Workshop Manuals Factory service & repair Alfa Romeo
01 Introduction and contents02 Technical data and maintenance03 Engine04 Clutch05 Gearbox06 Front axle and drive shafts07 Brakes08 Steering09 Suspension and wheels10 Heating and ventilation11 Bodywork12 Timing belt data sheets
Alfa Romeo 145/146 Factory Service Manual (1994-1999)11 · Bodywork
11 · Body & interior

Preparation

Make
Alfa Romeo
Model
145/146 Factory Service Manual
Year
1994–1999
Section
Fixed bodywork components › Preparation
BodyworkPreparation
  1. Using a circular saw, cut following the lines shown in the diagram, without damaging the underlying areas.
Cut lines (1) on the door sill rail
  • Using a rotating brush, clean the areas to be spot-cut to show up the welding points.
  1. Using a chamfering machine, remove the accessible welding points; remove the remaining welding points using a drill.
  2. Open the clinch tabs.
Door sill rail with welding points (1) and clinch tabs (2); view A arrowed
View A: welding points at position 1
  • Remove the door sill rail cutting away the sealant if necessary.

PREPARATION

  1. Working on a bench with a jig saw cut the new door sill rail allowing enough or overlapping.
  2. Trace out the rail and drill with a 5 mm bit as shown in the diagram.
Door sill rail with drilling points 2 and cut lines 1, with a 25 mm dimension
  • Using a rotating brush, clean the areas which are to be welded .
  1. Apply a thick layer of electroweldable protection to the lower part of the door sill rail and in the rear wheel housing.
Applying electroweldable protection to the lower part of the door sill rail, position 1

Parts & tools for this job For 1994 Alfa Romeo 145/146

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