Apz Mecánica Automotriz Renault 19 Carrocería (Sheet Metal Work)

Sheet metal work
GENERAL LOWER STRUCTURE UPPER FRONT STRUCTURE UPPER SIDE STRUCTURE UPPER REAR STRUCTURE UPPER BODY SECTION BODY PROTECTION SIDE OPENINGS BONNET AND TAILGATE
77 11 190 877
NOVEMBER 1996
All copyrights reserved by Renault.
Edition Anglaise
"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 by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed".
Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.
Renault S.A. 1988
EXPLODED VIEW
PRS4011
Panels
Contents
Pages Pages
40 GENERAL
Engine - Clutch - Gearbox Vehicle dimensions Lifting Description of parts (exploded views) Description of symbols Opening clearances Collision damage assessment Dimensions of the lower structure Main bodywork dimensions Body jig bench Special tools 40-1 40-2 40-7 40-11 40-18 40-20 40-27 40-32 40-34 40-35 40-42
42 UPPER FRONT STRUCTURE

A B C D E F G H I J Wing Complete radiator grille upper cross member Part radiator grille upper cross member Bonnet lock support Headlight carrier panel Part front wing panel (front section) Wheel arch (shock absorber turret) Part heater bulkhead partition Part windscreen aperture lower cross member Front pillar upper stiffener 42-1 42-4 42-6 42-7 42-8 42-9 42-10 42-14 42-16 42-18
41 LOWER STRUCTURE
A B C D E F G H I J K L M N O P Q R S T U V W Complete front end cross member Part front end cross member Complete front end panel Part front end panel Side member closing panel Front side member front section Part front side member front section Front side member rear section Front side cross member Front half unit Part centre floor panel Rear floor panel (part centre section) Rear floor panel Utility vehicle floor panel Lateral side member lower section Lower side spacer Sill closing panel stiffener Front pillar lower section stiffener Floor and cross member side stiffener Floor panel upper cross member Assembled rear end panel Part rear end panel cross member Body 41-1 41-3 41-4 41-5 41-6 41-7 41-9 41-10 41-12 41-13 41-16 41-17 41-18 41-22 41-23 41-25 41-26 41-28 41-29 41-30 41-31 41-34 41-36
43 UPPER SIDE STRUCTURE

A B C D E F G H I J K L M N O Front pillar lower section Front door pillar by cutting at windscreen upright Door hinges (on front pillar) Front door pillar Front pillar Front door pillar seal fastening (KSM) Centre pillar Centre pillar lining Sill panel Body side Part sill panel Sill panel Sill panel front stiffener Sill panel rear stiffener Roof arch 43-1 43-3 43-5 43-6 43-8 43-9 43-10 43-15 43-19 43-21 43-22 43-23 43-27 43-29 43-30
Contents
44 UPPER REAR STRUCTURE

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z 2A Complete wing panel Complete rear wing panel Part wing panel Part rear wing panel Quarter panel lining Assembled wing panel lining Wing panel lower front lining Wing panel upper front lining Wing panel rear lining Tailgate upper rain channel Outer wheel arch Complete quarter panel arch Part quarter panel arch Backrest mounting stiffener Outer wheel arch stiffener Upper cross member between wheel arches Hood compartment base partition Hood compartment rear cross member Backrest mounting stiffener Jack support (right hand side) Centre shelf Half unit Rear end panel Rear end panel lining and assembled end panel Part end panel cross member Rear end panel extension piece Side rain channel Boot lid rain channel Lighting support panel 44-1 44-8 44-13 44-25 44-26 44-32 44-36 44-37 44-38 44-39 44-40 44-44 44-46 44-47 44-48 44-49 44-51 44-53 44-54 44-55 44-56 44-58 44-64 44-70 44-71 44-73 44-75 44-77 44-79
45 UPPER BODY SECTION

A B C D E F Roof panel Windscreen surround Linings and stiffeners Windscreen pillar lining Windscreen aperture upper cross member Rear roof cross member 45-1 45-7 45-9 45-10 45-11 45-12
46 BODY PROTECTION
A B Sub-frame front protector Wheel arch mud shield 46-1 46-2
47 SIDE OPENINGS
A B C D Door hinges Front door panel Rear door panel Front door - rear door 47-1 47-2 47-4 47-6
48 BONNET AND TAILGATE

A B C D E F Bonnet Tailgate Boot lid Hood cover panel Broken boot lid counter balance ball joint Roof cross member (noise reduction) 48-1 48-3 48-5 48-11 48-13 48-14
GENERAL Engine - Clutch - Gearbox
40
Engine Vehicle type Type Cubic capacity (cm 3) 1237 1397 1397 1390 1390 1390 1390 1171 1721 Clutch type Manual and automatic gearbox type
B530 - C530 - L530 S530 B531 - C531 - L531 B53H - B53P - C53P
L53H - L53P
C1G C1J C2J C3J E6J E7J E7J E7F F2N
180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 200 CP 4000
JB0 - JB1 - JB4 - JB5 JB0 - JB1 - JB4 - JB5 JB0 - JB1 - JB4 - JB5 JB0 - JB1 JB0 - JB1 - MB1 JB1 - MB1 JB1 - MB1 JB0 - JB1 - JB3
B532 - C532 - L532 B53G - B537 - C537 L53G - L537 - S537 B53A - C53A - L53A B535 - C535 - L535 B53W - C53W - L53W B53E - B53M - B533 B536 - C53E - C53M C533 - L533 - L536 B53B - B53C - B53F C53B - C53C - C53F D53C - L53B - L53C L53F B53V - B53Y - B538 C53V - C53Y - C538 D53V - D53Y - L53V L53Y - L538 - 353A 353C - 353D - 353F 453A - 453C - 453D 453F - 453H - 553A 553C - 553D - 553F 553H - 853A - 853C 853F B53D - B539 - C53D C539 - D53D - L53D L539 B53I - B53J - B53K B53T - B53Z - B534 C53I - C53J - C53K C53T - C53Z - C534 L53I - L53J - L53K L53T - L53Z - L534 S53I - S53J - S53K S534
JB0 - JB1 - JB3 - AD4
F3N
1721
200 CP 4000
AD4 - JB3 - MB3
F3P
1794
200 CP 4000
AD4 - JB3 - JC5
F7P
1764
200 CP 4400
JB3 - JC5
200 CPV 4600 F8Q 1870 200 CPV 3500

JB1 - JB3 - JC5
40-1
B53 Phase I
GENERAL Vehicle dimensions
40
91936R1
Mark A B C D E F
Dimensions in metres 2.545 4.155 1.418 1.416 unladen 1.406 to 1.417 1.676 or 1.694
40-2
B53
Phase II
40
95890R
Mark A B C D E F G H I
Dimensions in metres 0.813 2.540 - 2.544 (1) 0.805 - 0.809 (1) 4.158 - 4.166 (1) 0.120 (2) 1.426 1.684 - 1.696 (1) 1.400 - 1.420 (1) - (3) 1.406 - 1.417 (1)
(1) Depending on version with option (2) Laden (3) Unladen
40-3
L53 Saloon Except Sport
40
92866R
Mark A B C D E F * Depending on version
Dimensions in metres 2.545 or 2.540 * 4.262 1.412 unladen 1.418 1.406 to 1.417 * 1.684 or 1.694 *
40-4
B - C - L539 Sport
40
92764R
Dimensions in metres Mark B and C A B C D E F 4.150 1.389 1.429 1.406 1.684 2.540 4.259 1.400 L
40-5
D53 Cabriolet
40
94726R
Mark A B C D E F
Dimensions in metres 2.545 4.155 1.375 5 1.418 1.406 to 1.417 1.676 or 1.694
40-6
GENERAL Lifting
LIFTING USING A JACK FROM THE SIDE USING AXLE STANDS
40
Use cross piece Cha. 280-02 . Take the load under the front door sill. Position the body sill flange correctly in the cross piece groove.
To place the vehicle on axle stands, the stands must be positioned under jacking points (1) provided for lifting the vehicle using the jack supplied with the vehicle. To position the axle stands at the rear, lift the vehicle from the side.
87709R
85679-1G7
91936G3
40-7
GENERAL Lifting
Safety symbol (special precautions to be taken while working)
40
ESSENTIAL SPECIAL TOOLS
Cha. Cha. or Cha.
280 -02 408 -01
Adjustable cross piece on trolley jack Adjustable dowel on trolley jack
408 -02 For B537 and C537 type vehicles, make a clearance notch in cross piece Cha. 280-02 to prevent it from coming into contact with the exhaust.
USING A TROLLEY JACK FROM THE REAR
Appropriate axle stands must be used if a trolley jack is used.
The vehicle must not be lifted by taking the load under the front suspension arms. Depending on the type of trolley jack , use dowels Cha. 408-01 or Cha. 408-02 to fit cross piece Cha. 280-02. To lift the front or the rear, take the load under the lifting points provided for the on-board jack.
USING A TROLLEY JACK FROM THE FRONT
The rear of the vehicle MUST NOT be lifted by taking the load under the rear axle. Lift each wheel separately taking the load at the lifting points provided for the on-board jack.
Apply the handbrake or chock the rear wheels. Use cross piece Cha. 280-02 . Take the load under the front sub-frame. Ensure that the cross piece does not come into contact with the gearbox or the exhaust downpipe.
92556R
40-8
GENERAL Lifting
AXLE STANDS WHEEL FREE LIFT SAFETY ADVICE
40
To place the vehicle on axle stands, the stands must be positioned: - either under the jacking points provided for lifting the vehicle using the on-board jack, - or under the pads located behind the stiffeners. To position the axle stands at the rear, lift the vehicle sideways.
Several possibilities must be considered:

1 - REMOVAL OF COMPONENTS
In general, never use a two post lift when a four post lift is suitable. If this is not possible, fit the lifting pads under the sill flange at the lifting points provided for the onboard jack.
FRONT
98703S
REAR
85679-1G7
98336G 98704S
The pads must be placed to the right of the jacking points. They must be engaged in the openings in the sill panel flanges.
40-9
GENERAL Lifting
2 - SPECIAL CASE FOR REMOVAL - REFITTING OF THE ENGINE AND TRANSMISSION ASSEMBLY FRONT
40
In this case, the vehicle body must be connected to the arms of the two post lift using special pads.
FOG :
Part number FOG 449 8111 - 449 8411 or

CHEMICO :
Part number 39 2550 0001 or

SCHENCH
Part number 776 684
98705S
LASHING FOR TOWING FOR TOWING REFER TO THE CURRENT LEGISLATION FOR EACH COUNTRY. NEVER USE THE DRIVESHAFTS AS TIE-DOWN POINTS.
REAR
The towing points are only to be used for towing on the road. They must never be used for pulling the vehicle out of a ditch, for any other similar operations or for lifting the vehicle directly or indirectly.
98702S
40-10
B53 / C53
GENERAL Description of parts (exploded views)
40
PRS4012
LOWER STRUCTURE ALL TYPES
1 2 2A 2B 3 4 5 6 7 8 8A 8B
Sill closing panel Centre floor panel Part centre floor panel Part centre floor panel Centre floor panel cross member Front seat mounting cross member Front 1/2 unit (wheel arch) Rear 1/2 unit (wheel arch) Assembled rear floor panel with side member Rear floor panel rear section Part rear floor panel Part rear floor panel
9 10 11 12 13 14 15* 16* 17 18 18A 19 19A 20 20A
Rear floor panel front section Rear floor panel Floor panel stiffener cross member Fuel tank mounting cross member Cross member under rear floor panel Rear side member Front side cross member Front side member rear section Front side member closure panel Front side member front section Part front side member Lower front cross member Part lower cross member Assembled front panel Part assembled front panel
* Steel part with high degree of flexibility
40-11
B53 / C53
40
PRS4013
UPPER STRUCTURE
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65
Front roof panel cross member Windscreen pillar lining B53 roof drip moulding lining Rear roof cross member Roof panel Centre pillar lining B53 quarter panel lining Quarter panel arch Rear outer wheel arch Quarter panel lining (C53) Sill panel partition (C53) Door pillar lining (C53) Body top lining (C53) Centre pillar lower lining Front wing bracket Front wing
66 67 68 69 70 71 71A 72 72A 72B 73 73A 74 75 75A 76
Front wheel arch Front wheel arch extender Diesel engine mounting cup Headlight carrier panel Bonnet lock support Front upper cross member Part front upper cross member Inner wheel flange panel - front pillar lining Part inner wheel flange panel - front pillar lining Part inner wheel flange panel - front pillar lining Heater bulkhead partition Part heater bulkhead partition Bulkhead Windscreen aperture lower cross member Part lower cross member Bonnet
40-12
B53 / C53
40
PRS4014
UPPER STRUCTURE
80 81 82 83 84 85 86 87 88 89 90
Tailgate Front door Rear door Rear door panel Front door panel Lighting support Rear end panel Assembled rear end panel with cross member Rear end panel lining Sill panel (C53) Wing panel (C53)
90A 90B 91 92 93 94 95 96 97 97A 97B 98 99
Part wing panel in line with cross-section A Part wing panel in line with cross-section B Body top (roof drip moulding) (C53) Sill panel (B53) Body top (B53) Front pillar Body side Centre pillar Rear wing panel (B53) Part rear wing panel (cross-section A) Part rear wing panel (cross-section B) Wing panel upper rain channel Wing panel lower rain channel
40-13
B53 / C53 / L53

LOWER STRUCTURE
40
PRS4015
1 Rear floor panel with side member 2 Part rear floor panel (rear section) 3 Rear floor pnel 4 Rear side member 5 Part rear end panel cross member
40-14
L53
SALOON

UPPER STRUCTURE
40
PRS4016
1 2 3 4 5 6 7 8 9 10
Roof panel Rear roof cross member Boot lid Counter balance ball joint Boot lid strut Quarter panel lining Quarter panel arch Outer wheel arch Wing panel side rain channel Wing panel
11 12 13 14 15 16 17 18 19
Rear end panel cross member Rear end panel cross member blanking piece Lighting support panel Assembled rear end panel Rear end panel side extender Jack support (right hand side only) Backrest mounting stiffener Rear centre shelf Half unit
40-15
D53
CABRIOLET
40
PRS4017
1 2 3 4 5 6 7 8 9
Windscreen surround Rear floor panel upper cross member Floor panel and cross member side stiffener Lower side spacer Lateral side member lower section Sill panel stiffener Sill panel rear stiffener Sill panel outer panel Bare sill panel outer panel
10 11 12 13 14 15 16 17 18
Door panel Door Front pillar upper stiffener Front pillar Front wing Sill panel front stiffener Front pillar lower lining Windscreen pillar lining Windscreen aperture upper cross member
40-16
D53
CABRIOLET
40
PRS4018
28 29 30 31 32 33 34 35 36 37
Upper cross member between wheel arches Hood compartment base partition Hood compartment rear cross member Boot lid rain channel Hood compartment cover Boot lid Hood compartment cover hinge Boot lid hinge Wing panel rear lining Lighting support component
38 39 40 41 42 43 44 45 46 47
Lighting support component stiffener Rear wing panel Outer wheel arch stiffener Outer wheel arch Wing panel lower front lining Wing panel upper front lining Centre pillar Centre pillar lining Assembled wing panel lining Boot lighting support
40-17
GENERAL Description of symbols
40
Cut using a cold chisel
Grind the weld fillet or spot welds Straight grinding wheel fitted with a 75mm diameter 1.8 to 3.2 mm thick Bakelite disc. Rotary grind the spot welds 20,000 rpm straight grinding wheel with a 10 or 16mm diameter spherical cutter. Rotary grind the spot welds Spot weld drill. Speed of rotation 800 to 1,000 rpm.
MIG stitch welding Note: for good quality welding, it is recommended that a gas composed of Argon + 15% CO2, which is considered to be an active gas, is used (MIG)
Plug welding MIG welding Inject wax into the hollow sections Gun under pressure fitted with a flexible end piece. Safety symbol This means that the welding operation in question concerns one or more aspects of vehicle safety Lead fill Hot air gun Nozzle output temperature 600 min. Palette+ 33% lead stick+ tallow Note: to a large extent, the soft solder finish compensates for the risks of deformation due to welding Application of electrically weldable mastic This conductive mastic, inserted between two panels to be spot welded, seals the panels and prevents corrosion of the spot welds Application of aluminium based paint This must be applied to the mating surfaces of each of the parts to be plug welded. This paint is conductive and can withstand high temperatures; it gives anti-corrosion protection around welds.
Unpick the metal strip
Clean the surfaces to be welded 100 mm fibre disc
Cut using a hacksaw Pneumatic power hacksaw Cut the part by grinding the flange or grind down the remaining bits of spot weld Angle grinder fitted with a rubber backing pad and a 120 to 180 mm P36 grade fibre disc Release brazed joint
Dimensions and types of electrodes to be used for the operation: L = 100 L = 100 L = 100 +flat L = 250 L = 350 +ball joint L = 330
Apply a bead of extruded mastic gun with a manual or pneumatic cartridge crimping or mating mastic with one or two parts Apply mastic by spraying gun under pressure anti-chipping and anti-corrosion mastic with two parts
40-18
GENERAL Description of symbols

LOCATION OF OPERATIONS TYPES OF TOOL AND ORDER OF OPERATIONS CUTTING-UNPICKING LOCATION OF OPERATIONS
40
TYPES OF TOOL AND ORDER OF OPERATIONS WELDING (cont)
or saw saw plug weld
chisel
stitch weld
FINISHING
rotary grind
unpick
clean
stud extractor grind unpick clean

PROTECTION OF CRIMPED WELD JOINTS
rotary grind
bead of mastic in cartridge
sand
unpick
clean
bead and spraying of mastic

ANTI-CHIPPING PROTECTION
grind
spraying of mastic release brazed joint

WELDING
X 1-2 3-4 5 6 8 L (en mm) 100 100 250 350 330
sand
PROTECTION OF HOLLOW SECTIONS
injection using angled nozzle

PAINTING STYLED AREAS
electric spot welder
stitch weld
grind
lead fill
aerosol can
40-19
B53 Phases I and II
GENERAL Opening clearances
40
91936-4R
92309-1R1
40-20
B53 Phases I and II
40
92309-1R2
40-21
L53 Saloon
40
92866R1
93126R
NOTE: for front section parts, refer to the B53 diagrams on previous pages.
40-22
D53 Cabriolet
40
94726R1
40-23
D53 Cabriolet
40
94772-3R
94772R
2
94772-4R
94772-1R
3
94772-5R
94772-2R
40-24
D53 Cabriolet
40
10
94772-6R
94772-9R
94772-7R
11
94772-10R
94772-8R
40-25
D53 Cabriolet
40
12
94772-11R
40-26
GENERAL Collision damage assessment

CHECKING THE FRONT CROSS MEMBER AND THE FRONT END PANEL SUB-FRAME MOUNTING (1)
40
Compare lengths:
CG = DH CH = DG
If lengths (CH - DG) and diagonals (CG - DH) are not identical, point (3) on the sub-frame must be checked as shown on the following pages. If points (1) and (2) are correct, the front axle angles must be checked and adjusted. If the front axle cannot be adjusted, it will then be necessary to change front axle components (stub axle carrier, etc.).
PRS4019
C
85591R 85593R
40-27

CHECKING THE CENTRE SECTION (3) OF THE SUB-FRAME
40
Compare lengths:
EI = FJ EJ = FI
If points (2) and (3) are correct, it will be possible to straighten or partially change the front section of the side member and refit a new cross member without having to place the vehicle on a body jig bench. Point (1) is aligned using the engine sub-frame, after having changed the sub-frame if necessary. If all the sub-frame check points (1), (2) and (3) are correct, it will then be necessary to check and adjust the front axle. If adjustment is not possible, front axle components must be changed (stub axle carrier, etc.). If points (1) and (3) are not correct, the vehicle must be placed on the bench in order to change the front section of the side member.
PRS4020
E
85860-1R
J
85592S
40-28

CHECKING THE LATERAL SIDE MEMBERS (6) (REAR ARM MOUNTINGS)
40
Compare lengths:
GO = HP GP = HO
Following a side or rear impact, if there is a difference in length, the vehicle must be placed on the frame bench in order to re-align the lateral side member or partially change it.
IT IS NOT NECESSARY TO REMOVE THE FRONT MECHANICAL COMPONENTS IN ORDER TO PLACE THE VEHICLE ON THE JIG BENCH FOLLOWING A REAR OR SIDE IMPACT. SUPPORTS SPECIALLY PROVIDED FOR THE PURPOSE MUST BE PLACED AT POINTS (2).
If there is no difference in length, check points (4) as shown below.
92381R4
O
85588S
H
85593R
40-29

CHECKING THE ENDS OF THE REAR SIDE MEMBER (4)
40
Compare lengths:
EK = FL EL = FK
If points (4) and (6) are correct and there is no apparent distortion, repair is possible without using the bench on condition that the upper structure is not too badly damaged and not too many parts need to be changed. If there is a difference in length (FK - EL), the method of repair to be used (on or off the bench) depends on the number of upper structure parts to be changed.
PRS4021
F K
85595R 85589S
40-30

CHECKING THE REAR ARMS (5)
40
Compare lengths:
FM = EN
Following a rear impact or a wheel impact, it is possible to quickly check whether or not the arms are deformed. If the diagonals are different, change the rear arms. This operation for checking the arms (5) must be followed by a trammel gauge check of the mounting of the arms to the lateral side members (6).
PRS4022
M
85589S
85594R
40-31
GENERAL Dimensions of the lower structure

REMINDER OF ALIGNMENT
40
The intersection of the three planes X - Y -Z determines initial point 0 of the vehicle and the three reference lines: 1 2 3 Dimension start line: Body centreline: Base line: L - D - C (position of body jig bench bracket at X, in relation to this line). A - D - C (position of body jig bench bracket at Y, in relation to this line). L-D-B (position of body jig bench bracket at Z, in relation to this line).
The bodywork repair body jig brackets and their positions on the bench are designed in accordance with these three lines.
PRS4023
40-32
ALL TYPES
GENERAL Dimensions of the lower structure
40
92381R3
40-33
D53 Cabriolet
GENERAL Main bodywork dimensions
40
NOTE: the dimensions are measured in the centreline of the various welded nuts.
PRS4027
40-34
GENERAL Body jig bench

BRACKETS AND REFERENCE POINTS
SUB-FRAME FRONT MOUNTING
40
drilling of the shock absorber upper cup mounting holes.
(refer to the method described in sub-section 41)
DIESEL ENGINES UPPER MOUNTING
92631S
Jig used for repairing the front of the vehicle, with the front sub-frame removed. This enables positioning of the lower cross member and the end of the side member.
FRONT SHOCK ABSORBER UPPER MOUNTING
92662S
The jig is used to position the engine mounting securing cup so that it can be welded to the cowl side panel.
SUB-FRAME REAR MOUNTING
92633S
92632S
A - Repairing the front (front sub-frame removed) The jig allows positioning of the side member or the front 1/2 unit.
Jig used for repairing the front of the vehicle, front sub-frame removed. This allows: - positioning of the wheel arch or the 1/2 unit,
40-35

B - Repairing the rear (front sub-frame fitted) The jig allows the front of the vehicle to be supported and aligned on the bench.
REAR AXLE MOUNTING
40
A - Repairing the front (rear sub-frame fitted) The jig allows the rear of the vehicle to be supported and aligned on the bench.
92634S
FRONT SEAT CROSS MEMBER
92637S
When the jig is centred along the length of the vehicle, it enables the vehicle to be supported and aligned when major repairing is being carried out: Eg. : front or rear unit It also allows alignment of the rear section of the front side member.
B - Repairing the rear (rear sub-frame removed) The jig allows positioning of the side member or the rear unit.
92635S
92636S
40-36

REAR SHOCK ABSORBER UPPER MOUNTING REAR SIDE MEMBER REAR END PANEL
40
During repairing of the rear, with the rear subframe removed, the jig allows positioning of the 1/2 unit (assembled wheel arch).
During repairing of the rear, the jig allows positioning of the side member or the rear unit.
92638S
92640S
FUEL TANK MOUNTING CROSS MEMBER
During repairing of the rear (sub-frame removed), the jig allows positioning of the fuel tank cross member.
92639S
40-37

FITTING CELETTE BRACKETS
40
PRS4024
40-38

FITTING BLACKHAWK BRACKETS
40
PRS4025
40-39
D53 Cabriolet

FITTING CELETTE BRACKETS
40
PRS4026
40-40

PART NUMBERS FOR SPECIAL TOOLS
40
Description
Figure
Special heads for the CELETTE body jig bench MZ system Please contact your local After Sales Office for further details.
92 673
Special heads for the BLACKHAWK body jig bench MS system Please contact your local After Sales Office for further details.
92 674
40-41
GENERAL Special tools

FRONT END PANEL JIG
40
92301R
Car. 1138-02 Part number 00 00 113 802 Points (A), (B), (C) and (D) are the reference points for positioning the jig on the vehicle. Before fitting the jig, it is necessary to ensure at damage assessment that the reference points are correct. Points (E), (F), (G), (H) and (J) are mainly used for mounting and positioning the replacement parts. However, if either point (A) or (B) cannot be used as a reference point, the points on the opposite side to the impact act as reference points.
40-42
GENERAL Special tools

TOOL FOR REMOVING DOOR HINGE PINS
40
Flush fitting adjustment This is obtained by pulling or pushing one or two hinges using tool Car. 956 fitted to impact extractor M.S. 580. Adjustment range: 3 mm
97129R
Car. 1055-02 Part number 00 00 105 502 Fitted to the FENWICK REN. 1303 type slide hammer. Tilt adjustment
ADJUSTING THE DOORS
85700-2S
It is possible to adjust the door clearances, front to rear and tilt, without removing the door from the vehicle, using a claw lever on the male hinges: Wilmonda BHA part number (Supplier: Z. INTERNATIONAL)
85899R
40-43
LOWER STRUCTURE Complete front end panel cross member

This operation is to be carried out on a body jig bench. Refer to sub-section 40 for instructions on fitting the components.
COMPOSITION OF THE REPLACEMENT PART
41 A
Welding
Assembled part with engine sub-frame mounting stiffeners.
92567S
2
PRS4112
BUTT WELDING JOINT ON THE SIDE MEMBER
Thickness of panels (mm) Cross member: Cowl side panel: Unpicking 1.25 1
Thickness of panels (mm) Cross member: Side member: Side member closure panel: Unpicking 1.25 1.25 0.8
3 spot welds
10 spot welds
92567-1S
41-1
LOWER STRUCTURE Complete front end panel cross member

3
BUTT WELDING JOINT ON THE HEADLIGHT CARRIER PANEL
41 A
1.25 1.5
BUTT WELDING JOINT ON THE LOCK SUPPORT
Thickness of panels (mm) Cross member: Headlight carrier panel: 1.25 0.8
Thickness of panels (mm) Cross member: Lock support:
Unpicking
Unpicking
8 spot welds One 15mm MAG weld fillet
4 spot welds
Welding
Welding
92562S
92561-1S
41-2
LOWER STRUCTURE Part front end panel cross member

Phase II vehicles This operation is a variation on the previous one. Therefore, only its special points are described below. It is not necessary to use the body jig bench for this operation. Front panel jig Car. 1138 is sufficient. For this operation, lock support (2) below must be ordered as well. Phase I vehicles
41
PRS4113
Same as previous part.
In order to carry out this operation on Phase I vehicles, the closure panel (3) above must be removed from the new replacement part.
PRS4127
41-3
LOWER STRUCTURE Complete front end panel

41
Welding
Special replacement part consisting of: - upper cross member - lower cross member - lock support -
92563S
PRS4128
For phase I vehicles: At A : cut out the two phase II headlight mounting lugs. At B : Add 2 washers (diameter 6 18) to compensate for the enlargement of the cut-outs.

92565-1S
Refer to the previous operation.
BUTT WELDING JOINT ON THE COWL SIDE PANEL PANEL
Thickness of the panels (mm) Upper cross member: Headlight carrier panel: Lower cross member: Cowl side panel: Unpicking 1.2 0.8 1.25 1
92567-1S
18 spot welds
41-4
LOWER STRUCTURE Part front end panel

This operation is a variation on the previous one. Therefore, only its special points are described below. It can only be carried out on phase I vehicles which do not have a lower cross member closure panel (refer to the part lower cross member operation). Welding
41 D
92561-4S
PRS4115
NOTE: cut (A) will only be made on the opposite side to the impact.
41-5
LOWER STRUCTURE Side member closure panel

This operation is carried out in addition to: - straightening of the front section of the side member following removal of the front lower cross member, - partial replacement of the front section of the side member following removal of the front lower cross member, - complete replacement of the front section of the cross member.
41
Welding
Panel only
92568S
PRS4116
UNPICKING
- 3 spot welds on the front cross member, - 10 single layer spot welds on the side member.
+
6 two layer spot welds
2 MAG weld fillets (15 mm x 2)
41-6
LOWER STRUCTURE Front side member front section

This operation is to be carried out on a body jig bench. Refer to sub-section 40 for instructions on fitting the components. Welding
41
Part only without closure panel (the closure panel must be ordered separately).
92567S
PRS4117
BUTT WELDING JOINT ON THE CLOSURE PANEL
BUTT WELDING JOINT ON THE LOWER CROSS MEMBER
Thickness of panels (mm) Cross member: Side member: Closure panel: Unpicking 1.25 1.25 0.8
10 spot welds
41-7
LOWER STRUCTURE Front side member front section

3
BUTT WELDING JOINT ON THE WHEEL ARCH
41
Unpicking
Thickness of panels (mm) Side member front section: Closure panel: Wheel arch: Unpicking 1.25 0.8 0.7
Welding
+
18 spot welds Two 15mm MAG weld fillets Welding
92569S
92566-2S
92570S
BUTT WELDING JOINT ON THE REAR SECTION OF THE SIDE MEMBER
Thickness of panels (mm) Side member front section: Side member rear section: Wheel arch: 1.25 2 0.7
After painting and before refitting the trim, protect the hollow sections with wax.
41-8
LOWER STRUCTURE Part front side member front section

This operation is a variation on the previous one. Therefore, only its special points are described below.
41 G
PRS4118
Welding
92571S
41-9
LOWER STRUCTURE Front side member rear section

41 H
Welding
(1) (2) (3) (4) (5)
Bare side member Side cross member Jack support Sub-frame support Stiffening plate
92572S
After painting and before refitting the trim, protect hollow sections with wax.
PRS4119
BUTT WELDING JOINT ON THE FRONT SECTION
BUTT WELDING JOINT ON THE FLOOR
Thickness of panels (mm) Side member rear section: Floor stiffener: Floor: Unpicking From inside the vehicle: 2 2 0.6
32 spot welds
41-10
LOWER STRUCTURE Front side member rear section

3
BUTT WELDING JOINT ON THE INNER SILL PANEL
41 H
BUTT WELDING JOINT ON THE SEAT CROSS MEMBER
Thickness of panels (mm) Side cross member: Jack support: Inner sill panel: Sill panel: 1 2 1.5 1
Thickness of panel (mm) Side member rear section: Seat cross member: 2 1.25
Unpicking
Unpicking
+
9 spot welds Welding 6 two layer spot welds Welding
92577S
92576S
D = 6 mm
41-11
LOWER STRUCTURE Front side cross member

41
Welding
(1) Bare side cross member (2) Jack support
92574S
PRS4120
BUTT WELDING JOINT ON THE INNER SILL PANEL
BUTT WELDING JOINT ON THE FLOOR

92575S
D = 5.5 mm
Thickness of panels (mm) Side cross member: Side member: 1 2 After painting and before refitting the trim, protect the hollow sections with wax.
+
9 spot welds One 30mm MAG weld fillet
41-12
LOWER STRUCTURE Front half unit

41
(1) (2) (3) (4) (5) (6)
Side member front section Wheel arch Shock absorber cup Wheel arch extender Cowl side panel Side member closure panel
92567-1S
BUTT WELDING JOINT ON THE UPPER CROSS MEMBER
Reminder
PRS4121
92563S
BUTT WELDING JOINT ON THE HEATER BULKHEAD PARTITION CHAMBER
Reminder
Reminder
92567S
92564S
41-13
41
92641S
92570S
BUTT WELDING JOINT ON THE BULKHEAD
COWL SIDE PANEL PARTIAL CUT
Reminder
On the vehicle, cut the cowl side panel in line with the dotted line on the diagram below. This line is level with the plenum chamber. Cut the replacement part in line with the continuous black line on the diagram. This line is 60 mm from the line cut on the vehicle.
92564-1S
BUTT WELDING JOINT ON THE SIDE MEMBER REAR SECTION

92573S
Reminder
92569S
41-14

7
DRILLING THE SHOCK ABSORBER UPPER MOUNTING
41
SPECIAL FEATURES OF DIESEL VEHICLES
With the vehicle positioned on the body jig bench, after welding the wheel arch, drill the front shock absorber upper mounting. To do this: - fit part (1) in the diagram below, - counter bore the four holes (A) to a diameter of 8 mm. Warning: part (1) is the same for both the right and left hand sides, it must be pivoted through a half turn when changing from one side to the other.
On these vehicles, the right hand wheel arch has an additional support for the engine pendulum mounting. Cup (C) must be welded during repair using a body jig bench bracket supplied with the body jig components.
92662R
92632R
41-15
LOWER STRUCTURE Part centre floor panel

41
Bare floor panel (panel only). Cutting the replacement part Cut (A) is made 20 mm above the round surface of the tunnel. Cut (B) on one side or other of the seat cross member location, at the front if the rear section of the floor panel is to be re-used, at the rear if the front section of the floor panel is to be reused.
92646S
Example of the front section cut: On the vehicle, use a chisel to cut the floor panel level with the seat cross member in line with the dotted line on the diagram below.
PRS4122
NOTE: if the rear section of the floor panel is to be
changed, the dotted line will be located at (C).
41-16
LOWER STRUCTURE Rear floor panel (part centre section)

In addition to:
UPPER REAR STRUCTURE- End panel PREPARATION OF THE NEW PART
41
44-U Method 3
Bare part
PRS4124
PRS4123
Cut the new part 20 mm beyond the cut made on the vehicle, in order to be able to superpose by plug welding.
CUTTING - UNPICKING
Welding
92369S 92369-1S
D = 0.7 mm
e = 1.7 mm H = 50 mm
NOTE: the general procedure for changing a welded component is described in Workshop Repair Manual M.R. 502 section 4.
After painting and before refitting the trim, protect the hollow sections of the side members with wax.
41-17
LOWER STRUCTURE Rear floor panel

Addition to:
UPPER REAR STRUCTURE - End panel
41
44-U Method 3 Before changing the fuel tank support cross member and the cross member under the floor.
COMPOSITION OF THE REPLACEMENT PARTS
(1) Rear floor panel bare part (2) Fuel tank support cross member Spare wheel well support (3) Cross member under the floor panel bare part
PRS4125
CUTTING - UNPICKING
92370S
92371S
NOTE: the general procedure for changing a welded component is described in Workshop Repair Manual M.R. 502 section 4.
41-18

UNPICKING THE CROSS MEMBERS ON THE OPPOSITE SIDE TO THE IMPACT
41 M
92374S
92372S
PREPARATION OF THE NEW PART
WELDING THE CROSS MEMBERS (right hand side)
PRS4126
92374-1S
D = 5.5 mm
Cut the new part 20 mm beyond the cut made on the vehicle, in order to be able to superpose by plug welding.
Position the cross member under the floor panel, in relation to the fuel tank support cross member, at the distance shown on the diagram.
41-19

(right hand side) (left hand side)
41 M
92372-1S
92373S
D = 5 mm
WELDING THE FLOOR PANEL
92369-2S
92370-1S
D = 4.5 mm
41-20
LOWER STRUCTURE Rear floor panel panel
41
92371-1S
e = 1.3 mm
H = 30 mm
After painting and before refitting the trim, protect the hollow sections of the side members with wax.
41-21
S53 Utility
LOWER STRUCTURE Utility vehicle floor panel panel
41 N
UNPICKING AND REMOVAL OF THE UTILITY VEHICLE FLOOR PANEL
PRJ4019
REMOVE:
the four lashing rings and the rear floor panel carpet, side sections (1) and (2) secured to the floor panel and the body sides.
Unpick sections (3) and (4) of the load floor panel by grinding out the stitch welds without separating the two sections. Remove the load floor panel and load area partition assembly from the vehicle. Re-use the 3 wheelbrace securing clips and the jack securing assembly.
REMINDER:
1/
Before starting the grinding operations, the internal surfaces of all of the windows and the dashboard must be protected. Before fitting the rear seats, carry out a conventional paint application procedure on all of the ground surfaces.
2/
41-22
D53 Cabriolet
LOWER STRUCTURE Lateral side member lower section

Welding Front section:
41 O
Bare part
Photo page 41-1
PRS4106
JOINT WITH THE FLOOR PANEL, SILL PANEL AND SILL PANEL STIFFENER
Thickness of panels (mm) Lateral side member Sill panel Sill panel stiffener Unpicking 42 spot welds on the floor panel. 22 spot welds on the sill panel. 1.5 1.5 1.5
Twenty 20mm MAG weld fillets. Two 40mm weld fillets.
41-23
D53 Cabriolet
LOWER STRUCTURE Lateral side member lower section
41 O
Centre section:
D = 8 mm
Photo page 41-2

Rear section:
Photo page 41-2
41-24
D53 Cabriolet
LOWER STRUCTURE Lower side spacer

Welding
41
This part can only be changed after removal of the lateral side member lower section.
Bare part
Photo page 41-3
PRS4107
JOINT WITH THE FLOOR PANEL AND THE LATERAL SIDE MEMBER LOWER SECTION
Thickness of panels (mm) Spacer Side member lower section Floor panel Unpicking 1.5 1.5 0.88
Ten 20mm MAG weld fillets.
41-25
D53 Cabriolet
LOWER STRUCTURE Sill panel stiffener

This operation can only be carried out after removal of the assembled sill panel.
41 Q
Bare part
PRS4108
JOINT WITH THE FLOOR PANEL
Thickness of panels (mm) sill panel stiffener sill panel 1.5 1.5
Unpicking
41-26
D53 Cabriolet
LOWER STRUCTURE Sill closure panel stiffener
41 Q
Welding On the joint near the front pillar, replace the inaccessible spot welds with MIG plug welds.
Photo page 41-5
D = 8 mm
JOINT WITH THE SILL PANEL FRONT STIFFENER
Refer to paragraphs : 43 - L - 1
41-27
D53 Cabriolet
LOWER STRUCTURE Front pillar lower section stiffener

Welding
41
This operation can only be carried out after removal of the front pillar.
Part only
Photo page 41-6
PRS4109
JOINT WITH THE COWL SIDE PANEL (pillar lining) AND SILL PANEL LINING
Thickness of panels (mm) Cowl side panel Pillar stiffener Sill panel lining 0.97 1.5 1.5
D = 8 mm After painting and before refitting the trim, protect the hollow sections with wax.
31 spot welds.
41-28
D53 Cabriolet
LOWER STRUCTURE Floor panel and cross member side stiffener

Welding
41
- Floor panel stiffener. - Cross member stiffener.
Photo page 41-7
PRS4110
JOINT WITH THE CENTRE FLOOR PANEL AND FLOOR PANEL CROSS MEMBER
Thickness of panels (mm) Stiffener Centre floor panel Cross member Centre pillar 1.5 0.8 1.5 1.5
Photo page 41-7
Unpicking
Thirty-six 25mm weld fillets. After painting and before refitting the trim, protect the hollow sections with wax.
41-29
D53 Cabriolet
LOWER STRUCTURE Floor panel upper cross member
41
Welding
Part only
Photo page 41-8
PRS4111
JOINT WITH THE FLOOR PANEL AND CROSS MEMBER STIFFENER
Thickness of panels (mm) Cross member Floor panel Stiffener 1.5 0.88 1.5
Photo page 41-8
Thirty-three 25mm MAG weld fillets. Two 50mm weld fillets. 31 spot welds.
D = 6 mm
41-30
L53 Saloon
LOWER STRUCTURE Assembled rear end panel

Welding
41 U
Assembled part consisting of: - rear end panel cross member - rear end panel - striker plate stiffener - end panel cross member The two blanking pieces (1) must be ordered separately.
93125S
- 1 triple layer spot weld (cross member - panel - lighting support) - 4 triple layer spot welds (cross member - lighting support - extender) Special point
PRS4105
JOINT WITH THE LIGHTING SUPPORT PANEL
Thickness of panels (mm) Lighting support panel End panel cross member Side panel End panel extender Unpicking 0.67 0.67 0.67 0.97
14 spot welds
93124R
After welding and before protecting the crimps, fit the 2 metal blanking pieces (1) by clipping them in place using the lugs.
41-31
L53 Saloon
LOWER SECTION Assembled rear end panel

3
41 U
1,25 1,00
JOINT WITH THE END PANEL EXTENDER
JOINT WITH THE REAR SIDE PANEL
Thickness of panels (mm) End panel cross member Rear end panel Rear end panel cross member End panel extender Unpicking 0.67 0.67 1.25 0.97
Thickness of panels (mm) Extreme rear cross member Rear side member
Unpicking
24 spot welds
14 spot welds
93122S
93123S
- 4 triple layer spot welds
41-32
L53 Saloon
LOWER STRUCTURE Assembled rear end panel

4
JOINT WITH THE Rear floor panel panel
41 U
Thickness of panels (mm) Extreme rear cross member Rear floor panel panel 1.25 0.60
Unpicking
Welding
93121S
41-33
L53 Saloon
LOWER STRUCTURE Part rear end panel cross member

Welding
41
Panel only
PRS4104
93123-3S
1 triple layer spot weld

JOINT WITH THE REAR END PANEL
Thickness of panels (mm) Rear end panel cross member End panel extender Rear end panel Unpicking 1.25 0.97 0.67
Thickness of panels (mm) Rear end panel cross member Rear end panel 1.25 0.67
Unpicking
6 spot welds
2 spot welds
41-34
L53 Saloon
LOWER STRUCTURE Part rear end panel cross member

4
41
Welding
JOINT WITH THE REAR CROSS MEMBER
Reminder: see 41-U -3
93120S 93122S
JOINT WITH THE REAR FLOOR PANEL
PARTIAL CUT
Welding
93121S
93119S
41-35
LOWER STRUCTURE Body
41
PRS4129
When a complete body is changed on a phase I vehicle, the Parts Department will supply a phase II type body. It will therefore be necessary to carry out the following operations (the details are described in the operations for each modified part, see contents). For all types: - cut out the headlight mounting lugs on the front panel upper cross member, - add washers under the bonnet lock mountings, - order a new set of sill moulding. For vehicles fitted with rubbing strips, order special replacement adhesive clips (refer to the parts list). For B, C and S53 type vehicles: - drill the piston switch hole in the rear end panel, - close the tailgate harness hole in the upper rain channel. For C and S53 type vehicles, drill the centre pillar trim 17 mm higher in order to refit the original seat belts.
41-36
ALL TYPES
UPPER FRONT STRUCTURE Wing
42 A
REPLACEMENT
92560R
A) Detach the bumper without removing it completely. To do this, remove: - Two T20 Torx bolts (1) - Two 10mm hexagonal bolts (2) B) Remove the wheel arch protector - One T20 Torx bolt (3) - Three clips (4) C) Detach the front end of the sill moulding: - One T20 Torx bolt (5) D) Slacken the bonnet strut mountings without removing them: - Two 13mm hexagonal bolts (6) E) Remove the wing mountings: - Six 10mm hexagonal bolts (7) - Two 11mm hexagonal nuts (8) F) Using a hot air gun, soften the anti-chipping mastic inside the wing and then remove the wing.
42-1
ALL TYPES
UPPER FRONT STRUCTURE Wing

When a front wing is changed on a vehicle fitted with rubbing strips, a mounting hole must be drilled (see diagram).
42 A
92676R
NOTE: the strip is bonded using a bead of "paint
joint" type mastic.
42-2
D53 Cabriolet
UPPER FRONT STRUCTURE Front wing
42 A
Photo page 42-1
PRS4207
The front wing is identical to that of the base vehicle 53, but the lower rear section of it has been modified. This section is mounted using bolt (1) (see diagram).
42-3
UPPER FRONT STRUCTURE

Complete radiator grille upper cross member
42
Welding
Refer to the diagram below.

NOTE: for phase I vehicles, cut out the headlight mounting lugs at (A).
92561S
PRS4209
BUTT WELDING JOINT ON THE COWL SIDE PANEL
BUTT WELDING JOINT ON THE LOCK SUPPORT
Thickness of panels (mm) Cross member: Cowl side panel: 1.2 1
Thickness of panels (mm) Cross member: Lock support: Unpicking 1.2 1.5
Unpicking
3 spot welds Welding
4 spot welds
92563S
42-4

Complete radiator grille upper cross member
42
Thickness of panels (mm) Cross member: Headlight carrier panel: Unpicking 1.2 0.8
7 spot welds
Welding
92563-2S
42-5
UPPER FRONT STRUCTURE Part radiator grille upper cross member

42
Identical to the previous part.
PRS4201
Welding
92561-2S
42-6
UPPER FRONT STRUCTURE Bonnet lock support

1
BUTT WELDING JOINT ON THE RADIATOR GRILLE UPPER CROSS MEMBER
42 D
Refer to the previous paragraph.
Refer to section 41-A.
42-7
UPPER FRONT STRUCTURE Headlight carrier panel

42
Unpicking
4 spot welds
Welding
PRS4202

92565-1S
Refer to sub-section 41-A.
BUTT WELDING JOINT ON THE COWL SIDE PANEL
Thickness of panels (mm) Headlight carrier panel: Cowl side panel: 0.8 1
42-8
UPPER FRONT STRUCTURE Part front wing panel (front section)

42
Welding
Part only, see diagram. Cutting of the new part to : Cutting of the part on the vehicle to : X = 435 mm X = 415 mm
92565S
PRS4203
PARTIAL CUT A
Refer to the relevant paragraph.
Refer to sub-section 41-A.

92563-1S
Refer to the relevant paragraph.
Thickness of panels (mm) Wing panel: Wheel arch: Unpicking 1 0.7
9 spot welds
42-9
UPPER FRONT STRUCTURE Wheel arch (shock absorber turret)

This operation is to be carried out on a body jig bench. Refer to sub-section 40 for instructions on fitting the components. Welding
42 G
Assembled part consisting of: (1) (2) (3) (4) Wheel arch Wheel arch extender Rubber bush support Shock absorber cup
92566S
BUTT WELDING JOINT ON THE HEATER BULKHEAD PARTITION
A - SHOCK ABSORBER CUP TO THE HEATER BULKHEAD PARTITION CHAMBER
Thickness of panels (mm)

PRS4204
Cup: Heater bulkhead partition : Unpicking
2 0.7
BUTT WELDING JOINT ON THE WING PANEL FRONT SECTION
5 spot welds Refer to the previous paragraph.
BUTT WELDING JOINT ON THE WING PANEL REAR SECTION
(Shock absorber cup to the cowl side panel) Thickness of panels (mm) Shock absorber cup: Wing panel: Unpicking 2 1
6 spot welds
92641S
42-10

B - WHEEL ARCH TO THE HEATER BULKHEAD PARTITION
42 G
0.7 0.7
Thickness of panels (mm) Wheel arch: Heater bulkhead partition : Unpicking 0.7 0.7
Thickness of panels (mm) Wheel arch: Bulkhead: Unpicking
7 spot welds
7 spot welds
Welding
Welding
92564S
92564-1S
42-11

5
42 G
DRILLING THE SHOCK ABSORBER UPPER MOUNTING
Thickness of panels (mm) Wheel arch: Side member front section: Side member closure panel: Side member rear section: Unpicking 0.7 1.25 0.8 2 With the vehicle positioned on the body jig bench, after welding the wheel arch, drill the front shock absorber upper mounting. To do this: - fit part (1) in the diagram below, - counter-bore the four holes (B) to a diameter of 8 mm. Warning: part (1) is the same for both the right and left hand sides, it must be pivoted through a half turn when changing from one side to the other.
21 spot welds Two 15mm MAG weld fillets Two 30mm MAG weld fillets Welding
92566-1S
92632R1
42-12

7
SPECIAL FEATURES OF DIESEL VEHICLES
42 G
On these vehicles, the right hand wheel arch has an additional support for the engine pendulum mounting. Cup (C) must be welded during repair using a body jig bench bracket supplied with the body jig components.
92662R
42-13
UPPER FRONT STRUCTURE Part heater bulkhead partition

42 H
0.7 1
BUTT WELDING JOINT ON THE WING PANEL
Consisting of: - heater bulkhead partition - component for joint with the windscreen aperture lower cross member(1) - battery support - windscreen wiper motor support - welded studs and nuts.
Thickness of panels (mm) Plenum chamber: Cowl side panel: Unpicking
+
8 spot welds
Welding
PRS4205

92573-1S
42-14
UPPER FRONT STRUCTURE Part heater bulkhead partition

3
42 H
PARTIAL CUT
Thickness of panels (mm) Heater bulkhead partition : Bulkhead: Unpicking 0.7 0.7
+
12 spot welds per 1/2 partition (i.e. 24 for the complete part)
92570-1S
Welding
92579S
Drilling of the bulkhead to a diameter of 5 mm for plug welding.
42-15

Part windscreen aperture lower cross member
42
Welding
Consisting of: - windscreen aperture lower cross member - steering support (1) - welded nuts and studs Cutting of the new part to : Cutting of the part on the vehicle to : X = 320 mm X = 300 mm
92578S
The welding operation above can only be carried out with the front pillar removed.
PRS4206
BUTT WELDING JOINT ON THE FRONT PANEL
Thickness of the panels (mm) Windscreen aperture lower cross member: Cowl side panel: Unpicking 1 1
+
92573-2S
5 spot welds Two 30mm MAG weld fillets
42-16

Part windscreen aperture lower cross member
42
BUTT WELDING JOINT ON THE FRONT PILLAR
PARTIAL CUT
Thickness of panels (mm) Windscreen aperture lower cross member: Cowl side panel: Unpicking 1 0.7

92580S
92573-3S
92579-1S
Drilling of the cross member to a diameter of 5 mm for plug welding.
42-17
UPPER FRONT STRUCTURE Front pillar upper stiffener

42
Welding
Part only
Photo page 42-2
PRS4208
JOINT WITH THE COWL SIDE PANEL AND THE FRONT PILLAR
Thickness of panels (mm) Stiffener Cowl side panel Front pillar Unpicking 11 spot welds 1.5 0.97 1.25
Seven 30mm MAG weld fillets.
42-18
UPPER SIDE STRUCTURE Front pillar lower section

DISMANTLING
43 A
(7) Upper hinge (8) Lower hinge Maximum length of the new part: 570 mm.
Remove: - front door, - front wing, - dashboard, - body side interior trim, - front seat. Partially fold back the carpet. Remove: - bonnet opening control, - electrical wiring in the pillar, - sill panel moulding.
COMPOSITION OF THE SPECIAL REPLACEMENT FRONT PILLAR
(1) (2) (3) (4) (5) (6)
Front pillar Upper hinge stiffener Lower hinge stiffener Door stop mounting Wing mounting stud Welded KSM
92363R
CUTTING - UNPICKING
92629R
92630R
Remove the damaged section in line with the diagrams above (refer to the key to symbols) (A) drill right through the spot welds at the pillar - hinge stiffener - lining joints (B) unpick using a chisel
43-1
UPPER SIDE STRUCTURE Front pillar lower section
43 A
92628-1R
92628R
e = 2.1 mm H = 65 mm
Grind the bits of unpicked spot weld remaining on the support panels. Take a section of the new part which is approximately 50 mm larger than that cut from the vehicle. Position the new part on the vehicle so that it is superposed, then secure it using a vice-grip wrench. Cut the two layers of metal simultaneously with a hacksaw in order to facilitate the fit.
PREPARATION BEFORE WELDING
B = 5 mm
WELDING
Carry out the following: retaining spot welds on the lines to be butt welded. the spot welds. The corresponding (e) and (H) values are given underneath each diagram. the MIG stitch welds. the MIG plug welds at the lining and hinge stiffener joints. lead fill the butt welded sections, after grinding down the weld fillet.
ANTI-CORROSION PROTECTION
Strip the internal and external surfaces of all areas to be welded. (On the vehicle and on the new parts) . Coat the sections to be spot welded with a bead of electro-plastic mastic. Apply aluminium paint to the sections to be plug welded. Adjust the new part, then secure it using a vicegrip wrench.
After painting and before refitting the trim, inject hollow section wax into the pillar.
43-2
UPPER SIDE STRUCTURE Front pillar by cutting at the upright

DISMANTLING
43
Remove: - front door, - front wing, - dashboard, - body side internal trim, - front seat. Partially fold back the carpet. Remove: - bonnet opening control, - electrical wiring in the pillar, - windscreen, - pillar upright seal, - sill panel moulding. Remove the electrical wiring.
PROTECTION
Protect the interior using a cover which is resistant to welding and grinding damage.
43-3
UPPER SIDE STRUCTURE Front pillar by cutting at the upright
43
92627R
92627-1R
Define cuts (A) and (B). The working method is identical to that for changing the lower section of the pillar. Cuts (A) and (B) must be opposite an opening in order to make it easier to protect the interior. In order to ease cutting and unpicking, welding of the butt welding joints will be shown.
Repair welding e = 2.1 mm H = 65 mm
D = 5 mm Original welding
Spot welding Lead fill the butt welded sections after grinding down the weld fillet. Stitch welding
After painting, inject hollow section wax into the new part.
43-4
D53 Cabriolet
UPPER SIDE STRUCTURE Door hinges (on the front pillar)
43
WELDING THE DOOR HINGES TO THE FRONT PILLAR
When a front pillar is changed, the door hinges, to be ordered separately, must be welded on. To do this, follow the procedure below. Temporarily spot weld the two male hinges to the pillar using the part which has been removed to mark the positions. Fit the door, with the front wing removed, and check that it is adjusted correctly before permanently welding the hinges in place.
92627-2R
B = 296 1 mm (theoretical value for information)
92630-1R
A = 115 1 mm (theoretical value for information) 1 = 20 mm
43-5
D53 Cabriolet
UPPER SIDE STRUCTURE Assembled front pillar

Unpicking 50 spot welds
43 D
This operation can only be carried out after removal of the upper pillar stiffener and is in addition to the partial changing of the windscreen frame.
- Bare front pillar. - Pillar stiffener tube. - Internal pillar stiffener.
Three 30mm MAG weld fillets. One 90mm MAG weld fillet.
Photo page 43-1
PRS4301
JOINT WITH THE WINDSCREEN PILLAR LINING
Refer to section: 45 ...
JOINT WITH THE PILLAR LINING AND SILL PANEL
Thickness of panels (mm) Front pillar Pillar lining Sill panel Sill panel front stiffener 1.25 0.97 1.5 1.5
D = 8 mm
43-6
D53 Cabriolet
UPPER SIDE STRUCTURE Assembled front pillar

3
JOINT WITH THE INTERNAL PILLAR STIFFENER
43 D
Thickness of panels (mm) Front pillar Stiffener Unpicking Two 30mm MAG weld fillets. One 10mm MAG weld fillet. 1.25 1.5
Welding
Photo page 43-2
JOINT WITH THE WINDSCREEN FRAME
Reminder: see 45-B
After painting and before refitting the trim, treat the hollow sections with wax.
43-7
C53
UPPER SIDE STRUCTURE Front pillar
43
COMPOSITION OF THE SPECIAL REPLACEMENT FRONT PILLAR
The parts warehouse supplies the B53 front pillar (for reasons of standardisation). When the front pillar of the C53 is changed, the sill panel section must be cut in order to hold the original butt welding joint more easily. Dimension of the cut: 345 mm
92363R1
Welding
92626-1G
92626G
Original welding Spot welding
Repair welding
D = 5 mm
43-8
UPPER SIDE STRUCTURE Pillar upright joint mounting (KSM)

DIMENSION OF THE KSMS WELDED TO THE UPRIGHT
43
92624R
At (A) KSM type welded mounting. The other 4 mountings are rivets: part number. 77 03 072 263 to be secured when the support is fitted. It is essential that electro-plastic mastic is put into the holes before riveting in order to ensure sealing and prevent corrosion.
43-9
UPPER SIDE STRUCTURE Centre pillar

DISMANTLING
43 G
Remove: - rear door, - body side trims, - front seat, - complete rear seat, Partially fold back the carpet. Remove: - sill panel moulding, - electrical wiring, - front door striker, - seat belt upper support, - seat belt.
(1) (2) (3) (4) (5) (6)
Centre pillar Seat belt mounting Upper hinge Lower hinge Hinge stiffener Striker mounting retainer
Maximum length of the new part: top 840 mm bottom 1 230 mm
92363R2
43-10

CUTTING - UNPICKING
43 G
92622R
Spot welding
Brazing
(B) sealing lining support.

92623R
(A) and (C) are the recommended cutting areas. To make cutting and unpicking easier, the original butt welding joints are shown above. NOTE: it is possible to make a cut at (C) to avoid having to change the part later. Take a section of the new part which is approximately 50 mm larger than that cut from the vehicle. Position the new section on the vehicle so that it is superposed, then secure it using a vice-grip wrench. At (A) cut 15 mm longer, this section to be plug welded. Cut the two layers of metal simultaneously with a hacksaw in order to facilitate the fit.
43-11

43 G
Strip the internal and external surfaces of all areas to be welded. (On the vehicle and on the new parts). Coat the sections to be spot welded with a bead of electro-plastic mastic (see the key to symbols at the beginning of the section). Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under each welding diagram and coat with aluminium paint. Adjust the new part, then secure it using a vice-grip wrench.
92622-1S
Repair welding
D = 4.5 mm
92621R
Lead fill at (A). Lead fill the butt welded sections, after grinding down the weld fillet.
43-12

43 G
After painting, inject hollow section wax into the new part.
92619S
92620S
Repair anti-corrosion protection.
43-13
D53 Cabriolet

Welding
43 G
This operation can only be carried out after removal of the rear wing panel.
Part only
Photo page 43-10
PRS4304
JOINT WITH THE CENTRE LINING AND SILL PANEL
Thickness of panels (mm) Centre pillar Lining Sill panel Unpicking 30 spot welds 1.25 1.5 1.5
D = 6 mm
On the front right hand section, some spot welds are made only after the wing panel has been refitted.
2
Four 25mm MAG weld fillets
JOINT WITH THE WING PANEL LINING
See 44 -D
15 MAG plug welds
43-14
UPPER SIDE STRUCTURE Centre pillar lining

COMPOSITION OF THE CENTRE PILLAR LINING
43 H
(1) Centre pillar lining, upper section (2) Seat belt mounting nut (3)
PRS4306
CUTTING - UNPICKING
92618S
92617S
Original welding
Stitch welding
Spot welding
NOTE: it is possible to change the complete centre pillar or make a cut at (A) to make a butt weld (if this method is used, the roof trim does not have to be removed).
43-15

43 H
Strip the internal and external surfaces of all of the areas to be welded. (On the vehicle and on the new parts). Spray zinc paint on the sections to be spot welded. Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under each welding diagram and coat with aluminium paint. Adjust the new part, then secure it using a vice-grip wrench.
92618-1R
92617-1S
Repair welding
D = 5 mm Spot weld at (A).
43-16
43 H
92616S
Original welding
92616-1S
Repair welding
D = 6 mm
43-17
D53 Cabriolet
43 H
This operation can only be carried out after removal of the wing panel lower front lining and the floor and cross member side stiffener.
- Centre pillar lining. - Seat belt mounting stiffener.
Photo page 43-11
PRS4305
JOINT WITH THE CENTRE PILLAR
JOINT WITH THE FLOOR
Thickness of panels (mm) Pillar lining Floor Unpicking Seven 40mm MAG weld fillets. 1.5 0.88
JOINT WITH THE WING PANEL LINING
Reminder: see 44-D
43-18
UPPER SIDE STRUCTURE Sill panel

The sill panel is supplied bare.
43
92363S
RECOMMENDATIONS FOR REPLACEMENT
Depending on the area which is deformed, it is possible to change the sill panel at several points (see diagrams).
92363S1
92363S2
92363S3
92363S4
All of the cuts must be butt welded using MIG stitch welds, then lead filled.
43-19
43
92615S
92615-1R
92622S
92622-1R
Original welding
Repair welding H = 35 mm
Spot welding
Brazing
(A) (B)
D = 4.5 mm D = 5 mm
After painting and before refitting the trim, inject hollow section wax.
43-20
ALL TYPES
Phase I
UPPER SIDE STRUCTURE Body side
43
PRS4308
These parts are affected by the modification to the sill panel moulding. The Parts Department will supply them with the two phase II type mounting rows. When one of the parts is changed on a phase I vehicle, the holes of the lower row must be closed using self-adhesive plugs before the anti-chipping mastic is applied. These plugs are available from the Parts Department (see PR).
NOTE: this course of action is already applied in
advance to production vehicles.
43-21
D53 Cabriolet
UPPER SIDE STRUCTURE Part sill panel

Unpicking
43
Bare part
Photo page 43-3
Photo page 43-3
Before cutting the sill panel on the vehicle, the spot welds at the joint of the sill panel with its longitudinal partition must be unpicked. The number of spot welds to be unpicked will depend on the length of the partial cut. On the new part, drill 6.5mm diameter holes at the butt welding joint with the longitudinal partition. Welding - Make the plug welds for the joint with the partition. - Spot welds for the joint with the inner sill panel. - Stitch welds at the ends of the partial cut. For further information, refer to the previous paragraph.
43-22
D53 Cabriolet
UPPER SIDE STRUCTURE Assembled sill panel

This operation can only be carried out after removal of the front pillar and the wing panel.
43
- Sill panel. -Longitudinal partition.
PRS4307
JOINT WITH THE FRONT PILLAR
Refer to section : 43 - D - 2 Note: If the front pillar has not been damaged, it is preferable cut part of the sill panel. To do this, refer to section: 43 - K.
JOINT WITH THE INNER SILL PANEL
Thickness of panels (mm) Sill panel Inner sill panel Inner sill panel stiffener Lateral side member Unpicking 62 spot welds. 3 MAG spot welds 1.5 1.5 1.5 1.5
43-23
D53 Cabriolet
43
Welding
Photo page 43-5
43-24
D53 Cabriolet
43
Photo page 43-6
D = 8 mm At the rear section, the sill panel lower joint is made only after the wing panel has been refitted. At the front section, the joint is only made after the pillar has been refitted. After painting and before refitting the trim, treat the hollow sections with wax.
43-25
B - C - L53 Sport
43
Using the dimensions shown on the diagrams below, mark the location of the 4 mounting points A, B, C and D. The dimensions are identical for B, C and L53 type vehicles.
92764R1
Points : A B C D h = 25 mm h = 25 mm h = 22 mm h = 11 mm
92309R
Drill the holes to 6 mm. Apply sealing mastic to the edge of the holes and fit clips (3).
43-26
D53 Cabriolet
UPPER SIDE STRUCTURE Sill panel front stiffener

Welding
43
Bare part
Photo page 43-7
PRS4302
JOINT WITH THE FRONT PILLAR, COWL SIDE PANEL AND WHEEL ARCH
Thickness of panels (mm) Stiffener Front pillar Cowl side panel Wheel arch Unpicking 1.5 1.25 0.97 0.7
D = 8 mm Four 20mm MAG weld fillets. Twelve 40mm MAG weld fillets. After painting and before refitting the trim, treat the hollow sections with wax.
7 MAG plug welds.
43-27
D53 Cabriolet
UPPER SIDE STRUCTURE Sill panel front stiffener

3
43
JOINT WITH THE SILL PANEL
JOINT WITH THE FLOOR AND FRONT SIDE MEMBER
Thickness of panels (mm) Stiffener Sill panel Unpicking 7 spot welds. 1.5 1.5 Unpicking Six 30mm MAG weld fillets.
Welding 7 MAG plug welds.
One 30mm MAG welds fillet.
Photo page 43-8
Welding
Photo page 43-8
D = 8 mm
43-28
D53 Cabriolet
UPPER SIDE STRUCTURE Sill panel rear stiffener

Welding
43 N
This operation can only be carried out after removal of the rear wing panel. Refer to paragraph: 44-A
Bare part
Photo page 43-9
PRS4303
JOINT WITH THE SILL PANEL AND WHEEL ARCH
Photo page 43-9
Thickness of panels (mm) Stiffener Sill panel Outer wheel arch Inner wheel arch Unpicking 16 spot welds. 1.5 1.5 0.88 1.2
Four 25mm MAG weld fillets.
D = 8 mm After painting and before refitting the trim, protect the hollow sections with wax.
43-29
B53
Phase II
UPPER SIDE STRUCTURE Roof arch

Welding
43 O
This part can only be changed after removal of the roof.

Part only.
95813R
PRS4309
JOINT WITH THE BODY SIDE
Thickness of panels (mm) Body side Stiffener Unpicking

ATTENTION: when fitting a sun roof as an accesso-
0.77 0.77
NOTE: at (C) apply two beads of filling mastic.
ry, the roof arch must be cut. The sun roof frame will then act as the stiffener. 4 spot welds
43-30
L53 Saloon
UPPER REAR STRUCTURE Complete wing panel
44 A
This operation is carried out with the roof removed.

Part only. The double seal support (1) must be ordered separately.
93126R1
At (2), apply a bead of metal bonding mastic.

PRS4412
Welding
JOINT WITH THE ROOF
Thickness of panels (mm) Wing panel Roof Body side support extender Unpicking 0.67 0.67 0.67
93118S
One 25mm MAG weld fillet
44-1
L53 Saloon

Unpicking
44 A
JOINT WITH THE BODY TOP
Thickness of panels (mm) Wing panel Body side Unpicking 0.67 1.1 21 spot welds
One 25mm MAG weld fillet Welding
93116S
93117S
JOINT WITH THE QUARTER PANEL LINING
Thickness of panels (mm) Wing panel Quarter panel lining Roof drip moulding lining Seat belt retractor support bracket Body side upper extender 0.67 0.67 0.67 1.2 0.67
93115S
44-2
L53 Saloon

5
44 A
0.67 0.67
JOINT WITH THE SIDE RAIN CHANNEL
JOINT WITH THE LIGHTING SUPPORT COMPONENT
Thickness of panels (mm) Wing panel Side rain channel Unpicking 0.67 0.87
Thickness of panels (mm) Wing panel Lighting support component Unpicking
One 20mm MAG weld fillet - see JOINT note 6
93114S
93113S
Depending on method: see JOINT 6
44-3
L53 Saloon

Welding
44 A
Thickness of panels (mm) Wing panel End panel extender Unpicking

NOTE: There is a spot weld located under the end panel cross member (see welding). If the cross member is not to be removed, a special cut must be made on the panel.
A - With removal of the end panel cross member 0.67 0.97
4 or 5 spot welds depending on the method
93111S
B - Without removal of the end panel cross member

93112S
A - With removal of the end panel cross member
One 20mm MAG weld fillet B - Without removal of the end panel cross member
93112-1S
44-4
L53 Saloon

Welding
44 A
93110S
93109S
JOINT WITH THE REAR FLOOR
Thickness of panels (mm) Wing panel Rear floor Outer wheel arch Inner wheel arch Unpicking 0.67 0.60 0.67 1.25
- 1 four layer spot weld - 1 triple layer spot weld
JOINT WITH THE OUTER WHEEL ARCH
Thickness of panels (mm) Wing panel Outer wheel arch Inner wheel arch Backrest mounting stiffener Side member closure panel Sill panel Unpicking 0.67 0.67 1.25 1.5 1.5 1.1
6 spot welds
19 spot welds
44-5
L53 Saloon

9
44 A
0.67 1.1
Welding
Thickness of panels (mm) Wing panel Sill panel Unpicking
6 spot welds
One 25mm brazed weld fillet

93108S
Welding
93106S

93107S
44-6
L53 Saloon

10
JOINT WITH THE DOUBLE SEAL SUPPORT
44 A
Thickness of panels (mm) Wing panel Double seal support Unpicking 0.67 0.67
3 spot welds
Welding
93105S
44-7
D53 Cabriolet
UPPER REAR STRUCTURE Complete rear wing panel

Welding
44 A
Bare panel. Window frame stiffener. Panel stiffener. Striker stiffener. Bumper stiffener. Window guide upper stiffener.
Photo page 44-1
JOINT WITH THE BOOT LID RAIN CHANNEL AND WING PANEL REAR LINING
Thickness of panels (mm)

PRS4413
JOINT WITH THE UPPER LINING
Wing panel Boot lid rain channel Lining Unpicking
0.8 1.0 0.88
Thickness of panels (mm) Wing panel Lining Unpicking 38 spot welds. 0.8 1.0
23 spot welds. One 30mm MAG weld fillet.
1 brazed weld fillet.
44-8
D53 Cabriolet
44 A
Note: When unpicking at the joint with the boot lid rain channel, drill out the spot welds using a spot weld rotary grinder. These holes will be plugged again by MAG welding. Welding
Photo page 44-2
Photo page 44-2
The MAG welds shown are to be made on both sides.
1 Photo page 44-2
JOINT WITH THE WHEEL ARCH AND SILL PANEL
Thickness of panels (mm) Wing panel Sill panel Wheel arch Unpicking 11 spot welds. 0.88 1.5 0.8
44-9
D53 Cabriolet
44 A
Preparation before welding:
Photo page 44-3 Photo page 44-3
Welding
Photo page 44-3
Photo page 44-3
44-10
D53 Cabriolet
44 A
JOINT WITH THE SILL PANEL AND CENTRE PILLAR
Thickness of panels (mm) Wing panel Sill panel Unpicking 15 spot welds. Two 30mm MAG weld fillets. 0.88 1.5
Photo page 44-4
1 brazed fillet.
Welds Note: At the lower section of the sill panel, the spot welds must be made in the recesses to avoid welding four overlapping panels.
Thickness of panels (mm) Wing panel Centre pillar Pillar lining Unpicking 14 spot welds. 0.88 1.25 1.5
44-11
D53 Cabriolet
44 A
Welding
Photo page 44-5
Photo page 44-5
Hollow section protection:
Photo page 44-5 6
JOINT WITH THE SILL PANEL AND PANEL STIFFENER
Thickness of panels (mm) Stiffener Sill panel Unpicking Two 10mm MAG weld fillets 0.6 1.5
Photo page 44-5
44-12
UPPER REAR STRUCTURE Part wing panel (cut A)

44
Assembled part consisting of: - bumper mounting stiffener - striker stiffener
92363R7
CUTTING - UNPICKING
92399S
92400-1S
(End panel - wing panel joint)
NOTE: the general procedure for changing a welded component is described in Workshop Repair Manual
M.R. 502 section 44.
44-13
44
92402S
92404S
Remove the double seal support.
92403S
92363R3
Area not used
44-14

SUPERPOSED CUT
44
92405-1S
PRS4410
Welding
e = 1.4 mm H = 30 mm
D = 5 mm
A: e = 1.4 mm H = 60 mm
PRS4411
e = 1.4 mm H = 30 mm
D = 5 mm
44-15
44
92407S
92402-1S
e = 1.4 mm H = 60 mm
D = 5 mm
D = 5 mm
92408S
92410S
e = 1.4 mm H = 60 mm
D = 5 mm
44-16
UPPER REAR STRUCTURE Part wing panel (cut B)

44
Assembled part consisting of: - bumper mounting stiffener - striker stiffener
92363R8
CUTTING - UNPICKING
92399S
92400S
(End panel - wing panel joint)
NOTE: the general procedure for changing a welded component is described in Workshop Repair Manual
M.R. 502 section 44.
44-17
44
92401S
92404S
(end panel - wing panel joint) Retain the edge of panel (A) and open it slightly in order to superpose the new part and plug weld it.
See WELDING.
92363R6
Area not used
44-18

SUPERPOSED CUT
44
92406S 92405S
e = 1.4 mm H = 60 mm Welding
92405-2S
D = 5 mm
44-19
44
92407S
92408S
D = 5 mm
e = 1.4 mm H = 60 mm
92409S
44-20
C53
44
92363R9
The general procedure for changing the panel is identical to that for the B53, only the positions of the superposed cuts are different.
Area not used
44-21
C53 / S53 Phase I
44
PRS4436
The Parts Department only supplies phase II type parts which only have one row of rubbing strip mounting holes. For phase I vehicles, remember to order the adhesive clips for mounting the phase I strip.
NOTE: as the last but one hole (A), is not used for
mounting the phase I strip, it must be closed to seal effectively using an adhesive plug or a small ball of mastic (see PR).
44-22
C53
UPPER REAR STRUCTURE Part wing panel (cut AB)

SPECIAL POINTS
44
PRS4414
The general procedure for changing the panel is identical to that for the B53, only the positions of the superposed cuts are different. Area not used
44-23
L53 Saloon
UPPER REAR STRUCTURE Part wing pane (cut A)

Welding
44
Same as the previous part.
93104S
PRS4416
44-24
D53 Cabriolet
UPPER REAR STRUCTURE Part rear wing panel (cut A)
44
Partially remove the damaged part following the recommendations for the previous operation.
PARTIAL CUT
Photo page 44-6
After painting and before refitting the trim, protect the hollow sections with wax (inner section of the wing panel).
PRS4415
X = 920 mm. Unpicking Length of cut: 400 mm.
44-25
All types Phase I
UPPER REAR STRUCTURE Quarter panel lining
44
PRS4445
These vehicles are fitted with an adjustable seat belt mounting. The Parts Department only supplies phase II type parts to which all types of seat belt can be fitted. Mounting hole (A) has been moved up 17 mm. Consequently, when either a quarter panel lining or a complete body is changed on a phase I vehicle, the original hole in the pillar trim must be extended 17 mm upwards (refer to the paragraph on pillar trim).
44-26
L53 Saloon

Special point for removal
44
Assembled part consisting of: - quarter panel lining, - body side upper extender.
93099S
PRS4418
To gain access to the body side extender spot welds, the roof drip moulding lining must be partially removed. Cut it to the dimension X = 125 mm
Welding
Thickness of panels (mm) Body side upper extender Body side Roof drip moulding lining Quarter panel lining Unpicking 0.67 1.1 0.67 0.67
93098S
8 spot welds
5 spot welds
44-27
L53 Saloon

Welding
44
93099-1R
93097S
Cut a piece of the new roof drip moulding lining to the dimension Z = 145 mm. On the diagram above, the dotted line represents the cut carried out on the vehicle during the unpicking operation. Dimension Y = 180 mm is used to position the new part.
3 2
JOINT WITH THE REAR ROOF CROSS MEMBER
Thickness of panels (mm) Quarter panel lining Outer wheel arch Quarter panel arch Side shelf Backrest mounting stiffener Unpicking 0.67 0.67 0.97 0.97 1.25
Thickness of panels (mm) Quarter panel lining Roof Rear roof cross member Unpicking 0.67 0.67 0.67
4 spot welds
9 spot welds
44-28
L53 Saloon

5
JOINT WITH THE SIDE SHELF
44
Welding
Thickness of panels (mm) Quarter panel lining Side shelf Quarter panel arch Outer wheel arch Unpicking 0.67 0.97 0.97 0.67
93096S
11 spot welds
Welding - 4 triple layer spot welds
JOINT WITH THE ROOF PANEL
93095S
93099-4S
- 3 triple layer spot welds Apply a bead of metal bonding mastic. - 2 plug welds to be made from inside the vehicle
44-29
L53 Saloon

7
JOINT WITH THE WING PANEL
44
Thickness of panels (mm) Quarter panel lining Side rain channel Seat belt retractor support bracket Unpicking 0.67 0.97 1.20
Reminder: see 44-A -3
2 spot welds
Welding
93116S
93094S 93115S
44-30
L53 Saloon
44
93126R1
JOINT WITH THE QUARTER PANEL ARCH
Reminder: see 44-J-1
93093S
44-31
D53 Cabriolet
UPPER REAR STRUCTURE Assembled wing panel lining

Welding
44
This operation can only be carried out after removal of the complete wing panel.
Upper front lining. Lower front lining. Rear lining. Outer wheel arch. Wheel arch stiffener. Inner wheel arch.
Photo page 44-7
Photo page 44-7

PRS4417
Thickness of panels (mm) Panel lining Centre pillar Centre pillar lining Unpicking 8 spot welds. Two 20mm MAG weld fillets. Two 30mm MAG weld fillets. 0.88 1.25 1.5
44-32
D53 Cabriolet

Two 30mm MAG weld fillets. One 20mm MAG weld fillet.
44 D
Welding (cont)
Photo page 44-8
Welding
Photo page 44-8
D = 6 mm
JOINT WITH THE SILL PANEL AND WHEEL ARCH
Photo page 44-8
Thickness of panels (mm) Panel lining Sill panel Wheel arch Sill panel stiffener Sill panel lining Unpicking 11 spot welds. 0.88 1.5 0.88 1.5 1.5
44-33
D53 Cabriolet
44 D
Thickness of panels (mm) Panel lining Rear floor Wheel arch Unpicking 25 spot welds. Two 30mm MAG weld fillets. 0.88 0.88 1.2
Photo page 44-9
Welding
Photo page 44-9
Thickness of panels (mm) Panel lining Lighting support Unpicking 12 spot welds. 0.88 0.67
44-34
D53 Cabriolet

5
44 D
Welding (cont)
JOINT WITH THE WHEEL ARCH UPPER CROSS MEMBER
Reminder: see 44-N
Photo page 44-10
Photo page 44-10
Note: For welding to the rear wing panel, refer to paragraph: 44 -A After painting and before refitting the trim, protect the hollow sections with wax.
44-35
D53 Cabriolet
UPPER REAR STRUCTURE Wing panel lower front lining

Welding
44
This operation can only be carried out after removal of the wing panel.
- Bare lining. - Window winder support.
Photo page 44-11
PRS4419
JOINT WITH THE CENTRE PILLAR, SILL PANEL AND WHEEL ARCH
D = 8 mm Thickness of panels (mm) Sill panel Inner sill panel Panel lining Centre pillar Centre pillar stiffener Unpicking 15 spot welds. 1.5 1.5 0.88 1.25 1.5
44-36
D53 Cabriolet
UPPER REAR STRUCTURE Wing panel upper front lining

Welding
44
- Hood mounting bracket. - Stiffener.
Photo page 44-12
PRS4420
JOINT WITH THE WHEEL ARCH AND REAR LINING
Thickness of panels (mm) Panel lining Inner wheel arch Outer wheel arch Unpicking 15 spot welds. 0.88 1.2 0.88
Refer to the "Assembled wing panel lining" operation: 44-D
44-37
D53 Cabriolet
UPPER REAR STRUCTURE Wing panel rear lining

Welding
44 G
- Counter balance stiffener. - Counter balance joint. - Lock stiffener.
Photo page 44-13
PRS4421
JOINT WITH THE WHEEL ARCH, BOOT LID RAIN CHANNEL AND FRONT LINING
D = 6 mm Thickness of panels (mm) Rear lining Front lining Rain channel Outer wheel arch Inner wheel arch Unpicking A - On the wheel arch: 10 spot welds 0.88 0.88 0.88 0.88 1.2
JOINT WITH THE REAR FLOOR AND LIGHTING SUPPORT
Refer to section: 44-2A
B - On the boot lid drip moulding: 5 spot welds.
C - On the front section: 5 spot welds.
44-38
All types Phase I
UPPER REAR STRUCTURE Tailgate upper rain channel

The parts supplied by the Parts Department are of the phase II type. Consequently, the wiring hole in the upper rain channel must be closed. (hole (B) on the diagram)
NOTE: For the type of blanking piece to be used, refer to the vehicle PR.
44 H
95785R
44-39
UPPER REAR STRUCTURE Outer wheel arch

44
Assembled part consisting of:
- bare outer wheel arch - wheel arch stiffener
PRS4422
CUTTING - UNPICKING
92411S
92412S
NOTE: the general, procedure for changing a welded component is described in Workshop Repair Manual M.R. 502 section 4.
44-40
44
92414S
92413S
Welding
If the quarter panel arch is not to be changed, unpick it from inside the wheel arch.
92415S
92411-1S
Spot welds (A) are to be unpicked from inside the sill panel.
Joints with: Inner wheel arch e = 2 mm H = 60 mm Backrest mounting stiffener e = 2.2 mm H = 60 mm Quarter panel lining e = 1.4 H = 60 mm
44-41
44
92414-1S
92412-1S
D = 5.5 mm
Joints with: Inner wheel arch e = 2 mm Quarter panel lining e = 1.4 mm Quarter panel arch e = 1.7 mm Floor e =1.4 mm
H = 60 mm H = 60 mm H = 60 mm H = 60 mm
92415-1S
If spot welds (A) and (B) cannot be reached by the spot welder, plug weld at D = 5 mm
e = 1.8 mm H = 60 mm
D = 5.5 mm
44-42
D53 Cabriolet

Welding
44
This operation can only be carried out after removal of the wing panel. Reminder: see 44-A
- Bare wheel arch. - Stiffener.
Photo page 44-14
PRS4423
JOINT WITH THE SILL PANEL AND INNER WHEEL ARCH
Thickness of panels (mm) Outer wheel arch Inner wheel arch Panel lining Wheel arch stiffener Unpicking 31 spot welds. 0.88 1.2 0.88 1.5
Photo page 44-14
D = 6 mm
44-43
L53 Saloon
UPPER REAR STRUCTURE Complete quarter panel arch

Welding
44
Panel only.
PRS4424
93093S
Thickness of panels (mm) Quarter panel arch Quarter panel lining Body side upper extender Side rain channel Unpicking 0.97 0.67 0.67 0.97
2
11 spot welds
Thickness of panels (mm) Quarter panel arch Outer wheel arch Quarter panel lining Unpicking 0.97 0.67 0.67
9 spot welds
44-44
L53 Saloon
UPPER REAR STRUCTURE Complete quarter panel arch

Welding
44
93093-1S
44-45
L53 Saloon
UPPER REAR STRUCTURE Part quarter panel arch

44
Panel only.
PRS4425
Welding (superposed)
93092S
44-46
L53 Saloon
UPPER REAR STRUCTURE Backrest mounting stiffener

44
Part only.
PRS4426
Thickness of panels (mm) Stiffener Quarter panel lining Wheel arch Unpicking 1.5 0.67 0.67
8 spot welds
Welding
93091S
44-47
D53 Cabriolet
UPPER REAR STRUCTURE Outer wheel arch stiffener

Welding
44
This operation can only be carried out after removal of the wing panel. Reminder: see 44-A
- Bare part.
Photo page 44-15
PRS4428
Thickness of panels (mm) Stiffener Wheel arch Panel lining Unpicking 8 spot welds. 0.88 0.88 0.88
44-48
D53 Cabriolet
UPPER REAR STRUCTURE

Upper cross member between wheel arches
44 N
This operation can only be carried out with the hood compartment base partition removed.
Welding
Cross member. Stiffening angle brackets. Boot partition stiffeners. Backrest locking supports. Seat belt supports.
Photo page 44-16
PRS4429
Photo page 44-16

JOINT WITH THE WHEEL ARCHES
Thickness of panels (mm) Cross member Inner wheel arch Wing panel lining Unpicking 12 spot welds. Twenty-two 30mm MAG weld fillets. 1.5 1.2 0.88
44-49
D53 Cabriolet

Upper cross member between wheel arches
44 N
Welding (cont)
Photo page 44-17
D = 8 mm Note: The 12 spot welds are replaced with plug welds. After painting and before refitting the trim, protect the hollow sections with wax.
44-50
D53 Cabriolet
UPPER REAR STRUCTURE Hood compartment base partition

Welding
44 O
This operation can only be carried out after removal of the hood compartment rear cross member and the boot lid rain channel.
- Bare partition. - Lighting support to be ordered separately.
Photo page 44-18
PRS4430
JOINT WITH THE CROSS MEMBER AND BODY SIDES
D = 6 mm
Thickness of panels (mm) Partition Cross member Wing panel lining Unpicking 52 spot welds 0.7 1.5 0.88
44-51
D53 Cabriolet
UPPER REAR STRUCTURE Hood compartment base partition

1
JOINT WITH THE WHEEL ARCHES
44 O
Thickness of panels (mm) Partition Wheel arch Unpicking Four 30mm MAG weld fillets. 0.7 1.2
Welding
PHOTO PAGE 44-19
44-52
D53 Cabriolet
UPPER REAR STRUCTURE Hood compartment rear cross member

Welding
44
This operation is carried out in addition to changing of the boot lid rain channel (previous operation).
- Bare part
PHOTO PAGE 44-20
PRS4431
Thickness of panels (mm) Cross member Boot partition Rain channel Wing panel rear lining Unpicking 60 spot welds. 1.5 1.0 0.88
D = 6 mm
44-53
L53 Saloon
UPPER REAR STRUCTURE Backrest mounting stiffener

44 Q
Part only.
PRS4426
Thickness of panels (mm) Stiffener Quarter panel lining Wheel arch Unpicking 1.5 0.67 0.67
8 spot welds
Welding
93091S
44-54
L53 Saloon
UPPER REAR STRUCTURE Jack support (right hand side)

44
Part only.
PRS4427
Thickness of panels (mm) Jack support Quarter panel lining Outer wheel arch Unpicking 1.2 0.67 0.67
3 spot welds
Welding
93090S
44-55
L53 Saloon
UPPER REAR STRUCTURE Centre shelf

2
44
JOINT WITH THE SEAT BELT RETRACTOR SUPPORT BRACKET
Assembled part consisting of: - bare centre shelf - rear screen lower cross member.
Thickness of panels (mm) Centre shelf Rear screen lower cross member Seat belt retractor support bracket Unpicking 0.67 0.67 1.2
4 spot welds
Welding
PRS4432
Reminder: see 44-Y-1
93089S
93103S
44-56
L53 Saloon
UPPER REAR STRUCTURE Centre shelf
44
JOINT WITH THE CENTRE SHELF
Thickness of panels (mm) Centre shelf Side shelf Seat belt retractor support bracket Unpicking 0.67 0.97 1.2
93087S
24 spot welds
Welding
93088S
44-57
L53 Saloon
UPPER REAR STRUCTURE Half unit

1
44
This operation is to be carried out on a body jig bench. Refer to sub-section 40 of the basic manual.
JOINT WITH THE SIDE MEMBER CLOSURE COMPONENT
Thickness of panels (mm) Outer wheel arch Inner wheel arch Closure component Unpicking Two 25mm MAG weld fillets Five 20mm MAG weld fillets 0.67 1.25 1.5
Assembled part consisting of: - wing panel, - assembled outer wheel arch, - assembled inner wheel arch, - quarter panel arch, - assembled quarter panel lining, - assembled side rain channel, - lighting support panel, - end panel extender, - assembled side shelf, - backrest mounting stiffener, - jack support (for right hand side only).
3 spot welds
Welding
93085S PRS4433
- One 20mm MAG weld fillet - Two 25mm MAG weld fillets
44-58
L53 Saloon

Welding
44
93086S 93084S
Four 20mm MAG weld fillets
3 triple layer spot welds Reminder: see 44-A -7
Thickness of panels (mm) Inner wheel arch Wing panel Rear floor Side member booster Unpicking 1.25 0.67 0.60 2.00
93109S
19 spot welds
44-59
L53 Saloon
44
Thickness of panels (mm) Wing panel Sill panel Outer wheel arch Unpicking 0.67 1.1 0.67
92415-1S
6 spot welds
4 spot welds
(A) 1 triple layer spot weld to be unpicked using the spot weld drill 1 spot weld
One 25 mm brazed weld fillet
Welding Reminder: see 44-A -9
JOINT WITH THE REAR SHELF
Reminder: see 44-Y-1
93106S
93103S
44-60
L53 Saloon

5
44
Reminder: see 44-S-2
JOINT WITH THE ASSEMBLED REAR END PANEL
93089S
Reminder: see 44-S-3
93123S
6
93088S
JOINT WITH THE END PANEL CROSS MEMBER
93087S
93125S
44-61
L53 Saloon

44
93124S 93117S
8
Reminder: see 44-C -1
93098S
93097S
93099-1S
44-62
L53 Saloon

9
JOINT WITH THE ROOF PANEL
44
93099-4S
93118S
44-63
UPPER REAR STRUCTURE Rear end panel

METHOD 1 COMPOSITION OF THE REPLACEMENT PART
44 U
- bare end panel - side brackets - striker stiffener
PRS4434
CUTTING - UNPICKING
92364S
92365S
NOTE: the general procedure for changing a welded component is described in Workshop Repair Manual M.R. 502 section 4
44-64

Welding
44 U
92364-1S
92365-1S
A= e = 1.4 mm H = 60 mm End panel - cross member joint e = 1.4 mm H = 60 mm e = 1.9 mm
92366-2S
44-65

METHOD 2 (end panel with lining)
44 U
1 - bare end panel - side brackets - striker stiffener
2 - lining
PRS4435
CUTTING - UNPICKING
92364-2S
92365-2S
44-66
44 U
92366S
Welding
92367S
92365-3S
Fit the lining and make a few retaining spot welds. e = 1.4 mm H = 60 mm End panel - cross member joint e = 1.9 mm
44-67
44 U
92364-3S
92366-1S
e = 1.4 mm H = 60 mm
e = 1.4 mm H = 60 mm
92366-2S
44-68

METHOD 3 WELDING
44 U
(end panel with lining and lower cross member)

Assembled part consisting of: - bare end panel - side brackets - striker stiffener - lining - lower cross member
92364-5S
PRS4437
CUTTING - UNPICKING
92364-4S
92366-2S
44-69
B - C - S53 Phase I

Rear end panel lining and assembled end panel
44
PRS4446
The difference between phase I and phase II parts is that the piston switch hole (B) has been discontinued. The Parts Department supplies both types of part, with or without hole (B). When a complete body is changed, the Parts Department will only supply phase II type bodies on which it will be necessary to cut hole (B) (see diagram below).
95788R1
Hole (B), (shaded area) is cut using a power hacksaw after making two 8mm diameter holes (C).
44-70
L53 Saloon
UPPER REAR STRUCTURE Part end panel cross member

Unpicking
44 W
Panel only The two blanking pieces (1) must be ordered separately.
PRS4438

93123-1S
- 1 triple layer spot weld Special point
93125S
Thickness of panels (mm) End panel cross member End panel extender Rear end panel 0.67 0.97 0.67
93124R
After welding and before protecting the crimps, fit the 2 metal blanking pieces (1) clipping them in place with the lugs.
44-71
L53 Saloon
UPPER REAR STRUCTURE Part end panel cross member

3
PARTIAL CUT
44 W
93100S
44-72
L53 Saloon
UPPER REAR STRUCTURE Rear end panel extender

Reminder: see 44-W -2
44
Panel only
PRS4439
JOINT WITH THE END PANEL CROSS MEMBER

93123-1S
JOINT WITH THE REAR END PANEL
Thickness of panels (mm) End panel extender Rear end panel Unpicking 0.97 0.67
1 spot weld
93125-1S
44-73
L53 Saloon
UPPER REAR STRUCTURE Rear end panel extender

4
44
Welding
93123-2S
93111S
JOINT WITH THE EXTREME REAR CROSS MEMBER
Reminder: see
41-V -1
93123-3S
44-74
L53 Saloon except Sport
UPPER REAR STRUCTURE Side bracket

Welding
44
Panel only
93103S PRS4440
JOINT WITH THE REAR SHELF
Thickness of panels (mm) Side bracket Rear screen lower cross member Unpicking 0.87 0.67
1 triple layer plug weld after unpicking using a spot weld drill.
2
1 spot weld
JOINT WITH THE SEAT BELT RETRACTOR SUPPORT BRACKET
Thickness of panels (mm) see welding 2 spot welds Unpicking Side rain channel Seat belt retractor support bracket Quarter panel lining 0.87 1.2 0.67
11 spot welds
44-75
L53 Saloon except Sport
UPPER REAR STRUCTURE Side rain channel

Welding
44
Welding
93102S
93101S
2 triple layer spot welds
Thickness of panels (mm) Side rain channel Lighting support panel Unpicking 0.87 0.67
3 spot welds
44-76
D53 Cabriolet
UPPER REAR STRUCTURE Boot lid rain channel

Welding
44
- Bare rain channel. - Hood cover lock stiffeners. - Boot lid hinge stiffeners.
Photo page 44-21
PRS4441
JOINT WITH THE HOOD COMPARTMENT REAR PARTITION AND BOOT PARTITION
Thickness of panels (mm) Rear partition Boot base partition Rain channel Unpicking 50 spot welds. 1.5 0.7 1.0
44-77
D53 Cabriolet
UPPER REAR STRUCTURE Boot lid rain channel

1
JOINT WITH THE WING PANEL AND LIGHTING SUPPORTS
44
Thickness of the panels (mm) Rain channel Wing panel Lighting support Unpicking 54 spot welds. 1.0 0.88 0.67
Welding
PHOTO PAGE 44-22
44-78
UPPER REAR STRUCTURE Lighting support panel

44
2A
Welding
Bare part
PRS4442
CUTTING - UNPICKING
92368-1S
e = 1.4 mm H = 60 mm
NOTE: the general procedure for changing a
welded component is described in Workshop Repair Manual M.R. 502 section 4
92368S
IMPORTANT: unpicking must be carried out from
the inside.
44-79
B - C - S53 Phase I
44
2A
PRS4447
Hole (B) has been added on phase II vehicles for centring the rear light. Initially, hole (A) for centring the light on phase I vehicles has been retained but in the future, this will be discontinued for reasons of economy. Consequently, when the phase I light is to be re-used, it will be necessary to cut the upper centring pin in order to fit it to the phase II support.
44-80
D53 Cabriolet

Welding
44
2A
This part can only be changed with its stiffener

- Bare parts. The lighting support and its stiffener must be ordered at the same time, they each have a separate part number.
Photo page 44-23
PRS4443
Thickness of panels mm) Lighting support Rain channel Wing panel End panel Lighting support stiffener Unpicking 42 spot welds. 0.7 1.0 0.88 0.7 1.0
1 brazed weld filet.
44-81
D53 Cabriolet

Welding (cont)
44
2A
Photo page 44-24
Photo page 44-24
44-82
L53 Saloon

2
JOINT WITH THE SIDE PANEL
44
2A
Part only
PRS4444

93113S
Reminder: see 44-2H-3
JOINT WITH THE END PANEL SIDE MEMBER
Reminder: see 41-V-1
93101S
93125S
44-83
UPPER BODY SECTION Roof panel

The roof panel is supplied bare, without cross member or roof drip moulding.
DISMANTLING
45 A
Remove: - seats, - interior trims, - windscreen, - tailgate.

PROTECTION
Protect the interior using a cover which is resistant to welding and grinding damage.
PRS4501
CUTTING - UNPICKING
Original welding
3 and 5 DOOR VEHICLES 5 DOOR VEHICLES
92607S
92609S
Roof: front cross member - 13 spot welds
92608-1S
92610S
Roof: body side - 14 spot welds
Roof: rear cross member - 40 spot welds
45-1

3 DOOR VEHICLES
45 A
92611-1S
92612S
Roof: body side - 14 spot welds Original welding

Cut A Cut B Cut C
PRS4502
PRS4503
PRS4504
Spot welding
Fillet welding
Brazing (1) (2) (3) (4) (5) (6) (7) Body side Roof drip moulding Roof panel Rear cross member Quarter panel top Quarter panel upper stiffener Structure bonding mastic (roof drip mouldings and roof, cross members and roof joints)
45-2

Repair welding
3 and 5 DOOR VEHICLES 5 DOOR VEHICLES
45 A
92607-1S
92609-1S
92608S
92610-1S
45-3

3 DOOR VEHICLES
45 A
92611-1S
92612-1S
Repair welding
Cut A Cut B Cut C
PRS4502
PRS4503
PRS4504
D = 4.5 mm
(1) (2) (3) (4) (5) (6) (7)
Body side Roof drip moulding Roof panel Rear cross member Quarter panel top Quarter panel upper stiffener Structure bonding mastic (roof drip mouldings and roof, cross members and roof joints)
NOTE: make a brazed weld at the roof-front pillar
upright joint.
45-4
L53 Saloon
45 A
Only special points specific to L53 type vehicles will be described for this operation. Refer to section 45-A for other joints.
Panel only
93118S
PRS4501
Thickness of panels (mm) Roof Roof cross member Body side upper extender Quarter panel lining Unpicking 0.67 0.67 0.67 067
Reminder:see
44-A -1
17 spot welds
93126R1
45-5
L53 Saloon

Welding
45 A
93083S
8 triple layer spot welds
93099-2S
Apply a bead of metal bonding mastic.
45-6
D53 Cabriolet
UPPER BODY SECTION Windscreen surround

Welding
45
- Frame. - Pillar closure panel. - Upper linings.
For fitting, refer to section 40 "Bodywork dimensions".
Photo page 45-1
PRS4506
Thickness of panels (mm) Frame Lining Front pillar Unpicking 98 spot welds. Four 20mm MAG weld fillets. Six 30mm MAG weld fillets. 1.0 1.5 1.25
Photo page 45-1
2 brazed weld fillets.
45-7
D53 Cabriolet
UPPER BODY SECTION Windscreen frame

2
PARTIAL CUT
45
Welding (cont)
Photo page 45-2
Photo page 45-2
Photo page 45-2
45-8
UPPER BODY SECTION Linings and stiffeners
45
PRS4505
Original welding
Joints (1) - (2) - (3) - (4) - (5) - (6)
NOTE: Joint (6): body side roof drip moulding
The repair welding is identical to the original welding.
45-9
D53 Cabriolet
UPPER BODY SECTION Windscreen pillar lining

Welding
45 D
This operation is carried out in addition to changing of the windscreen frame.

Part only.
Photo page 45-3
PRS4507
Thickness of panels (mm) Lining Front pillar Frame Unpicking 31 spot welds. 1.5 1.25 1.0
45-10
D53 Cabriolet
UPPER BODY SECTION Windscreen aperture upper cross member

Welding
45
This operation is carried out in addition to changing of the windscreen frame.

Bare part.
94955S
PRS4508
JOINT WITH THE WINDSCREEN APERTURE FRAME
Thickness of panels (mm) Cross member Pillar lining Frame Unpicking 42 spot welds. Four 30mm MAG weld fillets. 1.5 1.5 1.0
45-11
L53 Saloon
UPPER BODY SECTION Rear roof cross member

2
JOINT WITH THE ROOF
45
Panel only
Reminder : see 45-A-2
PRS4509
93083S
93099-2S
93097S
45-12
BODY PROTECTION Sub-frame front protector
46 A
PRS4601
Remove the four bolts (1) and detach the protector from the 4 lugs (2).
46-1
BODY PROTECTION Wheel arch mud shield

FRONT REAR
46
PRS4602
PRS4603
46-2
SIDE OPENINGS Door hinges

Production fitting
47 A
Special feature for the electrical wiring in the doors: to make removal easier without having to remove the trim, there is a connection unit located in each pillar.
92308R
(1) Welded hinges (B) 6 mm diameter screw pin fitted on bushes (C) (2) Torx end piece (T40)
After Sales fitting when changing a door
PRS4701
(B) 6 mm diameter screw pin fitted on bushes (C) (C) Special replacement bolted hinge
47-1
SIDE OPENINGS Front door panel

COMPOSITION OF THE REPLACEMENT DOOR PANEL
47
92614-1S PRS4702
(1) Exterior panel (2) Panel stiffener (3) Sound proofing

CUTTING - UNPICKING PREPARATION BEFORE WELDING
Take a section from the new part which is approximately 50mm larger then that cut from the vehicle. Position the new part on the vehicle so that it is superposed, then secure it with a vice-grip wrench. Cut the two layers of metal simultaneously using a hacksaw to facilitate the fit. Remove the panel and take off the surplus section remaining on the door.
92614S
47-2
SIDE OPENINGS Front door panel

Apply aluminium paint to the area which is to be plug welded. Apply a bead of metal bonding mastic. Fit the panel then secure it with a vice-grip wrench. Gradually crimp the edge of the panel.
47
92614-2S
D = 4.5 mm After painting, inject hollow section wax into the door, particularly in the welded areas.
47-3
SIDE OPENINGS Rear door panel

COMPOSITION OF THE REPLACEMENT DOOR PANEL
47
Drill out the three resistance spot welds at (A), panel - door inner panel joint. Remove the damaged section following the recommendations of the previous diagrams (refer to the key to symbols).
92333R
1 2 3
Exterior panel Panel stiffener Sound proofing
CUTTING - UNPICKING
92613-1S
Take a piece from the new part which is approximately 50mm larger then that cut from the vehicle. Position the new part on the vehicle so that it is superposed, then secure it with a vice-grip wrench. Cut the two layers of metal simultaneously using a hacksaw to facilitate the fit.
92613-2S
Remove the panel and take off the surplus section remaining on the door.
47-4
SIDE OPENINGS Rear door panel

Apply aluminium paint to the area which is to be plug welded. Apply a bead of metal bonding mastic. Fit the panel then secure it with a vice-grip wrench. Gradually crimp the edge of the panel.
47
92613R
D = 4.5 mm
After painting, inject hollow section wax into the door, in particular in the welded areas.
47-5
All types Phase I
SIDE OPENINGS Front door - rear door
47 D
PRS4703
The lower side rubbing strip mounting row has been discontinued. Consequently, as the Parts Department only supplies phase II type parts, the following must be ordered depending on the type of rubbing strips in order to refit phase I type rubbing strips: either self adhesive clips (A) for narrow rubbing strips (see PR), or apply 6mm wide double sided adhesive tape to the lower section of wide rubbing strips (see PR).
47-6
BONNET AND TAILGATE Bonnet

REMOVAL - REFITTING
48 A
The bonnet is removed via the four mounting bolts (A) on the strut.
PARTS CHANGED
PRS4802
PARTS RE-USED
PRS4803
48-1
BONNET AND TAILGATE Bonnet

ADJUSTMENTS
48 A
Carry out in the following order: 1 - Adjusting via the struts The clearance in mountings (A) allows adjustment of: - the peripheral bonnet clearances, alignment and backward movement, - the flush fitting (height) of the rear section of the bonnet with the front wings. The clearance of mountings (B) allows the rear section of the bonnet to be moved sideways without altering the height.
PRS4804
2 - Adjusting via the lock The clearance in lock mounting bolts (C) enables the flush fitting (height) of the front of the bonnet to be adjusted.
NOTE: adjustment via the lock must never be used for adjusting the alignment of the bonnet centreline with the wings. The lock must operate without any lateral stress.
48-2
BONNET AND TAILGATE Tailgate

REMOVAL
48
92459-1S
92459R
Adjust the peripheral clearances with the roof and the side panels using the mounting nuts.
Remove the rear headlining. Unclip the counter balances. Remove the 2 nuts (1).
ADJUSTMENTS
92458S
Adjust the flush fitting with the end panel and the rear lights using the striker mounting bolts.
PRS4805
Adjust the flush fitting with the roof using shims (2).
48-3
B - C - S53
Phase II
BONNET AND TAILGATE Tailgate
48
95787R
The phase I part supplied by the Parts Department consists of a phase II type inner panel and a phase I type panel. Consequently, for correct sealing, it will be necessary to close holes (A) and (B) in the inner panel (refer to PR for the part numbers for the blanking pieces)
48-4
B - C - S53
SPORT
BONNET AND TAILGATE Boot lid

FITTING THE REAR SPOILER
48
PRS4806
1 2
Spoiler Mounting stiffener
93175R
Using the diagram, mark the centrelines of the spoiler mounting points starting from the edge of the rear screen wiper hole (A). Drill the 4 mounting points to a diameter of 8 mm. Apply sealing mastic to the edge of the holes and fit the spoiler. From inside the tailgate, fit the 2 mounting stiffeners and secure using the 4 nuts.
48-5
L53 Saloon

ADJUSTMENT
48
PRS4807
(A) (B) (C)
Adjustment of the clearances, alignment, backward movement, flush fitting Lateral adjustment of the rear section Adjustment via the lock
48-6
L53 Saloon
Phase II
48
PRS4808
On phase II vehicle the "Chamade" badge is no longer fitted. The parts supplied by the Parts Department are specific to each vehicle.
48-7
L539 Saloon
48
DIMENSIONS FOR DRILLING THE REAR LIGHT EXTENDER MOUNTING HOLES
In order to standardise, the Parts Department will only supply undrilled boot lids. Consequently, if the boot lid is changed on Sport type vehicles (L539), the lighting extender mounting holes must be drilled by the repairer in line with the recommendations below.
FITTING LIGHTING EXTENDERS AND BADGES
Using the dimensions shown on the diagram below, mark the location of the six mounting holes for the rear lighting extenders and the three mounting holes for the badges. The holes must be drilled before painting in order to avoid any risk of corrosion.
97748R
A and B Existing holes
48-8
D53 Cabriolet
48
PRS4809
94814-1R
94815R
After removing the counter balances, remove the four bolts (A)
Different adjustments
48-9
D53 Cabriolet
48
DIMENSIONS FOR DRILLING THE BADGE MOUNTING HOLES
In order to standardise, the Parts Department will only supply phase III boot lids. Consequently, if the boot lid is to be changed on phase I and II D53 Sport type vehicles, the mounting holes for the badges must be drilled by the repairer in line with the recommendations below.
Using the dimensions shown on the diagram below, mark the location of the 2 + 2 badge mounting holes. The holes must be drilled before painting in order to avoid any risk of corrosion.
98085R
A Existing holes
After painting and before refitting the trim, inject the hollow sections with wax.
48-10
D53 Cabriolet
BONNET AND TAILGATE Hood cover panel
48 D
PRS4810
Removal
94793S
94794R
Disconnect the rear screen demisting harness
Remove the lock in order to unclip wire ( A ) Remove the jacks.
48-11
D53 Cabriolet
BONNET AND TAILGATE Hood cover panel
48 D
94795R
Remove mountings (B).
48-12
L53 Saloon
BONNET AND TAILGATE Broken boot lid counter balance ball joint
48
93143R
93142-1S
(1) (2)
Ball joint part number 77 00 753 309 Nut part number 77 01 422 012
Before fitting and tightening the ball joint, coat the thread with Loctite SCEL BLOC SCEL METAL
part number 77 01 394 072 or part number 77 01 421 041
NOTE: for the general procedure for fitting or
changing a tailgate or boot lid counter balance ball joint, refer to Technical Note n 258.
93142R
Drilling for the ball joint
93143R1
Cut the ball joint thread to a length of 8 mm.
48-13
X53 All types
BONNET AND TAILGATE Roof cross member (noise reduction)

Procedure for cutting the roof noise reduction cross member if an R19 sun roof is to be fitted, for vehicles manufactured from 1st December 1991.
48
PRS4811
Checking for the presence of the noise reduction cross member. (the special headlining is fitted with a boss) Mark its location on the jig to be prepared when cutting the roof. The roof and cross member are cut together in a single operation using a "compass saw" type tool.
2 3
IMPORTANT : do not try to cut the roof and cross member separately or to
use cross member (A) as a lever as this will deform the roof drip mouldings (B).
Before fitting the sun roof, it is essential to: - smooth the cuts, - reapply mastic between the roof and remaining ends of the cross member (noise reduction function), - apply anti-corrosion protection to all cuts.
48-14

Apz Mecánica Automotriz Renault 19 Carrocería (Sheet Metal Work)

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Apz Mecánica Automotriz Renault 19 Carrocería (Sheet Metal Work)

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Sheet metal work

Renault S.A. 1988

42 UPPER FRONT STRUCTURE

43 UPPER SIDE STRUCTURE

44 UPPER REAR STRUCTURE

45 UPPER BODY SECTION

48 BONNET AND TAILGATE

GENERAL Engine - Clutch - Gearbox

C1G C1J C2J C3J E6J E7J E7J E7F F2N

JB0 - JB1 - JB3 - AD4

AD4 - JB3 - MB3

AD4 - JB3 - JC5

200 CPV 4600 F8Q 1870 200 CPV 3500

GENERAL Vehicle dimensions

GENERAL Vehicle dimensions

(1) Depending on version with option (2) Laden (3) Unladen

L53 Saloon Except Sport

GENERAL Vehicle dimensions

Mark A B C D E F * Depending on version

GENERAL Vehicle dimensions

GENERAL Vehicle dimensions

ESSENTIAL SPECIAL TOOLS

Cha. Cha. or Cha.

280 -02 408 -01

Adjustable cross piece on trolley jack Adjustable dowel on trolley jack

Appropriate axle stands must be used if a trolley jack is used.

Several possibilities must be considered:

Part number FOG 449 8111 - 449 8411 or

Part number 39 2550 0001 or

Part number 776 684

GENERAL Description of parts (exploded views)

LOWER STRUCTURE ALL TYPES

9 10 11 12 13 14 15* 16* 17 18 18A 19 19A 20 20A

* Steel part with high degree of flexibility

GENERAL Description of parts (exploded views)

66 67 68 69 70 71 71A 72 72A 72B 73 73A 74 75 75A 76

GENERAL Description of parts (exploded views)

90A 90B 91 92 93 94 95 96 97 97A 97B 98 99

B53 / C53 / L53

GENERAL Description of parts (exploded views)

GENERAL Description of parts (exploded views)

GENERAL Description of parts (exploded views)

GENERAL Description of parts (exploded views)

GENERAL Description of symbols

Cut using a cold chisel

Unpick the metal strip

Clean the surfaces to be welded 100 mm fibre disc

GENERAL Description of symbols

or saw saw plug weld

stud extractor grind unpick clean

bead of mastic in cartridge

bead and spraying of mastic

spraying of mastic release brazed joint

PROTECTION OF HOLLOW SECTIONS

injection using angled nozzle

electric spot welder

B53 Phases I and II

GENERAL Opening clearances

B53 Phases I and II

GENERAL Opening clearances

GENERAL Opening clearances

GENERAL Opening clearances