INTRODUCTION

2429968 - Introduction - PANELS AND FRAME

Vehicle identification data

The vehicle has the following identification plates:

1. Vehicle identification data plate
2. Bodyshell marking
3. Bodywork paint identification plate.

Towing points

The vehicle has two threaded sockets, one at the front and one at the rear, for fitting the tow hook which is housed in the compartment in the spare wheel in the luggage compartment under the carpet.

Towing points

When towing the vehicle, the laws governing towing and road traffic must be obeyed. Before towing, make sure that the tow hook is fully tightened. Thoroughly clean the threaded housing before tightening the tow hook. Turn the ignition key to the ON position and then to the OFF position and DO NOT EXTRACT IT !When the key is extracted, the steering lock is immediately engaged and it is consequently impossible to steer the wheels. Whilst towing, as the brake servo is not working, greater force will have to be exerted on the brake pedal. The towing vehicle should be driven as smoothly as possible to prevent the two vehicles striking one another. Do not use flexible cables for towing and avoid jerking. During towing operations, check that the tow cable coupling does not damage parts with which it comes into contact.

For versions with automatic transmission, observe the following additional instructions: 1) place the gear lever in position N; 2) maintain a towing speed less than 30 km/h; 3) the maximum towing distance is 20 km For greater distances, raise the front end of the car to prevent damage to the transmission due to insufficient lubrication.

After having raised the vehicle, support it using safety stands.Before lifting the front of the vehicle, lock the wheels using chocks in behind the rear wheels.

When lifting the front of the vehicle, this may be done only by positioning the lift arm beneath the gearbox-differential unit and placing a wooden or rubber block between the arm and the vehicle.

Vehicle lifting points

To lift the vehicle using a ramp or hoist, place the ends of the arms or hoist only in the areas shown in the figure.With workshop liftWith lift with arms

Vehicle lifting points

Before lifting the vehicle using portable lifts, lock the wheels by placing chocks in front of (behind) the front (rear) wheels.

After having raised the vehicle, support it using safety stands.

General safety warnings

The activities connected with repairing the bodywork involve the use of equipment and tools in addition to the handling of chemical products and substances for which the supplier's instructions must be followed.

It is therefore necessary to pay special attention to:

the correct use of materials, instruments and equipment: before carrying out any sort of operation, read the instruction manuals carefully and follow the accident prevention and safety instructions with great care.
The workplaces for carrying out operations, which should have appropriate ventilation systems which satisfy the legal requirements concerning air exchange, the filtration of harmful substances (solvents) and the reduction of dust levels.
The handling of dangerous substances which should be carried out in accordance with the supplier's instructions and recommendations.
The collection and disposal of refuse which should be carried out in accordance with the laws in force.

When working with and handling harmful and dangerous substances, the appropriate safety equipment should be employed (clothing, masks, gloves, goggles, etc.).

Vehicle repair operating cycles

The vehicle repair operating cycles usually consist of the following stages:

checking the vehicle measurements;
cutting/removing damaged elements and preparing the bodyshell for welding;
welding replacement elements;
preparing for painting;
painting;
renewing the anti-corrosion treatments;
sound insulation, sealants.

CHECKING AND RESTORING THE VEHICLE MEASUREMENTS

This is the first stage of the repair operation during which the deformations suffered by the bodyshell are measured and evaluated and the elements involved are identified.During this stage the first actual repair operation is carried out: pulling the bodyshell to restore the measurements before cutting and removing the damaged elements.

PULLING THE BODYSHELL

Pulling the bodyshell, to restore the measurements, is carried out on straightening benchs where it is possible to secure the bodyshell using vices and attachments which should be fixed according to specific methods for each vehicle, with instructions provided by each supplier.Jigs are used to check the measurements of the bodyshell. They are positioned at specified points, and are used to check the measurements indicated by the jig manufacturer for each model, or alternatively the vehicle's own measurements given in the section 'Descriptions and Operation'.Example of a possible straightening bench configuration.

General repair instructions

Before carrying out any sort of operation on the vehicle, disconnect the battery terminals.

For safety reasons and for a better quality repair, IT IS PROHIBITED TO:

replace structural parts of the bodyshell without using a repair bench. The use of the bench makes it possible to guarantee the restructuring of the vehicle with the original manufacturing measurements, ensuring the correct position of the forecarriage and back-carriage elements.
heat the structural parts of the bodyshell to straighten them.
cut and weld, edge to edge, any bodywork element and reinforcement on the same line.

Remove the damaged elements, cutting them on the joins, following the cutting lines given in the Service Manual. Carried out correctly, the operation involves wasting a few centimetres between the two cutting lines in order to improve the distribution of the fusible points created by the welding.The diagram below illustrates a possible implementation.

General repair instructions

The removal of the damaged elements is the repair operation during which the potentially most dangerous equipment is used. Before carrying out any sort of operation, read the instruction manuals, the safety instructions and the manufacturer's warnings which come with the equipment very carefully and follow all the accident prevention and safety instructions to the letter.

The use of the following is required for the removal of damaged body panels:

hack-sawing machines;
circular saws;
power chisels (only in case of need);
plasma-arc cutting systems;
electric drills;
milling machines;
grinding machines;
dolly blocks and hammers;
disc grinding wheels;
air purifiers / extractor systems.

HACK-SAWING MACHINE

This type of saw makes it possible to carry out fast and precise cutting, with the possibility of regulating the speed of the blade to suit different situations. Example of the use of a hack-sawing machine

OSCILLATING CIRCULAR SAW

An oscillating saw is used in cases where high cutting precision is required; for example, when you need to replace the sheet metal of a box section that is laid over a panel which must not be damaged. By adjusting the speed and the number of oscillations it is possible to achieve the precision required according to the conditions of use. The high level of safety of this instrument makes it advisable to use it as an alternative to other types of saws.Example of an oscillating circular saw

POWER CHISEL

A pneumatic chisel is used to remove parts of body panels; it is advisable to use it:

when it is not possible to use a power saw, milling machine or drill; for example, when a panel that must not be damaged lies behind the panel that requires cutting;
when it is possible to directly separate the welded panels, inserting the power chisel between the two panels along the join edge in order not to leave edges which need removing later on.

The different attachments increase its versatility.Example of the use of a power chisel

PLASMA-ARC CUTTING SYSTEM

This cutting system, achieved through the combined effect of an electric arc and gas or a mixture of gases, is used whenever it is necessary to cut rather large panels. Depending on the thickness of the panel and the depth of the cut, adjust the current and the gas flow following the instructions in the Manufacturer's booklet.

The use of a plasma-arc cutting system requires the use of an extractor system to get rid of the fumes and harmful gases.

ELECTRIC DRILL

An electric drill is normally used in cases where a milling machine cannot be used; the correct use of the drill to remove spot welds if several panels are superimposed is illustrated in the diagrams below. The attachment to be used in these operations is identical to the one fitted on the milling machine. The spot weld should be marked using a drift, in order to provide a support point for the centring bit, this prevents the drill moving away from the spot and damaging the surrounding area; force should be exerted on the cutter until the depth reached is slightly greater than the thickness of the panel which should be removed (see diagram below).Example of the use of an electric drill

ELECTRIC DRILL

Example of the correct usage of a milling cutter

1. Panel to be removed. 2. Box section panel preventing the use of a milling cutter.

MILLING CUTTER

A milling cutter for removing weld spots should be used after cutting the panel to be replaced in order to allow the removal of the panel offcuts remaining on the edges of the bodyshell. The milling cutter acts on the panel which constitutes the offcut, cutting it as far as the panel underneath and thereby isolating the spot weld.After the reduction of all the spot welds. the offcut is removed using pliers.To facilitate the operation, use a cutting speed of around 1000 rpm.Adjust the depth of the cutting using the special screw.Example of the use of a milling cutter

MILLING CUTTER

Do not drill matching components. If holes are made by mistake, close them by (MIG) welding. The presence of holes reduces the strength of the component involved and can also give rise to the penetration of water and corrosive agents.

DOLLY BLOCKS AND LEVERS

These instruments are used when panels need to be straightened by beating, in order to have a counter-action point to support the panel. Dolly blocks are designed so that they adjust to the different panel conformations and, when the working area permits, they can replace a hammer.Levers are used in the same way as dolly blocks, however they are designed so that they can be introduced through restricted openings and spaces to get to areas which are difficult to reach.Dolly blocks and levers are also used to eliminate distortions from the edges of panels which are not removed thereby allowing correct matching with the replaced panels, avoiding weakening the structure.

Welding replacement elements

If welding operations or work which could produce flames near the fuel system components illustrated in the diagram or other flammable parts of the vehicle need to be carried out, the parts involved must be removed from the vehicle and the free pipe connections sealed if the connectors are removed. Disconnect the electronic control units (I.E., ABS, Air Bag, Air conditioning, Alarm, etc.) which could be damaged during the work.

Parts of the fuel system

Welding replacement elements

Welding bodywork elements should be carried out, according to requirements, using different methods:

Spot welding;
Seam (MIG) welding;

Brazing.

EQUIPMENT

The following equipment is used for these operations:

welding guns;
seam (MIG) welders;
oxyacetylene torches (brazing).

INTRODUCTION TO ELECTRICAL SPOT WELDING

In electrical spot welding the heat needed to melt the metal is supplied by the resistance to the current flow provided by the actual metal.Spot welding is carried out to panels where the join edges overlap and the panel metal melts; no metal filler is therefore needed for this type of welding. In areas where three or more panels overlap, spot welding should be repeated for a second time.The type of join produced is not continuous; to create a join with good mechanical strength the spot welds must be correctly spaced following precise instructions (see tables below).

SPOT WELDING

In the case of spot welding, check::

that the arms are correctly aligned;
that the diameter of the edges of the electrodes is correct;

the planarity and that the weld edges are correctly matched; the correct welding sequence.

Before welding, apply electro-weldable galvanizing protection to the edges of the join to protect the box sections from corrosion.

Spot welder, geometric characteristics of the electrode according to the thickness of the panel and the welding sequence.

A. Electro-weldable galvanizing protective B. Correct welding sequence C. Incorrect welding sequence D. Electrode dimensions

SPOT WELDING

Table of reference values for carrying out spot welds.

A. Table for determining the distance of the spot welds from the edges of the panels according to their thickness. B. Table of reference values for the correct spacing of the spot welds according to the thickness of the panel.

SPOT WELDING

Do not weld on angular shaped surfaces. Welding on this type of surface would create a concentration of tension which would result in breakage.

Example of correct spot welding at corners.

A. Area where welding should not be carried out.

SEAM (MIG) WELDING

MIG welding should be used for parts where spot welding cannot be used. When carrying out seam (MIG) welding, check:

the speed
that the seam weld beads have been correctly made (alternating weld sections)

In this welding system (automatic advance seam) a protective inert gas atmosphere is used (hence the name M.I.G. which stands for Metal Inert Gas). The continuous progress of the seam (which constitutes both the electrode and the filler metal), allows long welds to be made without interruption. The flow of inert gas sent to the welding area eliminates the surrounding air preventing the oxidation of the metal and therefore has the function of providing a protective layer for the weld. For these reasons, MIG welding differs from welding carried out with a covered electrode through the absence of dross on the welding bead; also there are no pores which can occur during normal arc welding.

The use of MIG welding requires an extractor system to get rid of the fumes and harmful gases.

OPERATING METHODS

In order to weld two panels correctly using a MIG welder: grind or pickle the panel thoroughly, place the equipment in a sensible position so that whilst carrying out the welding the outer casing of the torch does not become twisted or assume positions which could hinder progress, wear protective clothing and a suitable mask with non-actinic glass (glass standard no. 8 for currents of 40/60A and no. 9 for currents of 80/200A). Ensure good electrical contact. Regulate the flow of gas according to the instructions of the equipment Manufacturer. Make two spot welds at the two edges of the join line and one at the centre, then carry out spot welds in the middle of the two sections defined in this way. The spot welds should be 25-30 mm apart.The diagram below illustrates correct welding.

the correct gap is about 1 mm.

Carrying out a weld using inert gas (MIG) for joining two matched panels.

OPERATING METHODS

It is not advisable to initially carry out a seam weld because, in addition to being difficult to do, it can cause distortion of the panel through the accumulation of heat involved.The difficulty in carrying out a weld with a single bead lies in the need to move the torch fairly slowly in order to achieve good weld penetration which is also quick enough not to incur the risk of 'burning' the panel.Moving the torch too quickly also results in a poor weld bead content because after the subsequent operations of grinding the bead the layer of material remaining is not sufficient to guarantee the resistance of the join.After the initial spot welding of the panel, the spot welds should be ground to the level of the panel using a rigid disc grinder.At this point the alignment of the panels should be checked and, if necessary, corrected using a hammer and steel dolly block.Then proceed with filling the gaps between the various spot welds carrying out alternating welding sections, keeping the torch at an angle of around 60°, (see diagram above).1. Tacking the join. The inset shows the tack welds at the rear of the panel. Grinding join tack welds.2. Carrying out the welding.3. Two alternatives are illustrated for the correct sequence of welding to be carried out to avoid deformations of the panel.The fact that the weld has been carried out correctly is confirmed from the rear of the weld bead which should show a series of spherical bumps along the entire length of the join.The MIG welder can also be used for joining overlapping panels where only one side is accessible.To carry out the welding, the panels must adhere perfectly and the torch should be kept perpendicular to the surface.In this way the action of the electrode melts the first panel initially, then the second producing a crater which is filled.In order to carry out this operation correctly, the welding machine must be adjusted to the correct current value for the thickness of the panels being worked on and pressure must be applied to the surface, with the torch resting on its supports, to faciliate the matching of the panels.Where the thickness of the panels is more than 1.5 - 2.5 mm, holes 0.6 mm in diameter must be made level with the weld spots.Carrying out inert gas (MIG) welding to join overlapping panels

1. Area where panels are joined 2. Electrode 3. Weld spot 4. Torch 5. Hole (only for thick panels)

GENERAL INSTRUCTIONS FOR EXPOSED WELDING

Below are some important instructions not be underestimated:

the incomplete penetration (p) should be 15-30% of the thickness of the panel (see diagram below
point A incorrect welding, point B correct welding).
the height of the bead (a) should be 60% of the thinnest thickness (s), the clearance (g) between the panels before welding should be 20% of the thinnest thickness for at least two thirds of the length (l) of the bead, (see diagram below, point C and detail X). The diagram indicates the value of the convexity (c) of the bead according to the length (l) of the weld.
the shape of the bead section should have a convexity (e) which depends on the length of the actual bead (see diagram below, point D).

Examples of welding.

BRAZING

Brazing is only used if the panels being replaced have been welded by this method, with the welding only carried out at the points defined by the Manufacturer. This type of welding does not guarantee mechanical properties which are comparable with the other systems described previously and therefore are not applicable for joining structural parts.

When using oxyacetylene torches for brazing, follow the safety instructions relating to their usage and be sure to work in a safe environment. The use of this welding system requires the use of an extractor system to get rid of the fumes and harmful gases.

AIR FILTRATION AND PURIFICATION SYSTEM

When carrying out operations which produce fumes, gases and dust which is dangerous to the operator, air filtration and purification systems must be used.These systems are adapted to suit the varying requirements and their size depends on the volume of air to be purified. These systems usually operate through the combined action of mechanical and electro-static filtration and purification through active charcoal. The filtration takes place in two stages; mechanically eliminating the largest particles of dust through wire gauze and then by subjecting the air flow to ionization which statically charges the particles of dust which will then be eliminated through the electro-static process.The air flow is then purified by passing through active charcoal filters. In addition to their efficiency, handling and noise levels in these systems has been improved so that they never create a nuisance.The diagram below illustrates a possible conformation decribed above.Example of a portable air filtration and penetration system

Painting the bodyshell has two fundamental objectives; protecting the surfaces of the panels from environmental attack and, from an aesthetic point of view, producing a shiny, bright colour. The large number of chemical products used in painting operations requires special care to be taken over their handling and usage.These painting operations involve the emission of paint fumes and solvent vapours which, if inhaled by the operators, can seriously affect their health and they should only be carried out in special spray booths.The operator should always wear a mask and protective clothing.These masks can be the filtration type for brief operations and the total protection pressurized type for longer operations.

EQUIPMENT

The following equipment is used during painting operations:

filltration masks and protective clothing;
masking materials and tape;
spray booths and drying ovens;
spray guns;
infra-red lamps;
polishers;

PROTECTIVE CLOTHING

When carrying out painting operations, suitable clothing should always be worn, so that the operator is well protected from contact with harmful agents.It is also advisable to use a barrier cream applied to the most exposed uncovered areas (face, hands and arms) which should be removed at the end of the painting operations. be removed at the end of the painting operations.

FILTRATION MASK

This type of mask only protects the operator's respiratory tracts, so goggles and hair protection should also be used at the same time. Its use is recommended for small retouching operations.Example of a filtration mask.

PRESSURIZED MASK

This mask guarantees protection of both the face and hair and is supplied with pure air via the compressed air system which operates the spray gun.The air is further purified with a degree of separation approaching 100% by an active charcoal filter fitted to the operator's belt.The slight excess pressure created inside the helmet prevents the infiltration of paint vapours.The use of this mask is advisable for lengthy painting operations. Example of a pressurized mask

SPRAY BOOTH

Painting and drying operations for prepared parts should be carried out in spray booths. If the extent of the damage repaired is medium to large, it is advisable to use a special spray booth and a hot air oven for drying the paint.The workplace must be equipped with an air conditoning system and filtered by purifiers, mainly consisting of renewable active charcoal filters.

The optimum painting conditions which should be maintained in the booth during painting are as follows:

constant temperature of between 22 -25 °?
constant humidity of between 75-80%

The workplace in question can be:

a combined type spray booth and drying oven;
a separate type spray booth and drying oven.

SPRAY GUNS

The development of ergonomics and spraying techniques has led to the definition of a new type high air volume and low atomization pressure spray gun where the paint mist is considerably reduced. This type of spray gun is lighter with a grip designed to reduce tiredness and the onset of cramp and has a trigger which requires far less effort than traditional spray guns. The handling of the spray gun has also been made easier through the balance and the reduced visual restriction which allows greater control when working. The most interesting aspect of this spray gun is the supply system which allows painting in any direction, even with the reservoir pointing downwards, also improving cleaning procedures with a considerable saving in time and materials. The possibility of painting from above or below in addition to preventing the formation of areas which are either too wet or too dry, facilitates access to areas of the bodywork which are difficult to reach. Special attention has been paid to the ease of adjustment which requires minimal, simple movements. This type of gun combines great efficiency with a very refined atomization capacity for any produce, even those which are water-soluble and is used at pressures of 0.7 g (10 PSI) or less. Thanks to these capacities for exploiting the painting material, considerable savings are achieved in financial terms and the working environment is improved. The diagram below illustrates several possible ways of using the gun.Using a spray gun

A. Normal method of use

SPRAY GUNS

B. Use from the bottom to the topC. Use from the top to the bottom

PORTABLE INFRA-RED LAMPS

If the operation only involves small retouches, the use of a drying oven is not advisable. In these cases the paint can be dried using special infra-red lamps fitted on parabolid mirrors. The use of one or more lamps positioned in such a way that an even temperature is produced on the surface of the area retouched, allows the drying of the paint film and produces results which are comparable to those obtained in drying ovens.These types of lamps considerably reduce the drying times, also reducing energy consumption. The lamp should only be used when the paint has undergone a degree of drying so that it is 'outside the powder' condition.Drying a retouched area using a portable infra-red lamp

POLISHERS

The operation of polishing the paint should only be carried out after drying the enamel and after the base has cooled down to ambient temperature. Polishing is also necessary if there are defects in the paintwork such as dust, paint fumes, drips, orange peel, small scratches.There are many products designed to eliminate these defects which should be applied either manually or mechanically, using a polishing machine.The tool should be held parallel to the surface to be polished and should not be held at an angle, to avoid the paint overheating and the creation of circular, concentric grooves.The diagram below illustrates the correct way of holding the polisher.Correct use of a polisher

Painting cycles

When using chemical products, follow the safety instructions from the supplier closely.

The painting operations vary according to the type of operation. The sequence of operations is described in the paragraphs which follow. There is a special procedure for the colour 'Nuvola (cloud) Light Blue'.

PAINTING A REPLACED BODY PANEL (BOLTED)

With the original part treated with cataphoresis on electro-galvanized panels.1. Clean the replacement panel, to remove any traces of dust, grease, etc. using a 'VOC' low volatile organic compound detergent product.2. Carry out a slight 'surface' dry sanding using P 220 - P 240 grade abrasive paper, using a power sander equipped with a suction system only on the panel being painted.3. Suction the dust and clean with a low 'VOC' detergent product or an anti-silicone product.4. Apply a chrome-free passivating product (wash primer) in a single coat to the areas stripped following the instructions from the supplier.5. Apply sealant through extrusion to visible panel joins/matches following the supplier's instructions (for the subsequent application of the filler).6. Apply the high/medium solid filler, prepared previously, following the supplier's instructions.7. Finish off with P 320 - P 400 grade abrasive paper, dry sanding using power sanding machines fitted with a suction system and repeat operation 3.8. Blow through the entire panel thoroughly.9. Clean the surface with an anti-static cloth.10. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions.11. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions.

Check the panel and, if there is a slight dent, fill the part concerned with filler, then dry sand it using P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system. Repeat operation 3/4.

PAINTING A REPLACED BODY PANEL (WELDED)

With the original part treated with cataphoresis on electro-galvanized panels.1. Clean the (welded) replacement panel to eliminate any dust, grease, etc. using a low 'VOC' detergent or an anti-silicone product.2. Dry sand the areas involved in the welding with P 80 - P 120 grade abrasive paper using a sanding machine fitted with a suction system.3. Carry out a slight 'surface' sanding using P 220 - P 240 grade abrasive paper using a sanding machine fitted with a suction system only on the panel involved in the painting.4. Suction the dust and clean with a low 'VOC' detergent product or an anti-silicone product.5. Apply a chrome-free passivating product (epoxide base coat) to the stripped areas following the supplier's instructions.6. Fill the join areas involved in the welding with polyester filler, following the supplier's instructions.7. Dry sand with P 100 - P 120 grade abrasive paper using a sanding machine fitted with a suction system and carry out operation 4/5.8. Apply sealant through extrusion to visible panel joins/matches following the supplier's instructions (for the subsequent application of the filler).9. Apply the high/medium solid filler, prepared previously, following the supplier's instructions.10. Finish with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system and repeat operation 3.11. Clean the surface with an anti-static cloth.12. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions.13. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions.

PAINTING A (REPAIRED) BODY PANEL

1. Dry sand the 'repaired area' with P 80 - P 180 grade abrasive paper using a sanding machine fitted with a suction system.2. Suction the dust and clean with a low 'VOC' detergent product or an anti-silicone product.3. Apply a chrome-free twin component passivating product (epoxide base coat) to the repaired area in a single coat, following the supplier's instructions.4. Fill the areas with air drying twin component polyester filler.5. Dry sand with P 100 - P 120 grade abrasive paper using a sanding machine fitted with a suction system and carry out operation 2/3.6. Apply the high/medium solid filler by shading in the filled area prepared previously, following the supplier's instructions.7. Dry sand with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system and carry out operation 2.8. Blow through the entire panel thoroughly.9. Clean the surface with an anti-static cloth.10. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions.11. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions.

Check the panel, if there is a slight dent, fill the part concerned and then dry sand with P 320 - P 400 grade abrasive paper using a power sanding machine fitted with a suction system. Repeat operation 2/3.

PAINTING (REPLACEMENT) BUMPERS

1. Clean the bumper ordered from the Parts Division to remove any traces of dust, grease, etc. using an anti-static product because it is protected by a special base coat for the subsequent painting.2. Rub down the surface to be painted, with P 360 - P 400 grade abrasive paper, using a sanding machine fitted with a suction system.3. Suction the dust and clean using a low 'VOC' anti-static product.4. Blow through the entire panel thoroughly.5. Clean the surface with an anti-static cloth.6. Apply the chrome-free twin component passivating product (plastic base coat) to all the stripped areas in a single coat, following the supplier's instructions.7. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions.8. Apply the normal or high solid twin component acrylic clear coat, prepared by the supplier.

Add elasticized clear coat, following the supplier's instructions.

PAINTING A PLASTIC(REPLACEMENT) ELEMENT (KMC COMPOUND MATERIAL)

1. Clean the bolted (plastic) part ordered from the Parts Division to remove any traces of dust, grease, etc. using a low 'VOC' detergent product or an anti-silicone product.2. Carry out a slight 'surface' dry sanding, only on the plastic involved with the painting, with P 220 - P 240 grade abrasive paper using a sanding machine fitted with a suction system. 3. Suction the dust and clean using a low 'VOC' detergent product.4. Apply high/medium solid filler, prepared previously, following the supplier's instructions.5. Finish off with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system. Repeat operation 3.6. Blow through the entire panel thoroughly.7. Clean the surface with an anti-static cloth.8. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions.9. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions.

PAINTING A NON REPLACED BODY PANEL/PLASTIC (KMC) ELEMENT 'COSMETIC CYCLE'

1 . Dry sand the panel with the defect in the PV applied, with P 360 - P 400 grade abrasive paper, using a sanding machine fitted with a suction system.2. Suction the dust and clean the panels with low 'VOC' detergent or with an anti-silicone product, whilst a low 'VOC' anti-static product should be used for plastics.3. Blow through the entire panel thoroughly.4. Clean the surface with an anti-static cloth.5. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions.6. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions.

PAINTING REPLACEMENT OF REPAIRED PANELS USING SPECIAL 'NUVOLA' MICALIZED ENAMEL

'Nuvola' micalized enamel is a special colour with a CHANGING/PEARLESCENT appearance. The iridescent effect is achieved through a special enamel containing particles of mica coated in iridescent colourings; this type of enamel is an almost transparent paint which adds a pearlescent appearance to the base colour which shows through and gives the tone.

PAINTING A REPLACEMENT PANEL (WITH THE ORIGINAL PART TREATED WITH CATAPHORESIS)

Operating cycle for 'Nuvola' micalized enamel with iridescent colourings. 1. Clean the replacement panel to remove any traces of dust, grease, etc. using low 'VOC' detergents.2. If there is accidental rust due to storage, grind the area until the panel is stripped.3. Slightly dry sand the 'surface' of only the part of the panel involved in the painting, using 220 grade abrasive paper using a sanding machine fitted with a suction system.4. Clean the exposed part of the panel using a low 'VOC' detergent. 5. Blow through the entire panel with compressed air. 6. Apply the chrome-free twin component passivating product by spraying in a single coat. (film thickness from 5 -10 micron).7 . Apply plastic sealants to the joins where applied originally (see specific cycle in Notes chapter).8. Apply High Solid twin component filler, by spraying in two cross coats, with an interval of several minutes according to the desired thickness.9. Wait for 10 - 15 minutes before starting the drying.10 . Dry the primer in an oven at a temperature of 40°....60° ? f?? 30 - 40 minutes. (Film thickness from 70....80 micron; hardness F-H).11. Dry sand the element sprayed with suction using 400 grade abrasive paper. Make sure that the element is at ambient temperature for this operation.12. Blow with compressed air.13. Clean with low 'VOC' detergents and polish with an anti-static cloth.14. Apply a cross coat of twin layer pastel enamel.15. Dry for 10-15 minutes at ambient temperature (20°?) and then dry in an oven at a temperature of (60°?) for 40 minutes.16. Dry sand the element sprayed with suction using 800 grade abrasive paper. Make sure that the element is at ambient temperature for this operation.17. Blow with compressed air.18. Clean with low 'VOC' detergents and polish with an anti-static cloth.19. Apply the 'Nuvovla' base coat by spraying one light coat and four normal coats at intervals of several minutes then follow with a light, faded-in coat to even the paint (film thickness around 30 micron).20. Drying for 15-20 minutes at a temperature of 20°C. - 21. Application of normal or high solid twin component acrylic clear coat.22. For normal clear coat: spray a light coat followed by two coats at intervals of several minutes. 23. For High Solid clear coat: spray a light coat followed by another coat with an interval of several minutes. 24. Dry for 15......20 minutes at ambient temperature (20°?) and then dry in an oven at a temperature of 60°C for 40 minutes (film thickness 40....50 micron; hardness HB-F).25. Possible mechanical or manual polishing of the retouch or the painted panel (or the adjacent area) with fine grade abrasive paste and/or polish.

It is advisable to carry out this operation at least 24 hours after drying.

PAINTING A REPAIRED - RETOUCHED PANEL (OPERATION ON BARE PANEL)

Operating cycle for 'Nuvola' micalized enamel with iridescent colourings.1. Sand the area to be retouched using 150 - 220 grade abrasive paper taking care to level the surrounding area and eliminate any traces of corrosion on the exposed panel.2. Clean the exposed part of the panel and the surrounding area overhauled with low 'VOC' detergent.3. Blow through with compressed air.4. Apply the chrome-free twin component passivating product to the exposed areas of the panel by spraying in a single coat. (Film thickness from 5 - 10 micron).5. Possible filling with air drying twin component polyester product.6. Dry overhauling with suction of the area filled with 80 - 120 grade abrasive paper.7. Blow through with compressed air.8. Wash the sanded area with low 'VOC' detergents.9. Further application of the twin component passivating product on the areas of the panel exposed during sanding by spraying a single coat.10. Application of High Solid twin component filler by spraying 2....4 cross coats, with intervals of several minutes according to the desired thickness.11. Wait for 10 - 15 minutes before starting the drying.12. Drying of base coat with infra-red lamps.13. Initial distance 50 - 60 cm. for a period of 5 minutes; then place the lamp 35 - 40 cm away for 15 minutes. (Film thickness from 80 to 150 microns). hardness F-H). Alternatively, dry in an oven at a temperature of 60°C for 40 minutes.14. Dry sand the element sprayed with suction using 400 grade abrasive paper. Make sure that the element is at ambient temperature for this operation.15. Blow with compressed air.16. Clean with low 'VOC' detergent.17. Polish with an anti-static cloth.18. Carry out the cycle for replacement panels from point 1.12 to point 1.20.

PAINTING THERMO-PLASTIC MATERIAL COMPONENTS (OPERATIONS ON REPLACEMENT PARTS)

On the model in question, these parts are the: Bumper, Miniskirts.Operating cycle for 'Nuvola' micalized enamel with iridescent colourings.1. Apply the adhesion promoter (primer) for thermo-plastic materials.2. Carry out the cycle for replacement panels from point 1.12 to point 1.20.

PAINTING THERMO-HARDENING MATERIAL COMPONENTS (OPERATIONS ON REPLACEMENT PARTS)

On the model in question, the part involved is the fuel filler. Operating cycle for 'Nuvola' micalized enamel with iridescent colourings. 1. Carry out the cycle for replacement panels from point 1.7 to point 1.20.

All the operations of sprying the passivating product, the filler and the enamels should be carried out in a spray booth after having masked the area surrounding the component involved. Base coats, filler, enamels and solvents should be handled and used in well ventilated areas. Special solvents with a maximum of 3% toluene and xylene should be used for cleaning the equipment. Before carrying out any polishing, make sure that the panel and he surrounding area are at ambient temperature. Before spot welding panels, apply electro-weldable galvanizing protective (PPG D 386 - 459632 or an equivalent product) to the ground edges of the join area.

Renewing the anti-corrosion treatments, sound insulation and sealants.

The treatments to which the bodyshell is subjected to achieve the necessary resistance characteristics to corrosion, sound insulation and sealing can be damaged or destroyed by repair operations.They should therefore be renewed, as appropriate during the repair operations, so that the vehicle is restored to its original condition.

EQUIPMENT

The following equipment is used:

power guns for sealant product extrusion;
foam injection systems;
wax based oil injection systems;

In box sections which have been replaced or repaired by welding or overheating, the internal anti-corrosion protection must be renewed through:

the application of rust converter in the overheated or welded areas which require drying for at least 24 hours at ambient temperature (20 °C);
the application of wax based protection in the replaced or repaired box section (type PPG 853.764 or equivalent product);
Renew the rigid type expanded polyurethane foam in the box sections (e.g.: Schiuma - fix from BOSTON, Schiumal P.U.R. from TORGGLER - Merano or an equivalent product);
Where necessary, restore the sealing of the joins;
Carry out the sealing, following the instructions given below, in the flanges of the moving parts (tailgates, lids) supplied as spares; on a replaced component treated with cataphoresis, clean the areas involved with heptane or anti-silicon/anti-static solvents;
Apply a bead of SIKAFLEX 221 type polyurethane sealant manufactured by SIKA (*) in the shape and position illustrated in the diagram;
Leave the sealant to dry for 24 hours at ambient temperature (20 °C) or 40 minutes at 60 °C; - Carry out the normal painting of the component. Apply sound-deadening paint on external parts which have been replaced or repaired, as required.

(*) Alternatively, use a similar product manufactured by 3M or other equivalent products, following the supplier's instructions.Example of application of sealant

A. Sealant

EQUIPMENT

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user.