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EXPLODED VIEW
DI4017R
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Contents
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
40-640-7
LOWER STRUCTURE
41-1
41-2
41-5
41-741-8
41-11
41-14
PagePage
40
41
Sheet metal work
UPPER SIDE STRUCTURE43
A Absorber support mountingB Rear floor baseC Rear floor base supp ort
D Rear floor base fron t stiffenerE Rear end pillar lower reinforcementF Rear end cross mem ber assemblyG Rear floor unit
43-1A Top of body NON-SIDE OPENING ELEMENTS48
TOP OF BODY
SIDE OPENING ELEMENTS
45
47
45-1
45-6
45-845-10
A RoofB Roof acoustic cross mem ber
C Roof bowD Roof rear cross mem ber
47-1
48-1A Tailgate
A Rear door p anel
UPPER REAR STRUCTURE44
44-1
44-10
44-12
44-15
44-20
44-2144-27
44-31
A Rear wing pan elB Rear lights mou ntingC Upper side drip m ouldingD Rear pillar reinforcementE Rear inner wh eel arch
F Rear qu arter p anel lining assemblyG Outer w heel archH Rear end panel
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GENERAL
Dimensions 40
15309R
Dimensions in metres
* Unladen.
40-1
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GENERAL
Engine and equipment 40
(1) If necessary, un leaded fuel with an octane rating of 91 may be u sed.
Vehicle
typeVersion
Engine
Type Ratio InjectionCapacity
(cm3)
Idle speed
(rpm)Fuel type
KA0M
KA0V1.4 l E7J 9.5/ 1 Multipoint 1390
Non-
adjustable
Unleaded
95 or 98 (1)
KA0W
KA0D
1.4 l
16 VK4J 10/ 1 Multipoint 1390
Non-
adjustable
Unleaded
95 or 98 (1)
KA04
KA0B
1.6 l
16 VK4M 10/ 1 Multipoint 1598
Non-
adjustable
Unleaded
95 or 98 (1)
KA0J
VA0J1.9 l D F8Q 21.5/ 1 Indirect 1870 82550 Diesel
KA05
VA05
KA0N
VA0N
KA01
VA01
1.9 l
Dti
F9Q
Turbo18.3/ 1 Direct 1870
85050
Non-
adjustable
Diesel
Vehicle Rim Tyres
Tyre inflation pressure -
cold (bar) (1)
Front Rear
KA0M/ KA0V
KA0W/ KA0D5.5 J 14 175/ 70 R 14 2.2 2.0
KA04/ KA0B 6.0 J 15 185/ 60 R 15 2.2 2.0
KA0J/ VA0J 6.0 J 15 175/ 70 R 14 2.2 2.0
KA0N/ VA0N
KA05/ VA05
KA01/ VA01
6.0 J 15 185/ 60 R 15 2.2 2.0
(1) Fully laden and m otorway use.
Tightening torque for wheel nuts : 9 daN.m
Rim ru n-out: 1.2 mm
Identification
40-2
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GENERAL
Using symbols 40
11644R1
The above diagram show s parts on the vehicle for
wh ich a section of the panel butt w elding joint is
shown by the diagram s which follow.
This dashed line show s the centre line
of the sections
The point show s the exact position of
the w eld join
This letter d esignates the d rawing
corresponding to the section (It is gi-
ven in one of the up per corners of
each drawing )
F - G -H - I - J
CAA11538R8
G
1
e = 1+1
7
The following ind ications are found in th e section
diagrams :
The part in black is the one wh ich w illbe removed in th e operation
are the part nu mbers correspond ing to
the list on the introduction page1 and 7
e = 1 + 1are the th icknesses (in mm) of the
pan els affected by the spot weld
This arrow on the d iagram designatesthe access point for the u np icking of
spot weld s (see specific cases)
It also indicates the logical sequen ce of operations
in the symbols wh ich follow each diagram.
place of operation and logical sequen ce
spot welding
weldable m astic
unpicking with grinder
Example :
40-3
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GENERAL
Using symbols 40
The references which follow indicate d ifferentoperations :
unpicking
welding
SPECIFIC CASES
CAA11537-1R6
J
12
In this examp le, there is no d irect access for rem o-
ving part 1. The spot w elds should be u npicked
through part 2, which should be kept.
CAQ11697-1R5
I12
This arrow ind icates that it is necessary
to cut th e part it crosses before acces-
sing the joint.
Under diagram I
unpicking
with grinder
app ly weld fil-
let
1st opera-
tion
site of operation and order of operations
10354R
D
In this particular case, the arrow ind icates that
the joint is made by arc welding (MIG).
10349R
E
In this examp le, the joint is
made by bonding.
chisel the ed ge 2nd opera-
tion
40-4
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GENERAL
Key to symbols 40
- Cutting out part by grinding off flange
or grind ing 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.
Chiselling
Grind back beads or spot w elds.Straight grinding w heel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm .
Grind back spot welds.
20 000 rp m straight gr inder with 10 or 16
mm d iameter spherical burr.
Drill spot welds.
Hard ened steel bit. Speed of rotation 800
to 1 000 rpm .
Unpicking
Cleaning sur faces to be welded.
100 mm d iameter fibre d isc.
Cutting with a saw.
Pneum atic pow er hacksaw.
Unsoldering.
Plug welding.
Und er MAG gas protection.
Crimping of exterior d oor p anels.
Safety sym bol.
This means that the welding operation
in question concerns one or more of the
vehicles vital safety compon ents.
Body solder - lead fill.
Hot air torch.
Nozzle outpu t temperature 600 min.
Slipper+ 33 % tin solder + ta llow.Note : to a large extent, body solder
filling comp ensates for the heat
distortion caused by welding.
App lication of weldable mastic.
This mastic conducts electricity, app lied
between two p anels to be spot welded,
it ensures the seal between the pan els
and avoids corrosion of the spot w elds.
App lication of aluminium paint.
This is to be ap plied to the joint faces of
each of the par ts to be plug welded .
The paint cond ucts electricity and is is
resistant to high temperatu res. It
provides anti-corrosion protection
around the plug welds.
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
sp ray gu n.
two pot anti-gravel and anti-
corrosion mastic.
MAG stitch weld
Note : to obtain a good qu ality weld w e
recomm end the u se of a gas consisting
of argon + 15 % CO2. This is
considered to be an active gas (MAG).
Spot w eld
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GENERAL
Description of parts (exploded view) 40
PRE4005
290 Roof
* 291 Roof rear cross mem ber
292 Absorber su p por t
293 Rear en d p an el
294 Ligh ts m ou ntin g
295 Tailgate
* 296 Wing panel
* 297 Top of body
* 298 Rear door
* 299 Rear door panel
300 Rear end pillar lower reinforcement
* 301 Rear en d cross m em ber
302 Emergency spare wheel mounting sup-
port
303 Rear floor base
* Parts for wh ich rep aired areas mu st be electro zinc plated
304 Base su pp ort
305 Base stiffener
* 306 Sill panel
* 307 Front pillar
* 308 Body side, fron t section
309 Rear floor u nit
310 Rear pillar reinforcement
* 311 Rear quarter panel lin ing assembly
312 In ner wh eel ar ch
313 Stretcher extension
314 Roof cross member support
* 315 Wing p an el d rip mou ld in g
316 Sp eaker su p por t
317 Roof st iffener
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GENERAL
Opening clearances 40
15072R2
40-7
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GENERAL
Opening clearances 40
15344R
1
15348R
15342R 15345R
2
3
4
40-8
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GENERAL
Opening clearances 40
15346R
5
15343R
15347R
6
7
40-9
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LOWER STRUCTURE
Absorber support mounting
INTRODUCTION
Basic operation for a rear imp act.
This part is moun ted by three M8 nuts on the rearend p anel.
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Single par t.
251a01-15362
41 A
PRE4105
41-1
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LOWER STRUCTURE
Rear floor base
This part m ay be replaced in tw o ways:
A comp letely, as a complementary operation to
the rear end cross member.
B by p art section, as a comp lementary operation
to the rear end pillar lower reinforcement.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTSDEPARTMENT
Single par t.
PRE4106
41 B
or
PARTS CONCERNED (thickness in mm) :
1 Rear floor base 0.82 Rear end cross member 0.8
3 Rear end pillar lower reinforcement 14 Rear floor 0.75 Body side lining 0.76 Rear inner wheel arch 0.87 Rear floor base side side-member 18 Rear floor base intermediate st iffener 0.89 Rear floor base front stiffener 0.8
41-2
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LOWER STRUCTURE
Rear floor base
251b01-15363
41 B
A
CAS13033R1
1 1
C
CAA11538R3b
3
1
B
CAR11700R6
2 1
D
CAA11536-4R1
14
E
CAF11547-2R4
1
3
5
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LOWER STRUCTURE
Rear floor base 41 B
F
CAA11538R3a
1
5
G
CAA11538R4
1
6
H
CAA11538-1R6
1
8
I
CAW13605-4R2
1 1
8
J
CAA11536-3R5
1 1
K
CAS13028R4
1 19
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LOWER STRUCTURE
Rear floor base support
PRE4107
41 C
INTRODUCTION
The replacement of this par t is a complementary
operation to the rear floor base.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:- rear floor base side side-member,
- rear floor base intermediate stiffener,
- rear floor base front st iffener.
PARTS CONCERNED (thickness in mm) :
1 Rear floor base side side-member 12 Rear floor base intermediate st iffener 0.8
3 Rear floor base front stiffener 0.84 Rear floor 0.75 Rear side member 1.2
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LOWER STRUCTURE
Rear floor base support
251c01-15364
41 C
A
CAT13327R3
1
4
5
B
TOI14637-4R5
1
24
C
CAA11538R5
13
41-6
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LOWER STRUCTURE
Rear floor base front stiffener
PRE4108
41 D
INTRODUCTION
The replacement of this par t is a complementary
operation to the rear floor base supp ort.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Single par t.
PARTS CONCERNED (thickness in mm) :
1 Rear floor base front stiffener 0.82 Rear floor 0.7
251d01-15364-1
A
CAA11538R1
12
41-7
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LOWER STRUCTURE
Rear end pillar lower reinforcement
PRE4109
41 E
INTRODUCTION
The replacement of this par t is a complementary
operation to the rear end cross member.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dealt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled with welded n uts.
PARTS CONCERNED (thickness in mm) :
1 Rear end pillar low er reinforcement 1
2 Rear end cross member 0.83 Body side lining 0.74 Rear end pillar lining 15 Rear floor 0.76 Rear side member 1.27 Lights mounting 0.78 Rear end pillar lining 1
41-8
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LOWER STRUCTURE
Rear end pillar lower reinforcement
251e01-15365
41 E
A
CAA11537R4
1
2
B
CAN11689R4
1
7
C
CAD11545R4
1
7
8
D
CAA11536-2R7
1
8
E
CAA11536R7
1
3
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LOWER STRUCTURE
Rear end cross member assembly
PRE4110
41 F
INTRODUCTION
The replacement of this par t is a complementary
operation to the rear end p anel.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dealt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:- st riker plate reinforcement,
- cen tral rein forcement.
PARTS CONCERNED (thickness in mm) :
1 Rear end cross member 0.82 Rear end pillar low er reinforcement 13 Rear floor base 0.84 Rear floor 0.75 Tailgate striker p late central
reinforcement 1.2
6 Rear floor central reinforcement 0.8
41-11
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LOWER STRUCTURE
Rear end cross member assembly
251f01-15367
41 F
A
CAN11689R5
1 4
B
CAA11538-1R8
1
4
C
CAS13024-4R5
1 5
6
D
CAA11537-1R1a
12
E
CAA11536-1R2
61
41-12
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LOWER STRUCTURE
Rear end cross member assembly
251f02-15363-1
41 F
F
CAR11700-1R4
1 3
G
CAA11537-1R5
1 2
41-13
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LOWER STRUCTURE
Rear floor unit
PRE4111
41 G
INTRODUCTION
The replacement of this par t is iden tical to the me-
thod described in the basic manual (M.R. 313 -
Section 41). Only the joints at the r ear en d pillarlower reinforcements are different, which are des-
cribed in this document (section 41-E).
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dealt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTSDEPARTMENT
Part assembled w ith:
- side member assemblies,
- floor assem bly,
- cross member under the floor,
- floor base assembly ,
- rear end cross member assembly,
- rear end pillar reinforcement .
41-14
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UPPER SIDE STRUCTURE
Top of body
INTRODUCTION
The replacement of this par t is a complementary
operation to the replacement of the roof for a
front side impact.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dealt with in th eir respective section (re-
fer to the contents p age) and MR 313 for the front
section.
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled with welded pin.
43 A
PRE4310
PARTS CONCERNED (thickness in mm) :
1 Body side 0.772 Rear quarter panel lining 0.73 Rear pillar upper reinforcement 14 Rear pillar lower reinforcement 15 Stretcher lining 1.26 Centre pillar reinforcement 1.57 Rear corner reinforcement 1.28 Rear end pillar lining 1
9 Rear upper side drip moulding 1
or
43-1
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UPPER SIDE STRUCTURE
Top of body
253a01-15317
43 A
A
CAS13033R3
1
1
B
CAE11546-6R5
C
CAE11546-2R7
D
CAB11539R8
1
2
3
1
5
3
1
5
43-2
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UPPER SIDE STRUCTURE
Top of body 43 A
E
CAQ11697R1
F
CAT13326-1R1
G
TOW15255-3R1
12
12 7
1
7
2
8
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UPPER SIDE STRUCTURE
Top of body
253a02-15319
43 A
I
CAB11540-1R3
1
9
J
CAB11540-1R7
1
9
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UPPER REAR STRUCTURE
Rear wing panel
INTRODUCTION
This part m ay be replaced in tw o ways:
by part section as a basic operation for a rearside impact (see diagram),
completely, as a complementary operation to
the roof.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:
- st riker plate reinforcement,
- p in to be welded 3 x2.9,
- sou nd proofing,
- bumper mounting reinforcement assembly.
PRE4415
44 A
or
PARTS CONCERNED (thickness in mm) :
1 Wing panel 0.82 Rear quarter panel lining 0.7
3 Sill panel closure panel 1.54 Rear pillar reinforcement 15 Rear outer wheel arch 0.76 Rear upper side d rip mould ing 17 Lights mould ing 0.78 Rear end pillar lining 19 Rear end panel 1
10 Rear end pillar lower reinforcement 1
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UPPER REAR STRUCTURE
Rear wing panel
254a03-15385
44 A
A
CAS13033R4
B
CAE11546-6R5
C
CAQ11697R6a
D
CAE11546-8R1
1
1
1
2
4
2 1
1
42
E
CAE11546-2R1
1 5 2
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UPPER REAR STRUCTURE
Rear wing panel 44 A
F
CAB11539R6
G
CAQ11697R3
H
CAS13033R3
or
1 4
1
2
1
1
44-3
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UPPER REAR STRUCTURE
Rear wing panel
254a01-15368
44 A
I
CAN11691R7
J
CAS13033R4
or
1
1
5
1
44-4
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UPPER REAR STRUCTURE
Rear wing panel
254a02-15382
44 A
K
TOA14581R6
1 5
L
CAB11539R8
1
5
M
CAI11550R2
15
10
N
CAI11550R2
15
9
O
CAI11550R7
1
95
44-5
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UPPER REAR STRUCTURE
Rear wing panel
254a05-15381
44 A
P
CAB11540-1R7
1
6
Q
CAB11540-1R1
1 7
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UPPER REAR STRUCTURE
Rear wing panel
COMPLETE REPLACEMENT
(with rem oval of the roof)
254a07-15384
44 A
R
CAE11546-2R7
1
4
11
S
CAS13033R1
1 1
or
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UPPER REAR STRUCTURE
Rear wing panel
254a06-15387
44 A
T
CAB11540-1R3
1
6
254a04-15386
U
CAB11539R6
51
44-8
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UPPER REAR STRUCTURE
Rear wing panel 44 A
V
CAE11546-2R3
1
5
3
W
CAS13033R1
1 1
or
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UPPER REAR STRUCTURE
Rear lights mounting
PRE4416
44 B
INTRODUCTION
The replacement of this par t is a complementary
operation to the wing panel.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Single par t.
PARTS CONCERNED (thickness in mm) :
1 Lights mounting 0.72 Rear upper side drip moulding 1
3 Rear end pillar lining 14 Rear end panel 1
254b01-15380
A
CAA11536-2R7
1
2
44-10
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UPPER REAR STRUCTURE
Rear lights mounting 44 B
B
TOK14644-1R2
1
2
3
C
CAB11539R5
3 1
D
CAE11546-8R2
5
1
2
E
CAB11539R5
5 1
F
G
CAA11536-2R3
1
2
CAE11546-8R2
4
1
5
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UPPER REAR STRUCTURE
Upper side drip moulding 44 C
INTRODUCTION
The replacement of this par t is a complementary
operation to the rear wing panel.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dealt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:
- balancer ba ll join t,- parcel shelf mounting.
PARTS CONCERNED (thickness in mm) :
1 Rear upper side drip moulding 12 Lights mounting 0.73 Rear end pillar lining 14 Rear end pillar low er reinforcement 1
PRE4423
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UPPER REAR STRUCTURE
Upper side drip moulding
254c01-15378
44 C
A
CAA11536R1
14
B
CAJ11551-1R5
143
C
CAV13466R1
13
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UPPER REAR STRUCTURE
Upper side drip moulding
254c02-15379
44 C
D
CAT13319-1R7
1
2
E
CAE11546-8R2
3
1
2
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UPPER REAR STRUCTURE
Rear pillar reinforcement
PRE4417
44 D
INTRODUCTION
The replacement of this par t is a complementary
operation to the rear wing p anel for a rear side
impact.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:
- upper pillar reinforcement,
- mounting nuts,
- lower pillar reinforcement,
- acou stic p lu g.
NOTE : for this operation the up per p art of the
reinforcement m ust be unp icked on the new part.
PARTS CONCERNED (thickness in mm) :
1 Rear pillar lower reinforcement 12 Rear pillar upper reinforcement 1
3 Rear quarter panel lining 0.74 Rear outer wheel arch 0.75 Rear inner wheel arch 0.86 Sill panel closure panel 1.57 Seat belt mounting reinforcement 1.58 Stretcher lining 1.2
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UPPER REAR STRUCTURE
Rear pillar reinforcement
254d01-15377
44 D
A
CAA11536R5
1 2
B
CAN11689R5
1 2
C
CAO11694R7
1
3
D
CAW13602R7
1
3
4
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UPPER REAR STRUCTURE
Rear pillar reinforcement
254d02-15376
44 D
E
F
CAA11538R6
1 4
G
CAT13327R5
1
4
5
CAN11689R3
1
4
44-17
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UPPER REAR STRUCTURE
Rear pillar reinforcement
254d03-15374
44 D
H
CAF11547-2R1
1
6 4
I
CAS13024-1R4
1
4
7
J
CAA11536R6
14
REAR PILLAR UPPER REINFORCEMENT
A
CAN11689R5
2 8
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UPPER REAR STRUCTURE
Rear pillar reinforcement 44 D
B
CAJ11551R3
1
2
8
C
CAD11545-2R2
D
CAN11689R5
2 8
8 2 3
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UPPER REAR STRUCTURE
Rear inner wheel arch
1 Right hand side
2 Left hand side
INTRODUCTION
The replacement of this par t is a complementary
operation to the replacement of a wing p anel
with rear qu arter pan el lining or a rear floor unit.
For details of the operation refer to the basic ma-
nual (M.R. 313).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Welded stud.
PRE4418
44 E
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UPPER REAR STRUCTURE
Rear quarter panel lining assembly
PRE4419
44 F
INTRODUCTION
The replacement of this par t is a complementary
operation to a complete wing p anel.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:- ou ter wheel arch,
- seat mounting reinforcement,
- connecting bracket,
- rear end pillar lin ing assembly,
- upper corner reinforcement assembly.
PARTS CONCERNED (thickness in mm) :
1 Body side lining 0.72 Rear quarter panel lining 0.7
3 Centre pillar lining 1.24 Front sill closure panel 1.55 Rear sill closure panel 0.86 Rear inner wheel arch 0.87 Seat belt mounting reinforcement 1.58 Stretcher lining 1.29 Rear floor base 0.8
10 Rear floor 0.711 Rear end pillar lining 112 Rear end pillar lower reinforcement 1
or
NOTE : to avoid replacing the part located behind
the sill panel, cut the front lower section of the li-ning, see section (C) in the d iagram below.
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UPPER REAR STRUCTURE
Rear quarter panel lining assembly
254f01-15375
44 F
or
A
CAW13602R7
1
6
5
B
C
CAA11537-1R1a
11
D
TOA14581R4
1
5
CAA11536-1R2
1 5
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UPPER REAR STRUCTURE
Rear quarter panel lining assembly
254f04-15371
44 F
E
TOD14617R4
1
4
5
F
CAA11536R2
1 3
G
Ga
CAQ11697-2R1a
71 4
TOA14581R3
1
5
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UPPER REAR STRUCTURE
Rear quarter panel lining assembly
254f03-15372-1
44 F
254f02-15373
H
CAA11537R2
18
I
TOB14593R5
1
11
J
CAW13603-2R8
1
11
12
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UPPER REAR STRUCTURE
Rear quarter panel lining assembly 44 F
K
CAT13319-1R2
1
12
L
CAA11538-1R4
1
9
M
CAA11538-1R4
1
10
N
CAA11538-1R2
1
6
O
CAQ11697R6a
16
P
CAT13319-1R2
2
11
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UPPER REAR STRUCTURE
Rear quarter panel lining assembly 44 F
Q
TOK14646-3R5
1
11
2
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UPPER REAR STRUCTURE
Outer wheel arch
PRE4421
44 G
INTRODUCTION
This part can be rep laced in tw o ways:
by part section A , comp lementary to the rear
end pillar, by part section B , complementary to th e wing
panel.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:
- ou ter wheel arch,
- seat mounting reinforcement,
- connecting bracket,
- rear end pillar lin ing assembly,
- upper corner reinforcement assembly.
PRE4420
SECTION A : complementary to rear end pillar
reinforcement.
SECTION B : complementary to rear wing pan el.
PARTS CONCERNED (thickness in mm) :
1 Body side lining 0.72 Rear quarter panel lining 0.73 Rear end pillar lining 14 Rear floor base 0.85 Rear floor 0.76 Rear inner wheel arch 0.8
7 Seat belt mounting reinforcement 1.5
or
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UPPER REAR STRUCTURE
Outer wheel arch
COMPLEMENTARY TO REAR END PILLAR
REINFORCEMENT
254g01-15372
44 G
or
A
CAP11696-1R4
2
1
1
B
CAA11536-3R7
1
C
CAT13321-1R7
1
2
3
D
CAA11538-1R1
1
2
2
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UPPER REAR STRUCTURE
Outer wheel arch 44 G
E
CAA11538-1R8
1
4
F
CAA11538-1R7
1
5
G
CAA11536-2R5
11
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UPPER REAR STRUCTURE
Outer wheel arch
COMPLEMENTARY TO REAR WING PANEL
254g02-15370
44 G
or
A
TOB14593-1R7
1
1
B
TOB14593-1R2
1
1
C
CAA11536-1R1a
17
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UPPER REAR STRUCTURE
Rear end panel
PRE4422
44 H
INTRODUCTION
The replacement of this par t is a basic operation
for a rear impact.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith rear end pan el lower reinfor-cement.
PARTS CONCERNED (thickness in mm) :
1 Rear end panel 1
2 Body side lining 0.73 Lights mounting 0.74 Rear end p illar low er reinforcement 15 Rear end cross member 0.86 Rear end panel inner reinforcement 17 Tailgate str iker p late r ein forcem en t 1.28 Rear wing panel 1
254h01-15369
or
A
TOK14644-1R1
1
3
4
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UPPER REAR STRUCTURE
Rear end panel 44 H
B
CAA11536-2R8
1
3
C
CAB11539R7
D
CAE11546-2R8
1
4
1
4
5
E
CAB11539R7
1
5
F
CAE11546-2R8
1
4
6
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UPPER REAR STRUCTURE
Rear end panel
254h02-15383
44 H
G
J
CAE11546-8R4
5
17
H
CAT13326-1R6
14 5
I
CAQ11697R6
15
CAI11550R1
12
8
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TOP OF BODY
Roof
INTRODUCTION
The replacement of this par t is a basic operation
for a side impact or a roll-over.
COMPOSITION OF PART FROM PARTS
DEPARTMENT
PRE4501R
45 A
PARTS CONCERNED (thickness in mm) :
1 Roof 0.72 Front roof cross member 0.73 Windscreen pillar lining 1.54 Body side 0.775 Centre pillar reinforcement 1.56 Rear corner reinforcement 1.27 Rear roof cross member 0.78 Rear upper side drip moulding 19 Rear quarter panel lining 0.7
10 Stretcher lining 1.211 Centre pillar lining 1.2
12 Rear end pillar lining 0.9
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TOP OF BODY
Roof
255a01-15311
45 A
A
CAQ11697R8
B
CAT13326-1R8
C
CAT13326-3R3
D
TOA14580-1R6
1
2
1
2
3
3
1
4
1 4
45-2
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TOP OF BODY
Roof
255a02-15312
45 A
E
CAP11696-2R2
F
TOP15254R2
G
CAP11696-2R2
H
CAA11536R5
1 43
1 4 3 11
5 3
1 8
1
45-3
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TOP OF BODY
Roof 45 A
I
J
CAN11689R1a
K
CAP11696-2R1
L
TOP15254R1
M
N
CAW13602R2
1 6 12
17
14 6
19 6 4
CAP11696-2R1
14 9
CAP11696-2R1
14 5
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TOP OF BODY
Roof 45 A
O
P
CAJ11551-1R5
CAP11696-2R1
14 10
176
255a03-15312
15342R1
A = 70 mm
B = 500 mm
C = 500 mm
D = 300 mm
NOTE : apply a bead of adhesive mastic (C) in
zones (B) and (D) of the basic diagram, to rein-
force the roof where the roof bars are moun ted.
E
Bead C
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TOP OF BODY
Roof acoustic cross member
INTRODUCTION
The replacement of this par t is a complementary
operation to the replacement of the roof for a
roll-over.
For reasons of standard isation, the Parts
Department on ly supp lies parts for the version w i-
thou t sunroof.Where a sunroof is fitted or iginally,
the roof and the centre roof cross member m ust
be cut according to the diagram below.
These cuts m ust also be mad e to fit a sunroof as an
accessory.
IMPORTANT : the roof cross member h as a struc-
tural reinforcement function. For the version withsunroof, the sunroof frame fulfils this function.
When fitting a su nroof as an accessory it is re-
commended that only sunroofs approved by the
Renau lt accessories departm ent are used.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dea lt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Single par t.
PRE4502
45 B
PARTS CONCERNED (thickness in mm) :
1 Acoustic cross member 0.72 Centre pillar reinforcement 1.5
For sunroof
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TOP OF BODY
Roof acoustic cross member
LEFT HAND SIDE
255b01-15313
45 B
RIGHT HAND SIDE
255b02-15316
A
CAA11536-3R6
B
CAA11536-5R6
12
12
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TOP OF BODY
Roof bow
PRE4503
45 C
INTRODUCTION
The replacement of this par t is a complementary
operation to the replacement of the roof for a
roll-over.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary parts are not includ ed.
These are dealt with in th eir respective section (re-
fer to the contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Single par t.
Bows (A) and (B) are mounted by rivets.
Bow (C) is spot w elded .
PARTS CONCERNED (thickness in mm) :
1 Roof bow 0.72 Rear pillar upper reinforcement 13 Roof bow support 1.2
45-8
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TOP OF BODY
Roof bow
BOWS A and B
255c01-15315
45 C
A = rivet diameter 4.8 mm
(joint with bow supp ort)
255c02-15314
B
CAA11536-3R6
12
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TOP OF BODY
Roof rear cross member
PRE4504
45 D
INTRODUCTION
The replacement of this par t is a complementary
operation to the replacement of the roof for a
roll-over.
The method described only contains d escriptions
of joints specific to the part concerned . Joints w ith
complementary p arts are not included. These are
dealt with in their resp ective section (refer to the
contents page).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Single par t.
PARTS CONCERNED (thickness in mm) :
1 Roof rear cross member 0.72 Rear quarter panel lining 0.7
3 Rear corner reinforcement 1.2
45-10
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TOP OF BODY
Roof rear cross member
255d01-15318
45 D
A
CAT13318R2
1 3
B
CAA11538-1R2
C
TOD14617R4
1
3
1
2
3
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SIDE OPENING ELEMENTS
Rear door panel
INTRODUCTION
The replacement of this par t is a basic operation
for a side impact.
This par t may be par tially replaced (see cut and
method below).
NOTE : the original panels have MIG welded an -
chorage points. In rep air, these points are not
mad e (sections A on the d iagram below).
COMPOSITION OF PART FROM PARTS
DEPARTMENT
Part assembled w ith:- sou nd proofing,
- stiffener.
PRE4701
47 A
PARTS CONCERNED (thickness in mm) :
1 Door panel 0.72 Door box section 0.7
3 Door frame 0.8
or
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SIDE OPENING ELEMENTS
Rear door panel 47 A
257a04-15322
A
TOB14587R5
1 2
257a06-15324
A
TOB14587R1
1 2
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SIDE OPENING ELEMENTS
Rear door panel 47 A
257a01-15320
or
B
TOB14587R1
1 2
C
D
CAB11539R4
1
3
TOB14587R1
1 2
47-3
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SIDE OPENING ELEMENTS
Rear door panel 47 A
E
CAS13033R3
1
1
47-4
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SIDE OPENING ELEMENTS
Rear door panel
257a03-15321
47 A
or
F
CAQ11697R6a
G
CAS13033R3
13
1
1
H
TOB14587R2
1 2
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NON-SIDE OPENING ELEMENTS
Tailgate
REMOVAL
Remove the trim and disconnect the various wi-
ring h arnesses (see sections 52 and 71).
Remove:
- th e th ird stop ligh t,- the rear screen washer jet p ipe,
- th e w irin g h arn ess,
99386R1
48 A
PRE4803
- the headlining plugs using a screwdriver (torx
20).
99621R2
Unclip the ta ilgate balancers at (A).
Remove the mounting nu ts and remove thehinges (B) (two p ersons requ ired for this opera-
tion).
NOTE : if the tailgate or th e roof is being repla-
ced, retain the height adjustment shims located
un der th e hinges (B).
To do this, use a cut ting tool to destroy the finis-
hing seal around the shims and retain them.
The hinges are welded on the tailgate, so these
shims of thickness 1 mm are used to ad just the
clearance between the roof and the tailgate.
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NON-SIDE OPENING ELEMENTS
Tailgate
PROCEDURE FOR ADJUSTING THE STRIKER PLATEREFITTING
48 A
IMPORTANT
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 refi tting,
observe the opening clearances 4, 6 and 7 descri-
bed in section 40.
This adjustment must be made with the tailgate
fully fitted.
NOTE : before beginning the adjustments below,
slacken the lock striker plate mou nting bolt (C), so
there is no resistance to closing.
11295R199621R
48-2
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NON-SIDE OPENING ELEMENTS
Tailgate
The adjustment op eration is carried out with two
persons. To do th is, hook the lock on the striker
plate and press the tailgate against the lower
stops (D) and (E).
At the same time, from insid e the vehicle, tighten
the striker plate mou nting bolt.
At the end of the adjustment op eration, app ly a
bead of pain t joint mastic around th e three visible
faces of the ad justing sh ims for the hinges.
Carry out an op eration to paint these beads.
PRE4803R
48 A