R.R. BOOT FLOOR

Operation 7210B55 · STRUCTURE ELEMENTS-CENTRAL AND REAR PART

Removing

• Op. 7210B70 REAR TRIM
• 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.

• Use the power saw following the dotted lines in the diagram.
• Sections representing the most important cutting points in order to allow the operator to adjust the position and the depth of the cut so as not to damage the panels underneath.
• Remove the floor in the centre area.

• Trace the area to be cut using the circular saw on the floor.

1. Use the circular saw following the dotted lines in the diagram.

2. Cutting sections.

• Use the rotary brush to clean the edges of the panel to highlight the spot welds.

3. Use the drill and remove the spot welds shown in the diagram.

4. Use the chamfering machine on the spot welds shown.

• Use the hammer and chisel to remove the spot welds chamfered previously.

5. Remove the edges of the panel on the boot floor side members.

• Use the vibrating knife and special blade to remove the P.V.C. treatment.
• Straighten the edges of the vehicle using a hammer and dolly block.

• Remove the spot weld residues using a disc grinder.
• Apply electro-galvanizing paint.

• Continue inside the passenger compartment and proceed with the removal of the reinforcement brackets between the floor and inner wheel arch.

• Using the drill, make holes in the reinforcement (1a) between the floor and the wheel arch at the points (1b) shown in the diagram.

• Remove the reinforcement between the floor and the wheel arch.
• Repeat the operation on the left side.

• Working in the right rear wheel arch housing (1a) make holes using the drill at the points (1b) shown in the diagram.
• Working inside the passenger compartment, use the chamfering machine on the spot welds shown.
• Remove the lower reinforcement between the floor and the wheel arch.

• Repeat the operation on the left side of the vehicle.

• Use the power saw following the dotted lines (1a) in the diagram, then remove the edges of the panel (1b) taking care not to damage the floor supporting crossmember (1c) underneath.
• Section representing the most important cutting points in order to allow the operator to adjust the position and the depth of the cut so as not to damage the panels underneath.
• Use the power saw following the dotted lines (3a) in the diagram, then remove the edges of the panel (3b) taking care not to damage the floor supporting crossmember (3c) underneath.

1. Use the rotary brush to clean the edges of the panel to highlight the spot welds.

2. Use the chamfering machine on the spot welds shown.

3. Use the drill and chamfer the spot welds in the area shown in the diagram.

• Use the hammer and chisel to remove the spot welds chamfered previously.

4. Remove the edges of the boot floor panel.

• Straighten the edges of the panel using a hammer and dolly block.
• Remove the spot weld residues using a disc grinder.
• Use a rotary brush and clean the areas treated previously.

• Apply electro-galvanizing paint.

Refitting

• Position the replacement part in the vehicle and, using the drill, make holes at the points shown in the diagram, by the two centre floor supporting crossmembers.
• Drill the replacement part at the points shown in the diagram by the left and right rear side members.
• Drill the replacement part at the points shown in the diagram on the edge of the front panel.

• With the replacement part at the bench, remove the anti-corrosion treatment from the inner and outer part of the replacement part in the area shown.

• Apply electro-weldable paint to the edges in contact with the vehicle.

• Position the floor in the vehicle and secure it using self-locking clamps.
• Use the MIG welder to fill weld the openings made previously in the front part of the replacement panel.

• Use the spot welder and work in the areas shown in the diagram at the rear of the replacement part.
• Use the MIG welder to fill weld the openings made previously in the rear part of the replacement panel.

• Correct any distortions to the panel using a dolly block.

• Use a disc grinder to remove and level the welding residues.

1. Position the reinforcement brackets (1a) and (1b) between the floor and the inner wheel arch at the bench, then proceed with straightening the edges of the panel using a hammer and dolly block.

• Remove the spot weld residues using a disc grinder.
• Use a rotary brush and clean the areas treated previously.

2. Apply electro-galvanizing paint.

• Repeat the operation for the left side floor reinforcement brackets.

1. Position the lower reinforcement bracket (1a) between the floor and the wheel arch (1b), then secure it using self-locking clamps or parker screws.

• Check that the alignment is perfect.

2. Use a MIG welder and fill the openings made previously.

• Correct any distortions to the panel using a hammer and dolly block.
• Repeat the operation on the left side of the vehicle.

1. Position the upper reinforcement bracket (1a) between the floor and the wheel arch (1b), then secure it using self-locking clamps or parker screws.

• Check that the alignment is perfect.

2. Use a MIG welder and fill the openings made previously.

• Correct any distortions to the panel using a hammer and dolly block.
• Repeat the operation on the left side of the vehicle.

• Apply the anti-oxidant protective to the areas previously involved in the welding.

1. Seal the join lines between the replacement part and the vehicle using sealant.

• Renew the P.V.C. treatment.

2. Apply the sound insulation panels.

• Paint the load carrying compartment floor (following the recommended cycle).
• Proceed with the waxing stage.

• Op. 7210B70 REAR TRIM