GENERAL INFORMATION Key to Symbols Chiselling Crimping of exterior door panels. Safety symbol. This means that the welding operation in question concerns one or more of the Vehicle's vital safety components. Grind back beads or spot welds Straight grinding wheel with a 75mm diameter Bakelite disc, 1.8 to 3.2 mm thickness. Grind back spot welds ‘Straight grinding wheel 20 000 rpm fitted with a spherical burr @ 10 or 16 mm. Body solder - lead fill Hot air torch. Nozzle output temperature min. 600° Handle + 33% tin solder + tallow Note: to a large extent, body solder filing compensates for the heat distortion caused. by welding, Drill spot welds. Hardened steel bit. Speed of rotation 800 to 1000 rpm. Drill < @ 8mm ‘Steel drill bit ‘Speed of rotation 800 to 1000 rpm. Application of weldable mastic. This mastic is a conductor, interposed between two spot welding sheets, it ensures the seal between the sheets and avoids corrosion ofthe spot weld Drill > @ 8 mm Tapered burr ‘Speed of rotation 800 to 1000 rpm. Cleaning surfaces to be welded. Fibre dise © 100 mm Application of aluminium paint. This is to be applied to the joint faces of each of the parts to be plug welded. This paint is. conductive and can withstand high temperatures; it gives anti-corrosion protection around welds Cutting with a saw. Pneumatic power hacksaw. ‘Cut out part by grinding off fiange or grinding back remaining traces of spot weld. Weld finish refining Angle grinder fitted with a rubber pad anda fibre dise @ 120 to 180 mm epee Apply a filet of extruded mastic grain © from a manual or pneumatic spray gun, # one ortwo pot mastic for erimped and butt Unsoldering. Joints. MAG stitch weld Note: to ensure high quality welding, we recommend that you use gas composed of Argon + 15% CO2 which is considered an active gas (MAG) Apply mastic by spraying ‘® spray gun. ‘@ anti-chipping and anti-corrosion in two parts Apply a bead of extruded adhesive mastic ‘@ from a manual or pneumatic spray gun. adhesive mastic in one or two parts Resistance spot welding Plug welding. Under MAG gas protection. Thermal cleaning of extruded or spray mastic 40-4GENERAL INFORMATION Description of parts (exploded view) LOWER STRUCTURE PRF402)| Front towing ring mounting reinforcement (44-V) Acceleration sensor mounting (41-2) Front bearing mounting support (44-¥) Rear bearing mounting support (41-X) Central floor rear reinforcement (44 -AA) Rear side member (41-8) Rear towing ring bracket (44-W) Rear floor (41-P) Rear end cross member (44-T) wenanaensGENERAL INFORMATION Description of parts (exploded view) UPPER STRUCTURE 10 "1 12 13 14 15 16 7 8 PReso22| Light support (44-F) End panel (44) Luggage compartment lid stop mounting support (44-N) Upper hinge mounting support (44-L) Lower hinge mounting support (44-M) Rear wing panel (44-8) Lower hinge mounting reinforcement (44-K) Complete sill panel (43-H) Body side front section (43-F)GENERAL INFORMATION Description of parts (exploded view) REMOVABLE COMPONENTS 1 PRE4025| 49 Front wing (428) 20. Tailgate (48-C) 24 Luggage compartment lid (48-D)40 GENERAL INFORMATION Opening clearancesGENERAL INFORMATION Opening clearances 15042R] 40-9GENERAL INFORMATION 40 Opening clearances 3,342,5 1689618 40-10GENERAL INFORMATION Opening clearances 40-11GENERAL INFORMATION Opening clearances 13 14 6543 40-12GENERAL INFORMATION Collision fault finding Before carrying out repairs to the bodywork of a car, even ifthe damage seems slight, itis necessary to carry out a series of tests: @ VISUAL INSPECTION This inspection involves the examination of the sub-frame of the vehicle where mechanical ‘components are mounted and in the crumple zones or vulnerable areas in order to detect folds where materials have been deformed. ‘@ TRAMMEL GAUGE CHECK The visual inspection may be completed using a trammel gauge which will allow measurement of certain deformations by symmetrical comparisons (for more detail on each point to check, see the repair bench paragraph below). NOTE: to make the marking easier, the reference points located on the left of the vehicle are marked by a capital letter (e.g.: A) and the reference points opposite these with the same function are shown by the same letter with an additional index (e.g.: A’) @ AXLE GEOMETRY CHECK Itis the only check which determines whether the impact suffered by the vehicle has or has not affected its road holding. Important: in borderline cases, it is essential not to neglect checking the axle assembly ‘components which may also have been damaged. ‘On principle, no welded component in the body shell may be replaced without ensuring that the subframe was not affected by the impact 40-132 GENERAL INFORMATION Collision fault finding GAUGE POINTS Point ¢ Itis necessary to remove the front bumper rear protector and both homs to access this point. Front sub-frame front mounting Point M Start point for checking points (A) and (B). Point H Point A It is necessary to remove the engine undertray to Front end of front side member. access this point. ‘Sub-frame rear mounting, 40-14GENERAL INFORMATION Collision fault finding 16887R1 Point B41 Rear axle assembly guide. Point U Rear end panel side end. 40-15GENERAL INFORMATION Sub-frame dimensions Tl Ft 0 vate nce erg me | aes ‘ta ji 7 [Pest at-tane fitted ex mani moe f ame eat eae fie [Rear ave essermy ere ge sere ead |e Er 7 G || Fodiatad rane torimonitig eet [eae tel arertfieeine D [Penta fone tithe renter cea | ae caren [cine 3 @ | Reena ture tathecieearmnaatg eae fresno err une era + | fara aoe esas nonia se gre] oa ceeds aes a sev afm me =r | Seaton acer one ela ear eee = | cansarareneneewen etree rena ES i | tana ron astietoer eee Eorgate|Psseratt | tizoacttl| marcel tte 7) [an ranrarecnnennarera foes | ee [en 7 5 Taithadner Sis marberrar end GoonH frees ose ts D ©] esos nce eros perro wo |e | mo | ua | 52, 1 | eras crennnas popana uty ma | ow | mw | um | oe ea 0 Se ee (erece ae im 5 ie | Geetnorae mar sane ter nannare con i oe ne i F2_ | Erane mating (oer ae Tio [em | sw [wo 3 S| cavrae rotaivanan mang Se rears oe a ee | ttn rear dvecatnaning wo [es | wee er erent ethane ey wor | eo | re | ee 3 40-16GENERAL INFORMATION 40 Sub-frame dimensions 40-17GENERAL INFORMATION Repair Bench | - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL A-FRONT SUB-FRAME REAR MOUNTING Itis the main front reference point. 4-Front mechanical units removed NOTE: on the left hand side the hole is round, on the right hand side itis a slot, ‘When replacing the rear section of the side member, this reference point is replaced provisionally by point (M), located on the seat cross member, point (A) being used to position the replaced component. 2.-Front mechanical units in place ‘The bracket covers the sub-frame mounting bolt. NOTE: the two sides are not symmetrical, on the right hand side the mounting is set on the rubber mounting. Ifthe rear of the vehicle is being rebuilt, these two points alone may be used to align and support the front of the vehicle. It may be used for a light rear impact without removing the rear axle. 40-18GENERAL INFORMATION Repair Bench |- PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL (cont.) B -REAR SUB-FRAME FRONT MOUNTING Itis the main rear reference point. 4-Front mechanical units removed ‘The bracket rests under the rear axle assembly mounting unit and is centred in the sub-frame mounting hole. swaamra| If replacing the complete rear side member or the rear 2.-Fronimechanical unifs:inplace, floor unit, this reference point is replaced by point (M), located on the seat cross member, point (B) being used to position the replaced component. ‘The bracket covers the sub-frame mounting bolt. Ifthe front section is being rebuilt, these two points alone can be used to align and support the rear of the vehicle. 40-19GENERAL INFORMATION Repair Bench Il- ADDITIONAL REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL, ‘These are the provisional reference points which replace the main points, when they have been affected by the impact. M- SUPPORT UNDER FRONT FLOOR G-FRONT SIDE MEMBER REAR END (seat cross member) Point M is also used to position the replaced part. This point is also used as a positioning reference when replacing a rear section of the front side member. ‘These points enable the vehicle to be supported in addition to the main reference point on the impact side and allow only relatively accurate alignment of the vehicle. IMPORTANT NOTE: these reference points should only be used in the cases mentioned above, They are not required when both the main reference points (points A and B) are correct. This additional reference function may also be filled by the front side member ends check points for a rear impact and vice versa 40-20GENERAL INFORMATION Repair Bench ll -REFERENCE POINTS FOR POSITIONING REPLACED PARTS C -FRONT SUB-FRAME FRONT MOUNTING 4 -Front mechanical units removed 2-Front mechanical units in place ‘The bracket rests under the front cross member and is The bracket covers the sub-frame mounting bolt, centred in the subframe mounting hole. Itis used: itis used when replacing: = following a frontal collision for a slight impact, = the lower front cross member, = for fault finding for the jig inspection of the front = the assembled front, section. — a side member, part section, ~ a half unit, Itis necessary to remove the bumper to access the reference point. 40-21GENERAL INFORMATION Repair Bench lll -REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont.) S - DRIVESHAFT FRONT MOUNTING T- DRIVESHAFT REAR MOUNTING 2.-Mechanical units removed only The bracket rests against the rear connecting arches and is centred in the driveshaft bracket mounting hole. Itis used when replacing: = the complete centre floor, = the partial centre floor. 4/-Mechanical units removed only ‘The bracket rests against the front connecting arches and is centred in the driveshaft bracket mounting hole. ltis used when replacing: = the complete centre floor, = the partial centre floor. 40-22GENERAL INFORMATION Repair Bench lll -REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont.) F-FRONT SHOCK ABSORBER UPPER MOUNTING | P-ENGINE MOUNTING ‘The bracket rests under the shock absorber cup and is centred in the shock absorber mounting holes. The bracket is positioned from above the engine mounting and is centred in the mounting holes of the Itis used when replacing: pad. = awheel arch, = a front half unit. It should be used with the mechanical units removed to replace a front half unit. Itis also used when straightening. 40-23GENERAL INFORMATION Repair Bench lll -REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont.) D -REAR SUB-FRAME REAR MOUNTING 4/-Rear mechanical units removed 2.-Rear sub-frame in place ‘The bracket rests under the rear side member andis ‘The bracket covers the sub-frame mounting bolt. centred in the sub-frame mounting hole. It should be used in the event of a rear collision for a Itis used when replacing: ‘small impact. = the side member, part section, = arear unit. 40-24GENERAL INFORMATION Repair Bench lll -REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont.) J-REAR SIDE MEMBER END L -END OF REAR END CROSS MEMBER sre2sR2| ‘The bracket rests under the side member and is centred in the pilot hole. It should be used with the sub-frame in place to realign a side member, It should be used with the mechanical units removed, under the same conditions, to replace a side member. ‘The bracket rests vertically against the rear end cross member, and is then centred in the punching hole. It should be used when replacing the rear end panel assembly with or without the sub-frame. 40-2540| GENERAL INFORMATION Repair Bench Fa MODELE REF.No: REN-87998 RENAULT REN~87995 SCENIC 4x4 TYPE J64 BLACKHAWK te eowous/nme wecranes/ur uEEUKjeen uReEAteh es ®OOO wy Fee | Ty ‘| By he b. ‘iy thy @OOOCOCOCO cH FI 40-26Bi aacessassas nna | ott i i eReePeeeEE 715.304 ag [era [eran Semen RENAULT Repair Bench 40-27 GENERAL INFORMATION LPIAS ST HRT MN AUNT WOMAN Be Bw CELETTEGENERAL INFORMATION Repair Bench IV - SPECIAL TOOLING BLACKHAWK ‘Special heads for MS System Order from BLACKHAWK S.A, Contre Eurofret Rue de Rheinfeld 67100 STRASBOURG ‘Supplier's Part No.: REN 87 998 additional to basic kit REN 87 995. CELETTE ‘Special heads for System MZ Order from CELETTE S.A. BP.9 38026 VIENNE ‘Supplier's Part No.: 745.304 additional to kit 715.330. For “Sevenne” benches, it will be necessary to order belts with part number 715.SANGLE. These are not delivered in the basic kit. Please see the supplier's advice for fitting 40-28GENERAL INFORMATION Special tooling FRONT FACE JIG Points (A) and (B) are the reference points for positioning the jig on the vehicle. ‘The user must ensure that these points are correct when fault finding is carried out before fitting Points (C), (D), (E) and (F) help with the mounting and positioning of the replaced components. Ifpoints (A) or (B) can no longer be used as a reference (detected during a ‘ault nding inspection), the positioning points on the side opposite the impact futfl this function, 40-29GENERAL INFORMATION Special tooling 17589R| Car. 1546 Parts Stores reference: 00 00 154.600 IMPORTANT: the front face jig is not specific to the 4x4, itis also used for the new Scenic models. 40-30GENERAL INFORMATION Special tooling REAR FACE JIG This tool is mainly intended for fitting the luggage compartment lid hinge mountings. Points (A) and (B) are the reference points to position the jig on the vehicle, ‘The user must ensure that these points are correct ‘when fault finding is carried out before fitting, Points (C), (D), (E) and (F) help with the mounting and Positioning of the replaced components. NOTE: when fitting the jig to the vehicle, begin by inserting the lett hand side, 40-31 setzan| Car. 1563 Parts Stores reference: 00 00 156 300LOWER STRUCTURE Rear floor INTRODUCTION ‘The replacement of this part is a complementary ‘operation to the replacement of the rear end panel ora rear side member for a rear impact. This operation is carried out partially (see procedure below): = for the right rear section (according to cut A-A), = forthe left rear section (according to cut B-B). ‘The complete replacement method for this part is the same as for the basic vehicle. In the operation described below, only descriptions of the joints specific to the part concerned are given. The information on the additional parts will be dealt ‘with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part assembled with = floor, — mounting connecting arch. 41-4 PARTS CONCERNED (thickness in mm): ween Rear floor Rear floor rear section Rear centre cross member Rear side member Rear inner wheel arch [P] eresLOWER STRUCTURE Rear floor P [ wd _ oo " A) On the vehicle: o> Boao@) lo” On the Parts Department partLOWER STRUCTURE Rear floorLOWER STRUCTURE Rear fl A> DOD) loor H pe é S| OrpeG a4 e) A) > BraeLOWER STRUCTURE / Rear side member [S] INTRODUCTION The replacement of this part is a complementary operation to the replacement of the rear end panel. This operation is carried out partially (see cut A-A and the method given below): The complete replacement method for this part is the ‘same as for the basic vehicle. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). The repair bench must be used. COMPOSITION OF THE PART FROM THE PARTS: DEPARTMENT Part assembled with: — indentation ring, — mounting reinforcement on the towing ring bracket (tight hand side), — side member reinforcement, rear section, — side seatback mounting reinforcement, — bolt for welding, PARTS CONCERNED (thickness in mm): 4 Rear side member 2 Rearfloor es 41-5LOWER STRUCTURE Rear side member 41-6LOWER STRUCTURE Rear end cross member INTRODUCTION The replacement of this part is a complementary operation to the replacement of the rear end panel. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part assembled with: ~ striker stiffener, — welded nut reinforcements. PARTS CONCERNED (thickness in mm): 4 2 3 4 5 6 Rear end cross member Striker stiffener. Rear floor Tail wheel arch Rear side member Rear end cross member reinforcement sececeLOWER STRUCTURE Rear end cross memberLOWER STRUCTURE Front towing ring mounting reinforcement INTRODUCTION The replacement of this part is a complementary operation to the replacement of the front end cross. member. For standardisation purposes, the cross member is, delivered by the Parts Department without a reinforcement. twill be necessary to screw the towing ring bracket to the cross member to position the reinforcement. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part delivered alone 8 PARTS CONCERNED (thicknes: mm): 4 Front end cross member reinforcement 2 Front end cross member 3. Front end cross member closure panel sep 41-10LOWER STRUCTURE / Front towing ring mounting reinforcement Vv 41-14LOWER STRUCTURE Rear towing ring bracket Wi INTRODUCTION REMOVAL OF THE REAR TOWING RING BRACKET ‘The replacement of this part is a basic operation for a right hand rear collision. ‘The rear towing ring bracket is bolted to the right hand rear side member and to the lower section of the end Panel. This may help with positioning when replacing the rear end panel. COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT ‘Assembled part with threaded roller. Remove: = the two mounting bolts (A) passing through the side member and their reinforcement, = the mounting bolt (B) on the lower section of the end panel. PRES 5 41-12LOWER STRUCTURE / Bearing rear mounting support [Xx] INTRODUCTION The replacement of this part is a complementary operation to the replacement of the centre floor. For standardisation purposes, the floor is delivered by the Parts Department without the bearing rear ‘mounting support. twill be necessary to fit the support after fitting the centre floor, The repair bench must be used, In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part delivered alone. RFA 16| PARTS CONCERNED (thicknes: mm): 4 Bearing rear mounting support 2 Sleeve stop 3° Tunnel stiffener 4 Centre floor 41-13LOWER STRUCTURE / Bearing rear mounting support X 4414LOWER STRUCTURE Bearing front mounting support INTRODUCTION ‘The replacement of this part is a complementary operation to the replacement of the centre floor. For standardisation purposes, the floor is delivered by the Parts Department without the bearing front Mounting support. It will be necessary to fit the support after fitting the centre floor. ‘The repair bench must be used, In the operation described below, only descriptions of the joints specific to the part concerned are given. The information on the additional parts will be dealt ‘with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part delivered alone. PARTS CONCERNED (thickness in mm): 4 Bearing front mounting support 1 2 Front cross member under the front seat 1.5 41-15LOWER STRUCTURE J Acceleration sensor mounting "1 [Z] INTRODUCTION The replacement of this part is a complementary operation to the replacement of the centre floor. For standardisation purposes, the centre floor is delivered by the Parts Department without the acceleration sensor mounting. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS. DEPARTMENT Part delivered alone. PARTS CONCERNED (thicknes: Acceleration sensor mounting Front seat height adjuster Front seat height adjuster reinforcement Centre floor Tunnel stiffener von 41-16LOWER STRUCTURE / Acceleration sensor mounting zZ 4117LOWER STRUCTURE Central floor rear reinforcement INTRODUCTION ‘The replacement of this part is a complementary ‘operation to the replacement of the centre floor or the cross member. For standardisation purposes, these parts are delivered by the Parts Department without the rear floor reinforcement. In the operation described below, only descriptions of the joints specific to the part concerned are given. ‘The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part delivered alone. PARTS CONCERNED (thickness in mm): 4 Central floor rear reinforcement 15 2 Sill panel closure pane! component 18 3 Cross member 12 4 Rear side member 15 5 Centre floor 1 41-18LOWER STRUCTURE Central floor rear reinforcement | PY opr > mi PrpoPGF 41-19UPPER FRONT STRUCTURE Wing INTRODUCTION ‘The replacement of this part is a basic operation for a frontal or side impact. This is a detachable structure component. It will first be necessary to remove: — the side section of the scuttle panel grille (see section 55-G ofthe basic Workshop Repair Manual), = the front section of the valance, partially (see section 55-B), = the front wing extender (see section 55-C), = both sections of the front mudguard (see section 56 of the basic Workshop Repair Manual).UPPER FRONT STRUCTURE Wing REMOVAL Apply two strips of masking tape to the components around the wing, to prevent the paintwork from being scratched during refitting. Remove: = huts (A) and (B) (open the door), — bolts (C), (D), (E) and nuts (F) and (G). Separate the wing from the soundproofing mastic at (H) (see Technical Note 412A). REFITTING NOTE: when refitting, re-apply sealant (detachable components sealing mastic) between the mounting pads on the wing and the front pillar ADJUSTMENT Fitall the mountings without tightening before beginning to adjust the play and flush-fttings (see section 40). REPAIR REMINDER: see Technical Notes 392A and 473A for howto repair wings (Noryl). 42-2UPPER SIDE STRUCTURE / Body side front section [F] INTRODUCTION The replacement of this part is a basic operation following a front side collision The method for replacing this part has not changed, ‘see basic Workshop Repair Manual. For standardisation purposes, the front section of the body side is delivered by the Parts Department without the welded pins on the bottom section for mounting the plastic fittings panels and without the drilings for mounting the longitudinal flaps. It will be necessary to fit the riveted pins (pin rivets) and to make the drilings after the part has been replaced. The number of rivets required will depend on the location ofthe cut on the sill panel The dimensions of the drillings to be carried out are listed below. 43-4UPPER SIDE STRUCTURE Body side front sectionUPPER SIDE STRUCTURE / Body side front section [F] 7962R] DoD om) Hog NOTE: the plastic valance may be used as a dling jig for holes (B).UPPER SIDE STRUCTURE Complete sill panel INTRODUCTION The replacement of this part is a basic operation following a side collision. For the method for replacing this part, see the basic Workshop Repair Manual. The sill panel is delivered by the Parts Department with the welded pins for mounting the plastic fittings panels. The dimensions of the holes drilled are given for your information in sections 43-F and 44-A. COMPOSITION OF THE PART FROM THE PARTS. DEPARTMENT Part assembled with: — Front pillar hinge reinforcement, — Centre pillar hinge reinforcement, — Welded studs, — welded pins. P4202 43-4 [H]UPPER REAR STRUCTURE Rear wing panel [A] INTRODUCTION The replacement of this part is a basic operation for a rear side impact, For the method for replacing this part, see the basic Workshop Repair Manual. The rear wing panel is delivered by the Parts Department with the welded pins for mounting the plastic fittings panels. The dimensions of the holes drilled and and the welded pins are given below for your information. COMPOSITION OF THE PART FROM THE PARTS. DEPARTMENT Part assembled with: — bumper side mounting reinforcement, — striker plate stiffener, rear door, — plate cage, - plate, — sound-deadening material, — fuel pipe unit (right side). = welded nuts, — lower blanking cover, — welded pins. pRe4A 1] 44-4UPPER REAR STRUCTURE Rear wing panelUPPER REAR STRUCTURE Light support INTRODUCTION PARTS CONCERNED (thicknes: This partis replaced in addition to replacin 4 Light support 1 = case n°: the rear end panel andthe rear end pillar | 2 Rearend pillar 1 for a rear impact, 3 Rear wing panel os = case n° 2: the rear wing panel and the rear end pillar | 4 Tail wheel arch 4.2 for a rear side impact. 5 Upper hinge mounting support reinforcement 2 6 Upper hinge mounting support 3 This operation can only be carried out by partial 7 Light support reinforcement 1 cutting. 8 Rear end cross member os 9 End panel upper cross member 1 ‘The rear face jig Car. 1563 (part no. 00 00 156 300) must be used. ‘The Parts Department supplies the light support (1) without the rear end pillar (2). In both cases, it will be necessary to order the rear end pillar to carry out the operation. In the operation described below, only descriptions of the connections specific to the rear end pillar and the part concerned according to cases 1 and 2 are given The information on the additional parts will be dealt ‘with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Assembled part with upper hinge mounting support reinforcement (left hand side). FREAA 1]a4 UPPER REAR STRUCTURE Light support 44-4UPPER REAR STRUCTURE Light support 44)UPPER REAR STRUCTURE Light support F CASE N° 4 (with removal of the end panel) 44-6 (OoMGUPPER REAR STRUCTURE AS Light support F CASE N° 2 (with removal of the wing panel)UPPER REAR STRUCTURE Light support 9 7 Tomtas1aR7| Ope CAB 5205} BoaoUPPER REAR STRUCTURE End panel INTRODUCTION ‘The replacement of this part is a basic operation following a rear collision. ‘The rear face jig Car. 1563 (part no. 00 00 156 300) must be used. ‘There are two methods of carrying out this operation: 4 -Partial following cut A-A. For the left hand side, it will be Necessary to remove the lower hinge reinforcement (see section 44K), 2-Complete In this case it will be necessary to leave the light support reinforcement on the vehicle, opposite the impact and to remove on the unused Parts Department light support reinforcement (see REMINDER 1 in the method below) (On the other hand, it wll also be necessary to fold the metal panel of the upper section of the end panel and the rear end cross member, to ease insertion when fitting the part on the vehicle (see REMINDER 2 in the method described below). NOTE: in the event of complete replacement where the left hand light support reinforcement remains on the vehicle (for example, in case of a right hand side impact), itis not necessary to remove the lower hinge reinforcement completely. It is sufficient to grind the ‘welding bead to the upper section of the end panel (see REMINDER 3in the method described below). In the operation described below, only descriptions of the joints specific to the part concerned are given. Information on parts to which this is additional, will be dealt with in their respective sections (see contents), COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part assembled with: = end panel upper cross member, — bumper mounting angle brackets, — angle bracket supports, — light support reinforcement, — end panel lower cross member, — side member contact reinforcement, — end panel reinforcement, — welded nuts. End panel upper cross member Light support reinforcement, Tail wheel arch Rear wing panel End panel lower cross member Light support Rear end pillar, Rear end cross member Striker stiffener. Lower hinge reinforcement Bumper mounting angle brackets BS eonrvannens445 UPPER REAR STRUCTURE End panel BoDo@Be F} i 44-10UPPER REAR STRUCTURE Af End panel elUPPER REAR STRUCTURE End panel 445 Top14617-2R9| OxDo® 44-12 CopeUPPER REAR STRUCTURE / Ad End panel el atUPPER REAR STRUCTURE End panel Tost9a24.9R9| QB De R Toct4606-2n3| OMS 44.14UPPER REAR STRUCTURE / Ad End panel el 44-15 OMeUPPER REAR STRUCTURE AS End panel \ 0 44-16UPPER REAR STRUCTURE End panel 2-Complete REMINDER 1: it is necessary to remove the light support reinforcement on the Parts Department part (side opposite impact). a4\ a 4417 _ CAATIS26R3] Oop z i Ww > sOo@poGa4\ a UPPER REAR STRUCTURE End panel bey net a pan net of a3 ge Q3 = Z2 ie = es 44-18UPPER REAR STRUCTURE End panel REMINDER 3: in the event of complete replacement where the left hand light support remains in place (for example, in case of a right hand side impact), itis not necessary to remove the lower hinge reinforcement completely. It is sufficient to grind the welding bead to the upper section of the end panel (see section H').. a 10 opPG ToN19020-481 44-19UPPER REAR STRUCTURE Lower hinge reinforcement INTRODUCTION The replacement of this part is a complementary operation to the replacement of the left hand light ‘support and the end panel for a rear impact. The rear face jig Car. 1563 (Parts Department part no. 00 00 156 300) must be used. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS. DEPARTMENT Part delivered alone. PRE4A21| PARTS CONCERNED (thickness in mm): 4 Lower hinge reinforcement 2 Light support reinforcement, 3 End panel upper cross member 4 Rear end cross member 5 Tail wheel arch 6 Light support an oss 44-20UPPER REAR STRUCTURE Lower hinge mounting reinforcement K ope |-SeDe 44-24UPPER REAR STRUCTURE Lower hinge mounting reinforcement Toatse08-1R5| SoAo»PF To119020-2R yp» PGF 44-22UPPER REAR STRUCTURE Upper hinge mounting support INTRODUCTION The replacement of this part is a complementary operation to the replacement of the complete left hand light support, For standardisation purposes, the left hand light ‘support is delivered by the Parts Department without the upper hinge mounting. The rear face jig Car. 1563 (Parts Department part no. 00 00 156 300) must be used. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part assembled with: = upper hinge mounting angle bracket, = upper hinge mounting angle bracket reinforcement, @ prea PARTS CONCERNED (thickness in mm): 4 Upper hinge mounting 3 2 Upper hinge mounting reinforcement 2 3 Light support 1 4 Tail wheel arch 12 44-23UPPER REAR STRUCTURE Upper hinge mounting support [Lt] & 1 3 el oY TOF15607-2R7 44.24UPPER REAR STRUCTURE Ad Lower hinge mounting support [M] INTRODUCTION The replacement of this part is a complementary operation to the replacement of the left hand light ‘support, For standardisation purposes, the left hand light ‘support is delivered by the Parts Department without the lower hinge mounting support. The rear face jig Car. 1863 (Parts Departme part no. 00 00 156 300) must be used. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Assembled part with lower hin ge (bolted). Presa PARTS CONCERNED (thicknes: 4 Lower hinge mounting support 5 2 Light support 1 44-2644h ra UPPER REAR STRUCTURE Lower hinge mounting support CVS 44-27UPPER REAR STRUCTURE Luggage compartment lid stop mounting support [N] INTRODUCTION The replacement of this part is a complementary operation to the replacement of the complete end panel or the right hand side end panel, part section. For standardisation purposes, the end panel is delivered by the Parts Department without the luggage ‘compartment lid stop mounting support. The rear face jig Car. 1563 (Parts Department part no. 00 00 156 300) must be used. In the operation described below, only descriptions of the joints specific to the part concemed are given. The information on the additional parts will be dealt with in their appropriate chapters (see contents). COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT Part delivered alone. 9 prea PARTS CONCERNED (thickness in mm): 4 Luggage compartment lid stop mounting 1.5, 2 Bumper mounting angle brackets 18 3 Light support reinforcement, 1 4 End panel upper cross member 1 5 Bumper mounting angle bracket support 1.8, 44-28UPPER REAR STRUCTURE Luggage compartment lid stop mounting support N 44-29NON-SIDE OPENING ELEMENTS Tailgate REFITTING Before refitting it will be necessary to reseal between the roof rear cross member and the hinges using beading mastic. Stick two strips of masking tape to the edge of the tailgate, to prevent the paintwork from being scratched during refiting. Refit in reverse order to removal. REMOVAL Remove ~ the third brake light, ~ the de-icing connections (B), ~ the washer jet and disconnect. Release: — wiring hamess (A), ~ the two upper mounting protestors (C), ~ the two hinge nuts (E), ~ the balancers by removing the locking clips (D), ~ the tailgate (this operation should be carried out be two people for safety reasons). 48-4NON-SIDE OPENING ELEMENTS Tailgate ‘Suppression of beading and adjustment of the stifiness of closure are carried out at lock (G) and ‘The peripheral play is adjusted via the upper closure striker plate (H). mountings (A). These adjustments must not influence the peripheral NOTE: before beginning the sequence of adjustments, play previously adjusted. it will be necessary to loosen the striker plate and lock. mountings to prevent the tailgate becoming locked in NOTE: in all cases, you should begin by adjusting the the closed position, when checking the peripheral play. } contact surfaces at the hinges. See section 40 for peripheral play. 48-2NON-SIDE OPENING ELEMENTS Luggage compartment lid INTRODUCTION ‘The partis delivered by the Parts Department assembled with: — the casing (polyester composite), ~ the inner metal frame, — the outer panel (Xénoy), ‘See Workshop Repair Manual 502 for the repair methods for plastics. REMOVAL © with hinges (detailed method below), © without hinges, remove only bolts (A) and (B). Disconnect the electric supply cable in the let hand rear wing lining. 48\5) = the luggage compartment lid interior trim (see section 73-8), ~ the emergency spare wheel protector, ~ the emergency spare wheel, = the upper extension on the left hand rear wing panel (see section 56-A), = the left hand lower embellisher strip on the luggage compartment lid (see section 55-H), = the left hand rear wing extender (see section 55-D), = the right hand lower embelisher strip on the luggage compartment lid (see section 55-H), = the electric supply cable (see section 73-A), ~ the windscreen wiper arm (see section 56-B), — the windscreen wiper stop, — the wiper motor, ~ the tailgate closure lock (see section 52-A), — the lower tailgate seal, — the luggage compartment lid handle and lock (see section 52-A and B), — the lower balancer, ~ the tailgate surround seal, = the rear floor lining, ~ the left hand rear wing interior trim, 17514R| = the five mounting bolts (A) on the lower hinge. 48-3NON-SIDE OPENING ELEMENTS Luggage compartment lid Remove the four mounting bolts (B) from the upper = the two mounting bolts (D) on the lower hinge body, hinge. ifnecessary. WARNING: at this moment, a second person is, needed, REFITTING Refit in reverse order to removal. REMINDER: when refitting the hinges, ensure that the mating surfaces are sealed with beading mastic (see Technical Note n° 396A). Remove ~ the three mounting bolts (C) from the upper hinge,NON-SIDE OPENING ELEMENTS Luggage compartment lid SETTINGS In all cases, always begin by adjusting the hinges on the body at mounting points (E), (F) and (6). IMPORTANT. it is necessary to fit the peripheral ‘components and position the emergency spare wheel to check that the luggage compartment lid is flush. s751418NON-SIDE OPENING ELEMENTS Luggage compartment lid IMPORTANT: Mountings (B1) and (H1) are used as chain guides and only allow height adjustment. For additional adjustment settings, these mountings may be replaced by points (B2) and (H2) respectively. The beading and the closure stiffness are adjusted at the lock (I) and the closure striker plate (J), as well as via the lower stops (K) and (L). \ | 1754.18 ‘The peripheral play is adjusted via mountings (H) and (B). See section 40 for the setting values.NON-SIDE OPENING ELEMENTS Luggage compartment 48) 5) ‘SPECIAL FEATURE OF ADJUSTING THE LOWER, STOP Position the lower stop (L) and the two bolts (M).. Leave the central bolt loose. a 1751618 Close the cover. Pull tab (1) to the exterior (the stop comes into contact with the lower beading ofthe casing and allows play to. be eliminated). ‘Open the luggage compartment lid. Cut the tab and tighten the central bolt. NOTE: itis recommended that you order a new lower stop (K) for this operation. However, itis possible to use the old stop (without tab), but adjustment of the lower section will be more difficult.GENERAL Tooling E16. 1552 Special tool for removing the rear screen wiper arm. Unelipping pliers. ir-tree" clips and interior trim clips such as on door panels, soundproofing mats and mudguard mountings can be removed easily using these pliers, Door window winder handles can also be removed irst apply some pull-off tape to the main point with the door lining so that this is not damaged during removal) The heads of the clips are not deformed and can therefore be reused after removal due to the flat and bevelled nose allowing easy access without damaging the clips.NON-SIDE OPENING ELEMENT MECHANISMS Rear screen and luggage compartment lid locks INOTE: it is possible to unlock the rear screen lock manually (without removing the trim) and the luggage Jcompartment lid lock (after removing the trim), REAR SCREEN LOCK LUGGAGE COMPARTMENT LID LOCK After folding the rear seats, After removing the trim (section 73-A), move the lug (A) using a locally manufactured tool move lug (B) using a small screwdriver. (welding rod), This operation requires the help of a person outside the vehicle. 52-1NON-SIDE OPENING ELEMENT MECHANISMS Rear screen and luggage compartment locks [A] REMOVING THE REAR SCREEN LOCK REMOVING THE REAR SCREEN STRIKER PLATE After removing the trim (section 73-A), Remove the two mounting screws. The arrows indicate the adjustment options. disconnect connector (A). REFITTING Remaye:the:two:meunting ssrews:{8}.. To refit, proceed in the reverse order to removalNON-SIDE OPENING ELEMENT MECHANISMS Rear screen and luggage compartment lid locks REMOVING THE LUGGAGE COMPARTMENT LID LOCK AND STOP After removing the trim (section 73), \ Disconnect the connector from the lock. \ it savas Using a flat-nosed pliers, apply light pressure to the stop (C) and remove the lock. Remove: = the two mounting bolts on the stop, REFITTING Check that the lock operates coectly. To refit, proceed in the reverse order to removal. ~ the two mounting bolts on the lock. 52-3NON-SIDE OPENING ELEMENT MECHANISMS Rear screen and luggage compartment lid locks [Al REMOVING THE STRIKER PLATE AND THE PAD REFITTING ON THE BODY To refit, proceed in the reverse order to removal. ‘WARNING: If removing the striker plate and the pad at the same time, the striker plate is no longer supported. Remove: ~ the two striker plate bolts, ~ the two pad bolts. NOTE: the movement arrows indicate the adjustment options. 52-4NON-SIDE OPENING ELEMENT MECHANISMS Luggage compartment lid exterior handle REMOVAL After removing the luggage compartment lid trim (section 73-A), Remove the handle. REFITTING To refit, proceed in the reverse order to removal. remove the handle mounting bolt (A). Disconnect the connector from handle (B). 52-5WINDOWS Rear screen | [A] 18076R| 1 Location of the adjustment stops. 1688418 2 Adjustment stop 3 Adhesive tape IMPORTANT. itis vital that you fit the four self adhesive adjustment stops (part no. 82 00 048 913) to the rear window surround, before bonding it Referto Technical Note 374A for information on how to prepare and bond the windscreen. 54-4EXTERIOR PROTECTION Iss] Front bumper protection 9A] REMOVAL Remove: — the lower mounting bolts (A), ~ the two bolts attached to the towing brackets (C).EXTERIOR PROTECTION Front bumper protection ss07eR| Pull manually on the two ends of the protection to release the part. REFITTING To refit, proceed in the reverse order to removal: 55-2EXTERIOR PROTECTION Front and rear valance protections NOTE: it is not possible to remove the front protection section without first removing the rear protection section. 55-3EXTERIOR PROTECTION Front and rear valance protections REMOVING THE REAR PROTECTION SECTION Remove = the lower mounting clips, REMOVE THE FRONT PROTECTION SECTION Remove: = the lower mounting clips, ~ the three upper mounting clips. Protect the rear wing extender using masking tape. Using unclipping pliers and a flat screwdriver, release the valance protection ~ the upper mounting clips, ~ the mountings (B). Protect the front wing extender using masking tape. Using unclipping pliers, remove the valance protection REFITTING To refit, proceed in the reverse order to removal.EXTERIOR PROTECTION Front wing extender NOTE: it is necessary to prepare a tool to remove the wing extender retaining brackets 40mm s5t12R| Cut the end of an extrusion nozzle (= 15 mm), heat gently and flatten the end ina vice (= 40 mm). 55-5EXTERIOR PROTECTION Front wing extender REMOVAL After removing the front valance protector (section 55-B), Remove mounting screws (A). Protect the wing using masking tape and then release the extender using the special pliers, Disconnect the side repeater. Remove: = the front section of the mudguard, = the mounting bott (C) Disconnect the connector (D) from the fog light wiring harness. 55-6EXTERIOR PROTECTION Front wing extender Unclip the detachable cover upwards, then remove the mounting bolt (E), Protect the wing extender and the bumper using masking tape. Insert the locally manufactured tool between the two sections at (1) then at (2), to unclip the retaining brackets (F) below. REFITTING Offer up the extender ensuring that the wing guide (G) and retaining brackets are positioned correctly, then continue in the reverse order to removal. Pull on the extender to release it to the front. 55-7EXTERIOR PROTECTION Rear wing extender REMOVING THE RIGHT HAND EXTENDER = two mounting bolts (B), = the fuel filer flap, After removing the rear section of the valance protector (section 55-8), Remove = two mounting bolts (C), = mounting bolt (A), 1751628EXTERIOR PROTECTION Rear wing extender = mounting bolts (0), At the same time pull backwards (G) to release the retaining brackets and the extender. REMOVING THE LEFT HAND EXTENDER Special note twill be necessary to remove the left hand cover lower embellisher strip (section 55-H). ‘The operations are continued in the same manner as for the right hand rear extender. REFITTING To refit, proceed in the reverse order to removal. ~ three mounting bolts (E). Unclip the three retaining brackets (F) using a locally manufactured tool (section 55-C).EXTERIOR PROTECTION Front bumper (central section) [E) INTRODUCTION COMPLETE REMOVAL ‘There are two methods for removing the bumper: After removing the bumper protector (section 55-A) — complete removal of the part, and the front wing extenders (section 55-D), = partial removal allowing access to the lens unit mountings. & Remove: - 7S "éeemR2| ~ the central mounting bolt (B). Release the bumper. 55-10EXTERIOR PROTECTION Front bumper (central section) SSE] PARTIAL REMOVAL INCLUDING THE CENTRAL Remove: BUMPER AND THE EXTENDER = the front section of the mudguard, = the mounting bolt (E), After removing the bumper protector (section 55-8), Disconnect the connector (F) from the fog light wiring harness. i = Femove mounting bolts (C) and (D). Remove the central mounting bolts (G) Protect the wing using masking tape and then, release Partially release the wing extender unit with the the extender using the unclipping pliers. bumper. Disconnect the side repeater. 55-11EXTERIOR PROTECTION Front bumper (central section) REFITTING 175088] ‘Offer up the upper section of the bumper impact absorber above the two guides (H). To refit, proceed in the reverse order to removal: ADAPTING THE PART FROM THE PARTS DEPARTMENT FOR FITTING THE FRONT BUMPER PROTECTOR (section 55-A) NOTE: itis necessary to dril the central bumper when this has a protector. {307881 A 910mm B S17mm © Cut according to the markings 55-12EXTERIOR PROTECTION Rear bumper jw [F] REMOVAL ~ the four upper mounting bolts (B), , = the luggage compartment id balancers andits ‘After removing the rear wing extenders mounting ball joint (©) (section 55-D), WARNING: the balancer acts as a door check strap. It is necessary hold the cover using string. Release the bumper. REFITTING To refit, proceed in the reverse order to removal Remove: ~ the three lower mounting bolts (A), 55-13EXTERIOR PROTECTION Front and rear door panels Parsi] 55-14EXTERIOR PROTECTION Front and rear door panels REMOVING THE FRONT DOOR PANEL 55\c) REMOVING THE REAR DOOR PANEL (a 2S \, Pf A Remove the blanking cover (A), and the panel mounting bolt Remove the blanking cover (B), and the panel mounting bolt. Protect the door using masking tape and then release the panel using the unclipping pliers Protect the door using masking tape and then release the panel using the unclipping pliers.EXTERIOR PROTECTION Luggage compartment lid embellishers. REMOVAL After removing the emergency spare wheel, remove the lower mounting bolts (A). 55-16 Protect the luggage compartment lid using masking tape and then release the embellisher using the unclipping pliers (six clips). Disconnect the registration plate light connector. sreots| REFITTING To refit, proceed in the reverse order to removalEXTERIOR ACCESSORIES Rear wing corner extender [Al Extender embellisher (B) Itis possible to remove this part, which avoids masking before painting. REMOVAL swa791% Apply pressure to the retaining brackets (C). At the same time pull on the part which is held by the double sided achesive tape (D). REFITTING Apply double sided adhesive tape to the front embellisher before reclipping it Check that the seals are positioned correctly (E). To refit, proceed in the reverse order to removal. Remove: ~ the rear light, ~ the two mounting botts (A). — the lower clip using a small flat screwdriver, — the upper clip using the special clamp. 56-1EXTERIOR ACCESSORIES Rear windscreen wiper arm PRESo06| WARNING: Use the special tool Elé. 1552 to remove the rear screen wiper arm, 56-2EXTERIOR ACCESSORIES Rear windscreen wiper arm jw REMOVAL After removing the emergency spare wheel, remove the nut cover, unscrew the mounting nut on the am by one tum, insert the tool, 1 Extractor bolt (wedged on the loosened nut) 2 Short bend clip 3° Long bend clip After unlocking the arm, remove the extractor then ‘complete the operation manually, REFITTING Tightening torque for the nut 14.4 Nm 56-3