R.R. ROOF PANEL

Operation 7210E28 · EXTERNAL PARTS

3 door

Removing

Op. 7210E56 R.R. TAILGATE

- 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. Using the vibrating knife with the special blade, cut the sealant between the rib and the roof.

2. Use the hack saw following the cutting lines in the diagram.

- 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.

- Remove the panel offcuts.

- 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 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 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.

- 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.

Op. 7210E56 R.R. TAILGATE

5 door

Removing

Op. 7210E56 R.R. TAILGATE

- 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. Using the vibrating knife with the special blade, cut the sealant between the rib and the roof.

2. Use the hack saw following the cutting lines in the diagram.

- 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.

- 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 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 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.

- 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.

Op. 7210E56 R.R. TAILGATE