All language subtitles for How.Its.Made.Dream.Cars.S04E04.Peugeot.RCZ.R.1080p.DSCP.WEB-DL.AAC2.0.H.264-NTb_track3_[eng]

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.