R.R. ROOF SUPPORT CROSSMEMBER

Operation 7210B18 · Structure elements-central and rear part

5 doors

Removing

Check if any of the connected parts are deformed by checking body alignment dimensions. Use appropriate measurement tools (reference rigs, templates or gauges).

If necessary, straighten the body before cutting the part.

1. Undo the fixing bolts (1a) and remove the tailgate (1b).

- 7210E28 R.R. ROOF PANEL

To remove the front crossmember, proceed as described below:

1. Use a chamfering machine to reduce the spot welds as shown in the diagram.

2. Detach the front crossmember.

Use a grinding wheel to remove the spot weld residues.

Straighten the edges of the panel.

Apply electro-galvanizing paint to the areas which have been ground.

To detach the longitudinal crossmember, proceed as described below:

1. Use a chamfering machine to reduce the spot welds as shown in the diagram.

2. Detach the longitudinal crossmember.

Use a grinding wheel to remove the spot weld residues.

Straighten the edges of the panel.

Apply electro-galvanizing paint to the areas which have been ground.

To detach the centre crossmember, proceed as described below:

1. Reduce the spot welds for the longitudinal crossmember.

2. Use a chamfering machine to reduce the spot welds as shown in the diagram.

3. Detach the centre crossmember.

Use a grinding wheel to remove the spot weld residues.

Straighten the edges of the panel.

Apply electro-galvanizing paint to the areas which have been ground.

To detach the rear crossmember, proceed as described below:

1. Reduce the spot welds for the longitudinal crossmember.

2. Use a chamfering machine to remove the weld spots shown in the figure.

3. Detach the rear crossmember.

Use a grinding wheel to remove the spot weld residues.

Straighten the edges of the panel.

Apply electro-galvanizing paint to the areas which have been ground.

Refitting

To refit the front crossmember, proceed as described below:

Use a rotary brush to remove the corrosion-proofing around the edge of the parts.

Apply electro-galvanizing paint to the areas which have been ground.

1. Offer up the replacement front crossmember and secure it using self-locking clamps.

Check the parts are properly aligned.

2. Use a spot welder to weld the areas shown in the figure.

To refit the longitudinal crossmember, proceed as described below:

Use a rotary brush to remove the corrosion-proofing around the edge of the parts.

Apply electro-galvanizing paint to the areas which have been ground.

1. Offer up the replacement longitudinal crossmember and secure it using self-locking clamps.

Check the parts are properly aligned.

2. Use a spot welder to weld the areas shown in the figure.

To refit the centre crossmember, proceed as described below:

Use a rotary brush to remove the corrosion-proofing around the edge of the parts.

Apply electro-galvanizing paint to the areas which have been ground.

1. Offer up the replacement longitudinal crossmember and secure it using self-locking clamps.

Check the parts are properly aligned.

2. Use a spot welder to weld the areas shown in the figure.

3. Spot weld the contact area with the longitudinal crossmember.

To refit the rear crossmember, proceed as described below:

Use a rotary brush to remove the corrosion-proofing around the edge of the parts.

Apply electro-galvanizing paint to the areas which have been ground.

1. Offer up the replacement longitudinal crossmember and secure it using self-locking clamps.

Check the parts are properly aligned.

2. Use a spot welder to weld the areas shown in the figure.

3. Spot weld the contact area with the longitudinal crossmember.

- 7210E28 R.R. ROOF PANEL

Fit the tailgate.

Tighten the fixing bolts without torque tightening them.

Adjust the tailgate as described in the operation:

- 7015A14 tailgate - adjust centring and profile - includes hinge and compartment seal adaptation.