BODY - SHEET METAL PANELS GROUP 4Q CONTENTS GENERAL INFORMATION......... 49-2 Outer valance reinforcement. . 49:37 Identification data........ + 492 Front valance with valance extension Lifting points. . . 493 and outer valance reinforcement Wheel alignment. - 493 removed... . 66.0545 seneee 49-39 Tow hook installation ........ 49-4 Bracket connecting body side to BODY COMPONENT PARTS. - 495 beam with front fender removed ... 49-41 Body components . . 495 Front pillar with front fender Underbody components. 496 9. removed... eee eee 49.43 ad BODY CONSTRUCTION . 49-7 Windscreen rim (pillar partial Boxed part sections ............, 49-7 replacement) .. - 49-45 BODY SEALING... bene wees 498 Central pillar and central pillar boxed Description 49-8 section . 49-47 BODY ALIGNMENT... .. 4912 Door under-trim. . 49-49 Measurement operations . . 4912 Rear fender ...... » 49-51 Measurement points. ...... 49-13, Rear panel wees on .. 49-53 CAUTIONS FOR THE OPERATORS .. 49-15 Bumper connection reinforcement Safety rules ........ vee 49-15 beam with rear fender and rear panel Body and outer components FEMOVED . eee eee eee eee eee 49-55 Protections. ... 6.6... ese eee eee 49-15, Luggage compartment floor with Cautions during replacement rear panel removed. 49-56 operations... 2... 6s. eee eee . 49-16 Rear window lower panel. . . . 49-58 Cautions during welding operations. 49-16 Outer rear wheelarch with rear REPLACEMENT OPERATIONS. . . 49-21 fender removed 49-59 How to read this chapter . 49-21 Body side frame upper part....... 49-61 Symbols... errr . 49-22 Body side rear frame with rear Removal and installation procedures 49-23 fender removed ................ 49-63 Front cross member assembly with Roof ....... teens 4965 headlight support plate .......... 49-29 Windscreen rim with fender, Radiator support cross member .... 49-31 bonnet hinge and roof removed.... 49-69 Headlight support plate ..... . 49-33 Rear window upper cross member Valance extension . . cote eee, 49:35 with roof removed... . . 49-69 PA37140000000 May 1985BODY ~ SHEET METAL PANELS GENERAL IDENTIFICATION DATA IWentification label (identitestion number and Type approval umber! Identification and certification label Refer to Group 00 May 1985 INFORMATION : Service and Identification Data. —, WY LLussage compartment | floor abet (Chassin | type approval number pd serial number) | VY Chassis No. (according to CEE/ISO standard specifications) Refer to Group 00 - Service and Identification Data VY PA37140000000BODY — SHEET METAL PANELS LIFTING POINTS a ae —— —— tl eves ~ wa LON! JT Jack and safety stands WARNING: 4. After lifting the car by means of hydraulic jack, provide to support car weight by means of safety stands. b. Before lifting ear roar (front) side place whee! ‘chocks by positioning them at front (rear) wheels. Securely position hydraulic jack and safety stands in the points identified in figure. Axles and suspensions WHEEL ALIGNMENT CAUTION: ‘The technicians assigned to the repair and replacement ‘operations of sheet panels, shall always take into account, content of the re of the “Workshop Manual’ in order always tom original quality and fune- tioning conditions of car as a whole, As restoration of ‘car correct alignment is of particular importance, in the following part are provided the data relevant to geometry ‘of both front and rear suspensions. For any further information, refer to the sp ic Group Moder CS Inspection data eaten IGE Ea csoatse) A (@) BV Hon) ESTO Toeaut (€:0) mein £1 (0.039 #0039) 24110078 #0.050) TToravt ange @ ° “Town ange an) O10 Wheeiim diameter Omi) | e403 | RITA) 0139) 265 (144 camber ange 8 = 90" #30 Comber engie ae) o 200 Coster anal 7 Fa tar Fa0 #0 #30290 ox steering ook 3 3 ("1 For rear wheels only Tra) Not prewnt on EE) version 1.8. hoe aignent refers to vice in norsina eight (refer to Group OO} pa371400000002 49-3 January 1987 i a ec a 7 bn teBODY — SHEET METAL PANELS TOW HOOK INSTALLATION CONNECTION TO BODY The diagram shows the tow hook connection points. Positions of ‘sonnsction points must not be changed regardles of shape and dimension of tow hook. Side view: for Side view: for CZESE235) only assrement unit: mm fn) ‘Mesurement ent: mm (in) 70 2786) § 117 046) 5 8 = 4 ey | : dO, R i S=- , 77 PE] = 3 ft < comnineoun psn bt 3, Welding inspection The inspection procedure is similar to the spot welding 49-20 PA37140000000BODY — SHEET METAL PANELS REPLACEMENT OPERATIONS HOW TO READ THIS CHAPTER Spare par of the sheet metal panels of body, will not necessarily be supplied as shown in the figures below. The formulation of the present part of the manual is uniform for all the replacement operations. For its structure, refer to the following example: (i) LUGGAGE COMPARTMENT FLOOR WITH REAR PANEL REMOVED _{IV)ReuMocR nan nanowine In detail (I) LUGGAGE COMPARTMENT FLOOR WITH REAR PANEL REMOVED In the title it is indicated the element to be removed (luggage compartment floor) specifying, if required, the operative condition (in this case, rear panel removed). If the element is not in the required conditions, it is necessary, to execute preliminary removal of the other components; in this case, itis necessary to remove the ‘reat panel”, referring to the specific replacement procedures. (1) SERVICE JOINTS ‘Any Information concerning the welding operations to be carried out is shown in the figure indicating the welding method and the spot numbers, together with accurate location of spots on the elements to be joined. Example: a ® 3—Welding spot number \_ Welding type (spot welding: see see symbols on page 49-22) Parts to be welded ‘The welding spots applied by Manufacturer will be pro- vided along the text, The number of welding spots per PA37140000000 49-21 formed in the Service Workshops should be increased by 20 to 30% , since the efficiency of welders used in the Service Workshops is lower than that used by Manufac- turer. Where necessary, the parts represented by chain line, set in evidence the componants which must result to be removed or for which the preliminary removal is required according to step (I), (Wl) PARTS TO BE WELDED A list is provided relevant to the component which are to be welded using the methods indicated in step «0. (IV) REMINDER WHEN REMOVING/ INSTALLING Indication is provided, relevant to the main opera tions to be carried out, with special care in the identification of the areas concerned in the cut operations, selection of the equipment to be used and definition of welding methods to be adopted A decisive factor to perform a perfect replacement of @ sheet panel, is however strictly linked to the experience of the personnel in charge of the operation. The indications siven refer to particular operations for the and ‘must be considered as simple integrative information. May 1985BODY — SHEET METAL PANELS SYMBOLS CUTTING AND WELDING/BRAZING OPERATIONS ‘The symbols used for the cutting and welding/brazing operations are shown in the following figures. MWWW Cutting performed by means of air saw or air chisel eoce Spot welding Spot welding [So00 Spot welding ‘Three overlapped panels of three over lwnoed soem} note: The value in parenthesis () indicates the number of weld spots co; welding MIG seam weld/point weld Brazing Sealing May 1985 49-22 PA37140000000BODY — SHEET METAL PANELS REMOVAL AND INSTALLATION PROCEDURES COMPONENT REMOVAL (1) Make sure that all the damaged parts have been detected by measuring the installation main dimensions. Refer to “Body Alignment” drawing. Tools required: © Centering gauge Tracking gauge , © Convex rule © Rack-andt-lever jack or ear lift (2) With » body-frame repair system, carry out draw operations, depending on deformation condition. Reuse of the reclaimable parts must be performed in accordance with the figures contained in "Body Alignment’ Caution during operation: Carefully secure drawing chains to body and equip. ment, so as to prevent accidental release during ‘operation execution. © Apply draw stress in the direction opposite to collision. PA37140000000 49-23 (8) Cut-off damaged parts Tools requi © Airsaw © Air chisel (4) If welding spots are not visible, remove paint by means of rotary wire brush Tools required: © Rotary wire brush (6) Punch all the welding spots in order to make center ing of a drill Tools required: © Hammer © Center punch May 1985BODY — SHEET METAL PANELS Caution during operation ‘© Punch deeply in the center of each, welding spot. A non-centered punch does not allow complete cut of ‘nugget. Besides, a shallow marked hole location does not allow a reliable drive of drill ‘* Asa rule, punching must be executed from sides of ‘the components that are to be removed. Holes must have diameter J), low 8mm 10.31 i) (6) Remove welding spots by means of a spot cutter or an air drill Tools required: * Spot cutter © Air drill Caution during operat * Use a drill speed of about 1000 r.p.m. in order to ‘obtain the best results. Cautions during operation: ‘* Take care not to drill mating parts. In case holes have been made, plug them making use of autogenous or projection welding Presence of holes, decreases strength of the concerned ‘component, may generate water leakage. © When, for new components, are used holes already drilled in welded parts (just as per those of the spot welding) make use of a drilling machine having small diameter drill (below 8 mm ~ 0,31 in) and complete ‘welding as soon as possible. May 1985 49-24 E. replace door under tri leaving central pill in ts original position (7) By means of @ chisel remove the remaining spot welding parts Tools required © Chisel © Hammer PREPARATION FOR MATING PARTS INSTALLATION (1). By means of a sander, grind sheet in correspondence with welding spots Tools required: © Airsander © Disc sander Cautions when grinding ‘© Take care not to cut much on base metal: this may generate decreate of sheet thickness and, then, welding strength. INCORRECT CORRECT PA37140000000BODY — SHEET METAL PANELS ‘© Carefully remove iron powder from the surfaces which have been grinded and from surrounding areas. Presence of iron powder, causes decrease of welding efficacy and can also generate corrosion. (2) By means of a hammer and dolly correct deformed areas, Tools required: © Hammer © Dolly ‘Cautions during ope tor '* Check against presence of even the smallest deforma- tions, in particular, in the inner panels where they hhard to be found. Infact, if they are not removed, they can cause a strength decrease due to stress concentration. oe Carefully check mating parts of each pillar (3) Remove paint from welding edges. Tools required: © Belt sander ‘© Disc sander PA37140000000 (4) Apply primer to edges of new components and of body panels which are to be welded, 49-25 Before welding apply conductive antirust paint on edges Of all sheet parts which are to be assembled Recommended paint: Std. No. 3640-44401 SAVID: Zincovid No. 7949 SCHRAM LACK: Extrinum Punktschweissfarbe GLASURIT: Glassomax 7 F 4625 (red color) * * Tobe used with catalyst Glassomax Harter 965:7/1 in the proportion 1:10 (Std. No. 3514-20003) Panels must be welded within 15 minutes of the paint application (air drying time of paint film). The film thickness after drying must be 0.005 to 0.025 May 1985BODY — SHEET METAL PANELS PREPARATION INSTALLATION (1) If a partial replacement is to be carried out, it is necessary to maintain an overlapping tolerance of about '50 mm (1.97 in) during cut of non-usable sheets; in order ‘to have a sufficient mating surface FOR NEW COMPONENT Tools required: © Airsaw © Hack saw © Tracking gauge Convex rule (or equivalent) It is recommanded always to use genuine spare parts. This ensures a perfect repair and restoration of vehicle fune- tioning Overlapping (2) MIG plug weld This method must be used for those areas which can not be reached by spot welder. To carry out this opera tion, drill, in the welding spots, making holes having 5 t0 6 mm (0.20 to 0.24 in) dia, Tools required ‘= Puncher © Airditl (3) Remove paint from components to be welded, Tools required: © Belt sander © Disc sander May 1985 49-26 Cautions during operation: ‘* Remove paint from both sides of components that are to be welded, such as the surfaces to be spot welded, spot welding rims and edges of surfaces to be butt welded. The remaining paint, prevents current flowing into spot weldings, with consequent poor strongth of spot. It can also generate depressions in the plug MIG welding (4) Apply primer to component and body surfaces which are to be spot welded. Tools required: © Wire brush Conductive antirust paint INSTALLATION (1) New service parts temporary instalation. Tools requir Vise pliers Convex rule Tracking gauge (sight) Centering gauge Power supply unit Jack Spot welder Mig welder 437140000000BODY — SHEET METAL PANELS ear window Boot Ta Cautions during operation: + Position components as per figures provided in “Body Alignment”. Install the movable parts into body compartments, (windsereen, doors, bonnet, boot lid) des and parallelism. If necessary, adjust sheets until correct alignment is obtained. ‘© Clamp parts to be welded by means of pliers and some welding spot. (2) Execution of the required weldings Carry out welding complying with specifications provided in “Cautions during Welding Operations” Tools required: Spot welder MIG welder ‘© Autogenous welder (3) Grind MIG welding by means of @ sander machine. Tools required: © Ai sander © Dise sander CORRECT INCORRECT Cautions during operation: ‘© Take care not to grind excessively on spot weldings: it may generate decrease of sheet thickness and, consequently, welding strength © Remove iron powder from grinded surfaces and surrounding areas. Presence of iron powder, causes decrease of welding efficacy and can also generate corrosion. (4) After welding, remove clamps used for securing edges and remove possible dinging. 437140000000 49-27 May 1985BODY — SHEET METAL PANELS (7) For under body protection, apply 2 coat having 4 mm (5) Apply anticorrosion agent to the welded compo. (0.16 in) thickness. nents. (6) Apply sealant to joints ‘This operation must be carried out carefully in order to Antidrum: part. No. 3523-00001 prevent corrosion in the welded joints. Alternatives: 3M Refer to figures provided in "Body Sealing” Body Plast 8874 E Body Schutz 8864 E IVE Grey protective acrylic 854751 May 1985 49-28 pA37 140000000BODY — SHEET METAL PANELS FRONT CROSS MEMBER ASSEMBLY WITH HEADLIGHT SUPPORT PLATE Service joints Parts to be welded a. Front cross member assembly and valance extension b. Front headlight support plate and outer valance reinforcement ¢. Front headlight support plate and outer valance reinforcement and valance reinforcement REMINDER WHEN REMOVING By means of air chisel, cut according to lines A and B. PA37 140000000 49-29 Headlight support plate and valance extension ,. Front cross member assembly, headlight support plate and valance extension Front cross member assembly and connection sheet May 1985BODY — SHEET METAL PANELS © By means of a dil, remove the welding spots of the REMINDER WHEN INSTALLING three-overlapping sheets. ‘© MIG weld the three-overlapping sheets. May 1985 49-30 P437140000000BODY — SHEET METAL PANELS RADIATOR SUPPORT CROSS MEMBER Service joints Parts to be welded @ Radiator support cross member and front cross member assembly b. Radiator support cross member and valance extension REMINDER WHEN REMOVING ‘© Cut cross member with air saw according to lines A. and B. 437140000000 49-31 Radiator support cross_member and connection angular panel May 1985BODY — SHEET METAL PANELS — May 1985 49-32 PA37 140000000BODY — SHEET METAL PANELS HEADLIGHT SUPPORT PLATE Service joints Parts to be welded a, Headlight support plate and valance extension Headlight support plate and front cross member b. Headlight support plate and front cross member assembly assembly {. Headlight support plate and valance extension © Headlight support plate and outer valance ‘eintor- 9. Headlight support plate, front eross member assembly cement and valance extension d_ Headlight support plate, outer valance reinforcement and valance extension REMINDER WHEN REMOVING * By means of air saw, cut according to lines A, B and PA37140000000 49-33 ee) May 1985BODY — SHEET METAL PANELS ‘+ By means of a drill, remove the welding spots of the REMINDER WHEN INSTALLING three overlapping sheets. © MIG plug weld the three overlapping sheets from both sides, May 1985 49-34 PA37 140000000BODY — SHEET METAL PANELS VALANCE EXTENSION First remove the Headlight Support Plate, then carry out replacement (Refer to page 49-33), Service joints Parts to be welded Valance extension and outer front valance reinforce- _—¢. Valance extension and outer front valance ment d. Valance extension and connection angular panel b. Valance extension, outer front valance reinforcement and outer front valance REMINDER WHEN REMOVING © By means of air saw, cut according to line A. PA37 140000000 49-35 May 1985BODY — SHEET METAL PANELS © By means of a drill, remove welding spots from the REMINDER WHEN INSTALLING three overlapping sheets. © MIG plug wold the three overlapping sheets from both sides. May 1985 49-36 PA37 140000000BODY — SHEET METAL PANELS OUTER VALANCE REINFORCEMENT Service joints Parts to be welded Outer valance reinforcement and dashboard sidewall Outer valance reinforcement and dashboard sidewall Outer valance reinforcement and cowl top Outer valance reinforcement and dashboard sidewall Outer valance reinforcement and valance extension Outer valance reinforcement, valance, and valance extension 9 Outer valance reinforcement and headlight support plate PA37140000000 peosar 49-37 Outer valance reinforcement and headlight support plate Outer valance reinforcement and outer front valance Outer valance reinforcement and outer front valance Outer valance reinforcement and outer front valance Outer valance reinforcement and outer front valance Outer valance reinforcement, headlight support plate and valance extension Outer valance reinforcement and headlight support plate May 1985BODY — SHEET METAL PANELS REMINDER WHEN REMOVING REMINDER WHEN INSTALLING CS © Use an air chisel, and cut the outer valanee reinforce ‘© Drill (6 to 6 mm - 0.20 to 0.24 in dia) the component ment according to the line A shown in the figure in the points where the plug weldings are to be : performed. = Execute plug welding in the points that can not be accessed by welder, VY + Remove the component from body by removing the welding spots with an air chisel fitted with the : appropriate tool. May 1985 49-38 P37 140000000BODY — SHEET METAL PANELS FRONT VALANCE WITH VALANCE EXTENSION AND OUTER VALANCE REINFORCEMENT REMOVED Replacement is to be performed after having removed the Valance Extension and the Outer Valance Reinforcement. Service joints View from A Parts to be welded a. Outer front valance and dashboard sidewall ‘Outer front valance and central beam Inner front valance and central beam Inner front valance and central beam Inner front valance and outer valance reinforcement Inner front valance and central floor Inner front valance and dashboard sidewall Inner front valance and central beam. PA37140000000 49-39 May 1985BODY — SHEET METAL PANELS REMINDER WHEN REMOVING ‘+ Operating from the engine compartment side, use an air chisel to cut the inner front valance following the ‘race shown in the figure. REMINDER WHEN INSTALLING Operating at bench, assemble the outer front valance and lower reinforcement between dashboard and valance. Spot weld following the indications given in the figure. ‘+ By means of an air chisel, cut the outer front valance following the trace shown in the figura * By means of a pneumatic drilling machine, remove the welding spots and the remaining edges of the component to be replaced May 1985 49-40 Parts to be welded 2. Lower reinforcement between dashboard and valance, ‘and outer front valance © Drill the component (5 t0 6 mm - 020 to 0.24in dia.) in the points to be plug welded ‘* Plug weld in the points that can not be accessed by welder. Welding of the outer front valance with the dashboard sidewall must be executed by operating from inside the passenger compartment. Pa37140000000BODY — SHEET METAL PANELS BRACKET CONNECTING BODY SIDE WITH FRONT FENDER REMOVED Replacement is to be carried out after having removed the Front Fender. Service joints Parts to be welded Bracket connecting body side to beam, inner front valanee, and outer valance reinforcement b. Bracket connecting body side to beam, dashboard sidewall, and outer valance reinforcement c. Bracket connecting body side to beam, and central valance reinforcement REMINDER WHEN REMOVING © Use a metal brush to carefully remove the sealing compound from bracket to permit the previous ‘welding spots to be identified. PA37140000000 4, Bracket connecting body side to beam and front pillar Bracket connecting body side to beam and dashboard sidewall May 1985BODY — SHEET METAL PANELS © By means of @ drilling machine remove the welding REMINDER WHEN INSTALLING spots, and remove the bracket connecting body side to beam from body. Drill the component in the points which are to be MIG plug welded. May 1995 49-42 pas? 40000000BODY — SHEET METAL PANELS FRONT PILLAR WITH FRONT FENDER REMOVED Replacement is to be carried out after having removed Front Fender, Windscreen Rim Pillar, and Bracket Connecting Body Side to Beam Service joints y \ Front pillar frame Body side vim Parts to be welded: a. Front pillar and dashboard sidewall b._ Front pillar and front pillar frame REMINDER WHEN REMOVING ‘© Use an air chisel to eut according to line A shown in the figure, Pa37140000000 Front pillar and front pillar frame 49-43 May 1985BODY — SHEET METAL PANELS © Remove the welding spots, and remove the compo- nent to be replaced. REMINDER WHEN INSTALLING ‘+ Install the new pillar on body. ‘© Weld the connecting sheet panel to pillar © Temporarily secure the drip to front pillar and verity that the clearance of windscreen corner is correct. © Weld the drip to front pillar following the indications given in the figure below. Sect A Parts to be walded 4d, Connecting sheet panel and front pillar May 1985 49-44 @. Front pillar and drip, PA37140000000 ‘1BODY — SHEET METAL PANELS WINDSCREEN RIM (pillar partial replacement) Replacement is to be carried out after having removed Front Fender and Bonnet Hinge. Service joints Parts to be welded 4. Windscreen rim, front pillar frame, and body side rim Windscreen rim and drip REMINDER WHEN REMOVING '* Cut the windscreen rim eccording to the lines A and B shown in the figure. When cutting according to line A, cut 30mm (1.18 in) underneath the junction between roof and windscreen rim, taking eare not to damage the body side, 437140000000 49-45 Windscreen rim and front pillar d. Windscreen rim and dashboard sidewall 30 mm (1.189) May 1985BODY — SHEET METAL PANELS ‘¢ Lift the tab connecting windsereen rim and front. REMINDER WHEN INSTALLING velance © Adapt the new body side rim part to butt weld oat it to body. ‘© Drill the new component in the points to be MIG plug welded. '* Correctly place the windscreen rim on body, inserting the tab into the special slot on front valance, © Bend the tab, WV + Use an air saw to remove the remaining edges of windsereen rim from body. <7 May 1985 49-46 PA37 140000000YS BODY — SHEET METAL PANELS CENTRAL PILLAR AND CENTRAL PILLAR BOXED SECTION Service joints Parts to be welded 2. Central pillar and door under-trim Centra pillar and pillar boxed section b. Central pillar, door under-trim, and central floor e, Central pillar, body side, and drip ©. Pillar and pillar boxed section . f. Central pillar and body side rim REMINDER WHEN REMOVING © By means of an air chisel, cut the central pillar (complete with related boxed section) according to the lines A and 8 shown in the figure. PA37 140000000 49-47 May 1985BODY — SHEET METAL PANELS © Use a drilling machine to cut the welding spots © By means of a hacksaw adapt the pillar boxed section ‘and remove the remaining pieces (upper and lower) of 10 body to butt weld it to body side. pillar and boxed section from body. ‘© Position the pillar on body by tack welding it Drill the pillar for the following MIG plug welding © Tack weld the adjacent components such as front and rear doors, (Check clearances, angles and parallelisms. Sect. AA REMINDER WHEN INSTALLING © Operating at bench, assemble the central pillar and related boxed section [new]. Spot weld by following the indications given in the figure '* Complete the fixing of pillar complete with boxed section, to body, Parts to be welded ‘8. Central pillar and central pillar boxed section May 1985 49-48 PA37140000000 \BODY — SHEET METAL PANELS DOOR UNDER -TRIM Service joints LTS) = vs iy ml Parts to be welded ‘4. Door under-trim and central pillar Door under-trim, dashboard sidewall, and inner side Door under-trim, central pillar, and inner side mem member ber 4 Door undertrim and body side lower side member ©. Door undertrim and inner side member frame 4. Door under-trim and dashboard sidewall h Door under-trim and central pillar @ Door under-trim, inner side member, and inner j.__Door under-trim and inner side member Ww rear wheelarch | Door under-trim and outer rear wheelarch REMINDER WHEN REMOVING By means of an air chisel, cut the door under-trim ‘secording to line A, shown in the figure. When cutting, take care not to damage the adjacent components rear edge of door under-trim at =15 mm approx. from junction with rear fender. In this way, the fender will not be damaged as well 3s ah the related sel. as al 15mm (059 in) — wy PA37140000000 49-49 May 1985 aBODY — SHEET METAL PANELS ‘+ Use an air chisel to cut the body side taking care not to damage the central pillar. * Remove the welding spots and the remaining pieces of door under-trim from body, REMINDER WHEN INSTALLING Cut the door under-trim aligned with connecting sheet panels CAUTION: Should one of the trim under door be replaced, proceed at follows in order to correctly install the under-door plastic strips: 1. Operating at the bench, position the new under-door strips on the new door under-trim and using strips ‘themselves as templates, mark off the centres for holes A and B. 2. Drill taking into account that diameter of A type holes is 8 mm (0.31 in}, while diameter of B type holes is 7 mm (0.27 in) 3. Deburr all holes, then apply antirust agent Std. No. 3540-44401 to hol section. and inside the boxed 4, Weld and paint the door under-trim. 5. 0 ing on the upper section of door under-trim, insert the five nut screws (3) into B holes, and by ‘operating on the lower section, insert the five but tons (1) and a nut sorew (2 into holes, beng the nut serew in the junction’ area of plastic strips (SECT.D-D) DRILLING THE DOOR UNDER - TRIM - TOP VIEW Ke secr.ce SECT. £€ 1 Expansion button 2 Nutcrew 3 Nut ecrew January 1987 49-50 PA371400000002 VY GBODY — SHEET METAL PANELS REAR FENDER Service joints Parts to be welded PA37140000000 Rear fender, body side frame upper part, and body side rear frame Rear fender, inner rear wheelarch, and body side rear, frame Rear fender, outer rear wheeareh, and body side rear frame Rear fender and door under-trim ° Rear fender and outer rear wheelarch 4 Rear fender and outer rear wheelarch f Rear fender, luggage compartment floor, and bumper s. connection reinforcement beam t Rear fender, luggage compartment flooi, and inner u rear whearch Rear fender, rear panel, and bumper connection 49-51 reinforcement beam Rear fender and outer rear wheelarch Rear fender, luggage compartment floor, and bumper cconneetion reinforcement beam Rear fender, boot lid drip end, and bulkhead behind the seat Rear fender and rear window lower panel Rear fender and rear pane! Rear fender and body side frame upper part Rear fender and roof Fear fender, roof, and drip Rear fender, inner rear wheelarch, and luggage compartment floor Rear fender, roof, and body side frame upper part May 1985BODY — SHEET METAL PANELS REMINDER WHEN REMOVING + By means of an air saw, cut the fender according to the lines shown in the figure taking care not to ‘damage the components underneath, © Remove the welding spots (with pneumatic drilling machine or air chisel with appropriate tool) and detach the remaining edges of fender from body. ‘© Use an air chisel fitted with suitable tip. to remove ‘the edges of fender remained on body. REMINDER WHEN INSTALLING + By means of clips, temporarily secure rear fender to body, ‘Temporarily secure the adjacent components such as rear door and boot lid. CCheck clearances angles and paralelisms. MIG plug weld the three overlapping sheets from both sides Apply the sealing compound on wheelarch outer side. — A, May 1985 49-52 PA37 140000000 VY r SsBODY — SHEET METAL PANELS REAL PANEL Service joints VY Parts to be welded 2. Rear panel and luggage compartment floor © Rear panel, rear fender, and bumper connection \ bear panel and rear fender reinforcement beam REMINDER WHEN REMOVING * By means of an air saw, cut the rear panel according to the line A shown in the figure. Ww PA37140000000 49-53 May 1985BODY — SHEET METAL PANELS ‘© By means of an air saw remove the welding spots and the remaining pieces of rear panel from rear fenders ‘and luggage compartment floor. REMINDER WHEN INSTALLING ‘Temporarily secure the rear panel to body. May 1985 49- ‘© Temporarily secure the boot lid assembly to body Check clearances, angles and paralelisms, — Check thet bumper is correctly positioned and aligned. 54 PA37140000000BODY — SHEET METAL PANELS BUMPER CONNECTION REINFORCEMENT BEAM WITH REAR FENDER AND REAR PANEL REMOVED Removal is to be carried out after having removed Rear Fender and Rear Panel Service joints Parts to be welded ‘a. Bumper connection reinforcement beam and inner _b, Bumper connection reinforcement beam and outer rear wheelarch rear wheelarch REMINDER WHEN REMOVING REMINDER WHEN INSTALLING © Use an air saw to cut according to lines A and 8 When installing, tack weld the beam to luggage shown in the figure compartment floor. ‘© Remove the welding spots, and the remaining piece of beam PA37140000000 49-55 May 1985BODY — SHEET METAL PANELS LUGGAGE COMPARTMENT FLOOR WITH REAR PANEL REMOVED Replacement is to be carried out after having removed the Rear Panel, Service joints Parts to be welded 2. Luggage compartment floor and cross member d. connecting bars b. Luggage compartment floor and cross member. connecting bars Luggage compartment floor and cross member connecting bars Luggage compartment floor, rear fender, and inner rear wheelarch Luggage compartment floor, bumper connection reinforcement beam, and rear fender REMINDER WHEN REMOVING ‘© Use @ pneumatic drilling machine and remove the welding spots between luggage compartment floor and cross member connecting bars in correspondence. with the spare wheel compartment. May 1985 49-56 'PA37140000000BODY — SHEET METAL PANELS S ‘© Use an air saw to cut the floor to be replaced along Drill the front edge of luggage compartment floor and line A shown in the figure. spare wheel compartment for the following MIG plug welding, Do not go over the lin Prevent damaging the set in evidence in the figure to oss member connecting bars. YS ‘Install the floor on vehicle by overlapping the front edge to the remaining part of the old one, then . proceed with welding. ‘¢ Use an air saw to remove the welding spots of floor to bumper connection reinforcement beam. REMINDER WHEN INSTALLING ‘© Adapt the new floor for installation on vehicle: = By means of an air saw, cut the floor at the dimen: sion shown in the figure, VY 'PA37140000000 49-57 May 1985BODY — SHEET METAL PANELS REAR WINDOW LOWER PANEL Service joints Parts to be welded ‘a Rear window lower panel and bulkhead behind ¢. Rear window lower panel and rear fender the seat back b. Rear window lower panel and bulkhead behind the seat back REMINDER WHEN REMOVING '* Remove the welding spots and the rear window lower panel May 1985 49-58 PA37 140000000YY BODY — SHEET METAL PANELS OUTER REAR WHEELARCH WITH REAR FENDER REMOVED Replacement is to be carried out after having removed Rear Fender and Body Side Rear Frame, Service joints aris to bo welded a Outer rear wheslarch and inner rear wheelarch forcement beam bb. Outer rear wheelarch, bracket securing retractor, and d._Quter rear wheelarch and door under-trim inner rear wheelarch @. Outer rear wheelarch and door under-trim ‘©. Outer rear wheclarch and bumper connection rein REMINDER WHEN REMOVING ‘© Use an air chiset to cut according to line A shown in the figure, 437140000000 49-59 May 1985BODY — SHEET METAL PANELS Use an air chisel fitted with suitable tip to remove the remaining edges of outer rear wheelarch, When removing the welding spots of the bracket securing retractor, do not use the drilling machine sinee this could cause the bracket to come off. May 1985 49-60 pa37140000000VY BODY — SHEET METAL PANELS BODY SIDE FRAME UPPER PART Replacement is to be performed after having removed Rear Fender and Body Side Rear Frame. Service joints Parts to be welded 2. Body side frame upper part and bulkhead behind seat back b. Body side frame upper part, body side, and upper ‘beam frame © Body side frame upper part and body side (body side rear frame) d. Body side frame upper part and rear window upper cross member Body side frame upper part and upper beam frame 1. Body side frame upper part and inner rear wheelarch REMINDER WHEN REMOVING ‘+ By means of an air chisel, cut the component accord: ing to lines A and 8 shown in the figure pa37140000000 9. Body side frame upper part, inner rear wheolarch, and bulkhead behind seat back Body side frame upper part and upper beam frame i. Body side frame upper part and root 49-61 May 1985BODY — SHEET METAL PANELS Remove the welding spots of the remaining edges of body side frame upper part. REMINDER WHEN INSTALLING © Position the new component correctly on body inserting tho tab into the rear Window Upper cross mmemba Drill the new component in the points to be MIG : plug welded, When removing the upper edge, release the tab from the slot of rear window upper cross member. May 1985 49-62 PA37140000000BODY — SHEET METAL PANELS BODY SIDE REAR FRAME WITH REAR FENDER REMOVED VY Replacement is to be carried out after having removed Rear Fender. Service joints Parts to be welded a Body side rear frame and outer rear wheelarch e. Body side rear frame and body side frame uppor part jody side rear frame and inner rear wheelarc b. Body J heelarch REMINDER WHEN REMOVING ‘+ By means of an air chisel, cut the component accord- ing to the line shown in the figure. P37 140000000 49-63 May 1985BODY — SHEET METAL PANELS ‘+ By means of an air chisel remove the welding spots land the remaining parts of body side rear frame from body. REMINDER WHEN INSTALLING ‘Adapt the new component for installing it on body. Tack weld the body side rear frame to inner rear wheelarch and body side frame upper part in three points as shown in the figure. May 1985 49-64 PA37140000000BODY — SHEET METAL PANELS ROOF Service joints Parts to be welded 1. Roof and windsereen rim 4. Roof and rear fender b. Roof, front pillar frame, and windscreen rim 9. Roof, rear fender, and body side frame upper part ©. Roof, body side, and front pillar frame h. Roof and body side frame upper part, 4. Roof and drip |. Roof and rear window upper cross member fe. Roof, drip, and rear fender REMINDER WHEN REMOVING © Using a suitable too! remove the adhesive between roof and root bows PA37140000000 49-65 May 1985BODY — SHEET METAL PANELS ‘+ By means of an air chisel, cut the roof according to * ~—Apply the specific sealing compound in the body \_/ the line shown in the figure. ‘grooves shown in the figure. ‘Take care not to cut the roof bows. ‘Sealing compound * Braze as necessary. By means of an air chisel, remove the welding spots and the remaining parts of roof from body. REMINDER WHEN INSTALLING © Apply a suitable adhesive to root bows. My 1985 49-66 pA37140000000BODY — SHEET METAL PANELS WINDSCREEN RIM WITH FENDER, BONNET HINGE, AND ROOF REMOVED Replacement is to be carried out after having removed Front Fender, Bonnet Hinge and Roof Service joints see AA, Windscreen rim Parts to be welded Windsereen rim and windscreen lower eross member _—_e,_ Windsereen rim and front pillar b. Windscreen rim, front pillar frame, and body side rim f. Windscreen rim and dashboard sidewall ©. Windscreen rim, front pillar frame, and body side rim g._ Windscreen rim and cow! top 4. Windsereen rim and drip REMINDER WHEN REMOVING '¢ Cut the windscreen rim according to lines A, B and shown in the figure PA37140000000 49-67 May 1985BODY — SHEET METAL PANELS + Lift the tab connecting windscreen rim to front REMINDER WHEN REMOVING ww valance © Drill the new component in the points to be MIG plug welded. = Position the windscreen rim correctly on body, inserting the front valance tab into the related slot. © Bend the tab. ‘¢_By means of an air chisel, remove the remaining edges ‘of windscreen rim from body. G \ May 1985 49-68 PA37140000000BODY — SHEET METAL PANELS REAR WINDOW UPPER CROSS MEMBER WITH ROOF REMOVED Removal it to be performed after having removed the Roof. Service joints Parts to be welded 1. Rear window upper eross member, body side frame bear window upper cross member and body side Upper part, and body side frame upper part. REMINDER WHEN REMOVING ‘* By means of an air saw, cut the component according ‘to lines A and B shown in the figure. PA37 140000000 49-69 May 1985BODY — SHEET METAL PANELS © Use an air chisel to remove the welding spots, REMINDER WHEN INSTALLING ‘+ Position the eross member on body and bend the tabs as shown in the figure © Lift the tab shown in the figure and remove the © ‘NIG plug weld the three overlapping sheet from both remaining pieces of the rear window upper cross sides. member. 49-70 ‘PA37140000000 May 1985