R.R. ROOF PANEL

Operation 7210E28 · EXTERNAL PARTS

1.2 8v, 1.3 Multijet, 1.4 16v

Removing

- Ensure that the components connected are not distorted by checking the body alignment measurements with suitable equipment (reference rigs, templates or gauges).

- Straighten the body as necessary.

1. Use a jigsaw, following the cutting lines shown in the diagram.

- Work on the front part of the roof panel.

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

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

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

- Work on the rear part of the roof panel (on both sides).

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

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

2. Use the drill to chamfer the spot welds shown in the diagram.

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

1. Heat the area of the ribs to allow the sealant to be detached.

- Remove the roof panel.

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

1. Reduce the spot welds along the perimeter of the roof panel using a chamfering machine.

- Remove the panel trimmings using a hammer and chisel.

1. Straighten the edges of the panel.

- Remove the spot weld residues using a disc grinder.

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

- Apply electro-weldable paint along the edges of the body to be welded.

Refitting

1. Remove the anti-corrosion treatment from the perimeter of the spare part shown in the diagram using a rotary brush.

- Apply electro-galvanising paint to the previously treated surfaces.

1. Drill out the opening shown in the diagram on both sides of the rear part of the roof panel.

- Restore the sealant on the ribs in previously heated areas.

- Position the replacement part correctly on the body and secure it using self-locking clamps.

- Check that it is perfectly positioned and aligned.

1. Use a spot welder to weld the areas shown in the diagram.

2. Use a seam welder to fill-weld the areas shown in the diagram.

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

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

- Apply rustproofing to the areas involved in the welding.