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.- Use a rotary brush to remove the paint and gain access to the spot welds.- Remove the pillar from the vehicle.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 and gain access to the spot welds.3. 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.4. Remove the cut part of the outer component shown in the diagram.
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 and gain access to the spot welds.2. Use the chamfering machine to remove the spot welds shown in the diagram.- Use the drill to chamfer the spot welds that are not accessible to the chamfering machine.- Use a hammer and chisel to remove the previously chamfered spot welds.3. Remove the cut part of the outer component shown in the diagram.
- 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.2. Remove the upper part of the pillar (inner piece).
- Use a rotary brush to remove the paint and gain access to the spot welds.1. Use the chamfering machine on the spot welds shown in the diagram.- Use a hammer and chisel to remove the previously chamfered spot welds.2. Remove the outer offcut from the vehicle.
To remove the remaining part offcuts, proceed as follows:- 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.2. Remove the offcut from the vehicle.
- Straighten the edges of the vehicle using a hammer and dolly block.- Remove the spot weld residues using a disc grinder.- Use a rotary brush to clean the previously treated areas.1. Apply electro-galvanizing paint.
Refitting
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Removing
)
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. Use a spot welder to weld the areas shown in the diagram.3. Use the MIG welder to weld 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 previously welded areas.
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. 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 the part at the indicated points.- 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. Make a few tack welds along the door housings.3. Use a spot welder to weld the areas shown in the diagram.4. Use a MIG welder to 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 previously welded areas.
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. 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.- 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 to weld the areas shown in the diagram.3. Use an MIG welder to seam-weld in the join areas.
1. Use a spot welder to weld the areas shown in the diagram.2. Use an 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 previously welded areas.
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.
Removing
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Refitting
)
Op. 7210E38 R.R. REAR SIDE DOOR Op. 7210E56 R.R. TAILGATE Op. 7210E28 R.R. ROOF PANEL Op. 7210B18 R.R. ROOF PANEL SUPPORTING CROSSMEMBER - Ensure that the components connected are not distorted by checking the bodyshell alignment measurements with suitable equipment (gauges, templates or jigs).- Straighten the body as necessary.
