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XU7JPL3
Ikco XU7JPL3 User Manual
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71
Samand
Adjustment
and
replacement
W78R202
W78R203
2
1
330
W78R204
3
3
3
Replacing
the
front
of
a
front
side
member
and
the
front
lower
cross
member
Preliminary
operations
Remove
front
wing
front
panel
Prepare
new
part
1
Prepare
new
part
by
cutting
(final
cut),
to
measurement
shown.
2
Drill
out
spot
weld,
8
mm
for
later
plug
welding.
3
Mark
out
and
cut
the
front
side
member
.
IMPOR
T
ANT
DO
NOT
DESTROY
THE
INNER
REINFORCEMENT
.
72
74
Table of Contents
Contents
3
Body & Body Repairs
6
Technical Data
7
Body Dimensions
9
Measurements, Rear Body and Side
11
Measurements, Body B Pillar
12
Measurements, Underbody
13
Finish Paints
14
Setting of Badges
16
Special Tools
17
Technical Description
20
Body Design
20
Safety
22
Reinforcement
23
Galvanised Parts
24
Permissible Joints
30
Pillar Designations
32
Windscreen and Rear Window
32
Window Lifts
33
Door Mirrors
33
Surface Treatment
34
Corrosion
34
Sealant
36
Underseal (Anti-Chip)
38
Cavity Sealant
40
Painting Galvanised Sheet
42
Adjustment and Replacement
43
Bodywork Repairs
43
Checking the Body Dimensions
43
Cutting
44
Welding
45
Grinding
45
Welding Galvanised Sheet Metal
46
Primer
46
Method of Zinc Coating Electro-Zinc and Galvanised Panels for Repair
47
Preparing the Surface
47
Choice of Anode
48
Setting up
48
Depositing Zinc
49
Jig Mounting
50
Replace Front Subframe Fixing Nut
52
Complete Front Wheel Arch Replace
54
Cutting Damaged Panels
57
Replace Front Wing Inner Panel and Half Front Panel
68
Replacing Front of a Front Side Member and Front Lower Cross Member
73
Replace Part Front Side Member and Front Wing Inner Panel Side Panel
79
Side Member Centre Part Replace
85
Bodyside Outer a Pillar and Reinforcement Front Hinge Replace
91
Right Hand Side Member Replacement (Engine Mounting Bracket)
98
Windscreen Pillar Replace
99
Replace a Centre Pillar and Inner Panel
104
Outer Sill Panel Replace
112
Replacing a Roof Support
118
Tail Panel Assembly Replace
120
Roof Panel Replace
124
Replacing a Rear Wing Without Removing the Rear Screen
128
Replacing a Rear Wing Cutting the Rear Quarter Panel
135
Replacing a Part Wheel Arch Assembly
142
Replacing a Part Rear Floor Assembly
152
Part Rear Side Member Repair
159
Hood Removal
165
Hood Fitting
165
Hood Hinge Removal and Fitting
165
Hood Stay Removal and Fitting
166
Hood Stop Adjustment
166
Hood Release Cable Removal
167
Hood Latch Removal and Fitting
168
Hood Release Pull Removal and Fitting
168
Front Wheel Arch Removal and Refitting
169
Front Fender Removal and Refitting
170
Doors Removal and Refitting
171
Door Striker Adjustment
172
Front Door Glass Removal
173
Front Door Glass Refitting
174
Front Door Electric Window Lift Regulator Removal and Refitting
175
Front Door Front Slide Removal and Refitting
176
Door Mirror Glass Removal and Refitting
177
Front Door Electric Mirror Removal and Refitting
178
Rear Door Fixed Glass Removal and Refitting
179
Door Check Arm Removal and Refitting
180
Door Key Lock Removal and Refitting
181
Door Latch Removal and Refitting
183
Door Moulding Removal and Refitting
186
Front Window Glass Removal and Refitting
187
Rear Window Glass Removal and Refitting
192
Trunk Lid Removal and Refitting
193
Trunk Lid Adjustment
194
Trunk Lid Lock Striker Removal and Refitting
195
Trunk Lid Latch Removal and Refitting
196
Trunk Lid Lock Cable Removal and Refitting
197
Trunk Lid Key Lock Removal and Refitting
199
Trunk Lid Lock Motor Removal and Refitting
201
Trunk Lid Finisher Trim Removal and Refitting
202
Fuel Filler Flap Removal and Refitting
203
Front Bumper Removal and Refitting
204
Rear Bumper Removal and Refitting
207
Front Structure/Cooling Pack Removal and Refitting
209
Seals Removal and Refitting
212
Door Rubbing Strip Protectors Removal and Refitting
215
4
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Ikco XU7JPL3 Specifications
General
Brand
Ikco
Model
XU7JPL3
Category
Automobile
Language
English
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