Академический Документы
Профессиональный Документы
Культура Документы
01C
01D
MECHANICAL INTRODUCTION
02A
LIFTING EQUIPMENT
03B
COLLISION
04B
CONSUMABLES - PRODUCTS
04E
PAINT
X61
DECEMBER 2008
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
http://vnx.su
KANGOO II - Section 0
Contents
Page
01A
01C
03B
01A-1
01C-1
Vehicle clearances:
Adjustment values
01C-3
04B
COLLISION
Vehicle damaged at side:
Description
03B-5
03B-9
CONSUMABLES - PRODUCTS
Vehicle: Parts and
ingredients for the repairwork
01D
MECHANICAL INTRODUCTION
Vehicle: Precautions for
repair
Tightening torques: General
information
02A
04E
PAINT
01D-1
Colour code: Specifications
01D-3
LIFTING EQUIPMENT
Vehicle: Towing and lifting
03B
04B-1
02A-1
COLLISION
Damaged vehicle: Collision
fault finding
03B-1
03B-3
http://vnx.su
04E-1
01A
125086
Dimensions in metres:
Van
(A)
0.807
(B)
2.697
(C)
0.709
(D)
4.213
(E)
1.521
(F) (unladen)
1.839
(F) (laden)
1.751
(G)
1.533
(H)
2.133
Short van
(A)
0.807
(B)
2.313
01A-1
http://vnx.su
0.709
(D)
3.829
(E)
1.519
(F) (unladen)
1.800
(F) (laden)
1.772
(G)
1.533
(H)
2.133
01A
Combi
Standard payload
Increased payload
(A)
0.807
(B)
2.697
(C)
0.709
(D)
4.213
(E)
1.521
(F) (unladen)
1.842
1.844
(F) (laden)
1.747
1.746
(G)
1.533
(H)
2.133
Engine
Vehicle type
Engine type
Engine suffix
Gearbox
Cubic capacity(cc)
01A-2
http://vnx.su
Gearbox
type
Gearbox
suffix
Emissions
standard
FW0D
KW0D
K4M
FW0W
830
DP0
106
172
1598
834
01A
JR5
153
JH3
171
KW0W
FW0A
800
KW0A
154
802
FW0B
JR5
155
156
KW0B
KW0V
FW0C
804
KW0C
FW0F
K9K
806
1461
TL4
000
KW0F
EURO 4
FW0G
808
KW0G
812
FW0K
JR5
KW0K
155
156
FW0L
KW0L
KW0E
JH3
170
JR5
152
KW0Y
FW0E
FW0N
K7M
750
1598
FW0P
FW0Y
KW0N
KW0P
DETAILS OF VEHICLE TYPE
Example: KT01
K: Body type (five-door estate)
T: Project code
01: Engine code
01A-3
http://vnx.su
168
01C
Plate (A)
125689
19031
125690
01C-1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Equipment level
(9)
Vehicle type
(10)
Upholstery code
(11)
(12)
Fabrication number
(13)
http://vnx.su
125555
Note:
If the complete body is being replaced, it must be
marked in compliance with the current regulations.
01C-2
http://vnx.su
01C
01C
Section 1
127159
127197
(X1) = 7 mm 1.5
WARNING
The clearance values are given for information
purposes.
Section 2
127193
(X2) = 3.5 mm 2
01C-3
http://vnx.su
01C
Section 5
Section 3
127194
127195
(X3) = 3 mm 2
(X5) = 4 mm 2
Section 4
Section 6
127196
127199
(X6) = 4 mm 1
(X4) = 1 mm 1
01C-4
http://vnx.su
01C
Section 8
127200
127198
(X7) = 5 mm 1.5
(X8) = 4 mm 1.5
Section 9
127160
127201
(X9) = 4 mm 1.5
01C-5
http://vnx.su
01C
Section 12
Section 10
127168
127202
(X10) = 3 mm 1.5
(X12) = 4 mm 1.5
Section 11
Section 13
127204
127203
(X13) = 4.5 mm 2
(X11) = 4 mm 1.5
01C-6
http://vnx.su
01C
Section 16
K61
Section 14
127166
127164
Section 17
(X14) = 4 mm 1.5
Section 15
127165
(X17) = 4.5 mm 2
127167
(X15) = 4 mm 1.5
01C-7
http://vnx.su
01C
Section 20
Section 18
127169
127171
(X20) = 2 mm 1.8
(X18) = 5 mm 1.5
Section 19
F61
127170
(X19) = 4 mm 2
127161
01C-8
http://vnx.su
01C
Section 23
Section 21
127173
127172
(X23) = 4 mm 2
(X21) = 4 mm 1.2
Section 22
Section 24
127174
(X22) = 4 mm 2
127176
01C-9
http://vnx.su
01C
Section 26
127175
(X25) = 3.5 mm 1
127181
(X26) = 8 mm 3
Section 27
F61 or K61
127187
127163
(X27) = 4 mm 2
01C-10
http://vnx.su
Section 28
127188
127192
(X28) = 4 mm 2
(X30) = 4 mm 2
Section 29
Section 31
127191
(X29) = 4 mm 2
01C
127190
(X31) = 4 mm 2
01C-11
http://vnx.su
01C
Section 33
127189
(X32) = 7.2 mm 3
127186
(X33) = 8 mm 2
Section 34
K61
127182
(X34) = 4 mm 2
127162
01C-12
http://vnx.su
01C
Section 37 / 37a
Section 35
127184
127177
(X37) = 4 mm 2
(X35) = 4 mm 2
(X37a) = 2 mm 1.5
Section 36
Section 38
127183
(X36) = 4 mm 2
127179
(X38) = 1.5 mm 1
01C-13
http://vnx.su
01C
Section 41
Section 39
127178
127185
(X41) = 7.2 mm 3
(X39) = 4 mm 2
Section 40
127180
01C-14
http://vnx.su
Section 42
127184
127178
(X42) = 4 mm 2
(X44) = 4 mm 2
Section 43
Section 45
127177
(X43a) = 2 mm 1.5
01C
127185
(X45) = 7.2 mm 3
(X43b) = 4 mm 2
01C-15
http://vnx.su
127192
(X46) = 4 mm 2
01C-16
http://vnx.su
01C
MECHANICAL INTRODUCTION
Vehicle: Precautions for repair
GENERAL INFORMATION
All information contained in these manuals is intended
exclusively for automotive industry professionals.
The documentation is intended to cover all vehicles in
the RENAULT range throughout the world, but may not
cover equipment designed for use in specific countries.
The procedures and fault finding procedures recommended and described in this manual have been designed by automotive industry repair professionals.
1 - General recommendations
Observe basic principles of vehicle repair.
The quality of repair depends first and foremost on the
care exercised by the person in carrying it out.
To ensure good repair:
- protect the sensitive areas of the vehicle (seats, steering wheel, wings, etc.),
- disconnect the battery wherever possible (prevents
short circuits, erratic starting of the windscreen wiper
motor, etc.),
- when welding on the vehicle, it is advisable to remove
or disconnect components near the repair area that
could be affected by the heat,
- use recommended professional products and original
parts,
- observe the tightening torques,
01D
The repair procedures have been designed using special tools; they must therefore be carried out using these tools to ensure a high degree of working safety and
quality of repair.
The equipment we have approved has undergone careful research and testing, and must be used and maintained with care.
3 - Reliability - updating
- do not splash any liquid on the electrical and electronic components (computers, sensors, etc.),
- do not just replace parts one after the other, carry out
detailed fault finding beforehand,
- carry out a final check before returning the vehicle to
the customer (set the clock, check the alarm operation, check the lights and indicators etc.),
- clean and degrease the sections to be bonded
(threads, stub axle splines) to ensure proper adherence,
01D-1
http://vnx.su
MECHANICAL INTRODUCTION
Vehicle: Precautions for repair
01D
4 - Safety
5 - Conclusion
Working safely:
- use suitable tools which are in good condition (use of
multi-purpose tools, such as adjustable pliers,
etc., should be avoided wherever possible),
- use supports and adopt a correct posture when performing heavy work or raising loads,
- make sure that the procedure used is not dangerous,
- Do not wear any jewellery or other small objects during an operation,
- use personal protection (gloves, safety glasses, work
shoes, masks, skin barrier creams, etc.),
- always follow the safety instructions associated with
the operation to be performed,
- do not smoke when working on vehicles,
- use smoke extractors (welding, exhaust gases, etc.),
- do not use harmful products in unventilated rooms,
- do not overstrain yourself or attempt inappropriate
work operations,
- use axle stands when working under a vehicle raised
on a jack,
- do not ingest any chemicals (brake fluid, coolant,
etc.),
- do not open the cooling circuit when it is hot and pressurised,
- take care with components that are liable to start up
suddenly (engine cooling fan, etc.).
Respecting the environment:
- do not allow waste refrigerants to escape into the atmosphere,
- do not dispose of waste vehicle fluids (oil, brake fluid,
etc.) in drains,
- do not burn discarded products (tyres, etc.).
01D-2
http://vnx.su
MECHANICAL INTRODUCTION
Tightening torques: General information
I - TABLE OF STANDARD TORQUES
01D
Fastenings
Diameter
Property
class
Standard
tightening
torque
(N.m)
M6 *
8.8
10
M8 *
8.8
25
M10 *
8.8
50
M10
10.9
62
M12
10.9
105
M14
10.9
180
M16
10.9
280
M18
10.9
400
Standard
tightening
torque
(N.m)
M6
M8
21
M10
44
120737
120736
01D-3
http://vnx.su
MECHANICAL INTRODUCTION
Tightening torques: General information
01D
Customer complaints resulting from incorrect tightening may be, following assembly, a safety issue (fire,
loss of control of the vehicle etc.), an immobilising fault
or a noise.
The principle consists of putting the parts of the assembly in contact using a mating torque (approximately 25
to 30% of the final torque) then to tighten to a determined angle.
This method, which is not dependent on the friction of
the tightened assembly, gives more precise results
than torque tightening.
IV - OBSERVING THE TIGHTENING TORQUES AND
ANGLES
Bolted assemblies whose tightening torques and angles are explicitly specified in the removal / refitting
procedures must be observed using the appropriate tools (torque wrench, angle measuring disc). Failure to
observe this can lead to safety risks, immobilising
faults or unwanted noises.
120739
(3)
Bolt
(4)
Assembled components
(5)
(6)
Non-tightened assembly
(7)
(X1)
Tightened assembly
compression of the assembly
(Fo)
tension
(C)
tightening torque
01D-4
http://vnx.su
MECHANICAL INTRODUCTION
Tightening torques: General information
01D
For example:
- 1 torque wrench 4 - 40 N.m,
- 1 torque wrench 20 - 100 N.m,
- 1 torque wrench 80 - 400 N.m,
- 1 angle measurement disc.
The torque wrenches used must comply with the ISO
6789 standard. They must be calibrated regularly following the supplier's recommendations using the appropriate procedures.
120741
120742
- Apply the tightening effort perpendicular to the mounting observing a tolerance of 15 relative to the perpendicularity. If the wrench is not perpendicular to the
mounting axis, this will result in insufficient tightening.
120740
(6)
lever arm
- Place the hand in the centre of the handle. An incorrectly positioned hand on the handle will alter the trigger threshold.
01D-5
http://vnx.su
MECHANICAL INTRODUCTION
Tightening torques: General information
01D
120743
01D-6
http://vnx.su
LIFTING EQUIPMENT
Vehicle: Towing and lifting
02A
WARNING
See the current towing regulations in each country.
Never use the driveshafts, axle assembly components or suspension components as attachment
points.
Always fully tighten and lock the towing ring before
use.
Always pull in the direction of the rod's length in
order to avoid breaking it.
Vehicles fitted with automatic transmission:
- The vehicle should preferably be transported on a
platform or towed by lifting the front wheels. As an
exception, the vehicle may be towed with the
wheels on the ground but at a speed below 12
mph (20km/h) and over a maximum distance of 18
miles (30 km) (with the gear lever in neutral).
125855
IMPORTANT
To prevent any accidents, the trolley jack must only
be used to lift and/or move the vehicle. The vehicle
height must be maintained with axle stands which
are strong enough to support the weight of the vehicle.
WARNING
To avoid any damage to the original protection, use
equipment fitted with rubber pads to prevent the
equipment coming into direct contact with the vehicle.
To avoid any damage to the axle assemblies, the
vehicle must not be raised using the front suspension arms for support or under the rear axle.
125856
02A-1
http://vnx.su
LIFTING EQUIPMENT
Vehicle: Towing and lifting
02A
127407
14894
127408
02A-2
http://vnx.su
LIFTING EQUIPMENT
Vehicle: Towing and lifting
02A
IMPORTANT
Only the jacking points described in this section
allow the vehicle to be raised in complete safety.
Do not raise the vehicle using points other than
those described in this section.
To raise the vehicle, position the pads of the lift arms
as indicated below. Be sure to retract the pads far
enough to avoid damaging the underside of the sill panel (5) (6) .
Front lifting points
14893
Fit the lift arm pads under the front jacking points (3) .
02A-3
http://vnx.su
LIFTING EQUIPMENT
Vehicle: Towing and lifting
Rear lifting points
125853
Fit the lift arm pads under the rear jacking points (4) .
Note:
If it is necessary to disengage the jacking points,
follow the instructions for lifting using a trolley jack
(for example, fit anchoring clamps if placing on a
body jig bench for bodywork rebuilding).
02A-4
http://vnx.su
02A
COLLISION
Damaged vehicle: Collision fault finding
03B
126949
03B-1
http://vnx.su
COLLISION
Damaged vehicle: Collision fault finding
03B
127210
127208
127211
a
127209
03B-2
http://vnx.su
COLLISION
Vehicle damaged at front: Description
03B
127207
1st degree
126940
03B-3
http://vnx.su
COLLISION
Vehicle damaged at front: Description
- (14) front half-unit.
2nd degree
126941
126942
03B-4
http://vnx.su
03B
COLLISION
Vehicle damaged at side: Description
03B
127205
03B-5
http://vnx.su
COLLISION
Vehicle damaged at side: Description
03B
1st degree
126946
03B-6
http://vnx.su
COLLISION
Vehicle damaged at side: Description
03B
2nd degree
126947
03B-7
http://vnx.su
COLLISION
Vehicle damaged at side: Description
03B
3rd degree
126948
03B-8
http://vnx.su
COLLISION
Vehicle damaged at rear: Description
03B
127206
03B-9
http://vnx.su
COLLISION
Vehicle damaged at rear: Description
03B
1st degree
126943
03B-10
http://vnx.su
COLLISION
Vehicle damaged at rear: Description
03B
2nd degree
126944
03B-11
http://vnx.su
COLLISION
Vehicle damaged at rear: Description
03B
2nd degree
126945
03B-12
http://vnx.su
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
Consumables for mechanical repair:
DEFINITION
PACKAGING
PART NUMBER
MECHANICAL SEALANTS
SILICOR
85 g tube
77 11 236 470
100 g tube
77 11 236 172
Kit
77 11 237 896
100 g cartridge
77 11 227 484
45 g tube
77 11 223 369
SILICOJOINT
90 g tube
77 11 236 469
Cartridge
77 11 219 705
25 ml tube
77 11 237 640
1.5 kg tin
77 01 421 161
400 ml aerosol
77 11 236 176
sealing paste
MASTIXO
Joint face seal
BEARING SEALING KIT
For crankshaft bearing cap side
sealing
SILICONE ADHESIVE SEAL
Engine and gearbox sealing paste
ADHESIVES
FRENETANCHE
50 ml bottle
77 11 236 471
50 ml bottle
77 11 230 112
50 ml bottle
77 11 236 472
150 ml aerosol
04B-1
http://vnx.su
77 11 225 871
04B
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
INJECTOR CLEANER
355 ml container
500 ml aerosol
77 11 236 166
250 ml aerosol
77 11 420 439
300 ml aerosol
77 11 238 181
SURFACE CLEANER
5 L container
77 01 404 178
SILICONE LUBRICANT
400 ml aerosol
77 11 236 168
SILICONE-FREE LUBRICANT
400 ml aerosol
77 11 236 167
600 ml aerosol
77 11 422 413
150 ml aerosol
77 11 422 414
250 ml aerosol
77 11 230 498
CARBURETTOR CLEANER
Aerosol
77 11 236 177
BRAKE CLEANER
GREASE
BR2+ GREASE
1 kg pack
77 01 421 145
100 g tube
77 11 419 216
85 g tube
77 11 236 173
500 ml aerosol
77 11 236 169
180 g sachets
77 11 420 011
400 ml aerosol
77 11 236 174
For:
- the lower arm bearings,
- the anti-roll bar grooves,
- the driveshaft splines.
SILICONE GREASE
For:
- the tubular rear axle bushes,
- the anti-roll bar bushes.
COPPER ANTI-SEIZE GREASE
Grease for turbochargers (high
temperature)
COPPER-ALUMINIUM LUBRICANT
Grease for turbochargers (high
temperature)
GREASE
For driveshaft seals
WHITE GREASE
For wheel sensors
04B-2
http://vnx.su
04B
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
500 ml aerosol
77 11 236 170
250 ml aerosol
77 11 236 171
100 g tube
82 00 168 855
04B
MULTIPURPOSE GREASE
FLUORSTAR 2L
Silicone-free electric sealing grease
LACQUER
JELT ARGENT
5 g bottle
77 11 230 111
77 11 218 589
5 L container
77 11 238 318
25 L container
77 11 238 319
0.5 L container
77 11 172 381
5 L container
77 01 395 503
25 L container
77 11 171 926
DOT 4
0.5 L container
86 71 000 000
5 L container
86 71 014 277
25 L container
86 71 014 278
COOLING SYSTEM
ANTIFREEZE (TYPE D)
COOLANT (TYPE D)
1 L container
77 11 170 548
1 L container
77 11 171 589
2 L container
77 11 170 545
5 L container
77 11 170 546
OIL
ENGINE OIL
GEARBOX OIL
AXLE OIL
(see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubricants)
04B-3
http://vnx.su
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
ELF RENAULT MATIC D2
2 L container
77 01 402 037
1 L container
77 11 172 668
250 ml container
77 01 419 313
77 11 223 052
5 kg pack
77 11 223 053
400 ml tube
77 11 221 296
300 ml tube
77 11 222 802
TYRE PASTE
Injection type
Part no.
F5R
77 01 206 382
F8Q
77 01 206 340
F9Q
77 01 208 229
77 01 208 229
K9K
DELPHI
77 01 206 804
K9K
SIEMENS
77 01 476 857
M9R
77 01 209 062
P9X
77 01 474 730
ZD3
77 01 208 229
MISCELLANEOUS
77 01 405 943
1 L container
77 11 172 672
SPR CC SPRAY
500 ml aerosol
77 11 211 654
04B-4
http://vnx.su
04B
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
STRUCTURAL ADHESIVE
STRUCTURAL ADHESIVE
Kit =2 80 ml cartridges
77 11 219 885
1 195 ml cartridge
77 11 419 113
310 ml cartridge
77 11 421 430
310 ml cartridge
77 11 421 431
310 ml cartridge
77 11 421 432
310 ml cartridge
77 11 421 433
2 225 ml cartridges
77 11 421 434
LINT-FREE CLOTH
77 11 237 262
METAL PRIMER
Bottle
77 11 419 599
310 ml cartridge
77 11 170 222
77 11 425 759
Cloth
77 11 423 222
20 m roll
77 11 226 308
FRENETANCHE
50 ml bottle
77 11 236 471
ADHESIVE PATCH
82 00 043 181
ADHESIVE PAD
77 05 042 163
SEALS
310 ml cartridge
77 11 172 676
310 ml cartridge
77 11 172 677
2.6 m roll
77 01 423 330
BRUSH MASTIC
1 kg pack
77 11 228 113
FILLER MASTIC
60 beads 6 mm by 0.3 m
77 11 170 230
GREASE
04B-5
http://vnx.su
04B
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
CLEAN GREASE
300 ml aerosol
77 11 236 174
20 g sachets
77 11 419 865
SOUNDPROOFING
SPR GREY EVOLUTION
1 l cartridge
77 11 419 114
400 ml aerosol
77 11 419 116
1 l cartridge
77 11 419 115
Pack of 10
77 01 423 546
Pack of 5
77 01 423 269
POLISHING
POLISHING LIQUID
1 L container
77 11 420 288
FINISHING LIQUID
1 L container
77 11 420 289
MASTIC
Universal mastic
GALAXI
2.5 kg pack
77 11 172 238
OPTIMAX
1.23 l cartridge
77 11 172 239
EXCELLENCE +
960 g cartridge
77 11 423 539
1 kg pack
77 11 423 540
Plugging mastic
XFIBRE FIBREGLASS MASTIC
975 kg pack
77 11 172 235
1.975 kg pack
77 11 172 234
975 kg pack
77 11 172 236
Sprayable mastic
PIXTO SPRAYABLE POLYESTER
MASTIC
1.5 kg tin
77 11 172 237
Finishing mastic
IXTRA POLYESTER MASTIC
1.625 kg pack
77 11 172 233
Anti-grit mastic
MAG PRO 1
310 ml cartridge
77 11 172 679
1.5 kg tin
77 11 218 364
SURFACE CLEANER
04B-6
http://vnx.su
04B
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
HEPTANE
500 ml container
77 11 170 064
5 L container
77 01 404 178
5 L container
77 11 421 337
400 ml aerosol
77 01 408 493
04B
77 11 170 064
77 11 423 523
1 L container
77 11 423 517
150 ml bottle
77 11 423 518
2 x 25 ml bicomponent cartridge
77 11 423 519
90 m roller
77 11 423 520
12 nozzles
77 11 423 522
77 11 425 742
PROTECTIVE STRIPS
77 11 425 744
Bag of 2 meshes
77 11 425 743
COOLER
400 ml aerosol
77 11 425 745
BRUSH
Box of 10 brushes
77 11 237 793
77 11 171 708
20 MM WINDSCREEN TAPE
77 11 171 709
PROTECTIVE WELDING
ANTI-SPLASH SPRAY
400 ml aerosol
77 11 218 270
SPECIFIED UNDERCOAT
PRE-TREATMENT
PRIMER
WITHOUT ZINC CHROMATE (IAlpha) + THINNER
1 L container
3.5 l container
04B-7
http://vnx.su
77 11 419 416
CONSUMABLES - PRODUCTS
Vehicle: Parts and ingredients for the repairwork
ADHRA SPRAY (adhesion promoter for thermoplastics)
400 ml aerosol
04B
77 11 423 734
77 11 423 735
1 L container
1 L container
LEVIA
3.5 l container
77 11 228 651
FORTIA
3.5 l container
77 11 228 650
04B-8
http://vnx.su
PAINT
Colour code: Specifications
04E
Colour description
Colour Code
Glacier White
O389
220 112
Bright red
O719
230 103
Beige Grey
TEC66
205 296
TEENC
230 109
Island Blue
TERNP
TEDNK
Mint Blue
TEJ42
Emerald Grey
OKNF
Poppy Red
TENNG
230 110
Shiny grey
TEB64
205 262
OENG
Volga Blue
ORNQ
Metallic Black
TEGND
215 145
205 316
04E-1
http://vnx.su
GENERAL INFORMATION
51A
52A
54A
WINDOWS
55A
EXTERIOR PROTECTION
56A
EXTERIOR EQUIPMENT
57A
INTERIOR EQUIPMENT
59A
SAFETY ACCESSORIES
X61
MARCH 2009
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
http://vnx.su
KANGOO II - Section 5
Contents
Page
50A
51A
51A
GENERAL INFORMATION
50A-1
51A-21
51A-24
51A-1
52A
51A-3
51A-4
51A-6
51A-8
51A-9
52A-1
52A-2
52A-3
52A-8
52A-10
52A-11
52A-13
51A-11
51A-16
51A-19
52A-19
52A-21
52A-22
http://vnx.su
Contents
52A
54A
55A
52A-24
52A-26
52A-27
52A-28
Sunroof operating
mechanism: Removal Refitting
Sunroof moving panel:
Removal - Refitting
55A-1
55A-3
55A-7
55A-9
55A-12
52A-29
55A-14
52A-32
55A-15
55A-17
55A-18
55A-19
55A-20
55A-21
54A-1
54A-3
54A-5
54A-6
54A-7
WINDOWS
Windscreen: Removal Refitting
EXTERIOR PROTECTION
56A
54A-9
54A-10
54A-11
54A-13
54A-18
http://vnx.su
EXTERIOR EQUIPMENT
Scuttle panel grille: Removal
- Refitting
56A-1
56A-2
56A-4
56A-5
56A-6
56A-7
Contents
56A
EXTERIOR EQUIPMENT
Roof rack bar: Removal Refitting
Upper rear opening element
strip: Removal - Refitting
57A
59A
56A-9
56A-11
INTERIOR EQUIPMENT
Dashboard: Removal Refitting
57A-1
57A-4
57A-6
57A-7
57A-9
Dashboard glovebox:
Removal - Refitting
57A-11
57A-13
57A-15
57A-16
57A-18
57A-19
57A-20
57A-21
Separating components:
Removal - Refitting
57A-22
http://vnx.su
SAFETY ACCESSORIES
Belt height adjustment
system: Removal - Refitting
59A-1
GENERAL INFORMATION
Pair of unclipping pliers: Use
50A
99799
121062
121060
121061
50A-1
http://vnx.su
GENERAL INFORMATION
Pair of unclipping pliers: Use
107941
50A-2
http://vnx.su
50A
51A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Raise the window fully.
a Disconnect the front side door connector.
a Remove:
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim),
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the front side door lock barrel (see 51A, Side opening element mechanisms, Front side door lock
barrel: Removal - Refitting, page 51A-3) ,
- the exterior door handle (see 51A, Side opening
element mechanisms, Door exterior handle:
Removal - Refitting, page 51A-4) .
126869
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the front side door module rivet (1) .
108049
WARNING
To avoid any risk of corrosion after the localised
stripping of the panel, reapply the protective coating (see Technical Note 0592A).
51A-1
http://vnx.su
51A-2
http://vnx.su
51A
Tightening torquesm
lock barrel bolt
2 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Unclip the cover to access the front side door lock
barrel release mechanism.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
108047
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Position the front side door lock barrel.
a Torque tighten the lock barrel bolt (2 Nm).
II - FINAL OPERATION.
a Clip on the blanking cover.
a Carry out a function test.
51A-3
http://vnx.su
51A
51A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Disconnect the front side door connector.
a Remove:
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim),
- the front speaker (see Front speakers: Removal Refitting) (85A, Radio),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the front side door lock barrel (see 51A, Side opening element mechanisms, Front side door lock
barrel: Removal - Refitting, page 51A-3) .
108046
REFITTING
I - REFITTING PREPARATION OPERATION
127455
108048
51A-4
http://vnx.su
51A
a Refit the front side door lock barrel (see 51A, Side
opening element mechanisms, Front side door
lock barrel: Removal - Refitting, page 51A-3) .
a Connect the front side door connector.
a Carry out a function test on all functions.
a Refit new door sealing film (see Door sealing film:
Removal - Refitting) (65A, Opening element sealing).
a Carry out a sealing test (see Technical Note 0653).
a Refit:
- the front speaker (see Front speakers: Removal Refitting) (85A, Radio),
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim).
a Carry out a function test on all functions.
127457
127456
51A-5
http://vnx.su
51A
REMOVAL
126868
126915
a Remove the bolts (1) from the front side door sliding
window glass.
a Secure the window in the raised position using masking tape.
51A-6
http://vnx.su
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
126868
a Refit:
- the front side door electric window winder mechanism,
- the bolts in the sequence (1) , (2) , (3) , (4) and (5) .
a Connect the connector for the front side door electric
window motor (2) .
II - FINAL OPERATION.
a Refit the front side door sliding window glass.
a Connect the front side door connector.
a Carry out a function test on all functions.
a Refit new door sealing film (see Door sealing film:
Removal - Refitting) (65A, Opening element sealing).
a Carry out a sealing test (see Technical Note 653A).
a Refit:
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio),
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim).
a Carry out a function test on all functions.
51A-7
http://vnx.su
51A
51A
LEFT SLIDING + OPENING WINDOW, and R SLID+OPENING WINDOW, and ELEC. REAR WINDOW SW.
REMOVAL
126867
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
127454
51A-8
http://vnx.su
51A
REMOVAL
132061
a Remove:
- the bolts (2) ,
- the front side door manual window winder mechanism.
132062
a Remove the bolts (1) from the front side sliding door
window.
a Secure the window in the raised position using masking tape.
51A-9
http://vnx.su
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
132061
a Refit:
- the front side door manual window winder mechanism,
- the bolts in the sequence (1) , (2) , (3) , (4) and (5) .
II - FINAL OPERATION.
a Refit the front side door sliding window glass.
a Carry out a function test.
a Refit the door sealing film (see Door sealing film:
Removal - Refitting) (65A, Opening element sealing).
a Carry out a sealing test (see Technical Note 653A).
a Refit:
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio),
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim).
a Carry out a function test on all functions.
51A-10
http://vnx.su
51A
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
2 - Sliding side door intermediate runner
Essential equipment
K61
diagnostic tool
a Remove:
- the rear wing light (see Rear light on wing: Removal - Refitting) (81A, Rear lighting),
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
a Remove the sliding side door intermediate drive mechanism (see 51A, Side opening element mechanisms, Sliding side door carriage: Removal Refitting, page 51A-16) .
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
a Remove:
- the sliding side door lower drive mechanism (see
51A, Side opening element mechanisms, Sliding side door carriage: Removal - Refitting,
page 51A-16) ,
Note:
For partial removal of the runners, it is not necessary to remove the sliding side door.
REMOVAL
K61
a Remove:
51A-11
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
F61
126861
a Remove:
127582
51A-12
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Sliding side door upper runner
126864
a Remove:
- the nut (5) ,
126862
a Remove:
- the bolts (3) ,
- the sliding side door upper runner.
2 - Sliding side door intermediate runner
126863
51A-13
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
REFITTING
126866
a Remove:
- the bolts (6) ,
- the nut (6) ,
51A-14
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
- the flaps and floor panel storage compartments
(see 57A, Interior equipment, Floor flap and storage: Removal - Refitting, page 57A-15) ,
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
- the centre console (see 57A, Interior equipment,
Centre console: Removal - Refitting, page 57A13) .
F61
a Refit:
- the soundproofing (2) ,
- the floor carpet.
a Remove:
- the B-pillar lower trims (see B-pillar lower trim:
Removal - Refitting) (71A, Body internal trim),
- the complete front seat (see Complete front seat:
Removal - Refitting) (75A, Front seat frames and
runners),
- the sliding side door lower drive mechanism (see
51A, Side opening element mechanisms, Sliding side door carriage: Removal - Refitting,
page 51A-16) .
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (88C, Airbags and pretensioners).
a Refit the rear side door (see Rear side door: Removal - Refitting) (47A, Side opening elements).
51A-15
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Note:
For partial removal of the sliding side door drive
mechanisms, it is not necessary to remove the sliding side door.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the rear side door (see Rear side door:
Removal - Refitting) (47A, Side opening elements).
1 - Sliding side door upper drive mechanism
127427
127429
a Remove:
K61
a Remove the rear wing light (see Rear light on wing:
Removal - Refitting) (81A, Rear lighting).
51A-16
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
- the sliding side door intermediate runner stop.
127449
a Remove:
- the bolt (4) ,
- the sliding side door intermediate runner stop (5) .
127428
a Remove:
- the bolts (7) ,
F61
127450
a Remove:
- the bolt (6) ,
51A-17
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
REFITTING
K61
a Refit:
- the rear wing light (see Rear light on wing: Removal - Refitting) (81A, Rear lighting).
a Remove:
- the bolts (9) ,
- the sliding side door intermediate drive mechanism.
3 - Sliding side door lower drive mechanism
a Remove:
F61
a Refit the sliding side door intermediate runner stop.
51A-18
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
REMOVAL
a Remove:
- the sliding side door trim (see Sliding side door
trim: Removal - Refitting) (72A, Side opening element trim),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the exterior door handle (see 51A, Side opening
element mechanisms, Door exterior handle:
Removal - Refitting, page 51A-4) .
127451
a Remove:
127452
51A-19
http://vnx.su
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Clip on the sliding side door lock control cable for the
sliding side door exterior door handle module.
a Refit the sliding side door lock - exterior door handle module assembly
a Clip on the sliding side door interior and exterior
opening control cables.
a Refit the sliding side door exterior door handle module.
a Connect the connector (2) .
a Refit the sliding side door lock.
127453
II - FINAL OPERATION.
WARNING
To avoid any risk of corrosion after the localised
stripping of the panel, reapply the protective coating (see Technical Note 0592A).
a Unclip the sliding side door interior and exterior opening control cables.
a Remove the sliding side door lock - exterior door
handle module assembly.
a Unclip the sliding side door lock control cable from
the sliding side door exterior door handle module.
a Refit the door exterior handle (see 51A, Side opening element mechanisms, Door exterior handle:
Removal - Refitting, page 51A-4) .
a Carry out a function test.
a Refit new door sealing film (see Door sealing film:
Removal - Refitting) (65A, Opening element sealing).
a Carry out a sealing test (see Technical Note 653A).
a Refit the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening
element trim).
51A-20
http://vnx.su
51A
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING + FIXED
WINDOW or R SLID+OPENING WINDOW
REMOVAL
I - REMOVAL PREPARATION OPERATION
Sliding side door exterior handle:
a Remove:
- the sliding side door trim (see Sliding side door
trim: Removal - Refitting) (72A, Side opening element trim),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the dummy lock.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
127459
127455
126456
51A-21
http://vnx.su
51A
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING + FIXED
WINDOW or R SLID+OPENING WINDOW
REFITTING
127457
127453
127456
51A-22
http://vnx.su
51A
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING + FIXED
WINDOW or R SLID+OPENING WINDOW
2 - Sliding side door interior handle:
a Clip:
- the sliding side door interior door handle cable,
- the sliding side door interior handle,
- the trim (4) .
III - FINAL OPERATION.
Sliding side door exterior handle:
a Fit the dummy lock.
a Carry out a function test.
a Refit new door sealing film (see Door sealing film:
Removal - Refitting) (65A, Opening element sealing).
a Carry out a sealing test (see Technical Note
0653A).
a Refit the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening
element trim).
51A-23
http://vnx.su
51A
REMOVAL
I - REMOVAL PREPARATION OPERATION
126859
126826
a Remove:
- the fuel filler cap,
- the bolts (1) ,
- the bolt (2) ,
- the fuel filler flap,
- the rear wheel arch trim (see Rear wheel arch
lining: Removal - Refitting) (71A, Bodywork interior trim),
- the sliding side door intermediate drive mechanism
(see 51A, Side opening element mechanisms,
Sliding side door carriage: Removal - Refitting,
page 51A-16) ,
- the sliding side door intermediate runner (see 51A,
Side opening element mechanisms, Sliding
side door tracks: Removal - Refitting, page 51A11) .
126858
a Remove:
- clip (4) ,
- the fuel filler flap mechanism.
51A-24
http://vnx.su
51A-25
http://vnx.su
51A
52A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the battery (see Battery : Removal - Refitting)
(80A, Battery)
- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),
- the air filter unit (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
- the bonnet catch (see 52A, Non-side opening element mechanisms, Bonnet latch: Removal - Refitting, page 52A-2) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126888
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the bonnet opening control cable.
a Refit the bonnet opening control (2) .
126319
a Remove the access flap (1) to the passenger compartment fuses and relay.
II - FINAL OPERATION.
a Refit the bonnet catch (see 52A, Non-side opening
element mechanisms, Bonnet latch: Removal Refitting, page 52A-2) .
a Carry out a function test.
a Refit:
- the access flap (1) to the passenger compartment
fuses and relays,
- the air filter unit (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),
- the battery (see Battery : Removal - Refitting)
(80A, Battery).
52A-1
http://vnx.su
52A
Tightening torquesm
bonnet catch bolts
21 Nm
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126887
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Clip on the bonnet opening release cable (2) .
126886
a Refit:
52A-2
http://vnx.su
52A
F61
REMOVAL
Note:
The upper and lower locks of the rear right-hand
loading door are removed independently.
142574
142575
WARNING
To prevent any risk of corrosion after stripping
the panel, reapply the anticorrosion protection
(see Technical Note 0592A).
a Remove the lock - exterior handle module assembly from the front side door box section.
a Unclip the loading door locking cable from the loading door exterior handle module.
52A-3
http://vnx.su
52A
F61
II - REFITTING OPERATION FOR PART
CONCERNED
a Unclip the locking cables for the upper lock (5) and
the lower lock (6) .
a Clip on the locking cables for the upper lock (5) and
the lower lock (6) .
a Remove:
- the bolts (7) ,
a Remove:
a Refit:
- the loading door exterior handle (see 52A, Nonside opening element mechanisms, Rear loading door exterior handle: Removal - Refitting,
page 52A-8) ,
52A-4
http://vnx.su
52A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a
Note:
In the event of an electric fault, it is possible to
open the loading door manually.
This operation is performed from inside the vehicle.
141002
52A-5
http://vnx.su
52A
140636
140635
140637
52A-6
http://vnx.su
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
140639
a Refit:
- the loading door lock onto its index (7) ,
- the loading door lock bolts (5) ,
- the cable in the lock actuator.
a Clip the cable stop in its housing.
a Connect the loading door lock connector (3) .
II - FINAL OPERATION
a Carry out a function test.
a Refit:
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the tailgate trim (see Tailgate lining: Removal Refitting) (73A, Non-side opening elements trim).
52A-7
http://vnx.su
52A
52A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the rear left-hand loading door trim (see Left-hand
rear loading door trim: Removal - Refitting)
(73A, Non-side opening elements trim),
- the dummy lock.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Rear loading door exterior handle module (viewed
from inside the door box section)
142572
REFITTING
I - REFITTING PREPARATION OPERATION
127455
142573
52A-8
http://vnx.su
52A
127457
a Activate the rear loading door exterior handle locking mechanism (5) .
a Lock the locking mechanism by pressing on the lever (6) .
127456
a Refit:
- the rear loading door exterior handle at (7) and at
(8) ,
- the dummy lock.
a Carry out a function test.
52A-9
http://vnx.su
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the tailgate trim (see Tailgate lining: Removal - Refitting) (73A, Non-side opening elements trim).
126473
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Connect the tailgate lock connector (2) .
a Refit the tailgate lock.
II - FINAL OPERATION.
a Refit the tailgate trim (see Tailgate lining: Removal
- Refitting) (73A, Non-side opening elements trim).
52A-10
http://vnx.su
52A
Tightening torquesm
lock bolts
2.5 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Open the panel of the upper rear opening element.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
138562
a Remove:
- the bolts (1) ,
- the lock of the upper rear opening element (2) .
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the lock of the upper rear opening element (2) ,
- the bolts (1) .
a Torque tighten the lock bolts (2.5 N.m).
II - FINAL OPERATION
a Carry out a function test.
52A-11
http://vnx.su
52A
52A
ROOF FLAP or PLASTIC ROOF FLAP or TINTED WINDOW ROOF FLAP, and HORIZONTAL OPENING DOOR
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Open the panel of the upper rear opening element.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
140631
a Remove:
- the bolts (1) ,
- the upper rear opening element locks (2) .
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the upper rear opening element locks (2) ,
- the bolts (1) .
II - FINAL OPERATION
a Carry out a function test.
52A-12
http://vnx.su
52A
STANDARD CHASSIS
Tightening torquesm
upper bolt of the rear
side seat belt
21 N.m
Note:
If it is necessary to remove the guide slide supports, make a mark before removing them.
REMOVAL
I - REMOVAL PREPARATION OPERATION
1 - Guide bar
SHORT CHASSIS
a Remove:
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim),
138563
141078
52A-13
http://vnx.su
52A
141079
141081
a Unclip the upper trim from the rear wheel arch (4) .
STANDARD CHASSIS
141080
a Remove:
- the rear side seat belt upper bolt (3) ,
- the rear seat belt return mechanism.
138584
a Remove:
- the bolts (5) ,
- the thread supports.
52A-14
http://vnx.su
52A
138583
140904
138582
a Remove:
- the clips (7) ,
140903
52A-15
http://vnx.su
52A
138581
140902
a Open the upper rear opening element panel midway and extract the upper rear opening element rails
at (11) .
a Support the upper rear opening element panel using
a block.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Guide bar
a Remove the struts of the upper rear opening element (see 52A, Non-side opening element mechanisms, Upper rear opening element strut:
Removal - Refitting, page 52A-22) .
a Open the panel of the upper rear opening element.
138580
138580
52A-16
http://vnx.su
52A
2 - Guide slide
II - FINAL OPERATION
1 - Guide bar
a Refit:
- the roof rear side trim,
- the clips (7) ,
- the rear centre trim (6) .
STANDARD CHASSIS
a Refit:
- the net supports,
141000
a Remove:
REFITTING
SHORT CHASSIS
I - REFITTING OPERATION FOR PART
CONCERNED
1 - Guide bar
a Refit the upper rear opening element mechanism.
a Tighten the bolts (13) of the upper rear opening element mechanism.
a Refit:
a Refit:
2 - Guide slide
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim).
a Refit:
- the guide slides,
52A-17
http://vnx.su
52A-18
http://vnx.su
52A
52A
REMOVAL
I - REMOVAL PREPARATION OPERATION
140902
140904
a Open the upper rear opening element panel midway and extract the upper rear opening element rails
at (4) .
a Support the upper rear opening element panel using
a block.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
140903
140901
a Remove:
- the nuts (5) from the upper rear opening element
rails,
52A-19
http://vnx.su
REFITTING
I - REFITTING PREPARATION OPERATION
140925
52A-20
http://vnx.su
52A
52A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a
WARNING
The strut is fitted in such a way as to prevent
leaks. Note the strut's direction of fitting (position
of the body and cylinder rod) before removing it,
in order to refit the strut identically.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126471
REFITTING
I - REFITTING PREPARATION OPERATION
a Position the clips (1) on the tailgate strut.
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit the tailgate strut (2) .
90920
52A-21
http://vnx.su
52A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Open the panel of the upper rear opening element.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
138560
REFITTING
I - REFITTING PREPARATION OPERATION
138559
52A-22
http://vnx.su
138561
52A-23
http://vnx.su
52A
52A
REMOVAL
140212
a Remove:
- the blanking covers (2) ,
- the nuts (3) ,
- the bolts (4) .
140216
140214
52A-24
http://vnx.su
52A
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
140213
a Refit:
- the rear lower section at (5) and then the rear upper
section of the rear opening element window winder
mechanism,
140218
a Refit:
52A-25
http://vnx.su
126472
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the tailgate exterior opening control.
a Connect the connector (1) .
II - FINAL OPERATION.
a Refit the tailgate trim (see Tailgate lining: Removal
- Refitting) (73A, Non-side opening elements trim).
52A-26
http://vnx.su
52A
52A
K61
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the sunroof mobile panel (see 52A, Nonside opening element mechanisms, Sunroof moving panel: Removal - Refitting, page 52A-32) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
140915
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the sealing pins (2) ,
140913
a Remove:
52A-27
http://vnx.su
52A
F61
REMOVAL
REFITTING
126883
52A-28
http://vnx.su
52A
K61
Essential equipment
diagnostic tool
cutting wire insertion tool
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
140922
a Protect the edge of the sunroof operating mechanism using 20 MM WINDSCREEN TAPE (see Vehicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbag and pretensioners).
a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
a Remove:
- the front section of the headlining (see Headlining:
Removal - Refitting) (71A, Body internal trim),
- the sunroof mobile panels (see 52A, Non-side
opening element mechanisms, Sunroof moving
panel: Removal - Refitting, page 52A-32) .
a Protect the vehicle interior.
52A-29
http://vnx.su
52A
K61
II - OPERATION FOR REMOVAL OF PART
CONCERNED
140986
140923
a Fit the cutting handles on the two sections of the cutting wire inside the vehicle.
a Cut the cement bead and leave the other handle in
place until it is needed.
a Insert:
- the cutting wire insertion tool at one end,
Note:
Note:
a Bond the sunroof operating mechanism (this operation requires two people).
Note:
52A-30
http://vnx.su
52A-31
http://vnx.su
52A
52A
K61
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
138610
a Remove:
- the bolts (4) ,
- the hinge supports (5) .
140910
REFITTING
140909
a Press the locking button (2) and pull the sunroof mobile panel at (3) .
a Remove the sunroof mobile panel by opening it
completely.
52A-32
http://vnx.su
WINDOWS
Windscreen: Removal - Refitting
54A
Universal protector
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing),
- the scuttle panel grille (see 56A, Exterior equipment, Scuttle panel grille: Removal - Refitting,
page 56A-1) ,
- the interior rear-view mirror (see 57A, Interior
equipment, Interior rear-view mirror Removal Refitting, page 57A-16) ,
- the rain and light sensor (see Rain and light sensor: Removal - Refitting) (85A, Wipers Washing),
108156
a
WARNING
When cutting the cement bead, take care not to
cut the wiring harness.
- the windscreen pillar trims (see A-pillar trim: Removal - Refitting) (71A, Body internal trim).
a Protect around the windscreen using masking tape.
Note:
When cutting the cement seal, protect the dashboard using the tool (Car. 1847).
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace:
- the shims,
- the rain and light sensor adhesive base (see Rain
and light sensor: Removal - Refitting) (85C, Wipers - Washing),
- the windscreen seal (1) .
126909
54A-1
http://vnx.su
WINDOWS
Windscreen: Removal - Refitting
II - REFITTING OPERATION FOR PART
CONCERNED
a Bond the windscreen (this operation requires two
people).
a Respect the following clearances and shut lines:
- windscreen - roof ,
- windscreen - A-pillar .
III - FINAL OPERATION.
a Refit:
- the windscreen pillar trims (see A-pillar trim: Removal - Refitting) (71A, Body internal trim),
- the rain and light sensor (see Rain and light sensor: Removal - Refitting) (85A, Wipers Washing),
- the interior rear-view mirror (see 57A, Interior
equipment, Interior rear-view mirror Removal Refitting, page 57A-16) ,
- the scuttle panel grille (see 56A, Exterior equipment, Scuttle panel grille: Removal - Refitting,
page 56A-1) ,
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing).
54A-2
http://vnx.su
54A
WINDOWS
Sliding window in front side door: Removal - Refitting
54A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim),
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the front side door exterior weatherstrip (see Front
door side exterior weather strip: Removal - Refitting) (66A, Window sealing),
- the front side door interior weatherstrip.
126916
REFITTING
II - FINAL OPERATION.
PAS ELEC ONE-TCH WIND SW
a Connect the front side door connector.
a Refit:
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio),
54A-3
http://vnx.su
WINDOWS
Sliding window in front side door: Removal - Refitting
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim).
54A-4
http://vnx.su
54A
WINDOWS
Sliding window in rear side door: Removal - Refitting
54A
LEFT SLIDING + OPENING WINDOW, and R SLID+OPENING WINDOW, and ELEC. REAR WINDOW SW.
REMOVAL
REFITTING
II - FINAL OPERATION.
a Remove:
a Refit:
- the fixed rear side door window (see 54A, Windows, Rear side door fixed window: Removal Refitting, page 54A-7) ,
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the window lift mechanism (see 51A, Side opening element mechanisms, Rear side door electric window mechanism: Removal - Refitting,
page 51A-8) ,
- the window lift mechanism (see 51A, Side opening element mechanisms, Rear side door electric window mechanism: Removal - Refitting,
page 51A-8) ,
- the fixed rear side door window (see 54A, Windows, Rear side door fixed window: Removal Refitting, page 54A-7) .
126913
54A-5
http://vnx.su
WINDOWS
Quarter panel light
54A
K61
REMOVAL
a Remove:
- the rear wheel arch trim (see Rear wheel arch
lining: Removal - Refitting) (71A, Body internal
trim),
- the rear quarter panel trim (see Rear quarter panel trim: Removal - Refitting) (71A, Body internal
trim).
a Protect the body around the rear quarter panel window using masking tape.
- the rear quarter panel trim (see Rear quarter panel trim: Removal - Refitting) (71A, Body internal
trim).
- the rear wheel arch trim (see Rear wheel arch
lining: Removal - Refitting) (71A, Body internal
trim).
126911
REFITTING
I - REMOVAL PREPARATION OPERATION
a Always replace the shims.
a For preparation and bonding (see Technical Note
560A).
54A-6
http://vnx.su
WINDOWS
Rear side door fixed window: Removal - Refitting
54A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Open the window halfway.
a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
a Remove:
- the sliding side door trim (see Sliding side door
trim: Removal - Refitting) (72A, Side opening element trim),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the rear side door exterior weatherstrip (see Rear
side door exterior weather strip: Removal - Refitting) (66A, Window sealing),
126912
a Remove:
- the bolts (2) ,
- the fixed window pillar from the rear side door (3) .
126914
127454
54A-7
http://vnx.su
WINDOWS
Rear side door fixed window: Removal - Refitting
ELEC. REAR WINDOW SW.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the fixed rear side door window (4) ,
- the fixed window pillar on the rear side door (3) .
a Clip the sliding window on the rear side door.
II - FINAL OPERATION.
a Refit:
- the rear side door electric window lift mechanism
(see 51A, Side opening element mechanisms,
Rear side door electric window mechanism:
Removal - Refitting, page 51A-8) ,
- the interior weatherstrip,
- the rear side door exterior weatherstrip (see Rear
side door exterior weather strip: Removal - Refitting) (66A, Window sealing).
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
a Carry out a function test.
a Refit new door sealing film (see Door sealing film:
Removal - Refitting) (65A, Opening element sealing).
a Carry out a sealing test (see Technical Note 653A).
a Refit the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening
element trim).
54A-8
http://vnx.su
54A
WINDOWS
Sliding side door window: Removal - Refitting
WITHOUT REAR WINDOW WINDER
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
127440
a Remove:
- the bolts (1) ,
- the sliding side door glass.
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Refit the sliding side door glass.
54A-9
http://vnx.su
54A
WINDOWS
Rear screen: Removal - Refitting
54A
K61
REMOVAL
REFITTING
a Remove:
- the tailgate trim (see Tailgate lining: Removal Refitting) (73A, Non-side opening elements trim),
- the rear screen wiper arm (see Rear screen wiper
arm: Removal - Refitting) (85A, Washing - Wiping),
- the rear screen wiper motor (see Rear screen wiper motor: Removal - Refitting) (85A, Wiping Washing).
a Refit:
126910
54A-10
http://vnx.su
WINDOWS
Opening rear screen: Adjusting
54A
Tightening torquesm
bolts on the rear loading door sliding window
8 N.m
Note:
Perform all manoeuvres on the rear loading door
sliding window with the vehicle engine running.
Note:
Close the rear loading door each time an adjustment is made to check the result.
140208
REMOVAL
141948
140996
54A-11
http://vnx.su
WINDOWS
Opening rear screen: Adjusting
54A
141949
140218
a Place the rear loading door sliding window at the dimensions shown: (X1) = 4.5 + /- 1.5 mm
a Place the rear loading door sliding screen at the dimensions shown. Once adjusted it must be located
in the adjustment range between 15 and 19 mm in
relation to the roof flap seal.
a Remove:
a Place three pieces of masking tape on the rear loading door sliding window and draw two lines 15 and
19mm from the top edge of the sliding window.
54A-12
http://vnx.su
WINDOWS
Rear loading door window: Removal - Refitting
54A
F61
REMOVAL
132064
132063
54A-13
http://vnx.su
WINDOWS
Rear loading door window: Removal - Refitting
F61
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the shims.
a For preparation and bonding (see Technical Note
560A).
II - REFITTING OPERATION FOR PART
CONCERNED
a Bond the rear loading door window.
a Equal out the clearances and shut lines.
III - FINAL OPERATION.
REAR LEFT-HAND LOADING DOOR
a Connect the connectors for the rear loading door
heated window wiring.
a Refit the rear screen wiper arm (see Rear screen
wiper arm: Removal - Refitting) (85A, Washing Wiping).
54A-14
http://vnx.su
54A
WINDOWS
Rear loading door window: Removal - Refitting
54A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the tailgate trim (see Tailgate lining: Removal Refitting) (73A, Non-side opening elements trim),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing).
a Lower the rear loading door window.
140205
140203
a Remove the exterior weatherstrip from the rear loading door at (2) using the tool (Car. 1363) and at (3) .
140206
54A-15
http://vnx.su
WINDOWS
Rear loading door window: Removal - Refitting
54A
140207
140208
a Remove the bolts (6) from the rear loading door window.
140209
140996
54A-16
http://vnx.su
WINDOWS
Rear loading door window: Removal - Refitting
K61, and SHORT CHASSIS
REFITTING
I - REFITTING PREPARATION OPERATION
140210
54A-17
http://vnx.su
54A
WINDOWS
Fixed roof window: Removal - Refitting
54A
Essential equipment
diagnostic tool
cutting wire insertion tool
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
140999
a Insert:
- the cutting wire insertion tool at one end,
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
Note:
Be careful to pass the cutting wire correctly
between the roof and the roof fixed window
frame.
Note:
The Parts Department sells the roof fixed window
assembled with its frame.
REMOVAL
Note:
When routing the cutting wire into the vehicle
interior, be careful not to cross the two wires, as
this would make cutting the seal impossible.
a Insert:
a Protect:
- the cutting wire insertion tool alongside the cutting wire already present,
- the cutting wire in the cutting wire insertion tool
towards the vehicle interior.
54A-18
http://vnx.su
WINDOWS
Fixed roof window: Removal - Refitting
54A
REFITTING
I - REFITTING PREPARATION OPERATION
a For preparation and bonding (see Technical Note
560A).
a Always replace the positioning shims.
II - REFITTING OPERATION FOR PART
CONCERNED
a Bond the fixed glass - fixed roof window frame
assembly(this operation requires two people).
a Adjust the clearances and flush fitting.
III - FINAL OPERATION
a Remove:
- the protection from the frame of the sunroof operating mechanism,
140997
a Fit the cutting handles on the two sections of the cutting wire inside the vehicle.
a Cut the cement bead and leave the other handle in
place until it is needed.
Note:
Reduce the length of the cutting wire as you cut.
138607
54A-19
http://vnx.su
WINDOWS
Fixed roof window: Removal - Refitting
54A
REMOVAL
140953
140926
140987
a
Note:
When removing and refitting the fixed roof glass,
avoid cutting the indexing pins (2) which are used
to correctly position the fixed roof glass.
a Cut the cement bead; (see Technical Note 560A)
(this operation requires two people).
a Remove the fixed roof glass.
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the shims.
a For preparation and bonding (see Technical Note
560A).
54A-20
http://vnx.su
WINDOWS
Fixed roof window: Removal - Refitting
K61, and SHORT CHASSIS
II - REFITTING OPERATION FOR PART
CONCERNED
a Bond the fixed roof glass.
a Equal out the clearances and shut lines.
III - FINAL OPERATION
a Remove the 20 MM WINDSCREEN TAPE.
a Refit the finishing seal.
54A-21
http://vnx.su
54A
EXTERIOR PROTECTION
Front bumper: Removal - Refitting
55A
FOG LIGHT
a Disconnect the fog light connector (4) .
126428
126427
55A-1
http://vnx.su
EXTERIOR PROTECTION
Front bumper: Removal - Refitting
126429
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the front bumper (this operation requires two
people).
a Clip on the front bumper.
II - FINAL OPERATION.
a Clip on the pipe (3) .
FOG LIGHT
a Connect the fog light connector (4) .
Carry out a function test.
a Refit the front wheel arch liners, front part (see 55A,
Exterior protection, Front wheel arch liner: Removal - Refitting, page 55A-19) .
a Clip on the radiator grille.
55A-2
http://vnx.su
55A
EXTERIOR PROTECTION
Front bumper: Stripping - Rebuilding
55A
STRIPPING
K61
I - STRIPPING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the front wheel arch liners, front part (see 55A, Exterior protection, Front wheel arch liner: Removal - Refitting, page 55A-19) ,
- the front bumper (see 55A, Exterior protection,
Front bumper: Removal - Refitting, page 55A-1)
.
FOG LIGHT
a Remove:
- the front bumper wiring (see Front bumper wiring: Removal - Refitting) (88A, Wiring),
- the front fog lights (see Front fog light: Removal Refitting) (80B, Headlights).
126434
126430
a Remove:
- the bolts (3) ,
- the diffuser.
126431
55A-3
http://vnx.su
EXTERIOR PROTECTION
Front bumper: Stripping - Rebuilding
55A
141226
132046
141227
55A-4
http://vnx.su
EXTERIOR PROTECTION
Front bumper: Stripping - Rebuilding
55A
141230
141228
REASSEMBLING
I - REBUILDING PREPARATION OPERATION
a parts always to be replaced: front bumper rivet
(50,05,02,18).
II - REBUILDING OPERATION FOR PART
CONCERNED
55A-5
http://vnx.su
EXTERIOR PROTECTION
Front bumper: Stripping - Rebuilding
K61
a Refit:
- the diffuser,
- the bolts (3) .
a Clip:
- the impact strips (2) ,
- the absorber (1) .
a Refit the front bumper (see 55A, Exterior protection, Front bumper: Removal - Refitting, page
55A-1) .
a Carry out a function test.
a Refit the front wheel arch liners, front part (see 55A,
Exterior protection, Front wheel arch liner: Removal - Refitting, page 55A-19) .
55A-6
http://vnx.su
55A
EXTERIOR PROTECTION
Rear bumper: Removal - Refitting
55A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove the rear wing lights (see Rear light on
wing: Removal - Refitting) (81A, Rear lighting).
126438
126436
126446
126438
55A-7
http://vnx.su
EXTERIOR PROTECTION
Rear bumper: Removal - Refitting
55A
132067
132066
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the rear bumper extension clips.
55A-8
http://vnx.su
EXTERIOR PROTECTION
Rear bumper: Stripping-Rebuilding
55A
STRIPPING
F61 or K61, and LONG CHASSIS or STANDARD
CHASSIS
126475
a Remove:
- the rear fog light (see Rear fog lights: Removal Refitting) (81A, Rear lighting),
- the rear bumper wiring (see Rear bumper wiring:
Removal - Refitting) (88A, Wiring).
126476
126474
a Remove:
- the bolts (1) ,
- the reflector.
55A-9
http://vnx.su
EXTERIOR PROTECTION
Rear bumper: Stripping-Rebuilding
55A
REASSEMBLING
K61, and SHORT CHASSIS, and OFF-ROAD
I - REBUILDING PREPARATION OPERATION
140989
a Refit:
- the reflector,
- the rear fog light (see Rear fog lights: Removal Refitting) (81A, Rear lighting),
- the rear bumper wiring (see Rear bumper wiring:
Removal - Refitting) (88A, Wiring).
PROXIMITY RADAR
a Refit the proximity radars (see Proximity radar Removal - Refitting) (87F, Parking distance control).
55A-10
http://vnx.su
EXTERIOR PROTECTION
Rear bumper: Stripping-Rebuilding
III - FINAL OPERATION
a Refit:
- the rear bumper (see 55A, Exterior protection,
Rear bumper: Removal - Refitting, page 55A-7) ,
- the rear wing lights (see Rear light on wing: Removal - Refitting) (81A, Rear lighting).
a Carry out a function test.
55A-11
http://vnx.su
55A
EXTERIOR PROTECTION
Front side door strip: Removal - Refitting
55A
REMOVAL
I - REMOVAL PREPARATION OPERATION
140948
140947
a Remove:
- the blanking cover (1) ,
- the bolt (2) .
140950
a Unclip the front side door strip using the tool (Car.
1363).
a Detach the front side door strip.
a The front side door strip must always be replaced.
55A-12
http://vnx.su
EXTERIOR PROTECTION
Front side door strip: Removal - Refitting
K61, and SHORT CHASSIS
REFITTING
I - REFITTING PREPARATION OPERATION
140949
55A-13
http://vnx.su
55A
EXTERIOR PROTECTION
Rear side door strip: Removal - Refitting
55A
REFITTING
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
140951
140952
a Unclip the rear side door strip using the tool (Car.
1363).
55A-14
http://vnx.su
EXTERIOR PROTECTION
Rear loading door strip: Removal - Refitting
55A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Open the rear loading door.
140628
a Remove:
- the rear screen wiper arm nut,
- the rear screen wiper arm using the tool (Ele.
1841).
a Disconnect the screen washer pipe from the rear
loading door, marking the direction of the T union.
140629
140630
55A-15
http://vnx.su
EXTERIOR PROTECTION
Rear loading door strip: Removal - Refitting
K61, and SHORT CHASSIS
140616
a Disconnect:
- the number plate light connectors (4) ,
- the brake lights connector (5) .
a Unclip the wiring from the rear loading door strip.
a Remove the rear loading door strip.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Clip the wiring onto the rear loading door strip.
a Connect:
- the brake lights connector (5) ,
- the number plate light connectors (4) .
a Clip on the rear loading door strip.
II - FINAL OPERATION
a Refit:
- the screen washer pipe for the rear loading door,
- the rear screen wiper arm,
- the rear screen wiper arm nut (2) .
a Clip on the blanking cover (1) .
a Carry out a function test.
55A-16
http://vnx.su
55A
EXTERIOR PROTECTION
Front side door moulding: Removal - Refitting
55A
REMOVAL
I - REMOVAL PREPARATION OPERATION
126441
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
126440
55A-17
http://vnx.su
EXTERIOR PROTECTION
Rear wing protective strip: Removal - Refitting
F61
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126477
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Clip on the rear wing protective strip (1) .
55A-18
http://vnx.su
55A
EXTERIOR PROTECTION
Front wheel arch liner: Removal - Refitting
55A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
Note:
It is not necessary to remove the front wheel to
remove the front wheel arch liner.
Note:
The front and rear parts of the front wheel arch
liner can be removed independently.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126444
a Remove:
- the clips (3) ,
- front wheel arch liner, rear section.
REFITTING
REFITTING OPERATION FOR PART CONCERNED
1 - Front wheel arch liner, front section
a Refit the front wheel arch liner, rear section.
2 - Front wheel arch liner, rear section
a Refit the front wheel arch liner in the rear section.
126443
a Remove:
- the bolt (1) ,
- the clips (2) ,
- front wheel arch liner, front section.
55A-19
http://vnx.su
EXTERIOR PROTECTION
Rear side door moulding: Removal - Refitting
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126442
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Clip on the rear side door protective strip (1) .
55A-20
http://vnx.su
55A
EXTERIOR PROTECTION
Rear wheel arch liner: Removal - Refitting
55A
126446
a Remove:
- the bolts (2) ,
- the rear wheel arch liner.
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Refit the rear wheel arch liner.
126445
55A-21
http://vnx.su
EXTERIOR EQUIPMENT
Scuttle panel grille: Removal - Refitting
56A
REMOVAL
I - REMOVAL PREPARATION OPERATION
126448
126447
a remove:
a Remove:
- the nuts (3) ,
REFITTING
I - REFITTING PREPARATION OPERATION
a Check the cleanliness of the windscreen and the
scuttle panel grille before refitting the scuttle panel
grille.
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit the scuttle panel grille (4) .
III - FINAL OPERATION.
a Refit the windscreen wiper arms (see Windscreen
wiper arm: Removal - Refitting) (85A, Wiping Washing).
a Carry out a function test.
a Refit:
- the seal (2) ,
- the trims (1) .
56A-1
http://vnx.su
EXTERIOR EQUIPMENT
Scoop under scuttle panel grille: Removal - Refitting
56A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing),
- the scuttle panel grille (see 56A, Exterior equipment, Scuttle panel grille: Removal - Refitting,
page 56A-1) ,
- the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing).
a Remove:
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
126449
a Remove:
56A-2
http://vnx.su
EXTERIOR EQUIPMENT
Scoop under scuttle panel grille: Removal - Refitting
II - FINAL OPERATION.
a Refit:
- the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing).
- the scuttle panel grille (see 56A, Exterior equipment, Scuttle panel grille: Removal - Refitting,
page 56A-1) ,
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing).
a Carry out a function test.
56A-3
http://vnx.su
56A
EXTERIOR EQUIPMENT
Door mirror: Removal - Refitting
56A
REMOVAL
I - REMOVAL PREPARATION OPERATION
126479
126478
a Remove:
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the door mirror (4) .
II - FINAL OPERATION.
a Connect the connector (2) (depending on equipment
level).
a Carry out a function test.
a Refit the trim (1) .
126479
56A-4
http://vnx.su
EXTERIOR EQUIPMENT
Door mirror casing: Removal - Refitting
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the door mirror glass (see 56A, Exterior
equipment, Door mirror glass: Removal - Refitting, page 56A-6) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126451
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Clip on the door mirror casing.
II - FINAL OPERATION.
a Refit the door mirror glass (see 56A, Exterior equipment, Door mirror glass: Removal - Refitting,
page 56A-6) .
56A-5
http://vnx.su
56A
EXTERIOR EQUIPMENT
Door mirror glass: Removal - Refitting
REFITTING
56A
REMOVAL
II - FINAL OPERATION.
a Carry out a function test.
126452
126453
56A-6
http://vnx.su
EXTERIOR EQUIPMENT
Rear badges: Removal - Refitting
2 - Fitting
56A
"KANGOO" badge
I - CONSTRUCTOR BADGE
1 - Removal
126877
2 - Refitting
a Clip on the manufacturer's badge (1) .
II - VEHICLE BADGE
1 - Refitting preparation operation
a Clean the adhesive surface of the vehicle badge
using a LINT-FREE CLOTH soaked in HEPTANE
(see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products).
a Wipe the adhesive surface of the vehicle badge with
a clean, dry LINT-FREE CLOTH.
56A-7
http://vnx.su
EXTERIOR EQUIPMENT
Rear badges: Removal - Refitting
F61
"RENAULT" badge
126878
56A-8
http://vnx.su
56A
EXTERIOR EQUIPMENT
Roof rack bar: Removal - Refitting
56A
K61
Roof bar front trim
Tightening torquesm
roof bar bolts
21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Put the roof bars in the transverse position.
132068
132069
a Unclip the roof bar trims using the tool (Car. 1363) at
(1) and (2) .
a Put the roof bars in the longitudinal position.
56A-9
http://vnx.su
EXTERIOR EQUIPMENT
Roof rack bar: Removal - Refitting
56A
K61
Roof bar front trim
132070
126455
a Remove:
- the bolts (3) ,
- the roof bar (4) .
REFITTING
I - REFITTING PREPARATION OPERATION
a Check the condition and cleanliness of:
- the roof bar,
- the roof,
- the support plates of the roof bar (replace them if
necessary).
132071
56A-10
http://vnx.su
EXTERIOR EQUIPMENT
Upper rear opening element strip: Removal - Refitting
56A
ROOF FLAP or PLASTIC ROOF FLAP or TINTED WINDOW ROOF FLAP, and HORIZONTAL OPENING DOOR
Essential special tooling
Car. 1363
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Open the panel of the upper rear opening element.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
140905
a Unclip the rear section of the upper rear opening element strip using the tool (Car. 1363).
140907
56A-11
http://vnx.su
EXTERIOR EQUIPMENT
Upper rear opening element strip: Removal - Refitting
56A
ROOF FLAP or PLASTIC ROOF FLAP or TINTED WINDOW ROOF FLAP, and HORIZONTAL OPENING DOOR
140906
140908
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the upper rear opening element strip.
a Clip on the rear section of the upper rear opening
element strip.
a Refit the bolts (1) .
II - FINAL OPERATION
a Close the upper rear opening element panel.
56A-12
http://vnx.su
INTERIOR EQUIPMENT
Dashboard: Removal - Refitting
57A
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
Essential equipment
diagnostic tool
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
- the control panel (see Control panel: Removal Refitting) (61A, Heating),
- the lower dashboard trim (see 57A, Interior equipment, Lower section of dashboard trim: Removal - Refitting, page 57A-4) (71A, Body internal
trim),
- the windscreen pillar trims (see A-pillar trim: Removal - Refitting) (71A, Body internal trim),
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
- the glovebox (see 57A, Interior equipment, Glovebox: Removal - Refitting, page 57A-9) .
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbags and pretensioners).
a Disconnect the battery (see Battery: Removal - Refitting) (81A, Battery).
a Remove:
- the driver's front airbag (see Driver's front airbag:
Removal - Refitting) (88C, Airbags and pretensioners),
- the steering wheel (see Steering wheel: Removal
- Refitting) (36A, Steering assembly),
- the steering column switch assembly (see Steering wheel controls assembly: Removal - Refitting) (84A, Control - Signals),
- the instrument panel (see Instrument panel: Removal - Refitting) (83A, Instrument panel),
- the radio (see Car radio: Removal - Refitting)
(86A, Radio) (depending on equipment level),
57A-1
http://vnx.su
INTERIOR EQUIPMENT
Dashboard: Removal - Refitting
57A
126857
126857
Mark the positions of the various wiring harnesses before removing the dashboard.
a Remove the dashboard (this operation requires two
people).
REFITTING
126497
57A-2
http://vnx.su
INTERIOR EQUIPMENT
Dashboard: Removal - Refitting
- the windscreen pillar trims (see A-pillar trim: Removal - Refitting) (71A, Body internal trim),
- the lower dashboard trim (see 57A, Interior equipment, Lower section of dashboard trim: Removal - Refitting, page 57A-4) (71A, Body internal
trim),
- the control panel (see Control panel: Removal Refitting) (61A, Heating),
- the display or the central glovebox (see Display:
Removal - Refitting) (86A, Radio) (depending on
equipment level),
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
- the radio (see Car radio: Removal - Refitting)
(86A, Radio),
- the instrument panel (see Instrument panel: Removal - Refitting) (83A, Instrument panel),
- the steering column switch assembly (see Steering wheel controls assembly: Removal - Refitting) (84A, Control - Signals),
- the steering wheel (see Steering wheel: Removal
- Refitting) (36A, Steering assembly),
- the driver's airbag (see Driver's front airbag: Removal - Refitting) (88C, Airbags and pretensioners).
a Connect the battery (see Battery: Removal - Refitting) (81A, Battery).
a Carry out a function test on all functions.
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (88C, Airbags and pretensioners).
57A-3
http://vnx.su
57A
INTERIOR EQUIPMENT
Lower section of dashboard trim: Removal - Refitting
57A
REMOVAL
LEFT-HAND DRIVE
I - REMOVAL PREPARATION OPERATION
a Remove:
- the radio (see Car radio: Removal - Refitting)
(86A, Radio),
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
- the front side door seal partially.
126849
126179
a Remove:
- the cover bolts (1) under the steering wheel,
- the covers under the steering wheel by pressing on
the clips (2) .
RIGHT-HAND DRIVE
a Remove the inhibitor switch (see Inhibitor switch:
Removal - Refitting) (88C, Airbags and pretensioners).
126830
a Remove:
- the bolts (4) ,
- the radio mounting.
57A-4
http://vnx.su
INTERIOR EQUIPMENT
Lower section of dashboard trim: Removal - Refitting
II - OPERATION FOR REMOVAL OF PART
CONCERNED
57A
RIGHT-HAND DRIVE
a Refit the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners).
a Refit:
- the cowlings under the steering wheel,
- the front side door seal,
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
- the radio (see Car radio: Removal - Refitting)
(86A, Radio).
126831
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Connect the connectors (depending on equipment
level).
a Clip on the dashboard lower trim.
II - FINAL OPERATION.
a Refit the radio mounting.
LEFT-HAND DRIVE
a Clip on the dashboard side panel (3) .
57A-5
http://vnx.su
INTERIOR EQUIPMENT
Dashboard air vent: Removal - Refitting
57A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Protect the dashboard around the air vents using
masking tape.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Dashboard centre air vent
126855
a Unclip the side dashboard air vent (2) using flatnosed pliers protected by masking tape.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
126856
a Unclip the centre dashboard air vent (1) using flatnosed pliers protected by masking tape.
57A-6
http://vnx.su
INTERIOR EQUIPMENT
Centre front panel: Removal - Refitting
57A
REMOVAL
I - REMOVAL PREPARATION OPERATION
126853
126851
126854
REFITTING
126852
57A-7
http://vnx.su
INTERIOR EQUIPMENT
Centre front panel: Removal - Refitting
II - FINAL OPERATION.
a Clip on the gear lever gaiter (1) .
57A-8
http://vnx.su
57A
INTERIOR EQUIPMENT
Glovebox: Removal - Refitting
57A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the front side door seal partially,
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) .
LEFT-HAND DRIVE
a Remove the inhibitor switch (see Inhibitor switch:
Removal - Refitting) (88C, Airbags and pretensioners).
RIGHT-HAND DRIVE
126850
a Remove:
- the bolts (2) ,
- the glovebox (3) .
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the glovebox (3) .
II - FINAL OPERATION.
126849
LEFT-HAND DRIVE
a Refit the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners).
RIGHT-HAND DRIVE
a Clip on the dashboard side panel (1) .
57A-9
http://vnx.su
INTERIOR EQUIPMENT
Glovebox: Removal - Refitting
a Refit:
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
- the front side door seal.
57A-10
http://vnx.su
57A
INTERIOR EQUIPMENT
Dashboard glovebox: Removal - Refitting
57A
F61
REMOVAL
RIGHT-HAND DRIVE
132047
126849
a Remove:
- the bolts (3) ,
- the dashboard storage compartment.
57A-11
http://vnx.su
INTERIOR EQUIPMENT
Dashboard glovebox: Removal - Refitting
F61
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the dashboard glovebox.
a Clip on the lower trim at (2) .
II - FINAL OPERATION.
LEFT-HAND DRIVE, and AIRBAG 01
a Refit the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners).
RIGHT-HAND DRIVE
a Clip on the dashboard side panel (1) .
a Refit:
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
- the front side door seal.
57A-12
http://vnx.su
57A
INTERIOR EQUIPMENT
Centre console: Removal - Refitting
57A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Move the front seats forward.
126846
126847
a Remove:
- the bolts (1) ,
- the central armrest at (2) and at (3) (depending on
equipment level).
126848
57A-13
http://vnx.su
INTERIOR EQUIPMENT
Centre console: Removal - Refitting
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the centre console.
a Connect the connectors (depending on equipment
level).
a Refit the trims (2) (depending on equipment level).
II - FINAL OPERATION.
a Refit the central armrest (depending on equipment
level).
57A-14
http://vnx.su
57A
INTERIOR EQUIPMENT
Floor flap and storage: Removal - Refitting
K61
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126841
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Clip on the floor storage flap.
57A-15
http://vnx.su
57A
INTERIOR EQUIPMENT
Interior rear-view mirror Removal - Refitting
57A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Unclip the small additional interior rear view mirror.
127387
127386
a Remove the rain and light sensor (see Rain and light sensor: Removal - Refitting) (85A, Wiping Washing) (depending on equipment level).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
127388
126837
57A-16
http://vnx.su
INTERIOR EQUIPMENT
Interior rear-view mirror Removal - Refitting
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
126836
57A-17
http://vnx.su
57A
INTERIOR EQUIPMENT
Sun visor: Removal - Refitting
57A
REMOVAL
REFITTING
126834
126835
a Remove:
- the bolt (2) ,
- the sun visor (3) .
57A-18
http://vnx.su
INTERIOR EQUIPMENT
Grab handle: Removal - Refitting
57A
REMOVAL
I - REMOVAL PREPARATION OPERATION
126833
REFITTING
126832
57A-19
http://vnx.su
INTERIOR EQUIPMENT
Front storage compartment under roof: Removal - Refitting
57A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the sun visors (see 57A, Interior equipment, Sun visor: Removal - Refitting, page 57A18) .
126829
117839
REFITTING
a Remove:
I - REFITTING OPERATION FOR PART
CONCERNED
57A-20
http://vnx.su
INTERIOR EQUIPMENT
Rear storage compartment: Removal - Refitting
57A
REMOVAL
REFITTING
126827
126827
a Remove:
126828
57A-21
http://vnx.su
INTERIOR EQUIPMENT
Separating components: Removal - Refitting
57A
F61
REMOVAL
I - REMOVAL PREPARATION OPERATION
132050
a Remove:
- the bolts (2) ,
- the nuts (3) ,
- the separation component (4) .
132058
132049
57A-22
http://vnx.su
INTERIOR EQUIPMENT
Separating components: Removal - Refitting
57A
F61
- the connection component (11) .
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or 1/3 STEEL PARTITION
PIVOTING PARTITION
132051
a Remove:
119772
132053
a Remove:
- the bolts (10) ,
57A-23
http://vnx.su
INTERIOR EQUIPMENT
Separating components: Removal - Refitting
57A
F61
TUBULAR PARTITION
132054
a Remove:
132055
132056
132059
a Remove:
- the nut (21) ,
57A-24
http://vnx.su
INTERIOR EQUIPMENT
Separating components: Removal - Refitting
57A
F61
132057
132060
REFITTING
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or 1/3 STEEL PARTITION
Note:
Always use STRUCTURAL ADHESIVE (see
Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products).
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or 1/3 STEEL PARTITION
57A-25
http://vnx.su
INTERIOR EQUIPMENT
Separating components: Removal - Refitting
F61
PIVOTING PARTITION
a Refit:
- the separation components (18) ,
- the mobile separation component (12) .
TUBULAR PARTITION
a Refit the separation component (22) .
II - FINAL OPERATION.
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or PIVOTING PARTITION
a Refit the B-pillar upper trim (see B-pillar upper
trim: Removal - Refitting) (71A, Body internal trim).
57A-26
http://vnx.su
57A
SAFETY ACCESSORIES
Belt height adjustment system: Removal - Refitting
59A
II - FINAL OPERATION.
a Refit:
Tightening torquesm
seatbelt height adjustment system bolt
21 Nm
- the B-pillar lower trim (see B-pillar lower trim: Removal - Refitting) (71A, Body internal trim).
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the B-pillar lower trim (see B-pillar lower trim: Removal - Refitting) (71A, Body internal trim),
- the B-pillar upper trim (see B-pillar upper trim:
Removal - Refitting) (71A, Body internal trim).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
127511
a Remove the bolt (1) from the seat belt height adjustment system.
a Remove (2) the seat belt height adjustment system.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Remove the seat belt height adjustment system.
a Torque tighten the seatbelt height adjustment
system bolt (21 Nm).
59A-1
http://vnx.su
Panelwork
40A
GENERAL INFORMATION
41A
41B
41C
41D
42A
43A
44A
45A
TOP OF BODY
47A
48A
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
http://vnx.su
KANGOO II - Section 4
Contents
Page
40A
40A-1
Sub-frame: Specifications
40A-4
40A-9
41A-3
41A-4
41A-6
41A-8
40A-12
40A-15
41A-11
40A-17
41A-15
40A-19
41A-17
40A-20
41A-20
40A-22
41A-21
41A-23
41A-24
41A-26
41A-27
41A-29
Structure components to be
positioned on body repair
bench: Description
41A
41A
GENERAL INFORMATION
40A-24
41A-1
41A-2
http://vnx.su
Contents
41A
41B
41A-30
41A-32
41A-33
41D-1
41D-2
41D-4
41D-6
41D-8
41B-1
41D-10
41B-3
41D-13
41B-6
41D-16
41D-17
41D-18
41D-20
41D-21
41C
41D
41B-8
41C-1
41C-4
41C-15
41D-22
41C-16
41D-23
41C-22
41D-24
41C-24
41C-28
41C-30
42A
http://vnx.su
42A-1
42A-3
42A-5
42A-8
Contents
42A
44A
42A-9
44A-1
44A-2
42A-10
42A-12
44A-28
42A-15
44A-34
42A-16
44A-35
42A-18
44A-38
42A-19
44A-39
44A-42
42A-21
44A-44
42A-22
44A-62
42A-23
45A
43A
TOP OF BODY
Roof: General description
45A-1
Roof: Description
45A-2
45A-5
45A-6
45A-7
45A-8
45A-9
43A-1
43A-5
43A-7
43A-8
B-pillar: Description
43A-9
B-pillar reinforcement:
General description
43A-15
B-pillar reinforcement:
Description
43A-16
43A-20
43A-22
http://vnx.su
45A-10
Contents
47A
48A
47A-1
47A-4
47A-6
47A-8
47A-12
47A-14
48A-1
48A-3
Bonnet: Adjustment
48A-4
48A-7
Tailgate: StrippingRebuilding
48A-10
Tailgate: Adjusting
48A-11
48A-14
48A-20
48A-26
48A-34
48A-36
http://vnx.su
GENERAL INFORMATION
Vehicle on repair bench: Description
40A
127213
The jig covers the rear bolt of the front subframe (A) .
40A-1
Note:
If it is suspected that one of these points may be
deformed, use two additional points located in an
area not affected by the impact in order to confirm
trim-setting.
http://vnx.su
GENERAL INFORMATION
Vehicle on repair bench: Description
40A
127213
The jig rests under the front side member and is centred on the hole (C) .
127210
Use this situation for a major front impact requiring replacement of the front subframe rear mounting unit.
The jig rests under the rear axle fork and is centred on
the rear axle assembly pilot hole (B) .
40A-2
http://vnx.su
GENERAL INFORMATION
Vehicle on repair bench: Description
40A
127217
The jig rests under the rear side member and is centred on tapped hole (B1) .
Use this situation for a rear impact with removal of the
mechanical components.
127217
The jig rests under the front side member rear section
and is positioned in the hole (M) .
Use this situation for a major rear impact when replacing the rear side member assembly.
It is also used to confirm the vehicle level if deformation
of a main rear reference point is suspected.
Note:
If it is suspected that one of these points may be
deformed, use two additional points located in an
area not affected by the impact in order to confirm
trim-setting.
40A-3
http://vnx.su
GENERAL INFORMATION
Sub-frame: Specifications
40A
STANDARD CHASSIS
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(Ag)
301
-305
77.8
24.5/M12
(Ad)
301
-305
77.8
24.5 x 29/M12
(B)
1952
-580.6
110
30
(B1)
2204.8
-522.4
110
M14 x 1.5
(B1)
2204.8
-522.4
104
M14 x 1.5
(Cg)
-141.5
-478
252
16.5/M12
(Cd)
-141.4
478
261
16.5/M12
(E)
2368.5
-534.6
252
15
(F1g)
-53.5
-602
702.2
15.5
(F1d)
-44
632.14
701.7
15.5
(F2g)
52.5
-529.7
687.2
15.5
(F2d)
-22.4
530
696.35
15.5
(F3g)
75.1
-632
687.1
15.5
(F3d)
84.4
601.8
685.29
15.5
(G)
547.5
-408.7
-9.8
20.5
(Hg)
-531
-475.5
50
M12
(Hd)
-531
492
50
M12
(J)
2891
-570.2
220.3
20 x 25
(K1g)
-553.7
-535.1
414.7
M10
(K1d)
-553.15
-542.5
414.8
M10
(K2g)
-557.6
-478.8
267.11
M10
(K2d)
-557.25
483.91
267.11
M10
(Lg)
3133
-565.22
155.1
M10
(Lg)
3133
575.22
155.1
40A-4
http://vnx.su
Angle
()
6.27
GENERAL INFORMATION
Sub-frame: Specifications
40A
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(L1)
3172.2
-513
225
M8
(L2)
3173.2
-570.67
135.08
M8
(M)
1772.6
171.6
(P1)
Engine mounting
-309.6
507
531.9
M10
(P2)
Engine mounting
-149.2
529
531.9
M10
(Q1)
Gearbox mounting
-238.4
-429.4
378
M10
(Q2)
Gearbox mounting
-118
-417.8
319.2
M10
Angle
()
20.5
SHORT CHASSIS
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(Ag)
301
-305
77.8
24.5/M12
(Ad)
301
-305
77.8
24.5 x 29/M12
(B)
1952
-580.6
110
30
(B1)
1820.8
-522.4
110
M14 x 1.5
(B1)
1820.8
-522.4
104
M14 x 1.5
(Cg)
-141.5
-478
252
16.5/M12
(Cd)
-141.4
478
261
16.5/M12
(E)
1984.5
-534.6
252
15
(F1g)
-53.5
-602
702.2
15.5
(F1d)
-44
632.14
701.7
15.5
(F2g)
52.5
-529.7
687.2
15.5
(F2d)
-22.4
530
696.35
15.5
(F3g)
75.1
-632
687.1
15.5
(F3d)
84.4
601.8
685.29
15.5
(G)
547.5
-408.7
-9.8
20.5
40A-5
http://vnx.su
Angle
()
6.27
GENERAL INFORMATION
Sub-frame: Specifications
40A
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(Hg)
-531
-475.5
50
M12
(Hd)
-531
492
50
M12
(J)
2507
-570.2
220.3
20 x 25
(K1g)
-553.7
-535.1
414.7
M10
(K1d)
-553.15
-542.5
414.8
M10
(K2g)
-557.6
-478.8
267.11
M10
(K2d)
-557.25
483.91
267.11
M10
(Lg)
2949
-565.22
155.1
M10
(Lg)
2949
575.22
155.1
(L1)
2788.2
-513
225
M8
(L2)
2789.2
-570.67
135.08
M8
(M)
1388.6
171.6
(P1)
Engine mounting
-309.6
507
531.9
M10
(P2)
Engine mounting
-149.2
529
531.9
M10
(Q1)
Gearbox mounting
-238.4
-429.4
378
M10
(Q2)
Gearbox mounting
-118
-417.8
319.2
M10
40A-6
http://vnx.su
20.5
Angle
()
GENERAL INFORMATION
Sub-frame: Specifications
40A
126949
40A-7
http://vnx.su
GENERAL INFORMATION
Sub-frame: Specifications
40A
126950
40A-8
http://vnx.su
GENERAL INFORMATION
Hollow body parts inserts: List and location of components
40A
126951
126953
126954
40A-9
http://vnx.su
GENERAL INFORMATION
Hollow body parts inserts: List and location of components
126955
126959
126958
40A
126957
40A-10
http://vnx.su
GENERAL INFORMATION
Hollow body parts inserts: List and location of components
126956
40A-11
http://vnx.su
40A
GENERAL INFORMATION
Earths on the body: List and location of components
40A
126951
40A-12
http://vnx.su
GENERAL INFORMATION
Earths on the body: List and location of components
40A
126952
126961
40A-13
http://vnx.su
GENERAL INFORMATION
Earths on the body: List and location of components
126964
126962
126963
40A
126962
40A-14
http://vnx.su
GENERAL INFORMATION
Vehicle front section structure: Description
40A
126966
No.
Description
Classification
Type
Thickness
(mm)
(1)
HLE
1.2
(2)
(3)
(see 41A, Front lower structure, Front side member: Description, page 41A-11)
(4)
(see 41A, Front lower structure, Front side member closure panel: Description, page 41A-17)
(5)
(see 41A, Front lower structure, Battery tray support: General description, page 41A-20)
(6)
(7)
Engine stand
(8)
40A-15
http://vnx.su
GENERAL INFORMATION
Vehicle front section structure: Description
Classification
Type
40A
No.
Description
Thickness
(mm)
(9)
Front half-unit
(10)
(11)
(12)
(13)
(see 42A, Front upper structure, Windscreen aperture lower cross member: Description, page 42A22)
40A-16
http://vnx.su
GENERAL INFORMATION
Vehicle side section structure: Description
40A
126968
No.
Description
Classification
(1)
(see 41C, Side lower structure, Sill panel: Description, page 41C-4)
(2)
(see 41C, Side lower structure, Sill panel reinforcement: Description, page 41C-24)
(3)
(4)
(5)
(see 41C, Side lower structure, Sill panel reinforcement: Description, page 41C-24)
(6)
(see 41C, Side lower structure, Sill panel: Description, page 41C-4)
(7)
(see 41C, Side lower structure, Sill panel rear reinforcement: Description, page 41C-28)
(8)
40A-17
http://vnx.su
Type
Thickness
(mm)
GENERAL INFORMATION
Vehicle side section structure: Description
Classification
No.
Description
(9)
A-pillar reinforcement
(see 43A, Side upper structure, A-pillar reinforcement: Description, page 43A-5)
(10)
(11)
(see 43A, Side upper structure, A-pillar lining stiffener: Description, page 43A-8)
(12)
A-pillar
(13)
A-pillar reinforcement
(see 43A, Side upper structure, A-pillar reinforcement: Description, page 43A-5)
40A-18
http://vnx.su
Type
40A
Thickness
(mm)
GENERAL INFORMATION
Vehicle central section structure: Description
40A
126967
No.
Description
Classification
Type
Thickness
(mm)
(1)
(2)
(3)
(4)
Roof
(5)
(6)
(7)
(see 45A, Top of body, Roof panel arch: Description, page 45A-9)
(8)
40A-19
http://vnx.su
GENERAL INFORMATION
Vehicle structure rear section: Description
40A
126969
No.
Description
Classification
Type
Thickness
(mm)
(1)
Rear floor
(see 41D, Rear lower structure, Rear floor: Description, page 41D-2)
(2)
(3)
(see 41D, Rear lower structure, Rear floor stiffener: Description, page 41D-8)
(4)
(5)
(6)
(7)
(8)
(see 41D, Rear lower structure, Front cross member under rear seat: Description, page 41D-21)
(see 41D, Rear lower structure, Rear side member:
Description, page 41D-13)
(see 41D, Rear lower structure, Rear floor centre
cross member: Description, page 41D-17)
40A-20
http://vnx.su
GENERAL INFORMATION
Vehicle structure rear section: Description
Classification
Type
40A
No.
Description
Thickness
(mm)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
B-pillar
(21)
40A-21
http://vnx.su
GENERAL INFORMATION
Vehicle removable section structure: Description
40A
126965
No.
Description
Classification
Type
Thickness
(mm)
(1)
(2)
(3)
Front wing
(4)
(5)
(6)
(7)
(8)
Bonnet
40A-22
http://vnx.su
GENERAL INFORMATION
Vehicle removable section structure: Description
Classification
No.
Description
(9)
Tailgate
(10)
(see 48A, Non-side opening elements, Rear loading door: Removal - Refitting, page 48A-14)
40A-23
http://vnx.su
Type
40A
Thickness
(mm)
GENERAL INFORMATION
Structure components to be positioned on body repair bench: Description
40A
127212
40A-24
http://vnx.su
GENERAL INFORMATION
Structure components to be positioned on body repair bench: Description
40A
127213
The jig rests against the rear section of the side member and is centred in the sub-frame rear mounting hole.
127214
IMPORTANT
This/these point/s help(s) to ensure axle geometry.
IMPORTANT
This/these point/s help(s) to ensure axle geometry.
127214
40A-25
http://vnx.su
GENERAL INFORMATION
Structure components to be positioned on body repair bench: Description
40A
5 - Gearbox mounting
127214
127216
The jig rests on the engine and is centred on the engine mounting holes (P1) and (P2) .
The jig is used with the subframe removed for the replacement of:
- a front half unit.
- the engine mounting.
127215
The jig rests under the shock absorber cup and is centred on the shock absorber head mounting holes (F) .
The jig is used to replace:
- a wheel arch,
- a front half unit.
40A-26
http://vnx.su
GENERAL INFORMATION
Structure components to be positioned on body repair bench: Description
40A
IMPORTANT
This/these point/s help(s) to ensure axle geometry.
7 - Rear axle assembly front mounting
127218
The jig rests under the rear side member and is centred on the hole (J) .
The jig is used:
- to realign a rear side member with the mechanical
components in place,
127217
IMPORTANT
This/these point/s help(s) to ensure axle geometry.
127218
40A-27
http://vnx.su
GENERAL INFORMATION
Structure components to be positioned on body repair bench: Description
The jig rests vertically against the side lining of the rear
end panel and is centred on the rear impact lower
cross member mounting holes (L1) and (L2) and under
the cross member mounting reinforcements. (L)
The jig is used to replace the rear end panel and the
rear impact cross member mounting reinforcement.
40A-28
http://vnx.su
40A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
110517
41A-1
http://vnx.su
41A
41A
II - FINAL OPERATION.
REMOVAL
a Refit:
I - REMOVAL PREPARATION
a Partially remove the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting) (55A,
Exterior protection).
a Remove:
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
- the headlights (see Front headlight: Removal Refitting) (80B, Headlights),
127529
a Remove:
- the bolts (1) ,
- the front impact cross member (2) .
REFITTING
I - REFITTING
a Refit:
- the front impact cross member,
- the bolts (1) .
41A-2
http://vnx.su
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading this general information, check that
there are no special notes associated with this vehicle. These special notes will be specified if applicable in other parts of this subsection dealing with the
part.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
110077
This steel part, which bolts onto the front axle subframe, combines two functions:
- distribution of front impact forces,
- radiator support cross member.
41A-3
http://vnx.su
41A
41A
II - REMOVAL
Tightening torquesm
F61, and K4M or K7M or K9K
radiator mounting cross
member nut
21 Nm
62 Nm
106 Nm
106 Nm
REMOVAL
I - REMOVAL PREPARATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection),
127760
a Remove:
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
41A-4
http://vnx.su
41A
REFITTING
I - REFITTING
127650
a Remove:
- the radiator mounting cross member bolts (2) ,
- the radiator mounting cross member.
F61, and K4M or K7M or K9K
a Refit the radiator mounting cross member.
a Torque tighten the radiator mounting cross member bolts (106 Nm) (1) .
II - FINAL OPERATION.
a Detach the radiator.
a Refit:
- the engine undertray,
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
127652
a Remove:
41A-5
http://vnx.su
41A
128606
126971
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
41A-6
No.
Description
Type
Thickness
(mm)
(1)
Radiator cross
member mounting unit
HLE
1.2
(2)
Closure panel of
the front impact
cross member
mounting unit
THLE
2.5
(3)
Interior closure
panel of radiator
cross member
mounting
HLE
1.2
http://vnx.su
41A
II - PART FITTED
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
126970
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
126960
41A-7
http://vnx.su
41A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
110510
1 - Cut 1:
I - DESIGN OF THE STRUCTURAL COMPONENT
This line shows the centre of the area in which it is possible to carry out a partial replacement.
This operation allows you to access the inside of the
hollow section of the structural element to straighten it.
Note:
For the partial replacement of parts constituting a
single structural component, it is essential to stagger the welds of each of the components.
In this case, the side member weld line must be staggered from that of its closure panel.
110509
The special feature of this type of part is that it combines the functions of front section and rear section of
the front side member and that it is made of two different kinds of panels of different thicknesses assembled
by laser butt welding.
41A-8
http://vnx.su
2 - Cut 2:
The cut is made along the butt weld.
41A
130093
130095
130094
130096
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
41A-9
http://vnx.su
110511
41A-10
http://vnx.su
41A
41A
Right-hand side
Left side
127236
Left side
126972
No.
Description
Type
Thickness
(mm)
(1)
HLE/
THLE
1.67/2.5
(2)
Mild
steel
1.5/2
(3)
Front mounting of
front sub-frame
HLE
1.2
(4)
Front subframe
rear mounting
HLE
(5)
Interior closure
panel component of radiator
cross member
mounting
HLE
1.2
(6)
Closure panel
component of
front
impact
cross member
mounting unit
VHEL
2.5
127237
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
41A-11
http://vnx.su
41A
II - PART FITTED
1 - Partial replacement of the front end section
126978
No.
Description
Type
Thickness
(mm)
126976
Cut
(1)
HLE/
THLE
1.67/2.5
(3)
Front mounting of
front sub-frame
HLE
1.2
(4)
Front subframe
rear mounting
HLE
(5)
Interior closure
panel component of radiator
cross member
mounting
HLE
1.2
(6)
Closure panel
component of
front
impact
cross member
mounting unit
VHEL
2.5
(7)
Bulkhead cross
member righthand bracket
Mild
steel
1.47
(8)
Engine stand
HLE/
Mild
steel
1.47/2
126977
41A-12
http://vnx.su
41A
126975
126979
Note:
When cutting, do not damage the rear reinforcement (A) .
Left side
Note:
For a detailed description of the welded connections, see MR 400.
126973
41A-13
http://vnx.su
126960
126961
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41A-14
http://vnx.su
41A
41A
Note:
For the replacement of parts constituting a single
structural component, it is essential to stagger the
welds of each of the components
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes relating
to the vehicle. These special notes are specified if
applicable in other parts of this subsection dealing
with the component.
Note:
For a description of a particular connection, see MR
400.
Left side
127234
1 - Cut 1:
127234
126980
41A-15
http://vnx.su
126982
This line shows the centre of the area in which it is possible to carry out a partial replacement.
This operation allows you to access the inside of the
hollow section of the structural component to straighten it.
41A-16
http://vnx.su
41A
41A
Right-hand side
127235
115111
Left side
No.
Description
Type
Thickness
(mm)
(1)
HLE/
THLE
1.7/2.5
(2)
Interior closure
panel of radiator
cross member
mounting
HLE
1.2
(3)
Front subframe
front mounting
unit
HLE
1,7
(4)
Reinforcement
bracket
Mild
steel
1.2
(5)
Front subframe
front mounting
support
Mild
steel
127234
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
41A-17
http://vnx.su
41A
Complete replacement
II - PART FITTED
Partial replacement of the front section
126980
126982
Cut
Cut
126981
126983
Note:
For a detailed description of the welded connections, see MR 400.
41A-18
http://vnx.su
WARNING
Respect the position of this cut which has been
determined in accordance with the position of the
inner stiffeners or acoustic inserts, in order to prevent damaging the parts (inner stiffener and/or
acoustic insert).
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
126960
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41A-19
http://vnx.su
41A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part. Before reading
the following general information, make sure that
there are no special notes associated with the vehicle. These special notes are specified if necessary
in other parts of the sub-section dealing with the
component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
101415
41A-20
http://vnx.su
41A
41A
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
1.5
(2)
Mild
steel
(3)
Mild
steel
1.2
II - PART FITTED
101415
128394
WARNING
If the mating faces of the parts to be welded are not
accessible, use GMAW plug welds in place of the
original electrical resistance welds (see MR 400).
128395
41A-21
http://vnx.su
126960
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
41A-22
http://vnx.su
41A
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
101422
41A-23
http://vnx.su
41A
41A
No.
Description
Type
Thickness
(mm)
(1)
Front support of
front subframe
HLE
1.5
(2)
Front support
reinforcement of
front subframe
HLE
2.5
II - PART FITTED
128393
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
I - COMPOSITION OF THE SPARE PART
128392
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
128393
41A-24
http://vnx.su
126960
Right-hand side
126961
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
41A-25
http://vnx.su
41A
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
41A
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading this general information, check that
there are no special notes associated with this vehicle. These special notes will be specified if applicable in other parts of this subsection dealing with the
part.
110489
41A-26
http://vnx.su
41A
No.
Description
Type
Thickness
(mm)
(1)
Sub-frame rear
mounting reinforcement
Very
high
yield
strengt
h
(2)
Sub-frame
mounting
HEL
rear
II - PART FITTED
127238
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
I - COMPOSITION OF THE SPARE PART
128390
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
128391
41A-27
http://vnx.su
126961
Left-hand side
126960
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
41A-28
http://vnx.su
41A
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading this general information, check that
there are no special notes associated with this vehicle. These special notes will be specified if applicable in other parts of this subsection dealing with the
part.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
102623
41A-29
http://vnx.su
41A
41A
No.
Description
Type
Thickness
(mm)
(1)
Engine mounting
rear section
HLE
1.5
(2)
Engine mounting
upper section
HLE
(3)
Engine mounting
height adjuster
reinforcement
Mild
steel
1.97
(4)
Engine mounting
rear reinforcement
HLE
II - PART FITTED
127240
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
I - COMPOSITION OF THE SPARE PART
127530
Note:
For a detailed description of the welded connections, see MR 400.
127531
41A-30
http://vnx.su
126961
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41A-31
http://vnx.su
41A
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
127232
The special feature of this type of part is that it combines the functions of front side member, front wheel
arch, centre floor front side cross member and front
end side cross member, and is made up of several panels of different types and thicknesses.
41A-32
http://vnx.su
41A
41A
Right-hand side
Right-hand side
127232
Left-hand side
126984
No.
Description
Type
Thickness
(mm)
(1)
Front subframe
front
s u p p o rt
reinforcement
HLE
2.5
(2)
Exterior closure
panel component of radiator
cross member
mounting
HLE
1.2
(3)
Front right-hand
side member closure panel
HLE THLE
1.7/2.5
(4)
Closure panel
component of
front
impact
cross member
mounting unit
Very
high
yield
strengt
h
2.5
(5)
Engine stand
HLE Mild
steel
1.47/2
(6)
Front right-hand
side member
HLE THLE
1.67/2.5
127233
41A-33
http://vnx.su
41A
No.
Description
Type
Thickness
(mm)
No.
Description
Type
Thickness
(mm)
(7)
Radiator cross
member support
unit
HLE
1.2
(3)
Front right-hand
side member closure panel
HLE THLE
1.7/2.5
(8)
Front mounting of
front sub-frame
HLE
1.2
(4)
THLE
2.5
(9)
Front subframe
rear mounting
HLE
Closure panel
component of
front
impact
cross member
mounting unit
(10)
Bulkhead cross
member righthand bracket
Mild
steel
1.47
(6)
Front left-hand
side member
HLE THLE
1.67/2.5
(7)
Radiator cross
member support
unit
HLE
1.2
(8)
Front mounting of
front sub-frame
HLE
1.2
(9)
Front subframe
rear mounting
HLE
(11)
Mild
steel
1.5/2
Left-hand side
II - PART FITTED
Complete replacement
Left-hand side
126986
No.
Description
Type
Thickness
(mm)
(1)
Front subframe
front
s u p p o rt
reinforcement
HLE
2.5
(2)
Exterior closure
panel component of radiator
cross member
mounting
HLE
1.2
126985
41A-34
http://vnx.su
41A
126960
126961
41A-35
http://vnx.su
41B
Note:
For a detailed description of a particular connection, (see MR 400).
I - DESIGN OF THE STRUCTURAL COMPONENT
110541
This cutting line (4) affects the option of partially replacing the centre floor side section.
III - ASSEMBLY METHOD FOR A PARTIAL
REPLACEMENT
Only the connections which are specific to the partial
replacement by cutting are indicated.
WARNING
If the spot welds cannot be made as they were originally using an electrical spot welding machine,
they should be replaced with plug welds after holes
have been drilled in the first panel.
110540
If there are other issues regarding access to mating faces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400, 40A, General Information).
41B-1
http://vnx.su
110542
41B-2
http://vnx.su
41B
41B
II - PART FITTED
Partial replacement of the front section
127242
No.
Description
Type
Thickness
(mm)
(1)
HLE
0.7
127082
41B-3
http://vnx.su
41B
Complete replacement
127079
Note:
For a detailed description of the welded connections, see (MR 400).
126962
41B-4
http://vnx.su
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41B-5
http://vnx.su
41B
127243
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.5
(2)
HLE
1.5
(3)
HLE
1.5
(4)
HLE
1.5
(5)
HLE
(6)
HLE
(7)
HLE
1.5
(8)
HLE
1.5
(9)
Centre
member
side
VHEL
(10)
Centre
side
member reinforcement
UHLE
2.5
127084
41B-6
41B
http://vnx.su
41B
II - PART FITTED
Partial replacement
126962
127085
Complete replacement
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
127083
Note:
For a detailed description of the welded connections, (see MR 400).
41B-7
http://vnx.su
41B
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.17
(2)
1.47
(3)
VHEL
(4)
Jacking
support
HLE
1.8
point
II - PART FITTED
127244
Partial replacement
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
127086
Note:
The cut is made at the end of the front side member.
127087
41B-8
http://vnx.su
102000
Note:
For a detailed description of the welded connections, (see MR 400).
41B-9
http://vnx.su
41B
41C
Note:
For a detailed description of a particular connection, (see MR 400).
I - DESIGN OF THE STRUCTURAL COMPONENT
110580
The lines (1) , (2) and (3) mark the cutting areas for the
complete replacement of the sill panel.
III - AREA TO BE CUT FOR PARTIAL
REPLACEMENT
122757
110582
The lines (1) and (4) mark the areas for the partial replacement of the front of the sill panel.
41C-1
http://vnx.su
41C
110578
110574
The lines (3) and (5) mark the cutting areas for the partial replacement of the rear of the sill panel.
110576
110572
The lines (4) and (8) mark the cutting areas for the partial replacement of the sill panel section under the door.
41C-2
http://vnx.su
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
If there are other issues regarding access to mating faces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400).
110575
Lines (1) , (2) and (5) on the drawing show a butt weld
by continuous EGW welding.
The welds described in this procedure are all identical.
41C-3
http://vnx.su
41C
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
I - COMPOSITION OF THE SPARE PART
127245
When replacing this part, also order the B-pillar reinforcement insert, A-pillar reinforcement insert and the sill
panel rear reinforcement insert (see 40A, General information, Hollow body parts inserts: List and location of components, page 40A-9) .
127088
No.
Description
Type
Thickness
(mm)
(1)
Sill panel
Mild
steel
0.75
(2)
Mild
steel
(3)
Upper closure
panel for bottom
rail unit
Mild
steel
0.75
(4)
Lower closure
panel for bottom
rail unit
Mild
steel
0.75
41C-4
http://vnx.su
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
II - PART FITTED
1 - Partial replacement of the front section
127093
Cut A
Cut B
127092
41C-5
http://vnx.su
127094
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
2 - Rear section replacement
127095
Cut C
Cut D
127097
41C-6
http://vnx.su
127096
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Cut E
3 - Complete replacement
127091
127089
41C-7
http://vnx.su
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Note:
For a detailed description of the welded connections, see (MR 400).
41C-8
http://vnx.su
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
127246
When replacing this part, also order the B-pillar reinforcement insert, A-pillar reinforcement insert, and the sill
panel rear reinforcement insert (see 40A, General information, Hollow body parts inserts: List and location of components, page 40A-9) .
The options for replacing this part are as follows:
- partial replacement under door:
- partial replacement of the front section,
- partial replacement of the rear section,
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
Description
Type
Thickness
(mm)
(1)
Sill panel
Mild
steel
0.75
41C-9
http://vnx.su
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
II - PART FITTED
1 - Partial replacement under door
127105
Cut A
Cut B
127104
41C-10
http://vnx.su
127102
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
2 - Partial replacement of the front section
127101
Cut C
127100
41C-11
http://vnx.su
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
3 - Partial replacement of the rear section
127103
41C-12
http://vnx.su
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Cut F
127099
Note:
For a detailed description of the welded connections, see (MR 400).
41C-13
http://vnx.su
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
4 - Complete replacement
127098
Note:
For a detailed description of the welded connections, see (MR 400).
41C-14
http://vnx.su
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading this general information, check that
there are no special notes associated with this vehicle. These special notes will be specified if applicable in other parts of this subsection dealing with the
part.
Note:
For a detailed description of a particular connection, (see MR 400).
124602
This is a basic part; its only function is that of a sill panel closure panel.
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
If there are other issues regarding access to mating faces, the various options are described in the basic instructions for structural bodywork repair (see MR 400).
41C-15
http://vnx.su
41C
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
127350
No.
Description
Type
Thickness
(mm)
(1)
HLE
0.9
41C-16
http://vnx.su
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
II - PART FITTED
Complete replacement
127106
Detailed view A
Detailed view B
127108
41C-17
http://vnx.su
127107
41C
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Partial replacement of the front section
127109
Detailed view C
127110
Note:
For a detailed description of the welded connections, see (MR 400).
41C-18
http://vnx.su
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
127248
No.
Description
Type
Thickness
(mm)
(1)
HLE
0.9
41C-19
http://vnx.su
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
II - PART FITTED
Complete replacement
127111
Detailed view A
Detailed view B
127112
41C-20
http://vnx.su
127113
41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Partial replacement of the front section
127114
126962
Detailed view C
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
127115
Note:
For a detailed description of the welded connections, see (MR 400).
41C-21
http://vnx.su
41C
II - PART FITTED
Complete replacement
127247
127403
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.2
Note:
For a detailed description of the welded connections, see (MR 400).
126962
41C-22
http://vnx.su
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41C-23
http://vnx.su
41C
41C
II - PART FITTED
Partial replacement of the front section
127250
Detailed view A
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
Description
Type
Thickness
(mm)
(1)
VHEL
0.9
127119
41C-24
http://vnx.su
41C
Detailed view B
127121
127118
41C-25
http://vnx.su
41C
Detailed view C
127123
Complete replacement
127122
41C-26
http://vnx.su
Note:
For a detailed description of the welded connections, see (MR 400).
III - POSITION OF LOCAL ELECTRICAL EARTHS
126962
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41C-27
http://vnx.su
41C
41C
II - PART FITTED
Complete replacement
127251
127124
Note:
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.9
126964
Disconnect the electrical earth (2) from the front section of the rear wheel arch liner.
41C-28
http://vnx.su
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41C-29
http://vnx.su
41C
41C
II - PART FITTED
Complete replacement
127249
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.2
Detailed view A
127117
Note:
For a detailed description of the welded connections, see (MR 400).
41C-30
http://vnx.su
126962
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41C-31
http://vnx.su
41C
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following information, make sure
that there are no special notes associated with the
vehicle. These special notes are specified if necessary in other parts of the sub-section dealing with
the component.
Note:
For a detailed description of welded connections,
see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
127254
41D-1
http://vnx.su
41D
41D
II - PART FITTED
Partial replacement
127254
- partial replacement,
- complete replacement.
Cut
No.
Description
Type
Thickness
(mm)
(1)
Rear floor
HLE
0.75
127127
41D-2
http://vnx.su
41D
Complete replacement
127125
Note:
126964
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
126963
41D-3
http://vnx.su
41D
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
Note:
For a detailed description of a particular connection, see MR 400.
If there are other issues regarding access to mating faces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400).
127255
41D-4
http://vnx.su
41D
110650
41D-5
http://vnx.su
41D
F61
(2)
HLE
0.8
(3)
HLE
0.8
II - PART IN POSITION
127255
127128
Note:
For a detailed description of the welded connections, see MR 400.
127129
No.
Description
Type
Thickness
(mm)
(1)
Front section of
rear floor
HLE
0.75
41D-6
http://vnx.su
126962
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41D-7
http://vnx.su
41D
41D
II - PART FITTED
127256
127130
No.
(1)
Description
Type
VHEL
Thickness
(mm)
0.8
126963
41D-8
http://vnx.su
126964
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41D-9
http://vnx.su
41D
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
41D
Note:
For a detailed description of a particular connection, see MR 400.
I - DESIGN OF THE STRUCTURAL COMPONENT
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading this general information, check that
there are no special notes associated with this vehicle. These special notes will be specified if applicable in other parts of this subsection dealing with the
part.
110631
41D-10
http://vnx.su
41D
110632
Cut 1:
This line marks the area in which it is possible to make
a partial replacement.
III - ASSEMBLY INSTRUCTIONS FOR A PARTIAL
REPLACEMENT
Only the connections which are specific to the partial
replacement by cutting are indicated.
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
If there are other issues regarding access to mating faces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400).
41D-11
http://vnx.su
41D
110633
41D-12
http://vnx.su
41D
127252
127136
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
No.
Description
Type
Thickness
(mm)
(1)
Rear
shock
absorber spacer
(2)
Rear
shock
absorber spacer
support
VHEL
1.8
(3)
HLE
1.5
(4)
HLE
1.2
(5)
Rear
impact
cross member
mounting reinforcement
VHEL
1,7
Note:
If replacing the complete rear side member, do not
damage the rear axle mounting reinforcement.
41D-13
http://vnx.su
41D
Complete replacement
II - PART FITTED
Partial replacement of the rear section
127133
127137
Detailed view A
Cut
127134
127138
41D-14
http://vnx.su
127135
Note:
If replacing the complete rear side member, do not
damage the rear axle mounting reinforcement.
Note:
For a detailed description of the welded connections, see MR 400.
41D-15
http://vnx.su
41D
41D
II - PART FITTED
Complete replacement
127253
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
Description
Type
Thickness
(mm)
(1)
Rear
impact
cross member
mounting reinforcement
VHEL
1.5
Note:
For a detailed description of the welded connections, see MR 400.
41D-16
http://vnx.su
41D
II - PART FITTED
Complete replacement
127259
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
Description
Type
Thickness
(mm)
(1)
HLE
Note:
For a detailed description of the welded connections, see MR 400.
41D-17
http://vnx.su
41D
II - PART FITTED
Complete replacement
127261
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
(1)
Description
Type
HLE
Thickness
(mm)
1.5
Note:
For a detailed description of the welded connections, see MR 400.
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
126963
41D-18
http://vnx.su
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41D-19
http://vnx.su
41D
41D
II - PART FITTED
127262
127141
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.5
41D-20
http://vnx.su
No.
Description
Type
Thickness
(mm)
(1)
VHEL
(2)
HLE
(3)
HLE
(4)
HLE
(5)
HLE
(6)
HLE
127258
41D
II - PART FITTED
127132
127131
Note:
For a detailed description of the welded connections, see MR 400.
41D-21
http://vnx.su
41D
No.
Description
Type
Thickness
(mm)
(1)
HLE
(2)
HLE
1.2
(3)
HLE
1.2
II - PART FITTED
127257
127142
Note:
For a detailed description of the welded connections, see MR 400.
127143
41D-22
http://vnx.su
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
101411
41D-23
http://vnx.su
41D
41D
II - FINAL OPERATION.
REMOVAL
a Refit:
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
- the rear bumper (see Rear bumper: Removal Refitting) (55A, Exterior protection),
- the rear wing lights (see Rear light on wing: Removal - Refitting) (81A, Rear lighting).
a Remove:
- the rear wing lights (see Rear light on wing: Removal - Refitting) (81A, Rear lighting),
- the rear bumper (see Rear bumper: Removal Refitting) (55A, Exterior protection).
127144
a Remove:
- the bolts (1) ,
- the rear impact lower cross member (2) .
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the rear impact lower cross member (2) ,
- the bolts (1) .
41D-24
http://vnx.su
42A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
III - ADJUSTMENT
Note:
The front wing is the penultimate removable component to be fitted to the vehicle body in the factory.
For final adjustment, correctly position all the other
components including the bumper and the headlights for them to be correctly positioned.
112606
II - REMOVAL - REFITTING
Note:
In all cases of removal of a component without its
replacement with a new one, mark the position of
the mountings before removing the mountings to
avoid adjustments during refitting.
To remove or replace the front wing, remove:
- the windscreen lower trim piece,
- the radiator grille,
- the front bumper,
42A-1
http://vnx.su
42A
112041
127225
Adjust the flush fitting and alignment with the front door
using mountings (4) and (5) .
127224
42A-2
http://vnx.su
42A
II - REMOVAL
REMOVAL
I - REMOVAL PREPARATION
a Remove:
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
- the headlight (see Front headlight: Removal Refitting) (80B, Headlight),
- the front wheel arch liner (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection),
- the side indicator (see Side indicator: Removal Refitting) (80A, Headlight).
127220
127219
127221
42A-3
http://vnx.su
42A
127222
127223
a Remove:
- the bolts (5) ,
- the front wing.
REFITTING
I - REFITTING
a Refit:
- the front wing,
42A-4
http://vnx.su
42A
ADJUSTMENT VALUES
a For all information regarding wing adjustment values, (see Vehicle clearances: Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are three possible front wing adjustments:
- Adjustment with the front door
- Adjustment with the bonnet
- Adjustment with the headlight and bumper
109496
127159
127227
42A-5
http://vnx.su
42A
127226
127224
a Adjust the panel gaps with the front door and the sill
panel.
a Remove the windscreen lower trim piece (see Scuttle panel grille: Removal - Refitting)
a Adjust the clearances with the door and A-pillar
a
Note:
Adjust the front wing with bonnet during reinstallation of the front wing upper mounting support.
42A-6
http://vnx.su
127225
a Adjust the shut lines with the front bumper and the
headlight.
a Refit:
- the front wheel arch liner (see Front wheel arch
liner: Removal - Refitting)
- the front bumper (see Front bumper: Removal Refitting)
42A-7
http://vnx.su
42A
42A
110082
42A-8
http://vnx.su
REFITTING
I - REMOVAL PREPARATION
I - REFITTING
42A
a Remove:
- the radiator grille,
II - FINAL OPERATION.
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
a Refit the bonnet lock (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).
a Connect:
- the various connectors,
a Refit:
a Disconnect:
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
- the radiator grille.
II - REMOVAL
127228
a Remove:
- the bolts (4) ,
- the front of the vehicle.
42A-9
http://vnx.su
42A
Note:
For a detailed description of a particular connection, see MR 400.
I - DESIGN OF THE STRUCTURAL COMPONENT
110638
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
112703
If there are other issues regarding access to mating faces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400).
42A-10
http://vnx.su
110639
42A-11
http://vnx.su
42A
No.
Description
Type
Thickness
(mm)
(1)
Dashboard
mounting interior
unit
HEL
2.5
(2)
A-pillar lining
HEL
(3)
Mild
steel
0.77
(4)
Very
high
yield
strengt
h
(5)
Very
high
yield
strengt
h
1.8
(6)
Very
high
yield
strengt
h
1.8
(7)
A-pillar impact
upper reinforcement
(8)
A-pillar impact
lower reinforcement
HEL
1.2
127264
127526
42A-12
42A
http://vnx.su
42A
Detailed view A
II - PART FITTED
1 - Front section replacement
130524
2 - Complete replacement
130522
Cut
130525
130523
Note:
For a detailed description of welded connections,
see MR 400.
42A-13
http://vnx.su
126960
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
42A-14
http://vnx.su
42A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
112704
This type of part secures the front panel and the front
wing upper mounting support.
42A-15
http://vnx.su
42A
42A
No.
Description
Type
Thickness
(mm)
(1)
HEL
1.2
(2)
Bonnet hinge
mounting reinforcement
HEL
2.5
(3)
Scuttle
side
panel upper reinforcement
HEL
1.2
II - PART FITTED
127267
130529
Note:
For a detailed description of welded connections,
see MR 400.
128388
42A-16
http://vnx.su
126960
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
42A-17
http://vnx.su
42A
42A
Right-hand side
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
110634
Two wheel arches are available, depending on the vehicle engine type:
110635
42A-18
http://vnx.su
No.
Description
Type
Thickness
(mm)
(1)
Windscreen
aperture lower
cross member
side angle bracket
Mild
steel
1.2
(2)
Shock absorber
cup reinforcement
Very
high
yield
strengt
h
(3)
Shock absorber
cup
HEL
(4)
Shock absorber
cup reinforcement
Very
high
yield
strengt
h
(5)
Shock absorber
cup height adjuster
Mild
steel
1.12
(6)
Mild
steel
1.2
127266
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
42A
130528
130527
42A-19
http://vnx.su
Note:
42A
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
126960
Right-hand side
126961
42A-20
http://vnx.su
42A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
104570
102674
42A-21
http://vnx.su
42A
II - PART FITTED
127269
130530
No.
Description
Type
Thickness
(mm)
(1)
Windscreen
aperture lower
cross member
Mild
steel
0.75
42A-22
http://vnx.su
42A
diagnostic tool
a Remove:
Tightening torquesm
centring nut of the dashboard cross member
6 N.m
8 N.m
21 N.m
N.m
- the front side doors (see 47A, Side opening elements, Front side door: Removal - Refitting,
page 47A-1) (47A, Side opening elements),
- the dashboard (see Dashboard: Removal - Refitting) (57A, Interior equipment),
- the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit).
a Partially remove:
- the steering column (see Steering column: Removal - Refitting) (36A, Steering assembly),
- the dashboard wiring (see Dashboard wiring harness: Removal - Refitting) (88A, Wiring).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
128641
a Remove:
- the bolts (1) ,
- the dashboard flange (2) .
a Unclip the passenger compartment fuse box.
42A-23
http://vnx.su
42A
128640
128642
128639
a Remove:
- the dashboard cross member tie-rod bolts (4) ,
- the bolts (5) from the dashboard cross member,
- the blanking covers (6) .
42A-24
http://vnx.su
42A
II - FINAL OPERATION.
a Refit:
- the passenger compartment fuse and relay box (2)
,
- the dashboard flange.
a Refit:
- the dashboard wiring (see Dashboard wiring harness: Removal - Refitting) (88A, Wiring),
- the steering column (see Steering column: Removal - Refitting) (36A, Steering assembly),
- the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit),
- the dashboard (see Dashboard: Removal - Refitting) (57A, Interior equipment),
128638
- the front side doors (see 47A, Side opening elements, Front side door: Removal - Refitting,
page 47A-1) (47A, Side opening elements).
a Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (88C, Airbags and pretensioners).
a Remove:
- the dashboard cross member side bolt (8) ,
- the dashboard cross member (this operation requires two people).
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the dashboard cross member (this operation
requires two people).
a Tighten to torque:
- the centring nut of the dashboard cross member (6 N.m) using the tool (Car. 1765),
- the dashboard cross member side bolts (8 N.m)
(7) and (8) ,
- the dashboard cross member bolts (21 N.m) (5)
,
- the dashboard cross member tie-rod bolt8
(N.m) (4) ,
a Refit the blanking covers (6) .
42A-25
http://vnx.su
43A
127272
No.
Description
Type
Thickness
(mm)
(1)
A-pillar
Mild
steel
0.75
II - PART IN POSITION
126992
43A-1
http://vnx.su
43A
Cut
126993
Detailed view A
Detailed view B
126994
126995
This cut allows replacement of the A-pillar lining reinforcement (see 43A, Side upper structure, A-pillar
lining stiffener: Description, page 43A-8)
43A-2
http://vnx.su
43A
126996
43A-3
http://vnx.su
43A
Cut
126997
Note:
For a detailed description of the welded connections, see MR 400.
43A-4
http://vnx.su
43A
No.
Description
Type
Thickness
(mm)
(1)
A-pillar reinforcement
HLE
1.2
(2)
VHEL
(3)
VHEL
II - PART IN POSITION
Lower section replacement
127274
When replacing this part, also order the A-pillar reinforcement insert and the A-pillar lining insert (see 40A,
General information, Hollow body parts inserts:
List and location of components, page 40A-9) .
The options for replacing this part are as follows:
- lower section replacement,
- complete replacement.
I - COMPOSITION OF THE SPARE PART
127056
127055
43A-5
http://vnx.su
127057
127054
Note:
For a detailed description of the welded connections, see MR 400.
43A-6
http://vnx.su
43A
43A
II - PART IN POSITION
Complete replacement
128607
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
Description
Type
Thickness
(mm)
(1)
Windscreen pillar
lining
HEL
0.8
Detailed view A
126988
Note:
For a detailed description of welded connections,
see MR 400.
43A-7
http://vnx.su
43A
II - PART IN POSITION
Complete replacement
127273
126989
No.
Description
Type
Thickness
(mm)
(1)
Windscreen pillar
lining reinforcement
HLE
Detailed view A
126990
This operation supplements the replacement of the Apillar upper section (see 43A, Side upper structure,
A-pillar: Description, page 43A-1)
Note:
For a detailed description of the welded connections, see MR 400.
43A-8
http://vnx.su
43A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
The options for replacing this part are as follows:
- Complete replacement
- partial replacement of the lower section.
I - COMPOSITION OF THE SPARE PART
141249
141250
43A-9
http://vnx.su
43A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
No.
(1)
Description
Thickness
(mm)
Mild
steel
0.75
Upper
runner
mounting reinforcement
Mild
steel
(3)
Upper
runner
mounting reinforcement
Mild
steel
(4)
Mild
steel
0.75
(2)
B-pillar
Type
No.
Description
Type
Thickness
(mm)
(5)
Mild
steel
0.75
(6)
Mild
steel
0.75
(7)
Mild
steel
0.75
(8)
Lowe r
runner
stop mounting
reinforcement
Mild
steel
II - PART IN POSITION
Complete replacement
127014
43A-10
http://vnx.su
43A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Cut
127015
Detailed view A
Detailed view B
127016
43A-11
http://vnx.su
127017
43A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Detailed view C
127004
Detailed view D
127007
43A-12
http://vnx.su
127024
43A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Partial replacement of the lower section
127019
43A-13
http://vnx.su
43A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Cut
127020
Detailed view E
Note:
For a detailed description of the welded connections (see MR 400).
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
127012
43A-14
http://vnx.su
Note:
43A
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
If there are other issues regarding access to mating faces, the various options are described in the basic instructions for structural bodywork repair (see MR 400).
Note:
For a detailed description of a particular connection, see MR 400.
101971
Line (2) on the drawing shows a butt weld by continuous EGW welding.
110565
43A-15
http://vnx.su
No.
Description
Type
Thickness
(mm)
(1)
B-pillar reinforcement
VHEL
1.8
(2)
B-pillar centre
reinforcement
VHEL
1.5
(3)
Collapsible
mounting pad of
door striker panel
HLE
2.5
127275
127059
43A-16
43A
http://vnx.su
43A
II - PART IN POSITION
Lower section replacement
127060
Cut
Detailed view A
127061
43A-17
http://vnx.su
127062
43A
Detailed view B
127063
127508
This cut allows replacement of the sill panel reinforcement (see 41C, Side lower structure, Sill panel reinforcement: Description, page 41C-24)
Cut
127509
43A-18
http://vnx.su
43A
Complete replacement
127058
Note:
For a detailed description of the welded connections, see MR 400.
43A-19
http://vnx.su
43A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection (see MR 400).
DESIGN OF THE STRUCTURAL COMPONENT
The three parts must be welded at the joint (1) and (2)
or (1) and (3) and butt welded by continuous EGW welding.
141322
127272
43A-20
http://vnx.su
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING
+ FIXED WINDOW or R SLID+OPENING WINDOW
141324
If there are other issues regarding access to mating faces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400).
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
The body side is achieved by welding the rear wing and
the body side front section.
43A-21
http://vnx.su
43A
43A
Note:
For a detailed description of a particular connection, see MR 400.
POSITIONING OF LOCAL ELECTRICAL EARTHS
127271
126963
127272
43A-22
http://vnx.su
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
43A-23
http://vnx.su
43A
44A
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection (see MR 400).
DESIGN OF THE STRUCTURAL COMPONENT
L SLIDING PANEL or LEFT SLIDING + FIXED
WINDOW or LEFT SLIDING + OPENING WINDOW, and R SLIDING PANEL or RIGHT SLIDING
+ FIXED WINDOW or R SLID+OPENING WINDOW
141322
141324
44A-1
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
- complete replacement with roof.
In both cases, order parts (1) + (2) and solder them together.
I - COMPOSITION OF THE SPARE PART
141324
141247
44A-2
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.75
(2)
B-pillar
Mild
steel
0.75
(3)
Upper
runner
mounting reinforcement
Mild
steel
(4)
Mild
steel
0.75
(5)
Mild
steel
0.75
(6)
Mild
steel
0.75
(7)
Mild
steel
0.75
(8)
Lowe r
runner
stop mounting
reinforcement
Mild
steel
(9)
HLE
1.2
(10)
Central
unit
runner
Mild
steel
1.5
(11)
Central runner
unit upper closure panel
Mild
steel
0.75
(12)
Central runner
unit lower closure panel
Mild
steel
0.75
44A-3
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
II - PART IN POSITION
Complete replacement without roof
141283
44A-4
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Cut
127000
Detailed view A
Detailed view B
127001
44A-5
http://vnx.su
127004
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Complete replacement with roof
141284
44A-6
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Cut
127006
Detailed view C
127008
44A-7
http://vnx.su
127009
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Note:
For a detailed description of the welded connections, (see MR 400).
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
Locate the earths located near to the weld area (see
40A, General information, Earths on the body: List
and location of components, page 40A-12) .
44A-8
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
141462
141322
44A-9
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
I - COMPOSITION OF THE SPARE PART
L SIDE SCREEN+FIXED WINDOW or L SIDE
SCREEN+OPENING WINDOW, and R SIDE
SCREEN+FIXED WINDOW or R SIDE
SCREEN+OPENING WINDOW
127066
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.75
(2)
HLE
1.2
44A-10
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
141293
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.75
(2)
HLE
1.2
44A-11
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
II - PART IN POSITION
Replacement of the upper section
127044
44A-12
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Cut
127045
Detailed view A
Detailed view B
127046
44A-13
http://vnx.su
127047
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Detailed view C
Detailed view D
127048
127037
127049
44A-14
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Cut
127050
Detailed view E
Detailed view F
127038
44A-15
http://vnx.su
127051
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Detailed view G
127052
Detailed view H
127053
44A-16
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
141295
44A-17
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
141292
44A-18
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Cut
127036
44A-19
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
141294
44A-20
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
141291
44A-21
http://vnx.su
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Cut
127040
Detailed view I
127042
44A-22
http://vnx.su
127043
44A
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
Note:
For a detailed description of the welded connections, (see MR 400).
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
Locate the earths located near to the weld area (see
40A, General information, Earths on the body: List
and location of components, page 40A-12) .
44A-23
http://vnx.su
44A
SHORT CHASSIS
The options for replacing this part are as follows, lower
section replacement.
I - COMPOSITION OF THE SPARE PART
141460
141248
44A-24
http://vnx.su
44A
SHORT CHASSIS
II - PART FITTED
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.75
(2)
HLE
1.2
141287
44A-25
http://vnx.su
44A
SHORT CHASSIS
Cut
141286
Detailed view A
Detailed view B
141290
44A-26
http://vnx.su
141289
141288
Note:
For a detailed description of the welded connections, (see MR 400).
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
Locate the earths located near to the weld area (see
40A, General information, Earths on the body: List
and location of components, page 40A-12) .
44A-27
http://vnx.su
44A
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.75
(2)
Central runner
unit upper closure
Mild
steel
0.75
(3)
Central
unit
runner
Mild
steel
1.5
(4)
Central runner
unit lower closure
Mild
steel
0.75
(5)
HLE
1.2
141461
141282
44A-28
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Partial replacement of the rear section
127021
44A-29
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Cut
127022
Detailed view A
Detailed view A
127026
44A-30
http://vnx.su
127023
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Detailed view A: Welding
Detailed view G
127024
127025
127027
44A-31
http://vnx.su
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Cut
127028
Detailed view C
Detailed view D
127029
44A-32
http://vnx.su
127018
44A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
Detailed view E
127013
Note:
For a detailed description of the welded connections, (see MR 400).
II - POSITIONING OF LOCAL ELECTRICAL EARTHS
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
Locate the earths located near to the weld area (see
40A, General information, Earths on the body: List
and location of components, page 40A-12) .
44A-33
http://vnx.su
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
127277
44A-34
http://vnx.su
44A
44A
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.8
(2)
Rear
loading
door hinge upper
stiffener
HLE
1.8
(3)
Rear
loading
door hinge lower
stiffener
HLE
1.8
II - PART IN POSITION
Partial replacement of the lower section
127277
127069
127068
44A-35
http://vnx.su
44A
Cut
127070
Complete replacement
127067
44A-36
http://vnx.su
Note:
44A
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
126964
126963
Note:
Only disconnect the earths on the side corresponding to the repaired side
44A-37
http://vnx.su
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
127280
44A-38
http://vnx.su
44A
44A
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.5
(2)
HLE
1.5
(3)
HLE
1.5
II - PART IN POSITION
Replacement of the lower section
127280
127073
127072
44A-39
http://vnx.su
44A
Cut
127074
Complete replacement
127071
44A-40
http://vnx.su
Note:
44A
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
126964
126963
Note:
Only disconnect the earths on the side corresponding to the repaired side
44A-41
http://vnx.su
127279
44A
No.
Description
Type
Thickness
(mm)
(1)
HLE
0.85
(2)
Mild
steel
0.7
(3)
Mild
steel
(4)
Mild
steel
1.2
(5)
HLE
1.2
(6)
HLE
1.8
II - PART IN POSITION
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
I - COMPOSITION OF THE SPARE PART
127075
127076
44A-42
http://vnx.su
44A
Detailed view A
127077
126964
Note:
Note:
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
126963
44A-43
http://vnx.su
44A
127276
127590
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.7
(2)
Mild
steel
0.85
(3)
Upper mobile
anchoring reinforcements
Mild
steel
1.5
(4)
Mild
steel
0.7
(5)
Lowe r
mobile
anchoring reinforcements
Mild
steel
1.5
(6)
Mild
steel
0.8
(7)
HLE
1.5
44A-44
http://vnx.su
44A
127539
44A-45
http://vnx.su
44A
127540
Detailed view A
Detailed view B
127541
44A-46
http://vnx.su
127542
44A
127543
44A-47
http://vnx.su
44A
127544
Detailed view C
Detailed view D
127562
44A-48
http://vnx.su
127563
44A
Detailed view E
127558
Cut
127560
127559
44A-49
http://vnx.su
127564
44A
Cut
127561
127565
127545
44A-50
http://vnx.su
127546
44A
127537
44A-51
http://vnx.su
44A
127538
44A-52
http://vnx.su
44A
127534
Detailed view H
Detailed view I
127535
44A-53
http://vnx.su
127536
44A
126964
126963
Note:
Only disconnect the earth on the repaired side of
the vehicle.
44A-54
http://vnx.su
44A
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.7
(2)
Mild
steel
0.85
(3)
Upper mobile
anchoring reinforcements
Mild
steel
1.5
(4)
HLE
1.5
(5)
Lowe r
mobile
anchoring reinforcement
Mild
steel
1.5
(6)
C-pillar lower
connecting bracket
Mild
steel
(7)
HLE
1.5
127276
127547
44A-55
http://vnx.su
44A
127548
44A-56
http://vnx.su
44A
127549
Detailed view A
127550
44A-57
http://vnx.su
127551
44A
127552
44A-58
http://vnx.su
44A
127553
Detailed view C
127554
44A-59
http://vnx.su
127557
44A
127555
126964
Detailed view E
127556
126963
Note:
Only disconnect the earth on the repaired side of
the vehicle.
44A-60
http://vnx.su
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
44A-61
http://vnx.su
44A
44A
Note:
For a detailed description of the welded connections, see MR 400.
127278
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.2
II - PART IN POSITION
127078
44A-62
http://vnx.su
TOP OF BODY
Roof: General description
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
127283
45A-1
http://vnx.su
45A
TOP OF BODY
Roof: Description
45A
127283
127283
MANUAL SUNROOF
No.
Description
Type
Thickness
(mm)
(1)
Roof
Mild
steel
0.65
MANUAL SUNROOF
128608
130521
45A-2
http://vnx.su
TOP OF BODY
Roof: Description
No.
Description
Type
Thickness
(mm)
(2)
HEL
0.8
(3)
Rear extension of
roof centre cross
member
HEL
(4)
Mild
steel
0.65
45A
MANUAL SUNROOF
II - PART FITTED
130520
Bonding area
Front section
127147
127148
45A-3
http://vnx.su
TOP OF BODY
Roof: Description
Rear section
127149
Note:
For a detailed description of the special connections, see MR 400.
45A-4
http://vnx.su
45A
TOP OF BODY
Roof front section: Description
45A
128609
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
(1)
Description
Front section of
roof
Type
Mild
steel
Thickness
(mm)
Note:
For a detailed description of welded connections,
see MR 400.
Bonding area
0.65
127148
45A-5
http://vnx.su
TOP OF BODY
Roof rear section: Description
45A
131165
- complete replacement.
I - COMPOSITION OF THE SPARE PART
No.
(1)
Description
Type
Mild
steel
Thickness
(mm)
Note:
For a detailed description of welded connections,
see MR 400.
Bonding area
0.65
127149
45A-6
http://vnx.su
TOP OF BODY
Roof front cross member: Description
45A
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.75
(2)
Mild
steel
0.75
II - PART IN POSITION
127284
127150
Note:
For a detailed description of the welded connections, see MR 400.
127151
45A-7
http://vnx.su
TOP OF BODY
Roof centre cross member: Description
45A
II - PART IN POSITION
127285
127152
No.
Description
Type
Thickness
(mm)
(1)
HLE
0.8
45A-8
http://vnx.su
TOP OF BODY
Roof panel arch: Description
45A
II - PART IN POSITION
127281
127154
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
0.8
45A-9
http://vnx.su
TOP OF BODY
Roof rear cross member: Description
127670
45A
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
(2)
Hinge mounting
reinforcement
HLE
1.5
(3)
HLE
1.5
127156
127158
45A-10
http://vnx.su
TOP OF BODY
Roof rear cross member: Description
No.
Description
Type
Thickness
(mm)
(1)
Mild
steel
(3)
HLE
1.5
(4)
Door stop
HLE
1.5
45A
II - PART IN POSITION
TAILGATE WINDOW
127155
Note:
For a detailed description of the welded connections, see MR 400.
127157
45A-11
http://vnx.su
47A
127287
a Remove:
- the nuts (2) ,
- the front side door (this operation requires two people).
II - REFITTING WITHOUT HINGES
1 - REFITTING
a Refit:
- the front side door (this operation requires two people),
126467
47A-1
http://vnx.su
47A
2 - REMOVAL
127286
a Remove:
- the bolts (4) ,
- the front side door (this operation requires two people).
IV - REFITTING WITH HINGES
1 - REFITTING
a Refit:
- the front side door (this operation requires two people),
- the front side door check strap bolt (3) .
126467
a Adjust the front side door clearances and flush fittings (see 47A, Side opening elements, Front side
door: Adjustment, page 47A-6) .
a Carry out a function test.
47A-2
http://vnx.su
47A-3
http://vnx.su
47A
47A
Note:
The order of the operations described below is specific to the front side door replacement.
The following procedure applies to the front side
door on the vehicle.
REASSEMBLING
REFITTING
a Refit:
STRIPPING
a Remove:
- the door mirror (see Door mirror: Removal - Refitting) (56A, Exterior equipment),
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim),
- the speaker (see Front speakers: Removal - Refitting) (86A, Radio),
- the front side door sealing film (see Door sealing
film: Removal - Refitting) (65A, Door sealing),
- the front side door exterior weatherstrip (see Front
door side exterior weather strip: Removal - Refitting) (66A, Window sealing),
- the front side door interior weatherstrip.
47A-4
http://vnx.su
47A-5
http://vnx.su
47A
47A
ADJUSTMENT VALUES
a For information on the front side door adjustment values, (see Vehicle clearances: Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are three options for adjusting the door:
- by means of the mountings on the door box section
(opening clearance adjustment),
- by means of the mountings on the A-pillar (panel
gaps adjustment); this operation requires the removal of the front wing,
- the striker panel.
109496
a
Note:
Symbols A, B, C, D represent the adjustment
options.
The black dot in the centre represents the body
of the bolt.
The grey section represents the component to be
adjusted.
The white section represents the adjustment
area.
127160
47A-6
http://vnx.su
47A
127288
127290
47A-7
http://vnx.su
47A
127448
a Remove:
- the bolts (1) ,
20625
127450
a Remove:
- the bolt (3)
- the intermediate runner stop (4) .
47A-8
http://vnx.su
47A
2 - REMOVAL
127429
127291
a Remove the rear side door by moving the upper runner roller aside. (This operation requires two people).
II - REFITTING WITH THE SLIDES
1 - REFITTING
a Refit the rear side door (If a door support tool is not
used this operation requires two people).
2 - FINAL OPERATION
a Refit:
- the lower runner stop (7) ,
- the bolts (6) ,
- the upper runner stop (5) ,
- the intermediate runner stop (4) ,
127292
a Remove:
- bolt (3) .
a Refit:
- the intermediate runner trim (2) ,
- the bolts (1) .
a Carry out a function test on all functions.
47A-9
http://vnx.su
47A
127294
127296
127293
47A-10
http://vnx.su
127295
a Remove:
- the bolts (11)
- the rear side door (this operation requires two people).
IV - REFITTING WITHOUT THE SLIDES
1 - REFITTING
a Refit:
- the rear side door,
- bolts (11) , (10) , (9) and (8) .
2 - FINAL OPERATION
a Carry out a function test on all functions.
47A-11
http://vnx.su
47A
47A
Note:
The order of the operations described below
applies specifically to replacing the rear side door.
REASSEMBLING
REBUILDING
STRIPPING
a Refit:
DISMANTLING
a Remove:
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the grab handle (see Grab handle: Removal - Refitting) (57A, Interior accessories),
- the rear side door electric window winder mechanism (see Rear side door electric window mechanism: Removal - Refitting) (51A, Side
opening element mechanisms) (depending on
equipment level),
- the window seal of the sliding side door (see Sliding side door window seal: Removal - Refitting) (66A, Window sealing),
- the sliding window of the rear side door (see Sliding window in rear side door: Removal - Refitting) (54A, Windows) (depending on equipment
level),
- the sliding window of the rear side door (see Sliding window in rear side door: Removal - Refitting) (54A, Windows) (depending on equipment
level),
- the rear side door electric window winder mechanism (see Rear side door electric window mechanism: Removal - Refitting) (51A, side
opening element mechanism),
- the window seal of the sliding side door (see Sliding side door window seal: Removal - Refitting) (66A, Window sealing),
- the grab handle (see Grab handle: Removal - Refitting) (57A, Interior accessories),
- the sliding side door exterior handle (see Sliding
side door opening controls: Removal - Refitting) (51A, Side opening element mechanisms),
- the sliding side door lock (see Sliding side door
lock: Removal - Refitting) (51A, Side opening
element mechanisms),
47A-12
http://vnx.su
47A-13
http://vnx.su
47A
47A
ADJUSTMENT VALUES
a For information on the rear side door adjustment values (see Vehicle clearances: Adjustment values)
(01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are three options for adjusting the rear side
door:
- using the rear side door mountings,
- using the centring devices,
- the striker panel.
109496
a
Note:
Symbols A, B, C and D show the adjustment
options.
The black dot in the centre represents the body
of the bolt.
The grey section represents the component to be
adjusted.
The white section represents the adjustment
area.
127160
Note:
It is not possible to adjust the female centring
devices on the door.
Note:
The centring devices must interlock completely
(auto centring), as exterior touching could cause
the door to come out of position.
47A-14
http://vnx.su
127300
127299
47A-15
http://vnx.su
47A
47A
127297
127295
127298
127296
47A-16
http://vnx.su
48A
2 - FINAL OPERATION
- Removal with the hinges: allows the initial adjustments to be kept and avoids the original paintwork
from coming off between the hinge and the bonnet
lining.
a Remove:
2 - REMOVAL
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
- the headlights (see Front headlight: Removal Refitting) (MR 417, 80B, Headlights),
- the front wings (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) .
a Disconnect the windscreen washer jet pipe.
a Unclip the windscreen washer jet pipe.
2 - REMOVAL
127306
a Remove:
- the nuts (1) ,
- the bonnet. This operation requires two people.
II - REFIT WITHOUT BONNET HINGES
1 - REFITTING
127305
a Remove:
48A-1
http://vnx.su
48A-2
http://vnx.su
48A
Note:
Described below is a special sequence of operations for bonnet replacement.
The procedure described below applies to the bonnet on the vehicle.
STRIPPING
REASSEMBLING
48A-3
http://vnx.su
48A
48A
Tightening torquesm
bonnet catch bolts
21 N.m
ADJUSTMENT VALUES
a For information on the bonnet adjustment values,
(see Vehicle clearances: Adjustment values)
(01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are two options for adjusting the bonnet:
- Flat adjustment using the bonnet hinge bolts in
areas (1) and (2) . This operation requires the removal of the front wing (see 42A, Front upper
structure, Front wing: Removal - Refitting, page
42A-3) ,
109496
Note:
It is not possible to adjust the height of the rear
section of the bonnet.
127159
48A-4
http://vnx.su
48A
128485
127306
WARNING
To avoid any risk of corrosion after the localised
stripping of the panel, reapply the protective coating (see Technical Note 0592A).
a Refit the bonnet (see 48A, Non-side opening elements, Bonnet: Removal - Refitting, page 48A-1)
.
a Adjust the panel gaps and flush fittings on the bonnet.
a Tighten the bonnet nuts.
a Carry out the anti-corrosion protection operations
(see Anti-corrosion protection products after assembly: Use) (04E, Paint).
II - ADJUSTMENT USING THE BONNET HINGE
BOLTS ON THE BODY
1 - ADJUSTMENT PREPARATION STAGE
a Raise the vehicle (see Vehicle: Towing and lifting)
(02A, Lifting equipment).
a Remove:
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection),
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
- the headlights (see Front headlight: Removal Refitting) (80B, Headlights),
- the front wings (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) .
48A-5
http://vnx.su
48A
2 - ADJUSTMENT
127308
126886
48A-6
http://vnx.su
48A
2 - REMOVAL
127309
a Remove:
a Remove:
- the tailgate wiring,
48A-7
http://vnx.su
48A
2 - REMOVAL
a Remove:
- the tailgate wiring,
1 - REFITTING
2 - FINAL OPERATION
a Refit:
- the tailgate gas struts (see Tailgate balancer: Removal - Refitting) (52A, Non-side opening element mechanisms).
- the tailgate washer jet tube,
- the tailgate wiring.
a Carry out a function test.
48A-8
http://vnx.su
48A-9
http://vnx.su
48A
48A
Note:
Described below is a special sequence of operations for tailgate replacement.
- the high level brake light (see 3rd brake light: Removal - Refitting) (81A, Rear lighting).
- the tailgate exterior opening control (see Tailgate
exterior opening control: Removal - Refitting)
(52A, Non-side opening element mechanisms),
STRIPPING
- the tailgate lock (see Tailgate lock: Removal - Refitting) (52A, Non-side opening element mechanisms),
a Remove:
- the tailgate trim (see Tailgate lining: Removal Refitting) (73A, Non-side opening elements trim),
- the rear screen wiper motor (see Rear screen wiper motor: Removal - Refitting) (85A, Washing Wiping),
- the tailgate lock (see Tailgate lock: Removal - Refitting) (52A, Non-side opening element mechanisms),
- the rear screen wiper motor (see Rear screen wiper motor: Removal - Refitting) (85A, Washing Wiping).
a Carry out a function test on all functions.
a Refit the tailgate trim (see Tailgate lining: Removal
- Refitting) (73A, Non-side opening elements trim).
REASSEMBLING
a Refit:
- a new rear badge (see Rear badges: Removal Refitting) (56A, Exterior accessories),
- the blanking covers,
- the tailgate gas struts (see Tailgate balancer: Removal - Refitting) (52A, Non-side opening element mechanisms),
48A-10
http://vnx.su
48A
ADJUSTMENT VALUES
a For information on the tailgate adjustment values
(see Vehicle clearances: Adjustment values)
(01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are three options for adjusting the tailgate:
- Adjustment of areas (1) and (2) using hinge attachments,
- Adjustment of area (3) using the tailgate striker plate,
- Adjustment of the side stops (4) ,
109496
a
Note:
Symbols A, B, C and D show the adjustment
options.
The black dot in the centre represents the body
of the bolt.
The grey section represents the component to be
adjusted.
The white section represents the adjustment
area.
127162
48A-11
http://vnx.su
48A
128485
a
Note:
During factory fitting, the hinges are mounted
with no possibility of adjustment (A), it is necessar y to countersink the holes to make adjustments (B).
127312
a Remove the rear section headlining (see Headlining: Removal - Refitting) (71A, Body internal
trim).
a Undo the tailgate hinge nuts.
a Adjust the panel gaps and flush fittings on the tailgate.
WARNING
To avoid any risk of corrosion after the localised
stripping of the panel, reapply the protective coating (see Technical Note 0592A).
48A-12
http://vnx.su
48A
127309
127314
127311
127313
48A-13
Note:
The stops (6) should be supported by the tailgate
side stops.
http://vnx.su
48A
2 - Removal
a Remove:
48A-14
http://vnx.su
48A
a Refit:
2 - Removal
127700
a Remove:
- the bolts (2) ,
- the rear loading door (this operation requires two
people).
IV - REFITTING WITH HINGES
1 - Refitting
a Refit the rear loading door (this operation requires
two people).
a Adjust the panel gaps and flush fittings (see 48A,
Non-side opening elements, Rear loading door:
Adjustment, page 48A-26) .
2 - final operation
a Refit:
- the rear loading door wiring,
- the rear screen jet pipe.
a Connect the connectors of:
- the number plate light,
- the high level brake light,
- the heated rear screen,
48A-15
http://vnx.su
48A
a Remove:
48A-16
http://vnx.su
48A
141077
141075
a Remove:
2 - Final operation
a Refit:
- the rear loading door wiring harness
48A-17
http://vnx.su
48A
141076
141082
a Remove:
- the nuts (2) ,
- the bolt (3) ,
- the rear loading door (this operation requires two
people).
48A-18
http://vnx.su
141077
48A-19
http://vnx.su
48A
48A
Note:
The order of the operations described below
applies specifically to replacing the rear loading
door.
REASSEMBLING
STRIPPING
- a new rear badge (see Rear badges: Removal Refitting) (56A, Exterior accessories),
a Remove:
- the rear left-hand loading door trim (see Left-hand
rear loading door trim: Removal - Refitting)
(73A, Non-side opening elements trim),
- the high level brake light (see 3rd brake light: Removal - Refitting) (81A, Rear lighting),
- the rear badge (see Rear badges: Removal - Refitting) (56A, Exterior accessories).
II - REAR RIGHT-HAND LOADING DOOR
a Remove:
a Refit:
- the rear right-hand loading door trim (see Righthand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim),
48A-20
http://vnx.su
48A-21
http://vnx.su
48A
48A
STRIPPING
STRIPPING OPERATION FOR PART CONCERNED
a Remove:
- the tailgate trim (see Tailgate lining: Removal Refitting) (71A, Body internal trim),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the rear loading door window (see Rear loading
door window: Removal - Refitting) (54A, Windows),
- the rear opening element window winder mechanism (see Rear opening element electric window mechanism: Removal - Refitting) (52A,
Non-side opening element mechanisms),
140946
- the loading door lock (see Loading door lock: Removal - Refitting) (52A, Non-side opening element mechanisms),
141003
a Remove:
- the clip (2) ,
- the interior weatherstrip of the rear loading door.
140945
48A-22
http://vnx.su
48A
141004
a Remove:
- the bolts (3) ,
- the rear loading door window guide.
141006
a Remove:
- the connector (6)
- the bolts (7) ,
- the opening control for the rear loading door.
141007
a Remove:
- the bolts (4) ,
141005
a Remove:
48A-23
http://vnx.su
48A
141076
141077
a Refit:
- the rear loading door channel,
REASSEMBLING
a Always replace:
48A-24
http://vnx.su
48A-25
http://vnx.su
48A
48A
ADJUSTMENT VALUES
a For all information regarding the adjustment values
for the rear loading doors, (see Vehicle clearances:
Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a The options for adjusting the rear loading door are
as follows:
-Adjustment using the lower and upper striker plate
bolts,
-Adjustment using the lock bolts,
-Adjustment using the centring device bolts,
-Adjustment using the hinge nuts on the body and on
the door box section.
109496
127163
48A-26
http://vnx.su
48A
127323
48A-27
http://vnx.su
48A
Upper lock
127321
127322
Lower lock
127320
48A-28
http://vnx.su
48A
127317
128485
Note:
During factory fitting, the hinges are mounted
with no possibility of adjustment (A), it is necessar y to countersink the holes to make adjustments (B).
WARNING
To prevent any risk of corrosion after stripping
the panel, re-apply the anticorrosion protection
(see Technical Note 0592A).
a Remove the rear loading door (see 48A, Non-side
opening elements, Rear loading door: Removal Refitting, page 48A-14) .
48A-29
http://vnx.su
48A
127301
127316
127303
127302
a Refit the rear loading door (see 48A, Non-side opening elements, Rear loading door: Removal - Refitting, page 48A-14) .
a Refit the rear loading door (see 48A, Non-side opening elements, Rear loading door: Removal - Refitting, page 48A-14) .
a Adjust the panel gaps and flush fitting of the rear loading door.
a Adjust the panel gaps and flush fitting of the rear loading door.
48A-30
http://vnx.su
48A
ADJUSTMENT VALUES
a For all information regarding the adjustment values
for the rear loading doors, (see Vehicle clearances:
Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a The rear loading door is adjusted in the following order:
- adjustment of the shut lines of areas (1) , (2) , (3)
and adjustment of the flush fitting of area (1) using
the hinge nuts on the body and on the door box
section,
- adjustment of the flush fitting of area (3) using the
bolts of the striker plate and centring device.
109496
141251
48A-31
http://vnx.su
48A
128485
a
Note:
During factory fitting, the hinges are mounted
with no possibility of adjustment (A) , it is necessary to countersink the holes to make adjustments (B) .
141075
a Adjust the height and flush fitting using the nuts (1)
2 - Adjustment using the hinge nuts on the body
WARNING
To prevent any risk of corrosion after stripping
the panel, reapply the anticorrosion protection
(see Technical Note 0592A).
a Remove the rear loading door (see 48A, Non-side
opening elements, Rear loading door: Removal Refitting, page 48A-14) .
a Remove the door hinges.
a Enlarge the holes on the hinges using a step milling
cutter (3 mm maximum).
a Refit the hinges on the door box section.
a Refit the rear loading door (see 48A, Non-side opening elements, Rear loading door: Removal - Refitting, page 48A-14) .
a Adjust the clearances and flush fitting of the rear loading door.
141082
48A-32
http://vnx.su
141285
48A-33
http://vnx.su
48A
48A
2.5 N.m
6 N.m
2.5 N.m
Note:
If it is necessary to remove the guide slide supports, make a mark before removing them.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a (see 48A, Non-side opening elements, Upper
rear opening element: Removal - Refitting, page
48A-36)
142576
a Remove:
- the bolts (2) ,
1 - Guide bar
108739
142576
a Remove:
- the bolts (1) ,
- the drive bar of the upper rear opening element.
48A-34
http://vnx.su
48A
108738
a Remove:
- the bolts (4) ,
- the handle.
4 - Upper rear opening element lock
a (see Upper rear opening element lock: Removal
- Refitting)
5 - upper rear opening element strip
a (see Upper rear opening element strip: Removal
- Refitting)
REFITTING
REFITTING OPERATION FOR PART CONCERNED
1 - Guide bar
a Refit the drive bar of the upper rear opening element.
a Torque tighten the drive bar bolts (2.5 N.m)
2 - Guide slide
a When refitting, check that the guide slides are parallel with the frame of the upper rear opening element
a Refit the guide slides of the upper rear opening element.
a Torque tighten the guide slide bolts (6 N.m)
3 - Handle
a Refit the handle of the upper rear opening element.
a Torque tighten the handle bolts (2.5 N.m)
a Clip on the blanking covers (3) .
48A-35
http://vnx.su
48A
SHORT CHASSIS
Tightening torquesm
upper bolt of the rear
side seat belt
21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION
SHORT CHASSIS
a Remove:
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim),
- the rear wheel arch trims (see Rear wheel arch
lining: Removal - Refitting) (71A, Body internal
trim).
141078
STANDARD CHASSIS
SHORT CHASSIS
138563
141079
48A-36
http://vnx.su
48A
SHORT CHASSIS
SHORT CHASSIS
141080
a Remove:
141081
a Unclip the upper trim from the rear wheel arch (5) .
STANDARD CHASSIS
138584
a Remove:
- the bolts (6) ,
48A-37
http://vnx.su
48A
140904
140903
138582
a Remove:
48A-38
http://vnx.su
48A
138580
a Remove:
- the upper rear opening element drive bar at (14) ,
- the upper rear opening element.
140902
a Open the upper rear opening element panel midway and extract the upper rear opening element rails
at (12) .
a Support the upper rear opening element panel using
a block.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the upper rear opening element in the rails of
the upper rear opening element at (12) .
138580
a Loosen the bolts (13) of the upper rear opening element drive bar.
STANDARD CHASSIS
a Refit:
- the net supports,
- the bolts (6) ,
48A-39
http://vnx.su
SHORT CHASSIS
a Clip on the rear wheel arch upper trim.
a Refit:
- the rear seat belt return mechanism,
- the rear side seat belt upper bolt (4) .
a Torque tighten the upper bolt of the rear side seat
belt (21 N.m).
a Clip on the blanking cover.
a Refit:
- the quarter panel upper trim,
- the rear wheel arch trims (see Rear wheel arch
lining: Removal - Refitting) (71A, Body internal
trim),
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim).
48A-40
http://vnx.su
48A
66A
WINDOW SEALING
68A
SOUNDPROOFING
X61
DECEMBER 2008
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
http://vnx.su
KANGOO II - Section 6
Contents
Page
65A
66A
68A
65A-1
65A-3
65A-4
WINDOW SEALING
Front side door glass run
channel: Removal - Refitting
66A-1
66A-3
66A-4
66A-5
SOUNDPROOFING
Bonnet soundproofing:
Removal - Refitting
68A-1
http://vnx.su
65A
REMOVAL
Note:
I - REMOVAL PREPARATION OPERATION
a Remove:
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening elements
trim) or the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening elements trim),
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio).
WARNING
To ensure the sealing film adheres correctly:
- The door must be clean (free of dust, grease
and anti-adhesive products), with no trace of
impurities and no condensation,
- The area of the door box section where the film
is to be applied must be painted completely,
- There must be a minimum temperature of 15
on the surfaces which are to be bonded.
1 - PROCEDURE ONE
a Strip off the sealing film using a heat stripper set to
approximately 100. Hold the heat stripper at a distance of approximately 20 cm, directing the hot air
flow onto the edge of the sealing film.
a Start by stripping off a corner of the sealing film.
a Carefully strip off the sealing film taking care not to
tear it.
2 - PROCEDURE TWO
a Remove the sealing film using a syringe filled with
HEPTANE (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Products).
a Start with the upper section of the sealing film.
a Remove the HEPTANE in small amounts between
the sealing film and the inner door panel as the sealing film peels away (pull slowly on the sealing film).
a Carefully strip off the sealing film taking care not to
tear it.
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the door sealing film.
65A-1
http://vnx.su
65A
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening elements
trim) or the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening elements trim).
126824
126825
65A-2
http://vnx.su
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the mobile sunroof panel (see Sunroof
moving panel: Removal - Refitting) (52A, Nonside opening element mechanisms).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
140924
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the sunroof seal.
II - FINAL OPERATION
a Refit the mobile sunroof panel (see Sunroof moving panel: Removal - Refitting) (52A, Non-side
opening element mechanisms).
65A-3
http://vnx.su
65A
65A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Open the panel of the upper rear opening element.
140627
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
140622
a Remove the bolts (1) from the rear loading door sill.
140625
65A-4
http://vnx.su
65A
140626
140623
II - FINAL OPERATION
a Refit the bolts (1) of the rear loading door sill.
140624
a Refit:
- the tailgate seal using the tool (Car. 1363) along
the rear light,
- the tailgate seal around the outside edge.
65A-5
http://vnx.su
WINDOW SEALING
Front side door glass run channel: Removal - Refitting
66A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lower the front side door sliding window.
a Remove:
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim),
- the front side door exterior weatherstrip (see 66A,
Window sealing, Front door side exterior weather strip: Removal - Refitting, page 66A-3) .
- the front side door interior weatherstrip.
- the door mirror (see Door mirror: Removal - Refitting) (56A, Exterior equipment).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126893
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
126892
126894
a Refit the front door window glass run channel starting with the top section (3) .
66A-1
http://vnx.su
WINDOW SEALING
Front side door glass run channel: Removal - Refitting
II - FINAL OPERATION.
a Refit:
- the door mirror (see Door mirror: Removal - Refitting) (56A, Exterior equipment),
- the front side door interior weatherstrip.
- the front side door exterior weatherstrip (see 66A,
Window sealing, Front door side exterior weather strip: Removal - Refitting, page 66A-3) .
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim).
a Carry out a function test.
66A-2
http://vnx.su
66A
WINDOW SEALING
Front door side exterior weather strip: Removal - Refitting
REFITTING
66A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lower the front side door sliding window.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126891
126461
a Carefully remove the front side door exterior weatherstrip at (1) and (2) using the tool (Car. 1363).
66A-3
http://vnx.su
WINDOW SEALING
Rear side door exterior weather strip: Removal - Refitting
K61
Essential special tooling
Car. 1363
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lower the rear side door's sliding window.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126462
a Carefully remove the rear side door exterior weatherstrip (1) using the tool (Car. 1363).
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Refit the rear side door exterior weatherstrip (1) .
66A-4
http://vnx.su
66A
WINDOW SEALING
Sliding side door window seal: Removal - Refitting
66A
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING + FIXED
WINDOW or R SLID+OPENING WINDOW
REMOVAL
126463
66A-5
http://vnx.su
WINDOW SEALING
Sliding side door window seal: Removal - Refitting
66A
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING + FIXED
WINDOW or R SLID+OPENING WINDOW
126890
126890
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
ELEC. REAR WINDOW SW.
II - FINAL OPERATION.
66A-6
http://vnx.su
WINDOW SEALING
Sliding side door window seal: Removal - Refitting
66A
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING + FIXED
WINDOW or R SLID+OPENING WINDOW
- a new door sealing film (see 65A, Opening element sealing, Door sealing film: Removal - Refitting, page 65A-1) .
66A-7
http://vnx.su
SOUNDPROOFING
Bonnet soundproofing: Removal - Refitting
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126460
a Remove:
- the clips (1) ,
- the bonnet soundproofing (2) .
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Refit the bonnet soundproofing (2) .
68A-1
http://vnx.su
68A
72A
73A
75A
76A
77A
78A
79A
SEAT COMPONENTS
X61
MARCH 2009
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
http://vnx.su
KANGOO II - Section 7
Contents
Page
71A
72A
71A-1
72A-1
Luggage compartment
carpet: Removal - Refitting
71A-5
72A-3
71A-7
73A
71A-12
71A-14
71A-15
71A-18
71A-19
75A
71A-21
71A-22
71A-24
71A-25
http://vnx.su
73A-1
73A-4
73A-5
75A-1
75A-2
75A-5
75A-7
75A-9
Contents
75A
76A
75A-11
75A-13
78A-6
78A-8
SEAT COMPONENTS
76A-1
79A-1
76A-2
79A-4
76A-4
79A-6
79A-7
76A-7
76A-8
76A-10
77A-1
77A-8
78A
79A
77A
78A
77A-16
78A-1
78A-4
http://vnx.su
71A
K61
- the B-pillar lower trims (see 71A, Body internal
trim, B-pillar lower trim: Removal - Refitting,
page 71A-14) .
Essential equipment
diagnostic tool
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
126546
a Remove:
- the clips (1) ,
- the trims (1) ,
REMOVAL
REFITTING
71A-1
http://vnx.su
71A-2
http://vnx.su
71A
71A
F61
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Essential equipment
diagnostic tool
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
126906
a Remove:
- the clips (1) ,
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
REMOVAL
71A-3
http://vnx.su
71A-4
http://vnx.su
71A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the loading door sill (see 71A, Body internal trim,
Loading door sill: Removal - Refitting, page
71A-25) ,
- the rear wheel arch trims (see 71A, Body internal
trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) ,
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Remove the luggage compartment carpet.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the luggage compartment carpet.
II - FINAL OPERATION.
a Refit:
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) .
- the rear wheel arch trims (see 71A, Body internal
trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) ,
- the loading door sill (see 71A, Body internal trim,
Loading door sill: Removal - Refitting, page
71A-25) .
71A-5
http://vnx.su
71A
71A
F61
REMOVAL
II - FINAL OPERATION.
a Refit:
a Remove:
- the rear sliding side door sill (see 71A, Body internal trim, Rear side door sill: Removal - Refitting, page 71A-24) ,
- the loading door sill (see 71A, Body internal trim,
Loading door sill: Removal - Refitting, page
71A-25) ,
- the rear wheel arch trims (see 71A, Body internal
trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) .
126905
a Remove:
- the bolts (1) ,
- the trim (2) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Remove the luggage compartment carpet.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the luggage compartment carpet.
71A-6
http://vnx.su
71A
Essential equipment
diagnostic tool
K61
a
IMPORTANT
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
F61
a Partially remove the front side door seals.
IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the
diagnostic tool.
When this function is activated, all the trigger
lines are inhibited and the airbag warning light on
the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or
naked flame - they may be triggered.
126903
a Remove:
REMOVAL
K61
a
K61
Note:
The front and rear parts of the headlining are
removed independently.
a Remove:
- the windscreen pillar trims (see 71A, Body internal trim, A-pillar trim: Removal - Refitting, page
71A-18) ,
71A-7
http://vnx.su
ROOF STORAGE
- the rear quarter panel trim (see 71A, Body internal trim, Rear quarter panel trim: Removal - Refitting, page 71A-21) .
a Remove:
- the B-pillar lower trims (see 71A, Body internal
trim, B-pillar lower trim: Removal - Refitting,
page 71A-14) ,
71A
126879
a Remove:
- the bolts (4) ,
- the thread supports (5) .
1 - Headlining front section
127505
71A-8
http://vnx.su
F61
126904
71A-9
http://vnx.su
71A
71A
REFITTING
K61
REFITTING PREPARATION OPERATION
126881
F61
a Refit:
- the cabin headlining.
- the upper storage compartment supports (11) in
the roof,
II - FINAL OPERATION.
K61
Headlining front section
126882
71A-10
http://vnx.su
71A
a Refit:
- the B-pillar upper trims (see 71A, Body internal
trim, B-pillar upper trim: Removal - Refitting,
page 71A-19) ,
- the B-pillar lower trims (see 71A, Body internal
trim, B-pillar lower trim: Removal - Refitting,
page 71A-14) .
K61
a Refit the side door seals and tailgate seal.
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components)(88C, Airbags and pretensioners).
ROOF STORAGE
a Refit the front storage compartment under the roof
(see Front storage compartment under roof: Removal - Refitting) (57A, Interior equipment).
a Refit:
- the headlining light (see Headlining light: Removal - Refitting) (81B, Interior lighting),
- the sun visors (see Sun visor: Removal - Refitting) (57A, Interior equipment),
- the windscreen pillar trims (see 71A, Body internal trim, A-pillar trim: Removal - Refitting, page
71A-18) .
K61
Headlining rear section
a Refit:
- the rear quarter panel trim (see 71A, Body internal trim, Rear quarter panel trim: Removal - Refitting, page 71A-21) ,
- the rear wheel arch trim (see 71A, Body internal
trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) .
F61
a Refit the headlining trims (2) .
a Refit the front side door seals.
71A-11
http://vnx.su
71A
F61
REMOVAL
126904
a Remove:
a Remove:
REFITTING
- the windscreen pillar trims (see 71A, Body internal trim, A-pillar trim: Removal - Refitting, page
71A-18) ,
a Refit:
- the cabin headlining,
- the front storage compartment supports under the
roof (5) .
- the sun visors (see Sun visor: Removal - Refitting) (57A, Interior equipment),
- the headlining light (see Headlining light: Removal - Refitting) (81B, Interior lighting).
II - FINAL OPERATION.
ROOF STORAGE
ROOF STORAGE
a Remove the front storage compartment under the
roof (see Front storage compartment under roof:
Removal - Refitting) (57A, Interior equipment).
71A-12
http://vnx.su
71A-13
http://vnx.su
71A
71A
REMOVAL
I - REMOVAL PREPARATION OPERATION
126845
REFITTING
I - REFITTING PREPARATION OPERATION
71A-14
http://vnx.su
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Tilt the rear bench seat.
a Remove the rear parcel shelf.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126899
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the rear wheel arch trim.
II - FINAL OPERATION.
a Refit the rear parcel shelf.
a Tilt the rear bench seat back to its initial position.
71A-15
http://vnx.su
71A
71A
F61
REMOVAL
2 - Second fitting
126898
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
1 - First fitting
126897
71A-16
http://vnx.su
71A
REMOVAL
REFITTING
a Remove the rear panel trim (see 71A, Body internal trim, Rear panel trim: Removal - Refitting,
page 71A-22) .
140621
140620
71A-17
http://vnx.su
126896
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the windscreen pillar trim.
II - FINAL OPERATION.
a Refit the front side door seal.
71A-18
http://vnx.su
71A
71A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the seals of the front and rear side doors partially,
- the B-pillar lower trim (see 71A, Body internal
trim, B-pillar lower trim: Removal - Refitting,
page 71A-14) .
126843
a Remove:
- the front seat belt return mechanism bolt (3) ,
- the front seat belt return mechanism.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
126842
a Unclip the trim from the front seatbelt return mechanism (1) at (2) .
126844
a Unclip:
- the blanking cover (4) ,
- the B-pillar upper trim at (5) and (6) .
71A-19
http://vnx.su
71A-20
http://vnx.su
71A
71A
K61
REMOVAL
126902
REFITTING
126901
a Remove:
- the trim (1) ,
- the bolt (1) ,
- the rear side seatbelt return mechanism (2) .
71A-21
http://vnx.su
71A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Partially remove the front side door seal.
a Move the entire front seat forward.
a Remove the rear seat.
a Open the upper storage compartment in the rear
wheel arch trim.
a Remove the rear seat belt from its housing.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
140619
140617
140618
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Clip on:
- the rear wheel arch trim,
- the clips (1) .
II - FINAL OPERATION
a Fit the rear seat belt in its housing.
a Close the upper storage compartment in the rear
wheel arch trim.
71A-22
http://vnx.su
71A-23
http://vnx.su
71A
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126895
a Remove:
- the bolts (1) ,
- the rear side door seal (2) .
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Refit the rear side door sill (2) .
71A-24
http://vnx.su
71A
127506
a Remove:
- the bolts (1) ,
- the loading door sill (2) .
REFITTING
a Refit the rear wheel arch trims (see 71A, Body internal trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) .
REFITTING OPERATION FOR PART CONCERNED
a Refit the loading door sill (2) .
71A-25
http://vnx.su
71A
72A
REMOVAL
I - REMOVAL PREPARATION OPERATION
MAN. FRONT WINDOW WINDER
a Unclip the manual window winder control.
126468
126467
126469
a Unclip:
- the front side door trim at (5) and (6) .
- the front side door interior opening release cable.
72A-1
http://vnx.su
72A
REFITTING
I - REFITTING PREPARATION OPERATION
126470
a Always replace:
- the bracket (7) ,
- the front side door trim clips.
II - REFITTING OPERATION FOR PART
CONCERNED
PAS ELEC ONE-TCH WIND SW
a Connect the front window winder switch plate connectors.
72A-2
http://vnx.su
72A
REMOVAL
I - REMOVAL PREPARATION OPERATION
K61
K61
126458
126456
72A-3
http://vnx.su
72A
F61
K61
a Clip on the sliding side door opening release cable.
a Refit the sliding side door trim with new clips.
F61
a Refit a new sliding side door trim with new clips (4) .
a Remove:
- the clips (4) using an unclipping tool,
- the sliding side door trim.
REFITTING
I - REFITTING PREPARATION OPERATION
K61
a Always replace the clips on the sliding side door
trim.
F61
a Always replace:
- the sliding side door trim,
- the clips (4) .
72A-4
http://vnx.su
126459
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the tailgate trim clips.
II - REFITTING OPERATION FOR PART
CONCERNED
a Clip the tailgate trim in place.
73A-1
http://vnx.su
73A
73A
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
140632
REFITTING
I - REFITTING PREPARATION OPERATION
140633
a Remove:
- the blanking covers (1) ,
- the bolts (2) .
140634
73A-2
http://vnx.su
73A-3
http://vnx.su
73A
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126464
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace:
- the right-hand rear loading door trim,
- the clips (1) .
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit a new rear right-hand loading door trim.
73A-4
http://vnx.su
73A
73A
F61
REMOVAL
126466
126465
a Remove:
- the trim (1) ,
- bolt (1) .
a Unclip the rear left-hand loading door interior opening handle.
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace:
- the left-hand rear loading door trim,
- the clips (2) .
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit a new rear left-hand loading door trim.
III - FINAL OPERATION.
a Clip on the rear left-hand loading door interior handle.
a Refit the trim (1) .
73A-5
http://vnx.su
75A
127374
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
102189
IMPORTANT
All operations on airbag and pretensioner systems
must be carried out by qualified trained personnel.
The air bags have a pyrotechnic gas generator, with
an ignition module and bag which must not be
separated.
The pretensioners have a pyrotechnic gas generator and an ignition module which must under no circumstances be separated.
108298
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
Note:
Components may only be removed (lugs, wires,
brackets, etc.) to modify the replacement seat
frame according to the type of vehicle.
NO WELDING OPERATIONS ARE PERMITTED.
75A-1
http://vnx.su
75A
Essential equipment
diagnostic tool
- the front seat belt buckle stalk (see Front seat belt
buckle: Removal - Refitting) (88C, Airbags and
pretensioners).
IMPORTANT
Consult the safety and cleanliness advice and operational recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
a Refit:
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbags and pretensioners).
a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
a Remove the complete front seat (see 75A, Front
seat frames and mechanisms, Complete front
seat: Removal - Refitting, page 75A-13) .
- the front seat belt buckle stalk (see Front seat belt
buckle: Removal - Refitting) (88C, Airbags and
pretensioners).
- the front seatback trim (see 77A, Front seat trim,
Front seatback trim: Removal - Refitting, page
77A-8) ,
- the front seat cushion trim (see 77A, Front seat
trim, Front seat base trim: Removal - Refitting,
page 77A-1) ,
- the lower seat covers (see 77A, Front seat trim,
Front seat lower cover: Removal - Refitting,
page 77A-16) .
75A-2
http://vnx.su
75A-3
http://vnx.su
75A
75A
Essential equipment
diagnostic tool
- the front seat belt buckle stalk (see Front seat belt
buckle: Removal - Refitting) (88C, Airbags and
pretensioners),
IMPORTANT
Consult the safety and cleanliness advice and operational recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
a Refit:
- the front seat runners (see 75A, Front seat frames
and mechanisms, Front seat runner: Removal Refitting, page 75A-9) ,
- the front seat belt buckle stalk (see Front seat belt
buckle: Removal - Refitting) (88C, Airbags and
pretensioners).
- the front seatback trim (see 77A, Front seat trim,
Front seatback trim: Removal - Refitting, page
77A-8) ,
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbags and pretensioners).
a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
a Remove the complete front seat (see 75A, Front
seat frames and mechanisms, Complete front
seat: Removal - Refitting, page 75A-13) .
II - FINAL OPERATION.
a Refit the complete front seat (see 75A, Front seat
frames and mechanisms, Complete front seat:
Removal - Refitting, page 75A-13) .
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (88C, Airbags and pretensioners).
75A-4
http://vnx.su
75A
Essential equipment
diagnostic tool
Tightening torquesm
seat base frame bolts
- the front seat belt buckle stalk (see Front seat belt
buckle: Removal - Refitting) (88C, Airbags and
pretensioners).
60 Nm
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
127375
a Remove:
REMOVAL
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the seat base frame bolts (1) .
- the compete front seat (see 75A, Front seat frames and mechanisms, Complete front seat: Removal - Refitting, page 75A-13) ,
75A-5
http://vnx.su
75A-6
http://vnx.su
75A
75A
Essential equipment
diagnostic tool
Tightening torquesm
front seatback frame
bolts60
Nm
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
127571
a Remove:
REMOVAL
REFITTING
a Remove:
- the compete front seat (see 75A, Front seat frames and mechanisms, Complete front seat: Removal - Refitting, page 75A-13) ,
75A-7
http://vnx.su
a Refit:
- the front seatback trim (see 77A, Front seat trim,
Front seatback trim: Removal - Refitting, page
77A-8) ,
- the lower seat covers (see 77A, Front seat trim,
Front seat lower cover: Removal - Refitting,
page 77A-16) ,
- the entire front seat (see 75A, Front seat frames
and mechanisms, Complete front seat: Removal - Refitting, page 75A-13) .
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (88C, Airbags and pretensioners).
75A-8
http://vnx.su
75A
75A
DRIVER HEIGHT ADJUSTER or MANUAL AIR CON 1, and MANUAL PASSENGER SEAT 1
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Essential equipment
diagnostic tool
Tightening torquesm
front seat runner nuts
20 Nm
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
126876
a Remove:
- the nuts (1) from the front seat runners,
REFITTING
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
REMOVAL
75A-9
http://vnx.su
75A-10
http://vnx.su
75A
75A
Essential equipment
diagnostic tool
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbags and pretensioners).
a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
a Remove:
- the front seat (see 75A, Front seat frames and
mechanisms, Complete front seat: Removal Refitting, page 75A-13) ,
- the front seat "cover - foam" assembly partially
(see 77A, Front seat trim, Front seat base trim:
Removal - Refitting, page 77A-1) .
142564
75A-11
http://vnx.su
75A
a Refit:
- the strap for the rear seat access mechanism,
- a new rivet.
III - FINAL OPERATION
a Refit:
- the front seat base "cover - foam" assembly (see
77A, Front seat trim, Front seat base trim: Removal - Refitting, page 77A-1) ,
- the front seat (see 75A, Front seat frames and
mechanisms, Complete front seat: Removal Refitting, page 75A-13) .
142565
Note:
Mark the routing of the front seat unlocking cable
(3) .
a Unclip the unlocking cable of the front seat runners
on the front seat base frame.
a Release the unlocking cable from the front seat runners.
REFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Rivet of rear seat
access control (70,08,04,36).
II - REFITTING OPERATION FOR PART
CONCERNED
75A-12
http://vnx.su
75A
diagnostic tool
Tightening torquesm
new front seat bolts
35 N.m
21 N.m
21 N.m
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
126870
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbags and pretensioners).
a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
75A-13
http://vnx.su
75A
126871
126872
75A-14
http://vnx.su
75A
126873
142486
a Fit the tool (Car. 1848) onto the runners of the front
seat at the rear (5) .
75A-15
http://vnx.su
75A
126871
75A-16
http://vnx.su
75A
141684
REFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Front seat mounting on body (70,06,02,01).
75A-17
http://vnx.su
75A-18
http://vnx.su
75A
76A
REMOVAL
REFITTING
a Refit:
- the rear seat runner (see 76A, Rear seat frames
and mechanisms, Rear seat runner: Removal Refitting, page 76A-2) ;
- the rear seat headrest (see 79A, Seat components, Rear headrest: Removal - Refitting, page
79A-6) ,
- the rear seat headrest guides (see 79A, Seat components, Rear seat headrest guide: Removal Refitting, page 79A-7) ,
- the rear seat headrest guides (see 79A, Seat components, Rear seat headrest guide: Removal Refitting, page 79A-7) ,
- the rear seat base cover - foam assembly (see
78A, Rear seat trim, Rear seat base trim: Removal - Refitting, page 78A-1) ,
- the rear seat runner (see 76A, Rear seat frames
and mechanisms, Rear seat runner: Removal Refitting, page 76A-2) .
- the rear seat headrest (see 79A, Seat components, Rear headrest: Removal - Refitting, page
79A-6) .
II - FINAL OPERATION
a Refit the rear seat.
142556
a
IMPORTANT
In order not to weaken a seat frame or bench
seat frame, all welding operations on the seat
frames or bench seat frames are forbidden.
76A-1
http://vnx.su
76A
Tightening torquesm
new nuts of the rear
seat runner frame on
the rear seat frame
25 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the rear seat,
- the cover - foam assembly of the rear seat base
(see 78A, Rear seat trim, Rear seat base trim:
Removal - Refitting, page 78A-1) .
142553
142551
a Remove:
REFITTING
76A-2
http://vnx.su
142550
76A-3
http://vnx.su
76A
76A
K61
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
complete rear bench
seat bolts
44 Nm
62 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
127473
127472
a Remove:
- the bolts (1) ,
- the protective housing (2) .
76A-4
http://vnx.su
76A
K61
127474
127477
127475
a Remove:
- the complete rear bench seat bolts (8) ,
- the complete rear bench seat (9) .
Note:
It is to advisable to take out the entire rear bench
seat in the vertical position through the side door.
76A-5
http://vnx.su
REFITTING
I - REMOVAL PREPARATION OPERATION
a Always replace the bolts (8) .
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit the entire rear bench seat (9) .
a Torque tighten the complete rear bench seat bolts
(44 Nm) (8) .
a Tilt the universal joint (7) .
a Torque tighten the universal joint bolt (62 Nm) (6) .
a Remove the strap (5) .
a Tilt the entire rear bench seat.
a Refit the front legs.
a Lock the quicklock hooks into position on the rear
bench seat by tilting the entire rear bench seat.
III - FINAL OPERATION.
a Refit the protective cover (2) .
76A-6
http://vnx.su
76A
76A
K61
REMOVAL
II - FINAL OPERATION.
a Refit:
- the 1/3 and 2/3 rear bench seat base frame (see 1/
3 and 2/3 rear bench seat:Removal - Refitting) ,
a Remove:
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) ,
- the 1/3 and 2/3 rear bench seat seatback trim (see
78A, Rear seat trim, 1/3 and 2/3 rear bench seat
seatback trim: Removal - Refitting, page 78A-8)
,
- the 1/3 and 2/3 rear bench seat seatback trim (see
78A, Rear seat trim, 1/3 and 2/3 rear bench seat
seatback trim: Removal - Refitting, page 78A-8)
,
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) .
- the 1/3 and 2/3 rear bench seat base frame (see 1/
3 and 2/3 rear bench seat:Removal - Refitting) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Remove:
- the rear bench seat mechanism (see 76A, Rear
seat frames and mechanisms, Rear bench seat
mechanism: Removal - Refitting, page 76A-10) ,
- the rear seat belt stalks (see Rear seat belt buckle: Removal - Refitting) (88C, Airbag and pretensioners),
- the rear central seatbelt (see Rear centre seat
belt: Removal - Refitting) (88C, Airbag and pretensioners),
- the 1/3 and 2/3 rear bench seat base frame.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the 1/3 and 2/3 rear bench seat seatback frame,
- the rear central seatbelt (see Rear centre seat
belt: Removal - Refitting) (88C, Airbag and pretensioners),
- the rear seat belt stalks (see Rear seat belt buckle: Removal - Refitting) (88C, Airbag and pretensioners),
- the rear bench seat mechanism (see 76A, Rear
seat frames and mechanisms, Rear bench seat
mechanism: Removal - Refitting, page 76A-10) .
76A-7
http://vnx.su
76A
K61
2 - Section 1/3
Tightening torquesm
2/3 seatback/base bolts
19 Nm
19 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) ,
- the 1/3 and 2/3 rear bench seat base trim (see
78A, Rear seat trim, 1/3 and 2/3 rear bench seat
trim: Removal - Refitting, page 78A-6) .
127478
a Remove:
1 - Section 2/3
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the seatback/base bolts (5) and (2) .
II - REFITTING OPERATION FOR PART
CONCERNED
1 - Section 2/3
a Refit:
- the 2/3 rear bench seat base frame (3) ,
- the 2/3 seatback/base bolts (2) ,
- the cover at (1) .
a Torque tighten the 2/3 seatback/base bolts (19
Nm) (2) .
127479
a Remove:
- partially the cover at (1) ,
- the 2/3 seatback/base bolts (2) ,
- the 2/3 rear bench seat base frame (3) .
76A-8
http://vnx.su
76A-9
http://vnx.su
76A
76A
K61
Tightening torquesm
seat base lock bolts
23 N.m
23 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) ,
- the 1/3 and 2/3 rear bench seat seatback trim (see
78A, Rear seat trim, 1/3 and 2/3 rear bench seat
seatback trim: Removal - Refitting, page 78A-8)
.
127471
a Remove:
a Note the lock cable routing for the backrest and the
seat base.
127470
a Remove:
- the bolts for the backrest locks (1) ,
- the rivet (2) ,
- the 1/3 and 2/3 backrest locks (3) ,
- the logicbox unit (4) .
132072
76A-10
http://vnx.su
76A
K61
132073
132075
132076
132074
76A-11
http://vnx.su
76A
K61
Incorrectly fitted
132077
132078
Correctly fitted
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the bolts (1) , (5) and the rivet (2) .
II - REFITTING THE REAR BENCH SEAT
MECHANISM CABLES
a Refit the seatback lock unlocking cable mechanism assembly (16) .
a Clip:
- the seatback lock unlocking cable sleeve at (15) ,
- the seat base lock unlocking cable.
132079
a
Note:
When refitting the seatback lock mechanism, the
locking shaft must not be protruding from the
logicbox (1 7) but must be fitted flush with the
logicbox (18) .
76A-12
http://vnx.su
76A
K61
IV - FINAL OPERATION.
a Refit:
- the 1/3 and 2/3 rear bench seat seatback trim (see
78A, Rear seat trim, 1/3 and 2/3 rear bench seat
seatback trim: Removal - Refitting, page 78A-8)
,
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) .
a Carry out a function test.
132080
a
Note:
In the event that the locking shaft is not flush with
the logicbox (17) , it is necessary to remove the
unlocking cable - mechanism assembly and
turn the bolt (19) then refit the unlocking cable mechanism assembly.
a Close the logicbox.
a Clip:
- the cable on the seat base lock control,
- the cable on the seatback lock control,
- the tie rod on the seatback lock control.
III - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the rear bench seat mechanism,
- the 1/3 and 2/3 seat base locks (6) .
a Torque tighten the seat base lock bolts (23 N.m)
(5) .
a Refit:
- the logicbox unit (4) ,
- a new rivet (2) ,
- the 1/3 and 2/3 backrest locks (3) .
a Torque tighten the seatback lock bolts (23 N.m) (1)
.
76A-13
http://vnx.su
77A
Essential equipment
diagnostic tool
K61, and SHORT CHASSIS, and 2 ADDITIONAL
REAR SEATS, and DRIVER HEIGHT ADJUSTER
or MANUAL AIR CON 1, and MANUAL PASSENGER SEAT 1 or RETRACTABLE PASSENGER
SEAT
a
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and operation recommendations before carrying out any
repair:
- (see A i r b ag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners),
- (see Vehicle: Precautions for repair) (01D,
Mechanical introduction).
IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the
diagnostic tool.
When this function is activated, all the trigger
lines are inhibited and the airbag warning light on
the instrument panel lights up continuously (ignition on).
142568
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or
naked flame - they may be triggered.
77A-1
http://vnx.su
77A
142567
142566
77A-2
http://vnx.su
77A
127365
127367
127368
a Remove:
- the elastic retaining strap (4) on the seatback cover,
77A-3
http://vnx.su
77A
142559
142569
127366
142570
77A-4
http://vnx.su
77A
127369
a Remove:
127367
142571
77A-5
WARNING
To avoid any risk of damaging the foam, separate
the cover from the foam by holding the velcro
strips.
http://vnx.su
77A
REFITTING
K61, and SHORT CHASSIS, and 2 ADDITIONAL
REAR SEATS, and MANUAL AIR CON 1, and
MANUAL PASSENGER SEAT 1
a Refit:
- the elastic retaining straps on the seat base cover,
- the front, rear and side retaining sections (5) .
a Clip on the side retaining clips.
138022
a Refit:
Note:
WARNING
To avoid any risk of detaching or creating folds in
the cover, check that the velcro strips are secured correctly on the foam. If the velcro strips tear,
replace the foam.
77A-6
http://vnx.su
77A-7
http://vnx.su
77A
77A
Essential equipment
diagnostic tool
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and operation recommendations before carrying out any
repair:
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
127371
a Remove the elastic retaining strap (1) for the seatback cover.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbag and pretensioners).
a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
a Remove:
- the front seat headrest (see 79A, Seat components, Front headrest: Removal - Refitting,
page 79A-1) ,
77A-8
http://vnx.su
77A
142560
a Remove the elastic retaining straps (2) for the seatback cover.
127423
a Remove:
- the headrest guides (3) ,
- the side retaining section (4) of the seatback cover.
142705
77A-9
http://vnx.su
77A
127425
127426
127415
77A-10
http://vnx.su
127416
77A
127417
127409
a Remove the elastic retaining straps (13) for the seatback cover.
77A-11
http://vnx.su
77A
127420
127418
a Remove:
- the rivets (16) of the folding table,
- the seatback casing - folding table assembly on
the front seatback.
127419
77A-12
http://vnx.su
77A
127411
127409
a Remove the elastic retaining straps (20) for the seatback cover.
142558
127410
77A-13
http://vnx.su
77A
a Remove:
- the headrest guides (see 79A, Seat components,
Front seat headrest guide: Removal - Refitting,
page 79A-4) ,
- the "foam - cover" assembly of the front seatback.
138022
142561
WARNING
To avoid any risk of damaging the foam, separate
the cover from the foam by holding the velcro
strips.
Note:
The pre-markings on the foam are a guide for
positioning the ends of the velcro strips.
REFITTING
77A-14
http://vnx.su
77A
a Refit:
RETRACTABLE PASSENGER SEAT
- the front seat headrest (see 79A, Seat components, Front headrest: Removal - Refitting,
page 79A-1) .
a Refit:
- a new clip (14) ,
- the elastic retaining straps (13) on the front seatback cover.
77A-15
http://vnx.su
77A
REMOVAL
Essential equipment
I - REMOVAL PREPARATION OPERATION
diagnostic tool
IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the
diagnostic tool.
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or
naked flame - they may be triggered.
127377
77A-16
http://vnx.su
77A
127378
127380
a Remove:
- the bolts (5) ,
- the front seat lower cover (6) (internal part).
127380
a Remove:
127381
77A-17
http://vnx.su
77A
127382
a Remove:
- the bolts (8) ,
- the front seat base height adjuster control (9) (exterior part).
a Unclip the seatback hinge control (1 0) (exterior
part).
127385
127383
a Remove:
- the bolt (11) ,
- the front seat lower cover (12) (exterior part).
77A-18
http://vnx.su
77A
127384
REFITTING
FOLDING PASSENGER SEAT
II - FINAL OPERATION.
DRIVER HEIGHT ADJUSTER, and RETRACTABLE PASSENGER SEAT
77A-19
http://vnx.su
78A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the rear seat.
142546
a Drill out the rivets (2) of the rear seat runner casing.
WARNING
To avoid any risk of damaging the seat trims and
mechanisms, remove any metal residues from
the seat trim clips and/or from drilling the rivet.
142543
a Remove:
- the rear seatback angle adjustment control using
unclipping pliers,
- the rear seat belt stalks (see Rear seat belt buckle: Removal - Refitting) (88C, Airbag and pretensioners).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
142548
a Remove:
142552
78A-1
http://vnx.su
78A
REFITTING
I - REFITTING PREPARATION OPERATION
a
WARNING
To avoid any risk of detaching or creating folds in
the cover, check that the velcro strips are secured correctly on the foam. If the velcro strips tear,
replace the foam.
a parts always to be replaced: Rivet of rear seat
runner casing (70,14,04,34).
142547
a Remove:
- the cover - foam assembly partially,
- the cover at the hinges of the rear seat frame (7) ,
- the cover - foam assembly.
138022
142549
78A-2
http://vnx.su
78A-3
http://vnx.su
78A
78A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Fold down and lock the rear seatback.
a Remove:
- the rear seat,
- the rear seat headrest (see 79A, Seat components, Rear headrest: Removal - Refitting, page
79A-6) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Open the zip fastener of the rear seatback cover.
142545
a Remove:
- the rear seatback cover partially,
- the guides of the rear seat headrest (see 79A, Seat
components, Rear seat headrest guide: Removal - Refitting, page 79A-7) ,
- the cover - foam assembly of the rear seatback
trim.
WARNING
To avoid any risk of damaging the foam, separate
the cover from the foam by holding the velcro
strips.
a Remove the rear seatback cover.
REFITTING
142544
78A-4
http://vnx.su
78A
138022
142557
WARNING
To avoid any risk of damaging the zip fasteners,
close the zips using the tool (Car.1558) while
keeping the zips taut with the two edges as close
as possible to each other.
a Refit:
- the rear seat headrest (see 79A, Seat components, Rear headrest: Removal - Refitting, page
79A-6) ,
78A-5
http://vnx.su
78A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the complete rear bench seat (see 76A,
Rear seat frames and mechanisms, Complete
rear bench seat: Removal - Refitting, page 76A-4)
.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
127483
127373
a Remove:
- the retaining sections (1) ,
- the foam - trim assembly for the 1/3 and 2/3
rear bench seat cushion.
127482
a
Note:
Hold the velcro strips while separating the
foam-trim .
78A-6
http://vnx.su
78A-7
http://vnx.su
78A
78A
K61
Essential special tooling
Car. 1558
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) ,
- the rear left-hand side seat belt buckle (see Rear
side seat belt: Removal - Refitting) (88C, Airbags and pretensioners).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
127465
127460
127463
78A-8
http://vnx.su
78A
K61
127464
127469
127478
127466
a Remove:
- the bolts (13) ,
- the rear centre seat belt guide (14) .
78A-9
http://vnx.su
78A
K61
127461
127462
127479
127468
78A-10
http://vnx.su
78A
K61
1 - 1/3 rear bench seat seatback trim:
a Refit the 1/3 rear bench seat seatback trim foam assembly.
a Clip on the headrest guides (11) .
a Refit:
- the 1/3 rear bench seat seatback cover,
- the retaining strips (9) .
a Close the zip fasteners (8) using the tool (Car.
1558).
a Refit the new clips (7) and (6) .
2 - 2/3 rear bench seat seatback trim:
a Refit the 2/3 rear bench seat seatback trim foam assembly (21) .
127481
Note:
REFITTING
a Always replace:
- the clips (6) , (7) , (15) and (16) ,
a Refit:
- the headrests (4) ,
Note:
Before refitting the 1/3 and 2/3 rear bench seat
seatback trim, check that the velcro strips are
properly attached to the foam.
a Refit the 1/3 and 2/3 rear bench seat seatback trim
(22) .
a Refit:
- the rear left-hand side seat belt buckle (see Rear
side seat belt: Removal - Refitting) (88C, Airbags and pretensioners),
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) .
78A-11
http://vnx.su
SEAT COMPONENTS
Front headrest: Removal - Refitting
79A
REMOVAL
MANUAL AIR CON 1, and MANUAL PASSENGER
SEAT 1 or RETRACTABLE PASSENGER SEAT
127421
79A-1
http://vnx.su
SEAT COMPONENTS
Front headrest: Removal - Refitting
79A
127422
142487
a Press the unlocking button (5) of the front seat headrest guide.
Note:
The front seat headrest has an integrated control.
a Remove the front seat headrest.
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a
IMPORTANT
To avoid any risk of incorrectly positioning the
rods of the front seat headrest, align the rods
before inserting them in the headrest guides.
79A-2
http://vnx.su
SEAT COMPONENTS
Front headrest: Removal - Refitting
Headrest rods misaligned
142683
142684
IMPORTANT
To prevent the headrest coming away from the
guide during a collision, check that headrest
guide locking system is functioning correctly.
a Carry out a function test.
79A-3
http://vnx.su
79A
SEAT COMPONENTS
Front seat headrest guide: Removal - Refitting
79A
Essential equipment
diagnostic tool
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbag and pretensioners).
a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
a Remove:
- the front seat (see 75A, Front seat frames and
mechanisms, Complete front seat: Removal Refitting, page 75A-13) ,
- the front seat headrest (see 79A, Seat components, Front headrest: Removal - Refitting,
page 79A-1) ,
142562
142563
79A-4
http://vnx.su
SEAT COMPONENTS
Front seat headrest guide: Removal - Refitting
K61, and SHORT CHASSIS, and 2 ADDITIONAL REAR SEATS
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the headrest guides fully into the front seatback
frame.
Note:
To prevent the headrest guides from being mixed
up, each headrest guide has a specific indexing
device.
a Check that the headrest guides are secure in the
front seatback frame.
II - FINAL OPERATION
a Refit:
- the front seatback cover (see 77A, Front seat
trim, Front seatback trim: Removal - Refitting,
page 77A-8) ,
- the front seat headrest (see 79A, Seat components, Front headrest: Removal - Refitting,
page 79A-1) ,
- the front seat (see 75A, Front seat frames and
mechanisms, Complete front seat: Removal Refitting, page 75A-13) .
a Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components)(88C, Airbag and pretensioners).
a Carry out a function test.
IMPORTANT
To prevent the headrest coming away from the
guide during a collision, check that the headrest
guide locking system is functioning correctly.
79A-5
http://vnx.su
79A
SEAT COMPONENTS
Rear headrest: Removal - Refitting
K61, and SHORT CHASSIS, and 2 ADDITIONAL REAR SEATS
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
142488
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Refit the rear seat headrest.
IMPORTANT
To prevent the headrest coming away from the
guide during a collision, check that headrest
guide locking system is functioning correctly.
79A-6
http://vnx.su
79A
SEAT COMPONENTS
Rear seat headrest guide: Removal - Refitting
79A
REMOVAL
REFITTING
a Remove:
II - FINAL OPERATION
a Refit:
- the rear seatback cover partially (see 78A, Rear
seat trim, Rear seatback trim: Removal - Refitting, page 78A-4) ,
- the rear seat headrest (see 79A, Seat components, Rear headrest: Removal - Refitting, page
79A-6) .
IMPORTANT
To prevent the headrest coming away from the
guide during a collision, check that headrest
guide locking system is functioning correctly.
a Refit the rear seat.
142554
142555
79A-7
http://vnx.su