Preparation work
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| 4. | Care Point: Remove both sides.
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| 5. | Care Point: Remove both sides.
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| 8. | Care Point: Remove both sides.
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| 9. | Care Point: Remove both sides.
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| 10. | Care Point: Remove both sides.
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| 11. | Care Point: Remove both sides.
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| 13. | Care Point: Remove both sides.
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 WARNING!
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Risk of explosion and Fire hazard caused by handling solvent and adhesive.
Injury caused by fire or explosions.
No smoking!
| • | No open flames!
| | • | Always use skin protection cream, protective gloves and safety glasses.
| | • | Provide for good ventilation at workplace.
| | • | Keep storage containers closed wherever possible or close immediately after use.
| | • | Always work in an enclosed aluminium or composite booth with suitable dust and fume extraction.
| | • | Always follow instructions on manufacturer’s data sheets for solvents and adhesives.
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WARNING!
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Sharp vehicle parts.
Caused by scraping or cutting.
Always wear protective gloves when working on or near sharp and burred vehicle parts.
| • | Repair panels must be deburred.
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WARNING!
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Vapour inhalation or swallowing of adhesive material
When glue vapors are inhaled, the respiratory system could be damaged because even small amounts of the substances contained in some types of glues can attack the mucous membranes.
Swallowing glue can cause poisoning symptoms such as headaches, dizziness, cramps, stomach aches, vomiting, respiratory paralysis and unconsciousness. Moreover, irritation may occur to the respiratory paths and eyes.
Provide for good ventilation at workplace.
| • | No fire, sparks, open flames or smoking.
| | • | Wear protective gloves and safety glasses and, if necessary, respiratory protection and protective clothing.
| | • | Do not fill glue into beverage cups
| | • | Store glue where it is not accessible for unauthorized persons.
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WARNING!
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Explosion and Fire hazard from sawings, grindings, solvent and adhesive!
Fire and Explosion can result if glowing objects come into contact with flammable materials or substances.
Never allow smoking or an open flame in the work area.
| • | Always work in an enclosed aluminium or composite booth with suitable dust and fume extraction.
| | • | Always follow instructions on manufacturer data sheets for solvents and adhesives.
| | • | Wear protective clothing, safety glasses and heat resistant gloves.
| | • | Avoid sparks and keep objects away from flammable materials and substances when handling glowing objects.
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WARNING!
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Damage hazard from hot air gun, to adjacent panels.
Always apply heat treatment with care, avoid excessive application of heat to one area.
| • | Always follow instructions on manufacturer data sheets for adhesives.
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Remove crash structure - Rear
| 1. | Install rear bodyside bracket (1).
| | | 2. | | | | 3. | Detach clips (3).
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| | | Care Point: | For this procedure, the technician’s Personal Protective Equipment (PPE) must comply with Health and Safety for cutting and welding.
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| | | 4. | Cutting.
HS1
| Ear protection
| HS2
| Eye protection
| HS3
| Respiratory protection
| HS4
| Kevlar gloves and wrist protectors
| HS5
| Disposable Overall
| HS6
| Safety shoes
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| | | 5. | Solvents.
HS2
| Eye protection
| HS3
| Respiratory protection
| HS4
| Latex/ nitrile gloves
| HS5
| Disposable Overall
| HS6
| Safety shoes
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| 6. | Tools required.
T1
| Mini disc cutter
| T2
| Air saw
| T3
| Hammer
| T4
| Wire brush
| T5
| Solvent applicator
| T6
| Pincers
| T7
| Air grinder
| T8
| Welding mask
| T9
| Aluminium welder
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| | | Care Point: | Make sure that the engine bay is sealed off and the complete vehicle exterior is covered.
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| | | 7. | Mask up to all the working edges (4) of the crash can (5).
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| 8. | Mark out and baulk cut (A).
| | | 9. | Remove damaged panel section (6).
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| 10. | Make additional cuts (B) to remove panel remnants (7).
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| 11. | Sand and separate welded joints (7) in direction (D, E).
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| 12. | Remove remnants (7, C).
| | | 13. | Dress excess weld in preparation for new panel replacement.
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Install crash structure - Rear
| 1. | Fit and align new crash can using Celette jig points (ST1).
| | | 2. | Fix crash structure - Rear with test welds (F).
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| | | Care Point: | Using damaged crash can set up and complete test welds (G) before tacking and welding new crash can in position.
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| | | 3. | Tack and weld (G) crash structure - Rear in position.
| | | 4. | | | | 5. | Install components in reverse order.
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