R.R. CENTRE PILLAR

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

3 door

Removing

Op. 7210E52 R.R. REAR WING

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 hammer and chisel and remove the spot welds chamfered previously.

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 cut part of the outer component shown in the diagram.

Working inside the vehicle:

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

1. Undo the retaining bolts.

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

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

3. Remove the component (inner part and outer part) and the offcuts.

To remove the remaining offcuts for the inner part, proceed as follows:

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

1. 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.

2. Remove the offcut from the vehicle.

- Straighten the edges of the vehicle using a mallet and profiled 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. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the inner replacement part using a rotary brush.

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

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

Working inside the vehicle:

1. Tighten the fixing bolts.

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

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

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

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

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

- 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.

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

Op. 7210E28 R.R. ROOF PANEL

Op. 7210E52 R.R. REAR WING

5 door

Removing

Op. 7210E38 R.R. REAR SIDE DOOR

Op. 7210E56 R.R. TAILGATE

Op. 7210E28 R.R. ROOF PANEL

- 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 the hack sawing machine following the cutting lines illustrated in the diagram, but only cutting the panel of the outer part.

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

3. Remove the cut part of the outer component shown in the diagram.

1. Use the hack sawing machine following the cutting line illustrated in the diagram and making sure that the entire pillar (outer part, intermediate part and inner part) is cut.

2. Use the hack sawing machine following the cutting lines illustrated in the diagram, but only cutting the panel of the outer part.

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

3. 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.

4. Remove the cut part of the outer component shown in the diagram.

1. Undo the retaining bolts.

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

3. Remove the pillar (inner part and outer part) where the lower part has already been cut previously.

To remove the intermediate part offcuts, proceed as follows:

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

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

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

2. Remove the offcut from the vehicle.

To remove the remaining part offcuts, proceed as follows:

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

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

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

2. Remove the offcut from the vehicle.

- Straighten the edges of the vehicle using a mallet and profiled 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. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the inner replacement part using a rotary brush.

- 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. Tighten the fixing bolts.

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

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

2. Drill out part at the points indicated.

- 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 a spot welder in the areas shown in the diagram.

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

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

- Fit the front door housing seal and the striker and close the door temporarily.

- 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 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 to seam weld in the join areas.

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

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

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 replacement part and the vehicle.

- Proceed with the painting stage.

Op. 7210E28 R.R. ROOF PANEL

Op. 7210E56 R.R. TAILGATE

Op. 7210E38 R.R. REAR SIDE DOOR