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Body and Trim
Body Repair
Precautions
Paint
Ensure that there is efficient ventilation at all times. Paint spraying should be confined to spray booths.
Anyone with a history asthma should not be engaged in any process which involves the use of isocyanates.
Any operator working inside a spray booth where isocyanates are present must use air-fed breathing equipment.
Supplied air to the visor should be fed at the recommended pressure and filtered to remove oil, water and fumes.
Operators involved in handling, mixing or spraying should wear protective clothing, gloves and goggles to avoid
skin and eye contact. A Paticle mask or canister typr respirator should be worn when sanding.
Applied heat
When welding, flame cutting or brazing and so on, goggles, a mask or fume extractor and flameproof protective
clothing should be used always.
It is especially important when working with polyurethane compounds to use air-fed breathing equipment.
Ensure that at all times the appropriate fire fighting equipment isavailableand that personnel are trained in its use.
Metal repair
Wear appropriate eye and hand protection when sanding, drilling, cutting, chiselling, flatting or welding. Wear a
face mask or air-fed visor when sanding or flatting either body solder or
fillers.
When a soldering operation has been
completed,
remove swarf from the work area and wash your hands thoroughly.
General Repair Notes
The following precautions should be noted before any work is carried out:
• disconnect the vehicle battery ground
lead,
taking note of the reconnection procedures
• Make sure that you have read and understood the safety related procedures in this section.
Caution:
Electric arc
welding must not
be
used on the
vehicle as the high
voltages produced by
this process
will
cause
irreparable
damage
to the electrical control and
microprocessor
systems.
All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel
removal or replacement.
Welding and Gas Process Special Notes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated
metal.
The flanges of panels, which are to be welded together, must be clean, corrosion free and treated as
appropriate with either weld-through or inter-weld sealer.
The resistance spot welding equ ipment used in vehicle repair does not always produce
a
weld of
equ
ivalent strength
to that produced in manufacturing. This means that a single row of spot welds should be spaced on a pitch of 19-
25 mm, which will usually result in more spot welds than found in the original factory joint.
Use a resistance spot weld cutter to remove resistance spot welds. Where a new joint is to be MIC welded, cut the
old resistance spot welds from the panel that is to be retained; the resulting holes are then used for plug welding.
Suitable holes may be drilled or punched as follows:
• 8.0 mm for sections up to 1.5 mm thickness
• 10.0 mm for thicker sections.
Always refer to the welding equipment manufacturers diagrams and tables for the relevant procedure.
May 1996 7-3
^=2?
Body and Trim
Roof Hydraulic Control System
9. Position the rear edge of the roof to the body.
10.
Position the rear cable to the roof lower edge.
Position the loops on the cable (approximately 17in
equi-spaced apart). Position the cable to the
mou nti ng
brackets,
fit but do not tighten the
secu
ring
nuts.
Figure 3. Cable, Roof Channel and Body Channel
11.
Align the rear edge of the roof material to the body
and commence tightening the cable nuts evenly.
Stop frequently and check that the cable and roof
channel
are
correctly bedding into the body channel.
Continue tightening and checking until the roof is
fully seated in the body channel.
12.
Fit and secure the roof finishers.
13.
Reconnect the heated rear window connector.
14.
Position the roof inner curtain. Fit clips to the
curtain rods. Fit and tighten the securing screws.
15.
Refit all trim and check the roof mechanism for
correct operation and fitting.
9.0.02.3 - Roof Hydraulic
Control
System
Procedure
1.
Move the front seats forward for access.
Fully lower the roof.
2.
3.
4.
6.
Remove the rear seat squab and cushion. Remove
the rear quarter trim panels.
Remove both the cylinder pivot pins. Release the
ram cylinder assemblies (take care not to kink the
pipes).
Remove the screws from the hydraulicpipegrommet
in the rear of the roof stowage
well.
Remove the
grommet.
Release the pipe securing clips.
Figure 2. Ram Mountings
7. Open the boot and remove the boot floor trim
panel.
Remove the pump mounting plate securing
bolts.
8. Release and remove the pump cover.
9. Disconnect the pump multi-plug.
10.
Releasethe pump mounting rubbers from the plate.
11.
Feed both ram cylinders into the boot through the
aperture in the roof well rear
wall.
12.
Remove the complete hydraulic system from the
boot.
Note: Check that the reservoir fluid level is correct.
Always bleed the hydraulic
system
before topping up.
Refitting is the reverse of the removal procedure.
On completion of the refitting, check the roof
operation.
May 1996 7-11
