R.R. CENTRE PILLAR

Operation 7210B10 · STRUCTURAL ELEMENTS (CENTRE AND REAR SECTION)

Removing

Op. 7210E38 R.R. REAR SIDE DOOR

Op. 7210E28 R.R. ROOF PANEL

Op. 7210B18 R.R. ROOF PANEL SUPPORTING CROSSMEMBER

- Check that the components connected are not distorted by checking the bodyshell alignment measurements using suitable equipment (gauges, templates or jigs).

- Straighten the body as necessary.

1. Use a hack sawing machine following the cutting lines shown in the diagram.

- Use a rotary brush to remove the paint to gain access to the spot welds.

2. Use the chamfering machine to remove the spot welds shown in the diagram.

- Use the drill and chamfer the spot welds not accessible with the chamfering machine.

- Use the hammer and chisel and remove the spot welds chamfered previously.

3. Remove the outer part from the vehicle.

1. Use a hack sawing machine following the cutting lines shown in the diagram.

- Use a rotary brush to remove the paint to gain access to the spot welds.

2. Use the chamfering machine to remove the spot welds shown in the diagram.

- Use the drill and chamfer the spot welds not accessible with the chamfering machine.

- Use the hammer and chisel and remove the spot welds chamfered previously.

3. Remove the intermediate part from the vehicle.

1. Use a hack sawing machine following the cutting lines shown in the diagram.

- Use a rotary brush to remove the paint to gain access to the spot welds.

2. Use the chamfering machine to remove the spot welds shown in the diagram.

- Use the drill and chamfer the spot welds not accessible with the chamfering machine.

- Use the hammer and chisel and remove the spot welds chamfered previously.

3. Remove the inner part from the vehicle.

- Straighten the edges of the vehicle using a hammer and dolly block.

- Remove the spot weld residues using a disc grinder.

- Use a rotary brush to clean the areas treated previously.

1. Apply electro-galvanizing paint.

Refitting

1. Work at the bench and cut the inner replacement part, at the points shown in the diagram, making sure that a section of the panel remains for overlapping.

2. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the replacement part using a rotary brush.

3. Drill out part at the points indicated.

- Apply electro-weldable paint to the edges involved.

1. Position the inner part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use the circular saw to cut the edges of the panel so that the join line is perfect.

- Remove the replacement part, the excess panels and the components used for the adjustment.

1. Position the inner part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use a spot welder in the areas shown in the diagram.

3. Use a MIG welder and fill weld the openings made previously.

4. Use a MIG welder to seam weld in the join areas.

- Correct any distortions to the panel using a mallet and dolly block.

1. Use a disc grinder to level the welds.

- Use a rotary brush to clean the areas welded previously.

1. Apply anti-oxidant protection to the areas involved in the welding.

- Seal the join lines between the inner replacement part and the vehicle.

1. Apply electro-galvanizing paint.

1. Work at the bench and cut the intermediate replacement part, at the points shown in the diagram, making sure that a section of the panel remains for overlapping.

2. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the replacement part using a rotary brush.

- Apply electro-weldable paint to the edges involved.

1. Position the intermediate part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use the circular saw to cut the edges of the panel so that the join line is perfect.

- Remove the replacement part, the excess panels and the components used for the adjustment.

1. Position the intermediate part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use a spot welder in the areas shown in the diagram.

3. Use a MIG welder to seam weld in the join areas.

- Correct any distortions to the panel using a mallet and dolly block.

1. Use a disc grinder to level the welds.

- Use a rotary brush to clean the areas welded previously.

1. Apply anti-oxidant protection to the areas involved in the welding.

- Seal the join lines between the intermediate replacement part and the vehicle.

1. Apply electro-galvanizing paint.

1. Work at the bench and cut the outer replacement part, at the points shown in the diagram, making sure that a section of the panel remains for overlapping.

2. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the replacement part using a rotary brush.

3. Drill out part at the points indicated.

- Apply electro-weldable paint to the edges involved.

1. Position the outer replacement part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use the circular saw to cut the edges of the panel so that the join line is perfect.

- Remove the replacement part, the excess panels and the components used for the adjustment.

1. Position the outer replacement part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use a spot welder in the areas shown in the diagram.

3. Use a MIG welder and fill weld the openings made previously.

4. Use a MIG welder to seam weld in the join areas.

- Correct any distortions to the panel using a mallet and dolly block.

1. Use a disc grinder to level the welds.

- Use a rotary brush to clean the areas welded previously.

1. Apply anti-oxidant protection to the areas involved in the welding.

- Seal the join lines between the inner replacement part and the vehicle.

- Proceed with the painting stage.

Op. 7210B18 R.R. ROOF PANEL SUPPORTING CROSSMEMBER

Op. 7210E28 R.R. ROOF PANEL

Op. 7210E38 R.R. REAR SIDE DOOR