Renault

4 Panelwork
40A GENERAL INFORMATION
41A FRONT LOWER STRUCTURE
41B CENTRE LOWER STRUCTURE
41C SIDE LOWER STRUCTURE
41D REAR LOWER STRUCTURE
42A FRONT UPPER STRUCTURE
43A SIDE UPPER STRUCTURE
44A REAR UPPER STRUCTURE
45A TOP OF BODY
47A SIDE OPENING ELEMENTS
48A NON-SIDE OPENING ELEMENTS

X35
APRIL 2008 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

SYMBOL - THALIA - Section 4ContentsPage
SYMBOL - THALIA - Section 4
Contents
Page
40A GENERAL INFORMATION 41A FRONT LOWER STRUCTURE
Vehicle on repair bench: Front half-unit: Replacement 41A-13

Description 40A-1
Front tow eye: Replacement 41A-15
Sub-frame: Specifications 40A-4
Vehicle front section
structure: Description 40A-8
41B CENTRE LOWER STRUCTURE
Vehicle side section
structure: Description 40A-10 Centre floor side section:
Replacement 41B-1
Vehicle central section
structure: Description 40A-12 Centre floor front side cross
member: Replacement 41B-8
Vehicle structure rear
section: Description 40A-13 Front cross member under
front seat: Replacement 41B-10
Vehicle removable section
structure: Description 40A-15 Rear cross member under
front seat: Replacement 41B-12
Structure components to be
positioned on body repair
bench: Description 40A-17
41C SIDE LOWER STRUCTURE
41A FRONT LOWER STRUCTURE Sill panel: Replacement 41C-1
Sill panel closure panel:

Front end lower cross Replacement 41C-5
member: Replacement 41A-1
Sill panel reinforcement:
Front side member front Replacement 41C-8
section: Replacement 41A-2
Front side member closure

panel: Replacement 41A-5
41D REAR LOWER STRUCTURE
Front side member rear
section: Replacement 41A-8 Rear floor: Replacement 41D-1
Front subframe front Rear floor reinforcement:
mounting: Replacement 41A-10 Replacement 41D-4
Subframe rear mounting: Rear side member:
Replacement 41A-11 Replacement 41D-5
Engine mounting:
Replacement 41A-12
Contents
41D REAR LOWER STRUCTURE 44A REAR UPPER STRUCTURE
Rear tow eye: Replacement 41D-8 Rear wing panel:

Replacement 44A-1
Rear floor unit: Replacement 41D-9
Rear wing panel rain
channel: Replacement 44A-6
Rear light mounting:

42A FRONT UPPER STRUCTURE Replacement 44A-7
Front wing lower mounting Outer rear wheel arch:

support: Replacement 42A-1 Replacement 44A-9
Headlight carrier panel: Quarter panel lining:

Replacement 42A-2 Replacement 44A-11
Front wing: Removal - Rear parcel shelf:

Refitting 42A-3 Replacement 44A-14
Scuttle side panel: Rear parcel shelf side

Replacement 42A-5 section: Replacement 44A-16
Scuttle side panel upper Rear end panel assembly:

reinforcement: Replacement 42A-9 Replacement 44A-18
Rear upper reinforcement of

scuttle side panel:
Replacement 42A-10
45A TOP OF BODY
Front wheel arch:
Replacement 42A-11 Roof: Replacement 45A-1
Windscreen aperture lower Roof front cross member:

cross member: Replacement 42A-13 Replacement 45A-3
Front wing: Adjusting 42A-15 Roof centre cross member:

Replacement 45A-4
Front: Removal - Refitting 42A-18
Roof rear cross member:
Dashboard cross member: Replacement 45A-5
Removal - Refitting 42A-20

43A SIDE UPPER STRUCTURE
Front side door: Removal -
Windscreen pillar lining: Refitting 47A-1
Replacement 43A-1
Front side door: Stripping -
B-pillar lining: Replacement 43A-3 Restoring 47A-2
Body side front section: Front side door: Adjustment 47A-4
Replacement 43A-5
Rear side door: Removal -
Upper body: Replacement 43A-9 Refitting 47A-7
Rear side door: Stripping -

Restoring 47A-8
Contents
Rear side door: Adjustment 47A-10
Fuel filler flap: Removal -

Refitting 47A-13
48A NON-SIDE OPENING ELEMENTS
Bonnet: Removal - Refitting 48A-1
Bonnet: Stripping -
Rebuilding 48A-3
Bonnet: Adjustment 48A-4
Boot lid: Removal - Refitting 48A-6
Boot lid: Stripping -

Rebuilding 48A-8
Boot lid: Adjusting 48A-9

GENERAL INFORMATION
Vehicle on repair bench: Description 40A
L35
I - MAIN FRONT TRIM-SETTING REFERENCE 2 - Front sub-frame removed
POINTS
1 - Front sub-frame in place
132100
The jig rests under the subframe rear mounting and is
centred in the hole (A) .
120611 Use this situation for a front impact requiring removal of
The jig covers the front subframe rear bolt (A) . Use the front subframe.
this situation for a rear impact or a light frontal impact
without removal of the mechanical components.
Note:
This could be used in two cases:
If it is suspected that one of these points may be
- if the rear of the vehicle is being rebuilt, these two
deformed, use two additional points located in an
points alone may be used to align and support the
area not affected by the impact in order to confirm
front of the vehicle,
trim-setting.
- for a light frontal impact not requiring removal of the
front axle sub-frame.
40A-1
GENERAL INFORMATION
L35
II - SECONDARY FRONT TRIM-SETTING III - MAIN REAR TRIM-SETTING REFERENCE
REFERENCE POINT POINTS
1 - Rear mechanical components in place
132101
The jig covers the front subframe front mounting bolt
(C) . 132108
Use this situation to confirm the trim-setting following a The jig supports the underside of the rear axle fork and
rear impact (e.g.: to replace a rear side member). is centred in the rear axle mounting pilot hole (B) .
It is used to confirm the vehicle level in case of doubt Use this situation for a frontal impact or a light rear im-
about the deformation of a main rear reference point. pact.
2 - Rear mechanical components removed
132105
The jig rests under the rear side member and is cen-
tred in the tapped hole (B) .
40A-2
GENERAL INFORMATION
L35
Use this situation for a rear impact with removal of the
mechanical components.
Note:
If it is suspected that one of these points may be
deformed, use two additional points located in an
area not affected by the impact in order to confirm
trim-setting.
IV - SECONDARY REAR TRIM-SETTING

REFERENCE POINT
132107
The jig rests under the rear side member and is positio-
ned in the hole (J) .
Use this situation to confirm the trim-setting following a
front impact.
It is used to confirm the vehicle trim setting in case of
doubt about the deformation of a main front reference
point.
40A-3
GENERAL INFORMATION
Sub-frame: Specifications 40A
L35
Description Dimen- Dimen- Dimen- Diameter Angle (in

sion X sion Y sion Z (mm) degrees)
(mm) (mm) (mm)
(A) Front sub-frame rear mounting 205 402.5 71 18.5 0
(B) Rear axle assembly front moun- 2012 530 129 16.2 0
ting
(Cg) Front subframe front right-hand -418 447 130 10 x 10 0

mounting
(Cd) Front subframe front left-hand -418 465 130 10 x 10 0

mounting
(E) Rear shock absorber upper 2448.5 534.5 477.5 18.2 0

mounting
(F) Front shock absorber upper 18.5 545.50 657 48 X: 3˚

mounting
Y: 1˚
(Gg) Rear section of front left-hand 600 375 -3.7 20 x 20 0

side member
(Gd) Rear section of front right-hand 600 351.6 -5 20 x 20 0

side member
(J) Rear point of rear right-hand 3040 481 162.5 10.2 0

side member
(K) Front cross member -515 315 280 14.25 X: 4˚30

Z: 5˚
(P1) Front engine mounting -247 483.5 514 M 10 0
(P2) Rear engine mounting -113 483.5 514 M 10 0
40A-4
GENERAL INFORMATION
L35
132091
40A-5
GENERAL INFORMATION
L35
132093
40A-6
GENERAL INFORMATION
L35
132092
40A-7
GENERAL INFORMATION
Vehicle front section structure: Description 40A
L35
132086
No. Description Classification Type Thickness

(mm)
(1) Front tow eye (see 41A, Front lower structure, Front tow eye:
Replacement, page 41A-15)
(2) front-end lower cross member (see 41A, Front lower structure, Front end lower
cross member: Replacement, page 41A-1)
(3) Scuttle side panel rear upper reinforce- (see 42A, Front upper structure, Rear upper rein-
ment forcement of scuttle side panel: Replacement, page
42A-10)
(4) Scuttle side panel upper reinforcement (see 42A, Front upper structure, Scuttle side panel
upper reinforcement: Replacement, page 42A-9)
(5) Front wing lower mounting support (see 42A, Front upper structure, Front wing lower
mounting support: Replacement, page 42A-1)
(6) Scuttle side panel (see 42A, Front upper structure, Scuttle side
panel: Replacement, page 42A-5)
(7) Headlight carrier panel (see 42A, Front upper structure, Headlight carrier
panel: Replacement, page 42A-2)
(8) Front half-unit (see 41A, Front lower structure, Front half-unit:
40A-8
GENERAL INFORMATION
Vehicle front section structure: Description 40A
L35

(mm)
(9) Front side member closure panel (see 41A, Front lower structure, Front side mem-
ber closure panel: Replacement, page 41A-5)
(10) Front side member front section (see 41A, Front lower structure, Front side mem-
ber front section: Replacement, page 41A-2)
(11) Front support of front subframe (see 41A, Front lower structure, Front subframe
front mounting: Replacement, page 41A-10)
(12) Front wheel arch (see 42A, Front upper structure, Front wheel arch:
(13) Engine mounting (see 41A, Front lower structure, Engine mounting:
(14) Front side member rear part (see 41A, Front lower structure, Front side mem-
ber rear section: Replacement, page 41A-8)
(15) Sub-frame rear mounting (see 41A, Front lower structure, Subframe rear
mounting: Replacement, page 41A-11)
40A-9
GENERAL INFORMATION
Vehicle side section structure: Description 40A
L35
132087

(mm)
(1) Roof (see 45A, Top of body, Roof: Replacement, page

45A-1)
(2) Roof rear cross member (see 45A, Top of body, Roof rear cross member:
(3) Roof centre cross member (see 45A, Top of body, Roof centre cross member:
(4) Roof front cross member (see 45A, Top of body, Roof front cross member:
(5) Windscreen pillar lining (see 43A, Side upper structure, Windscreen pillar
lining: Replacement, page 43A-1)
(6) Roof panel (see 43A, Side upper structure, Upper body:
(7) Body side front section (see 43A, Side upper structure, Body side front
section: Replacement, page 43A-5)
(8) B-pillar lining (see 43A, Side upper structure, B-pillar lining:
40A-10
GENERAL INFORMATION
Vehicle side section structure: Description 40A
L35

(mm)
(9) Sill panel reinforcement (see 41C, Side lower structure, Sill panel reinforce-
ment: Replacement, page 41C-8)
(10) Sill panel (see 41C, Side lower structure, Sill panel: Replace-
ment, page 41C-1)
40A-11
GENERAL INFORMATION
Vehicle central section structure: Description 40A
L35
132088

(mm)
(1) Windscreen aperture lower cross (see 42A, Front upper structure, Windscreen aper-
member ture lower cross member: Replacement, page 42A-
13)
(2) Centre floor front side cross member (see 41B, Centre lower structure, Centre floor front
side cross member: Replacement, page 41B-8)
(3) Central floor, side section (see 41B, Centre lower structure, Centre floor side
section: Replacement, page 41B-1)
(4) Sill panel closure panel (see 41C, Side lower structure, Sill panel closure
panel: Replacement, page 41C-5)
(5) Front cross member under front seat (see 41B, Centre lower structure, Front cross
member under front seat: Replacement, page 41B-
10)
(6) Rear cross member under front seat (see 41B, Centre lower structure, Rear cross mem-
ber under front seat: Replacement, page 41B-12)
40A-12
GENERAL INFORMATION
Vehicle structure rear section: Description 40A
L35
132089

(mm)
(1) Rear wing panel (see 44A, Rear upper structure, Rear wing panel:
(2) Quarter panel lining (see 44A, Rear upper structure, Quarter panel
lining: Replacement, page 44A-11)
(3) Rear side member (see 41D, Rear lower structure, Rear side member:
Replacement, page 41D-5)
(4) Rear floor unit (see 41D, Rear lower structure, Rear floor unit:
(5) Rear floor (see 41D, Rear lower structure, Rear floor: Repla-
cement, page 41D-1)
(6) Rear end panel assembly (see 44A, Rear upper structure, Rear end panel
assembly: Replacement, page 44A-18)
(7) Rear towing eye (see 41D, Rear lower structure, Rear tow eye:
(8) Rear parcel shelf (see 44A, Rear upper structure, Rear parcel shelf:
40A-13
GENERAL INFORMATION
Vehicle structure rear section: Description 40A
L35

(mm)
(9) Rear parcel shelf side section (see 44A, Rear upper structure, Rear parcel shelf
side section: Replacement, page 44A-16)
(10) Outer rear wheel arch (see 44A, Rear upper structure, Outer rear wheel
arch: Replacement, page 44A-9)
(11) Rear wing panel rain channel (see 44A, Rear upper structure, Rear wing panel
rain channel: Replacement, page 44A-6)
(12) Rear lights support (see 44A, Rear upper structure, Rear light moun-
ting: Replacement, page 44A-7)
40A-14
GENERAL INFORMATION
Vehicle removable section structure: Description 40A
L35
132090
No. Description Classification Type
(1) Front end panel (see 42A, Front upper structure, HLE
Front: Removal - Refitting, page
42A-18)
(2) Bonnet (see 48A, Non-side opening ele- Mild steel

ments, Bonnet: Removal - Refit-
ting, page 48A-1)
(3) Dashboard cross member (see 42A, Front upper structure, Mild steel
Dashboard c ross member:
Removal - Refitting, page 42A-20)
(4) Fuel filler flap (see 4 7 A , Side opening ele- Noryl

ments, Fuel filler flap: Removal -
Refitting, page 47A-13)
(5) Boot lid (see 48A, Non-side opening ele- Mild steel
ments, Boot lid: Removal - Refit-
ting, page 48A-6)
(6) Rear side door (see 4 7 A , Side opening ele- Mild steel
ments, Rear side door: Removal
- Refitting, page 47A-7)
40A-15
GENERAL INFORMATION
Vehicle removable section structure: Description 40A
L35
No. Description Classification Type
(7) Front side door (see 4 7 A , Side opening ele- Mild steel
ments, Front side door: Removal
- Refitting, page 47A-1)
(8) Front wing (see 42A, Front upper structure, Mild steel
Front wing: Removal - Refitting,
page 42A-3)
40A-16
GENERAL INFORMATION
Structure components to be positioned on body repair bench: Description 40A
L35
PARTS REQUIRING THE USE OF A BODY JIG
BENCH
132094
- (1) Engine stand, 1 - Front sub-frame rear mounting
- (2) Front wheel arch,
- (3) Front half-unit,
- (4) Quarter panel lining,
- (5) Rear side member,
- (6) Front side member rear section,
- (7) Front side member front section,
- (8) Front sub-frame front mounting,
- (9) Sub-frame rear mounting,
- (10) Centre floor front side cross member.
132100
40A-17
GENERAL INFORMATION
L35
The jig rests under the rear section of the side member 3 - Front sub-frame mounting
and is centred in the sub-frame rear mounting hole (A)
.
The jig is used to replace:
- a front side member rear section,
- a complete half-unit,
- a centre floor front side cross member.
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
2 - Rear axle assembly front mounting
132098
The jig rests under the front sub-frame mounting and is
centred in the tapped hole (C) .
The jig is used to replace:
- the front side member closure panel,
- a complete front side member,
- a complete front half-unit.
IMPORTANT
132105
The jig rests under the rear axle assembly mounting
unit and is centred on the tapped hole of the rear axle
bearing mounting (B) .
The jig is used for replacing the rear side member as-
sembly.
IMPORTANT
40A-18
GENERAL INFORMATION
L35
4 - Front shock absorber upper mounting 5 - Engine mounting
132096 132095
The jig rests under the shock absorber cup and is cen- The jig rests on the engine mounting and is centred in
tred in the shock absorber head mounting hole (F) . the engine mounting holes (P1) and (P2) .
The jig is used to replace: The jig is used with the subframe removed for the re-
- the front wheel arch, placement of:
- the front half-unit. - the engine mounting,

- the half unit.
IMPORTANT
Use a repair bench to ensure the positioning of the 6 - End of rear side member
132107
The jig rests under the rear side member and is cen-
tred in the hole (J) .
40A-19
GENERAL INFORMATION
L35
The jig is used for replacing the rear side member.
7 - Inner rear wheel arch
132106
The jig rests under the rear shock absorber cup and is
centred in the mounting hole (E) .
The jig is used for replacing the quarter panel lining.
40A-20
FRONT LOWER STRUCTURE
Front end lower cross member: Replacement 41A
L35
I - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT
Complete replacement
a - Part in position
132113
No. Description Type Thic-

kness
(mm)
132114
(1) Cross member HLE 1.77
closure panel
component b - Position of electric earths
(2) Front tow hitch HLE 2.47

support WARNING
(3) Front end lower HLE 1.8 To avoid damaging the vehicles electric and electro-
nic components, the earths of any wiring harness
cross member
near the weld area must be disconnected.
Position the earth of the welding machine as close
as possible to the weld zone (see Bolted connec-
tion for earth: Fit) (see MR 400, 40H, Bolted con-
nections).
Locate the earths located near to the weld zone (see

Earths on the body: List and location of compo-
nents) .
c - Special notes on mating
WARNING
If the mating faces of the parts to be welded are not
accessible, use GMAW plug welds in place of the
original electrical resistance welds (see Gas shiel-
ded arc weld bead joints: Description) (MR 400,
40C, Gas metal arc welded connections (GMAW)).
41A-1
Front side member front section: Replacement 41A
L35
I - COMPOSITION OF THE SPARE PART
132117
132115
1 - Complete replacement A-C
kness
IMPORTANT
(mm)
(1) Front side mem- HLE 1.47 points and the geometry of the axle assemblies.
ber front section
(2) Front mounting of HLE 1.17 a - Part in position

subframe, outer
section
(3) Front mounting of HLE 1.17

subframe, inner
section
(4) Side member Mild 1.17

inner reinforce- steel
ment
II - IN THE EVENT OF REPLACEMENT

The options for replacing this part are as follows:
- complete replacement A-C,
- partial replacement B-C.
132116
41A-2
L35
b - Position of electric earths 2 - Partial replacement B-C
WARNING
To avoid damaging the vehicles electric and electro-
nections).

nents) .
c - Irremovable bodywork components - structures

to be removed in order to carry out the
replacement operation
Remove:
- the front end lower cross member (see 41A, Front
lower structure, Front end lower cross member:
Replacement, page 41A-1) ,
132118
- the headlight carrier panel (see 42A, Front upper
structure, Headlight carrier panel: Replacement, Cut B
page 42A-2) .
d - Special notes on mating
WARNING
accessible, use a GMAW plug weld in place of the
original electrical resistance weld (see Gas shiel-
132120
41A-3
L35
b - Position of electric earths
WARNING
nections).

nents) .

Remove:
structure, Headlight carrier panel: Replacement,
page 42A-2) .
WARNING
41A-4
Front side member closure panel: Replacement 41A
L35
132122
132121
kness a - Part in position
(mm)
(1) Front side mem- HLE 1.17

ber closure panel
II - IN THE EVENT OF A REPLACEMENT

- partial replacement A-B.
132123
41A-5
L35
b - Position of electric earths 2 - Partial replacement A-B
WARNING
Position the earth of the welding machine earth as
close as possible to the weld area (see Bolted
connection for earth: Fit) (see MR 400, 40H, Bol-
ted connections).
Locate the earths located near to the weld area (see

nents) .

Remove:
132124
- the front wheel arch (see 42A, Front upper structu-
re, Front wheel arch: Replacement, page 42A-11) . Cut B
WARNING
132126
41A-6
L35
WARNING
Position the earth of the welding machine earth as
close as possible to the weld area (see Bolted
connection for earth: Fit) (see MR 400, 40H, Bol-
ted connections).

nents) .

Remove the front end lower cross member (see 41A,
Front lower structure, Front end lower cross mem-
ber: Replacement, page 41A-1) .
Note:
For a partial replacement on the right-hand side, it
is necessary to remove the front right-hand wheel
arch.
Remove the front right-hand wheel arch (see 42A,

Front upper structure, Front wheel arch: Replace-
ment, page 42A-11) .
WARNING
41A-7
Front side member rear section: Replacement 41A
L35
I - COMPOSITION OF THE SPARE PART a - Part in position
132109
132110
No. Description Type Thic- b - Position of electric earths

kness
(mm)
(1) Front side mem- HLE 1.97 WARNING

ber rear part To avoid damaging the vehicles electric and electro-
(2) Sub-frame rear HLE 2.97 near the weld area must be disconnected.
mounting
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
Complete replacement Earths on the body: List and location of compo-
nents) .
IMPORTANT
Use a repair bench to ensure the positioning of the to be removed in order to carry out the
points and the geometry of the axle assemblies. replacement operation
Remove:
- the centre floor front side cross member (see 41B,

Centre lower structure, Centre floor front side
cross member: Replacement, page 41B-8) ,
- the sub-frame rear mounting (see 41A, Front lower

structure, Subframe rear mounting: Replacement,
page 41A-11) ,
- the front side member front section (see 41A, Front

lower structure, Front side member front section:
Replacement, page 41A-2) .
41A-8
Front side member rear section: Replacement 41A
L35
WARNING
41A-9
Front subframe front mounting: Replacement 41A
L35
132111 132112

kness
(mm)
WARNING
(1) Front mounting of HLE 1.17 To avoid damaging the vehicles electric and electro-
subframe, outer nic components, the earths of any wiring harness
section near the weld area must be disconnected.
(2) Front mounting of HLE 1.17
as possible to the weld area (see Bolted connec-
subframe, inner
section
nections).

nents) .
IMPORTANT
Use a repair bench to ensure the positioning of the WARNING
41A-10
Subframe rear mounting: Replacement 41A
L35
132135 132136

kness
(mm)
WARNING
(1) Sub-frame rear HLE 2.97 To avoid damaging the vehicles electric and electro-
mounting reinfor- nic components, the earths of any wiring harness
cement near the weld area must be disconnected.
(2) Sub-frame rear Mild 2.5
mounting steel
nections).
Complete replacement nents) .

IMPORTANT
points and the geometry of the axle assemblies. WARNING
41A-11
Engine mounting: Replacement 41A
L35
132129 132130

kness
(mm)
WARNING
(1) Engine support Mild 1.97 To avoid damaging the vehicles electric and electro-
plate steel nic components, the earths of any wiring harness
(2) Engine support Mild 1.47
bracket steel Position the earth of the welding machine as close
(3) Engine height HLE 1.97 tion for earth: Fit) (see MR 400, 40H, Bolted con-
adjuster reinfor- nections).
cement
(4) Engine support Mild 1.8 Earths on the body: List and location of compo-
height adjuster steel nents) .

Complete replacement WARNING

IMPORTANT original electrical resistance weld (see Gas shiel-
Use a repair bench to ensure the positioning of the ded arc weld bead joints: Description) (MR 400,
points and the geometry of the axle assemblies. 40C, Gas metal arc welded connections (GMAW)).
41A-12
Front half-unit: Replacement 41A
L35
I - COMPOSITION OF THE SPARE PART Right-hand side
Left-hand side
132133
132131 No. Description Type Thic-

kness
(mm)
kness (5) Front side cross HLE 1
(mm) member
(1) Front side cross HLE 1 (6) Front side mem- HLE 1.47
member ber front section
(2) Front side mem- HLE 1.47 (7) Front side mem- HLE 1.97
ber front section ber rear section
(3) Front side mem- HLE 1.97 (8) Front wheel arch Mild 1.17/1.97
ber rear section steel
(4) Front wheel arch Mild 1.17/1.97
steel II - IN THE EVENT OF REPLACEMENT
IMPORTANT
41A-13
Front half-unit: Replacement 41A
L35
a - Part in position b - Position of electric earths
Left-hand side
WARNING
nections).

nents) .

Remove:
132132 - the front end lower cross member (see 41A, Front
Right-hand side Replacement, page 41A-1) ,
- the scuttle side panel rear upper reinforcement (see

42A, Front upper structure, Rear upper reinforce-
ment of scuttle side panel: Replacement, page
42A-10) ,
- the scuttle side panel upper reinforcement (see 42A,

Front upper structure, Scuttle side panel upper
reinforcement: Replacement, page 42A-9) ,

structure, Headlight carrier panel: Replacement,
page 42A-2) ,
- the scuttle side panel partially (see 42A, Front upper

structure, Scuttle side panel: Replacement, page
42A-5) ,
- the front side member closure panel (see 41A, Front

lower structure, Front side member closure pa-
nel: Replacement, page 41A-5) .
132134
WARNING
41A-14
Front tow eye: Replacement 41A
L35
132127

kness
(mm)
132128
(1) Rear towing eye HLE 2.47
(2) Threaded bush b - Position of electric earths
WARNING
nections).

nents) .
WARNING
41A-15
CENTRE LOWER STRUCTURE
Centre floor side section: Replacement 41B
L35
132155
132154

kness
(mm)
(1) Central floor, side Mild 0.97

section steel
II - IN THE EVENT OF A REPLACEMENT

- partial replacement A-B,
41B-1
L35
132141
b - Position of electric earths c - Irremovable bodywork components - structures

WARNING
Remove:
nic components, the earths of any wiring harness - the sill panel (see 41C, Side lower structure, Sill pa-
near the weld area must be disconnected. nel: Replacement, page 41C-1) ,
Position the earth of the welding machine as close - the body side front section (see 43A, Side upper
as possible to the weld area (see Bolted connec- structure, Body side front section: Replacement,
tion for earth: Fit) (MR 400, 40H, Bolted connec- page 43A-5) ,
tions). - the B-pillar lining (see 43A, Side upper structure, B-
pillar lining: Replacement, page 43A-3) ,
Earths on the body: List and location of compo- - the roof (see 45A, Top of body, Roof: Replace-
nents) . ment, page 45A-1) ,
- the quarter panel lining partially (see 44A, Rear up-
per structure, Quarter panel lining: Replacement,
page 44A-11) ,
41B-2
L35
- the inner sill panel (see 41C, Side lower structure, - the rear cross member under front seat (see 41B,
Sill panel closure panel: Replacement, page 41C- Centre lower structure, Rear cross member under
5) , front seat: Replacement, page 41B-12) ,
- the sill panel reinforcement (see 41C, Side lower - the front cross member under front seat (see 41B,
structure, Sill panel reinforcement: Replacement, Centre lower structure, Front cross member un-
page 41C-8) , der front seat: Replacement, page 41B-10) .
132142
WARNING
41B-3
L35
2 - Partial replacement A-B
132144

WARNING
Remove:
page 44A-11) ,
41B-4
L35
- the inner sill panel (see 41C, Side lower structure, - the front cross member under front seat (see 41B,
Sill panel closure panel: Replacement, page 41C- Centre lower structure, Front cross member un-
5) , der front seat: Replacement, page 41B-10) .
- the sill panel reinforcement (see 41C, Side lower
structure, Sill panel reinforcement: Replacement, d - Special notes on mating
page 41C-8) ,
132145
WARNING
41B-5
L35
3 - Partial replacement B-C
132147

WARNING
Remove:
page 44A-11) ,
41B-6
L35
- the inner sill panel (see 41C, Side lower structure, - the rear cross member under front seat (see 41B,
Sill panel closure panel: Replacement, page 41C- Centre lower structure, Rear cross member under
5) , front seat: Replacement, page 41B-12) .
structure, Sill panel reinforcement: Replacement, d - Special notes on mating
page 41C-8) ,
132148
WARNING
41B-7
Centre floor front side cross member: Replacement 41B
L35
I - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF A REPLACEMENT
132151

kness
(mm) 132152
(1) Centre floor front HLE 1

side cross mem- b - Position of electric earths
ber
WARNING
tion for earth: Fit) (MR 400, 40H, Bolted connec-
tions).

nents) .

Remove the subframe rear mounting (see 41A, Front
lower structure, Subframe rear mounting: Replace-
ment, page 41A-11) .
41B-8
Centre floor front side cross member: Replacement 41B
L35
WARNING
40C, Gas metal arc welded connections (SEFG)).
41B-9
Front cross member under front seat: Replacement 41B
L35

kness
(mm)
(1) Front cross mem- HLE 0.97

ber under front
seat
(2) Front cross mem- HLE 1.17

ber reinforcement
(X1) = 263 mm between the mounting holes of the

132137 front seat.
132139
41B-10
Front cross member under front seat: Replacement 41B
L35
WARNING
tions).

nents) .

Remove:
- the sill panel (see 41C, Side lower structure, Sill pa-
nel: Replacement, page 41C-1) ,
- the inner sill panel (see 41C, Side lower structure,
Sill panel closure panel: Replacement, page 41C-
5) ,
structure, Sill panel reinforcement: Replacement,
page 41C-8) .
WARNING
41B-11
Rear cross member under front seat: Replacement 41B
L35

kness
(mm)
(1) Rear cross mem- HLE 0.97

ber under front
seat
(2) Rear cross mem- HLE 1.17

ber reinforcement
(X1) = 263 mm between the mounting holes of the

132138 front seat.
132140
41B-12
Rear cross member under front seat: Replacement 41B
L35
WARNING
tions).

nents) .

Remove:
- the body side front section (see 43A, Side upper
structure, Body side front section: Replacement,
page 43A-5) ,
- the B-pillar lining (see 43A, Side upper structure, B-
- the sill panel closure panel (see 41C, Side lower
structure, Sill panel closure panel: Replacement,
page 41C-5) ,
page 41C-8) .
WARNING
41B-13
SIDE LOWER STRUCTURE
Sill panel: Replacement 41C
L35
132163
132162
1 - Complete replacement A-B-C
(mm)
(1) Sill panel Mild 1.2/0.7

steel

- complete replacement A-B-C,
- partial replacement A-B-D,
- partial replacement B-E-C.
132164
41C-1
L35
Cut A Cut C
132171 132172
Cut B b - Position of electric earths
WARNING
tions).

nents) .
WARNING
132170
41C-2
L35
2 - Partial replacement A-B-D b - Position of electric earths
WARNING
tions).

nents) .
WARNING
132166 ded arc weld bead joints: Description) (MR 400,
Cut D
3 - Partial replacement B-E-C
132173
132168
41C-3
L35
Cut E
132174
WARNING
tions).

nents) .
WARNING
41C-4
Sill panel closure panel: Replacement 41C
L35
132176
132175
1 - Complete replacement A-D
(mm)
(1) Sill panel closure HLE 0.95

panel

- complete replacement A-D,
- partial replacement C-D.
132177
41C-5
L35
WARNING
tions).

nents) .

Remove:
- the sill panel (see 41C, Side lower structure, Sill pa- 132179
Cut B
page 43A-5) ,

page 44A-11) ,
- the roof (see 45A, Top of body, Roof: Replace-

ment, page 45A-1) ,


page 41C-8) .
d - Special notes on mating 132180
b - Irremovable bodywork components - structures

WARNING to be removed in order to carry out the
If the mating faces of the parts to be welded are not replacement operation
original electrical resistance weld (see Gas shiel- Remove:
ded arc weld bead joints: Description) (MR 400, - the sill panel (see 41C, Side lower structure, Sill pa-
40C, Gas metal arc welded connections (GMAW)). nel: Replacement, page 41C-1) ,
41C-6
L35
- the sill panel reinforcement, front section (see 41C, Cut C
Side lower structure, Sill panel reinforcement: Re-
placement, page 41C-8) .
WARNING
3 - Partial replacement C-D
132183
b - Irremovable bodywork components - structures

Remove:
page 44A-11) ,
page 41C-8) .

132182
WARNING
41C-7
Sill panel reinforcement: Replacement 41C
L35
132157
132156
1 - Complete replacement A-D
(mm)
(1) Sill panel reinfor- HLE 0.87

cement

- complete replacement A-D,
- partial replacement C-D.
132158
41C-8
L35
WARNING
tions).

nents) .

Remove:
- the body side front section (see 43A, Side upper 132159
page 43A-5) , Cut B
page 44A-11) .
WARNING
132393
41C-9
L35
b - Position of electric earths 3 - Partial replacement C-D
WARNING
tions).

nents) .

Remove the sill panel (see 41C, Side lower structure,
Sill panel: Replacement, page 41C-1) .

132394
WARNING Cut C
132161
41C-10
L35
WARNING
tions).

nents) .

Remove:
page 44A-11) .
WARNING
41C-11
REAR LOWER STRUCTURE
Rear floor: Replacement 41D
L35
I - COMPOSITION OF THE SPARE PART 1 - Complete replacement
132187
No. Description Type Thic- 132189

kness
(mm)
(1) Rear floor Mild 0.67
steel
WARNING
(2) Rear floor reinfor- Mild 1.17
cement steel To avoid damaging the vehicles electric and electro-
(3) Rear cushion Mild 1.17 near the weld area must be disconnected.
retaining bracket steel
(4) Emergency spare Mild 1.17
wheel front steel
tions).
mounting hook
(5) Emergency spare Mild 1.17 Locate the earths located near to the weld area (see
wheel rear moun- steel Earths on the body: List and location of compo-
ting hook nents) .
II - IN THE EVENT OF REPLACEMENT c - Irremovable bodywork components - structures

- Complete replacement
Remove:
- partial replacement.
- the rear end panel assembly (see 44A, Rear upper
structure, Rear end panel assembly: Replace-
ment, page 44A-18) ,
- the rear lights support (see 44A, Rear upper structu-

re, Rear light mounting: Replacement, page 44A-
7) .
41D-1
L35
d - Special notes on mating 2 - Partial replacement
132190
WARNING 132191
original electrical resistance weld (see Gas shiel- b - Position of electric earths
WARNING
This part is replaced by superimposing on the rear
bench seat mounting. nic components, the earths of any wiring harness
tions).

nents) .

Remove:


7) .
41D-2
L35
132192
WARNING
41D-3
Rear floor reinforcement: Replacement 41D
L35
132201

kness
(mm)
132202
(1) Rear floor reinfor- Mild 1.47
cement steel
WARNING
tions).

nents) .
WARNING
41D-4
Rear side member: Replacement 41D
L35
132197
132196
kness
IMPORTANT
(mm)
(1) Rear side mem- HLE 1.47 points and the geometry of the axle assemblies.
ber
(2) Shock absorber HLE 1.47 a - Part in position

turret reinforce-
ment
(3) Assembled con- HLE 1.47

nection compo-
nent
(4) Rear side cross HLE 0.97

member
(5) Rear axle bea- HLE 2.47

ring spacer
(6) Shock absorber HLE 1.47

cup
(7) Bumper moun- Mild 1.17/1.47

ting support brac- steel
ket

132198
41D-5
L35
b - Position of electric earths a - Part in position
WARNING
tions).

nents) .

Remove the rear end panel assembly (see 44A, Rear
upper structure, Rear end panel assembly: Repla-
132199
cement, page 44A-18) .
Cut B
WARNING
2 - Partial replacement B-C
IMPORTANT
132200
41D-6
L35
WARNING
tions).

nents) .

WARNING
41D-7
Rear tow eye: Replacement 41D
L35
132194

kness
(mm)
132195
(1) Rear towing eye HLE 1.77
(2) Threaded bush b - Position of electric earths
WARNING
tions).

nents) .
WARNING
41D-8
Rear floor unit: Replacement 41D
L35
132184

kness
(mm)
(1) Rear right-hand HLE 1.47 IMPORTANT

side member Use a repair bench to ensure the positioning of the
(2) Rear left-hand HLE 1.47
side member
(3) Cross member HLE 1.45
(4) Rear centre HLE 1.17

cross member
(5) Rear floor Mild 0.67

steel
41D-9
L35
132185
b - Position of electric earths - the rear lights support (see 44A, Rear upper structu-
7) ,
WARNING
- the rear wing panel rain channel (see 44A, Rear up-
To avoid damaging the vehicles electric and electro- per structure, Rear wing panel rain channel: Re-
nic components, the earths of any wiring harness placement, page 44A-6) ,
- the rear wing panel (see 44A, Rear upper structure,
Position the earth of the welding machine as close Rear wing panel: Replacement, page 44A-1) ,
tion for earth: Fit) (MR 400, 40H, Bolted connec- - the quarter panel lining (see 44A, Rear upper struc-
tions). ture, Quarter panel lining: Replacement, page
44A-11) .
nents)

Remove:
41D-10
L35
WARNING
as possible to the weld area (see Gas shielded arc
weld bead joints: Description) (MR 400, 40C,
Gas metal arc welded connections (GMAW)).
41D-11
FRONT UPPER STRUCTURE
Front wing lower mounting support: Replacement 42A
L35
132205

kness
(mm) 132206
(1) Front wing lower HLE 1.5

mounting support b - Special notes on mating
WARNING
42A-1
Headlight carrier panel: Replacement 42A
L35
132207

kness
(mm)
132208
(1) Side component HLE 1.47
of front end panel
upper cross b - Position of electric earths
member
(2) Front end panel Mild 1.17 WARNING

structure reinfor- steel
cement
tions).

nents) .
WARNING
42A-2
Front wing: Removal - Refitting 42A
L35
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).
a Remove:
- the front wheel arch liner (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),
- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),
- the headlight (see Front headlight: Removal -

Refitting) (80B, Headlights),
- the windscreen wiper arms (see Windscreen wi-

per arm: Removal - Refitting) (85A, Wiping -
132226
Washing),
a Remove the bolts (2) .
- the windscreen trim (see Windscreen trim: Re-
moval - Refitting) (54A, Windows),
- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment).
a Disconnect the side indicator connector.
II - OPERATION FOR REMOVAL OF PART

CONCERNED
132227
132225
a Remove the bolt (1) .
42A-3
Front wing: Removal - Refitting 42A
L35
132228
a Remove:
- the nut (4) ,

- the front wing.
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
a Refit the front wing.
II - FINAL OPERATION
a Connect the side indicator connector.
a Refit:
Removal - Refitting) (56A, Exterior equipment),

Washing),

tion).
42A-4
Scuttle side panel: Replacement 42A
L35
132210
132209

kness
(mm)
(1) Scuttle side Mild 1.2

panel steel
(2) Bonnet hinge Mild 1.15

mounting steel

- partial replacement A-B.
42A-5
L35
132211

WARNING
To avoid damaging the vehicles electric and electro- Remove:
near the weld area must be disconnected. - the rear upper reinforcement of the scuttle side panel
(see 42A, Front upper structure, Rear upper rein-
Position the earth of the welding machine as close forcement of scuttle side panel: Replacement,
as possible to the weld area (see Bolted connec- page 42A-10) ,
tions). - the scuttle side panel upper reinforcement (see 42A,
Locate the earths located near to the weld area (see reinforcement: Replacement, page 42A-9) ,
nents) . - the body side front section (see 43A, Side upper
page 43A-5) ,

page 41C-8) .
42A-6
L35
d - Special notes on mating Cut B
WARNING
2 - Partial replacement A-B
132214
WARNING
tions).
132212
nents) .

Remove the scuttle side panel upper reinforcement
(see 42A, Front upper structure, Scuttle side panel
upper reinforcement: Replacement, page 42A-9) .
WARNING
42A-7
L35
42A-8
Scuttle side panel upper reinforcement: Replacement 42A
L35
132215

kness
(mm)
132216
panel upper rein- steel
forcement b - Position of electric earths
WARNING
as possible to the weld area( (see Bolted connec-
tion for earth: Fit) MR 400, 40H, Bolted connec-
tions).

nents) .
WARNING
42A-9
Rear upper reinforcement of scuttle side panel: Replacement 42A
L35
132229

kness
(mm) 132230

panel rear upper steel b - Parts always to be replaced
reinforcement Replace the rear upper reinforcement plate of the scu-
ttle side panel.
WARNING
42A-10
Front wheel arch: Replacement 42A
L35
I - COMPOSITION OF THE SPARE PART Left-hand side
Right-hand side
132220
132218 No. Description Type Thic-

kness
(mm)
kness (5) Front wheel arch Mild 1.17
(mm) steel
(1) Front wheel arch Mild 1.17 (6) Side heater bulk- Mild 0.97
steel head steel
(2) Side heater bulk- Mild 0.97 (7) Cup height adjus- Mild 1.17
head steel ter steel
(3) Front cup height Mild 0.97 (8) Shock absorber Mild 1.97
adjuster steel cup steel
(4) Engine stand Mild 1.97 (9) Angle bracket Mild 1.97
steel steel
IMPORTANT
42A-11
Front wheel arch: Replacement 42A
L35
Complete replacement b - Position of electric earths
WARNING
Right-hand side nic components, the earths of any wiring harness
tions).

nents) .

Remove:
- the rear upper reinforcement of the scuttle side panel
forcement of scuttle side panel: Replacement,
page 42A-10) ,
132217
Left-hand side reinforcement: Replacement, page 42A-9) ,
- the scuttle side panel (see 42A, Front upper structu-
re, Scuttle side panel: Replacement, page 42A-5) .
WARNING
132219
42A-12
Windscreen aperture lower cross member: Replacement 42A
L35
132203

kness
(mm)
132204
(1) Column support Mild 1.5
on windscreen steel
aperture lower b - Position of electric earths
cross member
(2) Left-hand support Mild 1.2 WARNING

mounting bracket steel
(3) Right-hand sup- Mild 1.2 nic components, the earths of any wiring harness
port mounting steel near the weld area must be disconnected.
bracket Position the earth of the welding machine as close
(4) Windscreen Mild 1.2
aperture lower steel
tions).
cross member
nents) .

Remove:
- the rear upper reinforcement of the scuttle side panel

forcement of scuttle side panel: Replacement,
page 42A-10) ,
42A-13
Windscreen aperture lower cross member: Replacement 42A
L35
page 43A-5) ,
- the scuttle side panel (see 42A, Front upper structu-
re, Scuttle side panel: Replacement, page 42A-5) ,
- the windscreen pillar lining (see 43A, Side upper
structure, Windscreen pillar lining: Replacement,
page 43A-1) .
WARNING
42A-14
Front wing: Adjusting 42A
L35
ADJUSTMENT VALUES
a For information on the wing adjustment values (see
Vehicle clearances: Adjusting) (01C, Vehicle bo-
dywork specifications).
ADJUSTMENT
a There are three options for adjusting the front wing:
- Adjustment with the front door,
- Adjustment with the bonnet,
- Adjustment with the headlight and the bumper.
109496
Note:
Symbols A, B, C and D show the adjustment
options.
The black dot in the centre represents the body
of the bolt.
The grey section represents the component to be
adjusted.
The white section represents the adjustment
134728 area.
a Perform these adjustments in the following order:
- Adjustment of the rear zones (1) , (2) and (3) , I - PREPARATION FOR THE ADJUSTMENT.
- Adjustment with the bonnet (4) , a Position the vehicle on a two-post lift (see Vehicle:
- Adjustment with the headlight and the bumper (5) , Towing and lifting) (02A, Lifting equipment).
(6) .
a Remove:

tion),



Washing),

42A-15
L35
Removal - Refitting) (56A, Exterior equipment).
II - ADJUSTMENT WITH THE FRONT DOOR
132238
a Adjust the panel gaps with the front door and the sill
panel.
122064
132239
a Adjust the panel gaps with the front door.
42A-16
L35
III - ADJUSTMENT WITH THE BONNET IV - ADJUSTMENT WITH THE FRONT BUMPER
AND THE FRONT HEADLIGHT
132240
a Refit: 132241
a Refit:
Removal - Refitting) (56A, Exterior equipment), - the headlight (see Front headlight: Removal -
per arm: Removal - Refitting) (85A, Wiping - - the front bumper (see Front bumper: Removal -
Washing), Refitting) (55A, Exterior protection).
- the windscreen trim (see Windscreen trim: Re- a Adjust the panel gaps between the front bumper and
moval - Refitting) (54A, Windows). the front headlight.
a Adjust the panel gaps with the front door and the
windscreen trim. V - FINAL OPERATION
a Refit the front wheel arch liner (see Front wheel
arch liner: Removal - Refitting) (55A, Exterior pro-
tection).
42A-17
Front: Removal - Refitting 42A
L35
REMOVAL

a Remove:
- the front wheel arch liners (see Front wheel arch
tion),
- the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn),
- the bonnet catch (see Bonnet latch: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms).
132975
132976
42A-18
Front: Removal - Refitting 42A
L35
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

CONCERNED
a Refit the front end panel.
a Refit:
- the bonnet catch (see Bonnet latch: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
- the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn),
tion).
132221
132222
a Remove:
- the bolts (3) ,
- the front of the vehicle.
42A-19
Dashboard cross member: Removal - Refitting 42A
L35
Essential equipmentEssential equipment
diagnostic tool
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or preten-
sioners), lock the airbag computer using the dia-
gnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the ins-
trument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensio-
ners or airbags) near to a source of heat or naked
flame - they may be triggered.
IMPORTANT
To avoid any risk of damaging the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out the
repair (see Airbag and Pretensioners: Precau-
tions for repair) (88C, Airbags and pretensioners).
REMOVAL

a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbags and pretensioners).
a Disconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
a Remove the dashboard (see Dashboard: Removal

- Refitting) (57A, Interior equipment).
a Remove the steering column partially (see Steering

column: Removal - Refitting) (36A, Steering as-
sembly).
a Remove:
- the UCH (see UCH: Removal - Refitting) (87B,

Passenger compartment connection unit),
- the bolts,
- the fuse holder unit.
42A-20
L35
CONCERNED
132236
132231
132235
132233
42A-21
L35
132237
a Remove the bolts (1) from the dashboard cross

member.
a Unclip the dashboard cross member wiring.
a Remove the dashboard cross member.
REFITTING

CONCERNED
a Refit the dashboard cross member.
a Clip on the dashboard cross member wiring.
a Refit:
- the fuse holder unit,
- the UCH (see UCH: Removal - Refitting) (87B,

Passenger compartment connection unit),
- the steering column (see Steering column: Re-

moval - Refitting) (36A, Steering assembly),
- the dashboard (see Dashboard: Removal - Refit-

ting) (57A, Interior equipment).
a Connect the battery (see Battery: Removal - Refit-

ting) (80A, Battery).
a Unlock the airbag computer using the diagnostic

tool (see Fault finding - Replacement of compo-
nents) (88C, Airbags and pretensioners).
42A-22
SIDE UPPER STRUCTURE
Windscreen pillar lining: Replacement 43A
L35
132264

kness
(mm) 132265
(1) Windscreen pillar Mild 1.2

lining steel b - Position of electric earths
WARNING
tions).

nents) .
c - Parts always to be replaced

Replace the windscreen pillar insert (see Hollow body
parts inserts: List and location of components) and
(see Hollow body parts inserts: Precautions for re-
pair) .
43A-1
Windscreen pillar lining: Replacement 43A
L35
d - Irremovable bodywork components - structures
to be removed in order to carry out the repair
operation
Remove:
page 43A-5) ,
ment, page 45A-1) .
e - Special notes on mating
WARNING
43A-2
B-pillar lining: Replacement 43A
L35
132286

kness
(mm)
132242
(1) B-pillar lining Mild 0.7
steel b - Position of electric earths
WARNING
tions).

nents) .

Remove:
page 43A-5) ,
ment, page 45A-1) .
43A-3
B-pillar lining: Replacement 43A
L35
WARNING
43A-4
Body side front section: Replacement 43A
L35
132244
132243
1 - Complete replacement C-D
(mm)
(1) A-pillar reinforce- Mild 0.97

ment steel
(2) B-pillar reinforce- HLE 1.17

ment
(3) Door striker panel Mild 1.2

reinforcement steel
(4) Body side front Mild 1.2

section steel
(5) A-pillar lining rear Mild 1.27

reinforcement steel

- complete replacement C-D,
132245
- partial replacement A-E,
- partial replacement B-C-D-E.
43A-5
L35
Cut C b - Position of electric earths
WARNING
tions).

nents) .

Replace:
- the hollow section inserts (see Hollow body parts in-
132261 serts: List and location of components) and (see
Hollow body parts inserts: Precautions for repair)
Cut D ,
- the front double seal support.

Remove the roof (see 45A, Top of body, Roof: Repla-
WARNING
132253
43A-6
L35
2 - Partial replacement A-E Cut E
132255

132249
WARNING
Cut A
tions).

nents) .

Replace:
serts: List and location of components) and (see
,
132251 - the front double seal support.
43A-7
L35
d - Special notes on mating Cut E
WARNING
3 - Partial replacement B-C-D-E
132255
WARNING
tions).
132247
nents) .
Replace the hollow section inserts (see Hollow body

parts inserts: List and location of components) and
(see Hollow body parts inserts: Precautions for re-
pair) .
WARNING
43A-8
Upper body: Replacement 43A
L35
132256

kness
(mm) 132257
(1) Roof panel Mild 1.2

steel Cut A
132259
43A-9
Upper body: Replacement 43A
L35
Cut B b - Position of electric earths
WARNING
tions).

nents) .

Replace the front double seal support.
132260 d - Irremovable bodywork components - structures

Cut C replacement operation
WARNING
132261
43A-10
REAR UPPER STRUCTURE
Rear wing panel: Replacement 44A
L35
132276
132275

kness
(mm)
(1) Rear wing panel Mild 0.7

steel
(2) Door striker plate HLE 1.2

stiffener

- complete replacement A-B,
- partial replacement C-D-E.
44A-1
L35
1 - Complete replacement A-B
132277
Cut A Cut B
132281 132282
44A-2
L35
b - Position of electric earths - the rear double seal support.

WARNING
To avoid damaging the vehicles electric and electro- replacement operation
near the weld area must be disconnected. Remove the roof (see 45A, Top of body, Roof: Repla-
tion for earth: Fit) (MR 400, 40H, Bolted connec- e - Special notes on mating
tions).
Locate the earths located near to the weld area (see WARNING
Earths on the body: List and location of compo- If the mating faces of the parts to be welded are not
nents) . accessible, use a GMAW plug weld in place of the
c - Parts always to be replaced ded arc weld bead joints: Description) (MR 400,
Replace:
2 - Partial replacement C, D and E
serts: List and location of components) and (see
, a - Part in position
132279
44A-3
L35
Cut C Cut E
132284 132283
Cut D b - Position of electric earths
WARNING
tions).

nents) .

Replace:
132285 serts: List and location of components) and (see
,
- the rear double seal support.
44A-4
L35
WARNING
44A-5
Rear wing panel rain channel: Replacement 44A
L35
132271

kness
(mm)
132272
(1) Rear wing panel Mild 1
rain channel steel
(2) Luggage com- Mild 1.47
partment lid strut steel
reinforcement
WARNING
tion for earth: Fit) .

nents) .
WARNING
44A-6
Rear light mounting: Replacement 44A
L35
132269

kness
(mm) 132270
(1) Rear lights sup- Mild 1

port steel b - Position of electric earths
(2) Rear lower side Mild 1

rain channel steel WARNING
as possible to the weld area (see Earths on the
body: List and location of components) (MR
400, 40H, Bolted connections).

nents) .

44A-7
Rear light mounting: Replacement 44A
L35
WARNING
44A-8
Outer rear wheel arch: Replacement 44A
L35
I - COMPOSITION OF THE PART CONCERNED II - IN THE EVENT OF REPLACEMENT
132286

kness
(mm) 132288
(1) Outer rear wheel Mild 0.7

arch steel b - Position of electric earths
WARNING
tions).

nents) .

Remove the rear wing panel (see 44A, Rear upper
structure, Rear wing panel: Replacement, page
44A-1) .
44A-9
Outer rear wheel arch: Replacement 44A
L35
132287
WARNING
44A-10
Quarter panel lining: Replacement 44A
L35
132273

No. Description Type Thic- kness
kness (mm)
(mm)
(6) Hinge mounting HLE 1.47
(1) Quarter panel Mild 1.17
(7) Rear side parcel Mild 1.17
rear reinforce- steel
shelf steel
ment
(2) Quarter panel Mild 1

lining lower sec- steel
tion reinforce-
ment
(3) Quarter panel Mild 0.7

lining steel
(4) Inner rear wheel Mild 0.87

arch steel
(5) Rear shock HLE 1.97

absorber moun-
ting
44A-11
L35
132274
b - Position of electric earths c - Parts always to be replaced

Replace:
WARNING - the hollow section inserts (see Hollow body parts in-
To avoid damaging the vehicles electric and electro- serts: List and location of components) and (see
nic components, the earths of any wiring harness Hollow body parts inserts: Precautions for repair)
near the weld area must be disconnected. .

as possible to the weld area (see Bolted connec- d - Irremovable bodywork components - structures
tion for earth: Fit) (MR 400, 40H, Bolted connec- to be removed in order to carry out the
tions). replacement operation
Remove:
- the rear end panel assembly (see Rear end panel
assembly: Description) ,
- the rear wing panel (see 44A, Rear upper structure,
Rear wing panel: Replacement, page 44A-1) ,
44A-12
L35
7) .
WARNING
44A-13
Rear parcel shelf: Replacement 44A
L35
132266

kness
(mm) 132267
(1) Rear screen Mild 0.7

lower cross mem- steel
ber
(2) Centre rear par- Mild 0.77

cel shelf steel
(3) Centre rear par- Mild 0.97

cel shelf stiffener steel
(4) Centre rear iner- Mild 1.5

tia reel mounting steel
reinforcement
132268
44A-14
Rear parcel shelf: Replacement 44A
L35
WARNING
tion for earth: Fit) (MR 400 40H, Bolted connec-
tions).

nents) .
WARNING
44A-15
Rear parcel shelf side section: Replacement 44A
L35
132291

kness
(mm) 132292
(1) Rear parcel shelf Mild 1.17

side section steel
(2) Luggage com- Mild 1.2

part m e n t lid steel
hinge reinforce-
ment
132293
44A-16
Rear parcel shelf side section: Replacement 44A
L35
WARNING
tions).

nents) .
WARNING
44A-17
Rear end panel assembly: Replacement 44A
L35
132289

kness
(mm)
132290
(1) Rear end panel Mild 1.2
upper cross steel
member b - Position of electric earths
(2) Rear end panel Mild 1

lower cross mem- steel WARNING
ber
(3) Rear end panel Mild 1
steel
(4) Rear bumper Mild 1.5 as possible to the weld area (see Bolted connec-
mounting sup- steel tion for earth: Fit) (MR 400, 40H, Bolted connec-
port bracket tions).

nents) .
WARNING
44A-18
TOP OF BODY
Roof: Replacement 45A
L35
Front section view
132300

kness
(mm)
(1) Roof Mild 0.65 132301

steel
Rear section view
132302
b - Parts always to be replaced

Replace:
- the soundproofing pad,
45A-1
TOP OF BODY
Roof: Replacement 45A
L35
- the sealing mastic.
WARNING
Note:
For detailed information on welded connections
with three thicknesses (see Connection by points
of electrical resistance in three thicknesses:
Description) (MR 400, 40B, Electrical resistance
welded connections (SER)).
45A-2
TOP OF BODY
Roof front cross member: Replacement 45A
L35
132296

kness
(mm) 132297
(1) Roof front cross Mild 1.2

member steel b - Irremovable bodywork components - structures
WARNING
45A-3
TOP OF BODY
Roof centre cross member: Replacement 45A
L35
132294

kness
(mm) 132295
(1) Roof centre cross Mild 1.8

WARNING
45A-4
TOP OF BODY
Roof rear cross member: Replacement 45A
L35
132298

kness
(mm) 132299
(1) Roof rear cross Mild 0.65

WARNING
45A-5
SIDE OPENING ELEMENTS
Front side door: Removal - Refitting 47A
L35
Essential special toolingEssential special too-

lingEssential special tooling
Car. 1415-01 Pliers for removing door hinge

pins - Clio X65.
Note:
When replacing the door or replacing the body but
refitting the original opening elements, it is neces-
sary to use the specific After-Sales screw hinges
which enable the height of the front door to be
adjusted.
REMOVAL

a Disconnect the front side door wiring connector. 132304
II - OPERATION FOR REMOVAL OF PART a Remove:

CONCERNED
- the clips,
- the hinge pieces (2) using the tool (Car. 1415-01),
- the front side door (this operation requires two peo-

ple).
REFITTING

CONCERNED
a Refit:
- the front side door (this operation requires two peo-

ple),
- the hinge pieces (2) ,
133325 - the clips,

a Remove the front side door check strap bolt (1) .
- the bolt (1) of the front side door check strap.
a Adjust the panel gaps and flush fittings of the front

side door (see 47A, Side opening elements, Front
side door: Adjustment, page 47A-4) .
a Connect the front side door wiring connector.
47A-1
Front side door: Stripping - Restoring 47A
L35
Note: ELEC. FRONT WINDOW SW.
The order of the operations described below is spe- a Remove the front side door electric window mecha-
cific to the front side door replacement. nism (see Front side door electric window me-
chanism: Removal - Refitting) (51A, Side opening
The following procedure applies to the front side element mechanisms).
door on the vehicle.
STRIPPING
MAN. FRONT WINDOW WINDER
STRIPPING OPERATION FOR PART CONCERNED
a Remove the front side door manual window mecha-
a Remove: nism (see Front side door manual window winder
- the front side door trim (see Front side door trim mechanism: Removal - Refitting) (51A, Side ope-
decoration: Removal - Refitting) (72A, Side opening element mechanisms).
ning element trim),
- the door mirror (see Door mirror: Removal - Re-

fitting) (56A, Exterior equipment),
- the front side door sliding window (see Sliding REASSEMBLING
window in front side door: Removal - Refitting)
(54A, Windows),
REBUILDING OPERATION FOR PART
- the front side door exterior weatherstrip (see Front CONCERNED
door side exterior weather strip: Removal - Re-
fitting) (66A, Window sealing),
MAN. FRONT WINDOW WINDER
- the front side door interior weatherstrip (see Front
side door interior weatherstrip: Removal - Refit- a Refit the front side door manual window mechanism
ting) (66A, Window sealing), (see Front side door manual window winder me-
chanism: Removal - Refitting) (51A, Side opening
- the front side door glass run channel (see Front
element mechanisms).
side door glass run channel: Removal - Refit-
ting) (66A, Window sealing),
- the front speaker (see Front speakers: Removal -
Refitting) (86A, Radio),
- the front side door lock barrel (see Front side door ELEC. FRONT WINDOW SW.
lock barrel: Removal - Refitting) (51A, Side ope-
a Refit the front side door electric window mechanism
ning element mechanisms),
(see Front side door electric window mecha-
- the front side exterior door handle (see Door exte- nism: Removal - Refitting) (51A, Side opening ele-
rior handle: Removal - Refitting) (51A, Side ope- ment mechanisms).
- the front side door lock (see Front side door lock:
Removal - Refitting) (51A, Side opening element
mechanisms), a Refit:
- the front side door check strap (see Front side - the blanking covers,
door check strap: Removal - Refitting) (51A,
- the clips,
Side opening element mechanisms),
- the electrical wiring of the front side door,
- the electrical wiring of the front side door,
- the front side door check strap (see Front side
- the clips,
door check strap: Removal - Refitting) (51A,
- the blanking covers. Side opening element mechanisms),
47A-2
Front side door: Stripping - Restoring 47A
L35
- the front side door lock (see Front side door lock:
mechanisms),
- the front side exterior door handle (see Door exte-
rior handle: Removal - Refitting) (51A, Side ope-
- the front side door lock barrel (see Front side door
lock barrel: Removal - Refitting) (51A, Side ope-
- the front speaker (see Front speakers: Removal -
Refitting) (86A, Radio),
- the front side door glass run channel (see Front
side door glass run channel: Removal - Refit-
- the front side door sliding window (see Sliding
window in front side door: Removal - Refitting)
(54A, Windows),
- the door mirror (see Door mirror: Removal - Re-
fitting) (56A, Exterior equipment),
- the front side door interior weatherstrip (see Front
side door interior weatherstrip: Removal - Refit-
- the front side door exterior weatherstrip (see Front
door side exterior weather strip: Removal - Re-
fitting) (66A, Window sealing),
- the front side door trim (see Front side door trim
decoration: Removal - Refitting) (72A, Side ope-
ning element trim).
a Carry out a function test.
47A-3
Front side door: Adjustment 47A
L35

Car. 956 Door hinge aligning tool.
Ms. 580 Large slide hammer.
Note:
which enable the height of the rear door to be
adjusted.
ADJUSTMENT VALUES
a For information on the front side door adjustment va-
lues (see Vehicle clearances: Adjusting) (01C,
Vehicle bodywork specifications). 109496
a
ADJUSTMENT Note:
a There are three options for adjusting the front side Symbols A, B, C and D show the adjustment
door: options.
- by adjusting the mountings on the inner door panel, The black dot in the centre represents the body
- by adjusting the mountings on the A-pillar (this ope- of the bolt.
ration requires the front wing and front side door to The grey section represents the component to be
be removed), adjusted.
- by adjusting the front side door striker panel. The white section represents the adjustment
area.
134047
a Respect the following adjustment order (1) , (2) , (3)
, (4) and (5) .
47A-4
L35
I - ADJUSTMENT OF FLUSH FITTING WITH THE II - ADJUSTING THE PANEL GAPS WITH THE
FRONT WING AND THE REAR DOOR REAR SIDE DOOR
Original hinges
133819
132304 a Undo the front side door striker plate bolts.
a Adjust the clearances and flush fitting at (6) with the a Adjust the clearances and flush fittings with the rear
front wing using the tool (Car. 956) and tool (Ms. door.
580). a Tighten the front side door striker plate bolts.
Specific After-Sales hinges
132306
a Undo the bolts of the front side door hinges.

a Adjust the clearances and the flush fittings with the
front wing.
a Tighten the bolts of the front side door hinges.
47A-5
L35
47A-6
Rear side door: Removal - Refitting 47A
L35

Car. 1415-01 Pliers for removing door hinge

pins - Clio X65.
Note:
adjusted.
REMOVAL

a Disconnect the connector from the rear side door wi- 132303
ring.
a Remove:
CONCERNED - the clips,
- the hinge pieces (2) using the tool (Car. 1415-01),
- the rear side door (this operation requires two peo-

ple).
REFITTING

CONCERNED
a Refit:
- the rear side door (this operation requires two peo-

ple),
- the hinge pieces (2) ,
- the clips,
133325
a Remove the rear side door check strap bolt (1) . - the rear side door check strap bolt (1) .
a Adjust the rear side door clearances and flush fit-

tings (see 47A, Side opening elements, Rear side
door: Adjustment, page 47A-10) .
a Connect the connector for the rear side door wiring.
47A-7
Rear side door: Stripping - Restoring 47A
L35
Note: MANUAL REAR WINDOW WINDER
The order of the operations described below a Remove the rear side door manual window winder
applies specifically to replacing the rear side door. mechanism (see Front side door manual window
winder mechanism: Removal - Refitting) (51A,
The following procedure applies to the rear side Side opening element mechanisms).
door on the vehicle.
STRIPPING
REASSEMBLING
STRIPPING OPERATION FOR PART CONCERNED
a Remove: REBUILDING OPERATION FOR PART
CONCERNED
- the rear side door trim (see Rear side door trim:
trim), MANUAL REAR WINDOW WINDER
- the rear side door exterior handle (see Door exte- a Refit the rear side door manual window winder me-
chanism (see Front side door manual window
winder mechanism: Removal - Refitting) (51A,
- the rear side door lock (see Rear side door lock: Side opening element mechanisms).
mechanisms),
- the rear side door glass run channel (see Glass
run channel in rear side door: Removal - Refit-
ting) (66A, Window sealing), ELEC. REAR WINDOW SW.
- the rear side door sliding window (see Sliding win- a Refit the rear side door electric window mechanism
dow in rear side door: Removal - Refitting) (see Rear side door electric window mechanism:
(54A, Windows), Removal - Refitting) (51A, Side opening element
mechanisms).
- the frame of the rear side door fixed window (see
Rear side door fixed window frame: Removal -
Refitting) (66A, Window sealing),
- the rear side door fixed window (see Rear side a Refit:
door fixed window: Removal - Refitting) (54A,
Windows), - the blanking covers,
- the rear side door check strap (see Rear side door - the clips,
check strap: Removal - Refitting) (51A, Side - the electrical wiring of the rear side door,
opening element mechanisms),
- the rear side door check strap (see Rear side door
- the electrical wiring of the rear side door, check strap: Removal - Refitting) (51A, Side
- the clips, opening element mechanisms),
- the blanking covers. - the rear side door manual window winder mecha-
nism (see Front side door manual window win-
der mechanism: Removal - Refitting) (51A, Side
ELEC. REAR WINDOW SW. opening element mechanisms),
a Remove the rear side door electric window mecha- - the rear side door fixed window (see Rear side
nism (see Rear side door electric window mecha- door fixed window: Removal - Refitting) (54A,
nism: Removal - Refitting) (51A, Side opening Windows),
- the frame of the rear side door fixed window (see
Rear side door fixed window frame: Removal -
Refitting) (66A, Window sealing),
47A-8
Rear side door: Stripping - Restoring 47A
L35
- the rear side door sliding window (see Sliding win-
dow in rear side door: Removal - Refitting)
(54A, Windows),
- the rear side door glass run channel (see Glass
run channel in rear side door: Removal - Refit-
- the rear side door lock (see Rear side door lock:
mechanisms),
- the rear side door exterior handle (see Door exte-
- the rear side door trim (see Rear side door trim:
trim).
a Carry out a function test.
47A-9
Rear side door: Adjustment 47A
L35

Car. 956 Door hinge aligning tool.
Ms. 580 Large slide hammer.
Note:
When replacing a door or replacing the body but
adjusted.
ADJUSTMENT VALUES
a For information on the rear side door adjustment va-
lues (see Vehicle clearances: Adjusting) (01C,
Vehicle bodywork specifications). 109496
a
ADJUSTMENT Note:
a There are three options for adjusting the rear side Symbols A, B, C and D show the adjustment
door: options.
- by adjusting the mountings on the inner door panel, The black dot in the centre represents the body
of the bolt.
- by adjusting the mountings on the B-pillar; this ope-
ration requires the rear side door to be removed, The grey section represents the component to be
adjusted.
- by adjusting the rear side door striker panel.
The white section represents the adjustment
area.
134766
a Respect the following adjustment order (1) , (2) , (3)

and (4) .
47A-10
L35
I - ADJUSTING THE FLUSH FITTING WITH THE Original hinges
FRONT SIDE DOOR
Specific AFTER-SALES hinges
132303
a Remove the rear side door (see 47A, Side opening
elements, Rear side door: Removal - Refitting,
132305 page 47A-7) .
a Loosen the rear side door hinge bolts. a Adjust the clearances and flush fittings at (1) with the
front side door using the tool (Car. 956) and the tool
a Adjust the clearances and flush fittings with the front
(Ms. 580).
side door and the rear wing panel.
a Refit the rear side door (see 47A, Side opening ele-
a Tighten the rear side door hinge bolts.
ments, Rear side door: Removal - Refitting, page
47A-7) .
47A-11
L35
II - ADJUSTMENT OF THE PANEL GAPS AND
FLUSH FITTING WITH THE REAR WING PANEL
134048
a Undo the rear side door striker panel bolts.
a Adjust the clearances and flush fittings with the rear
wing panel.
a Tighten the rear side door striker panel bolts.
47A-12
Fuel filler flap: Removal - Refitting 47A
L35
REMOVAL
OPERATION FOR REMOVAL OF PART

CONCERNED
132307
a Remove:
- the nuts (1) ,
- the fuel filler flap.
REFITTING
REFITTING OPERATION FOR PART CONCERNED

a Refit the fuel filler flap.
47A-13
NON-SIDE OPENING ELEMENTS
Bonnet: Removal - Refitting 48A
L35
This operation can be carried out in two ways: 2 - FINAL OPERATION
- Removal without the hinges: used for replacing the a Clip on the windscreen washer jet pipe.
bonnet, a Connect the windscreen washer jet pipe.
- Removal with the hinges: allows the initial adjust-
ments to be kept and prevents the original paintwork III - REMOVAL WITH THE BONNET HINGES
from coming off between the hinge and the bonnet
lining.
1 - PREPARATION FOR REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
I - REMOVAL WITHOUT THE BONNET HINGES Towing and lifting) (02, Lifting equipment).
a Remove:
a Disconnect the windscreen washer jet pipe. liner: Removal - Refitting) (55A, Exterior protec-
tion),
a Unclip the windscreen washer jet pipe.
2 - REMOVAL - the headlights (see Front headlight: Removal -
Washing),
- the windscreen trims (see Windscreen trim: Re-
- the front wings (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) .
a Disconnect the windscreen washer jet pipe.
a Unclip the windscreen washer jet pipe.
132315
a Remove:
- the bolts (1) ,
- the bonnet. This operation requires two people.
II - REFITTING WITHOUT BONNET HINGES
1 - REFITTING
a Refit the bonnet; this operation requires two people.
a Adjust the opening clearances and flush fitting (see

48A, Non-side opening elements, Bonnet: Ad-
justment, page 48A-4) .
48A-1
Bonnet: Removal - Refitting 48A
L35
2 - REMOVAL - the front bumper (see Front bumper: Removal -
tion).
132316
a Remove:
- the bolts (2) ,
- the bonnet. This operation requires two people.
IV - REFITTING WITH THE BONNET HINGES
1 - REFITTING
a Refit the bonnet; this operation requires two people.
48A, Non-side opening elements, Bonnet: Ad-
justment, page 48A-4) .
2 - FINAL OPERATION
a Clip on the windscreen washer jet pipe.
a Connect the windscreen washer jet pipe.
a Refit:
- the front wings (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) ,
- the windscreen trims (see Windscreen trim: Re-
Washing),
- the headlights (see Front headlight: Removal -
48A-2
Bonnet: Stripping - Rebuilding 48A
L35
Note:
Described below is a special sequence of opera-
tions for bonnet replacement.
The procedure described below applies to the bon-
net on the vehicle.
STRIPPING
a Remove the bonnet catch (see Bonnet latch: Re-
moval - Refitting) (52A, Non-side opening element
mechanisms).
a Unclip:
- the windscreen washer jet pipe,
- the windscreen washer jets.
a Remove:
- the bonnet stay,
- the various blanking covers.
REASSEMBLING
a Refit:
- the blanking covers,
- the bonnet stay.
a Clip:
- the windscreen washer jets,
- the windscreen washer jet pipe.
a Refit the bonnet catch (see Bonnet latch: Removal
- Refitting) (52A, Non-side opening element mecha-
nisms).
48A-3
Bonnet: Adjustment 48A
L35
ADJUSTMENT VALUES
a For information on the bonnet adjustment values
(see Vehicle clearances: Adjusting) (01C, Vehicle
bodywork specifications).
ADJUSTMENT
a There are two ways to adjust the bonnet:
- by means of the bonnet bolts,
- by means of the bonnet hinge bolts; the front wing
needs to be removed for this operation (see 48A,
Non-side opening elements, Bonnet: Removal -
Refitting, page 48A-1) .
Note:
The bonnet catch must be adjusted in addition to
the bonnet adjustment.
109496
a Symbols A, B, C and D show the adjustment op-
tions.
The black dot in the centre represents the body of
the bolt.
adjusted.
The white section represents the adjustment area.
134045
a Respect the following adjustment order (1) , (2) and
(3) .
48A-4
Bonnet: Adjustment 48A
L35
I - ADJUSTMENT BY MEANS OF THE BONNET
BOLTS
132313
a Undo the bonnet hinge bolts.
132314
a Refit the front wing.
a Loosen the bonnet bolts.
a Adjust the panel gaps and flush fittings of the bon-
a Adjust the panel gaps and flush fittings on the bon-
net.
net.
a Remove the front wing.
a Tighten the bonnet bolts.
a Tighten the bonnet hinge bolts.
II - ADJUSTMENT BY MEANS OF THE BONNET a Refit the front wing (see 42A, Front upper structu-
HINGE BOLTS re, Front wing: Removal - Refitting, page 42A-3) .
a Remove the front wing (see 42A, Front upper
structure, Front wing: Removal - Refitting, page III - ADJUSTMENT BY MEANS OF THE BONNET
42A-3) . CATCH
a Loosen the bolts of the bonnet catch (see Bonnet
latch: Removal - Refitting) (52A, Non-side opening
a Adjust the flush fitting of the bonnet with the headli-
ghts and the radiator grille (see Vehicle clearan-
ces: Adjustment values) (01C, Vehicle bodywork
specifications).
a Tighten the bonnet catch bolts.
48A-5
Boot lid: Removal - Refitting 48A
L35
This operation can be carried out in two ways: 2 - FINAL OPERATION
- Removal without the hinges: used for replacing the a Connect the boot lid lock connector.
bonnet,
a Clip on the boot lid wiring.
- Removal with the hinges: allows the initial adjust-
ments to be kept. a Refit the boot lid trim (see Boot lid lining: Removal
- Refitting) (73A, Non-side opening elements trim).
I - REMOVAL WITHOUT THE BOOT LID HINGES

III - REMOVAL WITH BONNET HINGES

a Remove the boot lid trim (see Boot lid lining: Re-
moval - Refitting) (73A, Non-side opening ele- a Remove:
ments trim). - the rear parcel shelf trim (see Rear parcel shelf
a Disconnect the boot lid lock connector. lining: Removal - Refitting) (71A, Body internal
trim),
a Unclip the wiring from the boot lid.
- the boot lid trim (see Boot lid lining: Removal -
Refitting) (73A, Non-side opening elements trim),
2 - REMOVAL
- the rear wheel arch trims (see Rear wheel arch
lining: Removal - Refitting) (71A, Body internal
trim).
a Release the springs from their housing.
a Disconnect the boot lid lock connector.

a Unclip the wiring from the boot lid.
2 - REMOVAL
132309
a Remove:
- the bolts (1) ,

- the boot lid; this operation requires two people.
II - REFITTING WITHOUT BONNET HINGES
1 - REFITTING
133818
a Refit the boot lid; this operation requires two people. a Remove:
a Adjust the opening clearances and flush fitting (see - the bolts (2) ,
48A, Non-side opening elements, Boot lid: Re-
moval - Refitting, page 48A-6) . - the boot lid; this operation requires two people.
48A-6
Boot lid: Removal - Refitting 48A
L35
IV - REFITTING WITH BONNET HINGES
1 - REFITTING
a Refit the boot lid; this operation requires two people.
48A, Non-side opening elements, Boot lid: Re-
moval - Refitting, page 48A-6) .

a Connect the boot lid lock connector.
a Clip on the boot lid wiring.
a Fit the springs in their housing.
a Refit:
- the rear wheel arch trims (see Rear wheel arch
trim),
- the rear parcel shelf trim (see Rear parcel shelf
trim).
48A-7
Boot lid: Stripping - Rebuilding 48A
L35
Note:
Described below is a special sequence of opera-
tions for boot lid replacement.
The procedure described below applies to the boot
lid on the vehicle.
STRIPPING
a Remove:
- the boot lid lock (see Boot lid lock: Removal - Re-
fitting) (52A, Non-side opening element necha-
nisms),
- the boot lid opening control (see Boot lid release
catch: Removal - Refitting) (52A, Non-side ope-
ning element mechanisms). 133567
a Unclip the lower protective strip from the boot lid (2) .
a Remove:
- the wiring of the boot lid,
- the various blanking covers.
REASSEMBLING
a Refit:
- the blanking covers,
- the wiring of the boot lid.
a Clip on the lower protective strip for the boot lid (2) .
133602 a Refit:
a Remove the bolts (1) . - the boot lid opening control (see Boot lid release
catch: Removal - Refitting) (52A, Non-side ope-
- the boot lid lock (see Boot lid lock: Removal - Re-
fitting) (52A, Non-side opening element necha-
nisms),
Refitting) (73A, Non-side opening element trim).
48A-8
Boot lid: Adjusting 48A
L35
ADJUSTMENT VALUES
a For information on the boot lid adjustment values,
(see Vehicle clearances: Adjusting) (01C, Vehicle
bodywork specifications).
ADJUSTMENT
a The boot lid can be adjusted in two ways:
- by adjusting the boot lid bolts,
- by adjusting the boot lid hinge bolts. This operation
requires the rear parcel shelf trim to be removed
(see Rear parcel shelf lining: Removal - Refit-
ting) (71A, Body internal trim).
Note:
Adjustment of the boot lid striker supplements
the adjustment of the boot lid.
109496
a Symbols A, B, C and D show the adjustment op-
tions.
The black dot in the centre represents the body of
the bolt.
adjusted.
The white section represents the adjustment area.
I - ADJUSTMENT BY MEANS OF THE BOOT LID

BOLTS
a Remove the boot lid trim (see Boot lid lining: Re-
moval - Refitting) (73A, Non-side opening ele-
ments trim).
134046
a Respect the following adjustment order (1) , (2) and
(3) .
48A-9
L35
II - ADJUSTMENT BY MEANS OF THE BOOT LID
HINGE BOLTS
132311
a Loosen the boot lid bolts.
132310
a Adjust the panel gaps and flush fittings of the boot
a Remove the rear parcel shelf trim (see Rear parcel
lid.
shelf lining: Removal - Refitting) (71A, Body inter-
a Tighten the boot lid bolts. nal trim).
a Refit the boot lid trim (see Boot lid lining: Removal a Loosen the boot lid bolts.
- Refitting) (73A, Non-side opening elements trim).
a Adjust the panel gaps and flush fittings of the boot
lid.
a Tighten the boot lid bolts.
a Refit the rear parcel shelf trim (see Rear parcel
shelf lining: Removal - Refitting) (71A, Body inter-
nal trim).
48A-10
L35
III - ADJUSTMENT BY MEANS OF THE BOOT LID
LOCK
132312
a Loosen the boot lid striker panel bolt (see Boot lid
lock: Removal - Refitting) (52A, Non-side opening
a Adjust the panel gaps and flush fittings of the boot lid
(see Vehicle clearances: Adjustment values)
(01C, Vehicle bodywork specifications).
a Tighten the boot lid striker panel bolt (see Boot lid
lock: Removal - Refitting) (52A, Non-side opening
48A-11

Renault

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Renault

Uploaded by

Copyright:

Available Formats

4 Panelwork

40A GENERAL INFORMATION

41A FRONT LOWER STRUCTURE

41B CENTRE LOWER STRUCTURE

41C SIDE LOWER STRUCTURE

41D REAR LOWER STRUCTURE

42A FRONT UPPER STRUCTURE

43A SIDE UPPER STRUCTURE

44A REAR UPPER STRUCTURE

45A TOP OF BODY

47A SIDE OPENING ELEMENTS

48A NON-SIDE OPENING ELEMENTS

APRIL 2008 Edition Anglaise

© Renault s.a.s 2008

SYMBOL - THALIA - Section 4

40A GENERAL INFORMATION 41A FRONT LOWER STRUCTURE

Vehicle on repair bench: Front half-unit: Replacement 41A-13

41C SIDE LOWER STRUCTURE

41A FRONT LOWER STRUCTURE Sill panel: Replacement 41C-1

Sill panel closure panel:

Front side member closure

41D REAR LOWER STRUCTURE 44A REAR UPPER STRUCTURE

Rear tow eye: Replacement 41D-8 Rear wing panel:

Rear light mounting:

Front wing lower mounting Outer rear wheel arch:

Headlight carrier panel: Quarter panel lining:

Front wing: Removal - Rear parcel shelf:

Scuttle side panel: Rear parcel shelf side

Scuttle side panel upper Rear end panel assembly:

Rear upper reinforcement of

Windscreen aperture lower Roof front cross member:

Front wing: Adjusting 42A-15 Roof centre cross member:

47A SIDE OPENING ELEMENTS

Rear side door: Stripping -

47A SIDE OPENING ELEMENTS

Rear side door: Adjustment 47A-10

Fuel filler flap: Removal -

48A NON-SIDE OPENING ELEMENTS

Bonnet: Removal - Refitting 48A-1

Bonnet: Adjustment 48A-4

Boot lid: Removal - Refitting 48A-6

Boot lid: Stripping -

Boot lid: Adjusting 48A-9

1 - Front sub-frame in place

1 - Rear mechanical components in place

2 - Rear mechanical components removed

IV - SECONDARY REAR TRIM-SETTING

Description Dimen- Dimen- Dimen- Diameter Angle (in

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

(Cg) Front subframe front right-hand -418 447 130 10 x 10 0

(Cd) Front subframe front left-hand -418 465 130 10 x 10 0

(E) Rear shock absorber upper 2448.5 534.5 477.5 18.2 0

(F) Front shock absorber upper 18.5 545.50 657 48 X: 3˚

(Gg) Rear section of front left-hand 600 375 -3.7 20 x 20 0

(Gd) Rear section of front right-hand 600 351.6 -5 20 x 20 0

(J) Rear point of rear right-hand 3040 481 162.5 10.2 0

(K) Front cross member -515 315 280 14.25 X: 4˚30

(P1) Front engine mounting -247 483.5 514 M 10 0

(P2) Rear engine mounting -113 483.5 514 M 10 0

No. Description Classification Type Thickness

No. Description Classification Type Thickness

No. Description Classification Type Thickness

(1) Roof (see 45A, Top of body, Roof: Replacement, page

No. Description Classification Type Thickness