Sheet metal work

GENERAL LOWER STRUCTURE UPPER SIDE STRUCTURE UPPER REAR STRUCTURE TOP OF BODY SIDE OPENING ELEMENTS NON-SIDE OPENING ELEMENTS

KA0X
77 11 204 192
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

MARCH 1999
All copyrights reserved by Renault.

Edition Anglaise

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

Renault 1999

EXPLODED VIEW

DI4017R

Sheet metal work

Contents
Page Page

40 GENERAL
Dimensions Engine and equipment Identification Using symbols Key to symbols Description of parts (exploded) Opening clearances 40-1 40-2 40-2 40-3 40-5 40-6 40-7

44 UPPER REAR STRUCTURE

A B C D E F G H Rear wing panel Rear lights mounting Upper side drip moulding Rear pillar reinforcement Rear inner wheel arch Rear quarter panel lining assembly Outer wheel arch Rear end panel 44-1 44-10 44-12 44-15 44-20 44-21 44-27 44-31

41 LOWER STRUCTURE
A B C D E F G Absorber support mounting Rear floor base Rear floor base support Rear floor base front stiffener Rear end pillar lower reinforcement Rear end cross member assembly Rear floor unit 41-1 41-2 41-5 41-7 41-8 41-11 41-14

45 TOP OF BODY
A B C D Roof Roof acoustic cross member Roof bow Roof rear cross member 45-1 45-6 45-8 45-10

47 SIDE OPENING ELEMENTS

A Rear door panel 47-1

43 UPPER SIDE STRUCTURE

A Top of body 43-1

48 NON-SIDE OPENING ELEMENTS

A Tailgate 48-1

GENERAL Dimensions
Dimensions in metres

40

15309R

* Unladen.

40-1

GENERAL Engine and equipment

40
Idle speed (rpm) Nonadjustable Nonadjustable Nonadjustable 82550 Fuel type Unleaded 95 or 98 (1) Unleaded 95 or 98 (1) Unleaded 95 or 98 (1) Diesel

Engine Vehicle type Version Type Ratio Injection Capacity (cm 3) 1390 1390 1598 1870

KA0M KA0V KA0W KA0D KA04 KA0B KA0J VA0J KA05 VA05 KA0N VA0N KA01 VA01

1.4 l 1.4 l 16 V 1.6 l 16 V 1.9 l D

E7J K4J K4M F8Q

9.5/1 10/1 10/1 21.5/1

Multipoint Multipoint Multipoint Indirect

1.9 l Dti

F9Q Turbo

18.3/1

Direct

1870

85050 Nonadjustable

Diesel

(1) If necessary, unleaded fuel with an octane rating of 91 may be used.

Identification

Vehicle

Rim

Tyres

Tyre inflation pressure cold (bar) (1) Front Rear 2.0 2.0 2.0 2.0

KA0M/KA0V KA0W/KA0D KA04/KA0B KA0J/VA0J KA0N/VA0N KA05/VA05 KA01/VA01

5.5 J 14 6.0 J 15 6.0 J 15 6.0 J 15

175/70 R 14 185/60 R 15 175/70 R 14 185/60 R 15

2.2 2.2 2.2 2.2

(1) Fully laden and motorway use.

Tightening torque for wheel nuts : 9 daN.m Rim run-out: 1.2 mm

40-2

GENERAL Using symbols

40
The part in black is the one which will be removed in the operation

The following indications are found in the section diagrams :

and 7 the list on the introduction page

are the part numbers corresponding to

e = 1 + 1

are the thicknesses (in mm) of the panels affected by the spot weld

11644R1

This arrow on the diagram designates the access point for the unpicking of spot welds (see specific cases)

The above diagram shows parts on the vehicle for which a section of the panel butt welding joint is shown by the diagrams which follow.

It also indicates the logical sequence of operations in the symbols which follow each diagram.

This dashed line shows the centre line of the sections The point shows the exact position of the weld join This letter designates the drawing

Example : place of operation and logical sequence

F - G - corresponding to the section (It is giH - I - J ven in one of the upper corners of
each drawing ) spot welding weldable mastic 7 unpicking with grinder

CAA11538R8

e = 1+1

40-3

GENERAL Using symbols

SPECIFIC CASES

40

Under diagram I site of operation and order of operations

1st operation 2 1 chisel the edge

unpicking with grinder

apply weld fillet

2nd operation

CAA11537-1R6

In this example, there is no direct access for removing part 1. The spot welds should be unpicked through part 2, which should be kept.

I
2 1

10354R

In this particular case, the arrow indicates that the joint is made by arc welding (MIG).

E
CAQ11697-1R5

This arrow indicates that it is necessary to cut the part it crosses before accessing the joint.

The references which follow indicate different operations : unpicking

10349R

welding

In this example, the joint is made by bonding.

40-4

GENERAL Key to symbols

40
Plug welding. Under MAG gas protection. Crimping of exterior door panels.

Chiselling

Grind back beads or spot welds. Straight grinding wheel with 75 mm diameter bakelite impregnated disc, thickness 1.8 to 3.2 mm. Grind back spot welds. 20 000 rpm straight grinder with 10 or 16 mm diameter spherical burr. Drill spot welds. Hardened steel bit. Speed of rotation 800 to 1 000 rpm.

Safety symbol. This means that the welding operation in question concerns one or more of the vehicles vital safety components. Body solder - lead fill. Hot air torch. Nozzle output temperature 600 min. Slipper+ 33 % tin solder + tallow. Note : to a large extent, body solder filling compensates for the heat distortion caused by welding. Application of weldable mastic. This mastic conducts electricity, applied between two panels to be spot welded, it ensures the seal between the panels and avoids corrosion of the spot welds.

Unpicking

Cleaning surfaces to be welded. 100 mm diameter fibre disc.

Cutting with a saw. Pneumatic power hacksaw. - Cutting out part by grinding off flange or grinding back remaining traces of spot weld. - Finish surface after welding. - Angle grinder equipped with a rubber pad and a 120 to 180 mm diameter fibre disc grain size P36. Unsoldering.

Application of aluminium paint. This is to be applied to the joint faces of each of the parts to be plug welded. The paint conducts electricity and is is resistant to high temperatures. It provides anti-corrosion protection around the plug welds.

MAG stitch weld Note : to obtain a good quality weld we recommend the use of a gas consisting of argon + 15 % CO2. This is considered to be an active gas (MAG).

Apply a fillet of extruded mastic from a manual or pneumatic spray gun. one or two pot mastic for crimped and butt joints. Spray on sealer spray gun. two pot anti-gravel and anticorrosion mastic.

Spot weld

40-5

GENERAL Description of parts (exploded view)

40

PRE4005

290 * 291 292 293 294 295 * 296 * 297 * 298 * 299 300 * 301 302 303

Roof Roof rear cross member Absorber support Rear end panel Lights mounting Tailgate Wing panel Top of body Rear door Rear door panel Rear end pillar lower reinforcement Rear end cross member Emergency spare wheel mounting support Rear floor base

* * *

304 305 306 307 308 309 310 311 312 313 314 315 316 317

Base support Base stiffener Sill panel Front pillar Body side, front section Rear floor unit Rear pillar reinforcement Rear quarter panel lining assembly Inner wheel arch Stretcher extension Roof cross member support Wing panel drip moulding Speaker support Roof stiffener

* Parts for which repaired areas must be electro zinc plated

40-6

GENERAL Opening clearances

40

15072R2

40-7

GENERAL Opening clearances

40
3

15348R

15344R

15342R

15345R

40-8

GENERAL Opening clearances

40

15343R

15346R

15347R

40-9

LOWER STRUCTURE Absorber support mounting

INTRODUCTION

41 A

Basic operation for a rear impact. This part is mounted by three M8 nuts on the rear end panel.
COMPOSITION OF PART FROM PARTS DEPARTMENT

Single part.

PRE4105

251a01-15362

41-1

LOWER STRUCTURE Rear floor base

This part may be replaced in two ways: A completely, as a complementary operation to the rear end cross member. by part section, as a complementary operation to the rear end pillar lower reinforcement.

41

B
0.8 0.8 1 0.7 0.7 0.8 1 0.8 0.8

PARTS CONCERNED (thickness in mm) :

The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

1 2 3 4 5 6 7 8 9

Rear floor base Rear end cross member Rear end pillar lower reinforcement Rear floor Body side lining Rear inner wheel arch Rear floor base side side-member Rear floor base intermediate stiffener Rear floor base front stiffener

COMPOSITION OF PART FROM PARTS DEPARTMENT

Single part.

PRE4106

or

41-2

LOWER STRUCTURE Rear floor base

41
1

CAA11538R3b

251b01-15363

4 1 1

CAS13033R1

CAA11536-4R1

E
5 3 2 1 1

CAR11700R6

CAF11547-2R4

41-3

LOWER STRUCTURE Rear floor base

41
1

F
1

I
1

CAA11538R3a

CAW13605-4R2

G
1

CAA11538R4

CAA11536-3R5

1 8

CAA11538-1R6

CAS13028R4

41-4

LOWER STRUCTURE Rear floor base support

INTRODUCTION

41

C
1 0.8 0.8 0.7 1.2

PARTS CONCERNED (thickness in mm) :

The replacement of this part is a complementary operation to the rear floor base. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

1 2 3 4 5

Rear floor base side side-member Rear floor base intermediate stiffener Rear floor base front stiffener Rear floor Rear side member

COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with: - rear floor base side side-member, - rear floor base intermediate stiffener, - rear floor base front stiffener.

PRE4107

41-5

LOWER STRUCTURE Rear floor base support

41
1 4 2

TOI14637-4R5

251c01-15364

3 4 5
CAT13327R3

CAA11538R5

41-6

LOWER STRUCTURE Rear floor base front stiffener

INTRODUCTION

41 D

The replacement of this part is a complementary operation to the rear floor base support. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Single part.
251d01-15364-1

A
1 2

PRE4108 CAA11538R1

PARTS CONCERNED (thickness in mm) :

1 Rear floor base front stiffener 2 Rear floor

0.8 0.7

41-7

LOWER STRUCTURE Rear end pillar lower reinforcement

INTRODUCTION

41

The replacement of this part is a complementary operation to the rear end cross member. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with welded nuts.

PRE4109

PARTS CONCERNED (thickness in mm) :

1 2 3 4 5 6 7 8

Rear end pillar lower reinforcement Rear end cross member Body side lining Rear end pillar lining Rear floor Rear side member Lights mounting Rear end pillar lining

1 0.8 0.7 1 0.7 1.2 0.7 1

41-8

LOWER STRUCTURE Rear end pillar lower reinforcement

41

8 7

CAD11545R4

251e01-15365

A
1

D
8

2
CAA11536-2R7 CAA11537R4

B
7

1 1 3
CAA11536R7 CAN11689R4

41-9

LOWER STRUCTURE Rear end pillar lower reinforcement

41

6 1

CAA11538-1R7

251e02-15366

F
2 1

5 1

CAA11537R2

CAA11538-1R7

41-10

LOWER STRUCTURE Rear end cross member assembly

INTRODUCTION

41

The replacement of this part is a complementary operation to the rear end panel. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with: - striker plate reinforcement, - central reinforcement.

PRE4110

PARTS CONCERNED (thickness in mm) :

Rear end cross member Rear end pillar lower reinforcement Rear floor base Rear floor Tailgate striker plate central reinforcement 6 Rear floor central reinforcement 1 2 3 4 5

0.8 1 0.8 0.7 1.2 0.8

41-11

LOWER STRUCTURE Rear end cross member assembly

41

C
6

1
251f01-15367

5
CAS13024-4R5

D
2 1

CAN11689R5

CAA11537-1R1a

B
1 4

E
1 6

CAA11538-1R8

CAA11536-1R2

41-12

LOWER STRUCTURE Rear end cross member assembly

41

CAA11537-1R5

251f02-15363-1

CAR11700-1R4

41-13

LOWER STRUCTURE Rear floor unit

INTRODUCTION

41 G

The replacement of this part is identical to the method described in the basic manual (M.R. 313 Section 41). Only the joints at the rear end pillar lower reinforcements are different, which are described in this document (section 41-E). The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with: - side member assemblies, - floor assembly, - cross member under the floor, - floor base assembly, - rear end cross member assembly, - rear end pillar reinforcement.

PRE4111

41-14

UPPER SIDE STRUCTURE Top of body

43 A

INTRODUCTION

The replacement of this part is a complementary operation to the replacement of the roof for a front side impact. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page) and MR 313 for the front section.
COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with welded pin.

PRE4310

or

PARTS CONCERNED (thickness in mm) :

1 2 3 4 5 6 7 8 9

Body side Rear quarter panel lining Rear pillar upper reinforcement Rear pillar lower reinforcement Stretcher lining Centre pillar reinforcement Rear corner reinforcement Rear end pillar lining Rear upper side drip moulding

0.77 0.7 1 1 1.2 1.5 1.2 1 1

43-1

UPPER SIDE STRUCTURE Top of body

43 A
2 3

B
1

253a01-15317

CAE11546-6R5

A
1

C
5 3 1

CAS13033R3 CAE11546-2R7

D
5 1

CAB11539R8

43-2

UPPER SIDE STRUCTURE Top of body

43 A

CAQ11697R1

F
2 7 1

CAT13326-1R1

8 2 7

TOW15255-3R1

43-3

UPPER SIDE STRUCTURE Top of body

43 A
9

CAB11540-1R7

253a02-15319

I
1

CAB11540-1R3

43-4

UPPER REAR STRUCTURE Rear wing panel

INTRODUCTION

44 A
0.8 0.7 1.5 1 0.7 1 0.7 1 1 1

PARTS CONCERNED (thickness in mm) :

This part may be replaced in two ways: by part section as a basic operation for a rear side impact (see diagram), completely, as a complementary operation to the roof.

The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

1 2 3 4 5 6 7 8 9 10

Wing panel Rear quarter panel lining Sill panel closure panel Rear pillar reinforcement Rear outer wheel arch Rear upper side drip moulding Lights moulding Rear end pillar lining Rear end panel Rear end pillar lower reinforcement

COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with: - striker plate reinforcement, - pin to be welded 3 x2.9, - soundproofing, - bumper mounting reinforcement assembly.

PRE4415

or

44-1

UPPER REAR STRUCTURE Rear wing panel

44 A
1

C
2

CAQ11697R6a

254a03-15385

A
1

2 4 1 1
CAE11546-8R1 CAS13033R4

B
2 4 1

CAE11546-2R1 CAE11546-6R5

44-2

UPPER REAR STRUCTURE Rear wing panel

44 A

H
1

CAB11539R6

CAS13033R3

or

G
2

CAQ11697R3

44-3

UPPER REAR STRUCTURE Rear wing panel

44 A
1

CAS13033R4

or
254a01-15368

CAN11691R7

44-4

UPPER REAR STRUCTURE Rear wing panel

44 A
1

M
5

10

CAI11550R2

254a02-15382

K
1 5

N
1 5

CAI11550R2 TOA14581R6

L
5 1

O
5 9

CAI11550R7 CAB11539R8

44-5

UPPER REAR STRUCTURE Rear wing panel

44 A

Q
1 7

CAB11540-1R1

254a05-15381

P
6

CAB11540-1R7

44-6

UPPER REAR STRUCTURE Rear wing panel

COMPLETE REPLACEMENT

44 A

(with removal of the roof)

CAS13033R1

or
254a07-15384

R
11 4 1

CAE11546-2R7

44-7

UPPER REAR STRUCTURE Rear wing panel

44 A

254a06-15387

254a04-15386

T
1

1 6

CAB11540-1R3

CAB11539R6

44-8

UPPER REAR STRUCTURE Rear wing panel

44 A

1 5 3

CAE11546-2R3

CAS13033R1

or

44-9

UPPER REAR STRUCTURE Rear lights mounting

INTRODUCTION

44

The replacement of this part is a complementary operation to the wing panel. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Single part.
254b01-15380

A
2

PRE4416 CAA11536-2R7

PARTS CONCERNED (thickness in mm) :

1 2 3 4

Lights mounting Rear upper side drip moulding Rear end pillar lining Rear end panel

0.7 1 1 1

44-10

UPPER REAR STRUCTURE Rear lights mounting

44

1 2

TOK14644-1R2

CAB11539R5

4 5 1

CAB11539R5

CAE11546-8R2

G
1 5 2 1 2

CAE11546-8R2

CAA11536-2R3

44-11

UPPER REAR STRUCTURE Upper side drip moulding

INTRODUCTION

44

The replacement of this part is a complementary operation to the rear wing panel. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).
COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with: - balancer ball joint, - parcel shelf mounting.

PRE4423

PARTS CONCERNED (thickness in mm) :

1 2 3 4

Rear upper side drip moulding Lights mounting Rear end pillar lining Rear end pillar lower reinforcement

1 0.7 1 1

44-12

UPPER REAR STRUCTURE Upper side drip moulding

44

CAJ11551-1R5

254c01-15378

1 3
CAA11536R1

1
CAV13466R1

44-13

UPPER REAR STRUCTURE Upper side drip moulding

44

3 2 1

CAE11546-8R2

254c02-15379

D
1

CAT13319-1R7

44-14

UPPER REAR STRUCTURE Rear pillar reinforcement

INTRODUCTION

44 D
1 1 0.7 0.7 0.8 1.5 1.5 1.2

PARTS CONCERNED (thickness in mm) :

The replacement of this part is a complementary operation to the rear wing panel for a rear side impact.

The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).
COMPOSITION OF PART FROM PARTS DEPARTMENT

1 2 3 4 5 6 7 8

Rear pillar lower reinforcement Rear pillar upper reinforcement Rear quarter panel lining Rear outer wheel arch Rear inner wheel arch Sill panel closure panel Seat belt mounting reinforcement Stretcher lining

Part assembled with: - upper pillar reinforcement, - mounting nuts, - lower pillar reinforcement, - acoustic plug.

PRE4417

NOTE : for this operation the upper part of the

reinforcement must be unpicked on the new part.

44-15

UPPER REAR STRUCTURE Rear pillar reinforcement

44 D

CAN11689R5

254d01-15377

C
1

A
1 2 3

CAO11694R7 CAA11536R5

D
1 3 4

CAW13602R7

44-16

UPPER REAR STRUCTURE Rear pillar reinforcement

44 D

E
4

CAN11689R3

254d02-15376

G
5 4 4

1
CAA11538R6 CAT13327R5

44-17

UPPER REAR STRUCTURE Rear pillar reinforcement

44 D

REAR PILLAR UPPER REINFORCEMENT

CAF11547-2R1

I
1 4 7
254d03-15374

CAS13024-1R4

CAN11689R5

J
4 1

CAA11536R6

44-18

UPPER REAR STRUCTURE Rear pillar reinforcement

44 D

B
8 2 1

CAJ11551R3

CAD11545-2R2

CAN11689R5

44-19

UPPER REAR STRUCTURE Rear inner wheel arch

INTRODUCTION

44

The replacement of this part is a complementary operation to the replacement of a wing panel with rear quarter panel lining or a rear floor unit. For details of the operation refer to the basic manual (M.R. 313).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Welded stud.

PRE4418

1 2

Right hand side Left hand side

44-20

UPPER REAR STRUCTURE Rear quarter panel lining assembly

INTRODUCTION

44

F
0.7 0.7 1.2 1.5 0.8 0.8 1.5 1.2 0.8 0.7 1 1

PARTS CONCERNED (thickness in mm) :

The replacement of this part is a complementary operation to a complete wing panel. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

1 2 3 4 5 6 7 8 9 10 11 12

Body side lining Rear quarter panel lining Centre pillar lining Front sill closure panel Rear sill closure panel Rear inner wheel arch Seat belt mounting reinforcement Stretcher lining Rear floor base Rear floor Rear end pillar lining Rear end pillar lower reinforcement

Part assembled with: - outer wheel arch, - seat mounting reinforcement, - connecting bracket, - rear end pillar lining assembly, - upper corner reinforcement assembly.

PRE4419

or

NOTE : to avoid replacing the part located behind

the sill panel, cut the front lower section of the lining, see section (C) in the diagram below.

44-21

UPPER REAR STRUCTURE Rear quarter panel lining assembly

44
5

B
1

CAA11536-1R2

254f01-15375

C
or 1 1

A
1 6 5
CAA11537-1R1a

CAW13602R7

D
1

TOA14581R4

44-22

UPPER REAR STRUCTURE Rear quarter panel lining assembly

44

E
1 4 5

TOD14617R4

F Ga

254f04-15371

3 1
CAA11536R2

CAQ11697-2R1a

G
1

TOA14581R3

44-23

UPPER REAR STRUCTURE Rear quarter panel lining assembly

44

254f02-15373

254f03-15372-1

H
8 1

I
11 1

CAA11537R2

TOB14593R5

11 12

CAW13603-2R8

44-24

UPPER REAR STRUCTURE Rear quarter panel lining assembly

44
6 1

K
12 1

CAT13319-1R2

CAA11538-1R2

O
6 1

9 1

CAA11538-1R4

CAQ11697R6a

P
11 2

10 1

CAA11538-1R4

CAT13319-1R2

44-25

UPPER REAR STRUCTURE Rear quarter panel lining assembly

44

Q
11 2 1

TOK14646-3R5

44-26

UPPER REAR STRUCTURE Outer wheel arch

INTRODUCTION

44 G

This part can be replaced in two ways: by part section A , complementary to the rear end pillar, by part section B , complementary to the wing panel.

The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).
COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with: - outer wheel arch, - seat mounting reinforcement, - connecting bracket, - rear end pillar lining assembly, - upper corner reinforcement assembly.

PRE4421

SECTION B : complementary to rear wing panel.

or

PARTS CONCERNED (thickness in mm) :

1 2 3 4 5 6 7

Body side lining Rear quarter panel lining Rear end pillar lining Rear floor base Rear floor Rear inner wheel arch Seat belt mounting reinforcement

0.7 0.7 1 0.8 0.7 0.8 1.5

PRE4420

SECTION A : complementary to rear end pillar

reinforcement.

44-27

UPPER REAR STRUCTURE Outer wheel arch

COMPLEMENTARY TO REAR END PILLAR REINFORCEMENT

44 G

B
2

CAA11536-3R7

C
254g01-15372

3 2

or

2 1

1
CAT13321-1R7

D
1 2
CAP11696-1R4

CAA11538-1R1

44-28

UPPER REAR STRUCTURE Outer wheel arch

44 G

E
1 4

CAA11538-1R8

5 1

CAA11538-1R7

CAA11536-2R5

44-29

UPPER REAR STRUCTURE Outer wheel arch

COMPLEMENTARY TO REAR WING PANEL

44 G

1 1

TOB14593-1R2

254g02-15370

or

C
7 1

A
1 1

CAA11536-1R1a

TOB14593-1R7

44-30

UPPER REAR STRUCTURE Rear end panel

INTRODUCTION

44 H

The replacement of this part is a basic operation for a rear impact. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

254h01-15369

Part assembled with rear end panel lower reinforcement.

or

1 3

PRE4422

TOK14644-1R1

PARTS CONCERNED (thickness in mm) :

1 2 3 4 5 6 7 8

Rear end panel Body side lining Lights mounting Rear end pillar lower reinforcement Rear end cross member Rear end panel inner reinforcement Tailgate striker plate reinforcement Rear wing panel

1 0.7 0.7 1 0.8 1 1.2 1

44-31

UPPER REAR STRUCTURE Rear end panel

44 H
5 1

B
3

CAA11536-2R8

CAB11539R7

C
4 1

F
4 6 1

CAB11539R7

CAE11546-2R8

D
4 5 1

CAE11546-2R8

44-32

UPPER REAR STRUCTURE Rear end panel

44 H

CAT13326-1R6

254h02-15383

I
5 1

G
1 2

8
CAI11550R1

CAQ11697R6

5
CAE11546-8R4

44-33

TOP OF BODY Roof

INTRODUCTION

45 A

The replacement of this part is a basic operation for a side impact or a roll-over.

COMPOSITION OF PART FROM PARTS DEPARTMENT

PRE4501R

PARTS CONCERNED (thickness in mm) :

1 2 3 4 5 6 7 8 9 10 11 12

Roof Front roof cross member Windscreen pillar lining Body side Centre pillar reinforcement Rear corner reinforcement Rear roof cross member Rear upper side drip moulding Rear quarter panel lining Stretcher lining Centre pillar lining Rear end pillar lining

0.7 0.7 1.5 0.77 1.5 1.2 0.7 1 0.7 1.2 1.2 0.9

45-1

TOP OF BODY Roof

45 A
1

2 3
CAT13326-1R8

255a01-15311

C
1 1

3 2

CAT13326-3R3

CAQ11697R8

D
1 4

TOA14580-1R6

45-2

TOP OF BODY Roof

45 A

E
1 3 4

CAP11696-2R2

F H
1 8 1 4 3 11

255a02-15312

TOP15254R2

CAA11536R5

G
1 5 3

CAP11696-2R2

45-3

TOP OF BODY Roof

45 A

12

9 6

CAW13602R2

TOP15254R1

J
7 1

M
4 9 1

CAN11689R1a

CAP11696-2R1

K
4 6 1

N
4 5 1

CAP11696-2R1

CAP11696-2R1

45-4

TOP OF BODY Roof

45 A

O
4 10 1

CAP11696-2R1

255a03-15312

A= B= C= D=

70 mm 500 mm 500 mm 300 mm

E
6 7 1
CAJ11551-1R5

15342R1

Bead C

NOTE : apply a bead of adhesive mastic (C) in

zones (B) and (D) of the basic diagram, to reinforce the roof where the roof bars are mounted.

45-5

TOP OF BODY Roof acoustic cross member

INTRODUCTION

45

The replacement of this part is a complementary operation to the replacement of the roof for a roll-over. For reasons of standardisation, the Parts Department only supplies parts for the version without sunroof.Where a sunroof is fitted originally, the roof and the centre roof cross member must be cut according to the diagram below. These cuts must also be made to fit a sunroof as an accessory.
IMPORTANT : the roof cross member has a struc-

PRE4502

tural reinforcement function. For the version with sunroof, the sunroof frame fulfils this function. When fitting a sunroof as an accessory it is recommended that only sunroofs approved by the Renault accessories department are used. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

For sunroof
PARTS CONCERNED (thickness in mm) :

1 Acoustic cross member 2 Centre pillar reinforcement

0.7 1.5

COMPOSITION OF PART FROM PARTS DEPARTMENT

Single part.

45-6

TOP OF BODY Roof acoustic cross member

LEFT HAND SIDE RIGHT HAND SIDE

45

255b01-15313

255b02-15316

B
2 1

CAA11536-3R6

CAA11536-5R6

45-7

TOP OF BODY Roof bow

INTRODUCTION

45

The replacement of this part is a complementary operation to the replacement of the roof for a roll-over. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Single part.

PRE4503

Bows (A) and (B) are mounted by rivets. Bow (C) is spot welded.

PARTS CONCERNED (thickness in mm) :

1 Roof bow 2 Rear pillar upper reinforcement 3 Roof bow support

0.7 1 1.2

45-8

TOP OF BODY Roof bow

BOWS A and B

45

255c02-15314

255c01-15315

A = rivet diameter 4.8 mm (joint with bow support)

CAA11536-3R6

45-9

TOP OF BODY Roof rear cross member

INTRODUCTION

45 D

The replacement of this part is a complementary operation to the replacement of the roof for a roll-over. The method described only contains descriptions of joints specific to the part concerned. Joints with complementary parts are not included. These are dealt with in their respective section (refer to the contents page).
COMPOSITION OF PART FROM PARTS DEPARTMENT

Single part.

PRE4504

PARTS CONCERNED (thickness in mm) :

1 Roof rear cross member 2 Rear quarter panel lining 3 Rear corner reinforcement

0.7 0.7 1.2

45-10

TOP OF BODY Roof rear cross member

45 D
3 1

CAA11538-1R2

255d01-15318

C A
1 3 1 2 3

TOD14617R4 CAT13318R2

45-11

SIDE OPENING ELEMENTS Rear door panel

INTRODUCTION

47 A

The replacement of this part is a basic operation for a side impact. This part may be partially replaced (see cut and method below).
NOTE : the original panels have MIG welded an-

chorage points. In repair, these points are not made (sections A on the diagram below).

COMPOSITION OF PART FROM PARTS DEPARTMENT

Part assembled with: - soundproofing, - stiffener.

PRE4701

or

PARTS CONCERNED (thickness in mm) :

1 Door panel 2 Door box section 3 Door frame

0.7 0.7 0.8

47-1

SIDE OPENING ELEMENTS Rear door panel

47 A

257a04-15322

257a06-15324

A
1 2

TOB14587R5

TOB14587R1

47-2

SIDE OPENING ELEMENTS Rear door panel

47 A

1 2

TOB14587R1

257a01-15320

or

B

1 2

1 3

TOB14587R1

CAB11539R4

47-3

SIDE OPENING ELEMENTS Rear door panel

47 A

E
1

CAS13033R3

47-4

SIDE OPENING ELEMENTS Rear door panel

47 A

G
1

CAS13033R3

257a03-15321

or

H
1 2

F
3 1

TOB14587R2

CAQ11697R6a

47-5

NON-SIDE OPENING ELEMENTS Tailgate

-

48 A

the headlining plugs using a screwdriver (torx 20).

PRE4803

REMOVAL

Remove the trim and disconnect the various wiring harnesses (see sections 52 and 71). Unclip the tailgate balancers at (A). Remove: - the third stop light, - the rear screen washer jet pipe, - the wiring harness,

99621R2

Remove the mounting nuts and remove the hinges (B) (two persons required for this operation).

NOTE : if the tailgate or the roof is being repla-

ced, retain the height adjustment shims located under the hinges (B). To do this, use a cutting tool to destroy the finishing seal around the shims and retain them. The hinges are welded on the tailgate, so these shims of thickness 1 mm are used to adjust the clearance between the roof and the tailgate.

99386R1

48-1

NON-SIDE OPENING ELEMENTS Tailgate

REFITTING

48 A

PROCEDURE FOR ADJUSTING THE STRIKER PLATE

99621R

11295R1

IMPORTANT

NOTE : before beginning the adjustments below,

When refitting the hinges, remember to ensure sealing between the sealing washers (under the mounting nuts) and the roof panel. To do this, use plugging mastic Part Number 77 11 170 230 (refer to Technical Note 396A). To adjust the tailgate and its lock after refitting, observe the opening clearances 4, 6 and 7 described in section 40. This adjustment must be made with the tailgate fully fitted.

slacken the lock striker plate mounting bolt (C), so there is no resistance to closing.

48-2

NON-SIDE OPENING ELEMENTS Tailgate

48 A

PRE4803R

The adjustment operation is carried out with two persons. To do this, hook the lock on the striker plate and press the tailgate against the lower stops (D) and (E). At the same time, from inside the vehicle, tighten the striker plate mounting bolt. At the end of the adjustment operation, apply a bead of paint joint mastic around the three visible faces of the adjusting shims for the hinges. Carry out an operation to paint these beads.

48-3