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

Welding and finishing the sheet metal

Make
Alfa Romeo
Model
145/146 Factory Service Manual
Year
1994–1999
Section
Fixed bodywork components › Welding and finishing the sheet metal
BodyworkWelding and finishing the sheet metal · page 1 of 2

WELDING AND FINISHING THE SHEET METAL

  1. Using a spot welder, tack the door sill frame as shown in the diagram.
  2. Using a MIG welder, proceed as shown in the diagram.
Tack and MIG welding the door sill frame: weld counts 1 (3), 1 (3) and 2 (6)
  • Refit the reinforcing of the door sill proceeding as described in the relative paragraph.

REAR WING

PRELIMINARY OPERATIONS

  • Disconnect the negative (-) cable from the battery and remove the electronic control units.
  • Remove the trim components, electrical and mechanical system which could hinder the repair operations or get damaged during work (see specific paragraphs)
  • Remove the following sheet metal parts:
  • door on affected side (see specific paragraph).
  • front wing on affected side (see specific paragraph).

REMOVAL

Car body with the rear wing area highlighted
  1. Using a circular saw, cut following the lines indicated in the diagram, without damaging the underlying components.
Rear wing with cut lines (1) and dimensions 60 mm, 50 mm and 40 mm
  • Using a rotating brush, clean the areas to be spot-cut to highlight the welding points.
  1. Using a spot cutter, remove the accessible welding points; remove the remaining welding points using a drill or a chisel.

NOTE: If necessary free the sheet metal to facilitate the spot cutting operations

Removing the welding points along the rear wing, position 1

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

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