Panelwork: General Lower Structure Upper Rear Structure Top of Body Non-Side Opening Elements

Panelwork
GENERAL
LOWER STRUCTURE
UPPER REAR STRUCTURE
TOP OF BODY
NON-SIDE OPENING ELEMENTS
LB0P - LB03
77 11 203 838 SEPTEMBER 1999 EDITION ANGLAISE
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
© RENAULT 1999
Panelwork
Contents
Page Page
40 GENERAL 45 TOP OF BODY
Dimensions 40-1 A Roof 45-1

Towing 40-2 D Roof rear crossmember 45-5
Symbols used for methods 40-3
Identification of parts (exploded view) 40-4
Opening clearances 40-6
Collision fault finding 40-8
Sub-frame dimensions 40-10
Body jig bench 40-12 48 NON-SIDE OPENING ELEMENTS
A Tailgate 48-1
41 LOWER STRUCTURE
M Rear side member 41-1

O Rear floor 41-4
P Exhaust mounting unit 41-9
Q Rear floor unit 41-11
44 UPPER REAR STRUCTURE
A Rear wing panel 44-1

B Upper side rain channel 44-9
E Inner wheel arch 44-11
F Body side lining 44-14
G Rear end panel 44-20
H Rear lights support 44-23
I Central rear parcel shelf 44-27
J Jack mounting 44-29
140
GENERAL INFORMATION
Dimensions 40
Dimensions in metres
40-1
GENERAL INFORMATION
Towing 40
OBSERVE THE TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the
vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either directly or indirectly.
FRONT REAR
40-2
GENERAL INFORMATION
Using symbols 40
Chisel Crimping of exterior door panels.
Grind back beads or spot welds. Safety symbol.

Straight grinding wheel with 75 ∅ bakelite This means that the welding operation in
disc, thickness 1.8 to 3.2 mm. question concerns one or more of the
vehicle's vital safety components.
Grind back spot welds.
Lead filler
20 000 rpm straight grinding wheel with 10
Hot air torch.
or 16 mm ∅ spherical burr.
Nozzle output temperature 600° min.
Palette + 33 % tin solder + tallow.
Detach the spot welds Note: to a large extent, body solder filling
Hardened steel bit compensates for the heat distortion caused
Speed of rotation 800 to 1 000 rpm. by welding.
Application of weldable mastic.

Cleaning surfaces to be welded. This mastic is a conductor, laid between two
Fibre disc 100 mm ∅. sheets to be spot welded, it ensures the seal
between the sheets and avoids corrosion of
the spot weld
Cutting with a saw.
Application of aluminium paint.
Pneumatic power hacksaw.
This is to be applied to the joint faces of
each of the parts to be plug welded. This
– Disk the part by grinding off flange or paint is conductive and can withstand high
grinding back remaining traces of spot temperatures; it gives anti-corrosion
weld. protection around welds
– Finish surface after welding.
– Angle grinder fitted with a rubber pad and Apply a fillet of extruded mastic
a 120 to 180 mm ∅ P36 grain fibre disc ● from a manual or pneumatic spray gun.
● one or two pot mastic for crimped and butt
joints.
Unsoldering
Apply mastic by spraying
● spray gun
MAG stitch weld ● two-pot anti-chipping and anti-corrosion
Note: to obtain a good quality weld we mastic

recommend the use of a gas consisting of
argon + 15% CO 2 which is considered an Drill < 8 ∅
active gas (MAG) Sheet plate bit
speed of rotation 800 to 1000 rpm.
Resistance spot welding Drill < 8 ∅

Conical burr
speed of rotation 800 to 1000 rpm.
Plug welding.
Under MAG gas protection.
40-3
GENERAL INFORMATION
Description of parts (exploded view) 40
SUB-FRAME
1 Rear floor unit

2 Rear floor
3 Front crossmember of rear floor (crossmember)
4 Rear side member
5 Towing ring
6 Towing eye bracket
7 Exhaust mounting unit
8 Rear centre crossmember
40-4
GENERAL INFORMATION
Description of parts (exploded view) 40
SUPER STRUCTURE
9 Roof
10 Roof rear crossmember
11 Rear light support
12 Rear end panel
13 Central rear parcel shelf
14 Upper side rain channel
15 Inner wheel arch
16 Jack mounting
* 17 Body side lining
* 18 Rear wing panel
* Parts which must undergo electric zinc plating on repaired zones.
40-5
GENERAL INFORMATION
Opening clearances 40
40-6
GENERAL INFORMATION
Opening clearances 40
40-7
GENERAL INFORMATION
Collision fault finding 40
Before carrying out repairs to the bodywork of a car, even if the damage seems slight, it is 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 creases 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).
● AXLE GEOMETRY CHECK
It is 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 subject to deformation.
On principle, no welded component in the body shell may be replaced without ensuring that the subframe was not
affected by the impact.
40-8
GENERAL INFORMATION
Collision fault finding 40
GAUGE POINTS
Point J
Rear end of rear side member.
Right-hand side
Left-hand side
40-9
GENERAL INFORMATION
Sub-frame dimensions 40
DESCRIPTION X Y Z DIAMETER ANGLE%
A Front sub-frame rear mounting 205 402.5 71 18.5 0
B Rear axle assembly front mounting 2 012 530 129 16.2 0
10x10
C Front left sub-frame front mounting - 418 447 130 0
(square)
10x10
C' Front right sub-frame front mounting - 418 465 130 0
(square)
E Rear shock absorber upper mounting 2 448.5 534.5 477.5 18.2 0
X: 3°02
F Front shock absorber upper mounting 18.5 545.50 657 48
Y: 1°
20x20
G Rear section of front left side member 600 375 - 3.7 0
(square)
20x20
G' Rear section of front right side member 600 351.6 -5 0
(square)
J Rear point of right rear side member 3040 481 162.5 10.2 0
X: 4°30
K Front crossmember - 575 315 280 14.25
Z: 5°
P Front engine mounting - 247 483.5 514 M10 0
P1 Rear engine mounting - 113 483.5 514 M10 0
40-10
GENERAL INFORMATION
Sub-frame dimensions 40
40-11
GENERAL INFORMATION
Repair Bench 40
REFERENCES FOR POSITIONING OF REPLACEMENT PARTS SUPPLEMENTARY TO WORKSHOP REPAIR
MANUAL 338
E - REAR SHOCK ABSORBER UPPER F - FRONT SHOCK ABSORBER UPPER

MOUNTING MOUNTING
The calibre is fitted into the housing shock absorber

cup and is used to position this mounting when
replacing a wheel arch.
It is also used when straightening.
The bracket rests under the shock absorber cup and is

centred in the shock absorber mounting hole.
It is used when replacing:

– a wheel arch,
– a front half unit.
It is also used when straightening.
40-12
GENERAL INFORMATION
Repair Bench 40
J - REAR SIDE MEMBER REAR END
1 - Without mechanism 2 - With mechanism
It may be used for a light rear impact without removing

the rear axle.
40-13
GENERAL INFORMATION
Repair Bench 40
Fitting the CELETTE elements
Fitting the BLACKHAWK elements
40-14
GENERAL INFORMATION
Repair Bench 40
SPECIAL TOOLING PART NUMBER
CELETTE
Special heads for MS System
Order from: CELETTE S.A.

B.P. 9
38026 VIENNA
Supplier reference: 715.308
BLACKHAWK
Special heads for MS System
Order from: BLACKHAWK S.A.

Centre Eurofret
Rue de Rheinfeld
67100 STRASBOURG
Supplier reference: REN 88 242
40-15
141 LOWER STRUCTURE
Rear side member 41 M
INTRODUCTION PARTS CONCERNED (thickness in mm):
Replacing the rear side member, part section, is an 1 Rear side member 1.5
additional operation to the rear end panel, refer to cut 2 Rear floor 0.7
A-A and the method described below. 3 Exhaust mounting 1.5
4 Wheel arch 2
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 sections (see contents).
Using the body jig bench is vital for replacing the entire
side member.
COMPOSITION OF THE PART FROM THE PARTS

DEPARTMENT
Part assembled with:

– welded nuts,
– exhaust mounting stiffener (left side),
– cup stiffener of rear suspension spring,
– rear axle assembly mounting brace,
– side member/crossmember connection component,
– rear side crossmember,
– towing ring (right side),
– rear axle assembly mounting unit,
– rear suspension spring cup,
– rear side member stiffener.
41-1
LOWER STRUCTURE
41-2
LOWER STRUCTURE
41-3
LOWER STRUCTURE
Rear floor 41 O
The replacement of this part is an additional operation 1 Rear floor 0.7

to the replacement of: 2 Rear side member 1.5
3 Rear wing panel 0.8
A - For side impact: 4 Body side lining 0.7
the lights support. 5 Rear inner wheel arch 2
6 Front mounting hook 1
B - For rear impact: 7 Side member/crossmember connection
the rear end panel. component 1.5
This operation is partially carried out in two possible

ways (refer to the method given below):
– for the left rear section (according to cut A - A),

– for the front section (according to cut B - B).



DEPARTMENT

– rear floor reinforcement,
– front mounting hook,
– rear mounting hook,
– rear cushion holding clamp.
41-4
LOWER STRUCTURE
Rear floor 41 O
Original part
Parts Department part
41-5
LOWER STRUCTURE
Rear floor 41 O
41-6
LOWER STRUCTURE
Rear floor 41 O
Original part
41-7
LOWER STRUCTURE
Rear floor 41 O
41-8
LOWER STRUCTURE
Exhaust mounting unit 41 P
INTRODUCTION
The replacement of this part is a basic operation for a

sub-frame impact.



DEPARTMENT
Assembled part with mounting bracket.
PARTS CONCERNED (thickness in mm):
1 Exhaust mounting 1.3

2 Rear side member 1.5
3 Rear floor 0.7
4 Wheel arch 2
41-9
LOWER STRUCTURE
Exhaust mounting unit 41 P
41-10
LOWER STRUCTURE
Rear floor unit 41 Q
INTRODUCTION
The replacement of this part is an additional operation

to the replacement of the rear end panel for a rear
impact.


The body jig bench must be used.

DEPARTMENT
1 Rear floor upper side panel 1.5
Part assembled with: 2 Rear floor 0.7
– seat support, 3 Tunnel reinforcement 1
– welded nuts, 4 Cable sleeve stop mounting 1.2
– exhaust mounting (left side), 5 Centre floor 1.47
– rear axle assembly mounting unit, 6 Inner sill panel 1
– rear axle assembly mounting brace, 7 Sill panel reinforcement 1
– rear side member stiffener, 8 Rear axle assembly mounting unit 1
– towing eye bracket, 9 Rear side member 1.8
– rear suspension spring cup, 10 Wheel arch 0.8
– cup stiffener of rear suspension spring, 11 Floor reinforcement 1.5
– side member/crossmember connection component,
– rear side member,
– rear floor,
– rear floor upper side panel,
– towing ring,
– rear mounting hook,
– front hook,
– rear cushion holding clamp,
– rear seat back mounting stiffener,
– floor side stiffeners,
– rear centre crossmember,
– rear side crossmember,
– seat belt stiffener.
41-11
LOWER STRUCTURE
41-12
LOWER STRUCTURE
41-13
LOWER STRUCTURE
41-14
LOWER STRUCTURE
41-15
LOWER STRUCTURE
41-16
Rear wing panel 44 A
INTRODUCTION
The replacement of this part is a basic operation for a

rear side impact.
This operation is carried out in two possible ways

(refer to the method given below):
Partial: along cut A - A.
Complete: along cut B - B, in this case, it will be

additional to the roof.

The information on the additional parts will be dealt PARTS CONCERNED (thickness in mm):
with in their respective chapters (refer to contents).
2 Body side lining 0.7
COMPOSITION OF THE PART FROM THE PARTS 3 Striker stiffener. 1.2
DEPARTMENT 4 Sill panel reinforcement 1
5 Inner sill panel 1
Part assembled with: 6 Rear lower side rain channel 0.7
– bumper side mounting stiffener, 7 Boot lid hinge mounting stiffener 1.2
– rear door striker stiffener, 8 Light support 1
– plate cover, 9 Floor 1.5
– plate, 10 Wheel arch 0.9
– sound-deadening material, 11 Bumper side mounting stiffener, 1.2
– fuel pipe unit (right side).
44-1
44-2
44-3
44-4
44-5
44-6
44-7
44-8
Upper side rain channel 44 B
INTRODUCTION
This part is changed in addition to changing the rear

wing panel.



DEPARTMENT
Assembled part with balance mounting stiffener.
1 Rear side rain channel 0.7

3 Boot lid hinge/opening mounting stiffener 1.2
4 Lower screen crossmember 1.2
44-9
Upper side rain channel 44 B
44-10
Inner wheel arch 44 E
INTRODUCTION
This part is changed in addition to changing the body

side lining.



DEPARTMENT

– shock absorber mounting cup,
– shock absorber mounting cup stiffener,
– shock absorber support.
1 Rear inner wheel arch 0.9

2 Rear floor 0.7
4 Side tray/parcel shelf 1.2
5 Rear axle assembly mounting unit, 1
6 Floor reinforcement, 1.5
44-11
44-12
44-13
Body side lining 44 F
This part is changed in addition to changing: 1 Body side lining 0.7

2 Quarter panel upper reinforcement 1.2
– For side impact 3 Rear inner wheel arch 0.9
rear wing panel (cut A - A). 4 Sill panel reinforcement 1
– For upper side impact 6 Roof rear crossmember 0.7
rear wing panel and roof (cut B - B). 7 Rear lower side rain channel 0.7
8 Boot lid hinge mounting stiffener 1.2
This operation is carried out partially in two possible 9 Floor 0.7
ways (refer to the method given below):



DEPARTMENT

– boot lid hinge/opening mounting stiffener
– wheel arch,
– side tray/parcel shelf
– jack mounting (left side),
– quarter panel rear reinforcement.
44-14
Original part
44-15
44-16
Original part
44-17
44-18
44-19
Rear end panel 44 G
The changing of this part is a basic operation to be 1 Rear end panel 1

carried out following a rear collision. 2 Rear floor 0.7
3 Windscreen end panel lower crossmember 1
In the operation described below, only descriptions of 4 End panel upper crossmember 1.2
the joints specific to the part concerned are given. 5 Rear side member 1.5
6 Rear lights support 1
The information on the additional parts will be dealt 7 Towing hook 1.5

DEPARTMENT

– end panel upper crossmember,
– end panel lower crossmember,
– bumper mounting angle bracket,
– welded nuts.
44-20
Rear end panel 44 G
44-21
Rear end panel 44 G
44-22
Rear lights support 44 H
This part is replaced in addition to replacing: 1 Rear lights support 1

2 Rear lower side rain channel 0.7
– the rear end panel for a rear collision, 3 Rear wing panel 0.8
– the wing panel for a rear side impact. 4 Rear floor 0.7
This operation may be carried out partially (following 6 Windscreen end panel lower crossmember 1
cut A - A). 7 Rear end panel 1



DEPARTMENT
Assembled part with welded nut.
44-23
44-24
44-25
Original part
44-26
Central rear parcel shelf 44 I
INTRODUCTION

to the rear wing panel and to the body side lining for a
rear side impact.



DEPARTMENT

– lower screen crossmember
– third brake light support.
1 Central rear parcel shelf 0.8

3 Rear screen aperture lower crossmember 1
4 Boot lid hinge mounting stiffener 0.8
44-27
Central rear parcel shelf 44 I
44-28
Jack mounting 44 J
INTRODUCTION
The replacement of this part is a basic operation.



DEPARTMENT
Part supplied on its own.
1 Jack mounting 1.2

2 Left quarter panel lining 0.7
44-29
Jack mounting 44 J
44-30
145 TOP OF BODY
Roof 45 A
INTRODUCTION
The replacement of this part is a basic operation.



DEPARTMENT

– sound-deadening material,
– washer.
1 Roof 0.7
2 Roof front crossmember 1.2
3 Windscreen pillar lining 1.2
4 A-pillar 1.2
5 Body side 1.2
7 B-pillar reinforcement. 1
9 Roof rear crossmember 1
45-1
TOP OF BODY
Roof 45 A
655A4-14253
45-2
TOP OF BODY
Roof 45 A
45-3
TOP OF BODY
Roof 45 A
45-4
TOP OF BODY
Roof rear crossmember 45 D
INTRODUCTION

to the roof.



DEPARTMENT
Part supplied on its own.
1 Roof rear crossmember 0.7

45-5
148NON-SIDE OPENING ELEMENTS
Tailgate 48 A
REMOVAL - REFITTING
Remove:
– the four mounting bolts (A) of the hinge,
– the tailgate (this operation should be carried out by
two people for safety reasons).
48-1
NON-SIDE OPENING ELEMENTS
Tailgate 48 A
SETTINGS
The peripheral play is adjusted at the mountings (A).
Adjustment is carried out at the lock (B) and the striker

of the closure panel (C).
NOTE: always start by adjusting the supports at the

hinge (D) before touching the lock when carrying out
complete replacement with removal of the hinge.
For your information: the tailgate hinge springs have

two possible hardness adjustment positions (E) and
(F).
48-2

Panelwork: General Lower Structure Upper Rear Structure Top of Body Non-Side Opening Elements

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Panelwork: General Lower Structure Upper Rear Structure Top of Body Non-Side Opening Elements

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Panelwork

UPPER REAR STRUCTURE

NON-SIDE OPENING ELEMENTS

77 11 203 838 SEPTEMBER 1999 EDITION ANGLAISE

40 GENERAL 45 TOP OF BODY

Dimensions 40-1 A Roof 45-1

M Rear side member 41-1

44 UPPER REAR STRUCTURE

A Rear wing panel 44-1

NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.

Grind back beads or spot welds. Safety symbol.

Application of weldable mastic.

MAG stitch weld ● two-pot anti-chipping and anti-corrosion

Note: to obtain a good quality weld we mastic

Resistance spot welding Drill < 8 ∅

1 Rear floor unit

* Parts which must undergo electric zinc plating on repaired zones.

● TRAMMEL GAUGE CHECK

● AXLE GEOMETRY CHECK

Rear end of rear side member.

A Front sub-frame rear mounting 205 402.5 71 18.5 0

B Rear axle assembly front mounting 2 012 530 129 16.2 0

E Rear shock absorber upper mounting 2 448.5 534.5 477.5 18.2 0

P Front engine mounting - 247 483.5 514 M10 0

P1 Rear engine mounting - 113 483.5 514 M10 0

E - REAR SHOCK ABSORBER UPPER F - FRONT SHOCK ABSORBER UPPER

The calibre is fitted into the housing shock absorber

It is also used when straightening.

The bracket rests under the shock absorber cup and is

It is used when replacing:

It is also used when straightening.

1 - Without mechanism 2 - With mechanism

It may be used for a light rear impact without removing

Fitting the BLACKHAWK elements

Special heads for MS System

Order from: CELETTE S.A.

Supplier reference: 715.308

Special heads for MS System

Order from: BLACKHAWK S.A.

Supplier reference: REN 88 242

INTRODUCTION PARTS CONCERNED (thickness in mm):

The information on the additional parts will be dealt

COMPOSITION OF THE PART FROM THE PARTS

Part assembled with:

INTRODUCTION PARTS CONCERNED (thickness in mm):

The replacement of this part is an additional operation 1 Rear floor 0.7

This operation is partially carried out in two possible

– for the left rear section (according to cut A - A),

In the operation described below, only descriptions of

The information on the additional parts will be dealt

COMPOSITION OF THE PART FROM THE PARTS

Part assembled with:

Parts Department part

Parts Department part

The replacement of this part is a basic operation for a

In the operation described below, only descriptions of

The information on the additional parts will be dealt

COMPOSITION OF THE PART FROM THE PARTS

Assembled part with mounting bracket.

PARTS CONCERNED (thickness in mm):

1 Exhaust mounting 1.3

The replacement of this part is an additional operation

In the operation described below, only descriptions of