCH OF ANY
POTENTIAL FLAWS.

THIS IS JUST THE FIRST
STEP OF A DETAILED,

MULTI-PHASE
QUALITY-CONTROL PROCESS.

SPECIALLY-TRAINED TEST DRIVERS
TAKE EVERY CAR FOR A RUN

ON THE MAGNA
FACILITY'S TEST TRACK.

ACCELERATING TO NO MORE
THAN 60 MILES PER HOUR

OVER THE COURSE OF
THREE TO FIVE MINUTES,

THEY COVER ROUGHLY
2,500 FEET OF TRACK

AS THEY WEAVE AND CORNER,

LISTENING FOR ANY
ABNORMAL NOISES.

THEY ALSO CHECK THE
CAR'S HANDLING, LIGHTS,

BRAKES, AND GENERAL
PERFORMANCE.

WHEN PEUGEOT LAUNCHED
THE RCZ IN 2010,

IT WAS ADMIRED FOR ITS DESIGN.

THE 2014 LAUNCH OF THE
RCZ R EDITION OF THE CAR

BROUGHT NEW LEVELS OF POWER
AND PERFORMANCE TO THE MODEL.

THE RED OVERSTITCHING AND
AVIATION-INSPIRED DESIGN

OF THE COCKPIT AND SEATS
SIGNAL THE CAR'S FASTER,

MORE AGGRESSIVE CAPABILITIES.

YET REMARKABLY, PEUGEOT DIDN'T
ENHANCE THE CAR'S PERFORMANCE

AT THE EXPENSE OF
ENVIRONMENTAL CONSIDERATIONS.

WHILE THEY WERE BUSY
INCREASING THE CAR'S POWER,

THE COMPANY MANAGED TO
ACTUALLY REDUCE EMISSIONS

BY BUILDING THE MOST
POWERFUL AND EFFICIENT

1.6-LITER FOUR-CYLINDER
ENGINE THERE IS.