Panel Work 2009-2015 Renault Fluence

GENERAL INFORMATION
Vehicle on repair bench: Description 40A

I - MAIN FRONT TRIM-SETTING REFERENCE Use this situation for a frontal impact with removal of
POINTS the mechanical components.
1 - Front sub-frame in place 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.
II - SECONDARY FRONT TRIM-SETTING

REFERENCE POINT
136905
The jig covers the front subframe rear bolt (A) .
Use this situation for a rear impact or a light frontal im-

pact without removal of the mechanical components.
2 - Front mechanical components removed

144419
The jig covers the radiator mounting cross member bolt
(C)
Use this situation to confirm trim-setting in the event of
a rear impact (for example: to replace a rear side mem-
ber assembly).
The secondary reference is used to confirm the vehicle
trim-setting if deformation of a main front reference
point is suspected.
136906
The bracket rests under the subframe mounting unit

and is centred in the hole (B) .
40A-1
GENERAL INFORMATION
III - MAIN REAR TRIM-SETTING REFERENCE Use this situation for a rear impact with removal of the
POINTS mechanical components.
1 - Rear mechanical components in place

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
B32
136048
The jig rests under the rear axle fork and is centred on
the rear axle bolts (D) .
Use this situation for a frontal impact or a light rear im-
pact.
2 - Rear mechanical components removed
144420
136047
The jig rests under the rear side member and is cen-
tred in the holes (E) .
40A-2
GENERAL INFORMATION
V - FITTING THE VEHICLE ANCHOR KIT
L38
Front
144422
136911
Position the anchorage kit in the square holes (1) of the
front side cross member of the centre floor.
tred in the pilot hole (F) .
Rear
Use this situation to confirm the trim-setting following a
frontal impact (e.g.: to replace a front half unit).
It is used to confirm the vehicle trim setting in case of
doubt about the deformation of a main front reference
point.
136910
Position the anchorage kit in the square holes (2) of the
rear side member.
40A-3
GENERAL INFORMATION
Subframe: Specifications 40A
136004
40A-4
GENERAL INFORMATION
136005
40A-5
GENERAL INFORMATION
136006
B32
Description X (mm) Y (mm) Z (mm) Diameter (mm) Angle
(A) Front subframe rear mounting, 301 -305 77.8 Ø25.5 / M14
without mechanical components
(A) Front subframe rear mounting 301 -305 6.8 M14

with mechanical components
(B) Rear axle leader pin without 2148.2 -650 116 20.5x20.5
mechanical components
(B1) Rear axle mounting without 2040 -635 116 M14

(B1) Rear axle mounting with 2040 -635 111 M14




40A-6
GENERAL INFORMATION

(C) Front subframe front mounting 152 -489 258 M12


(E) Rear shock absorber upper 2435 -398 262.5 Ø10.7 / M10 90˚
mounting
(F) Front shock absorber upper -5.7 -591.3 672.5 Ø47

support
(F1) Front shock absorber upper -62.6 -537.8 662.1 16.2x6.2

support

support
(F3) Front shock absorber upper 70.2 -592.1 650.7 16.2x6.2

support
(G) Front side member rear leader 547 -408.7 -9.8 Ø20.5
pin
(Hg) Front side member front pilot pin -525 -476 84.5 M14
(Hd) Front side member front pilot pin -525 492 84.5 M14
(Jg) Rear side member rear leader 3005 -563.5 235 20.5x20.5
pin
(Jd) Rear side member rear leader 3005 523.5 235 20.5x20.5
pin
(K1g) Front cross member mounting -552.9 -439.3 410.9 M10 90˚
(K1d) Front cross member mounting -522.3 447.6 409 M10 90˚
(K2g) Front cross member mounting -546.2 -535.1 276 M10 90˚
(L1g) Rear end cross member mount- 3096.7 -513.2 253 M8 90˚
ing
(L1d) Rear end cross member mount- 3096.7 571 253 M8 90˚
ing
40A-7
GENERAL INFORMATION
ing
(L2d) Rear end cross member mount- 3096.7 471 277 M8 90˚
ing
(P1) Engine mounting -179 512 475.4 M10
(R) Additional mounting (tie rod) -344 544 475.1 M10
L38
(A) Front subframe rear mounting, 301 -305 77.8 Ø25.5 / M14
(A) Front subframe rear mounting 301 -305 6.8 M14

(B) Rear axle leader pin without 2208.2 -650 116 20.5x20.5








(E) Rear shock absorber upper 2495 -398 262.5 Ø10.7 / M10 90˚
mounting
(F) Front shock absorber upper -5.7 -591.3 672.5 Ø47

support
40A-8
GENERAL INFORMATION

support

support
(F3) Front shock absorber upper 70.2 -592.1 650.7 16.2x6.2

support
(G) Front side member rear leader 547 -408.7 -9.8 Ø20.5
pin
(Hg) Front side member front pilot pin -525 -476 65 M14
(Hd) Front side member front pilot pin -525 492 65 M14
(Jg) Rear side member rear leader 3065 -563.5 235 20.5x20.5
pin
(Jd) Rear side member rear leader 3065 523.5 235 20.5x20.5
pin
(K1g) Front cross member mounting -552.9 -439.3 410.9 M10 90˚
(K2g) Front cross member mounting -546.2 -535.1 276 M10 90˚
ing
(L1d) Rear end cross member mount- 3386.4 570.9 253 M8 90˚
ing
ing
(L2d) Rear end cross member mount- 3386.4 470.9 277 M8 90˚
ing
(R) Additional mounting (tie rod) -344 544 475.1 M10
40A-9
GENERAL INFORMATION
40A-10
GENERAL INFORMATION
Hollow section inserts: List and location of components 40A
B32
136025
40A-11
GENERAL INFORMATION
L38
144430
136030
Windscreen pillar reinforcement insert (2) .
136026
A-pillar insert (1) .
40A-12
GENERAL INFORMATION
136027 136029
B-pillar insert (3) . Rear wing panel insert (5) .
B32
L38
136028
Outer wheel arch insert (4) .
144424
Outer wheel arch insert (4) .
40A-13
GENERAL INFORMATION
144440
Rear wing panel insert (5) .
40A-14
GENERAL INFORMATION
Earths on body: List and location of components 40A
For the earth stud fitting procedure (see Earth screw
connection: Description) (MR400, 40H, Bolted con-
nections).
136031
40A-15
GENERAL INFORMATION
B32
144415
40A-16
GENERAL INFORMATION
L38
144468
DETAILED VIEW OF THE EARTH POSITIONS ON
THE VEHICLE
136043
Earth studs on the front left-hand side member (1) .
40A-17
GENERAL INFORMATION
136042 136035
Earth studs on the left-hand front end side cross mem- Earth stud on the bulkhead (4) .
ber (2) .
136041
136036 Earth studs on the tunnel and centre floor side section
Earth stud on the front right-hand side member (3) . (5) .
40A-18
GENERAL INFORMATION
B32
144412
Earth stud on the left-hand interior quarter panel rear
144413
reinforcement (8) .
Earth studs on the tailgate (6) .
L38
144414
Earth stud on the rear left-hand outer wheel arch (7) .
144464
Earth stud on the left-hand rear quarter lining (6) .
40A-19
GENERAL INFORMATION
144465 144467
Earth stud on the right-hand rear quarter lining (6) . Earth stud on the rear right-hand outer wheel arch (7) .
144466
Earth stud on the rear left-hand outer wheel arch (7) .
40A-20
GENERAL INFORMATION
Vehicle structure, front section: Description 40A
136012
No. Description Classification Type Thickness (mm)
(1) Scuttle side panel upper (see 42A, Front upper structure, Scuttle side panel upper
reinforcement reinforcement: Replacement, page 42A-9)
(2) Scuttle side panel (see 42A, Front upper structure, Scuttle side panel: Replace-
ment, page 42A-6)
(3) Front end side cross mem- (see 41A, Front lower structure, Front end side cross mem-
ber ber: Replacement, page 41A-1)
(4) Bulkhead side reinforce- (see 42A, Front upper structure, Bulkhead side reinforce-
ment ment: Replacement, page 42A-15)
(5) Front side member closure (see 41A, Front lower structure, Front side member closure
panel panel: Replacement, page 41A-12)
(6) Front side member (see 41A, Front lower structure, Front side member: Replace-
ment, page 41A-5)
(7) Front left-hand wheel arch (see 42A, Front upper structure, Front wheel arch: Replace-
ment, page 42A-10)
(8) Front mounting of front (see 41A, Front lower structure, Front subframe front mount-
subframe ing: Replacement, page 41A-17)
(9) Connecting bracket THLE 1.8
40A-21
GENERAL INFORMATION
Vehicle structure, front section: Description 40A
(10) Front half-unit (see 41A, Front lower structure, Front half-unit: Replacement,
page 41A-20)
(11) Centre floor front side (see 41B, Centre lower structure, Centre floor front side
cross member cross member: Replacement, page 41B-8)
(12) Bulkhead lower cross (see Bulkhead lower cross member: Replacement)
member
(13) Windscreen aperture lower (see 42A, Front upper structure, Windscreen aperture lower
cross member cross member: Replacement, page 42A-12)
(14) Sub-frame rear mounting (see 41A, Front lower structure, Subframe rear mounting:
Replacement, page 41A-18)
(15) Radiator cross member (see 41A, Front lower structure, Radiator cross member
support mounting: Replacement, page 41A-3)
(16) Front end panel side sup- (see 42A, Front upper structure, Front end panel side sup-
port port: Replacement, page 42A-16)
(17) Battery tray bracket (see 41A, Front lower structure, Battery tray mounting:
(18) Engine stand (see 41A, Front lower structure, Engine mounting: Replace-
ment, page 41A-19)
(19) Front right-hand wheel (see 42A, Front upper structure, Front wheel arch: Replace-
arch ment, page 42A-10)
40A-22
GENERAL INFORMATION
Vehicle structure, side section: Description 40A
B32
144418
(1) Sill panel (see 41C, Side lower structure, Sill panel: Replacement, page
41C-1)
(2) A-pillar (see 43A, Side upper structure, A-pillar: Replacement, page
43A-1)
(3) B-pillar (see 43A, Side upper structure, B-pillar: Replacement, page
43A-11)
(4) B-pillar reinforcement (see 43A, Side upper structure, B-pillar reinforcement:
(5) B-pillar upper lining (see 43A, Side upper structure, B-pillar upper lining: Replace-
ment, page 43A-16)
(6) Sill panel reinforcement, (see 41C, Side lower structure, Sill panel reinforcement, front
front section section: Replacement, page 41C-16)
(7) Sill panel rear reinforce- (see 41C, Side lower structure, Sill panel rear reinforcement:
ment Replacement, page 41C-24)
(8) A-pillar reinforcement (see 43A, Side upper structure, A-pillar reinforcement:
40A-23
GENERAL INFORMATION
(9) Windscreen pillar lining (see 43A, Side upper structure, Windscreen pillar lining:
(10) Windscreen pillar lining (see 43A, Side upper structure, Windscreen pillar lining rein-
reinforcement forcement: Replacement, page 43A-9)
(11) Roof rear cross member (see 45A, Top of body, Roof rear cross member: Replace-
ment, page 45A-8)
(12) Roof centre cross member (see 45A, Top of body, Roof centre cross member: Replace-
ment, page 45A-7)
(13) Roof front cross member (see 45A, Top of body, Roof front cross member: Replace-
ment, page 45A-5)
(14) Roof (see 45A, Top of body, Roof: Replacement, page 45A-1)
L38
144429
40A-24
GENERAL INFORMATION
(1) Sill panel (see 41C, Side lower structure, Sill panel: Replacement, page
41C-1)
(2) Sill panel reinforcement, (see 41C, Side lower structure, Sill panel reinforcement, front
front section section: Replacement, page 41C-16)
(3) Sill panel rear reinforce- (see 41C, Side lower structure, Sill panel rear reinforcement:
ment Replacement, page 41C-24)
(4) B-pillar (see 43A, Side upper structure, B-pillar: Replacement, page
43A-11)
(5) A-pillar (see 43A, Side upper structure, A-pillar: Replacement, page
43A-1)
(6) A-pillar reinforcement (see 43A, Side upper structure, A-pillar reinforcement:
(7) Windscreen pillar lining (see 43A, Side upper structure, Windscreen pillar lining rein-
reinforcement forcement: Replacement, page 43A-9)
(8) Windscreen pillar lining (see 43A, Side upper structure, Windscreen pillar lining:
(9) B-pillar upper lining (see 43A, Side upper structure, B-pillar upper lining: Replace-
ment, page 43A-16)
(10) B-pillar reinforcement (see 43A, Side upper structure, B-pillar reinforcement:
(11) Roof rear cross member (see 45A, Top of body, Roof rear cross member: Replace-
ment, page 45A-8)
(12) Roof centre cross member (see 45A, Top of body, Roof centre cross member: Replace-
ment, page 45A-7)
(13) Roof front cross member (see 45A, Top of body, Roof front cross member: Replace-
ment, page 45A-5)
(14) Version with sunroof (see 45A, Top of body, Roof: Replacement, page 45A-1)
(15) Version without sunroof (see 45A, Top of body, Roof: Replacement, page 45A-1)
40A-25
GENERAL INFORMATION
Vehicle structure, centre section: Description 40A
136013
(1) Sill pane stiffener (see 41C, Side lower structure, Sill panel stiffener: Replace-
ment, page 41C-31)
(2) Sill panel closure panel, rear (see 41C, Side lower structure, Sill panel closure panel, rear
section section: Replacement, page 41C-14)
(3) Centre floor, side section (see 41B, Centre lower structure, Centre floor, side section:
Replacement, page 41B-1)
(4) Seat mounting side reinforce- (see 41D, Rear lower structure, Rear floor, front section:
ment Replacement, page 41D-1)
(5) Rear floor front cross member, (see 41D, Rear lower structure, Rear floor front cross mem-
centre section ber, centre section: Replacement, page 41D-18)
(6) Rear floor, front section (see 41D, Rear lower structure, Rear floor, front section:
Replacement, page 41D-1)
(7) Sleeve stop support (see 41D, Rear lower structure, Rear floor, front section:
(8) Rear cross member under front (see 41B, Centre lower structure, Rear cross member under
seat front seat: Replacement, page 41B-12)
40A-26
GENERAL INFORMATION
Vehicle structure, centre section: Description 40A
(9) Front cross member under front (see 41B, Centre lower structure, Front cross member under
seat front seat: Replacement, page 41B-10)
(10) Centre side member (see 41B, Centre lower structure, Centre side member:
Replacement, page 41B-6)
(11) Rear passenger retaining cross (see 41D, Rear lower structure, Rear passenger retaining
member cross member: Replacement, page 41D-22)
(12) Rear floor front cross member (see 41D, Rear lower structure, Rear floor front cross mem-
reinforcement ber reinforcement: Replacement, page 41D-23)
40A-27
GENERAL INFORMATION
Vehicle structure, rear section: Description 40A
B32
144416
(1) Rear wing panel (see 44A, Rear upper structure, Rear wing panel: Replace-
ment, page 44A-1)
(2) Rear wing panel extension (see 44A, Rear upper structure, Rear wing panel extension:
(3) Rear wing panel rain chan- (see 44A, Rear upper structure, Rear wing panel rain chan-
nel nel: Replacement, page 44A-14)
(4) Rear light mounting (see 44A, Rear upper structure, Rear light mounting:
(5) Light mounting lining (see 44A, Rear upper structure, Light mounting lining:
(6) Rear side roof rail lining (see Side roof rail rear lining: Replacement)
(7) Outer rear wheel arch (see 44A, Rear upper structure, Outer rear wheel arch:
(8) Quarter panel lining (see 44A, Rear upper structure, Outer rear wheel arch:
40A-28
GENERAL INFORMATION
(9) Inner rear wheel arch (see 44A, Rear upper structure, Inner rear wheel arch:
(10) Rear wheel arch closure (see 44A, Rear upper structure, Rear wheel arch closure
panel panel: Replacement, page 44A-29)
(11) Quarter panel upper rein- (see 44A, Rear upper structure, Quarter panel upper rein-
forcement forcement: Replacement, page 44A-32)
(12) Rear side roof rail rein- (see 44A, Rear upper structure, Side roof rail rear reinforce-
forcement ment: Replacement, page 44A-35)
(13) Rear end panel (see 44A, Rear upper structure, Rear end panel: Replace-
ment, page 44A-40)
(14) Rear end panel side lining (see 44A, Rear upper structure, Rear end panel side lining:
(15) Rear end panel assembly (see 44A, Rear upper structure, Rear end panel assembly:
(16) Rear impact cross mem- (see 41D, Rear lower structure, Rear impact cross member
ber mounting reinforce- mounting reinforcement: Replacement, page 41D-16)
ment
(17) Rear side member (see 41D, Rear lower structure, Rear side member: Replace-
ment, page 41D-13)
(18) Rear floor, rear section (see 41D, Rear lower structure, Rear floor, rear section:
(19) Rear section of rear floor (see 41D, Rear lower structure, Rear section of rear floor cen-
central cross member tral cross member: Replacement, page 41D-19)
(20) Rear floor centre cross (see 41D, Rear lower structure, Rear floor centre cross mem-
member ber: Replacement, page 41D-20)
(21) Rear side member assem- (see 41D, Rear lower structure, Rear side member assembly:
bly Replacement, page 41D-9)
40A-29
GENERAL INFORMATION
L38
144427
(1) Rear wing panel (see 44A, Rear upper structure, Rear wing panel: Replace-
ment, page 44A-1)
(2) Rear wing panel extension (see 44A, Rear upper structure, Rear wing panel extension:
(3) Rear light mounting (see 44A, Rear upper structure, Rear light mounting:
(4) Rear wing panel rain chan- (see 44A, Rear upper structure, Rear wing panel rain chan-
nel nel: Replacement, page 44A-14)
(5) Outer rear wheel arch (see 44A, Rear upper structure, Outer rear wheel arch:
(6) Rear side roof rail lining (see Side roof rail rear lining: Replacement)
(7) Rear impact cross mem- (see 41D, Rear lower structure, Rear impact cross member
ber mounting reinforce- mounting reinforcement: Replacement, page 41D-16)
ment
(8) Rear side member (see 41D, Rear lower structure, Rear side member: Replace-
ment, page 41D-13)
40A-30
GENERAL INFORMATION
(9) Rear side member assem- (see 41D, Rear lower structure, Rear side member assembly:
bly Replacement, page 41D-9)
(10) Inner rear wheel arch (see 44A, Rear upper structure, Inner rear wheel arch:
(11) Rear floor, rear section (see 41D, Rear lower structure, Rear floor, rear section:
(12) Rear parcel shelf, side sec- (see 44A, Rear upper structure, Rear parcel shelf, side sec-
tion tion: Replacement, page 44A-34)
(13) Rear end panel assembly (see 44A, Rear upper structure, Rear end panel assembly:
(14) Rear end panel (see 44A, Rear upper structure, Rear end panel: Replace-
ment, page 44A-40)
(15) Rear parcel shelf (see 44A, Rear upper structure, Rear parcel shelf: Replace-
ment, page 44A-33)
40A-31
GENERAL INFORMATION
Vehicle structure, removable section: Description 40A
B32
144417
(1) Front impact cross member (see 41A, Front lower structure, Front impact cross member:
Removal - Refitting, page 41A-25)
(2) Front end panel (see 42A, Front upper structure, Front end panel: Removal -
Refitting, page 42A-22)
(3) Front bumper mounting (see 42A, Front upper structure, Front bumper mounting:
port port: Removal - Refitting, page 42A-24)
(5) Front wing upper mounting (see 42A, Front upper structure, Front wing upper mounting
support support: Removal - Refitting, page 42A-20)
(6) Front wing (see 42A, Front upper structure, Front wing: Removal - Refit-
ting, page 42A-3)
(7) Bonnet (see 48A, Non-side opening elements, Bonnet: Removal -

(8) Dashboard cross member (see 42A, Front upper structure, Dashboard cross member:
40A-32
GENERAL INFORMATION
(9) Fuel filler flap cover (see 47A, Side opening elements, Fuel filler flap cover:
(10) Front side door (see 47A, Side opening elements, Front side door: Removal -
(11) Rear side door (see 47A, Side opening elements, Rear side door: Removal -
(12) Rear impact lower cross (see 41D, Rear lower structure, Rear impact lower cross
member member: Removal - Refitting, page 41D-25)
(13) Tailgate (see 48A, Non-side opening elements, Tailgate: Removal -

L38
144428
(1) Front impact cross member (see 41A, Front lower structure, Front impact cross member:
(2) Front end panel (see 42A, Front upper structure, Front end panel: Removal -
40A-33
GENERAL INFORMATION
(3) Front bumper mounting (see 42A, Front upper structure, Front bumper mounting:
port port: Removal - Refitting, page 42A-24)
(5) Front wing upper mounting (see 42A, Front upper structure, Front wing upper mounting
support support: Removal - Refitting, page 42A-20)
(6) Front wing (see 42A, Front upper structure, Front wing: Removal - Refit-
ting, page 42A-3)
(7) Bonnet (see 48A, Non-side opening elements, Bonnet: Removal -

(8) Dashboard cross member (see 42A, Front upper structure, Dashboard cross member:
(9) Fuel filler flap cover (see 47A, Side opening elements, Fuel filler flap cover:
(10) Front side door (see 47A, Side opening elements, Front side door: Removal -
(11) Rear side door (see 47A, Side opening elements, Rear side door: Removal -
(12) Rear impact lower cross (see 41D, Rear lower structure, Rear impact lower cross
member member: Removal - Refitting, page 41D-25)
(13) Luggage compartment lid (see 48A, Non-side opening elements, Luggage compartment
lid: Removal - Refitting, page 48A-8)
40A-34
GENERAL INFORMATION
Structural components to be positioned on the repair bench: Description 40A
I - PARTS REQUIRING THE USE OF A BODY JIG
BENCH
136016
- (1) Front wheel arch

- (2) Engine stand
- (3) Front half-unit
- (4) Radiator cross member support
- (5) Front subframe front mounting unit
- (6) Front subframe rear mounting unit
- (7) Front side member
- (8) Rear side member
- (9) Rear side member assembly
40A-35
GENERAL INFORMATION
II - REFERENCE POINTS FOR POSITIONING THE 2 - End of front side member
PARTS REPLACED
1 - Front shock absorber upper mounting
136020
The jig rests under the front side member and is cen-
tred in the threaded hole (H) of the radiator cross mem-
136022 ber support.
The jig rests under the shock absorber cup and is cen-
It should be used with the mechanical components re-
tred in the hole (F) of the shock absorber cup.
moved for replacement of:
- the front side member,
- the front wheel arch, - the front half-unit,
- the front half-unit. - the radiator cross member support.

It is also used when straightening.
3 - Front impact cross member mounting
IMPORTANT
This/these point(s) help to ensure the correct axle
assembly geometry.
136020
40A-36
GENERAL INFORMATION
The jig rests vertically against the radiator cross mem- 5 - Front sub-frame front mounting
ber support and is centred in the threaded mounting
holes (K1) and (K2) of the front impact cross member.
- the front half-unit,
- the radiator cross member support.
4 - Engine mounting
136017
The jig rests under the front mounting unit of the front
subframe and is centred in the threaded hole (C) of the
front subframe mounting.
- the front half-unit.
136022 IMPORTANT
The jig rests against the engine mounting and is cen- This/these point(s) help to ensure the correct axle
tred on the threaded holes (P1) and (P2) of the engine assembly geometry.
mounting.
- the engine mounting,
- the front half-unit.
40A-37
GENERAL INFORMATION
6 - Subframe rear mounting 7 - Rear shock absorber mounting
136017 136023
The jig rests against the front subframe rear mounting The jig is centred and attached inside the shock ab-
unit and is centred in the hole (A) . sorber shaft (E) .
It should be used with the mechanical components re- It should be used with the mechanical components re-
moved for replacement of: moved for replacement of:
- the front subframe rear mounting unit. - the rear side member assembly.
IMPORTANT
assembly geometry.
40A-38
GENERAL INFORMATION
8 - End of rear side member It should be used with the mechanical components re-
B32 - the rear side member,

- the rear side member assembly
It is also used when straightening.
9 - Rear impact cross member mountings
B32
144439
L38
136021
144422
tred in the guide hole (J) .
40A-39
GENERAL INFORMATION
10 - Rear axle mountings
L38
136019
144423
The jig rests under the rear axle mounting unit and is
centred in the threaded holes (B1) and (B2) of the rear
axle bearing mounting.
The jig rests vertically against the side lining of the rear moved for replacement of:
end panel and is centred on the rear impact cross
member mounting studs (L) and (L1) . - the rear side member assembly.
It is to be used when replacing:

- the rear side member, IMPORTANT
- the rear side member assembly.
assembly geometry.
40A-40
FRONT LOWER STRUCTURE
Front end side cross member: Replacement 41A
I - COMPOSITION OF THE SPARE PART
No. Description Type Thick-

1 - Right-hand side ness (mm)
(2) A-pillar lining Mild 1

connection ele- steel
ment
II - IN THE EVENT OF REPLACEMENT

There is only one way of replacing this part:
- complete replacement
1 - Complete replacement left-hand side
Part in position
136095

ness (mm)
(1) Front section HLE 1.6

engine mounting
2 - Left-hand side
136092
136093
41A-1
Front end side cross member: Replacement 41A
2 - Complete replacement right-hand side
Part in position
136094
41A-2
Radiator cross member mounting: Replacement 41A
I - COMPOSITION OF THE SPARE PART Right-hand side
Left-hand side
136089
136088 No. Description Type Thick-

ness (mm)
No. Description Type Thick- (4) Additional mount- HLE 1.17
ness (mm) ing front unit
(1) Additional mount- HLE 1.17 (5) Front right-hand THLE 3
ing for front left- side member
hand unit connection plate
(2) Front left-hand THLE 3
side member II - IN THE EVENT OF REPLACEMENT
connection plate
- complete replacement.
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
41A-3
Radiator cross member mounting: Replacement 41A
a - Part in position
136759
b - Position of electric earths
WARNING
To avoid damaging the vehicles electric and elec-
tronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as close
as possible to the weld area (see Bolted connec-
tion for earth: Fitting) (MR 400, 40H, Bolted con-
nections).
Locate the earths located near to the weld area (see

40A, General information, Earths on body: List and
location of components, page 40A-15) .
c - Special notes on mating
WARNING
If the mating faces of the parts to be welded are not
accessible, use a GMAW plug weld in place of the
original electrical resistance weld (see Connec-
tions by arc welding under shielding gas:
Description) (MR 400, 40C, Gas metal arc welded
connections (GMAW)).
41A-4
Front side member: Replacement 41A
I - COMPOSITION OF THE SPARE PART 2 - Left-hand side
1 - Right-hand side
136073

ness (mm)
No. Description Type Thick- (8) Left-hand radia- HLE 1.17

ness (mm) tor cross mem-
ber support
(1) Right-hand radia- HLE 1.17
tor cross mem- (9) Front subframe HLE 1.8
ber support front left-hand
mounting
(2) Front subframe HLE 1.8
front right-hand (10) Reinforcement THLE 1.8
mounting unit of front left-
hand side mem-
(3) Front right-hand Mild 3 ber end
plate for sub- steel
frame mounting (11) Left-hand mount- Mild 2
support ing of front end steel
panel upper
(4) Right-hand rein- THLE 1.8 cross member
forcement unit for
front right-hand (12) Front left-hand HLE 1.47
side member end side member
reinforcement
(5) Right-hand Mild 2
mounting of front steel (13) Left-hand side Mild 1.5
end panel upper member gearbox steel
cross member rear reinforce-
ment
(6) Front right-hand THLE 2.5
side member (14) Front left-hand THLE 2.5
side member
(7) Bulkhead cross Mild 1.47
member right- steel
hand bracket
41A-5
1 - Front partial replacement left-hand side A-B
ness (mm)
(15) Front left-hand Mild 1.5
side member rear steel
reinforcement
(16) Front gearbox Mild 1.5

reinforcement steel

The options for replacing this part are as follows:
- front partial replacement A-B,
- rear partial replacement A-C.
136075
Detailed view of cut B
136074
IMPORTANT
136077
41A-6
b - Position of electric earths 2 - Front right-hand partial replacement A-B
WARNING
nections).

c - parts to be systematically replaced
136081
136077
Note:
Also order the side member reinforcement (12) .
d - Special notes on mating 136083
WARNING
41A-7
b - Position of electric earths 3 - Rear left-hand partial replacement A-C
WARNING
nections).

136754
Special features of cut C
136084
Unclip the connecting bracket between the front side
member and the radiator mounting (17) .
WARNING
original electrical resistance weld (see Connec- 136751
connections (GMAW)). Note:
When cutting, be careful not to damage the rear
inner reinforcement (15) .
41A-8
b - Position of electric earths d - Special notes on mating
WARNING WARNING
To avoid damaging the vehicles electric and elec- If the mating faces of the parts to be welded are not
tronic components, the earths of any wiring harness accessible, use a GMAW plug weld in place of the
near the weld area must be disconnected. original electrical resistance weld (see Connec-
nections).
4 - Rear right-hand partial replacement A-C
location of components, page 40A-15) . a - Part in position
c - Part always to be replaced:
136080
144395
Note:
For standardisation purposes, the Parts Depart-
ment only supplies B95 side members. When
replacing an X38 side member, also order the side
panel mounting reinforcement plate (18) .
41A-9
Special features of cut C c - Irremovable bodywork components - structures
to be removed in order to carry out the
replacement operation
136751
Note: 136079
inner reinforcement (15) .
Note:
Unclip the bracket (7) on the part from the Parts
b - Position of electric earths Department.
WARNING d - Part always to be replaced:

nections).

144510
41A-10
Note:
ment only supplies B95 side members. When
replacing an X38 side member, also order the side
panel mounting reinforcement plate (19) .
e - Special notes on mating
WARNING
41A-11
Front side member closure panel: Replacement 41A
I - COMPOSITION OF THE SPARE PART 2 - Left-hand side
1 - Right-hand side
136065

ness (mm)
No. Description Type Thick- (5) Front left-hand THLE 1.67/3
ness (mm) side member clo-
sure panel
(1) Front right-hand THLE 1.67/2.5
side member clo- (6) Subframe front HLE 1.8
sure panel mounting unit
closure panel
(2) Subframe front HLE 1.8
mounting unit (7) Left-hand brake Mild 2
closure panel hose stop mount- steel
ing
(3) Right-hand brake Mild 2
hose stop mount- steel (8) Front mounting HLE 1.47
ing unit closure panel
(4) Front mounting HLE 1.17
unit closure panel II - IN THE EVENT OF REPLACEMENT
- front partial replacement AB,
- partial replacement AC.
41A-12
136066 136070
1 - front partial replacement AB, b - Position of electric earths
WARNING
nections).

Note:
Also order the connection bracket from the Parts
Department
136068
41A-13
d - Special notes on mating c - Part always to be replaced:
WARNING Note:
If the mating faces of the parts to be welded are not Also order the connection bracket from the Parts
accessible, use a GMAW plug weld in place of the Department
Description) (MR 400, 40C, Gas metal arc welded d - Special notes on mating
WARNING
2 - Partial replacement AC
a - Part in position original electrical resistance weld (see Connec-
136067
WARNING
nections).

41A-14
Battery tray mounting: Replacement 41A
I - COMPOSITION OF THE SPARE PART Complete replacement
136087
No. Description Type Thick- 136757

ness (mm)
(1) Battery tray Mild 2

mounting steel

136758
41A-15
Battery tray mounting: Replacement 41A
WARNING
nections).

WARNING
41A-16
Front subframe front mounting: Replacement 41A
I - COMPOSITION OF THE SPARE PART a - Part in position
136086 136756

ness (mm)
(1) Subframe mount- HLE 1.8 WARNING

ing front unit To avoid damaging the vehicles electric and elec-
(2) Subframe mount- HLE 3 near the weld area must be disconnected.
ing support front
plate
II - IN THE EVENT OF REPLACEMENT nections).
There is only one way of replacing this part: Locate the earths located near to the weld area (see
Complete replacement
IMPORTANT
WARNING
41A-17
Subframe rear mounting: Replacement 41A
136755

ness (mm)
(1) Subframe rear HLE 2
mounting unit
WARNING
(2) Subframe rear THLE 3
mounting rein-
forcement
II - IN THE EVENT OF REPLACEMENT as possible to the weld area (see Bolted connec-
There is only one way of replacing this part: tion for earth: Fitting) (MR 400, 40H, Bolted con-
nections).
IMPORTANT location of components, page 40A-15) .
points and the geometry of the axle assemblies. c - Special notes on mating
WARNING
41A-18
Engine mounting: Replacement 41A
136760

ness (mm)
(1) Engine mounting Mild 1.1
lower section steel
WARNING
(2) Engine mounting HLE 2.2
centre section
(3) Engine mounting Mild 1.8 near the weld area must be disconnected.
height adjuster steel Position the earth of the welding machine as close
reinforcement as possible to the weld area (see Bolted connec-
(4) Engine mounting HLE 1.6 nections).
rear section
II - IN THE EVENT OF REPLACEMENT location of components, page 40A-15) .
- complete replacement. c - Special notes on mating
IMPORTANT WARNING
Use a repair bench to ensure the positioning of the If the mating faces of the parts to be welded are not
points and the geometry of the axle assemblies. accessible, use a GMAW plug weld in place of the
41A-19
Front half-unit: Replacement 41A
ness (mm)
1 - Left-hand side
(9) Subframe rear HLE 2
left-hand mount-
ing
(10) Radiator cross HLE 1.17

member support
(11) Subframe mount- HLE 1.8

ing front left-hand
unit
(12) Front left-hand

side member
2 - Right-hand side
136059

ness (mm)
(1) Left-hand bracket THLE 1.8

of front side
member end
reinforcement
(2) Front left-hand HLE 1.17

side cross mem-
ber
(3) Front end side Mild 1 136062

cross member steel
(4) Front left-hand HLE/ 1.67/3 No. Description Type Thick-

side member clo- THLE ness (mm)
sure panel
(13) Right-hand THLE 1.8
(5) Front left-hand HLE 2 bracket of front
shock absorber side member end
cup reinforcement
(6) Front left-hand Mild 1.1 (14) Front right-hand HLE 1.17
cup height steel side cross mem-
adjuster ber
(7) Air filter retaining Mild 1.2 (15) Front end side HLE 1.6
bracket steel cross member
(8) Battery tray Mild 2
mounting steel
41A-20
ness (mm)
(16) Front right-hand HLE/ 1.6 / 2.5

side member clo- THLE
sure panel
(17) Front right-hand HLE 2

shock absorber
cup
(18) Front right-hand Mild 1.1

cup height steel
adjuster
(19) Upper tie-rod HLE 2.5

mounting
(20) Engine stand Mild 1.1

steel
(21) Subframe rear HLE 2 136063

right-hand
mounting
IMPORTANT
(22) Front right-hand
side member
(23) Expansion valve
mounting
1 - Front left-hand partial replacement A-B
(24) Lower tie rod
mounting a - Part in position

- partial replacement A-B.
136749
41A-21
Special feature of cut B b - Position of electric earths
WARNING
nections).

136751
Note:
inner reinforcement (C) .
144395
Note:
ment only supplies B95 half units. When replacing
an X38 half unit, also order the side panel mounting
reinforcement plate.
136061
41A-22
d - Special notes on mating Special feature of cut B
WARNING
2 - Partial replacement of front right-hand half unit
136751
Note:
inner reinforcement (C) .
136752
136064
41A-23
b - Position of electric earths d - Special notes on mating
WARNING WARNING
nections).

144510
Note:
ment only supplies B95 half units. When replacing
an X38 half unit, also order the side panel mounting
reinforcement plate (F) .
41A-24
Front impact cross member: Removal - Refitting 41A
REMOVAL II - FINAL OPERATION
a Clip on the wiring.
I - REMOVAL PREPARATION a Refit:
a Remove: - the audible warning (see Audible warning: Re-

moval - Refitting)
- the front wheel arch liners (see Front wheel arch - the front bumper (see Front bumper: Removal -
liner: Removal - Refitting) (55A, Exterior protec- Refitting) (55A, Exterior protection),
tion),
- the front wheel arch liners (see Front wheel arch
- the front bumper (see Front bumper: Removal - liner: Removal - Refitting) (55A, Exterior protec-
Refitting) (55A, Exterior protection), tion).
- the audible warning (see Audible warning: Re-

moval - Refitting)
a Unclip the wiring.
II - REMOVAL
144460
a Remove:
- the bolts (2) ,
- the front impact cross member.
REFITTING
I - REFITTING
a Refit:
- the impact cross member,
- the bolts
41A-25
CENTRE LOWER STRUCTURE
Centre floor, side section: Replacement 41B
136913
137232
1 - Complete replacement A
ness (mm) a - Part in position
(1) Centre floor, side Mild 0.67/1.17

section steel/
HLE
(2) Centre side THLE 2

member

- complete replacement A,
- front partial replacement B,
- front end partial replacement C,
- rear partial replacement D.
136914
41B-1
WARNING
nections).

WARNING
If the mating faces of the parts to be welded are not 136918
original electrical resistance weld (see Connec- b - Position of electric earths
connections (GMAW)). WARNING
2 - Front partial replacement B near the weld area must be disconnected.
a - Part in position as possible to the weld area (see Bolted connec-
nections).

136917
41B-2
c - Special notes on mating 3 - Front end partial replacement C
136917
Make a superimposed connection (see Partial re-

placement connections by overlapping: Descrip- 136915
tion) (MR400, 40E, Partial replacement connections)
WARNING
136916
41B-3
b - Position of electric earths 4 - Rear partial replacement D
WARNING
nections).

136919
136915
placement connections by overlapping: Descrip-
WARNING
41B-4
WARNING
nections).

136919
placement connections by overlapping: Descrip-
WARNING
41B-5
Centre side member: Replacement 41B
I - COMPOSITION OF THE PART Complete replacement
136927

ness (mm)
(1) Centre side THLE 2

member
(2) Centre side UHLE 2.5

member rein-
forcement

137234
41B-6
Centre side member: Replacement 41B
WARNING
nections).

c - Irremovable bodywork components - structures

to be removed in order to carry out the repair
operation
Remove:
- the front cross member under front seat (see 41B,
Centre lower structure, Front cross member un-
der front seat: Replacement, page 41B-10) ,
- the rear cross member under front seat (see 41B,
Centre lower structure, Rear cross member under
front seat: Replacement, page 41B-12) .
d - Special notes on mating
WARNING
41B-7
Centre floor front side cross member: Replacement 41B
136930
136928
1 - Complete replacement AC
(1) Front side cross HLE 1.17

member
(2) Side cross mem- Mild 1.5

ber reinforcement steel
(3) Side cross mem- THLE 3

ber impact rein-
forcement

- complete replacement AC,
- partial replacement AB.
136929
41B-8
Centre floor front side cross member: Replacement 41B
WARNING
nections).

WARNING
2 - Partial replacement AB near the weld area must be disconnected.
nections).

WARNING
136931
41B-9
Front cross member under front seat: Replacement 41B
136924

ness (mm)
Distance between the front cross member under the
(1) Front cross mem- HLE 1.5 front seat and the rear cross member under the front
ber under front seat = 209 mm.
seat
(2) Seat mounting HLE 1.47
reinforcement
WARNING
II - IN THE EVENT OF REPLACEMENT To avoid damaging the vehicles electric and elec-
There is only one way of replacing this part: tronic components, the earths of any wiring harness
nections).


Remove:
- the sill panel (see 41C, Side lower structure, Sill

panel: Replacement, page 41C-1) ,
- the sill panel closure panel (see Sill panel closure

panel: Replacement) ,
41B-10
Front cross member under front seat: Replacement 41B
- the sill panel reinforcement (see Sill panel reinforce-
ment: Replacement) .
WARNING
41B-11
Rear cross member under front seat: Replacement 41B
I - COMPOSITION OF THE SPARE PART a - Part in position
136922 144261
No. Description Type Thick- B32

ness (mm)
The distance between the rear cross member under
(1) Side floor rear UHLE 1.5 the front seat and the rear floor front section (X1) = 238
cross member mm.
(2) Seat mounting HLE 1.5

reinforcement
II - IN THE EVENT OF REPLACEMENT L38

The distance between the rear cross member under
Complete replacement the front seat and the rear floor front section (X1) = 298
mm.
WARNING
nections).

41B-12
Rear cross member under front seat: Replacement 41B
Remove:
- the sill panel (see 41C, Side lower structure, Sill
panel: Replacement, page 41C-1) ,
- the sill panel closure panel (see Sill panel closure
panel: Replacement) ,
- the sill panel reinforcement (see Sill panel reinforce-
ment: Replacement) .
WARNING
41B-13
SIDE LOWER STRUCTURE
Sill panel: Replacement 41C
136098
136096

ness (mm)
(1) Sill panel Mild 0.65

steel
(2) Sill panel blank- Mild 0.65

ing cover steel
(3) Jack bearing sup- THLE 2

port

- complete replacement A-D-F,
- front end partial replacement A-C,
- front section partial replacement A-D-E,
- partial replacement under door B-C,
- rear section partial replacement C-D-F,
- rear end section partial replacement E-F.
41C-1
1 - Complete replacement A-D-F
136099
41C-2
Cut
136097
Detailed view A Detailed view D
136100 136101
41C-3
Detailed view F 2 - Front end partial replacement A-C
136102

136107
WARNING Cut
nections).

c - Parts always to be replaced

Replace the hollow section inserts (see 40A, General
information, Hollow section inserts: List and loca-
tion of components, page 40A-11) and (see Hollow
section inserts: Precautions for the repair) .
WARNING
41C-4
Detailed view A Locate the earths located near to the weld area (see
WARNING
136100
Detailed view C
136106
WARNING
nections).
41C-5
3 - Front section partial replacement A-D-E
136112
41C-6
Cut
136113
Detailed view A Detailed view D
136100 136101
41C-7
Detailed view E 4 - Partial replacement under door B-C
136114

136103
WARNING Cut
nections).


Replace the B-pillar insert (see 40A, General informa-
tion, Hollow section inserts: List and location of
components, page 40A-11) and (see Hollow section
inserts: Precautions for the repair) .
WARNING
41C-8
Detailed view B Locate the earths located near to the weld area (see
WARNING
136105
Detailed view C
136106
WARNING
nections).
41C-9
5 - Rear section partial replacement C-D-F
136116
41C-10
Cut
136117
Detailed view C Detailed view D
136118 136101
41C-11
Detailed view F 6 - Rear end section partial replacement E-F
136102

136109
WARNING Cut
nections).


WARNING
41C-12
Detailed view E Locate the earths located near to the weld area (see

Replace the rear wheel arch insert (see 40A, General
WARNING
136111 connections (GMAW)).
Detailed view F
136102
WARNING
nections).
41C-13
Sill panel closure panel, rear section: Replacement 41C

ness (mm)
(1) Sill panel closure HLE 1.37

panel rear sec-
tion

136119
136120
41C-14
Sill panel closure panel, rear section: Replacement 41C
WARNING
nections).

WARNING
41C-15
Sill panel reinforcement, front section: Replacement 41C
L38
B32
144432
136126

No. Description Type Thick- ness (mm)
ness (mm)
(1) Sill panel rein- HLE 0.9
(1) Sill panel rein- HLE 0.9 forcement, front
forcement, front section
section
WARNING
nections).

B32
- complete replacement A-D,
41C-16
- front section partial replacement A-C,
- rear section partial replacement B-D.
136127
41C-17
1 - Complete replacement A-D
Part in position
B32
136128
41C-18
2 - Front section partial replacement A-C
Part in position
B32
136130
41C-19
Detailed view C 3 - Rear section partial replacement B-D
Part in position
B32
136129
136132
41C-20
Detailed view B 4 - Complete replacement A-C
Part in position
L38
136134
L38
144431
- complete replacement A-C,
- front section partial replacement A-B,
- rear section partial replacement B-C.
142411
41C-21
5 - Front section partial replacement A-B 6 - Rear section partial replacement B-C
Part in position Part in position
L38 L38
142482 142414
Detailed view B Detailed view B
136129 142413
41C-22
WARNING
41C-23
Sill panel rear reinforcement: Replacement 41C

B32 ness (mm)
(1) Sill panel rear HLE 1

reinforcement
WARNING
nections).

136135
B32
L38 - complete replacement A-C,

- front section partial replacement A-B,
- rear section partial replacement B-C.
144433
136136
41C-24
1 - Complete replacement
Part in position
B32
136137
41C-25
2 - Partial replacement of the front section
Part in position
B32
136146
41C-26
Cut
136153
B32
Detailed view B
142458
41C-27
3 - Partial replacement of the rear section
Part in position
B32
136140
41C-28
Cut
136141
B32
Detailed view B
142409
41C-29
L38
Part in position
144434
WARNING
41C-30
Sill panel stiffener: Replacement 41C
136123

ness (mm)
b - Position of electrical earths
(1) Sill pane stiffener THLE 1.8
WARNING
as possible to the weld area (see Earth screw con-
nection: Description) .

c - Bodywork components that cannot be removed

- structures to be removed in order to carry out the
Remove the sill panel (see 41C, Side lower structure,
Sill panel: Replacement, page 41C-1) .
41C-31
REAR LOWER STRUCTURE
Rear floor, front section: Replacement 41D
I - COMPOSITION OF THE SPARE PART - Partial replacement A-B.
136334
136332

ness (mm)
(1) Rear floor, front Mild 0.67

section steel
(2) Support of hand- Mild 1.17

brake rear sleeve steel
stop
(3) Support of hand- Mild 1.17

brake rear sleeve steel
stop
(4) Tube for hand-

brake cable rout-
ing
(5) Tube for hand-

brake cable rout-
ing
(6) Exhaust front Mild 1.17

mounting support steel
(7) Exhaust front Mild 2.5

mounting rein- steel
forcement
- Complete replacement A-C,
41D-1
1 - Complete replacement A-C
136333
b - Position of electric earths c - Special notes on mating
WARNING WARNING
nections).

41D-2
2 - Partial replacement A-B
136335
Detailed view B b - Position of electric earths

Carry out a weld by overlapping at (B) (see 40A, Gen-
eral information, Earths on body: List and location
of components, page 40A-15) .
WARNING
nections).

136337
41D-3
WARNING
41D-4
Rear floor, rear section: Replacement 41D
B32
L38
144236
144254
No. Description Type Thickness

No. Description Type Thickness (mm)
(mm)
(4) Rear floor, rear Mild 0.65
(1) Rear floor, rear Mild 0.65 section steel
section steel
(2) Closure panel Mild 0.95

component of steel
rear left-hand
inner wheel II - IN THE EVENT OF REPLACEMENT
arch
(3) Closure panel Mild 0.95 - complete replacement A-C,
component of steel
rear right-hand - partial replacement section A-B.
inner wheel
arch
41D-5
L38 WARNING
nections).

L38
144255
B32
144257
144237
41D-6
B32
L38
144239
144256
b - Special notes on mating Make a superimposed connection at (5) (see Partial
replacement connections by overlapping: Descrip-
tion) , (MR 400, 40E, Partial replacement connec-
WARNING tions).
accessible, use a GMAW plug weld in place of the Detailed view B
144258
41D-7
b - Special notes on mating
B32
WARNING
144238
Make a superimposed connection at (6) (see Partial
tion) , (MR 400, 40E, Partial replacement connec-
tions).
Detailed view B
144240
41D-8
Rear side member assembly: Replacement 41D

B32 (mm)
(5) Rear shock HLE 1.2

absorber
mounting yoke

absorber rein-
forcement
(7) Rear side HLE/ 2/1.6

member HLE
(8) Connection HLE 2

component
between rear
side member
and rear end
panel lining
(9) Rear axle HLE 2

assembly
mounting rein-
144229
forcement
(10) Rear shock THLE 1.8

absorber cup
ness (mm)
(11) Adapter sup- HLE 2.5
(1) Rear axle assem- HLE 1.8
port of rear
bly mounting unit
axle on body
(2) Rear side mem- THLE 2
(12) Rear sill HLE 1.37
ber unit reinforce-
ment connection (13) Rear section of HLE 1.37
component sill lining
(3) Rear cross mem- HLE 1.37 (14) Rear sill lining THLE 1.8
ber/rear side reinforcement
member connec-
tion component
reinforcement
(4) Rear centre HLE 1.17

cross member -
rear side member
connection com-
ponent
41D-9
L38 No. Description Type Thickness
(mm)
(5) Rear centre HLE 1.17

cross member
- rear side
member con-
nection com-
ponent
(6) Rear shock THLE 1.8

absorber cup

absorber rein-
forcement

absorber
mounting yoke
(9) Rear side HLE/ 2/1.6

member HLE
144247
(10) Connection HLE 2
component
between rear
ness (mm)
side member
(1) Rear axle assem- HLE 1.8 and rear end
bly mounting unit panel lining
(2) Rear side mem- THLE 2 (11) Rear sill HLE 1.37
ber unit reinforce-
(12) Rear section of HLE 1.37
ment connection
sill lining
component
(13) Rear sill lining THLE 1.8
(3) Rear cross mem- HLE 1.37
reinforcement
ber/rear side
member connec-
tion component
reinforcement
(4) Rear axle assem- HLE 2

bly mounting II - IN THE EVENT OF REPLACEMENT
reinforcement
IMPORTANT
41D-10
B32 L38
View from above View from above
144230 144248
View from below View from below
144231 144249
41D-11
WARNING
nections).

WARNING
41D-12
Rear side member: Replacement 41D
IMPORTANT
Partial replacement A-B
L38
144232

ness (mm)
(1) Rear side mem- HLE/ 2/1.6

ber HLE
There is only one way of replacing this part: 144252
144233
41D-13
Detailed view B Detailed view B
144253 144235
B32
WARNING
nections).

144234
B32
Note:
Also order the exhaust rear support (6)
41D-14
WARNING
41D-15
Rear impact cross member mounting reinforcement: Replacement 41D
B32
144241

ness (mm)
(1) Rear impact HLE 2 144242

cross member
mounting rein-
forcement
L38
144260
41D-16
Rear impact cross member mounting reinforcement: Replacement 41D
WARNING
nections).

Remove:
- the rear end panel side lining (see 44A, Rear upper
structure, Rear end panel side lining: Replace-
ment, page 44A-42) ,
- partially the rear side member closure panel (see
Rear side member closure panel: Replacement) .
WARNING
41D-17
Rear floor front cross member, centre section: Replacement 41D
136767

ness (mm)
(1) Rear axle assem- HLE 1.17
bly rear cross
member WARNING
(2) Rear seat belt HLE 1.97
anchorage cen-
tre reinforcement
(3) Nut plate Mild 2.47 as possible to the weld area (see Bolted connec-
steel tion for earth: Fitting) (MR 400, 40H, Bolted con-
nections).
(4) Rear seat belt HLE 1.47
anchorage cen- Locate the earths located near to the weld area (see
tre reinforcement 40A, General information, Earths on body: List and
(5) Nut plate Mild 2.47
steel

WARNING
- complete replacement. accessible, use a GMAW plug weld in place of the
41D-18
Rear section of rear floor central cross member: Replacement 41D
B32
144245
No. Description Type Thickness 144246

(mm)
(1) Rear section of Mild 1
rear floor cen- steel
tra l cross WARNING
member
There is only one way of replacing this part: Description) (MR 400, 40C, Gas metal arc welded
- complete replacement. connections (GMAW)).
WARNING
nections).

41D-19
Rear floor centre cross member: Replacement 41D
B32
L38
144244
136342

ness (mm)
(1) Rear floor centre HLE 0.97
(1) Rear centre HLE 0.97 cross member
cross member
(2) Emergency spare Mild 1.2
wheel subframe steel
joint support

41D-20
Rear floor centre cross member: Replacement 41D
Complete replacement b - Position of electric earths
a - Part in position WARNING

L38 tronic components, the earths of any wiring harness
nections).

WARNING
136343
B32
144243
41D-21
Rear passenger retaining cross member: Replacement 41D
136348

ness (mm)
(1) Passenger retain- HLE 0.87
ing cross mem-
ber WARNING
(2) Rear cushion Mild 2
retaining bracket steel
(3) Rear cushion Mild 2 Position the earth of the welding machine as close
retaining bracket steel as possible to the weld area (see Bolted connec-
(4) Passenger retain- HLE 0.97 nections).
ing cross mem-
ber reinforcement
(5) Passenger retain- HLE 0.97
ing cross mem-
ber reinforcement WARNING
II - IN THE EVENT OF REPLACEMENT accessible, use a GMAW plug weld in place of the
There is only one way of replacing this part: tions by arc welding under shielding gas:
- complete replacement. Description) (MR 400, 40C, Gas metal arc welded
41D-22
Rear floor front cross member reinforcement: Replacement 41D
I - COMPOSITION OF THE SPARE PART Partial replacement A-B
136340
136764
ness (mm)
Detailed view B
(1) Cross member HLE 0.85
reinforcement
136766
136340
41D-23
Rear floor front cross member reinforcement: Replacement 41D
WARNING
nections).

WARNING
41D-24
Rear impact lower cross member: Removal - Refitting 41D
REMOVAL II - REFITTING OPERATION FOR PART
CONCERNED
I - REMOVAL PREPARATION OPERATION a Refit:
a Position the vehicle on a two-post lift (see Vehicle: - the rear impact lower cross member (5) ,
Towing and lifting) (02A, Lifting equipment). - the outer support of the rear tow eye (4) ,
a Remove: - the nuts (3) .
- the rear wing lights (see Rear wing light: Remov-
al - Refitting) (81A, Rear lighting), III - FINAL OPERATION
- the rear wheel arch liners (see Rear wheel arch a Refit:
liner: Removal - Refitting) (55A, Exterior protec-
tion), - the rear bumper (see Rear bumper: Removal -
Refitting) (55A, Exterior protection),
- the rear bumper (see Rear bumper: Removal -
Refitting) (55A, Exterior protection). - the rear wheel arch liners (see Rear wheel arch
tion),
II - OPERATION FOR REMOVAL OF PART
CONCERNED - the rear wing lights (see Rear wing light: Remov-
al - Refitting) (81A, Rear lighting).
144487
a Remove:
- the nuts (3) ,
- the outer support of the rear tow eye (4) ,
- the rear impact lower cross member (5) .
REFITTING
I - REFITTING PREPARATION OPERATION

a
Note:
When refitting the rear impact lower cross mem-
ber, check that the foam is in good condition.
41D-25
FRONT UPPER STRUCTURE
Front bumper mounting: Removal - Refitting 42A
REMOVAL II - OPERATION FOR REMOVAL OF PART
CONCERNED
I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
tion),
- the front headlight (see Headlight: Removal - Re-
fitting) (80B, Front headlights).
- the front bumper (see Front bumper: Removal -
136854
136855
a Remove:
- the bolts (1) ,
- the front bumper support.
42A-1
Front bumper mounting: Removal - Refitting 42A
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
a Refit:
- the front bumper support,
- the bolts.
II - FINAL OPERATION
a Refit:
- the headlight (see Headlight: Removal - Refit-
ting) (80B, Headlights),
tion).
42A-2
Front wing: Removal - Refitting 42A
REMOVAL

a Remove:
tion),
- the windscreen lower trim (see Scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment).
136838
a Remove the front wing panel (2) .
136837
a Remove the front wing trim (1) .
144411
a Remove the bolts (3) from the front wing positioning
component.
a Remove the front wing positioning component.
42A-3
CONCERNED
136834
136832
136835
136833
42A-4
136836
a Remove:
- the bolts (4) ,

- the front wing.
REFITTING

CONCERNED
a Refit:
- the front wing,

- the bolts.
a Refit:
- the front wing positioning component,
- the front wing panel,

- the front wing trim,

ment),

tion).
a Adjust the clearances and flush fitting
42A-5
Scuttle side panel: Replacement 42A
I - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT
- front partial replacement AB,
- rear partial replacement BC.
136871

ness (mm)
(1) Left-hand A-pil- HLE 0.95

lar lining
136874
(2) Connection com- Mild 1.2
ponent of upper steel
section of side 1 - Complete replacement AC
member A-pillar
lining
(3) Cross member HLE 2
mounting unit
(4) A-pillar upper HLE 2

reinforcement
(5) A - p i l l a r l o wer THLE 2.5

reinforcement
(6) A-pillar lining THLE 2

connecting
bracket
(7) A-pillar lining HLE 1.5

reinforcement
component
(8) Windscreen Mild 2

wiper mounting steel
bridge piece
136872
42A-6
2 - front partial replacement AB,
136873

136875
WARNING
detailed view of cut B
nections).

WARNING
tions by arc welding under shielding gas: 136876
42A-7
WARNING
nections).

WARNING
3 - Rear partial replacement BC near the weld area must be disconnected.
nections).

WARNING
136877
42A-8
Scuttle side panel upper reinforcement: Replacement 42A
136846

ness (mm)
(1) A-pillar lining HLE 1.2
reinforcement
WARNING
There is only one way of replacing this part: near the weld area must be disconnected.
- complete replacement. Position the earth of the welding machine as close
nections).

WARNING
42A-9
Front wheel arch: Replacement 42A
I - COMPOSITION OF THE SPARE PART 2 - Right-hand side
1 - Left-hand side
136841

ness (mm)
No. Description Type Thick- (4) Front right-hand Mild 1.1
ness (mm) cup height steel
adjuster
(1) Front left-hand HLE 2
shock absorber (5) Front right-hand HLE 2
cup shock absorber
cup
(2) Front left-hand Mild 1.1
cup height steel (6) Upper tie-rod HLE 2.5
adjuster mounting
(3) Air filter bracket Mild 1.2 (7) Compressor Mild 1.2
steel expansion valve steel
support
(8) Lowe r tie-rod HLE 2

mounting
IMPORTANT

42A-10
Front wheel arch: Replacement 42A
WARNING
Left-hand side tronic components, the earths of any wiring harness
nections).

WARNING
136842 connections (GMAW)).
Right-hand side
136843
42A-11
Windscreen aperture lower cross member: Replacement 42A
136880
136879
1 - Complete replacement AC
(1) Windscreen Mild 0.65

aperture lower steel
cross member
(2) Wiper central Mild 2

mounting support steel

- partial replacement AB.
136882
42A-12
WARNING
nections).

WARNING
original electrical resistance weld (see Connec- Detailed view of cut B
2 - Partial replacement AB
136884
WARNING
136881
nections).
42A-13
WARNING
42A-14
Bulkhead side reinforcement: Replacement 42A
136844

ness (mm)
(1) Side member A- UHLE 1.67
pillar lining con-
nection element WARNING
Position the welding machine earth as close as
- complete replacement. possible to the weld zone (see MR 400).

WARNING
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
42A-15
Front end panel side support: Replacement 42A
136851

ness (mm)
(1) Front end panel Mild 2
upper cross steel
member support WARNING
- complete replacement. as possible to the weld area (see Bolted connec-
nections).

WARNING
42A-16
Front wing: Adjustment 42A
ADJUSTMENT VALUES
a For all information regarding wing adjustment values
(see Vehicle panel gaps: Adjustment value) (01C,
Vehicle bodywork 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 bumper.
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.
The grey section represents the component to be
adjusted.
The white section represents the adjustment area.
I - PREPARATION FOR THE ADJUSTMENT.

144509
a Perform these adjustments in the following order:
a Remove:
- Adjustment of the rear zones (1) , (2) and (3) ,
- the front wheel arch liner (see Front wheel arch
- Adjustment with the bonnet (4) , (5) , liner: Removal - Refitting) (55A, Exterior protec-
- Adjustment with the headlight and the bumper (6) , tion),
(7) . - the front bumper (see Front bumper: Removal -
ment).
42A-17
II - ADJUSTMENT WITH THE FRONT DOOR III - ADJUSTMENT WITH BONNET
144461 144463
a Refit the windscreen lower trim (see Scuttle panel

ment).
a Adjust the shut lines with the bonnet.
IV - ADJUSTMENT WITH THE FRONT BUMPER

AND THE HEADLIGHT
144462
a Adjust the panel gaps with the front door.
144461
a Refit the front bumper (see Front bumper: Remov-

al - Refitting) (55A, Exterior protection).
42A-18
a Adjust the panel gaps between the front bumper and
the headlight.
V - FINAL OPERATION
a Refit the front wheel arch liner (see Front wheel
arch liner: Removal - Refitting) (55A, Exterior pro-
tection).
42A-19
Front wing upper mounting support: Removal - Refitting 42A
REMOVAL
L38
a Remove:
tion),
- the bumper support (see 42A, Front upper struc-
ture, Front bumper mounting: Removal - Refit-
ting, page 42A-1) ,
- the front wing (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) .
144438
CONCERNED a Remove:
- the bolts (1) ,
B32 - the front wing upper mounting support,
REFITTING

CONCERNED
a Refit:
- the front wing upper mounting bracket,
- the bolts.
a Adjust the front wing panel upper mounting support,
with the front wing panel in place.
a Refit:
144409 - the front wing (see 42A, Front upper structure,
a Remove: Front wing: Removal - Refitting, page 42A-3) ,
- the bolts (1) , - the bumper support (see 42A, Front upper struc-
- the front wing upper mounting support, ting, page 42A-1) ,
42A-20
Front wing upper mounting support: Removal - Refitting 42A
tion).
42A-21
Front end panel: Removal - Refitting 42A
REMOVAL II - OPERATION FOR REMOVAL OF PART
CONCERNED

a Remove:
tion),
- the front impact cross member (see 41A, Front
lower structure, Front impact cross member:
Removal - Refitting, page 41A-25) .
- the headlights (see Headlight: Removal - Refit-
ting) (80B, Headlights).
- the front bumper support (see 42A, Front upper
structure, Front bumper mounting: Removal -
Refitting, page 42A-1) ,
136839
- the condenser (see Condenser: Removal - Refit-
ting) , a Remove:
- the radiator (see Cooling radiator: Removal - Re- - the bolts (2) ,
fitting) . - the clips (3) ,
a Disconnect the engine cooling fan.
- the front of the vehicle.
a Remove the bonnet catch (see Bonnet lock: Re-
a Remove the fan assembly (see Engine cooling fan
moval - Refitting) .
assembly: Removal - Refitting) .
REFITTING

CONCERNED
a Refit:
- the fan assembly (see Engine cooling fan assem-
bly: Removal - Refitting)
- the front panel,
- the clips (depending on the equipment level),
- the bolts.
a Refit the bonnet catch (see Bonnet lock: Removal
- Refitting) .
a Connect the engine cooling fan.
a Refit:
- the cooling radiator (see Cooling radiator: Re-
moval - Refitting) ,
42A-22
Front end panel: Removal - Refitting 42A
- the condenser (see Condenser: Removal - Refit-
ting) ,
- the front bumper support (see 42A, Front upper
structure, Front bumper mounting: Removal -
Refitting, page 42A-1) ,
tion).
42A-23
Front end panel side support: Removal - Refitting 42A
REMOVAL - the nut (4) ,
- the retaining arm (A) .
a Position the vehicle on a two-post lift (see Vehicle: B32
a Remove: Complete removal

tion),
ting, page 42A-1)
- the front panel (see 42A, Front upper structure,
Front end panel: Removal - Refitting, page 42A-
22)
144405
CONCERNED Partial removal
Partial removal
144403
a Remove:
141865
- the bolts (5) ,
a Remove:
- the bolt (2) ,
- the bolt (3) ,
42A-24
- the front panel side support. - the front panel side support.
REFITTING
L38

Complete removal CONCERNED
144436
136868
Partial removal a
Note:
In addition, order the front panel mounting ele-
ment and the front panel mounting bracket (B) .
a Refit:
- the front panel (see 42A, Front upper structure,

Front end panel: Removal - Refitting, page 42A-
22)

ting, page 42A-1)

144435 lower structure, Front impact cross member:
a Remove:
- the bolts (6) , Refitting) (55A, Exterior protection),
42A-25
tion).
42A-26
Dashboard cross member: Removal - Refitting 42A
a Remove:
Equipment required - the front side doors (see 47A, Side opening ele-
ments, Front side door: Removal - Refitting,
Diagnostic tool page 47A-1) (47A, Side opening elements),
- the dashboard (see Dashboard: Removal - Refit-
ting) (57A, Interior equipment),
- the UCH (see UCH: Removal - Refitting) (87B, In-
IMPORTANT terconnection unit).
To avoid any risk of triggering when working on or
a Partially remove:
near a pyrotechnic component (airbags or preten-
sioners), lock the airbag computer using the diag- - the steering column (see Steering column: Re-
nostic tool. moval - Refitting) (36A, Steering assembly),
When this function is activated, all the trigger lines - the dashboard wiring (see Dashboard wiring: Re-
are inhibited and the airbag warning light on the moval - Refitting) (88A, Wiring).
instrument panel lights up continuously (ignition
on).
LEFT-HAND DRIVE
IMPORTANT
Never handle the pyrotechnic systems (pretension-
ers or airbags) near to a source of heat or naked
flame - they may be triggered.
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see Airbag and pretensioners: Precau-
tions for the repair) (88C, Airbags and pretension-
ers).
REMOVAL
REMOVAL PREPARATION OPERATION

136858
a Lock the airbag computer using the Diagnostic tool
(see Fault finding - Replacement of components) a Remove:
(88C, Airbags and pretensioners). - the bolts (1) ,
a Disconnect the battery (see Battery: Removal - Re- - the dashboard flange.
fitting) (80A, Battery).
42A-27
RIGHT-HAND DRIVE LEFT-HAND DRIVE
136860 136859
a Remove:
a Remove the bolts from the cross member (3) .
- the bolts (1) ,
- the dashboard flange.
RIGHT-HAND DRIVE
144508
136861
a Remove the bolts (2) .
a Remove the bolts from the cross member (3) .
42A-28
- the front side doors (see 47A, Side opening ele-
ments, Front side door: Removal - Refitting,
page 47A-1) (47A, Side opening elements).
136857
a Remove the left-hand side bolt using the tool (Car.

1765).
a Remove the dashboard cross member (this opera-

tion requires two people).
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Refit the dashboard cross member (this operation

requires two people).
a Refit the left-hand side bolt using the tool (Car.

1765).
a Refit the dashboard cross member bolts.
a Refit:
- the dashboard flange.
- the bolts.
a Refit:
- the dashboard wiring (see Dashboard wiring: Re-

moval - Refitting) (88A, Wiring),
- the steering column (see Steering column: Re-

moval - Refitting) (36A, Steering assembly),
- the UCH (see UCH: Removal - Refitting) (87B, In-

terconnection unit).
- the dashboard (see Dashboard: Removal - Refit-

ting) (57A, Interior equipment),
42A-29
SIDE UPPER STRUCTURE
A-pillar: Replacement 43A
I - COMPOSITION OF THE REPLACEMENT PART
136302
142504
1 - Complete replacement E-C

(1) Body side Mild 0.65

steel
(2) Sill front blanking Mild 0.65

cover steel
(3) Jacking point THLE 2

mounting

- complete replacement E-C,
- partial replacement D-C.
142505
43A-1
Detailed view E Locate the earths located near to the weld area (see

tion of components, page 40A-11) and see (see Hol-
low section inserts: Precautions for the repair) .
d - Irremovable bodywork components - structures

Remove the roof (see 45A, Top of body, Roof: Re-

placement, page 45A-1) .

136306
Detailed view C WARNING

2 - Partial replacement D-C
136305
WARNING
nections).
136774
43A-2
Detailed view D Locate the earths located near to the weld area (see
WARNING
136309
Detailed view C
136305
WARNING
nections).
43A-3
A-pillar reinforcement: Replacement 43A
136794

ness (mm)
Detailed view A
(1) A-pillar reinforce- HLE 1.2
ment
(2) Front door stop HLE 2.5

reinforcement
(3) A-pillar upper HLE 2

hinge reinforce-
ment
(4) A - p i l l a r l o wer THLE 2

hinge reinforce-
ment

136796
43A-4
A-pillar reinforcement: Replacement 43A
Detailed view B
136797
WARNING
nections).

WARNING
43A-5
Windscreen pillar lining: Replacement 43A
136788
136785

(1) Windscreen pil- HLE 1.5

lar lining
(2) Gra b handle HLE 1.3

mounting bridge
piece
(3) Windscreen pil- Mild 1

lar lining connect- steel
ing bracket

136786
43A-6
136787

136789
WARNING
nections).

WARNING
original electrical resistance weld (see Connec- 136790
43A-7
Detailed view B
136791
WARNING
nections).

WARNING
43A-8
Windscreen pillar lining reinforcement: Replacement 43A
136807

ness (mm)
Detailed view
(1) Windscreen pil- HLE 1.1
lar lining rein-
forcement

136809
43A-9
Windscreen pillar lining reinforcement: Replacement 43A
WARNING
nections).


tion of components, page 40A-11) and see (see Hol-
low section inserts: Precautions for the repair) .
WARNING
43A-10
B-pillar: Replacement 43A
I - COMPOSITION OF THE REPLACEMENT PART 1 - Complete replacement A-D
142506

ness (mm)
Detailed view A
(1) B-pillar Mild 0.65
steel

- complete replacement A-D,
- partial replacement C-D-E.
136780
142507
43A-11
Detailed view B Detailed view D
136771 136772
Detailed view C b - Position of electric earths
WARNING
nections).


components, page 40A-11) and see (see Hollow
136781

43A-12
e - Special notes on mating Detailed view E
WARNING
2 - Partial replacement C-D-E
136784
Detailed view C
136782
136781
43A-13
Detailed view D
136772
WARNING
nections).


components, page 40A-11) and see (see Hollow
WARNING
43A-14
B-pillar reinforcement: Replacement 43A
144291

ness (mm)
(11) B-pillar upper THLE 1.8
reinforcement
WARNING
(12) B - p i l l a r l o wer HLE 1.5
reinforcement
(13) B-pillar impact THLE 1.8 near the weld area must be disconnected.
reinforcement Position the earth of the welding machine as close
II - IN THE EVENT OF REPLACEMENT nections).
- complete replacement. 40A, General information, Earths on body: List and
WARNING
43A-15
B-pillar upper lining: Replacement 43A
136792

ness (mm)
(1) B-pillar upper lin- HLE 1.5
ing
WARNING
nections).

WARNING
43A-16
Side roof rail lining: Replacement 43A
L38
B32
144293
136812

ness (mm)
(9) Rear side roof rail Mild 0.9
(1) Rear side roof rail HLE 0.95 lining steel
lining
(10) Mounting bridge HLE 1.3
(2) Mounting bridge HLE 1.3 piece
piece

43A-17
Side roof rail lining: Replacement 43A

B32 tronic components, the earths of any wiring harness
nections).

WARNING
136813
L38
144294
43A-18
REAR UPPER STRUCTURE
Rear wing panel: Replacement 44A
B32
136947
136944
1 - Complete replacement A-D
(3) Jacking point THLE 2

support

steel
(5) Rear door striker Mild 0.95

panel reinforce- steel
ment

- Complete replacement A-D
- Partial replacement B-C
- Partial replacement B-D
136945
44A-1
B32
Detailed view A b - Position of electric earths
WARNING
nections).


Replace:
- the hollow section inserts (see 40A, General infor-
137236 mation, Hollow section inserts: List and location
of components, page 40A-11) and (see Hollow sec-
Detailed view D tion inserts: Precautions for the repair) .

WARNING
136946
44A-2
B32
2 - Partial replacement B-C Detailed view B
136122
Detailed view C
137239
136948
137240
44A-3
B32
b - Position of electric earths 3 - Partial replacement B-D
WARNING
nections).


Replace:
mation, Hollow section inserts: List and location
tion inserts: Precautions for the repair) .
137237
WARNING
137238
44A-4
B32
Detailed view B b - Position of electric earths
WARNING
nections).


Replace:
136122 mation, Hollow section inserts: List and location
Detailed view D tion inserts: Precautions for the repair) .
WARNING
136946
44A-5
L38
144325
144324
WARNING
No. Description Type Thick- To avoid damaging the vehicles electric and elec-
ness (mm) tronic components, the earths of any wiring harness
steel Position the earth of the welding machine as close
(2) Rear door striker Mild 0.95 tion for earth: Fitting) (MR 400, 40H, Bolted con-
panel reinforce- steel nections).
ment
(3) Adjustable pad HLE 2.5 40A, General information, Earths on body: List and

- Complete replacement A-D
- Partial replacement B-C
- Partial replacement B-D
44A-6
L38
1 - Complete replacement A-D Detailed view D
144327
b - Parts always to be replaced

144326 Replace the hollow section inserts (see 40A, General
Detailed view A tion of components, page 40A-11) and (see Hollow

WARNING
144328
44A-7
L38
2 - Partial replacement B-C Detailed view C
144332

Detailed view B tion of components, page 40A-11) and (see Hollow
WARNING
144330
44A-8
L38
3 - Partial replacement B-D Detailed view D
144332

Detailed view B tion of components, page 40A-11) and (see Hollow
WARNING
144330
44A-9
Rear wing panel extension: Replacement 44A
L38
B32
144317
136980

ness (mm)
(4) Outer rear wheel Mild 0.65
(1) Outer rear wheel Mild 0.65 arch closure steel
arch closure steel panel component
panel component
B32
44A-10
WARNING
nections).

WARNING
136982 If the mating faces of the parts to be welded are not
1 - Complete replacement A-C original electrical resistance weld (see Connec-
137245
137246
44A-11
WARNING
L38
136984
Detailed view B
136985
WARNING 144318
nections).
44A-12
WARNING
nections).

WARNING
44A-13
Rear wing panel rain channel: Replacement 44A
L38
B32
144309
136942

ness (mm)
(21) Rear side rain Mild 0.65
(1) Rear side rain Mild 0.9 channel steel
channel steel
(22) Rear lower side Mild 0.65
(2) Strut mounting Mild 1.5 rain channel steel
reinforcement steel
(3) Outer wheel arch Mild 0.65

closure panel steel
component
(4) Rear light mount- Mild 0.7
ing component steel
B32
44A-14
Complete replacement d - Special notes on mating
WARNING
L38
136943
WARNING
nections).

c - Bodywork components that cannot be removed

- structures to be removed in order to carry out the
144310
44A-15
WARNING
nections).

WARNING
44A-16
Rear light mounting: Replacement 44A
L38
B32
144335
136970

ness (mm)
(1) Rear light mount- Mild 0.7 ing steel
ing steel
ing side section steel
B32
44A-17
WARNING
as possible to the weld area (see 4 0 A, General
information, Earths on body: List and location
of components, page 40A-15) (MR 400, 40H,
Bolted connections).


136972
WARNING
137243
137244
44A-18
WARNING

136975
Detailed view B
137242
tion) (MR 400, 40E, Partial replacement connections).
136977
Use a butt weld at (9) (see Connections for edge to
edge partial replacements: Description) (MR 400,
40E, Partial replacement connections).
44A-19
WARNING
If the mating faces of the parts to be welded are not WARNING
accessible, use a GMAW plug weld in place of the To avoid damaging the vehicles electric and elec-
original electrical resistance weld (see Connec- tronic components, the earths of any wiring harness
tions by arc welding under shielding gas: near the weld area must be disconnected.

L38 40A, General information, Earths on body: List and
There is only one way of replacing this part: location of components, page 40A-15) .
WARNING
a - Part in position If the mating faces of the parts to be welded are not
144336
44A-20
Light mounting lining: Replacement 44A
B32
136934
144355

ing lining steel
(11) Inner q u a rter Mild 0.70

panel rear rein- steel
forcement, lower
section

- Complete replacement
- rear section replacement,
- partial replacement of the rear section.
137235
44A-21
B32
b - Position of electric earths b - Position of electric earths
WARNING WARNING
To avoid damaging the vehicles electric and elec- To avoid damaging the vehicles electric and elec-
tronic components, the earths of any wiring harness tronic components, the earths of any wiring harness
near the weld area must be disconnected. near the weld area must be disconnected.
Position the earth of the welding machine as close Position the earth of the welding machine as close
as possible to the weld area (see Bolted connec- as possible to the weld area (see Bolted connec-
tion for earth: Fitting) (MR 400, 40H, Bolted con- tion for earth: Fitting) (MR 400, 40H, Bolted con-
nections). nections).
Locate the earths located near to the weld area (see Locate the earths located near to the weld area (see
40A, General information, Earths on body: List and 40A, General information, Earths on body: List and
location of components, page 40A-15) . location of components, page 40A-15) .
c - Special notes on mating c - Special notes on mating
WARNING WARNING
If the mating faces of the parts to be welded are not If the mating faces of the parts to be welded are not
accessible, use a GMAW plug weld in place of the accessible, use a GMAW plug weld in place of the
original electrical resistance weld (see Connec- original electrical resistance weld (see Connec-
tions by arc welding under shielding gas: tions by arc welding under shielding gas:
Description) (MR 400, 40C, Gas metal arc welded Description) (MR 400, 40C, Gas metal arc welded
connections (GMAW)). connections (GMAW)).
2 - Rear section replacement 3 - Partial replacement of the rear section
a - Part in position a - Part in position
136935 136936
44A-22
B32
WARNING
nections).

WARNING
136937 If the mating faces of the parts to be welded are not
Detailed view original electrical resistance weld (see Connec-
136938
44A-23
Outer rear wheel arch: Replacement 44A

B32 ness (mm)
(1) Quarter panel lin- Mild 0.65

ing steel
B32
136949
L38
137241
WARNING
144319 tronic components, the earths of any wiring harness
nections).
44A-24
Locate the earths located near to the weld area (see 1 - Complete replacement A-C
WARNING
L38
- partial replacement A-B. 144321
WARNING
nections).

144320
WARNING
44A-25
2 - Partial replacement A-B b - Position of electric earths
WARNING
nections).

WARNING
144322 tions by arc welding under shielding gas:
P (Pitch) = 25 mm
D = 30 mm
tion) (MR 400, 40E, Partial replacement connections).
144323
44A-26
Inner rear wheel arch: Replacement 44A
L38
B32
144333
144490

ness (mm)
(12) Rear left-hand Mild 0.65
(10) Rear left-hand HLE 0.67 inner wheel arch steel
inner wheel arch
(13) Left-hand support Mild 1.5
(11) Left-hand support HLE 1.47 mounting for steel
mounting for seatback of rear
seatback of rear seat
seat

44A-27
Inner rear wheel arch: Replacement 44A

nections).

WARNING
136967
L38
144334
44A-28
Rear wheel arch closure panel: Replacement 44A
B32
136987
144301
(11) Front protection Mild 0.65

connection com- steel
ponent for outer
wheel arch
(12) Stiffener of quar- Mild 1.2

ter panel rear steel
reinforcement
(13) Rear protection Mild 0.65

connection com- steel
ponent for outer
wheel arch
(14) Rear section rear HLE 0.65

inner wheel arch

- Complete replacement 136988
- front section replacement,

- rear section replacement.
44A-29
B32
b - Position of electric earths b - Position of electric earths
WARNING WARNING
To avoid damaging the vehicles electric and elec- To avoid damaging the vehicles electric and elec-
tronic components, the earths of any wiring harness tronic components, the earths of any wiring harness
near the weld area must be disconnected. near the weld area must be disconnected.
Position the earth of the welding machine as close Position the earth of the welding machine as close
as possible to the weld area (see Bolted connec- as possible to the weld area (see Bolted connec-
tion for earth: Fitting) (MR 400, 40H, Bolted con- tion for earth: Fitting) (MR 400, 40H, Bolted con-
nections). nections).
Locate the earths located near to the weld area (see Locate the earths located near to the weld area (see
40A, General information, Earths on body: List and 40A, General information, Earths on body: List and
location of components, page 40A-15) . location of components, page 40A-15) .
c - Special notes on mating c - Special notes on mating
WARNING WARNING
If the mating faces of the parts to be welded are not If the mating faces of the parts to be welded are not
accessible, use a GMAW plug weld in place of the accessible, use a GMAW plug weld in place of the
original electrical resistance weld (see Connec- original electrical resistance weld (see Connec-
tions by arc welding under shielding gas: tions by arc welding under shielding gas:
Description) (MR 400, 40C, Gas metal arc welded Description) (MR 400, 40C, Gas metal arc welded
connections (GMAW)). connections (GMAW)).
2 - Front section replacement 3 - Rear section replacement
a - Part in position a - Part in position
137247 136989
44A-30
B32
WARNING
nections).

WARNING
44A-31
Quarter panel upper reinforcement: Replacement 44A
B32
144315

ness (mm) 144316
(7) Quarter panel Mild 0.65

rear upper rein- steel b - Position of electric earths
forcement
WARNING
- complete replacement. near the weld area must be disconnected.
nections).

WARNING
44A-32
Rear parcel shelf: Replacement 44A
L38
I - COMPOSITION OF THE SPARE PART Locate the earths located near to the weld area (see
144337

(mm)
(1) Centre parcel Mild 0.95

shelf stiffener steel 144338
(2) Centre parcel Mild 0.8

shelf steel
(3) Brake light Mild 0.65

mounting steel WARNING
bridge piece If the mating faces of the parts to be welded are not
(4) Rear screen Mild 0.65 original electrical resistance weld (see Connec-
lowe r c r o s s steel tions by arc welding under shielding gas:
member Description) (MR 400, 40C, Gas metal arc welded
WARNING
nections).
44A-33
Rear parcel shelf, side section: Replacement 44A
L38
144339
144340
(mm) b - Special notes on mating
(1) Rear parcel Mild 1.2
shelf, side sec- steel
tion WARNING
(2) Rear side iner- Mild 1.45 accessible, use a GMAW plug weld in place of the
tia reel mount- steel original electrical resistance weld (see Connec-
ing tions by arc welding under shielding gas:
reinforcement Description) (MR 400, 40C, Gas metal arc welded
WARNING
nections).

44A-34
Side roof rail rear reinforcement: Replacement 44A
B32
136810

ness (mm) 136811
(1) Side roof rail rear Mild 0.85

reinforcement steel b - Position of electric earths
II - IN THE EVENT OF REPLACEMENT WARNING

There is only one way of replacing this part: To avoid damaging the vehicles electric and elec-
nections).


to be removed in order to carry out the repair
operation
Remove:
- the rear wing panel (see 44A, Rear upper structure,

Rear wing panel: Replacement, page 44A-1)
- the roof (see 45A, Top of body, Roof: Replace-

ment, page 45A-1) .
44A-35
Side roof rail rear reinforcement: Replacement 44A
B32
WARNING
44A-36
Rear end panel assembly: Replacement 44A
L38
B32
144299
144297

ness (mm)
(1) Rear end panel Mild 0.65
(1) Emergency spare Mild 1.2 steel
wheel lock rein- steel
forcement (2) Luggage com- Mild 1
part m e n t lid steel
(2) Rear end panel Mild 0.65 striker panel rein-
steel forcement
(3) Luggage com- Mild 1 (3) Rear end panel Mild 0.65
part m e n t lid steel lining steel
striker panel rein-
forcement on (4) Luggage com- Mild 1.2
body partment lid stop steel
bridge piece
lining, centre sec- steel
tion

44A-37
L38
Interior view
B32
Interior view
144489
Exterior view
144488
Exterior view
144300
144298
44A-38
WARNING
nections).

WARNING
44A-39
Rear end panel: Replacement 44A
L38
B32
144313
144311

ness (mm)
(1) Rear end panel Mild 0.65 steel
steel

44A-40
Rear end panel: Replacement 44A
Part in position a - Position of electric earths
B32 WARNING
nections).

WARNING
144312 Description) (MR 400, 40C, Gas metal arc welded
L38
144314
44A-41
Rear end panel side lining: Replacement 44A
B32
144295

ness (mm) 144296
(1) Rear end panel HLE 0.65

lining, side sec- b - Position of electric earths
tion
WARNING
- complete replacement. near the weld area must be disconnected.
nections).

WARNING
44A-42
TOP OF BODY
Roof: Replacement 45A

L38 ness (mm)
Normal roof (3) Normal roof Mild 0.75

steel
(4) Roof with sunroof Mild 0.75

steel
B32
144500
Sunroof
144494

ness (mm)
(5) Roof Mild 0.75

steel
144502 II - IN THE EVENT OF REPLACEMENT

- complete replacement
45A-1
TOP OF BODY
Sunroof version
WARNING
Position the welding machine earth as close as
possible to the weld zone (see MR 400).

B32
144495
Standard roof version
L38
Standard roof version
144493
144499
45A-2
TOP OF BODY
Sunroof version Rear zone
144501 144491
b - Bonding area L38
B32 Front zone
Front zone
144498
144492
45A-3
TOP OF BODY
Rear zone
144497
WARNING
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
45A-4
TOP OF BODY
Roof front cross member: Replacement 45A
136365

ness (mm)
(1) Roof front cross Mild 0.65
member steel
WARNING


Remove the front section of the roof (see Roof front
section: Replacement) .
45A-5
TOP OF BODY
Roof front cross member: Replacement 45A
WARNING
45A-6
TOP OF BODY
Roof centre cross member: Replacement 45A
144504

ness (mm)
(7) Roof centre cross UHLE 1.8
member
WARNING

WARNING
45A-7
TOP OF BODY
Roof rear cross member: Replacement 45A
L38
B32
144506
136361

ness (mm)
(10) Roof rear cross HLE 0.85
(1) Roof rear cross HLE 0.85 member
member
(2) Roof rear cross Mild 1.2

member rein- steel
forcement
45A-8
TOP OF BODY
Roof rear cross member: Replacement 45A
Complete replacement b - Position of electrical earths


WARNING
136363
L38
144505
45A-9
SIDE OPENING ELEMENTS
Front side door: Removal - Refitting 47A
This operation can be carried out in two ways: 2 - REMOVAL
- removal with hinges: allows the initial adjustments to
be kept,
- removal without hinges: used when replacing the
door.
I - REMOVAL WITHOUT THE HINGES
1 - PREPARATION FOR REMOVAL
137565
a Remove the front side door check strap bolt (2) .
137569
a Disconnect the front side door wiring connector (1) .
137566
a Remove:
- the nuts (3) ,
- the front side door (this operation requires two peo-
ple).
47A-1
II - REFITTING WITHOUT HINGES
1 - REFITTING
a Refit:

ple),
- the nuts (3) ,
- the front side door check strap bolt (2) .
a Adjust the front side door clearances and flush fit-

tings (see 47A, Side opening elements, Front side
door: Adjustment, page 47A-6) .
a Carry out a function test.
2 - FINAL OPERATION
a Connect the front side door wiring connector. 137568

a Remove:
a Carry out a function test on all functions.
- the clips (5) ,
III - REMOVAL WITH HINGES - the wing panel.
1 - PREPARATION FOR REMOVAL
137565
a Remove the front side door check strap bolt (6) .
137569
a Disconnect the front side door wiring connector (4) .

a Remove the front wheel arch liner (see Front wheel

arch liner: Removal - Refitting) .
47A-2
2 - REMOVAL a Refit the front wheel arch liner (see Front wheel
arch liner: Removal - Refitting) .
a Connect the front side door wiring connector.
137567
a Remove the bolts (7) .
a Remove the front side door (this operation requires

two people).
IV - REFITTING WITH HINGES
1 - REFITTING
Note:
Apply a bead of sealing mastic on the door
hinges (see Anti-corrosion protection product
before assembly: Use) (MR 400, 04F, Body-
work products and mountings).
a Refit:

ple),
- the front side door check strap bolt (6) .
a Adjust the front side door clearances and flush fit-

2 - FINAL OPERATION
a Refit:
- the wing panel,
- the clips (5) .
47A-3
Front side door: Stripping - rebuilding 47A
- the anti-fouling seal,
Equipment required - the front side door glass run channel (see Front
side door window run channel: Removal - Refit-
Diagnostic tool
ting) (66A, Window sealing),
- the support of the front side door run channel (see

Front side door slide mounting: Removal - Re-
fitting) ,
Note:
The order of the operations described below is spe- - the window motor (see Electric window motor:
cific to the front side door replacement. Removal - Refitting) (87D, Electric windows -
Sunroof),
The following procedure applies to the front side
door on the vehicle. - the front side door sliding window (see Front side
door sliding window: Removal - Refitting) (54A,
Windows),
STRIPPING
- the front speaker (see Front speakers: Removal -
Refitting) (86A, Radio),
I - STRIPPING PREPARATION OPERATION
a Lock the airbag computer. Apply the before repair - the front side door electric window mechanism (see
procedure using the Diagnostic tool : Front side door electric window mechanism:
Removal - Refitting) (51A, Side opening element
- connect the Diagnostic tool, mechanisms),
- select « Airbag computer » ,
- the front side door lock barrel (see Front side door
- go to repair mode, lock barrel: Removal - Refitting) (51A, Side
opening element mechanisms),
- apply the « Before repair procedure » .
a Disconnect: - the front side exterior door handle (see Exterior
door handle: Removal - Refitting) (51A, Side
- the battery (see Battery: Removal - Refitting) opening element mechanisms),
(80A, Battery),
- the front side door lock (see Front side door lock:
- the supply connector from the front side door wiring
harness.
mechanisms),
II - STRIPPING OPERATION FOR PART - the front side door check strap (see Front side
CONCERNED door check strap: Removal - Refitting) (51A,
Side opening element mechanisms),
a Remove:
- the front side door trim (see Front side door trim: - the driver's or passenger's front side door wiring
Removal - Refitting) (72A, Side opening element (see Driver's front side door wiring: Removal -
trim), Refitting) or (see Passenger's front side door
wiring: Removal - Refitting) (88A, Wiring).
- the front side door sealing film (see Door sealing
film: Removal - Refitting) (65A, Door sealing),
- the door mirror (see Door mirror: Removal - Re- REBUILDING
fitting) (56A, Exterior equipment),
- the front side door exterior weatherstrip (see Front I - REBUILDING PREPARATION OPERATION
side door exterior weatherstrip: Removal - Re-
fitting) (66A, Window sealing), a Always replace:
- the front side door protective strip (see Front side - the sealing film,
door protective strip: Removal - Refitting) (55A,
Exterior protection), - the tyre pressure label,
- the front side door pillar exterior trim (see Front - the foam pads.
side door pillar exterior trim: Removal - Refit-
ting) (56A, Exterior equipment), a Order a door fitting kit in addition.
47A-4
Front side door: Stripping - rebuilding 47A
II - REBUILDING OPERATION FOR PART - the front side door sealing film (see Door sealing
CONCERNED film: Removal - Refitting) (65A, Door sealing),
a Refit: - the front side door trim (see Front side door trim:
- the driver's or passenger's front side door wiring trim).
(see Driver's front side door wiring: Removal -
Refitting) or (see Passenger's front side door
wiring: Removal - Refitting) (88A, Wiring), III - FINAL OPERATION
- the front side door check strap (see Front side a Connect:
door check strap: Removal - Refitting) (51A, - the supply connector to the front side door wiring
Side opening element mechanisms), harness,
- the front side door lock (see Front side door lock: - the battery (see Battery: Removal - Refitting)
Removal - Refitting) (51A, Side opening element (MR 415, 80A, Battery).
mechanisms),
a Unlock the airbag computer. Apply the after repair
- the front side exterior door handle (see Exterior procedure using the Diagnostic tool :
door handle: Removal - Refitting) (51A, Side
opening element mechanisms), - connect the Diagnostic tool,
- select « Airbag computer » ,
- the front side door lock barrel (see Front side door
lock barrel: Removal - Refitting) (51A, Side - go to repair mode,
- apply the « After repair procedure » .
- the front side door electric window mechanism (see
Front side door electric window mechanism:
mechanisms),
- the front speaker (see Front speakers: Removal -
- the front side door sliding window (see Front side
Windows),
- the window motor (see Electric window motor:
Removal - Refitting) (87D, Electric windows -
Sunroof),
- the front side door glass run channel (see Front
- the front side door glass run channel (see Front
- the front side door pillar exterior trim (see Front
side door pillar exterior trim: Removal - Refit-
ting) (56A, Exterior equipment),
- the front side door protective strip (see Front side
Exterior protection),
- the front side door exterior weatherstrip (see Front
side door exterior weatherstrip: Removal - Re-
fitting) (66A, Window sealing),
- the door mirror (see Door mirror: Removal - Re-
fitting) (56A, Exterior equipment),
47A-5
Front side door: Adjustment 47A
ADJUSTMENT VALUES
a For information on the front side door adjustment
values, (see Vehicle panel gaps: Adjustment val-
ue) (01C, Vehicle bodywork specifications).
ADJUSTMENT
109496
a
Symbols A, B, C and D show the adjustment

options.
The black dot in the centre represents the body
of the bolt.
137570
a Respect the adjustment order of zones (1) , (2) , (3) adjusted.
, (4) , (5) , (6) , (7) and (8) .
The white section represents the adjustment
area.
Note:
Adjustment of zones (4) , (5) and (6) is only valid
I - HEIGHT AND LENGTH ADJUSTMENT
if the rear door is correctly adjusted.
1 - PREPARATION FOR ADJUSTING THE HEIGHT

AND LENGTH
a Remove the front wing panel (see 42A, Front upper
structure, Front wing: Removal - Refitting, page
42A-3) .
47A-6
2 - OPERATION FOR ADJUSTING THE HEIGHT II - DEPTH ADJUSTMENT
AND LENGTH
137582
137583
a Adjust in the following order: a
- the height of zones (1) , (2) and (3) , Note:

- the length of zones (4) , (5) , (6) , (7) and (8) . The original hinge mounting plates are bonded to
the door box section.
To carry out the adjustment, it is necessary to
remove the plate using a wooden block and a
hammer.
137584
a Adjust the depth of zones (1) , (2) , (3) , (7) and (8) .
47A-7
137581
a Adhere to the following adjustment sequence:
- adjust the height of the striker plate in relation to
the lock to prevent them touching,
- adjust the depth of zones (4) , (5) and (6) .
Note:
The striker plate is spot-welded on the reinforce-
ment inside the B-pillar.
To carry out adjustments, deform the fuse brack-
ets of the plate.
Note:
Adjustment of zones (4) , (5) and (6) is depen-
dent on the adjustment of the rear door (see
47A, Side opening elements, Rear side door:
Adjustment, page 47A-13) .
47A-8
Rear side door: Removal - Refitting 47A
There are two possible methods for this operation: a Adjust the rear side door clearances and flush fit-
- Removal with hinges: allows the initial adjustments to door: Adjustment, page 47A-6) .
be kept,
- Removal without hinges: used when replacing the
door.
2 - FINAL OPERATION
a Connect the connector for the rear side door wiring.
I - REMOVAL WITHOUT THE HINGES
a Carry out a function test on all functions.
1 - REMOVAL PREPARATION
III - REMOVAL WITH HINGES
a Disconnect the connector from the rear side door
wiring. 1 - REMOVAL PREPARATION
a Disconnect the connector from the rear side door
2 - REMOVAL wiring.
a Remove the bolt from the rear side door check strap. a Remove the bolt from the rear side door check strap.
2 - REMOVAL
137587
a Remove:
137586
- the nuts (1) , a Remove:
- the rear side door (this operation requires two peo- - the bolts (2) ,
ple).
- the rear side door (this operation requires two peo-
ple).
II - REFITTING WITHOUT HINGES
1 - REFITTING
a Refit:

ple),
- the bolt of the rear side door check strap.
47A-9
Rear side door: Removal - Refitting 47A
IV - REFITTING WITH HINGES
1 - REFITTING
a
Note:
Apply a bead of sealing mastic on the door
hinges (see Anti-corrosion protection product
before assembly: Use) (MR400, 04F, Body-
work products and mountings).
a Refit:
ple),
- the bolt of the rear side door check strap.
a Adjust the rear side door clearances and flush fit-
2 - FINAL OPERATION
a Connect the connector for the rear side door wiring.
47A-10
Rear side door: Stripping - rebuilding 47A
- the rear side door pillar exterior trim (see Rear side
Special tooling required door pillar exterior trim: Removal - Refitting)
(56A, Exterior equipment),
Car. 1363 Set of trim removal levers.
a Remove:
- the rear side door sliding window (see Rear side

Note: Windows),
The order of the operations described below - the rear side door fixed window (see Rear side
applies specifically to replacing the rear side door. door fixed window: Removal - Refitting) (54A,
The following procedure applies to the rear side Windows),
door on the vehicle.
a Remove:
- the exterior door handle (see Exterior door han-

STRIPPING dle: Removal - Refitting) (51A, Side opening ele-
ment mechanisms),
STRIPPING OPERATION FOR PART CONCERNED - the rear side door lock (see Rear side door lock:
mechanisms),
- the rear side door check strap (see Rear side door
check strap: Removal - Refitting) (51A, Side
- the rear side door protective strip (see Rear side

- the rear speaker (see Rear speakers: Removal -

- the wiring of the rear right-hand side door (see

Rear right-hand side door wiring: Removal - Re-
fitting) (88A, Wiring) or the wiring of the rear left-
hand side door (see Rear left-hand side door wir-
ing: Removal - Refitting) (88A, Wiring),
- the clips using the tool (Car. 1363),
142214
- the blanking covers.
a Disconnect the supply connector (1) from the rear

side door electrical wiring. REBUILDING
a Remove:
I - REBUILDING PREPARATION OPERATION
- the rear side door trim (see Rear side door trim:
Removal - Refitting) (72A, Side opening element a parts always to be replaced: parts included in
trim), the side opening element kit (40,10,01,02).
- the rear side door sealing film (see Door sealing
film: Removal - Refitting) (65A, Opening element II - REBUILDING OPERATION FOR PART
sealing), CONCERNED
- the anti-fouling seal, a Refit:
- the rear side door glass run channel (see Rear - the blanking covers,
ting) (66A, Window sealing), - the clips using the tool (Car. 1363),
47A-11
Rear side door: Stripping - rebuilding 47A
- the wiring of the rear right-hand side door (see
Rear right-hand side door wiring: Removal - Re-
fitting) (88A, Wiring) or the wiring of the rear left-
hand side door (see Rear left-hand side door wir-
ing: Removal - Refitting) (88A, Wiring),
- the rear speaker (see Rear speakers: Removal -

- the rear side door protective strip (see Rear side

- the rear side door check strap (see Rear side door
check strap: Removal - Refitting) (51A, Side
- the rear side door lock (see Rear side door lock:
mechanisms),
- the exterior door handle (see Exterior door han-

dle: Removal - Refitting) (51A, Side opening ele-
ment mechanisms).
a Refit:
- the rear side door fixed window (see Rear side

door fixed window: Removal - Refitting) (54A,
Windows),
- the rear side door sliding window (see Rear side

Windows).
a Refit:
- the rear side door pillar exterior trim (see Rear side
door pillar exterior trim: Removal - Refitting)
(56A, Exterior equipment),
- the rear side door glass run channel (see Rear

- the rear side door sealing film (see Door sealing

film: Removal - Refitting) (65A, Opening element
sealing),
- the rear side door trim (see Rear side door trim:
trim).
a Connect the supply connector to the rear side door

electrical wiring.
47A-12
Rear side door: Adjustment 47A
ADJUSTMENT VALUES
a For information on the rear side door adjustment val- L38
ues (see Vehicle panel gaps: Adjustment value)
(01C, Vehicle bodywork specifications).
ADJUSTMENT
B32
144525
a Respect the adjustment order of zones (1) , (2) , (3)
, (4) , (5) and (6) .
Note:
Adjustment of zones (5) and (6) is only valid if
137571 the front door is correctly adjusted.
a Respect the adjustment order of zones (1) , (2) , (3)
, (4) , (5) and (6) .
Note:
Adjustment of zones (5) and (6) is only valid if
the front door is correctly adjusted.
47A-13
I - HEIGHT AND LENGTH ADJUSTMENT
109496
a 137591
a Adjust in the following order:

options. - the height of zones (1) and (2) ,
The black dot in the centre represents the body - the length of zones (3) and (4) .
of the bolt.
adjusted.
area.
47A-14
II - DEPTH ADJUSTMENT
137590
137592 a Adhere to the following adjustment sequence:
a
- adjust the height of the striker plate in relation to
Note: the lock to prevent them touching,
The original hinge mounting plates are bonded to - adjust the depth of zones (3) and (4) .
the door box section.
To carry out the adjustment, it is necessary to Note:
remove the plate using a wooden block and a
The striker plate is spot-welded on the reinforce-
hammer.
ment inside the B-pillar.
a Adjust the depth of zones (1) and (2) . To carry out adjustments, deform the fuse brack-
ets of the plate.
Note:
Adjustment of zones (5) and (6) is dependent on
the adjustment of the front door (see 47A, Side
opening elements, F ront side door: Adjust-
ment, page 47A-6) .
47A-15
Fuel filler flap cover: Removal - Refitting 47A
REMOVAL
OPERATION FOR REMOVAL OF PART

CONCERNED
137588
a Unclip the fuel filler flap cover at (1) .
137599
a Remove the fuel filler flap cover at (2) .
REFITTING
REFITTING OPERATION FOR PART CONCERNED

a Refit the fuel filler flap cover.
47A-16
NON-SIDE OPENING ELEMENTS
Bonnet: Removal - Refitting 48A
This operation can be carried out in two ways: - the bolts (1) .
-removal without the hinges: used to replace the bon- a Adjust the opening clearances and flush fitting (see
net. 48A, Non-side opening elements, Bonnet: Ad-
justment, page 48A-5) .
-removal with the hinges: allows the initial adjustments
to be kept and prevents the original paintwork from
coming off between the hinge and the bonnet lining. 2 - FINAL OPERATION
a Refit the bonnet strut on the bonnet (if fitted to the
I - REMOVAL WITHOUT THE BONNET HINGES vehicle) (see Bonnet strut: Removal - Refitting)
a Connect the screen washer pipe.
1 - REMOVAL PREPARATION OPERATION a Refit the bonnet soundproofing.
a Remove the bonnet soundproofing.
III - REMOVAL WITH THE BONNET HINGES
a Disconnect the screen washer pipe.
a Remove the bonnet strut on the bonnet (if fitted to 1 - REMOVAL PREPARATION OPERATION
the vehicle) (see Bonnet strut: Removal - Refit-
ting) a Remove:
2 - OPERATION FOR REMOVAL OF PART liner: Removal - Refitting) (55A, Exterior protec-
CONCERNED tion),
- the front wings (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) .
a Remove the bonnet soundproofing.
a Disconnect the screen washer pipe.
a Remove the bonnet strut on the bonnet (if fitted to
the vehicle) (see Bonnet strut: Removal - Refit-
ting)
137606
a Remove:
- the bolts (1) ,
- the bonnet (this operation requires two people).
II - REFITTING WITHOUT BONNET HINGES
1 - OPERATION FOR REFITTING PART

CONCERNED
a Refit:
- the bonnet (this operation requires two people),
48A-1
Bonnet: Removal - Refitting 48A
2 - OPERATION FOR REMOVAL OF PART - the headlights (see Headlight: Removal - Refit-
CONCERNED ting) (80B, Headlights),
tion).
137605
a Remove:
- the bolts (2) ,

- the bonnet (this operation requires two people).
IV - REFITTING WITH BONNET HINGES

CONCERNED
a Refit:
- the bonnet (this operation requires two people),
- the bolts (2) .

a Adjust the opening clearances and flush fitting (see
48A, Non-side opening elements, Bonnet: Ad-
2 - FINAL OPERATION
a Refit the bonnet strut on the bonnet (if fitted to the

vehicle) (see Bonnet strut: Removal - Refitting)
a Connect the screen washer pipe.
a Refit the bonnet soundproofing.
a Refit:
- the front wings (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) ,
48A-2
Bonnet: Stripping - Rebuilding 48A
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
STRIPPING OPERATION FOR PART CONCERNED
138409
142266
a Remove:
- the clips (4) ,
- the bonnet soundproofing (5) .
141804
a Unclip:
- the windscreen washer jet pipe (6) ,
- the windscreen washer jets (7) .
48A-3
Bonnet: Stripping - Rebuilding 48A
a Refit:
- the various blanking covers on the bonnet,
- the bonnet striker plate.
a Clip on:
- the windscreen washer jets,
- the windscreen washer jet pipe.
a Refit:
- the bonnet soundproofing,
- the clips.
141805
a Remove:
- the striker retaining bolts (8) ,
141806
a Remove the blanking covers (9) and (10) from the
bonnet.
B32
a Remove the front badge.
REBUILDING
REBUILDING OPERATION FOR PART

CONCERNED
B32
a Refit the front badge.
48A-4
Bonnet: Adjustment 48A
ADJUSTMENT VALUES
a For information on the adjustment values for the L38
bonnet, (see Vehicle panel gaps: Adjustment val-
ue) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are two options for adjusting the bonnet:
- by means of the bonnet bolts,
- by means of the bonnet hinge bolts.
The bonnet striker plate must be adjusted in addition
to the bonnet adjustment.
B32
144518
a Observe the adjustment sequence (1) , (2) and (3) .
137572
a Observe the adjustment sequence (1) , (2) and (3) .
48A-5
I - ADJUSTMENT BY MEANS OF THE BONNET
BOLTS
109496
a Symbols A, B, C and D show the adjustment op-
tions. 137603
The black dot in the centre represents the body of
a Undo the bolts (1) .
the bolt.
The grey section represents the component to be a Adjust the bonnet panel gaps.
adjusted.
The white section represents the adjustment area.
II - ADJUSTMENT BY MEANS OF THE BONNET
HINGE BOLTS
137602
a Loosen the bonnet hinge bolts (3) .
a Adjust the bonnet panel gaps.
48A-6
III - BONNET STRIKER PLATE ADJUSTMENT
137601
Note:
When adjusting the bonnet striker plate, it is
imperative to remove the striker plate and fill in
the paintwork to protect the bonnet from corro-
sion.
a Remove:
- the bonnet striker plate bolts,
a Fill in the paintwork.
a Refit:
- the striker plate,
- the bolts.
a Adjust the bonnet striker plate with the bonnet lock.
48A-7
Luggage compartment lid: Removal - Refitting 48A
L38
2 - REMOVAL OPERATION
Tightening torquesm
boot lid hinge bolts 40 N.m
boot lid bolts 40 N.m
This operation can be carried out in two ways:

- removal without the hinges: this method is mainly
used if the boot lid is being replaced.
- removal with the hinges: this method is mainly used
when replacing the body and recovering the boot lid.
I - REMOVAL - REFITTING WITH THE HINGES
1 - REMOVAL PREPARATION OPERATION

a Disconnect the battery (see Battery: Removal - Re-
a Remove the boot lid trim (see Luggage compart-
ment lid trim: Removal - Refitting) (73A, Non-side 144523
opening element trim). a Remove the rear parcel shelf trim (see Rear parcel
shelf trim: Removal - Refitting) (71A, Body inter-
a Disconnect the following connectors:
nal trim).
- the boot lid lock,
a Remove:
- the boot lid release control,
- the bolts (1) ,
- the boot lid lights,
- the boot lid (this operation requires two people).
- the number plate light.
a Remove: 3 - REFITTING OPERATION
- the wiring of the boot lid, a Refit:
- the boot lid mechanism (see Luggage compart- - the boot lid (this operation requires two people),
ment lid mechanisms: Removal - Refitting)
- the bolts (1) .
(52A, Non-side opening element mechanisms),
- the rear parcel shelf trim (see Rear parcel shelf
48A, Non-side opening elements, Luggage com-
trim: Removal - Refitting) (71A, Body internal
partment lid: Adjustment, page 48A-11) .
trim).
a Torque tighten the boot lid hinge bolts (40 N.m).
4 - FINAL OPERATION
a Proceed in the reverse order to removal.
48A-8
Luggage compartment lid: Removal - Refitting 48A
L38
II - REMOVAL - REFITTING WITHOUT THE HINGES a Adjust the opening clearances and flush fitting (see
48A, Non-side opening elements, Luggage com-
partment lid: Adjustment, page 48A-11) .
a Torque tighten the boot lid bolts (40 N.m).
4 - FINAL OPERATION
a Remove:
a Proceed in the reverse order to removal.
- the hinge trims,
- the boot lid trim (see Luggage compartment lid
trim: Removal - Refitting) (73A, Non-side open-
ing element trim).
a Disconnect the following connectors:
- the boot lid lock,
- the boot lid release control,
- the boot lid lights,
- the number plate light.
a Remove the boot lid wiring.
2 - REMOVAL OPERATION
144524
a Remove:
- the bolts (2) ,
- the boot lid (this operation requires two people).
3 - REFITTING OPERATION
a Refit:
- the boot lid (this operation requires two people),
- the bolts (2) .
48A-9
Luggage compartment lid: Stripping - Rebuilding 48A
L38
Described below is a special sequence of operations REBUILDING
for boot lid replacement.
a Refit:
- the closing end stops,
Note:
- the wiring of the boot lid,
Stripping operations can be carried out on the vehi-
- the boot lid strip (see Rear opening element strip:
cle before the boot lid is removed.
Removal - Refitting) (55A, Exterior protection),
- the boot lid lights (see Rear opening element
STRIPPING light: Removal - Refitting) (81A, Rear lighting),
- the number plate light (see Number plate light:
a Remove:
Removal - Refitting) (81A, Rear lighting),
- the boot lid side trims, - the boot lid release control (see Luggage com-
- the boot lid trim (see Luggage compartment lid partment lid opening control: Removal - Refit-
trim: Removal - Refitting) (73A, Non-side open- t i n g ) (52A, Non-side opening element
ing elements trim), mechanisms),
- the boot lid lock (see Luggage compartment lid
- the badge (see Rear badges: Removal - Refit-
lock: Removal - Refitting) (52A, Non-side open-
ting) (56A, Exterior equipment),
ing element mechanisms),
- the boot lid lock (see Luggage compartment lid - the badge (see Rear badges: Removal - Refit-
lock: Removal - Refitting) (52A, Non-side open- ting) (56A, Exterior equipment),
ing element mechanisms),
- the boot lid trim (see Luggage compartment lid
- the boot lid release control (see Luggage com- trim: Removal - Refitting) (73A, Non-side open-
partment lid opening control: Removal - Refit- ing elements trim),
ting) (52A, Non-side opening element
mechanisms), - the boot lid side trims.
- the number plate light (see Number plate light:

Removal - Refitting) (81A, Rear lighting),
- the boot lid lights (see Rear opening element

light: Removal - Refitting) (81A, Rear lighting),
- the boot lid strip (see Rear opening element strip:

Removal - Refitting) (55A, Exterior protection).
144478
a Remove:
- the wiring (1) of the boot lid,
- the closing end stops (2) .
48A-10
Luggage compartment lid: Adjustment 48A
L38
ADJUSTMENT VALUES
a For information on the boot lid adjustment values,
ADJUSTMENT
a The boot lid can be adjusted in three ways:
- using the boot lid bolts,
- using the hinge bolts on the rear parcel shelf (this
operation requires the rear parcel shelf trim to be
removed),
- using the boot lid striker plate (this operation re-
quires the rear end panel lining to be removed).
109496
a
Note:
options.
of the bolt.
adjusted.
area.
144519
a Observe the adjustment sequence (1) , (2) , (3) and
(4) .
48A-11
L38
I - ADJUSTMENT USING THE BOOT LID BOLTS
144521
144522 a Undo the hinge bolts (2) on each side of the vehicle.
a Loosen the boot lid bolts (1) on each side of the ve-
a Adjust the boot lid edge panel gaps.
hicle.
a Tighten the hinge bolts on each side of the vehicle.
a Adjust the height clearances of boot lid zones (1) ,
(2) and (3) . a Refit the rear parcel shelf trim (see Rear parcel
shelf trim: Removal - Refitting) (73A, Non-side
a Tighten the boot lid bolts (1) .
opening elements trim).
II - ADJUSTMENT USING THE HINGE BOLTS ON

III - ADJUSTMENT USING THE BOOT LID STRIKER
THE REAR PARCEL SHELF
PLATE
a Remove the rear parcel shelf trim (see Rear parcel
a Remove the rear end panel lining (see Rear end
shelf trim: Removal - Refitting) (73A, Non-side
panel lining: Removal - Refitting) (71A, Body in-
opening elements trim).
ternal trim).
48A-12
L38
144520
a Undo the boot lid striker plate bolts (3) .
a Adjust the boot lid striker plate with the boot lid lock.
a Tighten the bolts of the boot lid striker plate.
a Refit the rear end panel lining (see Rear end panel
lining: Removal - Refitting) (71A, Body internal
trim).
48A-13
Tailgate: Removal - Refitting 48A
B32
This operation can be carried out in two ways: 2 - OPERATION FOR REMOVAL OF PART
CONCERNED
- removal without the hinges: this method is mainly
used if the tailgate is being replaced.
- removal with the hinges: this method is mainly used
when replacing the body and recovering the tailgate.
I - REMOVAL - REFITTING WITHOUT THE HINGES

a Remove the tailgate trim (see Tailgate trim: Re-
moval - Refitting) (73A, Non-side opening ele-
ments trim).
a Disconnect the following connectors :
- the rear screen wiper motor,
- the tailgate lock,
- the tailgate opening control,
137615
- the heated rear screen,
a Remove:
- the high level brake light.
- the bolts (1) ,
- the aerials,
- the tailgate (this operation requires two people).
- the tailgate lights.
a Remove:
- the tailgate wiring, CONCERNED
- the tailgate washer jet tube, a Refit:
- the tailgate struts (see Tailgate strut: Removal - - the tailgate (this operation requires two people),
Refitting) (52A, Non-side opening element mecha-
nisms). - the bolts (1) .
4 - FINAL OPERATION
a Refit:
- the tailgate struts (see Tailgate strut: Removal -
nisms),
- the tailgate washer jet tube,
- the tailgate wiring.
a Connect the connectors of:
- the aerials,
- the heated rear screen.
48A-14
B32
a Refit the tailgate trim (see Tailgate trim: Removal - 2 - OPERATION FOR REMOVAL OF PART
Refitting) (73A, Non-side opening elements trim). CONCERNED
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
48A, Non-side opening elements, Tailgate: Ad-
II - REMOVAL - REFITTING WITH THE HINGES

a Remove the tailgate trim (see Tailgate trim: Re-
moval - Refitting) (73A, Non-side opening ele-
ments trim).
a Disconnect the following connectors :
137614
- the tailgate opening control, a Remove:
- the heated rear screen, - the nuts (2) ,
- the high level brake light. - the tailgate (this operation requires two people).
- the aerials,
- the tailgate lights. 3 - OPERATION FOR REFITTING PART
CONCERNED
a Remove:
a Refit:
- the tailgate wiring,
- the tailgate (this operation requires two people),
- the nuts (2) .
- the rear section of the headlining (see Headlining:
Removal - Refitting) (71A, Body internal trim), a If necessary adjust the tailgate edge clearances
(see 48A, Non-side opening elements, Tailgate:
- the tailgate struts (see Tailgate strut: Removal - Adjustment, page 48A-19) .
nisms).
4 - FINAL OPERATION
a Refit:
- the tailgate struts (see Tailgate strut: Removal -
nisms),
- the tailgate wiring.
a Connect the connectors of:
- the aerials,
48A-15
B32
- the heated rear screen.
a Refit the tailgate trim (see Tailgate trim: Removal -
Refitting) (73A, Non-side opening elements trim).
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
a Adjust the clearances and flush fitting (see 48A,
Non-side opening elements, Tailgate: Adjust-
ment, page 48A-19) .
48A-16
Tailgate: Stripping - Rebuilding 48A
B32
Special tooling required
Car. 1363 Set of trim removal levers.
Note:
Described below is a special sequence of opera-
tions for tailgate replacement.
The procedure described below applies to the tail-
gate on the vehicle.
STRIPPING
142267
STRIPPING OPERATION FOR PART CONCERNED

a Remove:
- the rear badge (see Rear badges: Removal - Re-
fitting) (56A, Exterior accessories),
- the tailgate trim (see Tailgate trim: Removal - Re-
fitting) (73A, Non-side opening elements trim),
- the tailgate lock (see Tailgate lock: Removal - Re-
fitting) (52A, Non-side opening element mecha-
nisms).
141817
a Remove:
- the tailgate wiring (5) ,
- the tailgate stops (6) .
a Remove:
- the rear screen wiper arm (see Rear screen wiper

arm: Removal - Refitting) (85A, Washing - Wip-
ing),
- the rear screen wiper motor (see Rear screen wip-

er motor: Removal - Refitting) (85A, Washing -
Wiping),
- the tailgate opening switch (see Tailgate opening

switch: Removal - Refitting) (87C, Opening ele-
ment management),
- the high level brake light (see 3rd brake light: Re-
moval - Refitting) (81A, Rear lighting),
48A-17
Tailgate: Stripping - Rebuilding 48A
B32
- the rear screen (see Rear screen: Removal - Re- - the tailgate trim (see Tailgate trim: Removal - Re-
fitting) (54A, Windows). fitting) (73A, Non-side opening elements trim),
a Remove the rear opening element lights (see Rear - the rear badge (see Rear badges: Removal - Re-
opening element light: Removal - Refitting) (81A, fitting) (56A, Exterior accessories).
Rear lighting).
a Remove:
- the clips using the tool (Car. 1363),
- the blanking covers.
REBUILDING
I - PREPARATION FOR REBUILDING

a parts always to be replaced: parts included in
the rear opening element kit (40,10,10,02).
II - REBUILDING OPERATION FOR PART

CONCERNED
a Refit:
- the blanking covers,
- the clips.
a Refit the rear opening element lights (see Rear
opening element light: Removal - Refitting) (81A,
Rear lighting).
a Refit:
- the rear screen (see Rear screen: Removal - Re-
fitting) (54A, Windows),
- the high level brake light (see 3rd brake light: Re-
moval - Refitting) (81A, Rear lighting),
- the tailgate opening switch (see Tailgate opening
switch: Removal - Refitting) (87C, Opening ele-
ment management),
- the tailgate lock (see Tailgate lock: Removal - Re-
fitting) (52A, Non-side opening element mecha-
nisms),
- the covers (4) ,
- the tailgate stops (3) ,
- the tailgate stops (2) ,
- the tailgate wiring (1) .
a Refit:
- the rear screen wiper motor (see Rear screen wip-
er motor: Removal - Refitting) (85A, Washing -
Wiping),
- the rear screen wiper arm (see Rear screen wiper
arm: Removal - Refitting) (85A, Washing - Wip-
ing),
48A-18
Tailgate: Adjustment 48A
B32
ADJUSTMENT VALUES
a For information on the tailgate adjustment values,
ADJUSTMENT
a There are three options for adjusting the tailgate:
- using the tailgate bolts,
- using the tailgate hinge nuts: operation in addition
to removal of the headlining,
- using the tailgate striker plate.
109496
a
Note:
options.
of the bolt.
adjusted.
area.
137573
a Observe the adjustment sequence.
48A-19
Tailgate: Adjustment 48A
B32
I - ADJUSTMENT USING THE TAILGATE BOLTS a Adjust the tailgate edge clearances.
a Refit the headlining (see Headlining: Removal -
Refitting) (71A, Body internal trim).
III - ADJUSTMENT USING THE TAILGATE STRIKER

PLATE
a Remove the rear end panel trim (see Rear end pan-
el lining: Removal - Refitting) (71A, Body internal
trim).
137617
a Undo the tailgate bolts (7) on each side of the vehi-

cle.
a Adjust the height clearances of tailgate zones (1) ,

(2) and (3) .
II - ADJUSTMENT USING THE HINGE NUTS
a Partially remove the rear section of the headlining 137618

(see Headlining: Removal - Refitting) (71A, Body a Adjust the tailgate striker plate with the tailgate lock.
internal trim).
a Refit the rear end panel trim (see Rear end panel
lining: Removal - Refitting) (71A, Body internal
trim).
137616
a Undo the hinge nut (9) on both sides of the vehicle.
48A-20

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GENERAL INFORMATION

Vehicle on repair bench: Description 40A

1 - Front sub-frame in place Note:

II - SECONDARY FRONT TRIM-SETTING

The jig covers the front subframe rear bolt (A) .

Use this situation for a rear impact or a light frontal im-

2 - Front mechanical components removed

The bracket rests under the subframe mounting unit

1 - Rear mechanical components in place

IV - SECONDARY REAR TRIM-SETTING

2 - Rear mechanical components removed

Description X (mm) Y (mm) Z (mm) Diameter (mm) Angle

(A) Front subframe rear mounting 301 -305 6.8 M14

(B1) Rear axle mounting without 2040 -635 116 M14

(B1) Rear axle mounting with 2040 -635 111 M14

(B2) Rear axle mounting without 2131 -732 116 M14

(B2) Rear axle mounting with 2131 -732 111 M14

(B3) Rear axle mounting without 2169 -563 116 M14

(B3) Rear axle mounting with 2169 -563 111 M14

(C) Front subframe front mounting 152 -489 258 M12

(C) Front subframe front mounting 152 -489 199 M12

(F) Front shock absorber upper -5.7 -591.3 672.5 Ø47

(F1) Front shock absorber upper -62.6 -537.8 662.1 16.2x6.2

(F2) Front shock absorber upper -62.6 -645.4 666.2 16.2x6.2

(F3) Front shock absorber upper 70.2 -592.1 650.7 16.2x6.2

(P1) Engine mounting -179 512 475.4 M10

(P2) Engine mounting -334 480 475.4 M10

(R) Additional mounting (tie rod) -344 544 475.1 M10

Description X (mm) Y (mm) Z (mm) Diameter (mm) Angle

(A) Front subframe rear mounting 301 -305 6.8 M14

(B1) Rear axle mounting without 2100 -635 116 M14

(B1) Rear axle mounting with 2100 -635 111 M14

(B2) Rear axle mounting without 2191 -732 116 M14

(B2) Rear axle mounting with 2191 -732 111 M14

(B3) Rear axle mounting without 2229 -563 116 M14

(B3) Rear axle mounting with 2229 -563 111 M14

(C) Front subframe front mounting 152 -489 258 M12

(C) Front subframe front mounting 152 -489 199 M12

(F) Front shock absorber upper -5.7 -591.3 672.5 Ø47

(F1) Front shock absorber upper -62.6 -537.8 662.1 16.2x6.2

(F2) Front shock absorber upper -62.6 -645.4 666.2 16.2x6.2

(F3) Front shock absorber upper 70.2 -592.1 650.7 16.2x6.2

(P1) Engine mounting -179 512 475.4 M10

(P2) Engine mounting -334 480 475.4 M10

(R) Additional mounting (tie rod) -344 544 475.1 M10

No. Description Classification Type Thickness (mm)

(9) Connecting bracket THLE 1.8

No. Description Classification Type Thickness (mm)

No. Description Classification Type Thickness (mm)

No. Description Classification Type Thickness (mm)

No. Description Classification Type Thickness (mm)

No. Description Classification Type Thickness (mm)

(7) Bonnet (see 48A, Non-side opening elements, Bonnet: Removal -

(13) Tailgate (see 48A, Non-side opening elements, Tailgate: Removal -

No. Description Classification Type Thickness (mm)

(7) Bonnet (see 48A, Non-side opening elements, Bonnet: Removal -

- (1) Front wheel arch

1 - Front shock absorber upper mounting

- the front half-unit. - the radiator cross member support.

B32 - the rear side member,

9 - Rear impact cross member mountings

It is to be used when replacing:

No. Description Type Thick-

(2) A-pillar lining Mild 1