- 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. Use a jigsaw following the cutting lines shown in the diagram.

2. Grind the seam weld shown in the figure.

- Use a rotary brush to remove the paint and gain access to the spot welds.

3. Use the drill to chamfer 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 underdoor side member reinforcement from the vehicle.

1. Use the circular saw following the cutting line in the diagram.

2. Grind the seam weld shown in the figure.

- 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 the drill to chamfer the spot welds that aren''t accessible to the chamfering machine.

- Use a hammer and chisel to remove the previously chamfered spot welds.

- Remove the part and the offcuts 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

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 the part at the indicated points.

- 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 to weld the areas shown in the diagram.

3. Use a MIG welder to fill weld the openings made previously.

4. Use a 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.

1. Apply electro-galvanizing paint.

1. Work at the bench and cut the part at the points shown in the figure, 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 replacement part using a rotary brush.

3. Drill out the part at the indicated points.

4. Make three slots at the points shown on the replacement part using the drill.

- 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 the circular saw to cut the edges of the panel so that the join line is perfect.

- Remove the excess panels.

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 area shown in the diagram.

3. Use a MIG welder to fill weld the openings made previously.

4. Use a 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.

Op. 7210B75 R.R. REAR LIGHT CLUSTER HOUSING

Op. 7210B50 R.R. REAR WING LOWER FRAME

Op. 7210B10 R.R. CENTRE PILLAR

Op. 7210B65 R.R. REAR PILLAR (WING INTERIOR)

Op. 7210E72 R.R. FUEL FILLER BUSH WITH WING REMOVED

Op. 7210B51 R R UPPER CHANNEL STIFFENER, (ONE) LH OR RH

Op. 7210E52 R.R. REAR WING

Op. 7210E34 R.R. ROOF PANEL/SIDE PANEL CONNECTION PROFILE-MOULDING

Op. 7210E36 R.R. FRONT SIDE DOOR

Op. 7210E56 R.R. TAILGATE

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Parts & tools for this job Staging For 2005 Alfa Romeo Brera

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