Manual service Renault Scenic 2 tablarie

7/28/2019 Manual service Renault Scenic 2 tablarie

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© Renault s.a.s. 2006

"The repair methods given by the manufacturer in this document are based on the technical

specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

FEBRUARY 2006 Edition Anglaise

X84, and J84

4 Panelwork

40A GENERAL VEHICLE INFORMATION

41A FRONT LOWER STRUCTURE

41B CENTRE LOWER STRUCTURE

41C SIDE LOWER STRUCTURE

41D REAR LOWER STRUCTURE

42A UPPER FRONT STRUCTURE

43A SIDE UPPER STRUCTURE

44A REAR UPPER STRUCTURE

45A TOP OF BODY

47A SIDE OPENING ELEMENTS

48A NON-SIDE OPENING ELEMENTS



SCENIC II - Section 4

Contents

Page

SCENIC II - Section 4ContentsPage

40A GENERAL VEHICLE INFORMATION

Bodywork special tooling:Use 40A-1

Sub-frame: Specifications 40A-5

Hollow body parts inserts:List and location ofcomponents 40A-10

Hollow body parts inserts:Precautions for repair 40A-13

Earths on the body: List andlocation of components 40A-14

Vehicle front sectionstructure: Description 40A-17

Vehicle side section

structure: Description 40A-19

Vehicle central sectionstructure: Description 40A-21

Vehicle structure rearsection: Description 40A-24

Vehicle removable sectionstructure: Description 40A-26

Structure components to bepositioned on body repairbench: Description 40A-28

Structural bodyworkreference material: Use 40A-34



Vehicle central section

structure: Description 41A-3


Front impact cross member:Removal - Refitting 41A-8

Lower front end crossmember: General description 41A-9

Front end side crossmember: Description 41A-10

Radiator support crossmember: General description 41A-11

Radiator support crossmember: Removal - Refitting 41A-12

Front side member: General

description 41A-13

Front side member:Description 41A-16

Front section of front sidemember closure panel:General description 41A-20

Front section of front sidemember closure panel:Description 41A-22

Battery tray support: General

description 41A-25

Battery tray support:Description 41A-26

Radiator cross membermounting: Generaldescription 41A-27

Radiator cross membersupport: Description 41A-28

Front mounting of front sub-

frame: General description 41A-30




Contents

Front mounting of front sub-frame: Description 41A-31

Engine mounting: Generaldescription 41A-32

Engine mounting:Description 41A-33

Sub-frame rear mounting:General description 41A-34

Sub-frame rear mounting:Description 41A-35

Front half unit: General

description 41A-37

Front half unit: Description 41A-38


Vehicle front sectionstructure: Description 41B-1

Vehicle side section

structure: Description 41B-3

Vehicle central sectionstructure: Description 41B-5

Centre floor, side section:General description 41B-8

Central floor, side section:Description 41B-10

Centre floor stiffener:General description 41B-13

Centrefloor stiffener:Description 41B-14

Tunnel: Description 41B-15

Centre floor front lateralcross member: Generaldescription 41B-17

Centre floor front lateralcross member: Description 41B-19

Front cross member underfront seat: General

description 41B-21


Front cross member underfront seat: Description 41B-22

Front seat rear mountinginterior unit: Description 41B-24

Front seat rear outermounting unit: Description 41B-25

Rear cross member underfront seat: Description 41B-26

41C SIDE LOWER STRUCTURE

Vehicle side sectionstructure: Description 41C-1

Vehicle central sectionstructure: Description 41C-3

Sill panel: Description 41C-6

Complete sill panel: Generaldescription 41C-11

Full inner sill panel: General

description 41C-14

Rear inner sill panel:Description 41C-15

Sill panel reinforcement:General description 41C-18

Sill panel reinforcement:Description 41C-19

Sill panel rear reinforcement:Description 41C-21

Front jack support: Generaldescription 41C-24

41D REAR LOWER STRUCTURE

Vehicle central sectionstructure: Description 41D-1

Vehicle structure rearsection: Description 41D-4

Rear floor, front section:General description 41D-6




Contents

Rear floor, front section:Description 41D-8

Rear floor rear section:General description 41D-11

Rear floor rear section:Removal - Refitting 41D-12

Rear side member: Generaldescription 41D-18

Rear impact cross membermounting reinforcement:Description 41D-20

Rear side member:Description 41D-21

Rear side member closurepanel, rear section:Description 41D-26

Rear floor front crossmember, centre section:Description 41D-28

Rear floor centre crossmember: General description 41D-30

Rear floor centre crossmember: Description 41D-31

Far rear lower cross member,side section: Description 41D-32

Front cross member underrear seat: Description 41D-33

Rear cross member underrear seat: Description 41D-36

Exhaust mounting support:

Description 41D-39

Tank mounting support:Description 41D-40

Rear impact lower crossmember: General description 41D-41

Rear impact lower crossmember: Removal - Refitting 41D-42

41D REAR LOWER STRUCTURE 42A UPPER FRONT STRUCTURE


Vehicle central sectionstructure: Description 42A-3


Front wing: Generaldescription 42A-8

Front wing: Removal -Refitting 42A-10

Front wing: Adjusting 42A-12

Front wing lower mountingsupport: General description 42A-15

Front wing lower mountingsupport: Removal - Refitting 42A-16

Front wing upper mountingsupport: General description 42A-17

Front wing upper mountingsupport: Removal - Refitting 42A-18

Front: General description 42A-20

Front: Removal - Refitting 42A-21

Scuttle side panel: Generaldescription 42A-25

Cowl side panel: Description 42A-27

Scuttle side panel upperreinforcement: Generaldescription 42A-29

Scuttle side panel upperreinforcement: Description 42A-30

Front wheel arch: Generaldescription 42A-32

Front wheel arch: Description 42A-33

Heater bulkhead: Description 42A-36

Windscreen aperture lowercross member: Generaldescription 42A-38

Windscreen aperture lowercross member: Description 42A-39



Contents

Dashboard cross member:Removal - Refitting 42A-41

Windscreen aperture lowercross member closure panel:General description 42A-45

Windscreen aperture lowercross member closure panel:Description 42A-46

Bulkhead: Description 42A-48

Bulkhead reinforcement:Description 42A-50

Bulkhead lower crossmember: General description 42A-51

Bulkhead lower crossmember: Description 42A-52

Bulkhead panel: Removal -Refitting 42A-53

Bulkhead side reinforcement:General description 42A-54

Bulkhead upper cross

member: General description 42A-55Bulkhead upper crossmember: Description 42A-56

Bulkhead side stiffener:Description 42A-58

Windscreen wiper mounting:Description 42A-60


Vehicle side sectionstructure: Description 43A-1

A-pillar : General description 43A-3

A-pillar: Description 43A-4

A-pillar reinforcement:General description 43A-6

A-pillar reinforcement:Description 43A-7

42A UPPER FRONT STRUCTURE

Windscreen pillar lining:General description 43A-9

Windscreen pillar lining:Description 43A-10

B-pillar: General description 43A-12

B-pillar: Description 43A-15

B-pillar reinforcement:General description 43A-18

B-pillar reinforcement:Description 43A-19

B-pillar lower lining:Description 43A-21

B-pillar upper lining:Description 43A-22

Body side: Generaldescription 43A-23

Body side: Description 43A-24

Body side front section:General description 43A-27

Body side front section:Description 43A-28

Upper body panel: Generaldescription 43A-29

Upper body panel:Description 43A-30

44A REAR UPPER STRUCTURE

Vehicle structure rearsection: Description 44A-1

Rear wing panel: Generaldescription 44A-3

Rear wing panel: Description 44A-5

Rear wing panel rainchannel: General description 44A-9

Rear lights support: Generaldescription 44A-10

Rear lights support:Description 44A-11




Contents

Lights support lining:General description 44A-13

Lights support lining:Description 44A-14

Outer rear wheel arch:General description 44A-15

Outer rear wheel arch:Description 44A-17

Inner wheel arch: Generaldescriptions 44A-18

Inner wheel arch: Description 44A-19

Rear wheel arch closurepanel, front section:Description 44A-20

Rear wheel arch closurepanel, rear section:Description 44A-22

Quarter panel lining: Generaldescription 44A-24

Quarter panel reinforcement:

Description 44A-25Quarter panel lining:Description 44A-26

Quarter panel upperreinforcement: Description 44A-28

Roof rear drip mouldinglining: Description 44A-29

Rear end panel assembly:Description 44A-30

Rear end panel: Generaldescription 44A-31

Rear end panel: Description 44A-32

Rear end panel side lining:Description 44A-33

44A REAR UPPER STRUCTURE 45A TOP OF BODY

Vehicle side sectionstructure: Description 45A-1

Roof: General description 45A-3

Roof: Description 45A-4

Roof front section:Description 45A-6

Roof rear section:Description 45A-7

Roof front cross member:General description 45A-8

Roof front cross member:Description 45A-9

Roof centre cross member:General description 45A-10

Roof centre cross member:Description 45A-11

Roof rear cross member:General description 45A-12

Roof rear cross member:Description 45A-13



Front side door: Generaldescription 47A-3

Front side door: Removal -

Refitting 47A-5

Front side door: Adjustment 47A-7

Front side door: Stripping -Restoring 47A-10

Front side door panel:Description 47A-11

Rear side door: Generaldescription 47A-13

Rear side door: Removal -

Refitting 47A-15

Rear side door: Adjustment 47A-17



Contents

Rear side door: Stripping -Restoring 47A-20

Rear side door panel:Description 47A-21

Fuel filler flap cover: Generaldescription 47A-23

Fuel filler flap cover:Removal - Refitting 47A-24

48A NON-SIDE OPENING ELEMENTS


Bonnet: General description 48A-3

Bonnet: Removal - Refitting 48A-5

Bonnet: Adjustment 48A-7

Tailgate: General description 48A-10

Tailgate: Removal - Refitting 48A-11

Tailgate: Adjusting 48A-14

Tailgate: Stripping-Rebuilding 48A-17



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GENERAL VEHICLE INFORMATION

Bodywork special tooling: Use 40AUSING THE DASHBOARD CROSS MEMBERREMOVAL TOOL Car. 1673

Screw the rod (1) onto the body (2) as far as the stopand tighten gently.

Insert the assembly into the A-pillar, then screw intothe beam as far as the stop.

Firmly lock tool body (2) in the same way as a locknut against the dashboard cross member nut whileholding the hexagonal head of bolt (1) .

Unscrew the tool as far as the stop using hexagonbolt (2) and tighten it gently (during this operation,the beam nut, which has a left-hand thread, screwsinto the beam and disengages it from the A-pillar).

Hold the tool body and unlock rod (1) in the sameway as a lock nut.

Unscrew dashboard cross member rod (1) to remo-ve the tool.

Repeat the procedure for the second bolt.

This releases the dashboard cross member from theA-pillar.

101308

102527

102529

102530




Bodywork special tooling: Use 40ATo refit, screw the lock nut (left-hand thread) fullyinto the beam.

Fit the beam with the A-pillar hole.

As for the removal operation, prepare the tool, screwit completely into the beam nut then lock the toolbody (2) against the beam nut.

Simultaneously screw the rod (1) and the body (2) ofthe tool as far as the stop, tightening gently.

Hold the body (2) of the tool and unscrew the rod (1)in the same way as a lock nut and then remove thetool.

USING THE DASHBOARD PROTECTION TOOL Car.1764

Use this tool when replacing the windscreen:

- remove the A-pillar trims,

- position the dashboard protector to prevent dama-ge.

102528

WARNING

When removing the dashboard cross member, itis possible that the lock nuts may cause the twosides to become incorrectly adjusted. In thiscase, refit the dashboard to adjust the clearances

with the windscreen pillar trim and the door trim.

18263




Bodywork special tooling: Use 40APREPARATION OF TOOL Car. 1504

111554




Bodywork special tooling: Use 40A(1) Mandrel mounting

- (2) Mandrels

- (3) Tightening bolt

- (4) Body

- (5) Anvils

- (6) Special nut

- (7) Nuts

- (8) Studs

- (9) Thrust nut

- Select the mandrel, anvil and insert assemblyadapted to the crimping operation to be carried out.

- Into the mandrel mounting: (1) screw the mandrel(2) (left-hand thread).

- Tighten the bolt (3) onto the body (4) until the stop(left-hand thread).

- Into the body: (4) screw the anvil (5) (left-handthread).

- Fit the assembly (1) and (2) into the body of the to-ol.

- Screw the insert (left-hand thread) onto the pullrod.

USING TOOL CAR. 1504

Turn the bolt using a 24 spanner, holding the tool

handle manually.

To fit the special nut (6) , position the mandrelacross the crimped nut and tighten it onto thethrust nut (9) .

WARNING

Each time a panel is stripped in the workshop(e.g. when drilling), degrease and wipe the areaand then use a fine brush to apply the following:

- a pre-treatment primer,

- a two-part primer,

- paint in the vehicle body colour.

16069

WARNING

Completion of the crimping operation should befelt by the operator (increase in the tighteningeffort). Crimping of the insert is correct when itno longer has any rotational play; this should bechecked before removing the pull rod - mandrelassembly.




Sub-frame: Specifications 40A

STANDARD CHASSIS

DESCRIPTION DIMEN-SION X DIMEN-SION Y DIMEN-SION Z DIAMETER (inmm) ANGLE(indegrees)

A Front sub-frame rear mountingwithout mechanical components

301 305 77.8 ∅ 25.5; M12 0

Front sub-frame rear mountingwith mechanical components

301 305 6.5 M12 0

B Rear axle leader pin withoutmechanical components

2208.2 -650.8 116 ∅ 20.5; M10 0

B1 Rear axle assembly front moun-ting without mechanical compo-nents

2100 -635 116 M10 0

Rear axle assembly front moun-ting with mechanical components

2100 -635 111 M10 0


2191 -732.2 116 M10 0


2191 -732.2 111 M10 0

C Front sub-frame front mounting -141.5 -478 252 M12 0

C* Front sub-frame front mounting 141.4 477.9 261 M12 0

E Rear shock absorber upper moun-ting

2494 -398 262.5 ∅ 10.7; M10 90

F1 Front shock absorber upper stop - 53.7 - 602.1 700.3 M8

F1* Front shock absorber upper stop 84.1 601.9 683.3 M8

F2 Front shock absorber upper stop 52.2 -529.9 685.5 M8

F2* Front shock absorber upper stop - 22.6 530.1 694.4 M8


F3* Front shock absorber upper stop - 44 632.2 699.7 M8

F4 Front shock absorber mountingleader pin

82.9 - 597.6 683.5 17.2 x 17.2

F4* Front shock absorber mountingleader pin

- 52.5 597.9 700.1 17.2 x 17.2

G Front side member rear leader pin 547 -408.6 -9.8 ∅ 20.5 0

H Front side member front leaderpin, without mechanical compo-nents

-525 -476 84.5 M12 0





Front side member front leaderpin, with mechanical components

-525 -476 80.7 M12 0

H* Front side member front leaderpin, without mechanical compo-nents

-525 492 84 M12 0


-525 492 80.2 M12 0

J Rear side member rear leader pin 3065 -563.5 235 20x20 0

J* Rear side member rear leader pin 3065 523.5 235 20x20 0

K1 Front end cross member -552.9 -439.3 410.9 M10 90

K1* Front end cross member -552.2 447.6 409 M10 90

K2 Front end cross member -546.2 -535.1 276 M10 90


K3 Front panel support addit ionalmounting

- 321 - 725 643.5 M6 9.64

L Rear end cross member 3156.8 -515 315 M8 90

L* Rear end cross member 3156.8 575.2 315 M8 90

L1 Rear end cross member 3156.8 -612.5 217.5 M8 90

L1* Rear end cross member 3156.8 474.7 217.5 M8 90

P1 Engine mounting -309.2 507 528.9 M10 0


R Additional engine mounting (tie-rod)

-35.6 452.6 587 ∅ 14.5; M12 0

DESCRIPTION DIMEN-SION X

DIMEN-SION Y

DIMEN-SION Z

DIAMETER (inmm)

ANGLE(indegrees)

LONG CHASSIS


DIMEN-SION Y

DIMEN-SION Z

DIAMETER (inmm)

ANGLE(indegrees)

A Front sub-frame rear mountingwithout mechanical components

301 305 77.8 ∅ 25.5; M12 0

Front sub-frame rear mountingwith mechanical components

301 305 6.5 M12 0

B Rear axle leader pin withoutmechanical components

2258.2 - 650.8 116 ∅ 20.5; M10 0






2150 -635 116 M10 0


2150 -635 111 M10 0


22411 -732.2 116 M10 0


2241 -732.2 111 M10 0

C Front sub-frame front mounting -141.5 -478 252 M12 0

C* Front sub-frame front mounting 141.4 477.9 261 M12 0

E Rear shock absorber upper moun-ting

2544 -398 262.5 ∅ 10.7; M10 90

F1 Front shock absorber upper stop - 53.7 - 602.1 687.3 M8

F1* Front shock absorber upper stop 84.1 601.8 670.4 M8


F2* Front shock absorber upper stop - 22.6 530.1 681.4 M8


F3* Front shock absorber upper stop - 44 632.1 686.8 M8

F4 Front shock absorber mountingleader pin

82.9 -598.2 670.4 17.2 x 17.2

F4* Front shock absorber mountingleader pin

- 52.5 597.9 687.2 17.2 x 17.2

G Front side member rear leader pin 547 -408.6 -9.8 ∅ 20.5 0

H Front side member front leaderpin, without mechanical compo-nents

-525 -476 84.5 M12 0


-525 -476 80.7 M12 0

H* Front side member front leaderpin, without mechanical compo-nents

-525 492 84 M12 0

Front side member front leader

pin, with mechanical components

-525 492 80.2 M12 0

J Rear side member control withoutmechanics

3292 - 559 235 M10 0


DIMEN-SION Y

DIMEN-SION Z

DIAMETER (inmm)

ANGLE(indegrees)





Rear side member control withmechanics

3292 - 559 224 M10

J* Rear side member control withoutmechanics

3292 - 528 235 M10 0

Rear side member control withmechanics

3292 - 528 224 M10

K1 Front end cross member -552.9 -439.3 410.9 M10 90


K2 Front end cross member -546.2 535.1 276 M10 90

K2* Front end cross member -546.3 -533.6 276 M10 90

K3 Front panel support addit ionalmounting

-312.9 -737 643.5 M6 9.64

L Rear end cross member 3393.5 -515 315 M8 90

L* Rear end cross member 3393.5 572.2 315 M8 90

L1 Rear end cross member 3393.5 -612.5 217.5 M8 90

L1* Rear end cross member 3393.5 474.7 217.5 M8 90



R Addit ional engine mounting (t ie-rod)

-35.6 452.6 587 ∅ 14.5; M12 0


DIMEN-SION Y

DIMEN-SION Z

DIAMETER (inmm)

ANGLE(indegrees)

Note:

The reference points located on the right-hand sideof the vehicle are shown by an asterisk.




Sub-frame: Specifications 40AA and B = vehicle trim height reference

100030




Hollow body parts inserts: List and location of components 40A

A-pillar insert (1) . A-pillar reinforcement insert (2) .

115073

103501 103652





A-pillar insert (3) .

A-pillar lining insert (4) .

Front side member rear insert (5) .

B-pillar insert (6) .

103502

103653

102868

103498





B-pillar reinforcement insert (7) .

B-pillar interior reinforcement insert (9) .

Rear wing panel upper insert (9) .

Rear wing panel lower insert (10) .

103655

103654

103499

103500




Hollow body parts inserts: Precautions for repair 40AThe expanding inserts ensure that the vehicle cavitiesare sealed and soundproofed. They react to the tempe-rature when the bodywork is immersed in the catapho-retic bath at the factory. These conditions cannot bereproduced on the bodywork.

As inserts are not recoverable, always replace expan-ding inserts.

The inserts supplied by the Parts Department areidentical to the original parts.

To obtain the same sealing and soundproofing proper-ties, carry out the following operations:

- clean the bonding surfaces with heptane.

- if necessary, seal the holes in the insert using piecescut from a soundproofing pad.

- apply a bead of preformed trim sealing mastic aroundand inside the insert holes.

- fit the insert by compressing the mastic.

In some cases, it is possible to replace the accessiblepart of the insert only, which must be cut out of the re-placement part.

WARNING

Do not refit the part after compressing the bead.

When MIG welding, protect the inserts from spatterand heat dispersion.

For example, use a heat shield.




Earths on the body: List and location of components 40AFor the replacement procedure for earth studs, (seeMR 400, 40A, General information, Earth screwconnections ).IMPORTANT

To avoid damaging the vehicle's electric and elec-tronic components, the battery and the earths of

any wiring harness near the weld area must be dis-connected.

The earth of the welding machine must be placedas close as possible to the weld area.

115073




Earths on the body: List and location of components 40ADETAILED VIEW OF THE POSITION OF EARTHSON THE VEHICLE

Earth studs (1) on the front right-hand side member.

Earth studs (2) on the front left-hand side member andon the front end side cross member.

Earth studs (3) on the tunnel.

Left-hand side

Earths studs (4) on the rear end panel side lining.

115075

115076

115077

115102




Earths on the body: List and location of components 40ARight-hand side

Earth studs (5) on the rear end panel side lining and on

the inner wheel arch.

115106




Vehicle front section structure: Description 40AFRONT STRUCTURE

104367

Mark Description Classification Type Thickness(mm)

(1) Scuttle side panel upper reinforcement (see 42A , Upper front struc-ture, Scuttle side panel upperreinforcement: Description,page 42A-30)

HLE 1.2

(2) Scuttle side panel (see 42A , Upper front struc-

ture, Cowl side panel: Descrip-tion, page 42A-27)

HLE/

THLE

0.7/2.5

(3) Front end side cross member (see Front end side cross mem-ber: Description )

- 1.2

(4) Left-hand front half unit (see 41A, Front lower struc-ture, Front half unit: Descrip-tion, page 41A-38)

HLE/ THLE

1.1/3

(5) Front section of front side member clo-sure panel

(see 41A, Front lower struc-ture, Front section of front sidemember closure panel: Des-

cription, page 41A-22)

HLE/ THLE

1.7/3






Vehicle side section structure: Description 40ALATERAL STRUCTURE

104368


(1) Front side door panel (see Front side door panel:Description )

HLE 0.7/0.95

(2) Rear side door panel (see Rear side door panel:Description )

HLE 0.7/0.95

(3) Front jacking point ( (see Front jacking point:Description)

HLE 1.8

(4) Sill panel* (see 41C , Side lower struc-ture, Sill panel: Description,page 41C-6)

- 0.7

(5) Body top* (see 43A , Side upper struc-ture, Upper body panel: Des-cription, page 43A-30)

- 0.7

(6) Body side front section* (see 43A , Side upper struc-ture, B o dy side front sec-tion: Description, page 43A-28)

- 0.7




Vehicle side section structure: Description 40A

* Different parts for Grand Scenic, but the proceduresare identical.

(7) Body side front section reinforcement ( (see Body side front sec-tion reinforcement: Descrip-tion)

THLE/ HLE

1.2/2.5

(8) B-pillar reinforcement stiffener (see B-pillar reinforcementstiffener: Description )

HLE 2

(9) Rear inner sill panel (see 41C , Side lower struc-ture, Rear inner sill panel:Description, page 41C-15)

HLE 1

(10) B-pillar reinforcement stiffener, lowersection

HLE 1.8

(11) B-pillar lower lining (see B-pillar lower lining:Description )

- 0.7

(12) B-pillar upper lining (see B-pillar upper lining:Description )

HLE 1.5

(13) Rear roof drip moulding lining ( (see Roof drip mouldinglining: Description)

- 1

(14) Windscreen pillar lining (see 43A , Side upper struc-ture, Windscreen pillarlining: Description, page43A-10)

HLE 1.2

(15) Roof front cross member (see 45A, Top of body, Rooffront cross member: Des-cription, page 45A-9)

HLE 0.7

(16) Roof centre cross member (see 45A, Top of body, Roofcentre cross member: Des-cription, page 45A-11)

HLE 1.5

(17) Roof rear cross member with stan-dard roof

(see 45A, Top of body, Roofrear cross member: Descrip-tion, page 45A-13)

- 1/1.5

(18) Roof rear cross member with sunroof (see 45A, Top of body, Roofrear cross member: Descrip-tion, page 45A-13)

- 1/1.5

(19) Roof front section (see 45A, Top of body, Rooffront section: Description,page 45A-6)

- 0.7

(20) Roof* (see 45A, Top of body, Roof:Description, page 45A-4)

- 0.7

(21) Rear section of roof* (see 45A, Top of body, Roofrear section: Description,

page 45A-7)

- 0.7





Vehicle central section structure: Description 40ACENTRAL STRUCTURE

104693


(1) Bulkhead lower cross member (see 42A, Upper front struc-ture, Bulkhead lower crossmember: Description, page42A-52)

VHLE 2.5

(2) Steering column unit - 1.5

(3) Bulkhead (see 42A, Upper front struc-ture, Bulkhead: Description,page 42A-48)

- 0.9

(4) Bulkhead side reinforcement (see 42A, Upper front struc-ture, Bulkhead side stiffe-ner: Description, page 42A-58)

UHLE 1.7

(5) Bulkhead reinforcement (see 42A, Upper front struc-ture, Bulkhead reinforce-ment: Description, page

42A-50)

UHLE 1.7




Vehicle central section structure: Description 40A

(6) Bulkhead upper cross member (see 42A, Upper front struc-ture, Bulkhead upper crossmember: Description, page42A-56)

HLE 0.95/3

(7) Heater bulkhead (see 42A, Upper front struc-ture, Heater bulkhead: Des-cription, page 42A-36)

- 1

(8) Windscreen aperture lower cross mem-ber

(see 42A, Upper front struc-ture, Windscreen aperturelower cross member: Des-cription, page 42A-39)

- 0.7/1.5

(9) Windscreen aperture lower cross mem-ber closure panel (see 42A, Upper front struc-ture, Windscreen aperturelower cross member clo-sure panel: Description,page 42A-46)

- 0.7/1.2

(10) Front seat mounting exterior unit (see 41B , Centre lowerstructure, Front seat rearouter mounting unit: Des-cription, page 41B-25)

HLE 1.5

(11) Front seat mounting interior unit (see 41B , Centre lowerstructure, Front seat rear

mounting interior unit: Des-cription, page 41B-24)

HLE 1.5/2.5

(12) Front cross member under front seat (see 41B , Centre lowerstructure, Front cross mem-ber under front seat: Des-cription, page 41B-22)

HLE 1.5

(13) Steering column mounting - 1.3

(14) Tunnel (see 41B , Centre lowerstructure, Tunnel: Descrip-tion, page 41B-15)

HLE/ THLE

1/1.6

(15) Centre floor side section* (see 41B , Centre lowerstructure, Central floor, sidesection: Description, page41B-10)

VHLE 0.7/2.5

(16) Exhaust mounting support (see 41D, Rear lower struc-ture, Exhaust mounting sup-

port: Description, page 41D-39)

- 1.2/2.5

(17) Fuel tank mounting support (see 41D, Rear lower struc-ture, Tank mounting sup-


- 1.2







(18) Rear floor, front section* (see 41D, Rear lower struc-ture, Rear floor, front sec-tion: Description, page 41D-8)

HLE 0.7/2.5

(19) Sill panel rear stiffener* (see 41C , Side lower struc-ture, Sill panel rear reinfor-cement: Description, page41C-21)

HLE 1.4

(20) Sill panel reinforcement stiffener VHLE 1.8

(21) Front cross member under rear seat (see 41D, Rear lower struc-ture, Front cross member

under rear seat: Description,page 41D-33)

HLE 1.3/1.5

(22) Rear cross member under rear seat (see 41D, Rear lower struc-ture, Rear cross memberunder rear seat: Description,page 41D-36)

HLE 1.8/2

(23) Rear floor panel front cross member,centre section

(see 41D, Rear lower struc-ture, Rear floor front crossmember, centre section:Description, page 41D-28)

HLE 1.2/2





Vehicle structure rear section: Description 40AREAR STRUCTURE

104366


(1) Rear wing panel* (see 44A, Rear upper structure, Rear wingpanel: Description, page 44A-5)

- 0.7

(2) Quarter panel lining* (see 4 4 A, Rear upper structure, Quarterpanel lining: Description, page 44A-26)

- 0.6

(3) Rear quarter upper rein-forcement*

(see 4 4 A, Rear upper structure, Quarterpanel upper reinforcement: Description, page44A-28)

- 1

(4) Far rear lower crossmember, side section*

(see 4 1 D, Rear lower structure, Far rearlower cross member, side section: Descrip-tion, page 41D-32)

0.95

(5) Rear end panel (see 44A, Rear upper structure, Rear endpanel: Description, page 44A-32)

- 0.7

(6) Rear end panel sidelining*

(see 44A, Rear upper structure, Rear endpanel side lining: Description, page 44A-33)

- 0.7

(7) Rear end panel assem-bly*

(see 44A, Rear upper structure, Rear endpanel assembly: Description, page 44A-30)

HLE/ THLE

0.65/2.5




Vehicle structure rear section: Description 40A


(8) Rear floor centre crossmember

(see 41D, Rear lower structure, Rear floorcentre cross member: Description, page 41D-31)

HLE 1/2.5

(9) Rear side member* (see 41D, Rear lower structure, Rear sidemember: Description, page 41D-21)

HLE/ THLE

0.95/2

(10) Impact cross membermounting stiffener

(see Rear impact cross member mountingreinforcement: Description )

HLE 2

(11) Rear wheel arch rearsection*

(see 44A, Rear upper structure, Inner wheelarch: Description, page 44A-19)

HLE 0.7

(12) Rear light mounting* (see 44A , Rear upper structure, Rear lightssupport: Description, page 44A-11)

- 1

(13) Rear side member clo-sure panel, rear section*

(see 41D, Rear lower structure, Rear sidemember closure panel, rear section: Descrip-tion, page 41D-26)

- 0.7

(14) Inner rear wheel arch* (see 44A, Rear upper structure, Inner wheelarch: Description, page 44A-19)

HLE 0.7

(15) Rear wheel arch closurepanel front section*

(see 44A, Rear upper structure, Rear wheelarch closure panel, front section: Descrip-tion, page 44A-20)

- 1

(16) Rear wheel arch closurepanel, rear section

(see 44A, Rear upper structure, Rear wheelarch closure panel, rear section: Description,page 44A-22)

- 0.7

(17) Light mounting lining* (see 44A, Rear upper structure, Lights sup-port lining: Description, page 44A-14)

HLE 1/1.2

(18) Quarter panel reinforce-ment*

(see 4 4 A, Rear upper structure, Quarterpanel reinforcement: Description, page 44A-25)

- 1.5





Vehicle removable section structure: Description 40ASTRUCTURE WHICH CAN BE DISMANTLED

104694

Mark Description Classification Type

(1) Frontal impact cross member (see 41A, Front lower structure,Front impact cross member:Removal - Refitting, page 41A-8)

Aluminium

(2) Radiator mounting cross member (see 41A, Front lower structure,Radiator support cross member:Removal - Refitting, page 41A-12)

(3) Front end panel centre section (see 42A, Upper front structure,Front: Removal - Refitting, page42A-21)

Steel/SMC

(4) Front end panel side section (see 42A, Upper front structure,Front: Removal - Refitting, page42A-21)

SMC

(5) Bonnet (see 48A, Non-side opening ele-ments, Bonnet: Removal - Refit-ting, page 48A-5)

Aluminium

(6) Front wing upper mounting bracket (see 42A, Upper front structure,Front wing upper mounting sup-port: Removal - Refitting, page42A-18)




Vehicle removable section structure: Description 40A


(7) Front wing (see 42A, Upper front structure,Front wing: Removal - Refitting,page 42A-10)

Noryl

(8) Front wing lower mounting support (see 42A, Upper front structure,Front wing lower mounting sup-port: Removal - Refitting, page42A-16)

(9) Dashboard cross member (see 42A, Upper front structure,Dashboard cross mem ber :Removal - Refitting, page 42A-41)

(10) Bulkhead plate (see 42A, Upper front structure,Bulkhead panel: Removal - Refit-

ting, page 42A-53)

Aluminium

(11) Front side door (see 47A , Side opening ele-ments, Front side door: Removal- Refitting, page 47A-5)

(12) Rear side door* (see 47A , Side opening ele-ments, Rear side door: Removal- Refitting, page 47A-15)

(13) Fuel filler flap cover (see 47A , Side opening ele-ments, Fuel filler flap cover:Removal - Refitting, page 47A-24)

Noryl

(14) Rear floor rear section* ( (see Rear floor rear section:Description)

(15) Rear impact lower cross member (see 41D , Rear lower structure,Rear impact lower cross mem-ber: Removal - Refitting, page41D-42)

Polypropy-lene

(16) Tailgate (see 48A, Non-side opening ele-ments, Tailgate: Removal - Refit-ting, page 48A-11)




GENERAL VEHICLE INFORMATIONStructure components to be positioned on body repair bench: Description 40A

PART REQUIRING REPAIRS IN BODY JIG BENCH

- (1) Engine stand.

- (2) Front wheel arch.

- (3) Front half unit.

- (4) Front side member.

- (5) Radiator cross member mounting.

- (6) Front sub-frame front mounting unit.

- (7) Front sub-frame rear mounting unit.

- (8) Rear side member.

I - PRINCIPAL REFERENCE POINTS FOR SETTINGTRIM HEIGHT

1 - A - FRONT SUB-FRAME REAR MOUNTING

This is the principal front reference point for setting thetrim height.

a - Front mechanical components in place

The bracket covers the sub-frame mounting bolt (A) .

102044

101152




Two possible cases can arise:

- For rebuilding the rear of the vehicle, these two points

alone can be used to align and support the front of the

vehicle.

- For a light frontal impact not requiring removal of thefront axle sub-frame.

If in doubt about the damage to one of the main refe-

rence points (A or B), use the two additional points lo-

cated in the area not affected by the impact to confirmthe trim height.

b - Front mechanical components removed

If replacing the sub-frame rear support, this reference

point is replaced temporarily by point (G), located on

the rear part of the front side member, point (A) thus

being used for positioning the replaced component.

2 - B - REAR AXLE FRONT MOUNTING

This is the principal rear reference point for setting thetrim height.

a - Rear mechanical components in place

The bracket covers the rear axle bearing mountingbolts.

Used for a frontal impact or a light rear impact.

b - Rear mechanical components removed

101091

Note:

- on the left-hand side, the hole is round;

- on the right-hand side, it is a slot.

WARNING

This point contributes to ensuring the front axlegeometry, it aligns the front axle sub-frame with thebody and directly influences all the angles of thefront axle.

101154

101092




The bracket is supporting the underneath of the rearaxle assembly mounting unit and is centred in thethreaded holes of the rear axle bearing mounting.

If the complete rear side member is being replaced,this reference point is replaced by point (G) located onthe rear section of the front side member, points (B)being used to position the replaced component.

II - REFERENCE POINTS FOR POSITIONING THEPARTS REPLACED

1 - C - FRONT SUB-FRAME FRONT MOUNTINGUNIT

With just the front mechanical components removed,the bracket rests under the front sub-frame front moun-ting unit and is centred in the threaded hole of the sub-frame mounting.

It is used when replacing:

- a partial or complete front side member,

- a half unit.

2 - F - FRONT SHOCK ABSORBER UPPERMOUNTING

The bracket rests under the shock absorber cup and iscentred in the shock absorber cup hole.

It is used when replacing:

- a wheel arch,

- a front half unit.

It is also used when straightening.

WARNING

These points are used to align the rear axle with thebody and directly influence the vehicle trajectoryangle.

101090

WARNING

This point helps to maintain the front axle geometry.It directly influences the clearance in the space of

the lower wishbone and therefore the variations incastor angle and wheel alignment.

101088

WARNING

This point helps to maintain the front axle geometry.It directly influences the camber and castor pivotangles.




3 - P - ENGINE MOUNTING

The bracket is positioned from above the engine moun-ting and is centred in the mounting hole of the axle.

It should be used with the mechanical components re-moved for the replacement of:


- a front wheel arch.

4 - H - END OF FRONT SIDE MEMBER

The bracket rests under the side member and is cen-tred in the threaded hole of the radiator mounting crossmember.

It should be used with the mechanical components re-moved for the replacement of:

- a side member,


- a radiator cross member mounting support.

5 - K - FRONTAL IMPACT CROSS MEMBERMOUNTING

The bracket rests vertically against the radiator crossmember mounting and is centred in the threadedmounting holes of the frontal impact cross member.

When rebuilding, points (K) are used for replacing:

- a radiator cross member mounting,

- a partial or complete front side member,

- a half unit.

101094

101090

101093




They are also used as reference points for point (K3)for mounting the front wing upper support.

6 - J - REAR SIDE MEMBER END

The bracket rests under the side member and is cen-tred in the leader pin hole.

It should be used with the mechanical components inplace to realign a side member.

It is also used with the mechanical components remo-ved, in the same conditions, to replace the side mem-ber.

7 - E - REAR SHOCK ABSORBER MOUNTING

The bracket is centred and attached inside the shockabsorber shaft.

It should be used when replacing a complete rear sidemember.

8 - L - REAR END PANEL CROSS MEMBER

The bracket rests vertically against the side lining ofthe rear end panel and is centred on the rear impact

cross member mounting studs.

They are used when replacing:

- an impact cross member mounting stiffener,

101093

101087

101089

101095




- a partial or complete rear side member.




Structural bodywork reference material: Use 40AI - - CLASSIFYING INFORMATION

This information is classified in two additional docu-ments:

1 - Vehicle structure bodywork repair procedures(MR of the vehicle concerned)

This document comprises two sections:

a - Section 0:

This section does not contain repair procedures, it onlycontains descriptive information; It consists of severalsubsections:

- 01C Vehicle bodywork specifications

- 02A Lifting equipment

- 02B Bodywork innovations

- 03B Collision

- 04E Paintwork

- 05B Bodywork equipment and tooling

b - Section 4:

This section consists of several subsections:

- 40A General information

- 41A Lower front structure

- 41B Lower central structure

- 41C Lower side structure

- 41D Lower rear structure

- 42A Upper front structure

- 43A Upper side structure

- 44A Upper rear structure

- 45A Top of body

- 47A Side opening elements

- 48A Non-side opening elements

These subsections are linked to the ReplacementParts Catalogue and contain two types of information

- Part 1: General description containing information re-

lating to generic structural spare parts and to their de-sign. This information may be the same for severalvehicles.

- Part 2: Description, removal and refitting, strip and re-build, and adjustment; contains information about thestructure of the replacement parts and contains spe-cial notes about the vehicle being worked on.

2 - Fundamentals of structural bodywork repair(MR 400)

This document comprises two sections:

a - Section 0:

This section does not contain any repair procedures; it

only contains descriptive information and has only onesubsection:

- 03B Collision

b - Section 4:

This section contains information for using materialsand products, and the fundamental operating rangeswhich relate to the sheet metal worker's work. This sec-tion only contains a single subsection.

- 40A Structure general information

II - INFORMATION SEARCH

WARNING

Always read both parts in order to have all the

necessary information to repair the vehicle.

Questions Answers

Specifications of specific tools to repair a given vehi-cle.

Refer firstly to section 0 of the Vehicle's MR then referto the « special tooling catalogue » or the « garageequipment catalogue » .

Specifications of specific products to repair a givenvehicle.

Firstly refer to section 0 of the Vehicle's MR then referto the « IXELL product catalogue » .




Structural bodywork reference material: Use 40A

Use of a specific tool to repair a given vehicle. Firstly refer to subsection 0 of the Vehicle's MR

Using a bodywork tool. Firstly refer to subsection 40 of the Vehicle MR then

MR 400

Information concerning the replacement parts of agiven vehicle regarding:

- The replacement possibilities with the position onthe vehicle.

- A conversion before assembly.

- A cutting area with the special features of this cut.

- Special features of right-left symmetry.

- Special features of the version or equipment.

Refer to the subsection which corresponds to the partconcerned: 41 to 48 of the Vehicle MR, part 2

Information concerning the spare parts of a givenvehicle, the composition and the specifications ofeach part it contains.

Firstly refer to the parts description exploded view insubsection 40 of the Vehicle MR.

If this is detailed in the document, refer to subsections41 to 48 of the Vehicle MR part 2 which correspondswith the part concerned.

If this does not appear in the description, refer to sub-section 41 to 48 for the part in the next level up.

Information concerning:

- Details of panel overlap on a joint.- A procedure and an operational mode relating to a

new type of assembly in Renault.

- A procedure for using a tool or a new product whichis unfamiliar in Renault.

Refer to the subsection which corresponds to the partconcerned: 41 to 48 of the Vehicle MR then subsec-

tion 40 of Vehicle MR 400.

Towing and raising a vehicle after an accident. Firstly refer to subsection 40 of the Vehicle MR thenthe equipment catalogue.

Conveyance and handling of a vehicle after an acci-dent.

Firstly refer to subsection 40 of the MR 400 then theequipment catalogue.

Combination of impacts to repair a given vehicle. Refer to section 0 of the Vehicle's MR

Logic of the impact combination. Refer to section 0 of the Vehicle's MR

Fault finding on an impact for a given vehicle. Firstly refer to section 0 of the Vehicle's MR then sec-tion 0 of MR 400.

Questions Answers




Structural bodywork reference material: Use 40A

Logic of impact fault finding. Section 0 of MR 400.

General instructions for:

- Repair.

- Safety.

- Preparing a vehicle.

- Classification of tools.

- Precautions for repair.

Section 0 of MR 400.

Questions Answers



FRONT LOWER STRUCTURE


104367



HLE 1.2



HLE/

THLE

0.7/2.5


- 1.2


HLE/ THLE

1.1/3




HLE/ THLE

1.7/3




Vehicle front section structure: Description 41A

(6) Front mounting of front sub-frame (see 41A , Front lower struc-ture, F ront mounting of frontsub-frame: Description, page41A-31)

HLE 1.2

(7) Radiator cross member support (see 41A , Front lower struc-ture, Radiator cross membersupport: Description, page 41A-28)

- 1.2/2.5

(8) Front side member (see 41A , Front lower struc-ture, Front side member: Des-cription, page 41A-16)

HLE/ THLE

1.2/3

(9) Battery tray support (see 41A , Front lower struc-ture, Battery tray support: Des-cription, page 41A-26)

- 1.5/2

(10) Right-hand front half unit (see 41A , Front lower struc-ture, Front half unit: Descrip-tion, page 41A-38)

HLE/ THLE

1.1/3


- 1.2

(12) Engine stand (see 41A , Front lower struc-ture, Engine mounting: Des-


HLE 1.5/2

(13) Wheel arch (see 42A, Upper front struc-ture, Front wheel arch: Descrip-tion, page 42A-33)

- 1.1/2

(14) Engine tie-bar mounting HLE 1

(15) Sub-frame rear mounting (see Sub-frame rear mounting:Description )

HLE/ THLE

2/3

(16) Centre floor front side cross member (see 41B, Centre lower struc-ture, Centre floor front lateral

cross member: Description,page 41B-19)

HLE/ THLE

1.2/3

(17) Connecting bracket - -


HLE 1.1/2






104693



VHLE 2.5



- 0.9


UHLE 1.7


42A-50)

UHLE 1.7






HLE 0.95/3


- 1



- 0.7/1.5


- 0.7/1.2


HLE 1.5



HLE 1.5/2.5


HLE 1.5



HLE/ THLE

1/1.6


VHLE 0.7/2.5



- 1.2/2.5



- 1.2








HLE 0.7/2.5


HLE 1.4




HLE 1.3/1.5


HLE 1.8/2



HLE 1.2/2






104694



Aluminium



Steel/SMC


SMC


Aluminium








Noryl




ting, page 42A-53)

Aluminium




Noryl



Polypropy-lene






Front impact cross member: Removal - Refitting 41A

REMOVAL

I - REMOVAL PREPARATION OPERATION

Remove:

- the front bumper( (see Front bumper: Removal -Refitting) ,

- the headlights( (see Halogen headlight: Removal

- Refitting) .

II - OPERATION FOR REMOVAL OF PARTCONCERNED

Remove the side mounting bolts (1) (three on eitherside).

Move the retaining clips on the front end panel awayusing a flat-blade screwdriver and detach the frontalimpact cross member.

REFITTING

I - REFITTING OPERATION FOR PARTCONCERNED

Refit:

- the front impact cross member,

- the side mounting bolts (1) (three on each side).

Tighten to torque:

- the side mounting bolts (44 Nm) ,

- the unit bolts (35 Nm) .

II - FINAL OPERATION

Refit:

- Refit the headlights( (see Halogen headlight: Re-moval - Refitting) ,

- the front bumper( (see Front bumper: Removal -Refitting) .

Tightening torquesm

side mounting bolts 44 Nm

unit bolts 35 Nm

103897

Note:

Depending on the degree of impact, it may bepossible to replace the cross member via the unitbolts (2) .

101165

WARNING

The cross member contributes to the structuralrigidity of the engine compartment. For this

reason, the tightening torque must be observedfollowing any operation.




Lower front end cross member: General description 41A

DESIGN OF THE STRUCTURAL COMPONENT

A special feature of this part is that it is bolted to theends of the front side members via the radiator crossmember mounting support.

WARNING

The information contained in the following descri-bes the general repair procedure for all vehicles

having the same design for this part.

Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special notes will be specified if applica-ble in other parts of this subsection dealing with thepart.

Note:

For a detailed description of a particular connec-

tion, see MR 400, 40A, General Information .

110517




Front end side cross member: Description 41AThere is only one way of replacing this part:

- complete replacement.

I - COMPOSITION OF THE SPARE PART

Right-hand side

Left-hand side

II - PART FITTED

Right-hand side

Left-hand side

102624

101414

Mark Description Type Thickness

(mm)

(1) Front end sidecross member

- 1.2

101762

101591

WARNING

If the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,these should be replaced with plug welds afterholes have been drilled in the first panel.




Radiator support cross member: General description 41A


The distinctive feature of this part is that it combinestwo functions:

- distributing the force of frontal impacts,

- radiator mounting cross member.

WARNING




Note:



110077




Radiator support cross member: Removal - Refitting 41A

REMOVAL


Remove the front bumper( (see Front bumper: Re-moval - Refitting) .

Attach the radiator upper section.

Remove the engine undertray.


Remove:

- the mounting bolts (1) , (2) and (3) ,

- the radiator mounting cross member.

REFITTING


Refit:

- the radiator mounting cross member,

- the mounting bolts (1) , (2) and (3) .

Tighten to torque:

- the mounting nut (1) (21 Nm) ,

- the mounting bolts (2) (105 Nm) ,

- the mounting bolts (3) (62 Nm) .


Refit the engine undertray.

Detach the radiator upper section.

Refit the front bumper( (see Front bumper: Remo-val - Refitting) .

Tightening torquesm

the mounting nut (1) 21 Nm

the mounting bolts (2) 105 Nm

the mounting bolts (3) 62 Nm

102009




Front side member: General description 41A

I - DESIGN OF THE STRUCTURAL COMPONENT

The special feature of this type of part is that it combi-nes the functions of front section and rear section ofthe front side member and that it is made of two diffe-rent kinds of panels of different thicknesses assembledby laser butt welding.

II - AREA TO BE CUT FOR PARTIALREPLACEMENT

1 - 1- Cut 1:

This line shows the centre of the area in which it is pos-sible to carry out a partial replacement.

This operation allows you to access the inside of thehollow section of the structural element to straighten it.

In this case, the side member weld line must be stag-gered from that of its closure panel.

WARNING




IMPORTANT

The straightening bench must be used.

Note:

For a detailed description of a particular connec-tion, see MR 400, 40A, General Information .

110509

110510

Note:

For the partial replacement of parts constituting asingle structural component, it is essential to stag-ger the welds of each of the components.

1

2




Front side member: General description 41A

2 - 2 - Cut 2:

The cut is made along the butt weld.III - ASSEMBLY METHOD FOR A PARTIALREPLACEMENT

Only the connections which are specific to the partialreplacement by cutting are indicated.

108391

108396

108392

108390

WARNING

If the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,they should be replaced with plug welds after holeshave been drilled in the first panel.




Front side member: General description 41AIf there are other issues regarding access to mating fa-ces, the various replacement options are described inthe basic instructions for structural bodywork repair(see MR 400, 40A, General Information ).

Lines (3) and (4) of the diagram show a butt weld bycontinuous MAG welding.

Weld (4) along the butt weld line.

110511

3

4




Front side member: Description 41ARight-hand side

Left-hand side

The options for replacing this part are as follows:

- partial replacement of the front section,

- partial replacement.


Right-hand side

Left-hand side

115690

115689

115114

115115




Front side member: Description 41AII - PART FITTED

1 - Partial replacement of the front section

Right-hand side

Left-hand side

Mark Description Type Thickness(mm)

(1) Front section offront side mem-ber

HLE/ THLE 1.7/2.5

(2) Bulkhead crossmember right-hand bracket

- 1.5

(3) Stiffener unit forend of sidemember

VHLE 1.8

(4) Impact absorber

mounting unit

HLE/

THLE

1.2/3

(5) Sub-framemounting unit

HLE 1.8/3

(6) Front side mem-ber reinforce-ment

HLE 1.5

(7) Reinforcementfor gearbox onside member

- 1.5

(8) Side plate moun-ting reinforce-ment

- 1.7

101757

101756




Front side member: Description 41A2 - Partial replacement

Preparation of the replacement part

Right-hand side

To make the cut, unclip the connecting bracket (B) .

Left-hand side

III - POSITIONING OF LOCAL ELECTRICALEARTHS

101754

Note:

When cutting, be careful not to damage the rearinner reinforcement (A) .

101758

Note:

Do not reuse the connecting bracket previouslyremoved, a new one is available from the PartsDepartment .

101755

WARNING

The position of this cut must be observed, and isdetermined according to the position of the internal

reinforcements cut or the acoustic inserts.

115075




Front side member: Description 41A

115076

IMPORTANT

To avoid damaging the vehicle's electric and elec-tronic components, the battery and the earths ofany wiring harness near the weld area must be dis-connected.





Front section of front side member closure panel: General description 41A


The special feature of this type of part is that it combi-nes the functions of both the front section and rear sec-tion of the front side member closure panel and that itis made of two different kinds of panels of different thic-knesses assembled by laser butt welding.


1 - Cut 1:

This line shows the centre of the area in which it is pos-sible to carry out a partial replacement.

This operation allows you to access the inside of thehollow section of the structural component to straigh-ten it.

WARNING



Before reading the following general information,make sure that there are no special notes associa-ted with the vehicle. These special notes are speci-fied if necessary in other parts of the sub-sectiondealing with the component.

IMPORTANT


Note:


110512

Note:


101418




Front section of front side member closure panel: General description 41A

2 - Cut 2:

The cut must be made on the splice.

III - ASSEMBLY INSTRUCTIONS FOR A PARTIAL

REPLACEMENT

In this case, the side member weld line must be stag-gered from that of its closure panel.


For other issues of access to mating faces, the variousreplacement options are described in the structural bo-dywork repair basics (see MR 400, 40A, General in-formation ).



101596

101598

Note:


WARNING


110514

4

3




Front section of front side member closure panel: Description 41ARight-hand side

Left-hand side


- partial replacement of the front section: this operationcomplements straightening the radiator cross mem-ber mounting,

- partial replacement: this operation complements thepartial replacement of the front side member,


Right-hand side

Left-hand side

115688

115687

115111

115112




Front section of front side member closure panel: Description 41A

II - PART FITTED


2 - Partial replacement


(1) Side memberclosure panel HEL/ THLE 1.7/2.5

(2) Front assemblymounting unitclosure panelcomponent

HEL 1.8

(3) Brake hose stopbracket

- 2

(4) Additional unitinterior closure

panel compo-nent

HEL 1.2

(5) Washer fluidreservoir moun-ting

HEL 2

(6) Interior closurepanel compo-nent

HEL 1.5

(7) Front towing ring - -

101597

WARNING

If the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,

these should be replaced with plug welds afterholes have been drilled in the first panel.

101598

WARNING

Do not move the position of this weld as it is deter-mined by the position of the linings, reinforcementsor expanding inserts.




Front section of front side member closure panel: Description 41AIII - POSITIONING OF LOCAL ELECTRICALEARTHS

115075

115076

IMPORTANT

To avoid damaging the vehicle's electric and elec-

tronic components, the battery and the earths ofany wiring harness near the weld area must be dis-connected.

The earth of the welding machine must be placed

as close as possible to the weld area.




Battery tray support: General description 41A


This part functions only as a battery tray bracket. It iswelded to the vehicle structure.

WARNING




Note:



101415




Battery tray support: Description 41A

There is only one way of replacing this part:



II - PART FITTED

Complete replacement

101415

115119


(1) Battery t rayupper section - 2

(2) Battery t raylower section

- 1.5

(3) Air filter retai-ning bracket

- 1.2

115120

WARNING





Radiator cross member mounting: General description 41A


It is composed of the following components:

- cross member mounting component (1) ,

- mounting support unit (2) .

This part acts as:

- a radiator cross member support,

- front end cross member support,

- front end panel support.

WARNING




IMPORTANT


Note:


107397

2

1




Radiator cross member support: Description 41A

To replace this part, order an additional connectingbracket (A) .




II - PART FITTED


115683

Note:A straightening bench is essential when simulta-neously replacing the left-hand and right-handparts.

115108


(1) Radiator crossmember moun-ting unit

HEL 1.2

(2) Radiator crossmember moun-t ing closurepanel

HEL 2.5

101590

WARNINGIf the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,these should be replaced with plug welds afterholes have been drilled in the first panel.




Radiator cross member support: Description 41AIII - STRAIGHTENING

101589

Note:

When straightening a radiator cross member moun-ting, the side member closure panel can be partiallyreplaced to access the damaged area.




Front mounting of front sub-frame: General description 41A


This is a basic part; it functions only as a front mountingof front sub-frame.

WARNING




IMPORTANT


Note:


101422




Front mounting of front sub-frame: Description 41AThere is only one way of replacing this part:



II - PART FITTED

complete replacement

Note:


101422


(1) Front mountingof front sub-frame

HEL 1.8

115110

WARNING

If the spot welds cannot be made as they were ori-

ginally using an electrical spot welding machine,these should be replaced with plug welds afterholes have been drilled in the first panel.




Engine mounting: General description 41A


This is a basic part; it only functions as an enginemounting.

WARNING



Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special features will be specified if appli-cable in other parts of this sub-section dealing withthe part.

IMPORTANT


Note:


102623




Engine mounting: Description 41A


- complete replacement: this operation complementsthe replacement of the scuttle panel for a frontal im-pact and the partial replacement of the front sidemember and front wheel arch for a right-hand side im-pact.


II - PART FITTED


102623

Note:


115263


(1) Engine moun-ting rear section HEL 1.5

(2) engine moun-ting upper sec-tion

HEL 2

(3) Engine moun-t ing he igh tadjuster reinfor-cement

- 2

(4) Engine moun-

ting rear reinfor-cement

- 2

101761

WARNING





Sub-frame rear mounting: General description 41A


This is a basic part; its only function is that of a frontsub-frame rear cross member.

WARNING




IMPORTANT


Note:


110547




Sub-frame rear mounting: Description 41A




II - PART FITTED


101420

115121


(1) Sub-frame rearmounting HEL 2

(2) Sub-frame rearmounting rein-forcement

THLE 3

101999




Sub-frame rear mounting: Description 41ACut A

115123

WARNING





Front half unit: General description 41A


The special feature of this type of part is that it acts si-multaneously as front side member, front wheel arch,centre floor front side cross member and front end sidecross member and is composed of several differentkinds of panels of different thicknesses.

WARNING




IMPORTANT


Note:


109546




Front half unit: Description 41ARight-hand side

Left-hand side

To replace this part, order an additional engine tie-barmounting (A) or connecting bracket (B) depending onthe impact side.



101604

101603




Front half unit: Description 41AI - COMPOSITION OF THE SPARE PART

Right-hand side

115124




Front half unit: Description 41ALeft-hand side

II - PART FITTED


115125


(1) Front side mem-ber

HEL/ THLE

1.5/3

(2) Front section offront side mem-ber c losurepanel

HEL/ THLE

1.2/2.5

(3) Front wheel arch HEL 1.1/2

(4) Engine suppor t HEL 1.5/2

(5) Front end sidecross member

HEL 1.5

(6) Sub-frame rearmounting

HEL/ THLE

2/3

(7) Centre floorfront side crossmember

HEL/ THLE

1.2/3

(8) Battery t raybracket

- 1.5/2115126




Front half unit: Description 41A


IMPORTANT

For welded connections in three thicknesses, thespot welds on the part replaced should be made in

the same place as for the original joint to retain itsmechanical properties.

WARNING


115075

115076

IMPORTANT




http://slidepdf.com/reader/full/manual-service-renault-scenic-2-tablarie 85/35541B-1

CENTRE LOWER STRUCTURE

Vehicle front section structure: Description 41BFRONT STRUCTURE

104367



HLE 1.2



HLE/

THLE

0.7/2.5


- 1.2


HLE/ THLE

1.1/3




HLE/ THLE

1.7/3




Vehicle front section structure: Description 41B


HLE 1.2


- 1.2/2.5


HLE/ THLE

1.2/3


- 1.5/2


HLE/ THLE

1.1/3


- 1.2



HLE 1.5/2


- 1.1/2



HLE/ THLE

2/3



HLE/ THLE

1.2/3



HLE 1.1/2





Vehicle side section structure: Description 41BLATERAL STRUCTURE

104368



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


- 0.7


- 0.7


- 0.7




Vehicle side section structure: Description 41B



THLE/ HLE

1.2/2.5


HLE 2


HLE 1


HLE 1.8


- 0.7


HLE 1.5


- 1


HLE 1.2


HLE 0.7


HLE 1.5



- 1/1.5


- 1/1.5


- 0.7


- 0.7


page 45A-7)

- 0.7





Vehicle central section structure: Description 41BCENTRAL STRUCTURE

104693



VHLE 2.5



- 0.9


UHLE 1.7


42A-50)

UHLE 1.7




Vehicle central section structure: Description 41B


HLE 0.95/3


- 1



- 0.7/1.5


- 0.7/1.2


HLE 1.5



HLE 1.5/2.5


HLE 1.5



HLE/ THLE

1/1.6


VHLE 0.7/2.5



- 1.2/2.5



- 1.2





Vehicle central section structure: Description 41B



HLE 0.7/2.5


HLE 1.4




HLE 1.3/1.5


HLE 1.8/2



HLE 1.2/2





Centre floor, side section: General description 41B


The special feature of this type of part is that it is madeof two different kinds of panels of different thicknessesassembled by laser butt welding.


These cutting lines show the area in which it is possibleto carry out a partial replacement of the centre floorside section.

Cut 1, 2 and 3:

- cut (1) affects the partial replacement of the centrefloor side section.

- cuts (1) and (2) affect the partial replacement of therear section of the centre floor side section.

- cuts (1) and (3) affect the partial replacement of thefront section of the centre floor side section.

III - ASSEMBLY METHOD FOR A PARTIAL

REPLACEMENT


If there are other issues regarding access to mating fa-ces, the various replacement options are described inthe basic instructions for structural bodywork repair(see MR 400, 40A, General Information ).

WARNING




Note:



110500

110501

WARNING


3

2

1




Centre floor, side section: General description 41B

Line (1) in the drawing shows partial replacement and

a weld by joggling with plug welds at regular intervals.

Lines (1) and (2) in the diagram show the partial rearreplacement and a weld by joggling with plug welds atregular intervals.

Lines (1) and (2) in the diagram show the partial front

replacement and a weld by joggling with plug welds atregular intervals.

110502

110504

1

1

2

110503

1 3




Central floor, side section: Description 41B


- partial replacement of front end section: this operationcomplements the replacement of the A-pillar reinfor-cement,

- partial replacement of the front section,

- partial replacement of the rear section: this operationcomplements the replacement of the B-pillar reinfor-cement,



II - PART FITTED

1 - Partial replacement of the front end section

115691

115129


(1) Sidefloor - 0.7

(2) Centre sidemember reinfor-cement

THLE 2.5

(3) Centre sidemember

THLE 2

103089




Central floor, side section: Description 41B2 - Partial replacement of the front section

3 - Partial replacement of the rear section

4 - Complete replacement


103088

103090

115132

WARNING


115077




Central floor, side section: Description 41B

IMPORTANT







Centre floor stiffener: General description 41B


This is a basic part; it only fulfils the function of a centrefloor stiffener.

WARNING




Note:

For detailed instructions about a particular joint, see

MR 400, 40A, General Information .

104566

WARNING





Centre floor stiffener: Description 41BThere is only one way of replacing this part:



II - PART FITTED

Cut A

104566


(mm)

(1) Centre floor stif-fener

HLE 1.8

105394

115134

WARNING





Tunnel: Description 41B


- Complete replacement: this operation complementsthe complete replacement of the centre floor side sec-tion for a side impact.


II - PART FITTED

Front section

(X1) = 255 mm

115692

115136


(1) Tunnel - 1

(2) Centre crossmemberbeneath tunnel

HLE 1.5

(3) Steering columnmounting flange

- 1.3

(4) Steering columnmounting anglebracket

- 1.3

(5) Tunnel reinfor-cement THLE 1.6

(6) Rear secti ontunnel reinforce-ment

THLE 1.8

Note:

The spare part is supplied with the left-hand driveversion of the steering column mounting flange

only.In the case of a right-hand drive vehicle, it is neces-sary to order a right-hand steering column moun-ting available from the Parts Department andunclip the left-hand side version.

105933




Tunnel: Description 41B

Rear section

Note:

For right-hand drive vehicles, observe the valueindicated before to position the steering columnmounting flange.

105935

WARNING


they should be replaced with plug welds after holeshave been drilled in the first panel.




Centre floor front lateral cross member: General description 41B


This is a basic part; it functions only as a centre floorfront side cross member.


Line (1) in the diagram shows the area in which it ispossible to carry out a partial replacement.

III - ASSEMBLY METHOD FOR A PARTIALREPLACEMENT


If there are other issues regarding access to mating fa-ces, the various replacement options are described in

the basic instructions for structural bodywork repair(see MR 400, 40A, General Information ).

WARNING




IMPORTANT

For complete replacement, the straightening benchmust be used.

Note:

For detailed instructions about a particular join, seeMR400, 40A, General information .

110598

110599

WARNING


1




Centre floor front lateral cross member: General description 41B

Line (3) in the diagram shows a butt weld by conti-

nuous MAG welding.

110600

3




Centre floor front lateral cross member: Description 41B


- partial replacement,



II - PART FITTED


101417

115133

Mark Description Type Thic-kness(mm)

(1) Front side crossmember

HEL 1.2

(2) Front side crossmember reinfor-cement

- 1.5

(3) Front side crossmember impactreinforcement

THLE 3

101998

Note:

The cut is made at the end of the front side mem-ber.




Centre floor front lateral cross member: Description 41B2 - Complete replacement

102000

WARNING





Front cross member under front seat: General description 41B


This is a basic part; its function is to secure the frontsection of the front seat and to stiffen the bodywork inthe event of a side impact.

WARNING



Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special notes will be specified if applica-ble in other parts of this sub-section dealing withthe part.

Note:

For detailed instructions about a particular join, see

MR400, 40A, General information .

110507




Front cross member under front seat: Description 41B




II - PART FITTED


102653

115139


(1) Fron t cro ssmember underfront seat

HEL 1.5

(2) Seat mountingreinforcement

HEL 1.5

WARNING

If the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,these should be replaced with plug welds after

holes have been drilled in the first panel.

102954




Front cross member under front seat: Description 41B2 - Fitting the cross member

Left-hand side

(X1) = 355 mm

Right-hand side

(X2) = 355 mm

102952

102953

Note:

It is essential to observe the values indicatedbefore.




Front seat rear mounting interior unit: Description 41BThere is only one way of replacing this part:



II - PART FITTED

(X1) = 355 mm

102654

Number Description Type Thickness

(mm)

(1) Front seat rearinner mountingunit

HEL 1.5

102952

Note:

It is necessary to respect the dimension previouslyindicated.




Front seat rear outer mounting unit: Description 41B




II - PART FITTED

(X1) = 355 mm

102652

115140

Number Description Type Thickness(mm)

(1) Fron t sea tmounting unit HEL 1.5

(2) Fron t sea tmounting rein-forcement

HEL 1.5

WARNING

If the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,they should be replaced with plug welds after holes

have been drilled in the first panel.

102953

Note:

It is necessary to respect the dimension previouslyindicated.




Rear cross member under front seat: Description

LONG CHASSIS

41B

There is only one way of replacing this part:- complete replacement.


II - PART FITTED

(X1) = 355 mm


115653

115142


(1) Rear crossmember underfront seat

HLE 1.5

(2) Mounting rein-forcement plate

HLE 2.5

106331

WARNING


115077

IMPORTANT




http://slidepdf.com/reader/full/manual-service-renault-scenic-2-tablarie 111/35541C-1

SIDE LOWER STRUCTURE

Vehicle side section structure: Description 41CLATERAL STRUCTURE

104368



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


- 0.7


- 0.7


- 0.7




Vehicle side section structure: Description 41C



THLE/ HLE

1.2/2.5


HLE 2


HLE 1


HLE 1.8


- 0.7


HLE 1.5


- 1


HLE 1.2


HLE 0.7


HLE 1.5



- 1/1.5


- 1/1.5


- 0.7


- 0.7


page 45A-7)

- 0.7





Vehicle central section structure: Description 41CCENTRAL STRUCTURE

104693



VHLE 2.5



- 0.9


UHLE 1.7


42A-50)

UHLE 1.7




Vehicle central section structure: Description 41C


HLE 0.95/3


- 1



- 0.7/1.5


- 0.7/1.2


HLE 1.5



HLE 1.5/2.5


HLE 1.5



HLE/ THLE

1/1.6


VHLE 0.7/2.5



- 1.2/2.5



- 1.2





Vehicle central section structure: Description 41C



HLE 0.7/2.5


HLE 1.4




HLE 1.3/1.5


HLE 1.8/2



HLE 1.2/2





Sill panel: Description 41C

To replace this part, order the expanding inserts cor-

responding to each of the following cases.


- partial replacement of the front end section: order in-sert (A) ,

- partial front replacement: order insert (A) and (B) ,

- partial replacement under door:

- partial replacement centre section: order insert (B) ,

- Complete replacement: order inserts (A) and (B) aswell as an anti-grit protective film (C) .


II - PART FITTED

1 - Partial replacement of the front end section

Cut A

115681

115400


(1) Sill panel - 0.7

(2) Jacking point HLE 1.8

115395

115408




Sill panel: Description 41CCut B

2 - Partial front replacement

Cut C

Cut D

115419

103639

115410

115421




Sill panel: Description 41C3 - Partial replacement under door

Cut E

4 - partial central replacement

Cut F

115403

115417

115402

115412




Sill panel: Description 41C5 - Complete replacement

Cut G

115405

STANDARD CHASSIS

115414




Sill panel: Description 41C

Cut G

III - ANTI-GRAVEL PROTECTION

To fit anti-gravel protective adhesive film, see Techni-cal note 579A, Anti-gravel protective adhesive film,55A, Exterior protection, Anti-gravel protective ad-hesive film .

LONG CHASSIS

115415




Complete sill panel: General description 41C


The special feature of this part is that its lower sectionis butt welded by laser with two different types of paneland two different thicknesses.

This is a basic part; it only functions as a sill panel.

II - AREA TO BE CUT FOR COMPLETEREPLACEMENT

Cut 1, 2 and 3:

These cutting lines show the complete replacement ofthe sill panel.

III - AREA TO BE CUT FOR PARTIALREPLACEMENT

WARNING




Note:



IMPORTANT

Before any operation, remove the front seat belts.

110571

110580

110582

1

4




Complete sill panel: General description 41CCut 1 and 4.

These cutting lines show the partial front replacementof the sill panel.

Cut 3 and 5.

These cutting lines show the partial rear replacementof the sill panel.

Cut 4 and 6.

These cutting lines show the partial under door repla-cement of the sill panel.

It is possible to use cuts made previously to carry outlarger partial replacements:

- front partial replacement,

- rear partial replacement.

These operations allow you to access the inside of thehollow section of the structural element to straighten it.

IV - ASSEMBLY INSTRUCTIONS FOR A PARTIALREPLACEMENT


110578

110572

5

3

6

4

110574

110576




Complete sill panel: General description 41C


Lines (1) , (2) and (5) on the diagram show a butt weldby continuous MAG welding.

All the welds described in this procedure are identical.

WARNING



110575

2

1

5




Full inner sill panel: General description 41C


This is a basic part; it only functions as an inner sill pa-nel.


This part is replaced completely on this type of vehicle.




WARNING




Note:



LONG CHASSIS

104592

LONG CHASSIS

WARNING





Rear inner sill panel: Description 41CThe options for replacing this part are as follows:

- partial front replacement: this operation complementsthe replacement of the B-pillar reinforcement,

- partial rear replacement: this operation supplements

the partial replacement of the exterior section of therear wheel arch (cut specific to this operation),



II - PART FITTED

1 - Partial front replacement

Cut A

104592


(1) Rear inner sillpanel

- 1

105397

115429






Rear inner sill panel: Description 41C

IMPORTANT







Sill panel reinforcement: General description 41C


The distinctive feature of this part is that it combinesseveral functions:

- sill panel reinforcement,

- A-pillar reinforcement

- B-pillar reinforcement,

- body side front section reinforcement.


WARNING




Note:



115657

105381




Sill panel reinforcement: Description 41C

To replace this part, order the expanding inserts cor-

responding to each of the following cases.


- partial replacement of the front section: order insert(A) ,

- Complete replacement: order inserts (A) and (B) .


II - PART FITTED

1 - Partial replacement of the front section115680

115425


(1) Body side frontsection reinfor-cement

HLE 1.2/1.5

(2) Rear-view mir -ror reinforce-ment

- 1.2

(3) Upper hingereinforcement

THLE 2

(4) Lower hi ng ereinforcement

THLE 2.5

102039

WARNING

The position of this cut must be observed, and isdetermined according to the position of the internalreinforcements or acoustic inserts cut.




Sill panel reinforcement: Description 41C2 - Complete replacement

Cut A

Cut B

105381

115426

115427

WARNING


IMPORTANT






Sill panel rear reinforcement: Description 41C

To replace this part, also order the sill panel rear rein-

forcement stiffener (A) .


- Complete replacement: this operation complementsthe replacement of the rear inner sill panel.


II - PART FITTED


102663

102663


(1) Sill panel rearreinforcement HLE 1.4

STANDARD CHASSIS

115433

115435




Sill panel rear reinforcement: Description 41CCut A

Cut B

115432

LONG CHASSIS

115434

115436

115437

Note:

Replace the sill panel rear reinforcement via theinside of the vehicle in order to preserve the B-pillarwhen it is not damaged.




Sill panel rear reinforcement: Description 41C

To straighten the sill panel rear reinforcement, desol-

der the sill panel rear reinforcement stiffener (2) .

102587

WARNING



IMPORTANT

To avoid damaging the vehicle's electric and elec-tronic components, the battery and the earths ofany wiring harness near the weld area must be dis-

connected.





Front jack support: General description 41C


The special feature of this part is that it combines thefunctions of front and rear jacking point.

WARNING



Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special notes will be specified if applica-ble in other parts of this sub-section dealing withthe part.

Note:



102619


http://slidepdf.com/reader/full/manual-service-renault-scenic-2-tablarie 135/35541D-1

REAR LOWER STRUCTURE

Vehicle central section structure: Description 41DCENTRAL STRUCTURE

104693



VHLE 2.5



- 0.9


UHLE 1.7


42A-50)

UHLE 1.7




Vehicle central section structure: Description 41D


HLE 0.95/3


- 1



- 0.7/1.5


- 0.7/1.2


HLE 1.5



HLE 1.5/2.5


HLE 1.5



HLE/ THLE

1/1.6


VHLE 0.7/2.5



- 1.2/2.5



- 1.2





Vehicle central section structure: Description 41D



HLE 0.7/2.5


HLE 1.4




HLE 1.3/1.5


HLE 1.8/2



HLE 1.2/2





Vehicle structure rear section: Description 41DREAR STRUCTURE

104366



- 0.7


- 0.6



- 1



0.95


- 0.7



- 0.7



HLE/ THLE

0.65/2.5




Vehicle structure rear section: Description 41D




HLE 1/2.5


HLE/ THLE

0.95/2



HLE 2



HLE 0.7


- 1



- 0.7


HLE 0.7



- 1



- 0.7


HLE 1/1.2



- 1.5





Rear floor, front section: General description 41D


This is a basic part; its only function is that of rear floorfront section.


Cut 1:

This line marks the area in which it is possible to makea partial replacement.

III - ASSEMBLY INSTRUCTIONS FOR A PARTIALREPLACEMENT



WARNING




Note:



115695

102976

WARNING





Rear floor, front section: General description 41D

Line (2) on the diagram shows a joint made by jogglingconnected with plug welds at regular intervals.

110650




Rear floor, front section: Description 41DThe options for replacing this part are as follows:

- partial replacement: this operation complements thereplacement of the rear section of the body side aftera side impact,



105248

115251




Rear floor, front section: Description 41D

II - PART FITTED





(1) Front section ofrear floor - 0.7

(2) Rear seat moun-ting right-handside stiffener

HLE 1.65

(3) Rear seat moun-ting left-handside stiffener

HLE 1.65

(4) Reservoir frontmounting stiffe-

ner

- 1.2

(5) Cabl e sle evestop support

- 1.2

(6) Exhaust moun-ting support

- 1.2/2.5

(7) Cross memberreinforcement

HLE 0.85

102976

115252

WARNING


115077




Rear floor, front section: Description 41D

115106

IMPORTANT






Rear floor rear section: General description 41D


The special feature of this type of part is that it is affixedto the vehicle by bolts and by a cement bead.

The special feature of this type of part is that it is affixedto the vehicle by bolts and by a cement bead.

II - ASSEMBLY INSTRUCTIONS FOR A PARTIALREPLACEMENT



WARNING




Note:


tion, ( see MR 400, 40A, General information ).

STANDARD CHASSIS

102666

LONG CHASSIS

107239

WARNING


have been drilled in thefirst panel.




Rear floor rear section: Removal - Refitting 41D

REMOVAL


Remove:

- the rear wheel arch liners( (see Rear wheel archliner: Removal - Refitting) ,

- the rear bumper( (see Rear bumper: Removal -Refitting) ,

- the luggage compartment carpet( (see Luggagecompartment carpet: Removal - Refitting) ,

- the emergency spare wheel and the jack.

- the automatic parking brake emergency handle(see MR 370 Chassis, 37B, Automatic parkingbrake, Emergency handle ).

Remove the exhaust silencer mounting bolt (1) .

Remove the silencer towards the rear.

Remove the heat shield mounting bolts (2) .

Remove the heat shield.

Remove:- the two mounting bolts (3) from the reservoir,

- the funnel lower mounting bolt (4) .

Remove:

- the rear wheel arch liners( (see Rear wheel archliner: Removal - Refitting) ,


Tightening torquesm

rear floor rear section

mounting bolts

21 Nm

STANDARD CHASSIS

101107

101108

101109

LONG CHASSIS




Rear floor rear section: Removal - Refitting 41D- the second row rear seats( (see Second row com-plete rear seat: Removal - Refitting) ,



- the automatic parking brake emergency handle(see MR 370 Chassis, 37B, Automatic parkingbrake, Emergency handle ).

Remove the mounting bolts (1) from the body sup-port.

Remove the mounting bolts (2) .

Unclip:

- the cable guide (3) ,

- the cable.

Remove the body support connections.

Unclip the harness.

107245

107246

107249

107248





Remove the mounting bolt (4) .

Remove:

- the mounting bolt (5) from the silencer support,

- the silencer support.

Move the exhaust silencer to one side.

Remove:

- the mounting bolts (6) from the sub-frame on eachside of the vehicle,

- the rear sub-frame.

Remove the mounting bolts (7) from the reservoir.

107247

107235

107234

107236




Rear floor rear section: Removal - Refitting 41DII - OPERATION FOR REMOVAL OF PARTCONCERNED

Remove all the floor mountings.

Insert a flat chisel (5) into the rear right-hand cornerof the floor.

Use the flat chisel as a lever and carefully detach the

floor.

Remove all the floor mountings.

STANDARD CHASSIS

101114

104460

104459

Note:

During the operation, cut the mastic bead using asectioning tool if there is too much resistance to

the removal.

LONG CHASSIS

107239





Insert the flat chisel into the rear right-hand corner of

the floor.

Use the flat chisel as a lever and carefully detach the

floor.

REFITTING

I - REFITTING PREPARATION OPERATION

1 - Preparation of the replacement part

Remove the remaining cement bead.

Using heptane and a lint-free cloth, clean the surfa-ces to be attached.

Apply sealing mastic to the floor.

2 - Preparing the vehicle

Remove the remaining cement bead.

Using heptane and a lint-free cloth, clean the surfa-

ces to be attached.

II - REFITTING OPERATION FOR PARTCONCERNED

Refit:

- the rear floor,

- all the floor mountings.

Tighten to torque the rear floor rear section moun-ting bolts (21 Nm) .

107237

107238

Note:

During the operation, cut the mastic bead using asectioning tool if there is too much resistance tothe removal.

101110

Note:

To avoid any risk of damage to the mastic beadand to facilitate the positioning of the floor whenit is refitted, move the tank away using a woodenblock (A) .

Note:

Remove any visible excess mastic from the vehi-cle inter ior and exterior.





Refit:

- the lower mounting bolt (4) to the funnel,- the two tank mounting bolts (3) ,

- the silencer heat shield,

- the bolts (2) securing the heat shield,

- the exhaust silencer,

- the silencer mounting bolt (1) ,

- the automatic parking brake emergency handle(see MR 370 Chassis, 37B, Automatic parkingbrake, Emergency handle ),




- the rear wheel arch liners( (see Rear wheel archliner: Removal - Refitting) .

Refit:

- the reservoir mounting bolts (7) ,

- the rear sub-frame,

- the mounting bolts (6) to the sub-frame on eachside of the vehicle,

- the silencer support,

- the mounting bolt (5) to the silencer support,

- the mounting bolt (4) .

Refit the connections to the body support and clipthe wiring harness into place.

Clip on:

- the parking brake emergency handle cable,

- the cable guide (3) .

Refit:

- the mounting bolts (2) ,

- the body support mounting bolts (1) ,- the automatic parking brake emergency handle(see MR 370 Chassis, 37B, Automatic parkingbrake, Emergency handle ),



- the second row rear seats( (see Second row com-

plete rear seat: Removal - Refitting) ,


- the rear wheel arch liners( (see Rear wheel archliner: Removal - Refitting) .

STANDARD CHASSIS

LONG CHASSIS




Rear side member: General description 41D


This is a basic part; it only functions as a rear sidemember.


Cut 1:

This line marks the area in which it is possible to makea partial replacement.

This operation allows you to access the inside of thehollow section of the structural element to straighten it.




WARNING




IMPORTANT


Note:


115694

102668

WARNING





Rear side member: General description 41D

Line (2) of the diagram shows a butt weld by conti-

nuous MAG welding.

102970




Rear impact cross member mounting reinforcement: Description 41D


- complete replacement: this operation complementsthe replacement of the rear end panel assembly andthe rear side member closure panel.


II - PART FITTED

102661

Note:

The body jig bench must be used.

115242


(1) Rear side mem-ber c losurepanel compo-nent

VHEL 2

(2) Rear side mem-ber connectioncomponent

HEL 2

(3) Re ar t owingbushing

- -

102955

WARNINGIf the spot welds cannot be made as they were ori-ginally using an electric spot welding machine, theyshould be replaced with plug welds after holes havebeen drilled in the first panel.




Rear side member: Description 41D



- Complete replacement: this operation complementsthe partial replacement of the rear floor front sectionafter a rear impact.


115694

Note:


STANDARD CHASSIS

115243






(1) Rear side mem-ber HLE 1.6/2

(2) Rear cros smember/rearside memberconnection com-ponent

HLE/ THLE

1.2/1.8

(3) R e a r a x l eassembly unit

HLE 1.8

(4) Sill panel rear

reinforcement

HLE/

THLE

1.4/1.8

(5) Rear side mem-ber assemblyunit reinforce-ment connec-tion component

THLE 2

(6) R e a r a x l eassembly unitreinforcement

HLE 2

(7) Far rear lower

cross member,side part

- 1

(8) Rear impac tcross membermounting rein-forcement

HLE/ THLE

2

LONG CHASSIS

115244




Rear side member: Description 41DII - PART FITTED

Front section

Rear section


(9) Rear side mem-ber HLE 1.6/2

(10) Rear cross mem-ber/rear sidemember connec-tion component

HLE/ THLE

1.2/1.8

(11) R e a r a x l eassembly unit

HLE 1.8

(12) Sill panel rearreinforcement

HLE/ THLE

1.4/1.8

(13) Rear side mem-ber assemblyunit reinforce-ment connectioncomponent

THLE 2

(14) R e a r a x l eassembly unitreinforcement

HLE 2

(15) Far rear lowercross member,

side part

- 1

(16) Rear impac tcross membermounting reinfor-cement

HLE/ THLE

2

102958

102957




Rear side member: Description 41D1 - Partial replacement


STANDARD CHASSIS

102970

LONG CHASSIS

107297

102962

Note:

If the impact does not enable the side member tobe cut at (A) , remove the connecting bracket (B)from the spare part and weld it in area (X1) on therear side member.

The cutting procedure remains the same as pre-viously.

115245





WARNING



IMPORTANT






Rear side member closure panel, rear section: Description 41DThere is only one way of replacing this part:

- complete replacement: this operation complementsthe replacement of the rear end panel and the rearside member after a rear impact.


II - PART FITTED


Cut A

115682


(1) Rear side mem-ber c losurepanel, rear sec-tion

- 0.7

102972

115249




Rear side member closure panel, rear section: Description 41DFitting the side member closure panel

102971

WARNING

If the spot welds cannot be made as they were ori-ginally using an electric spot welding machine, theyshould be replaced with plug welds after holes havebeen drilled in the first panel.

IMPORTANT


The earth of the welding machine must be placed

as close as possible to the weld area.




Rear floor front cross member, centre section: Description 41D

there is only one way of replacing this part:

- complete replacement: this operation complementsthe replacement of the rear side member after a sideimpact.


II - PART FITTED

102669

115254


(1) Rear axle crossmember HEL 1.2

(2) Rear left-handseat belt ancho-rage centre stif-fener

HEL 2

(3) Rear r ight-handseat belt ancho-rage centre stif-fener

HEL 1.5

102961




Rear floor front cross member, centre section: Description 41DCut A

115255

WARNING





Rear floor centre cross member: General description 41D


This is a basic part; it only fulfils the function of a rearfloor centre cross member.

WARNING



Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special features will be specified if appli-cable in other parts of this sub-section dealing withthe part.

Note:



102667




Rear floor centre cross member: Description 41DThere is only one way of replacing this part:

- complete replacement: this operation supplementsthe replacement of the rear side member following arear or side collision.


II - PART FITTED


102667

Number Description Type Thic-kness(mm)

(1) Rear floor centrecross member

HEL 1

103111

WARNING


ginally using an electrical spot welding machine,they should be replaced with plug welds after holeshave been drilled in the first panel.




Far rear lower cross member, side section: Description 41DThere is only one way of replacing this part:

- complete replacement: this operation supplementsthe replacement of the rear wheel arch extension, theside lining of the rear end panel and the lower sectionof the rear wing panel rain channel.


II - PART FITTED


102645


(1) Far rear lowercross member,side section

- 1

102968

WARNING






Front cross member under rear seat: Description 41DThere is only one way of replacing this part:

- Complete replacement: this operation involves repla-cing the rear floor front section or removing the rearseat.


STANDARD CHASSIS

104616

LONG CHASSIS

115684

STANDARD CHASSIS

115257


(1) Front cros smember underrear seat

HLE 1.3

(2) Right-hand exte-rior stiffener

- 1.5

(3) Left-hand exte-rior stiffener

- 1.5

(4) Inner reinforce-ment

- 1.5




Front cross member under rear seat: Description 41DII - PART FITTED

Complete replacementLONG CHASSIS

115258


(1) Front cro ssmember underrear seat

HLE 1.5

(2) Front cro ssmember stiffe-ner under rearseat

HLE 1.5

(3) Right-handexterior stiffener

HLE 1.5

(4) Left-hand exte-rior stiffener HLE 1.5

(5) Front cro ssmember bridgepiece under rearseat

HLE 1.5

STANDARD CHASSIS

105780




Front cross member under rear seat: Description 41D

LONG CHASSIS

107243

WARNING





Rear cross member under rear seat: Description 41DThere is only one way of replacing this part:

- Complete replacement: this operation supplementsreplacing the rear floor front section or removing therear seat.


STANDARD CHASSIS

104615

LONG CHASSIS

115686

STANDARD CHASSIS

115259

Mark Description Type Thic-kness

(mm)

(1) Rear cros s

member underrear seat

HLE 1.8

(2) Rear cros smember right-hand stiffener

HLE 2

(3) Rear cros smember left-hand stiffener

HLE 2




Rear cross member under rear seat: Description 41DII - PART FITTED

Complete replacementLONG CHASSIS

115260


(4) Rear cross mem-ber under rearseat

HLE 2

(5) Centre mountings t i f f e n e r o f

2ndrow seat

HLE 2

(6) Rear upper cen-tre height adjus-ter

HLE 2

STANDARD CHASSIS

105779

LONG CHASSIS

107242




Rear cross member under rear seat: Description 41D

WARNING






Exhaust mounting support: Description 41DThere is only one way of replacing this part:

- complete replacement: this operation supplementsthe replacement of the tunnel.


II - PART FITTED


102664


(1) Exhaust moun-ting support

- 1.2

102963

Note:

The angle of the exhaust mounting support can be

adjusted using the two rivets which should be obtai-ned separately from the Parts Department .

WARNING





Tank mounting support: Description 41DThere is only one way of replacing this part:



II - PART FITTED


102660

Number Description Type Thickness

(mm)

(1) Fuel tank moun-ting support .

- 1.2

102956

WARNING






Rear impact lower cross member: General description 41D


This component is made from aluminium.

A feature of this component is that it is attached to theends of rear side members.

WARNING



Before reading the following general information,make sure that there are no special notes associa-ted with the vehicle. These special notes are speci-fied if necessary in other parts of the sub-sectiondealing with the part.

Note:



101411




Rear impact lower cross member: Removal - Refitting 41D

REMOVAL


Remove:

- the rear lights( (see Rear light on wing: Removal- Refitting) ,

- the rear bumper( (see Rear bumper: Removal -Refitting) .


Remove:

- the mounting nuts (1) ,

- the rear impact lower cross member.

REFITTING



Refit:

- the rear impact lower cross member,

- the mounting nuts (1) .

Tighten to torque the rear impact lower crossmember mounting nuts (21 Nm) .

III - FINAL OPERATION

Refit:


- the rear lights( (see Rear light on wing: Removal- Refitting) .

Tightening torquesm

rear impact lower cross

member mounting nuts

21 Nm

103908

102960

Note:

Replace the foam on the rear impact lower crossmember if it has been damaged.



UPPER FRONT STRUCTURE


104367



HLE 1.2



HLE/

THLE

0.7/2.5


- 1.2


HLE/ THLE

1.1/3




HLE/ THLE

1.7/3




Vehicle front section structure: Description 42A


HLE 1.2


- 1.2/2.5


HLE/ THLE

1.2/3


- 1.5/2


HLE/ THLE

1.1/3


- 1.2



HLE 1.5/2


- 1.1/2



HLE/ THLE

2/3



HLE/ THLE

1.2/3



HLE 1.1/2






104693



VHLE 2.5



- 0.9


UHLE 1.7


42A-50)

UHLE 1.7






HLE 0.95/3


- 1



- 0.7/1.5


- 0.7/1.2


HLE 1.5



HLE 1.5/2.5


HLE 1.5



HLE/ THLE

1/1.6


VHLE 0.7/2.5



- 1.2/2.5



- 1.2








HLE 0.7/2.5


HLE 1.4




HLE 1.3/1.5


HLE 1.8/2



HLE 1.2/2






104694



Aluminium



Steel/SMC


SMC


Aluminium








Noryl




ting, page 42A-53)

Aluminium




Noryl



Polypropy-lene






Front wing: General description 42A


This type of front wing has the following characteristics:

- plastic wing (NORYL),

- wing bolted to its upper mounting bracket.

II - REMOVAL - REFITTING

To remove or replace the front wing, remove:

- the front wheel arch liner,

- the front wing direction indicator,

- the front bumper,

- the headlight,

- the door mirror.

III - ADJUSTMENT

Two main areas of adjustment may be identified:

- the adjustment of the rear area,

- the adjustment of the front area

1 - Adjustment of the rear area:

Adjust the flush fitting and alignment with the front doorusing mountings (8) and (9) .

WARNING




104614

Note:

In all cases of removal of a component without itsreplacement with a new one, mark the position ofthe mountings before removing the mountings toavoid adjustments during refitting.

Note:

The front wing is the penultimate removable compo-nent to be fitted to the vehicle body in the factory.

For final adjustment, correctly position all the othercomponents including the bumper and the headli-ghts for them to be correctly positioned.

103886




Front wing: General description 42A2 - Adjustment of the front area:

Adjust the alignment of the front wing using mountings(16) and (17) .

103888

103887




Front wing: Removal - Refitting 42A

The front wing is a structural bodywork componentmade of thermoplastic, and can be removed.

REMOVAL


Remove:

- the front wheel arch liner( (see Front wheel arch

liner: Removal - Refitting) ,



- the headlight( (see Halogen headlight: Removal -

Refitting) ,

- the door mirror( (see Door mirror: Removal - Re-fitting) .


Remove:

- the bolts (A) ,

- the nut (B) ,

- the front wing.

Tightening torquesm

bolts (A) 6.5 Nm

nut (B) 6.5 Nm

103885

Note:

The upper section of the wing is attached to itsupper mounting support by an intermediateexpanding insert.

Heat the insert to detach it, in order to avoiddamaging the wing when removing it.




Front wing: Removal - Refitting 42AREFITTING


Always replace the expanding insert .


Refit:

- the front wing,

- the nut (B) ,

- the bolts (A) .

Adjust the panel gaps and flush fittings (see 42A ,Upper front structure, Front wing: Adjusting,

page 42A-12) .Tighten to torque:

-the bolts (A) (6.5 Nm) ,

-the nut (B) (6.5 Nm) .


Refit:

- the door mirror( (see Door mirror: Removal - Re-fitting) ,

- the headlight( (see Halogen headlight: Removal -Refitting) ,



- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting) .




Front wing: Adjusting 42A

ADJUSTMENT VALUES

For information on front wing adjustment values (seeVehicle panel gaps: Adjustment value ).

ADJUSTMENT

Observe the adjustment sequence.

I - BASIC ADJUSTMENT

Remove:

- the front wing (see 42A, Upper front structure,Front wing: Removal - Refitting, page 42A-10) .

- the front wing upper mounting support (see 42A,Upper front structure, Front wing upper moun-ting support: Removal - Refitting, page 42A-18),

Reapply anti-corrosion protection to the mountings

(6) .

Position the support and the wing on the vehicle.

Finger tighten all the attachments.

Adjust the shut lines and flush fitting between thewing, the door and the bonnet.

Tightening torquesm

mounting bolts of the

front wing upper moun-ting support

6.5 Nm

bolts (A) 6.5 Nm

bolts (B) 6.5 Nm

nut (C) 6.5 Nm

bolts (D) 6.5 Nm

115810

104228

103890

Note:

Only mountings (7) are accessible when the wing

is in position.




Front wing: Adjusting 42ARemove the front wing.

Mark the position of the upper mounting support.

Remove the front wing upper mounting support.

Torque tighten the mounting bolts of the frontwing upper mounting support (6.5 Nm) .

II - FINAL ADJUSTMENT

Adjust the shut lines and flush fitting of areas (1) and(2) .

If necessary, put a washer behind each front winghole (8) to adjust flush fitting with the door.

Tighten to torque the bolts (A) (6.5 Nm) .

Adjust the shut lines and flush fitting of areas (3) and(4) .

Tighten to torque:

-the bolts (B) (6.5 Nm) ,

-the nut (C) (6.5 Nm) .

103885




Front wing: Adjusting 42A

Adjust the shut lines and flush fitting of area (5) .

Tighten to torque the bolts (D) (6.5 Nm) .

103887

Note:

The bumper cannot be adjusted because it fitsinto the front wing.




Front wing lower mounting support: General description 42A


This is a basic part, it fulfils the function of a front winglower mounting support and it enables the front wing tobe adjusted in the Y axis.

This part is bolted to the scuttle side panel.

WARNING




104613




Front wing lower mounting support: Removal - Refitting 42A

REMOVAL


Remove:

- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting) ,




II - OPERATION FOR REMOVAL OF PART

CONCERNED

Remove:

- the mounting nuts (1) from the support,

- the front wing lower mounting support.

REFITTING


Refit:

- the front wing lower mounting support,

- the support mounting nuts (1) .

Torque tighten the mounting nuts of the frontwing lower mounting support (6.5 Nm) .


Refit:

- the front wing (see 42A , Upper front structure,

Front wing: Removal - Refitting, page 42A-10) ,- the headlight( (see Halogen headlight: Removal -

Refitting) ,



Tightening torquesm

mounting nuts of the

front wing lower moun-ting support

6.5 Nm

105928




Front wing upper mounting support: General description 42A


This is a basic part, it fulfils the function of front wingupper mounting support and it enables the front wing tobe adjusted in the X and Y axes.

WARNING




104612




Front wing upper mounting support: Removal - Refitting 42A

REMOVAL


Remove:

- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting) ,




Remove the bonnet via mountings (1) .


Remove:

- the support mounting bolts (2) ,

- the front wing upper mounting support ,

REFITTING


Do a trial assembly of the front wing and bonnet tomark the right spot for the front wing upper mountingsupport.

Tightening torquesm

front wing upper moun-

ting support bolts

6.5 Nm

104227

103890




Front wing upper mounting support: Removal - Refitting 42A

Apply anti-corrosion protection to the front wing up-

per mounting supports (3) .


Refit:

- the front wing upper mounting support,

- the support mounting bolts (2) .

Tighten to torque the front wing upper mountingsupport bolts (6.5 Nm) .


Refit:

- the front wing (see 42A, Upper front structure,Front wing: Removal - Refitting, page 42A-10) ,




104228




Front: General description 42A


A special feature of this type of component is that itcomprises an upper cross member (1) made from steeland composite material and two side sections (2) madefrom a composite material, which cannot be repairedand which are bolted on the vehicle.

This part is attached to the ends of the front side mem-bers and cannot be adjusted.

WARNING




101610

101609




Front: Removal - Refitting 42A

The side sections are removable structural compo-nents made of SMC type composite material.

The upper cross member is a component made up oftwo sections (steel and SMC) which are pressed to-gether.

REMOVAL

I - REMOVAL PREPARATION OPERATION FORSIDE SECTION

Remove:

- the front wheel arch liners( (see Front wheel archliner: Removal - Refitting) ,

- the front bumper( (see Front bumper: Removal -

Refitting) ,- the front headlights( (see Halogen headlight: Re-moval - Refitting) ,

- the front impact cross member (see 41A, Frontlower structure, Front impact cross member:Removal - Refitting, page 41A-8) .

Pull out the filling pipe (1) .

Disconnect the pipes (2) from the pump and the con-nector (3) .

Release the tank (4) by pulling it forwards strongly.

Drain the reservoir if necessary.

Unclip the radiator air deflector (5) .

Tightening torquesm

front end panel side

section mounting bolts

6.5 Nm

upper cross membermounting bolt

21 Nm

bumper support moun-ting bolts

6.5 Nm

103891

103893




Front: Removal - Refitting 42AII - OPERATION FOR REMOVAL OF SIDE SECTION

Remove:

- the mounting bolts (6) from the side section,

- the side sections from the front end panel.

REFITTING

I - REFITTING OPERATION FOR SIDE SECTION

Refit:

- the side sections to the front end panel.

- the side section mounting bolts (6) .

Tighten to torque the front end panel side section

mounting bolts (6.5 Nm) .


Clip the radiator air deflector (5) into place.

Refit the reservoir (4) .

Connect the pipes (2) and the connector (3) to the

washer fluid pump.

Refit the filler pipe (1) .

Fill the washer fluid reservoir.

REMOVAL

I - REMOVAL PREPARATION OPERATION FORTHE UPPER CROSS MEMBER

Unclip the upper section (7) of the plastic union anddetach the bonnet opening cable.

Remove:

- the mounting bolts (8) from the bumper support,

- the bumper support.

103896

101791

103898




Front: Removal - Refitting 42A

Using a screwdriver, unclip the radiator indexing

pins (9) .

Disconnect the audible warning connector (10) .

Detach the wiring harness from the upper crossmember.

II - OPERATION FOR REMOVAL OF THE UPPERCROSS MEMBER

Remove:

- the mounting bolts (11) from the side section,

- the mounting bolt (12) from the upper cross mem-ber,

- the upper cross member.

101783

103892

103895

103894




Front: Removal - Refitting 42AREFITTING

I - REFITTING OPERATION FOR THE UPPERCROSS MEMBER

Refit:

- the upper cross member,

- the mounting bolt (12) to the upper cross member,

- the side section mounting bolts (11) .

Tighten to torque:

-the upper cross member mounting bolt (21 Nm),

-the front end panel side section mounting bolts(6.5 Nm) .


Refit the wiring harness on the upper cross member.

Connect the audible warning connector (10) .

Clip the radiator indexing pins (9) into place.

Refit:

- the bumper support,

- the bumper support mounting bolts (8) .

Torque tighten the bumper support mountingbolts (6.5 Nm) .

Refit the bonnet opening cable to the upper crossmember.




Scuttle side panel: General description 42A


The special feature of this part it that it concurrentlyserves two functions:

- scuttle side panel.

- A-pillar lining.


Cutting line (3) shows the area in which it is possible tomake a cut.





WARNING




Note:



104562

101608

WARNING





Scuttle side panel: General description 42A

Line (6) on the diagram shows the partial replacement

and a MAG butt weld.

Depending on the exact position of the cut, a weldmade by joggling with plug welds at regular intervalsmay also be used.

101592




Cowl side panel: Description 42A


- partial replacement of the front section: this operationsupplements the partial replacement of the scuttleside panel stiffener for a frontal impact,

- partial replacement of the rear section: this operation

supplements the replacement of the A-pillar reinforce-ment for a side impact.



II - PART FITTED


104562

115262


(1) A-pillar lining HLE 1

(2) Driver's posi-t ion inter iormounting unit

HLE 3

(3) Exterior unit HLE 2.5

(4) A-pillar liningside stiffener

- 0.8

(5) A-pillar lining

stiffener compo-nent

HLE 1.8

(6) Exterior unitfront stiffener

THLE 1.8

(7) Exterior unitrear stiffener

THLE 1.8

(8) Dashboardmounting unitstiffener

THLE 2.5

101592




Cowl side panel: Description 42A2 - Partial replacement of the rear section



105927

WARNING


105926

IMPORTANT



115076

IMPORTANT






Scuttle side panel upper reinforcement: General description 42A


This type of component fixes the front wing uppermounting support.

WARNING




Note:



104563




Scuttle side panel upper reinforcement: Description 42AThe options for replacing this part are as follows:

- partial replacement of the front section.

- Complete replacement


II - PART FITTED


2 - Complete replacement104563


(1) Scuttle sidepanel upperreinforcement

HLE 1.2

105930

105929

WARNING





Scuttle side panel upper reinforcement: Description 42AIII - POSITIONING OF LOCAL ELECTRICALEARTHS

115076

IMPORTANT


connected.





Front wheel arch: General description 42A


This is a basic part; it only fulfils the function of a frontwheel arch.

WARNING




IMPORTANT


Note:


115796




Front wheel arch: Description 42AFront right-hand wheel arch

Front left-hand wheel arch


- complete replacement : this operation supplementsthe replacement of the scuttle side panel for a side im-pact or the front side member for a frontal impact.


Front right-hand wheel arch

115795

115796

Note:


115265


(1) Shock absor-

ber cup heightadjuster

- 1.1

(2) Shock absor-ber cup

HLE 2

(3) Cup reinforce-ment

- 2

(4) Engine sup-port connec-tionreinforcement

- 2




Front wheel arch: Description 42AFront left-hand wheel arch II - PART FITTED


Do not detach the windscreen aperture lower crossmember side bracket to replace the front wheel arch.

115264


(5) Shock absor-ber cup heightadjuster

- 1.1

(6) Shock absor-ber cup

HLE 2

(7) Air filter moun-ting support

- 1.2

101765

WARNING


101766




Front wheel arch: Description 42AIII - POSITIONING OF LOCAL ELECTRICALEARTHS

115076

IMPORTANT


connected.





Heater bulkhead: Description 42A


- Complete replacement: this operation supplementsthe replacement of the front wheel arch or the winds-creen aperture lower cross member for a side impact.


II - PART FITTED



104569

115268


(1) Heater bulkhead - 0.7

(2) Heater bulk-head brackets

- 1.2

105940

WARNING


ginally using an electrical spot welding machine,they should be replaced with plug welds after holes


115076




Heater bulkhead: Description 42A

IMPORTANT







Windscreen aperture lower cross member: General description 42A


This is a basic part; it only fulfils the function of winds-creen aperture lower cross member.

WARNING




Note:



104570




Windscreen aperture lower cross member: Description 42A


- partial replacement: this operation supplements thepartial replacement of the windscreen aperture lowercross member closure panel,

- Complete replacement: this operation supplementsthe replacement of the windscreen aperture lowercross member closure panel.

I - COMPOSITION OF THE SPARE PARTII - PART FITTED


104570

115271


(1) Windscreenaperture lowercross member

- 0.7

(2) Wiper centralsupport right-hand bracket

- 1.5

(3) Wiper centralsupport left-hand bracket

- 1.5

(4) Windscreen

aperture lowercross memberright-handreinforcement

- 1.5

(5) Wiper motorindexing sup-port

- 1.2

(6) Wiper moun-ting centralsupport

- 1.3

105938




Windscreen aperture lower cross member: Description 42A2 - Complete replacement

105939

WARNING





Dashboard cross member: Removal - Refitting

LONG CHASSIS

42A

REMOVAL


Remove:

- the front doors (see 47A, Side opening elements,Front side door: Removal - Refitting, page 47A-5) ,

- the dashboard( (see Dashboard: Removal - Refit-ting) ,

- the steering column( (see Steering column: Re-moval - Refitting) .


Remove the blanking cover (1) .

Remove the side mounting bolt (2) .

Special tooling required

Car. 1765 Dashboard beam playcompensation pin

repositioning bolts

Tightening torquesm

centring device (4) 8 Nm

mounting bolts (3) 21 Nm

side mounting bolt (2) 21 Nm

Note:

In the event of a front impact with triggering of air-bags, check the area of connection between bothdiameters of the beam. If there is any damage visi-ble to the naked eye, this part must be replaced.

104686

104688





LONG CHASSIS

42A

Remove the mounting bolts (3) .

Loosen the centring device (4) in order to align theholes in the A-pillar lining with the dashboard crossmember lock nuts.

Fit the (Car. 1765) onto body (6) as far as the stop.

Screw the rod (5) onto the body (6) as far as the stopand tighten gently.

Firmly lock tool body (6) in the same way as a locknut against the dashboard cross member nut whileholding the hexagonal head of bolt (5) .

Unscrew the tool as far as the stop using the hexa-gon bolt (6) and tighten it gently (during the opera-tion, the beam nut, which has a left-hand thread,screws into the beam and releases it from the A-pillar).

Hold tool body (6) and unlock rod (5) .

Unscrew dashboard cross member rod (5) to remo-ve the tool.

104687

104689

104691

104690





LONG CHASSIS

42A

Remove:

- the side mounting bolt (2) from the other side of thevehicle,

- the dashboard cross member.

REFITTING


Fully tighten the locking nut (left-hand thread) in thebeam.

Refit:

- the dashboard cross member,

- the side mounting bolt (2) from the side where thelock nut has not been adjusted.

Fit the (Car. 1765) onto body (6) as far as the stop.

Screw the rod (5) fully into the body (6) and tightengently.

Firmly lock tool body in the same way as a lock nutagainst the dashboard cross member nut while hol-ding the hexagon bolt.

Simultaneously screw the rod (5) and the tool body(6) fully, tightening gently.

Note:

To maintain the adjustment of the dashboardcross member and therefore make refittingeasier, only loosen the lock nut on one side.

102527

102528





LONG CHASSIS

42A

Hold the tool body (6) and release the rod (5) in thesame way as a lock nut.

Unscrew dashboard cross member rod to removethe tool.

Torque tighten the centring device (4) (8 Nm) .

Refit:

- the mounting bolts (3) ,

- the side mounting bolt (2) .

Tighten to torque:

-the mounting bolts (3) (21 Nm) ,

-the side mounting bolt (2) (21 Nm) .

Refit the blanking covers (1) .


Refit:

- the steering column( (see Steering column: Re-moval - Refitting) ,

- the dashboard( (see Dashboard: Removal - Refit-ting) ,

- the front doors (see 47A, Side opening elements,Front side door: Removal - Refitting, page 47A-5) .

It is possible to adjust the dashboard after it hasbeen refitted to the vehicle, by removing the dash-board side panel (7) to access the mounting bolts (3)

and the dashboard cross member centring device(4) .

102530

WARNINGDuring removal of the dashboard cross member,the lock nuts may loosen on both sides. If thishappens, refit the dashboard to adjust its clea-rances with the windscreen pillar and door trims.

101196



UPPER FRONT STRUCTUREWindscreen aperture lower cross member closure panel: General description 42A


This is a basic part; it only fulfils the function of thewindscreen aperture lower cross member closure pa-nel.

WARNING




Note:



104568




Windscreen aperture lower cross member closure panel: Description 42A




II - PART FITTED


104568

115275


(1) Windscreenaperture lowercross memberclosure panel

- 0.7

(2) Windscreenaperture lowercross memberleft-hand inte-rior reinforce-ment

- 1.2

(3) Windscreen

aperture lowercross memberright-hand inte-rior reinforce-ment

- 1.2

105937




Windscreen aperture lower cross member closure panel: Description 42A2 - Complete replacement


102987

WARNING


115076

IMPORTANT







Bulkhead: Description 42AThe options for replacing this part are as follows:


- Complete replacement: this operation supplementsthe replacement of the bulkhead side reinforcement

and the bulkhead lower cross member.


II - PART FITTED



Passenger compartment side view102677


(1) Bulkhead - 1

105932

102988




Bulkhead: Description 42AEngine side view


102978

WARNING


115076

IMPORTANT







Bulkhead reinforcement: Description 42AThere is only one way of replacing this part:



II - PART FITTED


102676


(mm)

(1) Bulkheadreinforcement

UHLE 1.7

102989

WARNING



115076

IMPORTANT






Bulkhead lower cross member: General description 42A


This is a basic part; it simply fulfils the function of abulkhead cross member.

WARNING

Before reading the following general information,make sure that there are no special notes associa-

ted with the vehicle. These special notes are speci-fied if necessary in other parts of the sub-sectiondealing with the component.

Note:


110640

WARNING





Bulkhead lower cross member: Description 42AThere is only one way of replacing this part:



II - PART FITTED


102670


(1) Bulkheadlower crossmember

THLE 2.5

102985

WARNING






Bulkhead panel: Removal - Refitting 42A

The removal/refitting of this part is an operation linkedto the replacement of the complete body shell.

REMOVAL

OPERATION FOR REMOVAL OF PARTCONCERNED

Remove the mounting bolts (A) .

Cut the cement bead using the pneumatic tool (seeTechnical Note 414 A ).

Remove the bulkhead panel.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

Refit the bulkhead panel.

Refit the mounting bolts (A) .

Tighten to torque the bolts (A) (8 Nm) .

Tightening torquesm

bolts (A) 8 Nm

103126

Note:

Wire cutting can be difficult due to the shape ofthe surrounding components, and the bulkheadpanel mounting bolts.

Note:

To refit, the bonding procedure is identical to thatfor replacing a bonded windscreen (refer to

Technical Note 371A ).




Bulkhead side reinforcement: General description 42A


This is a basic part, it simply fulfils the function of bulk-head side reinforcement.



WARNING




Note:



110084




Bulkhead upper cross member: General description 42A


This is a basic part; it only fulfils the function of a bulk-head upper cross member.

WARNING




Note:



102672




Bulkhead upper cross member: Description 42A


- Complete replacement: this operation supplementsthe replacement of the A-pillar.


II - PART FITTED

102672

115276


(1) Bulkhead uppercross member HLE 1

(2) Windscreenaperture lowercross memberleft-hand sideangle bracket

- 1.2

(3) Wiper left-handmounting pad

- 1

(4) Wiper right-hand

mounting pad

- 1

(5) Linkage supportreinforcementplate

HLE 2

(6) Tie-bar moun-ting

HLE 3

(7) Bulkhead uppercross memberbracket

- 2

102979

WARNING





Bulkhead upper cross member: Description 42AIII - POSITIONING OF LOCAL ELECTRICALEARTHS

115076

IMPORTANT


connected.





Bulkhead side stiffener: Description 42AThere is only one way of replacing this part:

- Complete replacement: this operation supplementsthe replacement of the A-pillar and the A-pillar lining.


II - PART FITTED

101607


(1) Bulkhead sidereinforcement

- 1.7

101997

IMPORTANT

For the weld joints in three thicknesses, the spotwelds on the part replaced should be executed inthe same place as the originals to retain the mecha-nical properties of the joint.

WARNING







Windscreen wiper mounting: Description 42AThere is only one way of replacing this part:

- Complete replacement: this operation supplementsthe replacement of the scuttle side panel and the scu-ttle side panel reinforcement


II - PART FITTED


102671


(1) Wiper mounting - 1.2

105931

WARNING


115076




Windscreen wiper mounting: Description 42A

IMPORTANT






SIDE UPPER STRUCTURE


104368



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


- 0.7


- 0.7


- 0.7







THLE/ HLE

1.2/2.5


HLE 2


HLE 1


HLE 1.8


- 0.7


HLE 1.5


- 1


HLE 1.2


HLE 0.7


HLE 1.5



- 1/1.5


- 1/1.5


- 0.7


- 0.7


page 45A-7)

- 0.7





A-pillar: General description 43A


The A-pillar is obtained by extension from the bodyside front section.

WARNING

The following information describes the generalrepair procedure for all vehicles with the same type

of design for this part.


Note:


115660

WARNING





A-pillar: Description 43A

To replace this part, also order insert (A) .


- partial replacement of the lower section,



II - PART FITTED

1 - Partial front replacement of the lower section

115679

115281


(1) Body side - 0.7

(2) Jacking pointsupport

HLE 1.8

IMPORTANT

For welded connections in three thicknesses, thespot welds on the part replaced should be made inthe same place as for the original joint to retain itsmechanical properties.

105385




A-pillar: Description 43ACut B

Cut C


Cut D

115406

115283

103647

115284

WARNING





A-pillar reinforcement: General description 43A


This part's special feature is that it serves as an A-pillarreinforcement, B-pillar reinforcement, body side frontsection reinforcement and sill panel reinforcement.

WARNING




Note:



104593

WARNING





A-pillar reinforcement: Description 43A

To replace this component you will need to order ex-

panding inserts (A) and (B) .





II - PART FITTED

1 - Partial replacement115678

115425


(1) Body side rein-forcement HLE 1.2

(2) Rear-view mirrorreinforcement

- 1.2

(3) A-pillar upperhinge reinforce-ment

THLE 2.5

(4) A-pi lla r lowerhinge reinforce-ment

THLE 2.5

105379

Note:

This cut is possible in the event of a localisedimpact.




A-pillar reinforcement: Description 43ACut C


Cut D

Cut E

115291

105386

WARNING

Do not alter the positioning of this weld; it is deter-mined by that of the linings, reinforcements orexpanding inserts.

115290

115289

WARNING






Windscreen pillar lining: General description 43A


This is a basic part, its only function is that of the winds-creen pillar lining.


WARNING




Note:



102613




Windscreen pillar lining: Description 43A




II - PART FITTED


Apply a safety bead (4) .

102607

115292


(1) Windscreen pillarlining HLE 1.2

(2) Roof bar moun-ting support

- 2

(3) Grab han dl emounting reinfor-cement

- 1

105782

22362




Windscreen pillar lining: Description 43A

WARNING






B-pillar: General description 43A


The B-pillar is obtained by extension from the front sec-tion body side.

WARNING




Note:


IMPORTANT


110591




B-pillar: General description 43AII - AREA TO BE CUT FOR PARTIALREPLACEMENT

Cutting lines (1) and (2) show the area in which it ispossible to carry out a partial replacement.

Make the cutting line (2) on the butt weld.




110592

1

2




B-pillar: General description 43A



110593

5

6

WARNING





B-pillar: Description 43A

To replace this part, order the expanding insert (A) .





II - PART FITTED


X1 = 70 mm

X2 = 300 mm

Make the cut in area (X2) .

115677

115281


(1) Body side - 0.7


HLE 1.8

103509




B-pillar: Description 43ACut B

It is possible to cut along the whole length of the sill pa-nel.

Cut C

115298

101970

115417

101964

Note:

It is not advisable to make the cut outside the area

(X3) to avoid cutting into the retention unit or theexpanding insert.




B-pillar: Description 43ACut D


Cut E

Cut F

115421

103648

115296

115320

WARNING






B-pillar reinforcement: General description 43A


The special feature of this part is that it combines seve-ral functions:

- B-pillar reinforcement,

- A-pillar reinforcement

- sill panel reinforcement,

- body side front section reinforcement.

II - ASSEMBLY METHOD FOR A PARTIALREPLACEMENT



Line (2) of the drawing shows a butt weld by conti-nuous MAG welding.

WARNING




Note:



115657

WARNING



101971




B-pillar reinforcement: Description 43A






II - PART FITTED

1 - Partial replacement115676

115425


(1) Body side rein-forcement HLE 1.2

(2) Rear-view mir-ror stiffener

- 1.2

(3) A-pillar upperhinge reinforce-ment

THLE 2.5

(4) A-pi llar lowerhinge reinforce-ment

THLE 2.5

105383




B-pillar reinforcement: Description 43ACut B

Cut C


115303

115305

105382

WARNING





B-pillar lower lining: Description 43AThere is only one way of replacing this part:

- Complete replacement: this operation supplementsthe replacement of the B-pillar reinforcement after aside impact.


II - PART FITTED


104590


(1) B-p ill ar lowerlining

- 0.7

105395

WARNING






B-pillar upper lining: Description 43AThere is only one way of replacing this part:

- Complete replacement: this operation supplementsthe replacement of the B-pillar reinforcement after aside impact.


II - PART FITTED


104589


(1) B-pillar upperlining

HLE 1.5

105777

WARNING





Body side: General description 43A


the two parts must be welded at the joint (1) and buttwelded by continuous MAG welding.


The body side is obtained by welding the rear wing andthe front section body side.

WARNING




Note:



104594

WARNING





Body side: Description 43A

To replace this component, order extra expanding in-

serts (A) , (B) , (C) , (D) , (E) and anti-grit protective film(F) .


115673

STANDARD CHASSIS

115317

LONG CHASSIS

115318


(mm)

(1) Body side - 0.7


HLE 1.8




Body side: Description 43AII - PART FITTED

III - DETAILS OF THE LOCATION OF CUTS

Cuts to prepare replacement parts

(X1) = 200 mm .

Cut G

(X2) = 500 mm .

104229

103497

115419

104523




Body side: Description 43ACut H

115815

WARNING





Body side front section: General description 43A


This part has two special features:

- it is welded under the roof,

- it is butt welded at section (1) .

WARNING




Note:



110491

WARNING


1




Body side front section: Description 43A

To replace this part, order expanding inserts (A) , (B)

and (C) .




II - PART FITTED


115674

115281


(1) Body side - 0.7


HLE 1.8

104230

WARNING






Upper body panel: General description 43A


This is a basic part; its only function is that of an upperbody.

II - ASSEMBLY METHOD FOR A PARTIALREPLACEMENT

Lines (4) , (5) and (6) of the drawing show a butt weldby continuous MAG welding.


WARNING




Note:



IMPORTANT


110603

110605

4

5

6




Upper body panel: Description 43A





II - PART FITTED


Cut B115675

104597


(1) Upper body - 0.7

103649

115313




Upper body panel: Description 43ACut C

Cut D

115314

115815

WARNING





REAR UPPER STRUCTURE

Vehicle structure rear section: Description 44AREAR STRUCTURE

104366



- 0.7


- 0.6



- 1



0.95


- 0.7



- 0.7



HLE/ THLE

0.65/2.5




Vehicle structure rear section: Description 44A




HLE 1/2.5


HLE/ THLE

0.95/2



HLE 2



HLE 0.7


- 1



- 0.7


HLE 0.7



- 1



- 0.7


HLE 1/1.2



- 1.5





Rear wing panel: General description 44A


This part has three special features:

- it is welded under the roof,

- it is butt welded on the body side front section.

- it is supplementary to the body side front section for acomplete body side replacement.


Lines (1) and (2) in the drawing show the areas inwhich it is possible to carry out a partial replacement.




WARNING




Note:



IMPORTANT

Before any operation is carried out, remove the seatbelts and curtain airbag.

107759

110611

WARNING


1

2




Rear wing panel: General description 44A

Lines (7) in the drawing show a butt weld by continuous

MAG welding.

110612




Rear wing panel: Description 44A

To replace this component, order expanding inserts

(A) , and (B) .



- Complete replacement: order anti-grit protective film(C) .


115672

STANDARD CHASSIS

115812

LONG CHASSIS

115813





II - PART FITTED


Cut D

(X1) = 350 mm .


(1) Rear wing panel - 0.7


HLE 1.8

(3) Door str ikerplate stiffener

- 1.2

103503

115820

103511

WARNING

Do not make cuts outside the limits shown, so that

the acoustic insert is not damaged during the wel-ding operation.




Rear wing panel: Description 44ACut E 2 - Complete replacement

115821

LONG CHASSIS

107275

Note:

After replacing the rear wing panel, attach a sound-proofing pad through the inside of the vehicle.

STANDARD CHASSIS

103650

LONG CHASSIS

115819





3 - Special features on replacing the rear wingpanel

The procedure for crimping the rear wing panel is iden-tical to that for replacing a door panel.

Cut F

Use an MJ Pro type adhesive to ensure correct appea-rance and sealing after crimping of the rear wing panel.

III - ANTI-GRAVEL PROTECTION

To fit anti-gravel protective adhesive film, see Techni-cal note 579A, Anti-gravel protective adhesive film,55A, Exterior protection, Anti-gravel protective ad-hesive film .

WARNING



104468

115822

103651

Note:

Use structural adhesive on the crimping area.




Rear wing panel rain channel: General description 44A


The special feature of this part is that it is made up of

three components:

- rear lights support (1) ,

- rear wing panel channel (2) ,

- rear wheel arch extender (3) .


the basic instructions for structural bodywork repair

(see MR 400, 40A, General Information ).

WARNING




Note:



104575




Rear lights support: General description 44A


This is a basic part; its only function is that of a rear li-ghts support and it is part of the rear wing panel rainchannel connection.

This is a basic part; its only function is that of a rear li-ghts support.


WARNING




Note:



104575




Rear lights support: Description 44A


- Partial replacement of the lower section

- partial replacement: this operation requires the repla-cement of the rear wing panel,

- Complete replacement: this operation requires the re-placement of the roof and the rear wing panel.


II - PART FITTED

1 - Partial replacement of the lower section

104575

115830


(1) Upper side rainchannel - 1

(2) Rear light moun-ting

- 1

(3) Outer rear wheelarch rear clo-sure panel com-ponent

- 1

104232




Rear lights support: Description 44A2 - Partial replacement



104231

104233

WARNING



115102

IMPORTANT






Lights support lining: General description 44A


This is a basic part, its only function is that of the lightmounting lining.

WARNING




Note:



104581




Lights support lining: Description 44AThere is only one way of replacing this part:

- Complete replacement: this operation involves repla-cing the rear light mounting and rear wing panel.


II - PART FITTED


104581


(1) Lights supportlining

- 1.2 105774

WARNING





Outer rear wheel arch: General description 44A


The special feature of this part is its extension from thequarter panel lining to create the external rear wheelarch.


The line (1) of the drawing shows the area in which it ispossible to carry out a partial replacement.


Only the connecting pieces relevant to partial replace-ment by cutting are shown.


WARNING




Note:



113248

110625

WARNING


1




Outer rear wheel arch: General description 44A

Line (2) in the drawing shows partial replacement anda weld by joggling with plug welds at regular intervals.

110626

2




Outer rear wheel arch: Description 44AThere is only one way of replacing this part:



II - PART FITTED


104578


(mm)

(1) Quarter panellining

- 0.7

105380

WARNING



115102

IMPORTANT

To avoid damaging the vehicle's electrical and elec-tronic components, it is essential to disconnect thebattery and the earths of any wiring near the weldzone.





Inner wheel arch: General descriptions 44A


This is a basic part; its only function is that of an inter-nal rear wheel arch and rear shock absorber mounting.


WARNING




IMPORTANT


Note:


110624




Inner wheel arch: Description 44AThere is only one way of replacing this part:

- Complete replacement: this operation complementsthe replacement of the quarter panel lining for a rearside impact.


II - PART FITTED


104576


(1) Inne r r ea rwheel arch

HLE 0.7

105781

IMPORTANT



WARNING





Rear wheel arch closure panel, front section: Description 44AThere is only one way of replacing this part:



II - PART FITTED


104579

Mark Description Type Thic-

kness(mm)

(1) Rear wheel archclosure panel,front section

- 1

105778

WARNING


115102




Rear wheel arch closure panel, front section: Description 44A

IMPORTANT







Rear wheel arch closure panel, rear section: Description 44AThere is only one way of replacing this part:



II - PART FITTED


104577


kness(mm)

(1) Rear wheel archclosure panel,front section

- 0.7

105776

WARNING


115102




Rear wheel arch closure panel, rear section: Description 44A

IMPORTANT







Quarter panel lining: General description 44A


The distinctive feature of this part is that it combinestwo functions:

- quarter panel lining,

- outer rear wheel arch.


WARNING




Note:



102647




Quarter panel reinforcement: Description 44AThere is only one way of replacing this part:

- Complete replacement: this operation complementsthe replacement of the quarter panel lining for a sideimpact.


II - PART FITTED


104580


(1) Quarter panelstiffener

- 1.5

105775

WARNING






Quarter panel lining: Description 44AThe options for replacing this part are as follows:


- Complete replacement: this operation requires the re-moval of the roof.


II - PART FITTED


2 - Complete replacement104578


(1) Quarter panellining

- 0.7

105391

105390

WARNING





Quarter panel lining: Description 44AIII - POSITIONING OF LOCAL ELECTRICALEARTHS

115102

IMPORTANT


connected.





Quarter panel upper reinforcement: Description 44AThere is only one way of replacing this part:

- Complete replacement: this operation complementsthe replacement of the complete body side or the up-per body for a side impact.


II - PART FITTED


115799


(1) Quarter panel

upper reinforce-ment

- 0,9

105392

Note:

To replace this part, partially detach the side lining(2) from the roof rear cross member.

WARNING





Roof rear drip moulding lining: Description 44AThere is only one way of replacing this part:

- Complete replacement: this operation complementsthe replacement of the complete body side or the up-per body for a side impact.


II - PART FITTED


104588


kness(mm)

(1) Rear roof dripmoulding lining

- 1

105393

WARNING






Rear end panel assembly: Description 44A




II - PART FITTED104582

115852


(1) Rear end panel - 0.7

(2) Rear end panellining, centresection

- 0.7

(3) Striker plate stif-fener

- 1.2

(4) Right-hand rearend panel sidelining

HLE 1,5

(5) Left-hand rearend panel sidelining

HLE 1,5

104235

IMPORTANT

For welded connections in three thicknesses, thespot welds on the part replaced should be made inthe same place as for the original joint to retain itsmechanical properties.

WARNING





Rear end panel: General description 44A


This is a basic part, and its only function is that of therear end panel.



WARNING




Note:



110438




Rear end panel: Description 44AThere is only one way of replacing this part:



II - PART FITTED

104583


(mm)

(1) Rear end panel - 0.7

104234

WARNING






Rear end panel side lining: Description 44AThere is only one way of replacing this part:



II - PART FITTED

104584


(mm)

(1) Rear end panelside lining

HLE 1,5

104236

IMPORTANT



WARNING




TOP OF BODY


104368



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


- 0.7


- 0.7


- 0.7



TOP OF BODY




THLE/ HLE

1.2/2.5


HLE 2


HLE 1


HLE 1.8


- 0.7


HLE 1.5


- 1


HLE 1.2


HLE 0.7


HLE 1.5



- 1/1.5


- 1/1.5


- 0.7


- 0.7


page 45A-7)

- 0.7




TOP OF BODY

Roof: General description 45A


This is a basic part; its only function is that of a roof.

The roof is welded onto the body sides.

There are also models with an aperture for a sunroof.


WARNING




Note:



112147



TOP OF BODY

Roof: Description 45A

To replace this part, also order the roof stiffener mate-

rial (A) (see Parts Catalogue ).




II - PART FITTED

Bonding area

Front section

104573

101613


(1) Roof - 0.7

104605

WARNING


104607



TOP OF BODY

Roof: Description 45ACentre section

Rear section

For a detailed description of a particular connection(see MR 400, 40A, General information ).

104609

103645



TOP OF BODY

Roof front section: Description

LONG CHASSIS

45A



This operation only affects versions equipped with asunroof.


Part supplied on its own.

II - PART FITTED

101615


(1) Front section ofroof

- 0.7

103642

Note:

There is no specific procedure for replacing thispart; all connections can be made as they originallywere.



TOP OF BODY

Roof rear section: Description

LONG CHASSIS

45A



This operation only affects versions equipped with a

sunroof.



II - PART FITTED

Bonding area

104574


(1) Rear section ofroof

- 0.7

103643

103645

WARNING




TOP OF BODY

Roof front cross member: General description 45A


This is a basic part; its only function is that of a rooffront cross member and roof stiffener by means of acemented connection.


WARNING




Note:


110529



TOP OF BODY

Roof front cross member: Description 45AThere is only one way of replacing this part:

- Complete replacement: this operation supplementsthe replacement of the roof for the normal roof versionand the roof front section for the sunroof version.


II - PART FITTED

Standard roof version

Sunroof version

102606


(1) Roof frontcross mem-ber

HLE 0.7

104606

103646

Note:




TOP OF BODY

Roof centre cross member: General description 45A


This is a basic part; its only function is that of a roofcentre cross member and roof stiffener by means of acemented connection.


WARNING




Note:



112723



TOP OF BODY

Roof centre cross member: Description 45AThere is only one way of replacing this part:

- Complete replacement: this operation supplementsthe replacement of the roof.



II - PART FITTED

102608


(1) Roof centrecross member

HLE 1.5

101834

Note:




TOP OF BODY

Roof rear cross member: General description 45A


This is a basic part; its only function is that of roof rearcross member as well as roof stiffener by means of acemented connection.


WARNING




Note:



112721



TOP OF BODY

Roof rear cross member: Description 45AStandard roof version

Sunroof version





Sunroof version

102618

104586

115145

115146



TOP OF BODY

Roof rear cross member: Description 45A

II - PART FITTED


Sunroof version


(1) Roof rearcross mem-ber

- 1

(2) Centre iner-tia reel moun-tingreinforcement

- 1,5

104610

103644

Note:




SIDE OPENING ELEMENTS


104694



Aluminium



Steel/SMC


SMC


Aluminium








Noryl




ting, page 42A-53)

Aluminium




Noryl



Polypropy-lene






Front side door: General description 47A

I - COMPONENT DESIGN

This part has the following specifications:

- "bolted and bolted" hinges mounted vertically on theA-pillar and the door box section,

- a door check rod integrated in the lower hinge.


If the front door hinge mountings are the "bolted andbolted" type it is possible to remove the front side door,depending on the operations to be performed:

- either by unscrewing the mountings on the compo-nent in the event of replacement of the front side door,

- or with the hinges by removing the mountings on theA-pillar in the event of replacement of the body.

III - ADJUSTMENT

There are four main areas where adjustments can bemade:

- adjustment of the front area,

- adjustment of the rear area,

- adjustment of the upper area,

- adjustment of the lower area.

Always begin the adjustments on the hinge side withthe lock striker plate loose and the stops in place.

1 - Adjustment of the front area:

Adjust the flushness and alignment with the front wingusing the front side door hinge mountings.

2 - Adjustment of the rear area

Adjust the flushness and alignment with the rear side

door and the closure length using the striker platemountings.

3 - Adjustment of the upper area

Adjust the shut lines and alignment with the roof and A-pillar using the front side door hinge mountings.

WARNING




101720

Note:

In all cases of removal of a component without itsreplacement with a new one, mark the position ofthe mountings before removing the mountings toavoid adjustments during refitting.

Note:

The front side door is the component positionedafter the rear side door, in the order of assembly ofremovable components in the factory.

For it to be completely adjusted, position all theother components correctly.

IMPORTANT

In this case, compromise between the closure firm-ness and the rear shut lines of the front door bygiving priority to closing in such a way that the doorpresses sufficiently onto the seal to avoid floating ofthe rear of the door.




Front side door: General description 47A4 - Adjustment of the lower area

Adjust the flushness and alignment with the sill panelwing using the front side door hinge mountings.




Front side door: Removal - Refitting 47A

I - REMOVAL WITHOUT THE HINGES

1 - REMOVAL PREPARATION OPERATION

Disconnect the door wiring harness supply connec-tor.

2 - OPERATION FOR REMOVAL OF PARTCONCERNED

Remove:

- the four mounting bolts (1) from the door,

- the door.

II - REFITTING WITHOUT HINGES

1 - OPERATION FOR REFITTING PARTCONCERNED

Refit:

- the door,

- the door's four mounting bolts (1) .

Adjust the door clearances and shut lines.

Tighten to torque the door mounting bolts (21 Nm).

2 - FINAL OPERATION

Connect the door wiring harness supply connector.

III - REMOVAL WITH HINGES


Remove the front wing (see 42A , Upper frontstructure, Front wing: Removal - Refitting, page42A-10) .



Remove:

- the door hinge mounting bolts (2) ,

- the door.

IV - REFITTING WITH HINGES

1 - OPERATION FOR REFITTING PART

CONCERNED

Refit:

- the door,

Tightening torquesm

door mounting bolts 21 Nm

door hinge mountingbolts

21 Nm

door retention device 8 Nm

104513

101721




Front side door: Removal - Refitting 47A- the door hinge mounting bolts (2) .

Adjust the door clearances and shut lines.

Tighten to torque the door hinge mounting bolts(21 Nm) .

2 - FINAL OPERATION

Connect the door's wiring harness supply connector.

Refit the front wing (see 42A, Upper front structu-re, Front wing: Removal - Refitting, page 42A-10).

V - PASSIVE SAFETY

At the end of the operation, check the presence andcondition of the door retention device (3) .

Torque tighten the door retention device (8 Nm) .

103928

REMINDER:

The function of this part is essential in the eventof a frontal impact. The door retention devicekeeps the door in its longitudinal plane, therebyabsorbing impact energy efficiently.




Front side door: Adjustment 47A

ADJUSTMENT VALUES

For information on the front side door adjustment va-lues, (see Vehicle shut lines: Adjustment value ).

ADJUSTMENT

There are two options for adjusting the door:

- by means of the mountings on the door box section(opening clearance adjustment),

- by means of the mountings on the A-pillar (shut lineadjustment):

The front wing needs to be removed for this opera-tion.


I - REAR DOOR SHUT LINE ADJUSTMENT

Undo the hinge mounting bolts (6) .

Adjust the shut lines with the rear door.

Tighten to torque the hinge mounting bolts (27Nm) .

Tightening torquesm

hinge mounting bolts 27 Nm

door box section moun-ting bolts

21 Nm

striker plate bolts 21 Nm

115804

101721




Front side door: Adjustment 47AII - ADJUSTMENT OF FLUSH FITTING WITH THEFRONT WING AND THE REAR DOOR

Special note on the hinge upper mounting

Replace the original indexing studs (7) with bolts (8), available from the Parts Department , to enableflush fitting adjustment.

Undo the door box section mounting bolts (9) .

Adjust the flush fitting with the front wing.

Tighten to torque the door box section mountingbolts (21 Nm) .

101719

Note:

To increase the adjustment available, enlarge theupper holes on the original hinges.

After-Sales hinges are supplied with squareslots.

101722




Front side door: Adjustment 47ASpecial notes on the striker plate

The striker plate is spot-welded at (A) on the reinfor-

cement inside the B-pillar.

To carry out adjustments, bend the fusible sections(B) of the plate.

This operation can only be performed by exerting arelatively strong force on the striker (e.g. by using a

hammer).

Undo the striker plate bolts (10) .

Adjust the flush fitting with the rear door, the contactand the closure firmness.

Tighten to torque the striker plate bolts (21 Nm) .

22751

101725




Front side door: Stripping - Restoring 47AThe order of the operations described applies specifi-cally to replacing the door.

STRIPPING

Remove:

- the interior trim( (see Front side door trim: Remo-val - Refitting) ,

- the sliding window( (see Sliding window in frontside door: Removal - Refitting) ,

- the fixed window( (see Fixed window in frontdoor: Removal - Refitting) ,

- the window lift mechanism( (see Front side doorelectric window mechanism: Removal - Refit-ting) ,

- the exterior handle( (see Door exterior handle:Removal - Refitting) ,

- the door lock( (see Front side door lock: Remo-val - Refitting) .

Remove:

- the exterior moulding( (see Front door protectivestrip: Removal - Refitting) .

REASSEMBLING

Refit:

- the exterior moulding( (see Front door protectivestrip: Removal - Refitting) ,

- the door lock( (see Front side door lock: Remo-val - Refitting) ,


- the window lift mechanism( (see Front side door

electric window mechanism: Removal - Refit-ting) ,

- the fixed window( (see Fixed window in frontdoor: Removal - Refitting) ,

- the sliding window( (see Sliding window in frontside door: Removal - Refitting) ,

- the interior trim( (see Front side door trim: Remo-val - Refitting) .

Note:

It is possible to carry out the stripping operations onthe vehicle before removing the door.

WARNING

For vehicles equipped with the « hands-free »

function, remove the exterior handle and the doorlock when the door interior trim is removed andleave the lock assembly in the interior trim dur ingremoval.




Front side door panel: Description 47A




II - PART FITTED



Car. 1657 Door panel uncrimpingpliers.

104601

115150


(1) Front side doorpanel

HLE 0.7

(2) Door panel rein-forcement

HLE 1.5

103439




Front side door panel: Description 47ACut A

Special note for removal of the door panel

The door panel can be removed using the (Car. 1657).

2 - Applying the structural adhesive

Use an M. J. Pro type setting adhesive.

3 - Positioning the panel soundproofing

115152

22436

103440

103441

Note:

If a panel straightening operation requiring evenpartial removal of soundproofing is necessary, thesoundproofing must be replaced.




Rear side door: General description 47A

I - COMPONENT DESIGN

This part has the following specifications:

- "bolted and bolted" hinges mounted vertically on theB-pillar and the door box section,

- a door check rod integrated in the lower hinge.


If the front side door hinge mountings are the "boltedand bolted" type it is possible to remove the rear sidedoor, depending on the operations to be performed:

- either by unscrewing the mountings on the compo-nent in the event of replacement of the rear side door,

- or with the hinges by removing the mountings on theA-pillar in the event of replacement of the body.

III - ADJUSTMENT

There are four main areas where adjustments can bemade:

- adjustment of the front area,





1 - Adjustment of the front area:

Adjust the shut lines and alignment with the front sidedoor using the rear side door hinge mountings.

2 - Adjustment of the rear area:

Adjust the shut lines and alignment with the rear wing

and the closure firmness using the striker plate moun-tings.

3 - Adjustment of the upper area:Adjust the shut lines and alignment with the roof andthe quarter panel using the rear side door hinge moun-tings.

WARNING




101730

Note:

If the component is to be removed and not repla-ced, mark the position of the mountings before uns-crewing them to avoid having making adjustmentswhen refitting the component.

Note:

The rear side door is the component positioned firstin the order of assembly of removable componentsin the factory.

For it to be completely adjusted, correctly positionall the other components.

IMPORTANT

In this case, compromise between the closure firm-ness and the rear shut lines of the rear side door bygiving priority to closing in such a way that the door

presses sufficiently onto the seal to avoid floating ofthe rear of the door.




Rear side door: General description 47A4 - Adjustment of the lower area:

Adjust the shut lines and alignment with the sill panelusing the rear side door hinge mountings.




Rear side door: Removal - Refitting 47A





Remove:

- the door mounting bolts (1) ,

- the door.


1 - REFITTING OPERATION FOR PARTCONCERNED

Refit:

- the door,

- the door mounting bolts (1) .

Adjust the door shut lines and flush fitting (see Vehi-cle shut lines: Adjustment value ).

Tighten to torque the door mounting bolts (21 Nm).

2 - FINAL OPERATION

Connect the door wiring harness supply connector.





Remove:

- the hinge mounting bolts (2) ,

- the door.


1 - REFITTING OPERATION FOR PARTCONCERNED

Refit:

- the door,

- the hinge mounting bolts (2) .

Tightening torquesm

door mounting bolts 21 Nm


door retention devicemounting bolts

21 Nm

101730 101730




Rear side door: Removal - Refitting 47AAdjust the door shut lines and flush fitting (see Vehi-cle shut lines: Adjustment value ).


2 - FINAL OPERATION

Connect the door's wiring harness supply connector.

V - PASSIVE SAFETY

At the end of the operation, check the presence andcondition of the door retention device (3) .

Tighten to torque the door retention device moun-ting bolts (21 Nm) .

101727

REMINDER:

This part's function is essential in the event of a

rear collision. The door retention device keepsthe door in its longitudinal plane, thereby absor-bing impact energy efficiently.




Rear side door: Adjustment 47A

ADJUSTMENT VALUES

For information on the rear side door adjustment va-lues, (see Vehicle shut lines: adjustment value ).

ADJUSTMENT

There are two options for adjusting the door:

- by means of the mountings on the door box section(opening clearance adjustment),

- by means of the mountings on the A-pillar (shut lineadjustment):


I - ADJUSTMENT OF FLUSH FITTING WITH THEFRONT DOOR AND THE REAR WING

Undo the hinge mounting bolts (6) .

Adjust the shut lines with the rear door.


Tightening torquesm


door box section moun-ting bolts

21 Nm

striker plate bolts 21 Nm

115805

101731




Rear side door: Adjustment 47AII - ADJUSTMENT OF FLUSH FITTING WITH THEFRONT DOOR AND THE REAR WING

Special note on the hinge upper mounting

Replace the original indexing studs (7) with bolts (8)available from the Parts Department , to enableflush fitting adjustment.

Undo the door box section mounting bolts (9) .

Adjust the flush fitting with the front door and the rearwing.

Tighten to torque the door box section mountingbolts (21 Nm) .

103950

Note:

To increase the adjustment available, enlarge theupper holes on the original hinges.

After-Sales hinges are supplied with squareslots.

101729




Rear side door: Adjustment 47ASpecial notes on the striker plate

The striker plate is spot-welded to the rear wing rein-

forcement at (A) .

To carry out adjustments, bend the fusible sections(B) of the plate.

This operation can only be performed by exerting arelatively strong force on the striker (e.g. by using a

hammer.

Undo the striker plate bolts (10) .

Adjust the flush fitting with the rear wing, the contactand the closure firmness.

Tighten to torque the striker plate bolts (21 Nm) .

103946

101728




Rear side door: Stripping - Restoring 47AThe order of the operations described applies specifi-cally to replacing the door.

STRIPPING

Remove:

- the interior trim( (see Rear side door trim: Remo-val - Refitting) ,

- the sliding window( (see Sliding window in rearside door: Removal - Refitting) ,


- the exterior frame seal( (see Rear side door frameseal: Removal - Refitting) ,

- the door lock( (see Rear side door lock: Removal- Refitting) .

Remove:

- the exterior door moulding( (see Rear door pro-tective strip: Removal - Refitting) .

REASSEMBLING

Refit:

- the exterior door moulding( (see Rear door pro-tective strip: Removal - Refitting) ,

- the door lock( (see Rear side door lock: Removal- Refitting) ,

- the exterior frame seal( (see Rear side door frameseal: Removal - Refitting) ,

- the exterior handle( (see Interior door handle onrear side door) ,

- the sliding window( (see Sliding window in rearside door: Removal - Refitting) ,

- the interior trim( (see Rear side door trim: Remo-val - Refitting) .

Note:

It is possible to carry out the stripping operations onthe vehicle before removing the door.

IMPORTANT

For vehicles equipped with the « hands-free »

function, remove the exterior handle and the doorlock when the door interior trim is removed and

leave the lock-exterior handle support assemblyin the trim during removal.




Rear side door panel: Description 47A




II - PART FITTED



Car. 1657 Door panel uncrimpingpliers.

104603

115151


(1) Rear side doorpanel HLE 0.7

(2) Door panel rein-forcement

- 1

103442




Rear side door panel: Description 47ACut A

Special note for removal of the door panel

The door panel can be removed using the (Car. 1657).

2 - Applying the structural adhesive

Use an M. J. Pro type setting adhesive.

3 - Positioning the panel soundproofing

115152

22436

103443

103444

Note:

If a panel straightening operation requiring evenpartial removal of soundproofing is necessary, thesoundproofing must be replaced.




Fuel filler flap cover: General description 47A

COMPONENT DESIGN

The fuel filler flap has two special features:

- it is made of plastic (NORYL),

- it is slotted into its plastic mounting (1) .

WARNING




110629

1




Fuel filler flap cover: Removal - Refitting 47AREMOVAL

OPERATION FOR REMOVAL OF PARTCONCERNED

Press gently with your fingers to disengage the co-ver of the four clips (1) and pull the cover outwards.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

Clip the fuel filler flap cover onto its mounting.

104452

104453



NON-SIDE OPENING ELEMENTS


104694



Aluminium



Steel/SMC


SMC


Aluminium








Noryl




ting, page 42A-53)

Aluminium




Noryl



Polypropy-lene






Bonnet: General description 48A


This type of bonnet has the following specifications:

- opening at the front, « bolted and bolted » , type hin-ges at the rear, mounted vertically on the bonnet hin-ge mounting and flat mounted and indexed on thebonnet lining,

- side stay mounted on the front wing mounting sup-port,

- side stops mounted with pedestrian impact absorbersbuilt into the front upper cross member,

- central lock with built-in safety retainer,

- with built-in and removable windscreen washer jets.


If the bonnet hinge mountings are of the « bolted andbolted » type, following the operations to be performed,it is possible to remove the bonnet:

- either by unscrewing the mountings on the compo-nent if the bonnet is to be replaced or removed formechanical work,

- or with the hinges by removing the mountings on theaperture if the body is to be replaced.

III - ADJUSTMENT

There are two main areas where adjustments can bemade:


- adjustment of the front area.


Adjustment of the rear area:

Adjust the shut lines and alignment with the scuttleaperture and the front wings using the bonnet hingemountings.

Adjustment of the front area:

Shut lines with the wings and clearance from the bum-per and headlights are not adjustable because the bon-net stops on the front upper cross member are fixed.

Only the closure firmness is adjustable by the fittingssecuring the lock.

WARNING




112034

Note:

If the component is to be removed and not repla-ced, mark the position of the mountings before uns-

crewing them to avoid having making adjustmentswhen refitting the component.

Note:

The bonnet is the last of the removable componentsto be fitted on the body in the factory assembly pro-cess.

For final adjustment, correctly position all the othercomponents including the bumper and the headli-ghts for them to be correctly positioned.




Bonnet: General description 48A

Note:

In this case, compromise between the closure firm-ness and the front height of the bonnet by givingpriority to closing in such a way as to retain a mini-mum bonnet drag in the direction of the support onthe stops to avoid the front of the bonnet floating.




Bonnet: Removal - Refitting 48A

I - REMOVAL BY MEANS OF THE BONNET BOLTS


Remove the bonnet soundproofing( (see Bonnetsoundproofing: Removal - Refitting) .

Disconnect the screen washer pipe union (1) .


Remove:

- the bonnet mounting bolts (2) ,

- the bonnet.

II - REFITTING BY MEANS OF THE BONNET BOLTS


Refit:

- the bonnet,

- the bonnet mounting bolts (2) .

Adjust the opening clearances and shut lines (see48A, Non-side opening elements, Bonnet: Ad-justment, page 48A-7) .

Torque tighten the bonnet mounting bolts (8 Nm) .

2 - FINAL OPERATION

Connect the screen washer pipe union (1) .

Refit the bonnet soundproofing( (see Bonnet soun-dproofing: Removal - Refitting) .

Tightening torquesm

bonnet mounting bolts 8 Nm

bonnet hinge mountingbolts

8 Nm

103904

104511




Bonnet: Removal - Refitting 48AIII - REMOVAL BY MEANS OF THE BONNET HINGEBOLTS


Remove:

- the front wing (see 42A, Upper front structure,Front wing: Removal - Refitting, page 42A-10) ,

- the bonnet soundproofing( (see Bonnet sound-proofing: Removal - Refitting) ,

Disconnect the screen washer pipe union (1) .


Remove:

- the bonnet hinge mounting bolts (3) ,

- the bonnet.

IV - REFITTING BY MEANS OF THE BONNETHINGE BOLTS


Refit:

- the bonnet,

- the bonnet hinge mounting bolts (3) .Adjust the opening clearances and shut lines (see48A, Non-side opening elements, Bonnet: Ad-justment, page 48A-7) .

Torque tighten the bonnet hinge mounting bolts(8 Nm) .

2 - FINAL OPERATION

Connect the screen washer pipe union (1) .

Refit:

- the bonnet soundproofing( (see Bonnet sound-proofing: Removal - Refitting) ,

- the front wing (see 42A , Upper front structure,Front wing: Removal - Refitting, page 42A-10) .

104238




Bonnet: Adjustment 48A

ADJUSTMENT VALUES

For all information about bonnet adjustment values((see Vehicle clearances: Adjustment values) .

ADJUSTMENTThere are two options for adjusting the bonnet:

- by means of the bonnet mounting bolts,

- by means of the bonnet hinge bolts.

The closing plunger must be adjusted in addition tothe bonnet adjustment.


I - ADJUSTMENT BY MEANS OF THE BONNETMOUNTING BOLTS

Undo the bonnet mounting bolts (4) .

Adjust the bonnet shut lines.

Torque tighten the bonnet mounting bolts (8 Nm) .

Tightening torquesm

bonnet mounting bolts 8 Nm

bonnet hinge mountingbolts

8 Nm

closing catch mountingbolts

8 Nm

115808

104512




Bonnet: Adjustment 48AII - ADJUSTMENT BY MEANS OF THE BONNETHINGE MOUNTING BOLTS

Undo the bonnet hinge bolts (5) .

Adjust the bonnet shut lines.

Torque tighten the bonnet hinge mounting bolts(8 Nm) .

III - ADJUSTMENT OF THE CLOSING PLUNGERAND SAFETY CATCH

Adjust the closing plunger with the bonnet lock.

104238 103903

Note:

When adjusting the closing plunger and safetycatch, it is essential to remove the closing plun-

ger and catch, and touch up the bonnet pain-twork with anti-corrosion protection.




Bonnet: Adjustment 48A

Adjust the safety catch then tighten it in position.

Torque tighten the closing catch mounting bolts(8 Nm) .

103900

Note:

It is essential to check that the safety catch ope-rates correctly following adjustment of the bonnetand lock mechanism.

104466

REMINDER:

When in the closed position, the bonnet shouldrest on stops (6) .




Tailgate: General description 48A


This type of tailgate has the following specifications:

- bottom opening, hinges at the top of the "bolted andbolted" type, fixed vertically on the tailgate hinge rein-forcements and flat mounted on the tailgate lining,

- side stays fixed onto the rain channels of the rearwings,

- fixed side stops built into the tailgate lining,

- central lock.


When the tailgate hinge mountings are of the "boltedand bolted" type, following the operations to be perfor-med it is possible to remove the tailgate:

- either by unscrewing the mountings on the compo-nent if the tailgate is to be replaced,

- or with the hinges by removing the mountings on theroof rear cross member if the body is to be replaced.

III - ADJUSTMENT

Two main areas of adjustment may be identified:



always begin the adjustments on the hinge side withthe lock striker plate loose and the stops in place.

Adjustment of the upper area:

Adjust the shut lines and alignment with the roof andthe rear wings using the tailgate hinge mountings.

Adjustment of the lower area:

Shut lines with the wings and clearance from the bum-per and rear lights are not adjustable because the tail-gate stops on the tailgate lining are fixed.

Only the closure firmness is adjustable by the fittingssecuring the lock.

WARNING




112177

Note:

If the component is to be removed and not repla-ced, mark the position of the mountings before uns-crewing them to avoid having making adjustmentswhen refitting the component.

Note:

For final adjustment, correctly position the rearlights and the bumper so that they remain correctlypositioned.

Note:

In this case, compromise between the closure

length and the lower shut lines of the tailgate bygiving priority to closing in such a way as to retainsufficient pressure by the tailgate on the stops toprevent the tailgate floating.




Tailgate: Removal - Refitting 48A



Remove the tailgate trim( (see Tailgate lining: Re-moval - Refitting) .

Disconnect the electrical connectors to:

- the hands-free opening button (if fitted to the vehi-

cle),

- the rear screen de-icer,

- the rear screen opening lock (if fitted to the vehi-cle),

- the wiper motor,

- the license plate lights.

Remove:

- the tailgate electrical supply harness,

- the tailgate washer jet tube,

- the tailgate gas struts.


Remove:

- the tailgate mounting bolts (1) ,

- the tailgate.



Refit:

- the tailgate,

- the tailgate mounting bolts (1) .

Torque tighten the tailgate mounting bolts (8 Nm) .

2 - FINAL OPERATION

Refit:

- the tailgate gas struts,



Connect the electrical connectors to:

- the license plate lights,

- the wiper motor,



Tightening torquesm

tailgate mounting bolts 8 Nm

hinge mounting bolt 21 Nm

103920




Tailgate: Removal - Refitting 48A- the hands-free opening button (if fitted to the vehi-cle).

Refit the tailgate trim( (see Tailgate lining: Remo-val - Refitting) .



Remove the tailgate trim( (see Tailgate lining: Re-moval - Refitting) .

Disconnect the electrical connectors to:

- the hands-free opening button (if fitted to the vehi-cle),



- the wiper motor,

- the license plate lights.

Remove:



- the tailgate gas struts.


Keep the headlining to one side using a wedge (2) .

Remove:

- the hinge mounting bolt (3) ,

- the tailgate.



Refit:

- the tailgate,

- the hinge mounting bolt (3) .

Tighten to torque the hinge mounting bolt (21 Nm).

Fit the headlining.

2 - FINAL OPERATION

Refit:

- the tailgate gas struts,



Connect the electrical connectors to:

- the license plate lights,

- the wiper motor,

101376




Tailgate: Removal - Refitting 48A- the rear screen opening lock (if fitted to the vehi-cle),


- the hands-free opening button (if fitted to the vehi-

cle).

Refit the tailgate trim( (see Tailgate lining: Remo-val - Refitting) .




Tailgate: Adjusting 48A

ADJUSTMENT VALUES

For any information regarding tailgate adjustmentvalues, see Vehicle shut lines: Adjustment value).

ADJUSTMENT

There are two options for adjusting the tailgate:

- by means of the tailgate mounting bolts,

- by means of the tailgate hinge mounting bolts:

The tailgate striker plate must be adjusted in addi-tion to the tailgate adjustment.


I - ADJUSTMENT BY MEANS OF THE TAILGATEMOUNTING BOLTS

Loosen the tailgate mounting bolts (6) .

Adjust the tailgate shut lines.

Torque tighten the tailgate mounting bolts (8 Nm) .

Tightening torquesm

tailgate mounting bolts 8 Nm

tailgate hinge moun-ting bolt

21 Nm

tailgate striker platemounting bolts

21 Nm

115809

103921




Tailgate: Adjusting 48AII - ADJUSTMENT BY MEANS OF THE TAILGATEHINGE MOUNTING BOLTS

Keep the headlining to one side using a wedge (7) .

Loosen the tailgate hinge mounting bolt (8) .

Adjust the tailgate shut lines.

Torque tighten the tailgate hinge mounting bolt

(21 Nm) .

Fit the headlining.

III - TAILGATE STRIKER PLATE ADJUSTMENT

Loosen the tailgate striker plate mounting bolts (9) .

Adjust the tailgate lower section shut lines.

Tighten to torque the tailgate striker plate moun-ting bolts (21 Nm) .

101376

103923




Tailgate: Adjusting 48A

103924

103733

Note:

When in the closed position, the stops (1 1)should rest on the stops (10) .

Documents

Manual service Renault Scenic 2 tablarie