BODY TOP Cab roof side extender 45\x) 46-27BODY TOP 45] Cab roof side extender [K] oss oars 46-28BODY TOP Cab roof drip moulding lining INTRODUCTION This part ischanged in addition tochanging the sideroof extender with roof drip moulding and the cab pillar upperstiffener. The cab roof drip moulding, the seat belt moun. ting upper stiffener and the eab rear pillar upper stiffener rust be ordered separately In the proce dure described below, you will only find descriptions of the connections which are specific to the part concemed. Connections asso- ciated with the additi onal parts are not taken into consideration, These connections will be dealt with in their respective section (referto contents) COMPOSITION OF THE REPLACEMENT PART A. Cabroof drip moulding ining Asserabled part with: eal eee be PARTS CONCERNED (thicknessin mmy: - tab pillar lower lining 4 Cab of dip moulding linmg O8 2 Cab roof 08 B Seat belt mounting upper stiffener 5 Led aaroct te 4 Front side panel 08 © Cob rearpiller upper stiffener 5 Cab roafeross memiber rear bracket Os 6 Cab rear pillar upper stiffener 08 7 Seat belt anchorage upper stiffener 12 8 Cab pillar roof lower rear crass rmemaber bracket 08 © Side panel connection component 08 410 Lead area front roof drip moulding 07 44 Load area frant roof drip moulding lining 08 12 Cob frame 08 45-29BODY TOP Cab roof drip moulding lining [L]BODY TOP Cab roof drip moulding lining 45\c) 48-31BODY TOP Cab roof drip moulding lining [L]BODY TOP Load area front roof drip moulding INTRODUCTION This part ischanged 1. a3. basic operation for the version with shi- ding side door, 2. imadditionto changing the side panel for the version without a sliding side door, The load area roof drip moulding closure panel rust be ordered separately. In the proce dure described below, you will only find desertpti ons of the connections which are specific to the part concemed. Connections asso- ciated with the additional parts are not taken into consideration, These connections will be dealt with in their respective section (referta contents) COMPOSITION OF THE REPLACEMENT PART 1 Load area front roof drip moul ding Part only § Load area roof drip mouldingel osure panel Part only 45-33 PARTS CONCERNED (thicknessin mm}: Load area front roof drip moulding Roofside extender Cab reat Load area root Load area roof drip moulding front dlosure panel Load area front roof drip moulding ining Cab rear pillar upper stiffener Cab roof daipmoulding lining Sliding cide door special roof drip moulding stiffener 40. Load area rear roof drip moulding 44 Rooferess member side bracket oe weuNne eon [M] Or ur 8 cir 8BODY TOP 45 Load area front roof drip moulding oss 48-34 oarsBODY TOP 45 Load area front roof drip moulding M 45-35BODY TOP 45 Load area front roof drip moulding M 48-36BODY TOP Load area front roof drip moulding 48-37BODY TOP 45 Load area front roof drip moulding M oars 48-38BODY TOP Load area rear reof drip moulding IN] INTRODUCTION This pert is changed in addition to changing the rear side panel Inthe procedure described below, you will only find descriptions of the connections which are specific tothe part concerned. Connections asso- ciated with the additional parts are not taken into consideration. These connections will be dealt, ‘with in their respective section (refer to contents). COMPOSITION OF THE REPLACEMENT PART Part only. PARTS CONCERNED fthiekness in rrrn}: Load areazear roof daip moulding a Load areafront roof drip moulding 0. Load arearocf a Roof rear cross member a Lights support panel Load arearoof drip moul ding ning Cob rear pillar upper stiffener Nomen 45-39BODY TOP Load area rear drip moulding 45\n0) 48-40BODY TOP Load area rear roof drip moulding [N] 48-41BODY TOP Load area front roof drip moulding lining INTRODUCTION This part is changed in ad dition to changing the oad area front roof drip moulding with closure Panel. Inthe procedure described below, you-will only find descriptions of the connections which are specific tothe part concerned. Connections a3s0- ciated with the additional parts are not taken into consideration. These connections will be dealt, ‘with in their respective section (refer to contents) COMPOSITION OF THE REPLACEMENT PART Part only. PARTS CONCERNED (thickness in mm): 4 Loadarearoof drip mouldinglining 1.8. 2° Cab roof driprnoulding bining 08. 3. Cab rear pillarupper stiffener 08 4 Cab roof sideextender a7 5 Centre pillar upper section 08, 6 Centre pillar ining 1 45-42BODY TOP Load area front roof drip moulding lining [Oo] h7s5R, 48-43 oarsBODY TOP Load area front roof drip moulding lining [Oo] mere} | Po cents 5 oss , Boag 48-44BODY TOP Load area rear roof drip moulding lining INTRODUCTION This pert is changed in addition to changing the load area rear roof drip moulding. Inthe procedure described below, you will only find descriptions of the connections which are specific tothe part concerned. Connections asso- ciated with the additional parts are not taken into consideration. These connections will be dealt, ‘with in their respective section (refer to contents). COMPOSITION OF THE REPLACEMENT PART Part only. PARTS CONCERNED fthiekness in rrrn}: 4 Load arearoof drip moulding rear lining 2. Exreme rear pillar upperstiffener . 3. Exreme rear pillar upper section 15 45-45BODY TOP Load area rear roof drip moulding lining [P] 48-46SIDE OPENINGS Front door INTRODUCTION The changing of this part is. basic operation ta be cartied out foll owing a side collision, Ibis aremovable body structures component, REMOVAL, Remove: - the front bumper (see section $5.4), - the radiator grille (see section 55-C), - the front wing (see section 42.4) aadSIDE OPENINGS Front door REFITTING TIGHTENING TORQUES (in daly v. Hinge mountingbolts Door check strap Fit the door support (see section 50) Remove the door check strap bolt, the door hinges (6 mounting bolts (4)) OPENING CLEARANCES areREMOVAL, IS (i ae SJ C3 Remove the door trim (clip (4). SIDE OPENINGS Sliding side door A7\e Remove: = the three mounting bolts (B)which seoure the arm to the door, = the cover (C) clipped onto the runner. Detach the reller by pulling the slider rearward outside the rumner.SIDE OPENINGS Sliding side door REMOVING THE GUIDE RUNNER 1420R Remove the runner mounting bolts (0) ‘At the front, the rummer is secured ta a metal an- eke bracket ‘This angle bracket is seoured to the body side with three mountingbalts B) a4SIDE OPENINGS Sliding side door REMOVINGTHE CENTRE SLIDER remove: the door trim, the three slider mounting bolts (4) Detach the slider from its location on the deer. To remove the slider from the guide runner, tlt it upwards to free the rumnerrollers. 47-5SIDE OPENINGS Sliding side door RE MOVINGTHE CENTRE GUIDE RUNNER - #0 jee to OOo. Sea Remove mounting nuts ®) Remove the runner fromthe rear wing panel REMOVAL OF THE LOWER ARM Remove the three arm mounting bolts 4), To remove the slider from the guide runner, tiltit upwards to free the runnerrollers. hesmen Remove mounting belts (1) and nut () Remove the runner frown the rear wing panel.SIDE OPENINGS Sliding side door REFITTING AND ADJUSTMENT For the sliding door refitting and adjustment ope- ration, refer to section 51-F. When refitting the door, observe the tightening torques below’ TIGHTENING TORQUES Centre runner Upper runner Lower runner Centre slider Upper arm Lower arm ATTSIDE OPENINGS Sliding door panel INTRODUCTION The changing of this part isa basic. operation to be carted out following aside collision. Ttean be changed in twa ways: 1- Complete replacernant for panelled versions 2- Partial replacement by cuttingthe window uprights following the cuts shown on the dia- gram below. COMPOSITION OF THE REPLACEMENT PART Part only. PARTS CONCERNED {thickness in mer} : 1 Door panel 08 2 Door bor section 1 47-8SIDE OPENINGS Sliding door panel 91H 7cSIDE OPENINGS Sliding door panel 2- VERSION WITH WINDOW FHS 47-10OTHER OPENINGS Bonnet reason Open the bonnet. Position the stay, Remove the two right and Jeft hand mounting bolts (4) (this operation must be carried out by two people) 48-1 REMOVING THE BONNET HINGES Afterremoving: = the bonnet, - the scuttle grille (see section 55-D), remove the hinge mounting belis @) (seeillustra- tion below). REFITTING TIGHTENING TORQUES (endat.m Bonnet fhinges mounting bolts 18OTHER OPENINGS Hinged doors 5 INTRODUCTION ‘The changing of this part isa basic operation ta be cared out followinga rear callision. Remove the door trim (see section 73.) Disconnect the heated rear sereen hamess if fit. ted. Remove the number plate lights from the plastic stiipand remove the supply c omnectors Detach hamess grommet (4) and detach the har ness 30 as to be able ta remove it from the door box section. Fit the doorsupport tool (see section 5(-B) Remove the doorhinge mounting bolts B). Remove: - the door check strap (C), - the hinges from their Locations on the bedy. 48-2OTHER OPENINGS Hinged doors REFITTING AND ADJUSTING THE DOORS Before refitting bolts (B) check that the metal spa- cers are present between the pillar and the bolt. heads, Refit in the reverse order to removal and refer to the opening clearances section to adjust in rela. tion to the roof and side panels. Tighten the hinge mounting bolts observing the tightening torque below. To adjust the opening clearance between the twa doors and of the hinged door locks and strikers, refer toseetion §2-C. 48-3OTHER OPENINGS Hinged door panel INTRODUCTION The changing of this part isa basic. operation to be carted out following aside collision. Ttean be changed in twa ways 1- Complete replacernent 2- Partial replacement of the lower section, 3- Partial replacement by cuttingthe window uprights in line with the euts shown on the diagram below. COMPOSITION OF THE REPLACEMENT PART Part only. PARTS CONCERNED (thickness in mr) : 1 Deor panel 08 2 Door bee section, 1 48-4OTHER OPENINGS Hinged door panel 1- ALL VERSIONS 48-6OTHER OPENINGS Hinged door panelOTHER OPENINGS Hinged door panel 48) c) BapOTHER OPENINGS Hinged door panel caviserRa|Master E4¥ Sheet metalwork EQ ceNeRAL LOWER STRUCTURE UPPER SIDE STRUCTURE TOP OF BODY HD All types 7711 204 087 FEBRUARY 1999 Edition Anglaise AMleqarighe teed Belt agg somnning prep dnc mf st v1 aol cedengettrusad bye ses reins See atadaea wnt er tn ery rely ncaa ewe emcee Ena ” © Pevsut 190EXPLODED VIEW PRHs008R1 4 A B c D E F c H 1 J K L M GENERAL Using symbols Key to symbols Description of parts (exploded) Special tooling Opening clearances LOWER STRUCTURE Rear end cross member closure panel Rear end cross member Rear sice member closure panel part section Rear leaf spring mounting unit Central centre cross member Centre side member Front leaf spring mounting unit Front centre cross member Rear centre cross member Cab rear step Cab rear pillar cross ember Double cab rear floor part section Tunnel support Sheet metalwork Contents Page 4041 40.3 40-4 40-7 40.8 415 418 41d 413 4116 4121 41-23 41-25 41.30 41-32 41-36 [as] UPPER SIDE STRUCTURE A B c D E F G H 1 J K Double cab rear pillar Double cab stretcher Double cab stretcher lining Side panel Side door sill panel Cab rear pillar sill panel Rear pillar sill panel closure panel Cab side sill panel Cab rear pillar closure Partition cross members Partition pillar TOP OF BODY Roof 451 Courtesy light mounting 45-4GENERAL Using symbols ‘The above dlagram shows parts on the vehicle for which a section of the panel butt welding jolnt Is. shown by the dlagrams which follow. w= This dashed line shows the centre line of the sections The potnt shows the exact position of the weld joint ‘This letter designates the drawing corresponding to the seetton dt ts gl- ven In one of the upper corners of each drawing } The following indications are found In the section dlagrarns ‘The part in black ts the one which will bbe removed In the operation are the part numbers corresponding to Tand7 the list on the introduction page This arrow on the diagram designates the access point for the unpicking of spot welds (ee specific cases) » Tealso indicates the logtcal sequence of operations in the symbols which follow each diagram. Example : place of operation and logical sequence 1 + i eS @ ae) unpleking with grinder fl t spot welding ‘weldable mastic 40-1GENERAL Using symbols SPECIFIC CASES J CAATISS?=IRS Oo In this example, there ts no direct aecess for remo- ving part 1. The spot welds should be unpicked through part 2, which should be kept. [cagrise7-1Rs (Ar @ao+ ZB ‘This arrow indicates that It Is necessary to cut the part it crosses before acces- sing the joint. ‘The references which follow Indicate different operations > unpieking > — welding Under diagram I site of operation and order of operations ’ ’ , QD 4 Is opera: npicking | apphy weld fk ton ‘with grinder vet chisel the edge 24 opera: tion 303542. > Y In this particular case, the arrow Indicates that the joints made by are welding (MIG). 7 | — 2 / 9 7 30349 in this example, the jolntis made by bonding. A» 40-2GENERAL Key to symbols Chiselting Plug welding. Under MAG gas protection. Grind back beads or spot welds. Stralght grinding wheel with 75 mm diameter bakelite impregnated disc, thickness 1.8 to 3.2 mm. Grind back spot welds. 20 000 rpm straight grinder with 10 or 16 mm diameter spherical burr. Crimping of exterlor door panels. Safety symbol. ‘This means that the welding operation In question concems one or more of the vehicle's vital safety components. Drill spot welds. Hardened steel bit, Speed of rotation 800 to 1000 rpm. Unpicking, Body solder - lead fl. Hot air torch. Nozzle output temperature 600° min. Slipper+ 33% tin solder + tallow. Note : toa large extent, body solder filling compensates for the heat distortion caused by welding. Cleaning surfaces to be welded, 100 mam diarneter fibre dlse. Cutting with a saw. Pneumatic power hacksaw. ~ Cutting out part by grinding off flange or grinding back remaining traces of spot weld. ~ Finish surface after welding. - Angle grinder equipped with a rubber pad and a 120 to 180 mm dlameter fibre dise grain size P36, Unsoldering. MAG stitch weld Note : to obtain a good quality weld we recommend the use of a gas consisting, of argon + 15% CO2. This is considered to be an active gas (MAG) Spot weld 4 Ss @ © & ® Application of weldable mastlc. ‘This mastic conducts electitcity. applied between two panels to be spot welded, ILensures the seal between the panels and avolds corrosion of the spot welds. Application of aluminium paint. ‘This is to be applied to the joint faces of each of the parts to be plug welded. The paint conducts electricity and ts ts resistant to high temperatures. It provides antl-corrasion protection around the plug welds. Apply a illet of extruded mastic + from a manual or pneumatic spray gun. + one or two part mastic for erimped and butt joints, Spray on sealer + spray gun. + two part antt-gravel and antt- corroston mastic. 40-3GENERAL 40 Description of parts (exploded view) LOWER STRUCTURE 160 (161 162 163 164 165 166 167 168 READS *160 Cab rear floor *172 Rearside member inner spacer *161 Front centre cross member closure panel “173 Rear side member *162 Front centre cross member “174 Leaf spring front mounting closure panel *163 Central centre cross member closure panel “175 Leaf spring mounting reinforcement *164 Central centre cross member *176 Leaf spring support inner reinforeernent *165 Tunnel support “177 Leaf spring mounting reinforcement 166 Rear centre cross member 7178 Leaf spring mounting support “167 Rear end cross member “179 Leaf spring support lower closure panel "168 Rear end cross member closure panel "180 Rear side member closure panel 169 Rear side member reinforcement "181 Double cab step “170 Lower rear leaf spring mounting "182 Cab rear pillar cross member “INL Upper rear leaf spring mounting * Parts for which repaired areas must be electro zinc plated. 40-4GENERAL Description of parts (exploded view) 191° 192 193 194 195 196 197 198 190 Courtesy light mounting 201 Partition lower cross member * 191 Cab roof * 202 Cab rear pillar panel 192 Roof centre cross member * 203. Cab rear pillar sill panel 193 Cross member reinforcement * 204 Cab rear pillar 194. Roof stiffener * 208. Cab rear pillar closure 195 Roof rear cross member * 206. Sill panel under door on double cab 196 Roof rear cross member closure panel * 207 Sill panel closure panel 197 Partition stiffener * 208 Cab side sill panel 198 Assembled partition * 209 Double cab body side 199 Partition upper cross member 210 Roof stretcher on double cab door 200 Partition reinforcement pillar 211 Roof stretcher lining * Parts for which repaired areas must be electro zinc plated 40-5 PREADOSGENERAL Description of parts (exploded view) REMOVABLE COMPONENTS: pepan07| Bonnet Rear side door Front stde door Front wing. 40-6GENERAL Special tooling 40 FRONT END JIG 142408 Points A and B are the reference points for positioning the jig on the vehicle. Before fitting the lg, ensure that these polnts are correct during collision examination. Points D,E, F, G and thetr symmetry are used for mounting and positioning the components replaced (headlight carrler panel, cowl side panel). Tretther of points or B cannot be used as a reference point (detected during faut finding) these points on the side opposite to the Impact may be used as a positioning reference pol. Note for fitting the jig: ‘The Jig Is supplied dis-assembled. The varlous parts mustbe assembled before It is used to restructure a vehicle. To do this, secure parts 1 and 2 using bars 3 and 4, and bolts H and C. Bars 5 are used to position the top of the jlg with the butkhead reinforcement at the windsereen wiper support mounting, “Methods Part Description reference Number e Drawing Car. 1451-0000 145 100 Frontend jig 4070s 40-7GENERAL Opening clearances 40 i 6542 1s705R e745 19702 et25 157088LOWER STRUCTURE Rear end cross member closure panel INTRODUCTION ‘The replacement of this part Is a baste operation fora rear Impact. COMPOSITION OF PART FROM PARTS DEPARTMENT Single part. 70521-15676 PARTS CONCERNED (thickness in mm) : 4. Rear end cross member closure panel 1.2 2. Rear end cross member 3. Rear end cross member relnforcement 1.5, 4. Rear side member closure panel 12 cABi1539R5| HCD 41-1LOWER STRUCTURE Rear end cross member closure panel [AlLOWER STRUCTURE Rear end cross member INTRODUCTION The replacement of thls part is a complementary operation to the replacement of the rear end cross member closure panel. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) ‘The repair bench mustbe used. COMPOSITION OF PART FROM PARTS DEPARTMENT Part assembled with side reinforcements. [pReanis PARTS CONCERNED (thickness in mm) : 4 Rearend cross member 2 2 Rearend cross member retnforcement 1.5 3. Rear side member closure panel 12 4 Rearside member extenston 18 41-3LOWER STRUCTURE Rear end cross member [Bl Beep» ~ BGGLOWER STRUCTURE Rear side member closure panel, part section INTRODUCTION The replacement of thls part is a complementary operation to the replacement of the rear end cross member. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) ‘This part may be partially replaced In two ways (see drawing of the cut and method below) - cut A for replacing the rear end section, - cut B for replacement after a side impact. COMPOSITION OF PART FROM PARTS. DEPARTMENT Single part. PREALIB| PARTS CONCERNED (thickness in mm) : 41 Rear side member closure panel 12 2. Rear side member 18 2 Rear side member reinforcement 12 41-5LOWER STRUCTURE Rear side member closure panel, part section [C] Gra)LOWER STRUCTURE Rear side member closure panel, part section [C] Gra)LOWER STRUCTURE Rear leaf spring mounting unit INTRODUCTION ‘The replacement of this part ts a complementary operation to the replacement of the rear side member, part section for a rear impact or an im. pact at a corner. The method described only contains deseriptions of joints specific to the part concerned. Joints with complementary parts are not Inclucied. These are dealt with in thelr respective section (refer to the contents page). The repair bench must be used, COMPOSITION OF PART FROM PARTS DEPARTMENT 1 Single part 7o1d2t.16670 2 Single part CAAT1S96R rg 1 Leaf spring mounting rear bracket closure pa- nel 2 Leaf spring mounting rear bracket PARTS CONCERNED (thickness in mm) : 1. Leaf spring mounting rear bracket closure panel 12 2. Leaf spring mounting rear bracket 15 3. Rear side member closure panel 12 4 Rear side member 18 5 Rear side member relnforcement 15 41-8LOWER STRUCTURE Rear leaf spring mounting unit [D]LOWER STRUCTURE Rear leaf spring mounting unit [D] CAYI265R2 Il | I s—_l 41-10LOWER STRUCTURE Central centre cross member [E| INTRODUCTION The replacement of thls part is a complementary operation to the replacement of the rear side member closure panel ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) ‘This part may be partially replaced (see diagram. of the cut below which ts not described in the me- thod). COMPOSITION OF PART FROM PARTS: DEPARTMENT Part assembled with: upper cross member, upper cross member reinforcement. PARTS CONCERNED (thickness in mm) : 41 Upper cross member 12 2. Upper cross member reinforcement 18 3. Rear side member closure panel 12 4 Rear side member 18 5 Lower cross member 12 41-11LOWER STRUCTURE Central centre cross member [E| 41-12LOWER STRUCTURE Centre side member [F] INTRODUCTION The replacement of this part is a complementary operation to the replacement of the centre cross member or the central centre crass member. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) COMPOSITION OF PART FROM PARTS: DEPARTMENT Part assembled with: - centre small side member, - cable sleeve stop section. PRE4120 PARTS CONCERNED (thickness In mm) : 4 Centre side member 12 2 Central centre cross member 12 2 Lower cross member 12 4 Rear centre cross member 12 41-13LOWER STRUCTURE Centre side member [F] PA Q 41-14LOWER STRUCTURE Centre side member 41-15LOWER STRUCTURE Front leaf spring mounting unit INTRODUCTION ‘The replacement of this part ts a baste operation, fora side impact. ‘The method described only contains descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with In thelr respective section (refer to the contents page). ‘The repair bench must be used. COMPOSITION OF PART FROM PARTS DEPARTMENT 1 Leaf spring mounting bracket lower relnforce- ‘ment Leaf spring mounting bracket. Leaf spring mounting bracket reinforcement Leaf spring mounting bracket closure panel Leaf spring mounting bracket closure panel relnforcement 6 Leaf spring mounting bracket closure panel reinforcement 41-16 ig) PARTS CONCERNED (thickness in mm) : 4 Front leaf spring mounting bracket lower reinforcement 15 Front leaf spring mounting bracket 2 Front leaf spring mounting bracket reinforcement 15 Front leaf spring mounting bracket closure panel 15 Front leaf spring mounting bracket closure panel connecting relnforcement Front leaf spring mounting bracket closure 18 panel reinforcement 18 Rear side member closure panel 12 Rear side member 18 Rear side member reinforcement 15LOWER STRUCTURE Front leaf spring mounting unit semoAPG B | & | I I /+——5 Oop 41-17LOWER STRUCTURE Front leaf spring mounting unit Ap Qog) A »Hoq) DoD’ F _ TOSH672-4R1 soggy Boog A — _l SVG 41-18LOWER STRUCTURE Front leaf spring mounting unit [S|LOWER STRUCTURE Front leaf spring mounting unit Oop 41-20LOWER STRUCTURE Front centre cross member [H] INTRODUCTION The replacement of thls part is a complementary operation to the replacement of the rear side member closure panel ‘The cross member closure panel must be ordered as an additional part. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with, complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) ‘This part may be partially replaced (see diagram. of the cut below which fs not described in the rne- thod). COMPOSITION OF PART FROM PARTS: DEPARTMENT Part assembled with: = upper cross member, = upper cross member reinforcement. PARTS CONCERNED (thickness in mm) : 4. Upper cross member 12 2 Upper crass member relnforcement 1.8 3° Rear side member closure panel 12 Rear side member 18 oe Bront centre cross member closure panel 1.2 41-21LOWER STRUCTURE Front centre cross member [H] 41-22LOWER STRUCTURE Rear centre cross member [1] INTRODUCTION The replacement of thls part is a complementary operation to the replacement of the rear side member closure panel. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) COMPOSITION OF PART FROM PARTS: DEPARTMENT Part assembled with: - Upper cross member, ~ Upper cross member reinforcement, - Emergency spare wheel mounting. PRES PARTS CONCERNED (thickness in mm} : 4 Rear centre cross member 12 2 Rear centre cross member reinforcement 1.3 3. Rear side member closure panel 12 4 Rear side member 18 41-23LOWER STRUCTURE Rear centre cross member [1] 41-24LOWER STRUCTURE Assembled cab rear step INTRODUCTION ‘The replacement of this part 1s a complementary operation to the replacement of the sill panel un- der the door and the rear pillar closure panel ‘The method described only contains descriptions of Joints specific to the part concerned. Joints with, complementary parts are not Included. These are dealt with In thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS DEPARTMENT Part asserabled with: = step. - step closure panel, - step support bracket, [pepaiz3 PARTS CONCERNED (thickness in mm) : 41 Double cab step 1 2 Step support bracket 12 3. Double cab step closure panel 12 4. Rear pillar bracket 15 5 Double cab floor 08 8 Front floor cross member 18 7. Rear floor cross member 15 8 Support cross member for the rear seat 1.2 cABi1539R5| 41-25LOWER STRUCTURE Assembled cab rear step [J] o@yoap Boao’ ]LOWER STRUCTURE Assembled cab rear step 41-27LOWER STRUCTURE Assembled cab rear step [J] SQ TOC 14608-1R1 41-28LOWER STRUCTURE Assembled cab rear step NOTE : if, during the replacement of the cab rear step, the rear seat support member must alse be replaced, cut off the metal tab (A) flush with the support on the part provided by the Parts ‘Department. rones-15692 ous. 15895 41-29LOWER STRUCTURE Cab rear pillar cross member [K] INTRODUCTION ‘The replacement of this part {sa complementary operation to the replacement of the rear pillar closure panel and the assembled cab step. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) COMPOSITION OF PART FROM PARTS: DEPARTMENT Part assembled with: - seal mounting bracket, ~ chassis mounting bracket, ~ rear pillar bracket PARTS CONCERNED (thickness in mm) : 4 Cab rear pillar cross member 15 2. Rear pillar bracket 15 3 Double cab floor 0.8 41-30ABI 1620R6| ogy» OeLOWER STRUCTURE Double cab rear floor part section INTRODUCTION ‘The replacement of this part ts a complementary operation to the the cab rear step and the cab rear pillar closure panel for a side impact. ‘The method described only contains descriptions of Joints specific to the part concerned. Joints with, complementary parts are not Included. These are dealt with In thelr respective section (refer to the contents page). ‘This part may be partlally replaced (see drawing of the cut and method belose) COMPOSITION OF PART FROM PARTS DEPARTMENT Single part PARTS CONCERNED (thickness in mn) : 1 Cab floor 1 2. Centre pillar partition 12 & i comawme S| SQBIOP 4. Cab floor front cross member: 12 5. Cab floor rear cross member lz 6 Double cab step closure panel 12 7 Partition closure reinforcement 08 8 Rear pillar bracket 15 casis025-4R2 41-32LOWER STRUCTURE Double cab rear floor part section 44aLOWER STRUCTURE Double cab rear floor part section [L] J 4 rc | fd oP K | o£ Td ao@GLOWER STRUCTURE Double cab rear floor part section [L]LOWER STRUCTURE Tunnel support [M] INTRODUCTION ‘The replacement of this part ts a complementary operation to the replacement of the upper part of the rear side member ‘The method described only contains descriptions of Joints specific to the part concerned. Joints with, complementary parts are not Included. These are dealt with In thelr respective section (refer to the contents page). ‘The repair bench must be used, COMPOSITION OF PART FROM PARTS DEPARTMENT Single part Ty [peeaiz2 PARTS CONCERNED (thickness in mm) : 4 Tunnel support 18 2. Rear side member closure panel 18 caar1s9692| ~L caarsseee| rg 41-36UPPER SIDE STRUCTURE Double cab rear pillar INTRODUCTION ‘The replacement of this part 1s a complementary operation to a cab rear pillar sill panel after a side Impact and to the cab rear stretcher for the upper section, The method described only contains deseriptions of joints specific to the part concerned. Joints with complementary parts are not Inclucied. These are dealt with in thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS DEPARTMENT Part assembled with: - rear pillar closure, ~ rear pillar, ~ rear pillar closure panel, - side panel, ~ striker plate reinforcement, = stitker plate threaded plate, = strlker plate cage [pRpaaze 43-1 PARTS CONCERNED (thickness in mm) : Cab rear pillar Side panel Cab rear pillar closure panel Upper seat belt reinforcement Lower seat belt retnforcement Cab rear pillar closure Rear roof, Cross member support Rear pillar sill panel closure panel 40 Double cab step 411 Double cab step closure panel 42. Cab rear partition 43 Double cab stretcher lining, wan ensens A] 0s os os LS LS 08 12 12 orUPPER SIDE STRUCTURE Double cab rear pillar [AlUPPER SIDE STRUCTURE Double cab rear pillar [AlUPPER SIDE STRUCTURE Double cab rear pillar [Al CABLIS4e.8R8|UPPER SIDE STRUCTURE Double cab rear pillar [Al CAQUIBe7-1R5a\UPPER SIDE STRUCTURE Double cab rear pillar [AlUPPER SIDE STRUCTURE Double cab stretcher INTRODUCTION The replacement of this part is a baste operation after a side Impact. ‘The method described only contains descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with in thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS: DEPARTMENT. Part assembled with: ~ stretcher closure panel, ~ stretcher. pResuzr| PARTS CONCERNED (thickness in mm) : 4 Double cab stretcher 08 2 Stretcher closure a7 3. Stretcher closure panel 07 4 Cab rear pillar closure panel 08 5. Cab rear pillar 08 6 Cab rear pillar side panel 08 7 Cross member support 12 8 Centre pillar, upper section 12 9. Centre pillar upper fining 08 410 Roof extension 07 41 Double cab rear roof 08 412 Front roof 08 43-7UPPER SIDE STRUCTURE Double cab stretcher 43(5 CAT 19925-2R1UPPER SIDE STRUCTURE Double cab stretcher [BlUPPER SIDE STRUCTURE Double cab stretcherUPPER SIDE STRUCTURE Double cab stretcher [BlUPPER SIDE STRUCTURE Double cab stretcher lining INTRODUCTION ‘The replacement of this part is a complementary operation to a double cab stretcher after a side Impact, ‘The method described only contains descriptions of Joints specific to the part concerned, Joints with, complementary parts are not Included. These are dealt with In thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS DEPARTMENT Single part persis PARTS CONCERNED (thickness in mm) : 1 Stretcher lining O27 2. Cab rear pillar closure panel 08 3. Centre pillar upper lining, 08 70481-15605 CAAIS97-188 CAYIA209R1 43-12UPPER SIDE STRUCTURE Side panel [D] INTRODUCTION The replacement of this part is a complementary operation to the cab rear pillar sill panel after a side Impact. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) ‘This part may be partially replaced (see drawing of the cut and method below) COMPOSITION OF PART FROM PARTS: DEPARTMENT Single part. Presta 2 PARTS CONCERNED (thickness in mm) : 41 Cab rear pillar side panel 08 2. Cab rear pillar 08 3. Cab rear pillar closure 1 4 Cab rear partition 1 43-13UPPER SIDE STRUCTURE Side panelUPPER SIDE STRUCTURE Side door sill panel [E| INTRODUCTION ‘The replacement of this part {sa complementary operation to a cab rear pillar sill panel or a cab side sill panel after a front side irapact. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) COMPOSITION OF PART FROM PARTS: DEPARTMENT Single part. PREGA2e| PARTS CONCERNED (thickness in mrn) : 4. Rear side door sill panel 1 2 Cab rear pillar 08 3. Step support bracket 12 4 Cab centre pillar 1 5. Cab sill panel closure panel 1 6 Rear pillar sill panel closure panel 1 7 Cab rear pillar closure panel 08 8 Double cab step 1 43-15UPPER SIDE STRUCTURE Side door sill panel [E| »UPPER SIDE STRUCTURE Side door sill panel H 43fe)UPPER SIDE STRUCTURE Side door sill panel [E| 43-18UPPER SIDE STRUCTURE Side door sill panel [E| caatiseane| xBepe 43-19UPPER SIDE STRUCTURE Cab rear pillar sill panel [F] INTRODUCTION The replacement of this part is a baste operation after a side Impact. ‘The method described only contains descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with in thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS: DEPARTMENT. Single part. PARTS CONCERNED (thickness in mm) : 4. Cab rear pillar sill panel o7 2 Cab rear pillar closure panel 08 3 Cab rear pillar 08 4. Cab rear pillar side panel 08 § Sill panel underside door 08 43-20UPPER SIDE STRUCTURE Cab rear pillar sill panel [F]UPPER SIDE STRUCTURE Rear pillar sill panel closure panel [S| INTRODUCTION ‘The replacement of this part is a complementary operation to a sill panel after a sice Impact. ‘The method described only contains descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with in thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS: DEPARTMENT. Single part. PARTS CONCERNED (thickness in mm) : 4 Rear pillar sill panel closure panel 1 2. Cab rear pillar closure panel 08 3 Cab rear pillar 08 4. Step support bracket 12 5 Cab sill panel closure panel 1 43-22UPPER SIDE STRUCTURE Rear pillar sill panel closure panel [S| CAsI2024. 188UPPER SIDE STRUCTURE Cab side sill panel INTRODUCTION ‘The replacement of this part ts a baste operation, after aside Impact. ‘The method described only contains descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with In thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS DEPARTMENT 1 left hand side: single part 2 right hand side: single part RIGHT HAND SIDE 70422-15505 Remove the four torx bolts @ 6 mm LEFT HAND SIDE 43-24 Zoah31-US606.1 Remove the stx torx bolts @ 6 mm.UPPER SIDE STRUCTURE Cab rear pillar closure INTRODUCTION ‘The replacement of this part ts a complementary operation to a cab rear pillarafter a side impact. ‘The method described only contalns descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with In thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS DEPARTMENT Part assembled with: ~ seat belt upper reinforcement, ~ rear pillar closure panel, - seat belt lower reinforcement. [pRpaase 43-25 PARTS CONCERNED (thickness in mm) : Cab rear pillar closure Cab rear pillar closure panel Seat belt upper reinforcement Seat belt lower retnforcement Cab rear partition Rear floor Rear pillar closure panel Double cab step Cab rear partition horizontal stiffener Cross member support Stretcher closure panel SSecareusuns os 1s LS 08 12 Lz 12 orUPPER SIDE STRUCTURE Cab rear pillar closure [1] CABLIS3e.1R6| CARI 547-3R4) 43-26UPPER SIDE STRUCTURE Cab rear pillar closure 708192-15598, rou 18604 E TOs 1S608Rs TOA IS;08R4| 43-27UPPER SIDE STRUCTURE Cab rear pillar closure [1] 43-28UPPER SIDE STRUCTURE Partition cross members INTRODUCTION The replacement of thls part is a complementary operation to the cab rear pillar closure after a side impact. ‘The method described only contains descriptions of joints specific to the part concerned. Jotnts with complementary parts are not Inclucled. These are dealt with In thelr respective section (refer to the contents page) ‘The lower cross member may be partlally replaced (see drawing of the cut and method below) COMPOSITION OF PART FROM PARTS DEPARTMENT Single part. RS Jppeasoa PARTS CONCERNED (thickness in mm) : 4 Cab rear partition 1 2. Partition upper cross member 12 3° Partition lower cross member LZ 43-29UPPER SIDE STRUCTURE Partition cross members CAAIIS30R36| casiz0a3R2 De® | Qoare 43-30UPPER SIDE STRUCTURE Partition pillar INTRODUCTION ‘The replacement of this part ts a complementary operation to a cab rear pillar closure after a sicle Innpact. ‘The method described only contains descriptions of Joints specific to the part concerned. Joints with, complementary parts are not Included. These are dealt with In thelr respective section (refer to the contents page). ‘The partition pillar support must be ordered se- parately for this operation COMPOSITION OF PART FROM PARTS DEPARTMENT Single part 1 Partition pillar 2 Partition pillar support PARTS CONCERNED (thickness in mm) : 4 Partition pillar 12 2 Cab rear floor 1 3 Cab rear partition 1 4. Partition upper cross member 12 § Partition lower cross member 12 6 Partition pillar support 1 caansiee| rg 43-31UPPER SIDE STRUCTURE Partition pillar 43-32TOP OF BODY Roof [Al INTRODUCTION The replacement of this part ts a complementary operation to a double cab stretcher. ‘The method described only contains descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with in thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS: DEPARTMENT Single part. PARTS CONCERNED (thickness in mm) : 1 Double cab rear roof 08 2 Front roof 08 3. Cab rear partition 1 4 Roof cross member 1 4 Roof stiffener 08 45-1TOP OF BODY Roa 45}TOP OF BODY Roof CAVIZ6RR] 1) CAVI2452RI Aes) NOTE : the sealing of the roof is carried out du- ring the preparation phase before painting using Paint Joint Mastic (PIM). 45-3TOP OF BODY Courtesy light mounting INTRODUCTION ‘The replacement of this part ts a complementary operation to a double cab roof. ‘The method described only contains descriptions of jolnts specific to the part concerned. Joints with complementary parts are not included. These are dealt with In thelr respective section (refer to the contents page). COMPOSITION OF PART FROM PARTS DEPARTMENT Single part. & PREUSOG PARTS CONCERNED (thickness in mm) : 1 Double cab roof 08 2 Courtesy light mounting 08 caansseas| rg 45-4Master Ey Sheet Metalwork BE) cenerat LOWER STRUCTURE UPPER SIDE STRUCTURE EZ] vprer REAR STRUCTURE TOP OF BODY NDOX 7711 202 404 SEPTEMBER 1993 Edition Anglaise eae a eames aco pacishmoaribiaahsarerecb enn. BE ett ara (2) rereunssEXPLODED VIEW FREWOOE4 El a ES 3 ~=r TR] ES Sheet Metalwork Contents GENERAL Description of parts (exploded views) LOWER STRUCTURE Load floor UPPER SIDE STRUCTURE Cab rear pillar lining UPPER REAR STRUCTURE Intermediate centre pillar lining Load area centre pillar lining Spare wheel support TOP OF BODY F G Pp Roof crossmember bracket Load area roof centre crossmember Load area rear drip moulding li Pages 401 4341 441 443 445GENERAL Information For reasons of standardisation, the bodywork replacement parts supplied for this vehicle are identical to the parts of the base vehicle of the same type. Consequently, they must be adapted following the instructions given below. However, complete bodies will be supplied entirely finished, In this section you will find the procedure for putting in place the bodywork specifications for the Master 16 seat minibus, NOTE: it will be essential to drill the bodywork components which are changed before they are painted, an anti-corrosion protection procedure will be necessary. WARNING: for safety reasons, it is essential to observe the original type of rivet supplied by the Parts Department. The fitting of these rivets requires the use of a pneumatic rivet gun which can take a rivetwith a diameter of 6.5 mm, 40-1GENERAL AO Description of parts, exploded views SUB-FRAME ERys052 1 2 8 4 5 6 7 8 40-2 Centre crossmertber stiffener Left rear seat support, front section Inner right rearseat supp ort Outer right sear seat support Left rear seat support, rear section Rear longitudinal stiffener Right rearstiffener Right front stiffenerGENERAL Description of parts, exploded views SIDE STRUCTURE TR Cab pillar retaining bar support Side trzato centre pillarmounting support Retaining bar on centre pillar support Side trim to intermediate pillar mounting support Side timate cente pillarmounting support Side timto intermediate pillar mounting support Spare wheel support 40-3 PRJsO61GENERAL Description of parts, exploded views TOP OF BODY Headlining centre support Headlining rear side support Headlining mounting support Right-hand loud speaker support Left-hand loud epeaker support Headlining mounting support Headlining rear side support Headlining front side support 1 2 3 4 5 6 7 8 40-4GENERAL Description of parts, exploded viewsLOWER STRUCTURE Load floor FITTING THE RIGHT REAR SEAT SUPPORTS ON THE REAR FLOOR INTRODUCTION The floor must be drilled to fit the right rearseat supports. Refer to the drilling diagram (section 40) COMPOSITION OF THE REPLACEMENT PARTS 3° Inner right rearseat support 4 Outer right rear seat support DRILLING T Drilling reference point (refer to the sub- frame drilling diagrand) Maam & holes it is advisable te pre-drill to prevent destruction of the cataphoresis pro- tection) © 7mm holes [Amti-corrosion protection ofthe paits laid bare The anti-comosion protection procedure must be applied before painting using the following pro- ducts: 1 -etch primer (using a pad) 2--piirer (MAXIMA) (usinga pad) 4LOWER STRUCTURE A4 Load floor FITTING NOTE: forassembly with parts 1- 7 8, refer tothe sections concemed forthe specifications A, Mounting using 8mm @ hexagonal sacket cl balis pert number 77 61471 538 fmm@ square washers part number 77 51471535 G 88mm @ rivets i : 3 aif Dimension between the two seat suppor part number 17 01471 537 yee ASSEMBLY WITH LOWER SECTIONS 1 Centre crossmember stiffener 3) inner right rearseat support 4 Outer right rear seat support 7. Right rearstiffner 8 Right front stiffener a2LOWER STRUCTURE Load floor FITTING THE LEFT REAR SEAT SUPPORT FRONT SECTION ON THE REAR FLOOR, INTRODUCTION The floor must be drilled to fit the left rear seat support front section. Refer to the drilling diagram (section 40) COMPOSITION OF THE REPLACEMENT PARTS 2 Left rear seat support front section E the first twornountings of the seat support on the righthand side are not used DRILLING Yi tolmes-1607F T Drilling reference point (refer to the sub- frame drilling diagram section 40) D> Manm @ holes (itis advisable to pre-drill to prevent destruction of the cataphoresis pro- tection) F ?am@ holes Anti-corrosion protection ofthe parts laid bare The anti-corrosion protection procedure must be applied before painting using the following pro- ducts: 1 -etch primer (using a pad) 2 primer (MAXIMA) (usinga pad) 41-3LOWER STRUCTURE Load floor FITTING ASSEMBLY WITH LOWER SECTIONS PRyal0g D Mounting wing 8mm @ hexaganel socket bali ts pert number 17 61471 538 # mm @ square washers part number 77 §1471 536 Fo 8.5 mm @ rivets part number 77 01471 537 F Mounting using 6.5mm @ rivets part number 77 51471 537 G Mounting underneath the handbrake H Mounting on trimsupport 4 Centre crosamember stiffener 2 Left rear seat support front seation NOTE: forassembly with the centre crossmember stiffener (1), refer to the section concemed forthe specificationsLOWER STRUCTURE Load floor ASSEMBLY WITH LEFT REAR SEAT SUPPORTREAR. SECTION 1 Hight 6.6 mm @ rivets partmumber 7701471 587 41-6LOWER STRUCTURE Load floor FITTING THE LEFT REAR SEAT SUPPORT REAR SECTION ON THE REAR FLOOR INTRODUCTION The floor must be drilled to fit the left rear seat, support rear section. Refer to the drilling diagram. COMPOSITION OF THE REPLACEMENT PARTS 5 Left rear seat support rear section DRILLING J Drilling to 11 mm @ (jtis advisable to pre-dnill to prevent destruction of the catapheresis protection) 41-6 Anti-corrosion protection ofthe parts laid bare [The anti-corrosion protection procedure must be applied before painting using the following pro- ducts: 1 -etch primer (using a pad) 2-pirer (MAXIMA) (usinga pad) FITTING PRISILS J Mounting using 6 mm @ hexagonal socket, balts part number 77 51471 536 8 ram © square washers part number 77 51471 835LOWER STRUCTURE Load floor ASSEMBLY WITH LOWER SECTIONS 5 Left rear seat support rear section 6 Rear longitudiral stiffener NOTE: forassembly with the rearlongitadinal stil: fener (6), refer to the sevtion concerned for the [44] ASSEMBLY WITH LEFT REAR SEAT SUPPORT REAR SECTION I Hight 6.5mm S nvets part nunaber 77 01471 887LOWER STRUCTURE Load floor FITTING THE RIGHT REAR STIFFENER INTRODUCTION The right rearstiffener mist be fitted using bolts. Itis essential to follow the anti-corrosion protec tion procedure after fitting. COMPOSITION OF THE REPLACEMENT PARTS Emais 7 Right rearstiffener FITTING On the outer and inner right rearseat support, Inner right rearseat support Outer right sear seat support Right rearstiffener a 4 7 ASSEMBLY TD Mounting using three 8 mm @ hexagonal socket belts: part number #7 51471 538 8 mm © square washes rs part number 77 51471 935 [Anti-corrosion prote Frocedure Spraying with MAG PRO1 41-8LOWER STRUCTURE Load floor FITTING THE RIGHT FRONT STIFFENER, INTRODUCTION ‘The right frontstiffener must be fitted using bolts, Itis essential to follow the anti-corrosion protection procedure after fitting. COMPOSITION OF THE REPLACEMENT PARTS ay? 8 Right front stiffener FITTING On the outer3ight rear seat support. 4 Outerright rear seat support 8 Right front stiffmer ASSEMBLY ‘Mounting using four 8am @ hexagonal socket belts: part number #7 51471 538 8 mm © square washers part number 77 51471 585 Mounting using four 6,5 man rivets part number #751471 537 Anti-corrosion protection procedure Spraying with MAG PRO 4 aeLOWER STRUCTURE Load floor FITTING THE CENTRE CROSSMEMBER STIFFENER, INTRODUCTION The centre crosstmember stiffener must be fitted using bolts, Itis essential to follow the anti. corresion protection procedure after fitting. COMPOSITION OF THE REPLACEMENT PARTS 1 Centre crossmember stiffener FITTING On the outer right rear seat support and left rear seat support front section. 4 Centre cressmember support 2 Left rear seat support front section 3) Inner right rearseat support ASSEMBLY Apply sprayed film of MAG PRO 4 before fitting the crossmernber stiffener. 4 Mounting using four 8 mm @ hexagonal socket bolts part number 77 51471 536 8 rern @ square washers part number 77 51471 835 [Anti-corrosion protection procedure Spraying with MAG PRO 1 AL-10LOWER STRUCTURE Load floor FITTING THE REAR LONGITUDINAL STIFFENER INTRODUCTION The rear longitudinal stiffener aust be fitted using bolts. Itis essential to fellow the anti- corresion protection provedure after fitting COMPOSITION OF THE REPLACEMENT PARTS 6 Rearlongitudirel stiffener FITTING ‘On the left rear seat support rear section, 5 Left rear seat support rear secti cm 6 Rear longitudinal stifferer 41-11LOWER STRUCTURE A4 Load floor AN-12UPPER SIDE STRUCTURE 43 Cab rear pillar lining FITTING THE CAB PILLAR RETAINING BAR. DRILLING SUPPORT INTRODUCTION The cab pillar lining nmst be drilled to fit the cab pillar retaining bar support. COMPOSITION OF THE REPLACEMENT PARTS mine X46 rom A. Six T mm @ holes 1 Cab pillarretaining bar support Anti-corrosion protection ofthe patts laid bare [The anti-comosion pretection procedure must be applied before painting using the fellowing pro- ducts: 1 -etch primer (using a pad) 2. primer (MAXIMA) (usinga pad) FITTING A. Mounting using six 6.5 mm @ rivets part nunaber 77 01471 837 43-1UPPER REAR STRUCTURE Intermediate centre pillar lining FITTING THE SIDE TRIM TO INTERMEDIATE CENTRE PILLAR MOUNTING SUPPORT INTRODUCTION The interne diate centre pillar lining must be drilled to fit the side trim to intermediate centre pillar mounting support. NOTE: the two sides are syrnmetrical. COMPOSITION OF THE REPLACEMENT PARTS 2. Side trim to intermediate centre pillar moun- ting support ae DRILLING roat21-15250 A Twelve Smm @ holesUPPER REAR STRUCTURE Intermediate centre pillar lining Anti-corrosion protection of the parts laid bare ‘The anti-corrosion protection procedure must be applied before painting using the following pro- ducts 1 etch primer (using a pad) 2- primer (MAXIMA) (using a pad) FITTING A. Mounting using twelve 4.8 mm @ rivets part number 77 01 471 538 44-2UPPER REAR STRUCTURE 44 Load area centre pillar lining FITTING THE SIDE TRIM TO CENTRE DRILLING PILLAR MOUNTING SUPPORT INTRODUCTION The load area centre pillar lining rst be drilled tofit the centre pillar upper stiffener: NOTE: the two sides are syrnmetrical. COMPOSITION OF THE REPLACEMENT PARTS MIs 17 man X2 = 82am A. Two Sm ® holes [Amti-corrosion protection ofthe parts laid bare The anti-comosion protection procedure must be 2 Side trim to centre pillar mounting support applied before painting using the following pro- ducts 1 -etch primer (using a pad) 2. puimer (MAXIMA) (usinga pad) FITTING A. Mounting using two 4.8 mun @ rivets part number #701471 538 44-3UPPER REAR STRUCTURE Load area centre pillar lining FITTING THE RETAINING BAR SUPPORT ON THE CENTRE PILLAR INTRODUCTION The load area centre pillar lining rst be drilled tofitthe retaining bar support on the centre pal. lar. COMPOSITION OF THE REPLACEMENT PARTS Leiswz, 3. Retainingbar support on centre pillar DRILLING ae) 624 Xl 46 ram X= 86 ram A Four? mm@ holes [Amti-corrosion protection ofthe parts laid bare The anti-comosion protection procedure must be applied before painting using the fallowing pro- ducts {etch primer (using a pad) 2. primer (MAXIMA) (usinga pad) FITTING A. Mounting using four 6,5 man @ rivets part number #701471 537 44-4UPPER REAR STRUCTURE Spare wheel support FITTING THE SPARE WHEEL SUPPORT INTRODUCTION The side panel upper horizontal stiffenerand the ear wheel arch must be drilled tofit the spare wheel support, COMPOSITION OF THE REPLACEMENT PARTS 7 Spare wheel support, 44-6 DRILLING X=Simm Position the spare wheel support at (4) B Seven?mm holes © Two 10mm Gi holes lit isadvisable to pre-drill to prevent destruction of the cataphoresis protection) Anti-corrosion protection ofthe parts laid bare The anti-comosion protection procedure must be Japplied before painting using the following pro- ducts 1-etch primer (using a pad) 2. puimer (MAXIMA) (using pad) FITTING 4. Mounting using 8.5mm @ rivets part number #7 01471 587 © Secured on the rearseat,TOP OF BODY Roof crossmember bracket FITTING THE HEADLINING SIDE SUPPORTS INTRODUCTION The roof crossmember brackets rmst be drilled to fit the headlining side supports COMPOSITION OF THE REPLACEMENT P ARTS Left-hand side: 8 Headlining front side support 7 Headlining rear side support Right-hand side: 2” Headlining rear side support DRILLING Headlining front side support. Xd? rom A. Three §mm @ holes Anti-corrosion protection ofthe parts laid bare [The anti-comasion protection procedure must be applied before painting using the following pro- ducts 1- etch primer (using a pad) 2- primer (MAXIMA) (usinga pad) FITTING Fit the two rivets before the third which will be se. cured on the headlining rear side support. A. Mounting using three 4.8 mm @ rivets part number #7 01471 538 45-1TOP OF BODY Roof crossmember bracket Headlining rear side support (the two sides are syrmetrical), @) ee ose. A a Anti comosion protection of the parts laid bare The anti-corrosion protection proce dure aust be applied before paintingusing the following pro- duets: 1 etch primer (using a pad) 2. primer (MAXIMA) (using a pad) FITTING A. Mounting using three 4.8 mm @ rivets partnumber 7701471538 45-2TOP OF BODY Roof crossmember bracket FITTING THE HEADLINING MOUNTING DRILLING SUPPORT INTRODUCTION The roof crossmernber bracket mast be drilled ta fit the headlining mounting support, NOTE: the two sides are syrnmetrical. COMPOSITION OF THE REPLACEMENT PARTS Align the mounting support with the headlining year support. X1=58 mm Xl =8rom A Two Sram Gholes 3 Right-hand headlining mounting support 6 Left-hand headlining mounting support Anti-corrosion protection ofthe parts laid bare [The anti-comasion protection procedure must be applied before painting using the following pro- ducts: 1 -etch primer (using a pad) 2- puimer (MAXIMA) (using pad) 45-3TOP OF BODY A5 Roof crossmember bracket FITTING nting using two 4.8 mm @ murmber 77 01471 £88 iFTOP OF BODY 4. 5 Load area roof centre crossmember FITTING THE HEADLINING CENTRE DRILLING SUPPORT INTRODUCTION The roof centre crossmernber must be drilled tofit the headlining centre support COMPOSITION OF THE REPLACEMENT PARTS Fit using the guide hole (A) asa guide Xs 18mm Exas0 B Seven Simm @ holes 1 Headlining centre support [Anti-corrasion protection ofthe paits laid bare The anti-corasion protection procedure must be applied before painting using the following pro- ducts 1 -etch primer (using a pad) 2. pumer (MAXIMA) (usinga pad) FITTING B Mounting using seven 4,8 mm rivets pert number #701471 538 45-6TOP OF BODY Load area rear drip moulding lining FITTING THE LEFT-HAND LOUD SPEAKER SUPPORT INTRODUCTION The load area rear drip moulding lining must be drilled to fit the left-hand loud speaker support. NOTE: the two sides are syrnmetrical. COMPOSITION OF THE REPLACEMENT PARTS 4 Right-hand loud speaker support 5 Left-hand loud speaker support DRILLING Xl=Srm M2 = 87 ram A. Seven 52mm @ holes [Amti-corrosion protection ofthe parts laid bare The anti-comosion protection procedure must be applied before painting using the fallowing pro- ducts {etch primer (using a pad) 2. primer (MAXIMA) (usinga pad) FITTING B Mounting using seven 4.8 mm rivets part number #701471 538Master E4¥ Sheet metalwork EQ ceNeRAL LOWER STRUCTURE UPPER SIDE STRUCTURE EZ] vprer REAR STRUCTURE EB Tor oF Bopy FD2 TT 11 205 213 ‘APRIL 1999 Edition Anglaise AMleqarighe teed Belt ayn testing pat rept ‘Te thoy bho el eng Ra amen 005 sag Som ta ott seonouby edie gi sevens rte (aided Bansehin sees ns * © Pevsut 190EXPLODED VIEW PRHOUER)[fe] cal =f Sheet metalwork Contents GENERAL Key to parts (in exploded view) LOWER STRUCTURE Load floor Fitting the front seat supports on the floor Fitting the rear seat support rear section on the floor Fitting the load space on the rear floor Drilling for fitting the inner sill support Drilling for routing pipes UPPER SIDE STRUCTURE Cab rear pillar inner panel Side panel lower inner panel UPPER REAR STRUCTURE Rear wheel arch Spare wheel support Rear pillar lower inner panel TOP OF BODY Central roof crossmember Rear roof crossmember Pages 401 ae 416 ala 414d 4145 44.1 44-2 443GENERAL Information For reasons of standardisation, bodywork replacement parts supplied by the Parts Department for this vehicle are identical to those of the base vehicle of the samne type. Consequently, it will be necessary to adapt ther in line with the instructions given below. However, complete bodies will be supplied completely finished. In this section you will find the procedure for applying the bodywork specifications for the Master 9 seat mini- bus. NOTE: it will be essential to drill the replaced bodywork components before painting, an anticorrosion pro- tection procedure will be necessary. WARNING: for safety reasons, it is essential to use the same type of rivets as those fitted originally, supplied by the Parts Department. The fitting of these rivets requires the use of a pneumatic rivet gun suitable for vels with a diameter of 6.5 mm, PNEUMATIC RIVET PRESS Type: OPRA 226 116 00000 Supplier BOLHOFF OTALU Z.1.de 'Albanne Route d’Apremont BP. 68 73490 LA RAVOIRE Cedex Tel, : 04.79.96.70.00 Fax : 04.79,96.70.11 Approval N°: 740 400 FOR THE UK: Straightset Engineering Services Ltd. Stadium Close Dukeries Industrial Estate Worksop Nottinghamshire S81 7BT Tel.: 01909 480055 Fax: 01909 500128 40-1GENERAL Key to parts in exploded view DRILLING DIAGRAM cHuoeDE ser07R, Inner sill hole drilled to @ T mm Seat support hole éfront section) drilled to @ 12 mm Spare wheel support hole @ 35 mm Seat support hole (rear section) drilled to @ 12 mm Guide hole Spare wheel securing hole 40-2GENERAL Key to parts in exploded view SUB-FRAME PREGOOS 1 Load space floor 2to8 Load space assembly panels 9-10 Load space side protection panels 11 Spare wheel support mounting nut 12 Spare wheel support 18 Mounting stiffener (multtple) 14 Mounting stiffener (single) 15 Front crossmember suffener 16 Spacer 17 Tapped plate 18 Rear seat support 19 Tapped plate 20 Rear sea support 21 Rear seat support mounting bolt 22 — Central crossmember stiffenerLOWER STRUCTURE Load floor FITTING THE FRONT SEAT SUPPORTS ON THE FLOOR INTRODUCTION ‘The floor mustbe drilled to fit the front seat supports, Refer to the drilling dlagram (section 40), COMPOSITION OF REPLACEMENT PARTS 41 \N) PRP4OO4 43 Mounting stiffener (multiple) 44 Mounting stiffener (single) 47° Tapped plate 49 Tapped plate 20 — Rear seat support 24 — Rear seat support mounting bolt 22 ~~ Central crossmember stiffenerLOWER STRUCTURE Load floor DRILLING Right-hand side T Drilling reference point refer to the sub- frame drilling dlagram in section 40) IN] B_ @ 12mm holes (predrilling ts recommended to prevent destruction of the cataphorests pro- tection) ‘Anticorrosion protection of parts laid bare ‘The anticorroston protection procedure mustbe applled before painting using the following pro- ducts; 1 - phosphate primer (using a pad) 2. primer (MAXIMA) (using a pad)LOWER STRUCTURE 41 Load floor FITTING PRRAGOE 43° Mounting stiffener (multiple) 414 Mounting stiffener (single) 47 Tapped plate 49 Tapped plate 20 — Rear seat support 24 Rear seat support mounting bolt (hexagonal socket bolt @ 10 min partnumber 77 01 471 964) 22 ~~ Central crossmember stiffenerLOWER STRUCTURE Load floor POSITIONING THE CENTRAL CROSSMEMBER Itvulll be necessary to spray MAG PRO 1 part num- ber 77 11 172 679 between the central crossmem- ber/central crossmember stiffener and onto the bolts after fitting, 16 Spacer (between floorand crassmmember) 24° Rear seat support mounting bolt 22 Central crossmember stiffener POSITIONING MOUNTINGS ON LEFT-HAND SIDE (tightening of bolts 47 Nm) Iwill be necessary to spray MAG PRO 1 part num- ber 77 11 172 679 onto the stiffeners and the bolts after Atting. 1970s 43 24 Mounting stiffener (multiple) Rear seat support mounting bolt Isr79s 13 24 Mounting stiffener (multiple) Rear seal support mounting bolt 41-4 43 24 Mounting stiffener (multiple) Rear seat support mounting boltLOWER STRUCTURE Load floor [N] POSITIONING MOUNTINGS ON RIGHT-HAND SIDE (Tightening of bolts 47 Nm) 13 Mounting stiffener (muldple) 14 Mounting stiffener (single) 43 21 Rear seat support mounting bolt 414 Mounting stiffener (single) 24 Rear seat support mounting bolt Mounting stiffener (multiple) 13 Monnting stiffener (multiple) 24 Rear seat support mounting boltLOWER STRUCTURE Load floor FITTING THE REAR SEAT SUPPORT REAR SECTION ON THE FLOOR INTRODUCTION ‘The floor must be drilled to fit the rear seat support rear section. Refer to the drilling dlagram (section 40). COMPOSITION OF REPLACEMENT PARTS 43 Mounting stiffener (muluple) 414 Mounting stiffener (single) 45 Front crossmember stiffener 46 Spacer 47° Tapped plate 48 — Rear seat support (rear section) 49 Tapped plate 24 Rear seat support mounting bolt.LOWER STRUCTURE Load floor DRILLING Left-hand side T Drilling reference point refer to the sub- frame drilling dlagram in section 40) IN] D_ @ 12mm holes iprediilling ts recommended to prevent destruction of the cataphorests pro- tection) ‘Anticorrosion protection of parts laid bare ‘The anticorroston protection procedure mustbe applled before painting using the following pro- ducts; 1 - phosphate primer (using a pad) 2. primer (MAXIMA) (using a pad)FITTING LOWER STRUCTURE Load floor Assembly with the lower seetions PRREGOS Mounting stiffener (multiple) Mounting stiffener (single) ‘Tapped plate Rear seat support Tapped plate Mounting using @ 10 mm hexagonal socket bolts part number 77 01 471 964 41-8LOWER STRUCTURE Load floor POSITIONING THE REAR CROSSMEMBER STIFFENER Itwill be necessary to spray MAG PRO 1 between the central crossmember/central crossmember stiffener and onto the bolts after fitting. Right-hand side 14 Mounting stiffener (single) 16 Spacer (between floor and erossmember) 48 Rear seat support 21 Rear seat support mounting bolt Left-hand side 14 Mounting stiffener (single) 16 Spacer (between floor and crossmember) 48 — Rearseat support 21 Rear seat support mounting bolt 41-9LOWER STRUCTURE Load floor POSITIONING MOUNTINGS ON LEFT-HAND SIDE POSITIONING THE REAR SEAT SUPPORTS. (Tightening of bolts 47 Nm) Itwill be necessary to spray MAG PRO 1 part num- ber 77 11 172 679 onto the stiffeners and bolts af- Ir * Xk SO ter fitting, 157885 ¥ S705 14 Mounting stiffener (single) 13 Monnting stiffener (rauluple) 47 Tapped plat 24° Rear seat support mounting bolt 418 Rear seat support 49 Tapped plate 21 Mounting using @ 10 mm hexagonal socket holts part number 77 01 471 964 41-10LOWER STRUCTURE Load floor [N] FITTING THE LOAD SPACE ON THE REAR FLOOR INTRODUCTION ‘The floor must be drilled to fit the load space. Refer to the drilling diagram (section 40 - raark C). Itwill be necessary to apply antivibration mastic between the rear floor and, the load space (procedure below). COMPOSITION OF REPLACEMENT PARTS PRFUONS 4 Load space floor 2 to 8 Load space assembly panels 9-10 Load space side protection panels 44 Spare wheel support mounting nut 12 Spare wheel support Mounting kit 1701 472030 2bolts (x 20) ‘77 08 009 227 22 rivets TOL ATI SST Gbalts 6 x 20) 7703 009 005 6bolts (6x 16) 7708001 959 6 clips 7708033014 Snuts 66 7703 001 959 41-11LOWER STRUCTURE Load floor DRILLING ASSEMBLING THE REAR LOAD SPACE Is7a¢R1 1s791R C @32mm holes (predrilling Is recommended to prevent dlesiruction of the cataphorests pro- tection). Anticorrosion protection of parts laid bare ‘The antlcorroston protection procedure must be applied before painting using the following pro- ducts: 1 - phosphate primer (using a pad) 2 primer (MAXIMA) (using a pad) 15728 Assemble the load space panels on the floor using the @ 6.5 mm rivets part number 77 01 471 537. 41-12LOWER STRUCTURE Load floor 1s73R 157908 Posttton the rear load space assembly and sorew on the spare wheel support retalning nut at (A). Apply the antivibration mastic as above, part, Secure the two side protectors at @). number 77 01 395 113 19795R Position the spare wheel support having sprayed MAG PRO 1 part number 77 11 172.679 41-13LOWER STRUCTURE Load floor [N] DRILLING FOR FITTING THE INNER SILL SUPPORT INTRODUCTION ‘The floor musthe drilled to fit the Inner sill sup- port, Refer to the drilling cliagram (section 40). The fitting of four @ 5 mm inserts part number 77 01 047 685 ‘will be cartted out using tool Car. 1504 DRILLING AND FITTING INSERTS T Dailling reference point (refer to the sub- frame drilling diagram in section 40) A. @Tmm holes (predrifling ts recommended to prevent destruction of the cataphoresis pro- tection) ‘Anticorrosion protection of parts laid bare ‘The antlcorroston protection procedure must be applied before painting nsing the following pro- duets: 1- phosphate primer ‘using a pad) 2- primer (MAXIMA) (using a pad) 41-14LOWER STRUCTURE Load floor DRILLING FOR ROUTING PIPES INTRODUCTION For vehicles fitted with alr conditioning and add- tonal heating, the floor must be cirilled in line with the procedure below. DRILLING (Airconditioning pipes) 185 mm, 222 mm. 135 mm. 85 mm. ‘Two @ 35 mm holes (prediilling ts recommended to prevent destruction of the calaphorests protec- ton). 41-15 DRILLING (Stand-alone air heating evacuation pipes) X1= 150mm sane ‘Anticorrosion protection of parts laid bare ‘The antlcorroston protection procedure mustbe applied before painting using the following pro- ducts: 1 - phosphate primer (using a pad) 2 primer (MAXIMA) (using a pad)UPPER SIDE STRUCTURE Cab rear pillar inner panel FITTING THE CAB PILLAR RETAINING BAR SUPPORT INTRODUCTION ‘The cab pillar inner panel must be drilled to fit the cab pillar retaining bar support. COMPOSITION OF REPLACEMENT PARTS 1 Cab pillar retaining bar support 43-1 DRILLING roue21-15074 X=45 mm A 687mm holes ‘Anticorrosion protection of parts laid bare ‘The antlcorroston protection procedure mustbe applied before painting using the following pro- ducts: 1 - phosphate primer (using a pad) 2 primer (MAXIMA) (using a pad) FITTING A. Securing using 6 @ 6.5 mm rivets part number 77 01 471 537UPPER SIDE STRUCTURE Side panel lower inner panel DRILLING THE INNER PANEL TO FIT THE Fitting ADDITIONAL HEATING PIPE SUPPORT. INTRODUCTION ‘The side panel lower inner panel must be drilled to fit the additional heating pipe support. ‘The fitting of the @ 5 mm insert part number 77 01 047 685 ‘will be carrled out using tool Car. 1504, DRILLING tse0r Securing using @ 4 mm bolts. A 267mm holes and fitting of two @ 5 mm inserts part number 77 01 047 685, ‘Anticorrosion protection of parts laid bare ‘The antlcorroston protection procedure must be applied before painting using the following pro- duets: 1 - phosphate primer (using a pad) 2 primer (MAXIMA) (using a pad)UPPER REAR STRUCTURE Rear wheel arch DRILLING THE REAR WHEEL ARCH TO FIT THE LOAD RETAINING NET HOOK INTRODUCTION ‘The rear wheel arch must be drilled to fit the load retaining net hook. ‘The fitting of the @ 5 mm inserts part number 77 01 047 685 ‘will be carrted out using tool Car. 1504 DRILLING Enlarging the existing hole to @ 7 mm A @7 mm holes and fitting of a @ 5 mm tnsert part number 77 01 047 685 Anticorrosion protection of parts laid bare The antleorroston protection procedure mustbe applied before painting using the following pro- ducts: 1- phosphate primer (using a pad) 2- primer (MAXIMA) (using a pad 44-1UPPER REAR STRUCTURE Spare wheel support DRILLING THE SPARE WHEEL SUPPORT TO FIT THE SIDE TRIMS INTRODUCTION ‘To fit the side trims, the spare wheel support must be drilled in line with the procedure below, DRILLING 7 Ise, A AG65 mm hole Anticorrosion protection of parts laid bare ‘The antlcorrosion protecUon procedure mustbe applied before painting using the following pro- ducts: 1 - phosphate primer (using a pad) 2 primer (MAXIMA) (using a pach 442UPPER REAR STRUCTURE Rear pillar lower inner panel [Zz] DRILLING THE REAR PILLAR LOWER INNER ‘The trim Is secured to the crossmember using PANEL TO FIT THE TRIM SUPPORT three @ 4.8 mm rivets part number 77 01 471 538. INTRODUCTION If the centre pillar lower inner panel Is changed, It must be drilled to fit the trim support. DRILLING e806 X= §mm X2= 288mm A AGS mm hole at each end Anticorrosion protection of parts laid bare ‘The anticorroston protection procedure must be applied before palnting using the following pro- duets: 1 - phosphate primer (using a pad) 2- primer (MAXIMA) (using a pad) 44-3TOP OF BODY Central roof crossmember DRILLING THE CENTRAL ROOF CROSSMEMBERS TO FIT THE AIR CONDITIONING SUPPORT FRAME AND THE PROTECTIVE TRIMS DRILLING A Fltrivets part number 7701 471 538 B Fitinserts part number 77 01 047 685 Anticorrosion protection of parts laid bare ‘The anticorrosion protection procedure mustbe applied before paln- ting using the following products: 1 - phosphate primer (using a pad) 2 primer (MAXIMA) (using a pad)TOP OF BODY Central roof crossmember el FITTING X Securing using sixteen rlvets @ 4.8 mm rivets. partnumber 77 01 471 538 Y Securing using two Inserts @ 5 mm inserts part number 77 01 047 685 45-2TOP OF BODY Rear roof crossmember DRILLING THE REAR ROOF CROSSMEMBER TO FIT THE AIR CONDITIONING SUPPORT FRAME INTRODUCTION The rear roof crossmember must be drilled to At the alr conditioning support frame. DRILLING {israee Drilfing (securing of the alr condiuoning support frame} Four @ 5 mm holes Yi= 100mm Ye= 45mm Y3= 55mm Anticorrosion protection of parts laid bare The anticorroston protection procedure must be applied before painting using the following pro- ducts: 1 - phosphate primer (using a pad) 2- primer (MAXIMA) (using a pad) FITTING 'Y = securing using four rivets @ 4.8 mm rivets part number 77 01 471 538, 45-3Master EJ Mechanisms and accessories WINDOWS LOWER INTERIOR ACCESSORIES UPPER INTERIOR ACCESSORIES INTERIOR SAFETY ACCESSORIES NDOX 711 202 40d SEPTEMBER 1998 Edition Anglaise A B c D E F I A Mechanisms and accessories EXTERIOR PROTECTION Front bumper Rear bumper Radiator grille Cowl vent grille Side protective mouldings Protective strip at base of swing-out doors EXTERIOR ACCESSORIES Exterior rear view mirror Large part of rear view mirror Plastic rear view mirror casing and small part of mirror Panel holding rear number plate lights Renault badge Dashboard Console Glove box door Notepad support Net retainer for storage compartment Centrall storage compartment ,OWER INTERIOR ACCESSORIES Pages 58-1 33-2 55-3 55-5 55-7 INTERIOR SAFETY ACCESSORIES Front seat belts 59-1GENERAL Safety AIR BAG AND PRETENSIONERS 9631018 1301 IMPORTANT: 41] operations on the air bagand Each time the steering wheel is removed, the stes- pretensioner systeme rst te carried out by ring wheel bolt MUST be renewed, Referto sec- qualified personnel who have been appropriately tions 88 and 57.4, trained The Air bag Workshop Repair Manual, section 88 MUST be consulted. IMPORTANT : Whenever the steering wheel is re- moved, the air bagconnector (B) MUST be dis- connected. The air bag has connector which short cirsuits when itis disconnected to prevent incorrect trig: gering. ATTENTION: When working under the vehicle do not subject the underside of the floor toimpects without removing the pretensioner fuse and waiting § minutes for the reserve capacity to discharge. HEAT SHIELDS Refer ta section 88 "Puse allocation’ Heat shields must be refitted, whether they are for body work or mechanical components, TIGHTENING TORQUES ‘The recommended tightening torques MUST be sbserved, PRODUCTS Read the precautions foruse with care and ob- serve the safety instructions by usingthe appro- priate protection (goves, mask, ete.) §0-1GENERAL Tooling Information on the tool specified furreplacing the windscreen is provided in Technical Note No. 371A on bonded windows 2) Threader tool from SODIGAM for inserting wire. geses Tool for removing the glass in the exterior rear view mirror Car. 1863- Part No, 00 00 136 300. This tool may also be used for removing roof trim andesterior doar weatherstrips. "Basy-cut" pneumatic tool for emaving bonded windows (DCAV /SODICAM) Consult Technical Note No, 414A for information about the method and specifications for using this tool. §0-2GENERAL Tooling geraas SODIGAM clip removal pliers Using these pliers itis eagy to remove "firtree” clips and interior trim clips such as on doorpanels, soundproofing mats and mudguard mountings Door window winder hand esrray also be remo- ved. (iret affiy.a small piece of masking tape to the doorpanel to avoid damagingit during remno- val) The pliershawe one flat and one bent nose, giving easy secess to remove clips without damaging them. The heads of the clips are not deformed, enabling them to be re-used when refitting. 40-3 wai. TOOL FOR SUPPORTING DOOR This frame assists the operator when removing or refitting swing-out orsliding doors This todd has been specifically adapted for the opening elements of utility vehicles. Itcan take the weight of one door with all compo nents fitted so that the assistance of a second per- son is noLonger required. Renault approval no: Renault 681000 Supplier: Z INTERNATIONAL. Part Mo.: SUP 01SIDE OPENING ELEMENT MECHANISMS Front door, outside handle A] WY Zz Z Z Zz, REMOVING Remove the door trim (ses section 724) 1-1Sila SIDE OPENING ELEMENT MECHANISMS Front door, outside handle Remove the two mounting belts (4) fromthe handle on the door. 51-2SIDE OPENING ELEMENT MECHANISMS Front door, outside handle [A] Remove the door Lock control linkage @). Push the handle forwards torelease the retaining lugs (C) and tale the pa- nel out ofits housing cn the door panel. §1-3SIDE OPENING ELEMENT MECHANISMS Outside handle for sliding door IB] a SS A zB Z Zz, Using pair of clip-removing pliers, tale out the retainingclips (4) Remove - the twomountingbolts (2), - the lock control linkage (C) Pull the handle to the front to release the rear retaining lug from the door panel. 1-4SIDE OPENING ELEMENT MECHANISMS Front door lock barrel IC] 1-6Bile SIDE OPENING ELEMENT MECHANISMS Front door lock barrel } a = the lower guidechanrel (twomounting bolts - the front door trim (see section 714), REMOVING Remove: 51-6SIDE OPENING ELEMENT MECHANISMS Front door lock barrel Fra Remove the lock control linkage at. () Tum the lock barrel retaining ring a quarter of a turn (C) Release the barrel fromits location on the door panel. S17SIDE OPENING ELEMENT MECHANISMS Sliding door lock barrel ID] Rernove the doortriza Using clip removing pliers, take out the retaining clips (4) Remove - The anti-tamper post (two mounting bolts (B)), - the lock control linkage (C) Tum the lock retaining ring a quarter of a turn. Release the barrel fram its vation on the door panel. 1-8SIDE OPENING ELEMENT MECHANISMS Front door lock [E| 1-9ile SIDE OPENING ELEMENT MECHANISMS Front door lock REMOVING ) ta) section 714), (eee + front door trim: ! - lower guide channel (two mounting bolts Remove: 51-10SIDE OPENING ELEMENT MECHANISMS Front door lock [E| reese Disconnect control linkage fram exterior door handle (4), lock barrel 8), opening handle (0) and locking tell-tale light (2) Remove connector for lock contra electric motor, ifappropriate. 51-11ile SIDE OPENING ELEMENT MECHANISMS Front door lock De" . fy ex // Sal Zi | ee 3 Remove the three mounting belts (B) from the dear lock. 51-12SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms fer sliding door TF] PRESLOS 1 Central lock for side door and contral linkage 2. Upper leckfor side door-and contra cable 3 Mechanism for controllimg lock 1-13SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door REMOVING CENTRAL LOCK (1) REMOVING UPPER LOCK @) blanking plate (4), mountingclip for upper lock control cable at @ Remove = twomounting bolts (C), = control eable ac instructed for removing con- tral Lock Remove lock and control cable from door bey se tien two mounting bolts forlock @), contral linkage. Remove lock from box section of door. 51-14SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms fer sliding door REMOVING LO GK CONTROL MECH ANISM@) This mechanism controls the central and upper locks simultaneously, Remove: stiding door trim (use clip-removing pliers to take off the retaining clips), docr barrel control linkage (A, exterior opening handle contral linkage (B), interior opening handle control linkage (C), door locking control linkage (D), control linkage for central and lower locks (B), control mechanism (three mounting bolts (F)}. NOTE: When the lock control linkage is refitted, do not pull on this un- {il the control mechanism is clipped in position. The position of this line ‘kage at rest ensures that the Lock will unlatch if the opening handle is operated. Ifthe lint ge is subjected toany strain, it may cause pro. blems with the unlatching. 51-18SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door IF REMOVING ARMAND UPPER RAL, REMOVING GUIDE RAIL Remove the rail mounting balts (G) ‘The front section of the rail is secured toa metallic. bracket, ‘This bracket is secured to the side of the body by rreans of three mounting bolts (D). REFITTING ‘When refitting the slide, make sure that the ten- sioner will not collide with the heads of the bolts (©) which seoure the guide rail REMOVING UPPER ARM Remove the three bolts forrounting the aren on the door (4), the cover clipped on the rail (8) Release the tensioner by pulling the slide towards the rear, out of the rail. 51-16SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door Pc ROMNIECERRESIE NEAL W SSS aol pee REMOVING CENTRAL GUIDE RAIL FERG1O5 Remove mounting muts (B) Rernove rear wing panel rail REMOVING CENTRAL SLIDE Remove: doortrim, - threeslide mounting bolts (4) Release slide fromits housing on door. To remove the guiderail side, tilt it upwards to release the rail tensio. ners 51-17SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door REFITTING ‘When the slide is refitted, you must make sure that the tensioner which supports the door makes contact vith the rail when the door is eased. To perform this operation, inserta flat serewdri- ‘ver between the rail the the slide tensioner. Position the tensioner so that it makes contact, ‘with the rail (1) and tighten the slide mounting belts . (Two people are required to perform this ‘operation. } NOTE: This operation should be carried out after the door has been adjusted. 51-18SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door IF REMOVING LOWER ARMS AND RAILS is. Toremove the guide rail slide, tlt the guide rail upwards to release the tensioners from the rail. ZY FERGIO6 a als a Me B B B Cfocon REMOVING LOWER ARM REMOVING LOWER GUIDE RAIL Remove the three mounting bolts for the arm (4), Remi belts a nut (C) To remove the guide rail slide, tilt the guide rail ove mounting P alts (B) and (C) upwards torelease the tensi ners froma the rail. Ratio eal ak wana Baal 51-19SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door REFITTING LOWER ARM Carry out the fellowing adjustment before refit- ting the am and and before tightening the mounting bolts. ‘When the doris opened, the slide link arm flewes under the weight of the deor. ‘This means that the centring fittings mounted at the front of the door are offsetin relation to the cones fixed on the door of the cab To counteract this problem, with the door half open you must take the strain off the deorsathat the centring fittings do not make contact with the cones-at the start of the process ‘One the door has been correctly positioned, rnove the lower ann dowm o0 that it makes contact with the guide ral Tighten the am mounting balts on the door. ‘Check the adjustment and check that, when it is opened, the door issupportedand deesnot drop suddenly NOTE : Two persons are required to perfor this: operation. 51-20SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door FEREIOG Afterrefitting the trim to the door, hold this in Position against the vehicle using the door sup- port tool (see section $0) Place in position the mounting bolts forthe upper and lowerarms and the mounting bolts for the central slide (see previous pages). Height adjustment Z and flush fitting dimension Y for the front part of the door is obtained by adjus- ting the centring attachrrents. Laer Height adjustment Z and flush fitting dimension Y for the rear part of the dooris obtained by adjus- ting the central lock, 51-21SIDE OPENING ELEMENT MECHANISMS Locks and mechanisms for sliding door I'the opening clearance between the sliding door and the rear wing panel or between the sliding door and the cab deor is out of parallel, it must be corrected by the following proce dure Adjustrent atZ of the centring fittings and the lower arm to pivot the door. After adjustment, consult the refitting method for ‘the lower arm (see page 51-20). 51-22