MR338CLIO4

Sheet Metalwork
GENERAL
LOWER STRUCTURE
UPPER FRONT STRUCTURE
UPPER SIDE STRUCTURE
UPPER REAR STRUCTURE
TOP OF BODY
SIDE OPENING ELEMENTS
NON-SIDE OPENING ELEMENTS
BB0A - BB0C - BB0D - BB0E - CB0A - CB0C - CB0D - CB0E
77 11 197 393 DECEMBER 1997 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of
manufacturer in the production of the various component units and accessories Renault.
from which his vehicles are constructed."
C Renault 1997
EXPLODED VIEW
PRH4015
Sheet Metalwork
Contents
Page Page
40 GENERAL 42 UPPER FRONT STRUCTURE

Dimensions 40-1 A Front wing 42-1
Engine and equipment 40-2 B Upper front cross member 42-3
Identification 40-3 C Headlight carrier panel 42-4
Means of lifting 40-4 D Bonnet strut mounting 42-7
Towing 40-6 E Cowl side panel 42-10
Using symbols 40-7 F Upper reinforcement of cowl side
Key to symbols 40-9 panel, front section 42-14
Description of parts (exploded view) 40-10 G Upper reinforcement of cowl side
Opening clearances 40-13 panel, rear section 42-17
Collision fault finding 40-21 H Wheel arch, front section 42-19
Sub-frame dimensions 40-24 I Wheel arch 42-24
Repair bench 40-26 J Side plenum chamber 42-31
Special tooling 40-36 K Bulkhead 42-33
Part number of special tooling 40-36 L Windscreen wiper mounting plate 42-37
M Windscreen aperture lower cross
member 42-39
N Steering column lower mounting 42-42
41 LOWER STRUCTURE
A Front end lower cross member 41-1
B Complete front end 41-5 43 UPPER SIDE STRUCTURE
C Front side member, front section 41-9
D Front side member closure panel 41-16 A Front pillar 43-1
E Sub-frame front mounting 41-19 B Front pillar lining (cowl side panel) 43-7
F Front half unit 41-22 C Windscreen aperture pillar lining 43-11
G Front side cross member 41-27 D Centre pillar 43-13
H Front side member, rear section 41-31 E Centre pillar lining 43-19
I Centre floor 41-34 F Centre pillar reinforcement 43-24
J Cross member under front seat 41-40 G Body side, front section 43-31
K Rear floor raised section 41-42 H Sill panel 43-32
L Rear floor centre cross member 41-44 I Sill panel reinforcement 43-38
M Rear side member 41-47 J Sill panel closure panel 43-41
N Lashing ring 41-51 K Complete body side 43-45
O Rear floor 41-52
P Exhaust mounting unit 41-60
Q Rear floor unit 41-62
Contents
44 UPPER REAR STRUCTURE

A Rear wing panel, complete and
partial 44-1
B Upper side rain channel 44-12
C Tailgate balancing ball joint 44-14
D Outer wheel arch 44-15
E Inner wheel arch 44-17
F Body side lining 44-19
G Rear end panel 44-27
H Rear lights mounting 44-30
45 TOP OF BODY
A Roof 45-1
B Roof front cross member 45-7
C Roof centre cross member 45-8
D Roof rear cross member 45-9
E Body top 45-10
47 SIDE OPENING ELEMENTS

A Front and rear doors 47-1
B Front door panel 47-4
C Rear door panel 47-8
NON-SIDE OPENING
48 ELEMENTS
A Tailgate 48-1
B Bonnet 48-4
GENERAL
Dimensions 40
Dimensions in metres
13491R3
40-1
GENERAL
Engine and equipment 40
Engine
Gearbox type
Vehicle type Clutch type
Capacity Manual
Type
(cm 3)
B/C B0A D7F 1149 180 CP 3300
B/C B0C E7J 1390 180 CP 3300

JB1
B/C B0D K7M 1598 200 CPOV 3500
B/C B0E F8Q 1870 200 CPOV 3250
VEHICLE IDENTIFICATION
Example : BB0A
B : Bodywork type (5-door)

B : Project code
0A : Engine suffix
40-2
GENERAL
Identification 40
LOCATION OF THE VEHICLE IDENTIFICATION
PLATE
13491R2
8
A RENAULT S.A.
9
e0-00/00-0000-000-000-00
10
1 VF000000000000000
2 0000 kg
3 0000 kg 11
4 1 - 0000 kg
12
5 2 - 0000 kg
000000000000000 13
1 The vehicle type mine and the chassis number 6 Technical specifications of the vehicle
2 MTMA (maximum permitted all up weight for 7 Paint reference
the vehicle) 8 Equipment level
3 MTR (Maximum permitted total train weight - 9 Vehicle type
vehicle fully laden and towing) 10 Trim code
4 Maximum permitted weight on front axle 11 Additional equipment definition
5 Maximum permitted weight on rear axle 12 Fabrication number
13 Interior matching trim code
40-3
GENERAL
Means of lifting 40
Safety symbol (special precautions to be taken when carrying out operations).
SPECIAL TOOLING REQUIRED
Cha. 280 -02 Adaptable cross piece for trolley

jack
Cha. 408 -01
or Adaptable socket for trolley jack
Cha. 408 -02
If a trolley jack is used, appropriate axle AXLE STANDS

stands must also be used.
To place the vehicle on axle stands, they MUST be
placed :
- either under the reinforcements provided for
The vehicle MUST NOT be lifted by supporting its lifting the vehicle with the jack which forms
weight under the front suspension arms or under part of the vehicle equipment,
the rear axle assembly. - or under the points behind the reinforcements.
Rear positioning of the axle stands can be carried
Depending on the type of trolley jack, use sockets out by lifting the vehicle from the side.
Cha. 408-01 or Cha. 408-02 to position the cross
piece Cha. 280-02.
To lift at the front or rear, take the weight under

the vehicle jacking points.
LIFTING FROM THE SIDE WITH A TROLLEY JACK
Use cross piece Cha. 280-02.
Take the weight under the valance at the front

door.
Position the flange correctly in the cross member

groove.
14275-1R
85679-1G15 13491G
40-4
GENERAL
Means of lifting 40
SAFETY SYMBOL FRONT
There are several examples to consider :
1 - WHEN REMOVING COMPONENTS
Generally speaking, never use a 2-post lift if a

four post lift would be more suitable.
If this is not possible, position the lifting pads

below the body flange at the jacking points for
the jack supplied with the vehicle.
2 - SPECIAL CASE OF THE REMOVAL - REFITTING 98703S

OF THE ENGINE AND TRANSMISSION
In this specific case, the body of the vehicle MUST

be fixed to the arms of the two post lift with REAR
special pads.
98704S
These MUST be placed to the right of the jacking

points. They must be clipped into the sill panel
flange openings.
40-5
GENERAL
Towing 40
OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS
The towing points should only be used for towing the vehicle on the road. They should never be used for re-
moving the vehicle from a ditch or for any other similar breakdown operation, or to lift the vehicle, either di-
rectly or indirectly.
FRONT REAR
13565S 13646S
40-6
GENERAL
Using symbols 40
The following indications are found in the section
diagrams :
The black part is the one which will be

removed in the operation
are the part numbers corresponding to

1 and 7 the list on the introduction page
are the thicknesses (in mm) of the

e = 1 + 1 panels for electrical spot welding
This arrow on the diagram designates

the access points for the unpicking of
spot welds (see specific cases)
11644R1
The above diagram shows the part on the vehicle

for which a section of the panel butt welding joint It also indicates the logical sequence of operations
is shown by the diagrams which follow. in the symbols which follow each diagram.
This dashed line shows the centre of

the sections. Example :
place of operation and logical sequence

The point shows the exact position of
the weld join.
This letter designates the diagram

F - G - corresponding to the section (it is gi-
H - I - J ven in one of the upper corners of
each diagram).
spot welding
weldable mastic
G
unpicking with a grinder
7
CAA11538R8 e = 1+1
40-7
GENERAL
Using symbols 40
SPECIFIC CASES Under diagram I
site of operation and logical sequence

J
1 2
1st opera- unpicking apply weld

tion with grinder fillet
chisel the edge 2nd opera-
2 1 tion
CAA11537-1R6 D
In this example, there is no direct access for remo-

ving part 1. The spot welds should be unpicked
through part 2, which should be kept.
I 10354R
2 1
In this particular case, the arrow indicates that

2 1 the joint is made by arc welding (MIG).
E
CAQ11697-1R5
1 2
This arrow indicates that the part which

it crosses must be cut before the joint
can be accessed .
The references which follow indicate different 10349R

operations:
1 unpicking
In this example, the joint is
2 welding made by bonding.
40-8
GENERAL
Key to symbols 40
Plug welding.
Chiselling
Under MIG gas protection.
Grind back beads or spot welds Crimping of exterior door panels.

Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 mm to 3.2 mm.
Safety symbol.
Grind back spot welds This means that the welding operation
20 000 rpm. straight grinder with 10 or in question concerns one or more of the
16 mm spherical burr. vehicle’s safety components.
Drill spot welds Body solder - lead fill.

Hardened steel bit. Speed of rotation 800 Hot air torch.
to 1 000 rpm. Nozzle output temperature 600° min.
BAT+ 33% tin solder + tallow
Note : to a large extent, body solder
Unpicking filling compensates for the heat
distortion caused by welding.
Clean the surfaces to be welded Application of weldable mastic.

100 mm diameter fibre disc. This mastic conducts electricity. Applied
between two panels to be spot welded,
it ensures the seal between the panels
Cutting with a saw and avoids corrosion of the spot welds.
Pneumatic power hacksaw.
- Cutting out part by grinding off flange Application of aluminium paint.

or grinding back remaining traces of This is to be applied to the joint faces of
spot weld. each of the parts to be plug welded.
- Finish surface after welding. The paint conducts electricity and is
- Angle grinder equipped with a rubber resistant to high temperatures; it
pad and a 120 to 180 mm fibre disc provides anti-corrosion protection
grain size P36 around the plug welds.
Unsoldering.
Apply a fillet of extruded mastic
• from a manual or pneumatic gun
MIG stitch weld • one or two pot mastic for crimped or
Note : for a high quality weld we butt joints.
recommend the use of a gas consisting
of argon + 15% CO2. This is considered
to be an active gas (MAG). Spray on sealer
For UK = MIG. • spray gun
• two pot anti-gravel and anti-
corrosion mastic.
Spot welding
40-9
GENERAL
Description of parts (exploded view) 40
PRH4010
20 Front end lower cross member 31 Front cross member of front seat
*21 Complete front panel 32 Rear cross member of front seat
22 Front mounting of front sub-frame *33 Rear floor unit
* 23 Right hand side front side member 34 Rear floor
*23A Front side member (cut A) 34AA’Rear floor (cut AA’)
* 24 Front side member closure panel 34BA Rear floor (cut BA)
* 24A Front side member closure panel (cut A) 35 Front cross member of rear floor (cross mem-
25 Engine mounting reinforcement ber)
*26 Front side cross member * 36 Lashing ring mounting
* 27 Left hand side front half unit * 37 Exhaust mounting support
*28 Right hand side front half unit * 38 Rear side member
29 Centre floor * 38A Rear side member (cut A)
29A Centre floor, part section *39 Rear centre cross member
*30 Sill panel closure panel * 40 Rear section of front side member
* 41 Left hand side front side member
* Part which must be subject to electro zinc plating of the repaired areas.
40-10
GENERAL
PRH4011
*60 Headlight carrier panel 81BB Centre pillar lining (version B)

*61 Upper front cross member *82 Sill panel reinforcement
*62A Right hand wheel arch, front section *83 Inner wheel arch
*63 Right hand wheel arch, complete *84 Rear quarter panel lining (version C)
* 64 Screen wiper mounting *84AA Centre pillar lining (version C)
*65 Plenum chamber closure panel *84BB Outer wheel arch (version C)
*66 Plenum chamber, centre section 85 Centre pillar reinforcement
*67 Double pedal mounting *86 Wing panel (version VB)
68 Bulkhead blanking cover without AC *87 Top of body (version B)
69A Bulkhead (cut A) * 88 Sill panel (version B)
*70 Windscreen aperture lower cross member *89 Wing panel (version C)
71 Right hand drive steering column mounting *89AA Wing panel (version C)
72 Left hand drive steering column mounting *90AA Sill panel under door
73 Roof front cross member *91 Top of body (version C)
74 Roof *92 Body side, front section
75 Roof centre cross member *92AA Front pillar (versions B and C)
76 Roof rear cross member *92BB Centre pillar (version B)
77 Windscreen aperture pillar lining(version B) *93 Double thickness joint support
77A Windscreen aperture pillar lining(version C) *94 Cowl side panel reinforcement, rear section
*78 Rear end panel *95 Cowl side panel reinforcement, front section
*79 Lights mounting panel *96 Cowl side panel
*80 Wing panel upper rain channel *96AA Front pillar lining
*81 Rear quarter panel lining (version B) * 97 Bumper mounting
*81AA Outer wheel arch (version B) *98 Left hand wheel arch, complete
*99 Left hand wheel arch, front section
*Part which must be subject to electro zinc plating of the repaired areas.
40-11
GENERAL
PRH4009
* 1 Bonnet
* 2 Front door panel (2 doors) along cut A
* 3 Front door (2 doors)
* 4 Rear tailgate
* 5 Rear door panel along cut A
* 6 Rear door
* 7 Front door panel (4 doors) along cut A
* 8 Front door (4 doors)
9 Front wing
* Part which must be subject to electro zinc plating of the repaired areas.
40-12
GENERAL
5 DOOR
VERSION
Opening clearances 40
13491R
13491R1
40-13
GENERAL
5 DOOR
VERSION
1 3
14105R 14111R
2 4
14108R
14106R 5
14118R
40-14
GENERAL
5 DOOR
VERSION
14119R 14121R
7 9
14120R 14122R
40-15
GENERAL
5 DOOR
VERSION
12
10
14123R 14125R
11
13
14124R 14127R
40-16
GENERAL
5 DOOR
VERSION
16
14 14141R
14144R
17
15
14129R
14145R
40-17
GENERAL
5 DOOR
VERSION
18
14104R
19
14140S
Section view of sun roof
40-18
GENERAL
3 DOOR
VERSION
13491-1R1
1 2
14098R
14138R1
40-19
GENERAL
3 DOOR
VERSION
14137R 14135R
14136R
40-20
GENERAL
Collision fault finding 40
Before carrying out repairs to the bodywork of a car, even if the damage seems slight, it is necessary to carry
out a series of tests :
• VISUAL INSPECTION
This inspection involves the examination of the sub-frame of the vehicle where mechanical components
are mounted and in the crumple zones or vulnerable areas in order to detect folds where materials have
been deformed.
• INSPECTION USING TRAMMEL GAUGE
The visual inspection may be completed using a trammel gauge which will allow measurement of certain
deformations by symmetrical comparisons (for more detail on each point to check, refer to the repair
bench paragraph below).
• INSPECTION OF AXLE ASSEMBLY GEOMETRY
It is the only check which determines whether the impact suffered by the vehicle has or has not affected
its road holding.
Important : In borderline cases, it is essential not to neglect checking the axle assembly components which
may also have been subject to deformation.
On principle, no welded component in the body shell may be replaced without ensuring that the sub-
frame was not affected by the impact.
14147R
40-21
GENERAL
GAUGE POINTS Left hand side
Point H :
Front end of front side member.
650a2-14203
650h1-14210-1
Point A :
Rear mounting of front sub-frame.
The starting point for a rear impact.
Right hand side
650a1-14201
40-22
GENERAL
Point B : Point J :
Front point of rear axle assembly. Rear end of rear side member.
The starting point for a frontal impact.
Right hand side Right hand side
650b1-14202
650j5-14245
Left hand side Left hand side
650b2-14200 650j4-14206
40-23
GENERAL
Sub-frame dimensions 40
DESCRIPTION X Y Z DIAMETER ANGLE %
A Front sub-frame rear mounting 205 402.5 71 18.5 0
B Rear axle assembly front mounting 2 012 530 129 16.2 0
Left hand front mounting of front sub- 10×10

C - 418 447 130 0
frame (squared)
Right hand front mounting of front sub- 10×10

- 418 465 130 0
frame (squared)
E Rear shock absorber upper mounting 2 448.5 534.5 477.5 18.2 0
X : 3°02
F Front shock absorber upper mounting 18.5 545.50 657 48
Y : 1°
20×20
G Rear section of front left side member 600 375 - 3.7 0
(squared)
20×20
Rear section of front right side member 600 351.6 -5 0
(squared)
J Rear point of rear right side member 2 791 496.5 182 10.7 0
Rear point of rear left side member 2 790 481 162.5 10.2 0
X : 4°30
K Front cross member - 575 315 280 14.25
Z : 5°
Rear end cross member, left hand side

2 879 - 420 200 12×16 X : 10°
(rear end panel)
P Front engine mounting - 247 483.5 514 M10 0
Rear engine mounting - 113 483.5 514 M10 0
40-24
GENERAL
Sub-frame dimensions 40
14146R
40-25
GENERAL
Repair Bench 40
I - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
A - FRONT SUB-FRAME REAR MOUNTING 2 - Front mechanical units in place
It is the principle front reference point.

Left hand side
1 - Front mechanical units removed
650a2-14203
Right hand side
650a3-14198
The bracket rests against the rear section of the

side member and is centred in the sub-frame
mounting hole.
NOTE :
- on the left hand side, the hole is round,
- on the right hand side it is a slot.
650a1-14201
The bracket covers the sub-frame mounting bolt

and rests against the mounting bolt washer.
NOTE : The two sides are not symmetrical, on the

right hand side the mounting is set on the rubber
mounting.
If the rear of the vehicle is being rebuilt, these

two points alone may be used to align and sup-
port the front of the vehicle.
40-26
GENERAL
Repair Bench 40
I - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL (cont)
B - FRONT POINT OF REAR AXLE ASSEMBLY 2 - Rear mechanical units in place
It is the main rear reference point.

Right hand side
1 - Rear mechanical units removed
650b1-14202
Left hand side
650b3-14199
The bracket rests under the side cross member of

the rear axle assembly front mounting and is cen-
tred in the control unit hole .
650b2-14200
The bracket rests under the rear axle assembly

bearing and covers the front mounting nut of the
rear axle assembly.
If the front section is being rebuilt, these two

points alone can be used to align and support the
rear of the vehicle.
40-27
GENERAL
Repair Bench 40
II - ADDITIONAL REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
These are the provisional reference points which

replace the main ones, when they have been af-
fected by the impact.
G - FRONT SIDE MEMBER, REAR SECTION
650g2-14198-1
This point is also used as a positioning reference

when replacing a rear section of the front side
member.
On the impact side, this point allows the vehicle

to be additionally supported with a main refe-
rence point on the opposite side.
NOTE : these points should only be used in the cir-

cumstances quoted, there is no need to use them
when the main reference points (points A and B)
are correct.
This additional reference function may also be fil-

led by the front side member ends check points
for a rear impact and vice versa.
40-28
GENERAL
Repair Bench 40
III - REFERENCE POINTS FOR POSITIONING REPLACED PARTS
C - FRONT SUB-FRAME FRONT MOUNTING 2 - Front mechanical units in place
650c1-14210
The bracket covers the sub-frame mounting bolt

and washer.
It is used:
- following a frontal collision for a slight im-
pact,
650c2-14211
- for fault finding for the gauge inspection of
the front section .
The bracket rests under the sub-frame front
mounting and is centred in the hole with the
mounting bolt.
It is used when replacing :

- a front end cross member,
- a side member, part section,
- a half unit.
40-29
GENERAL
Repair Bench 40
III - REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont)
E- REAR SHOCK ABSORBER UPPER MOUNTING F- FRONT SHOCK ABSORBER UPPER

MOUNTING
650e1-14208 12841R
The bracket is fitted at the shock absorber cup The bracket rests under the shock absorber cup
and positions this mounting when replacing a and is centred in the shock absorber mounting
wheel arch. hole.
It is also used when straightening. It is used when replacing :

- wheel arches,
- a front half unit.
It is also used when straightening.
40-30
GENERAL
Repair Bench 40
J - REAR END OF REAR SIDE MEMBER 2- With mechanical units
1- Without mechanical units

Left hand side
Left hand side
650j4-14206
Right hand side
650j2-14204
Right hand side
650j3-14207
It may be used for a slight rear impact without re-

moving the rear axle assembly.
650j1-14205
40-31
GENERAL
Repair Bench 40
K - FRONT END CROSS MEMBER
650k1-14211-1
The bracket helps with the fitting of the front

cross member and rests vertically against the
front end cross member, then it is centred by a
centring bolt at (K).
It is used for replacing the front end cross mem-

ber, with or without mechanical units.
NOTE : The operation for replacing the front end

cross member can be carried out without the re-
moval of the engine and transmission assembly,
but requires the removal of the radiator.
2 - Front mechanical units in place
The bracket helps with fault finding on the front

cross member.
This requires the removal of the plastic protective

shield located between the bumper and the en-
gine sub-frame.
40-32
GENERAL
Repair Bench 40
CELETTE REPAIR BENCH
PRH4014
40-33
GENERAL
Repair Bench 40
BLACKHAWK REPAIR BENCH
PRH4012
With mechanical units
PRH4013
40-34
GENERAL
Repair Bench 40
IV - SPECIAL TOOLING
BLACKHAWK CELETTE
Photo
Photo
Special heads for MS System Special heads for MS System
Order from : Consult your After Sales Head Office Order from : Consult your After Sales Head Office
Supplier’s Part Number : Supplier’s Part Number :
REN 88240 Complete kit 774.300 Complete kit
REN 88221 Addition to the Kangoo kit 760.309 Addition to Kangoo kit (760.300)
(REN 88220)
774.309 Addition to complete kit 774.300
REN 88241 Addition to complete kit REN for repairing a Kangoo
88240 for repairing a Kangoo
40-35
GENERAL
Special tooling 40
14553R
Points (A) and (B) are the references for the positioning of the jig on
the vehicle.
Before fitting, when fault finding is carried out, the user must ensure
that these points are correct.
Points (C), (D) (E) and (F) and their symmetry help with the mounting
and positioning of the replaced components.
When points (A) or (B) can no longer be used as a reference (detected

during a fault finding inspection), the points on the opposite side of
the impact fulfil the function of positioning reference.
Special Tooling Part Number
Manual Part Parts Department

Drawing Description
Number Number
Car. 1481 00 00 148 100 Front end jig.
40-36
LOWER STRUCTURE
Front end lower cross member 41 A
INTRODUCTION
The replacement of this part is a basic operation

for a frontal impact .
The repair bench does not have to be used, on

condition that the side members have not been
affected by the impact.
COMPOSITION OF THE PART FROM THE PARTS

DEPARTMENT
Part assembled with :

- front end lower cross member closure panel,
- towing ring mounting.
PRH4136
PARTS CONCERNED (thickness in mm) :
1 Front end lower cross member 1.8

2 Towing ring mounting 2.5
3 Headlight carrier panel 1.2
4 Front side member 1.5
5 Cowl side panel pillar lining 1.2
6 Wheel arch 0.8
7 Front side member closure panel 1.2
41-1
LOWER STRUCTURE
B
6 1
CAR11700-1R3
651a1-14461
A C
7
5 1
CAQ11697R1 CAA11538-1R1
41-2
LOWER STRUCTURE
D RIGHT HAND SIDE
4 1
4 1
CAR11700-1R3
CAA11536-1R6
E
4 LEFT HAND SIDE
1 F
CAA11538-1R2
1 2 4
CAS13025-5R6
41-3
LOWER STRUCTURE
651a2-14462
G 3
CAR11700-1R7
41-4
LOWER STRUCTURE
Complete front panel 41 B
INTRODUCTION

for a frontal impact .
The repair bench does not have to be used, on

condition that the side members have not been
affected by the impact.

DEPARTMENT

- front end cross member ,
- towing ring mounting ,
- threaded ring ,
- nuts to be welded ,
- front cross member closure panel ,
- front panel upper side cross member,
- front panel upper centre cross member,
- lock mounting reinforcement ,
- headlight carrier panel ,
- bumper mounting bridge.
PRH4137
1 Front end lower cross member 1.8

2 Towing ring mounting 2.5
6 Wheel arch 0.8
7 Front side member closure panel 1.2
8 Front sub-frame front mounting,
lower section 1.2
9 Front panel upper side cross member 1.2
10 Cowl side panel upper front reinforcement 1
41-5
LOWER STRUCTURE
6 1
CAR11700-1R3
651b1-14461-1
C
A 4
5 1
CAA11538-1R1
CAQ11697R1
4 1
CAR11700-1R3
41-6
LOWER STRUCTURE
E LEFT HAND SIDE
4
F
1
1 2 4
CAA11538-1R2
CAS13025-5R6
RIGHT HAND SIDE
F G
5
4 1
CAA11536-1R6
CAA11536R3
41-7
LOWER STRUCTURE
H 9
10
5
CAX13937-4R7
651b2-14462-1
I J
5 9 3
CAA11536-1R1a
CAA11536-3R3
K 3
CAR11700R7
41-8
LOWER STRUCTURE
Front side member, front section 41 C
INTRODUCTION
The replacement of this part can be done in two
ways :
A Front side member, complete front section .
B Front side member, partial front section (cut
to be made in front of the front mounting of
the sub-frame), see the following diagram.
In the two cases these are complementary opera-

tions to the replacement of the front end lower
cross member and the headlight carrier panel. As
a result, the joints with these parts will not be
considered here, they will be dealt with in the res-
pective sections. PRB4122R
The repair bench must be used when this is being

completely replaced. or
NOTE: the repair bench must also be used when

there is partial replacement of the two side mem-
bers .
The replacement of this part also requires the re-
placement of the side member closure panel 1 Front side member, front section 1.5
which will have to be ordered separately. 2 Front side member, rear section 2.5
3 Front wheel arch 0.8
4 Shock absorber cup height adjuster 0.8
COMPOSITION OF THE PART FROM THE PARTS 5 Side member closure panel 1.2
DEPARTMENT 6 Engine mounting height adjuster * 1.8
7 Engine mounting reinforcement * 1.5
1 - Side member
* Only the right hand side.
- engine mounting height adjuster (only on the
right hand side),
- sub-frame front mounting.
5 - Front side member closure panel
Part on its own.
41-9
LOWER STRUCTURE
COMPLETE REPLACEMENT
B
6
CAS13028-6R1
12903R
A C
3 4
1 1
5 5
CAS13028-6R1 CAS13028-6R1
41-10
LOWER STRUCTURE
D
4 5
CAA11537-3R2
13005R6
E
5 F
2
4
1
1
CAE11546-4R7
CAB11539R8
41-11
LOWER STRUCTURE
H
1
CAA11538R3
12896R
I
G 4
6
1
2
CAG11548-6R1
CAA11536R3
41-12
LOWER STRUCTURE
12894R 13010R
J K
3
2
1
1
5
CAN11689R3 CAS13028-6R2
41-13
LOWER STRUCTURE
PARTIAL REPLACEMENT
B
1 1
CAA11536-2R1
NOTE: to avoid using the repair bench for the par-

651c1-14463
tial replacement of a side member, on the new
side member, keep section (Z)which will ensure
that the part replaced will line up correctly in rela-
or
tion to the part remaining on the vehicle. This will
be removed when the overlapping part is cut.
1 1
CAA11536-1R6
41-14
LOWER STRUCTURE
651c2-14463-1
1 1
CAS13033R2
41-15
LOWER STRUCTURE
Front side member closure panel 41 D
INTRODUCTION PARTS CONCERNED (thickness in mm) :
The replacement of this part may be done in two 1 Front side member closure panel 1.2
ways : 2 Front side member, front section 1.5
3 Front sub-frame front mounting
A- Complete front side member closure panel reinforcement 1.2
(refer to the complete side member opera- 4 Front sub-frame front mounting 1.2
tion).
B- Front side member closure panel, partial

front section (cut to be made in front of the
sub-frame front mounting), see cut in the
diagram and the method following.
This operation is carried out by straightening or

replacing the front side member. It is complemen-
tary to the front end lower cross member and to
the wheel arch.
In the operation described below, there are only

descriptions of the connections specific to the part
concerned.
As a result, joints with other parts will not be

considered here, they will be dealt with in the res-
pective section(see contents).

DEPARTMENT
Front side member closure panel
Part on its own.
PRH4138
or
41-16
LOWER STRUCTURE
PARTIAL REPLACEMENT
B
RIGHT HAND SIDE
1
CAB11539-1R7
C
1
12903R3
3
A
3
CAT13323R3
2
1 D
CAT13322R7
4 1
CAB11539-1R1
41-17
LOWER STRUCTURE
E-F LEFT HAND SIDE
1 1
CAS13033R2
12902R1
41-18
LOWER STRUCTURE
Sub-frame front mounting 41 E
INTRODUCTION

for a collision affecting the sub-frame.
In the operation described below there are only

descriptions of the connections specific to the part
concerned.
Information concerning the other parts will be

dealt with in the respective sections.
The repair bench must be used.

DEPARTMENT
Part assembled with sub-frame front mounting

reinforcement.
PRB4127
1 Front sub-frame front mounting 1.5

2 Front side member, front section 1.2
3 Side member closure panel 1.2
4 Front sub-frame front mounting
reinforcement 1
41-19
LOWER STRUCTURE
C
2 1
2
4
CAA11538R6
1
12901R
2
A
5
D
3 2
CAR11700R4
CAT13322-1R4
B
1 2
CAA11536R5
41-20
LOWER STRUCTURE
4 3
CAB11539R1
12903R4
E
3
4
CAU13323-3R3
41-21
LOWER STRUCTURE
Front half unit 41 F
INTRODUCTION
The operation for the replacement of this part is

complementary to :
- the front end lower cross member,
- the headlight panel.
This operation requires the replacement of the

cowl side panel (pillar lining) and of the cowl side
panel upper reinforcements, which have to be or-
dered separately.

descriptions of the specific joints to the part
concerned, information concerning the parts to
be ordered separately is not considered here. This
will be dealt with in the respective sections.

PRB4124R

or
DEPARTMENT

A Front side member, rear section
- engine mounting height adjuster (right 1 Central plenum chamber 1
hand side) 2 Injection unit mounting and impact
- engine mounting reinforcement (right sensor (left hand side) 2
hand side), 3 Front side member, front section 1.5
- engine mounting plate (right hand side), 4 Front side member, rear section 1.8
- sub-frame front mounting , 5 Shock absorber cup height adjuster 1
- front side member closure panel, 6 Shock absorber cup 2
- wheel arch, 7 Cowl side panel (pillar lining) 1.5
- shock absorber cup, 8 Cowl side panel upper reinforcements 1
- shock absorber cup height adjuster, 9 Central plenum chamber 1
- ABS mounting (right hand side), 10 Side plenum chamber 1
- injection unit mounting and impact sensor 11 Bulkhead 0.7
(left hand side),
- side plenum chamber
Cowl side panel (pillar lining)
Cowl side panel upper reinforcement
NOTE : to avoid removing the bulkhead lining,

the side section of the new half unit plenum
chamber must be removed, if this part of the ve-
hicle is not damaged.
41-22
LOWER STRUCTURE
13007R1 13000R2
A B
6
1
5
CAA11536R8 CAS13024-3R3
Right hand side special feature.
41-23
LOWER STRUCTURE
13010R4 12894R1
C D
1
3
2
CAA11538R8 CAN11689R3
41-24
LOWER STRUCTURE
3 4
CAA11536-4R2
13005R7
E G
5
4
4
3
CAB11539R3 CAS13029-4R1
41-25
LOWER STRUCTURE
REPLACEMENT WITH SIDE CHAMBER
I
10 9
CAA11537R1
651f1-14465
H
11
10
CAA11538R7
41-26
LOWER STRUCTURE
Front side cross member 41 G
INTRODUCTION
The replacement of this part is a complementary

operation to the replacement of a front pillar or a
sill panel with a lining for a side impact.

descriptions of the joints specific to the part
concerned.

dealt with in the respective sections.

DEPARTMENT
Part on its own.
PRB4125
1 Front side cross member 1

2 Floor 1
3 Front side member, rear section 1.8
4 Front side member reinforcement,
rear section 2.5
5 Sill panel closure panel 1.2
6 Sill panel reinforcement 0.7
7 Sill panel 1
8 Front sub-frame rear mounting 2.5
41-27
LOWER STRUCTURE
B
3
CAG11548-2R8
651g1-14466
A C
1 4
3
1
CAA11536R7 CAF11547-2R3
41-28
LOWER STRUCTURE
F
8 1 3 4
CAM11557-5R5
651g2-14467
D G 7
5
1
5
1
CAT13329-1R7
CAA11538R6
E H
6
1 3 4
5
1
CAS13024-1R6 CAE11546-2R7
41-29
LOWER STRUCTURE
J
5
CAA11538-2aR3
651g3-14469
1
I 2 3
CAF11547-2R1
41-30
LOWER STRUCTURE
Front side member, rear section 41 H
INTRODUCTION

operation to the replacement of the half unit.

concerned.

dealt with in the respective sections (see
contents).

DEPARTMENT

- sub-frame front mounting ,
- front side cross member ,
- side member reinforcement.
PRH4139

2 Centre floor 1.47
3 Front side member, rear section 2
4 Front side member reinforcement 2.5
5 Sill panel closure panel 1
6 Sill panel reinforcement 1
7 Sill panel 1.2
8 Front sub-frame rear mounting 2.5
9 Front cross member under front seat 1
10 Rear cross member under front seat 1
41-31
LOWER STRUCTURE
C
5
1
CAA11538R6
651h1-14468
D
A 7
5
1
4 2
CAT13329-1R7
CAT13324R2
E
B 7
2
CAE11546-2R7
CAA11536R7
41-32
LOWER STRUCTURE
G 2 9
651h2-14470 CAF11547-2R2
H 2 10
4 2
3
CAT13324R2
CAF11547-2R2
41-33
LOWER STRUCTURE
Centre floor 41 I
INTRODUCTION

operation to the replacement of:
1 - For a frontal impact

- front side member, rear section,
- bulkhead.
2 - For a side impact

- front pillar with lining,
- sill panel closure panel
The replacement of this part is carried out in the PRH4140

same way for the front section as for the rear sec-
tion (see cut in the method below).
1 Centre floor 1.47
In the operation described below, there are only 2 Front side cross member 1
descriptions of the joints specific to the part 3 Bulkhead 0.7
concerned. 4 Front side member 1.5
Information concerning the other parts will be 6 Front side member reinforcement 2.5
dealt with in the respective sections (see 7 Tunnel reinforcement 1
contents). 8 Rear cross member under front seat 1
COMPOSITION OF THE PART FROM THE PARTS 10 Tunnel front reinforcement 1
DEPARTMENT 11 Cable sleeve stop mounting 1.2
12 Front cross member of rear
Part assembled with : floor cross member 1.5
- front cross member under front seat, 13 Tunnel reinforcement 1.5
- rear cross member under front seat, 14 Sill panel closure panel 1
- bolts to be welded,
- studs to be welded,
- tunnel front reinforcement,
- cable sleeve stop mounting,
- front cross member of rear floor cross mem-
ber.
41-34
LOWER STRUCTURE
Centre floor 41 I
B
3
1 4
CAK11552R1a
651i1-14471
or
A C
1 3
CAA11538-1R3 CAT13319R7
41-35
LOWER STRUCTURE
Centre floor 41 I
D G
13
5 1
CAA11538-1R6 CAA11536-1R4
E H
1
13
1 6
1
5
CAT13324-2R1 CAS13028R5
F I
1 1
10
CAA11538-1R5 CAA11536-2R2
41-36
LOWER STRUCTURE
Centre floor 41 I
J
3
1 1
CAN11690R5
CAA11536R7
41-37
LOWER STRUCTURE
Centre floor 41 I
M
9
651i2-14472 CAA11538-1R2
or
L N
1 9
9 1
14
5
CAF11547-1R2 CAN11690-1R5
41-38
LOWER STRUCTURE
Centre floor 41 I
12 1 11 1
651i3-14473 CAY14458-2R1
or
O Q
1 11 1
12 1
CAC11541-1R1 CAX13938-1R2
41-39
LOWER STRUCTURE
Cross member under front seat 41 J
INTRODUCTION

operation to the replacement of the sill panel clo-
sure panel following a side impact.

concerned.

contents).
651j1-14472-1

DEPARTMENT
1 - Front cross member under front seat

A
Part assembled with front seat spacer.
2 - Rear cross member under front seat

Part assembled with front seat spacer. 6
CAY14350R3
PRH4141
1 Rear cross member under front seat 1

3 Centre floor 1.47
5 Tunnel reinforcement 1.5
6 Tunnel front reinforcement 1.5
41-40
LOWER STRUCTURE
Cross member under front seat 41 J
B D
1 1
3 3
CAA11538R2 CAA11538R2
C E
3 4 2 3 4 1
CAF11547R2 CAF11547R2
41-41
LOWER STRUCTURE
Rear floor raised section 41 K
INTRODUCTION

operation to the replacement of a body side lining
or a wheel arch for a side impact.
This operation is carried out partially (see cut and

method below).

concerned.

contents).

DEPARTMENT 651k1-14474-1
Part assembled with fuel tank mounting.

or
1 2
PRH4142
CAC11541R1
1 Rear floor raised section 1.5

2 Rear floor 0.7
3 Tunnel reinforcement 1
4 Cable sleeve stop mounting 1.2
5 Centre floor 1.47
41-42
LOWER STRUCTURE
Rear floor raised section 41 K
B E
1
5 4
1 1
CAS13030-3R2 CAA11536-2R6
C F
1
3 4
2 1
CAS13030-3R2 CAC11541R5
D G
1 1 3 4
1 2 1
CAY14292R6 CAW13605-1R6
41-43
LOWER STRUCTURE
Rear floor centre cross member 41 L
INTRODUCTION

operation to the replacement of the sill panel clo-
sure panel, rear section.

concerned.
Information concerning additional parts will be

dealt with in the respective section (see contents).
651l1-14477
DEPARTMENT

- nut to be welded,
A
- seat belt mounting,
- seat back mounting reinforcement.
3
1
CAA11538R5
PRH4143
PARTS CONCERNED (thickness in mm):
1 Rear floor centre cross member 1.2

2 Rear floor 0.7
3 Rear side member 1.2
4 Rear axle assembly mounting unit 1
5 Side member / cross member
joining component 1.5
6 Seat belt mounting support 1.2
7 Seat back mounting reinforcement 1.2
41-44
LOWER STRUCTURE
B D
2
1
1 4
CAA11538R5 CAA11536-1R5a
C 6 2 E
4 1 3
CAF11547-2R2 CAH11549-2R5
41-45
LOWER STRUCTURE
2 1
CAF11547-1R2
651l2-14475
F H
1 1 2
CAA11538-1R8 CAA11536R5
41-46
LOWER STRUCTURE
Rear side member 41 M
INTRODUCTION
The replacement of this part can be carried out in

two ways:
A - Complete rear side member

(for a rear impact)
In this case it is a complementary operation to
the sill panel closure panel.
B - Complete rear side member, part section

(for a rear side impact) (cut to be made in
front of the side member reinforcement), see
cut, diagram and method below. PRH4144
In this case it is a complementary operation to
the rear end panel.
In the operation described below, there are only PARTS CONCERNED (thickness in mm):
concerned. 1 Rear side member 1.8
2 Exhaust mounting unit 1.2
Information concerning additional parts will be 3 Side member / cross member
dealt with in the respective section (see contents). joining component 1.5
4 Rear floor 0.7
The repair bench must be used when replacing 5 Front cross member of rear floor
the complete side member. cross member 1.5
7 Wheel arch 0.8
COMPOSITION OF THE PART FROM THE PARTS 8 Rear axle assembly mounting unit 1
DEPARTMENT 9 Sill panel closure panel 1
- welded nuts,
- exhaust mounting (left hand side),
- rear axle assembly mounting unit,
- rear axle assembly mounting spacer,
- rear side member reinforcement,
- towing ring mounting,
- rear suspension spring cup,
- rear suspension spring cup reinforcement,
- side member / cross member joining compo-
nent .
41-47
LOWER STRUCTURE
4
2
CAA11538R6
651m1-14478
4
1
A 7
CAA11538R5
4
D
2
1 1
CAS13028-8R2
CAS13033R5
41-48
LOWER STRUCTURE
4
1
651m2-14476 CAA11538R6
H
5
1
CAA11538R6 6
CAA11538-1R5
F 4 5
CAF11547-2R1
41-49
LOWER STRUCTURE
I L
9
8 9 10
CAA11538R8 CAE11546-2R1
J M 6 4
6 8
CAA11536R6 CAF11547-2R2
K N
6
1
1
6
CAA11538-1R6 CAA11538R7
41-50
LOWER STRUCTURE
Towing ring 41 N
INTRODUCTION

operation to the partial floor for a rear impact.

concerned.


DEPARTMENT 651n1-14479
Part assembled with a threaded support.
A
1
CAT13328R8
PRH4145

B
1 Towing ring 1.5
CAA11536R8
41-51
LOWER STRUCTURE
Rear floor 41 O
INTRODUCTION PARTS CONCERNED (thickness in mm):
The replacement of this part is a complementary 1 Rear floor 0.7

operation to the replacement of the : 2 Rear floor reinforcement 1.8
3 Rear inner wheel arch 0.8
A - Cut for a side impact : 4 Exhaust mounting 1.2
of the rear sill panel closure panel. 5 Rear side member 1.2
B - Cut for a rear impact : 7 Side member / cross member
of the rear end panel. joining component 1.5
8 Front cross member of rear floor
This operation is carried out partially , with three cross member 1.5
possibilities (see cut in the diagram below) : 9 Sill panel closure panel 1
- rear left hand section,
- rear right hand section,
- front section.

concerned.


DEPARTMENT

- emergency spare wheel mounting,
- rear floor reinforcement,
- bolts to be welded,
- stud to be welded,
- rear cushion retaining bracket.
PRH4146
41-52
LOWER STRUCTURE
Rear floor 41 O
B
3
4
1
CAS13028-7R1
651o1-14480
C
or 3
A
1
1 CAT13319R8
CAA11538-1R6
D
1 1
CAA11536-3R5
41-53
LOWER STRUCTURE
Rear floor 41 O
E
CAA11538-1R6
651o2-14481
F or
1
G
7
1 2
1
CAA11536-3R3
CAY14457-6R2
41-54
LOWER STRUCTURE
Rear floor 41 O
H K
2 1
1 2
CAT13324-2R1 CAA11536-1R1a
I L
3
1 2
1 1
CAA11536-1R2 CAX13946-4R5
J M
3
1 2
5
5
1
CAF11547-1R1 CAS13028-7R2
41-55
LOWER STRUCTURE
Rear floor 41 O
O
1 1
CAN11689R1a
651o3-14483
or P
N
1 1
1 6
CAY14459-2R1
CAA11536-3R7
41-56
LOWER STRUCTURE
Rear floor 41 O
R
CAA11538-1R6
651o4-14482
S
or
9 1
Q
8 9 1
CAN11689R1a
CAD11545R1
T
1
10
CAA11538R4
41-57
LOWER STRUCTURE
Rear floor 41 O
U X
5 1 1
1
10
CAS13032R3 CAA11536-3R5
V Y
3
1 1
5 10
CAX13946-4R6 CAA11538-1R6
W Z
1 1 2
6
8 1
CAY14456-2R2 CAA11537-1R6
41-58
LOWER STRUCTURE
Rear floor 41 O
AA
1 10 5
CAH11549R2
AB
10
CAA11538-1R6
41-59
LOWER STRUCTURE
Exhaust mounting unit 41 P
INTRODUCTION

operation to the replacement of the rear end pa-
nel.

concerned.


DEPARTMENT
Part assembled with welded nuts.
PRH4148
1 Exhaust mounting 1.2

3 Rear floor 0.7
4 Wheel arch 0.8
41-60
LOWER STRUCTURE
Exhaust mounting unit 41 P
3
1
CAA11538R5
651p1-14484
A C 4
2
3
CAA11538R7 CAS13028-8R1
41-61
LOWER STRUCTURE
Rear floor unit 41 Q
The replacement of this part is a complementary 1 Rear floor raised section 1.5
operation to the replacement of the rear end pa- 2 Rear floor 0.7
nel for a rear impact. 3 Tunnel reinforcement 1
4 Cable sleeve stop mounting 1.2
In the operation described below, there are only 5 Centre floor 1.47
descriptions of the joints specific to the part 6 Sill panel closure panel 1
concerned. 7 Sill panel reinforcement 1
Information concerning additional parts will be 9 Rear side member 1.8
dealt with in the respective section (see contents). 10 Wheel arch 0.8

DEPARTMENT

- fuel tank mounting,
- welded nuts,
- exhaust mounting (left hand side ),
- rear axle assembly mounting unit,
- rear axle assembly mounting spacer,
- rear side member reinforcement,
- towing ring mounting,
- rear suspension spring cup,
- rear suspension spring cup reinforcement,
- side member / cross member joining compo-
nent ,
- rear side members,
- rear floor ,
- rear floor raised section ,
- towing ring .
PRH4147
41-62
LOWER STRUCTURE
B
1
4 3
CAS13030-3R2
651q1-14474
C
A 1
5 4
1 4 3 CAS13030-3R2
CAG11548-2R6
1 5
CAC11541R1
41-63
LOWER STRUCTURE
G
6
1 2
653j2-14373 CAT13325-4R2
H
6
1
2 6
CAA11538R5
CAB11540R2
1 6
CAB11540R2
41-64
LOWER STRUCTURE
J
8 6 7
651q2-14476-1 CAE11546-2R1
I
6
CAA11538R8
41-65
LOWER STRUCTURE
L
10
654e1-14305R CAS13028-6R2
K
10
M
8
10
9
CAA11536-2R7
CAC11541R7
41-66
Front wing 42 A
INTRODUCTION
The replacement of this part is a basic operation for a frontal and side impact.
14197R
REMOVAL
Remove:
- the radiator grille and unclip it from the wing (1) (see section 55-C),
- the scuttle panel grille (see section 55-D),
- the front bumper (see section 55-A),
- the clips (A), the bolts (B), and the clips (C),
- the front and rear mudguards.
REMOVING THE WING
Open the door and remove the mounting nuts (D) and (E).
Remove the bolts (F), (G), (H), (I) and the nuts (J), (K).
42-1
Front wing 42 A
ADJUSTING PROCEDURE REPAIRING THE PLASTIC WING
First fit the sliding clips (L) and(M) onto the wing . Reminder
Fit all the mountings without tightening them, Certain types of repairs to the wing may be car-
before adjusting the opening clearances. ried out - scratches, score marks etc., ...
Observe the tightening order as follows : For more information, consult Technical Note n°
392A on the repair of bumpers.
• Bolt (I), nut (K), bolt (F), nut (J) with bonnet
and doors closed. In this note you will find information concerning
methods and products.
• Nut (E), nut (D) with door open.
• bolt (L) with bonnet open.
Adjust the flush fitting of the headlight unit on

the wing with bolts (G), then tighten these two
bolts.
TIGHTENING TORQUE (in daN.m)
All wing mounting bolts 0.5
13491R5
42-2
Upper front cross member 42 B
INTRODUCTION

for a frontal impact.
This is a removable bodywork component, secu-

red by 6 x 8 mm bolts :
- four Torx 40 bolts on the headlight carrier pa-
nel at (A),
- two hexagonal bolts on the front end lower
cross member (B).

DEPARTMENT
Part assembled with lock mounting.
652b1-14440
PRH4219
42-3
Headlight carrier panel 42 C
INTRODUCTION

The fitting jig must be used.

DEPARTMENT
Part assembled with:

- front panel upper side cross member,
- headlight carrier panel ,
- bumper mounting support,
- welded nuts.
PRH4215
1 Front panel upper side cross member 1.2

3 Front end cross member 1.8
5 Cowl side panel upper front
reinforcement 1
6 Front sub-frame front mounting,
lower section 1.2
42-4
B
5 1
CAA11536-1R1a
652c2-14438
A C 1
5
6
5
CAA11536R3 CAX13937-4R7
42-5
E
1
CAA11536-3R3
652c1-14439
D 2
CAR11700R7
42-6
Bonnet strut mounting 42 D
The replacement of this part is a complementary 1 Bonnet hinge mounting 1.2

operation to the : 2 Cowl side pillar lining 1.2
3 Windscreen aperture lower cross
1 - replacement of the bonnet for a frontal im- member 1.2
pact, in this case, this operation is carried out
partially (see cut and method below),
2 - replacement of the front pillar, in this case,

this operation is carried out completely.

concerned.


DEPARTMENT
Part assembled with welded nut.
PRH4220
or
42-7
PARTIAL REPLACEMENT
B
1
CAA11536-2R8
652d2-14436
or
CAA11538-1R6
42-8
D 2 1
CAS13028R3a
652d1-14437
E
C
3 1
2
CAB11540-1R5
CAA11538-1R6
42-9
Cowl side panel 42 E
The replacement of this part is a complementary 1 Cowl side panel pillar lining 1.2
operation to the replacement of the headlight 2 Engine support plate 2
carrier panel for a frontal impact. 3 Front shock absorber cup 2
4 Side plenum chamber 1
This operation is carried out partially (see cut and 5 Shock absorber cup height adjuster 1.2
method below). 6 Front end cross member 1.8
7 Engine support plate corner plate 1.5
In the operation described below there are only 8 Wheel arch 0.8
descriptions of the joints specific to the part 9 Bumper mounting corner plate 0.8
concerned.


DEPARTMENT
Part assembled with:

- nut to be crimped,
- bonnet hinge mounting,
- dashboard mounting bracket,
- welded nuts,
- wing mounting support.
PRH4216
42-10
B 1
9
CAS13026-1R7
652e2-14434
A C
7
1 5
CAQ11697R2 CAA11538-1R2
42-11
D F
1
1
2
CAA11538-1R3 CAA11536-1R8
E
1
CAA11536-1R8a
42-12
H
5
652e1-14435 CAA11538-1R2
G
3
I
1 4 1
1
CAA11536-1R3
CAG11548-7R3
CAO11694R4
42-13
Cowl side panel upper reinforcement, front section 42 F
INTRODUCTION

operation to the replacement of the cowl side pa-
nel for a frontal impact.

concerned.


DEPARTMENT
Part on its own.
PRH4217

reinforcement 1
4 Engine support plate 2
6 Cowl side panel upper rear reinforcement 1
7 Wheel arch 0.8
42-14
C
1
652f1-14425 CAA11538R4
A
D
1 5
3
2 2
CAS13024-1R7
CAF11547-2R3
B
1
CAA11538R4
42-15
E G
1 6
1 7
2
CAN11690-1R5 CAF11547-2R8
F H
1 4
6 1
CAA11536-2R2 CAS13026R7
42-16
Cowl side panel upper rear reinforcement, rear section 42 G
INTRODUCTION

operation to the replacement of the front pillar

concerned.


DEPARTMENT
Part assembled with welded shaft.
PRH4218
1 Cowl side panel upper rear reinforcement 1

reinforcement 1
4 Front pillar 1.2
42-17
Cowl side panel upper rear reinforcement, rear section 42 G
C
3
CAA11538R7
652g1-14433
A D
1 5
1 4
CAA11536R2
CAA11536-2R1
B E
1 3
4
2 1
2
CAN11690R2 CAF11547-2R3
42-18
Wheel arch, front section 42 H
The replacement of this part is an operation for a 1 Engine mounting height adjuster 1.8
frontal impact and is complementary to the repla- 2 Shock absorber cup height adjuster 1.5
cement of the cowl side panel (pillar lining). 3 Side member closure panel 1.2
4 Side member, front section 1.5
It can be carried out partially from the right hand 5 Front wheel arch 0.8
side (see cut, diagram and method below). 6 Front end cross member 1.8
7 Cowl side panel (pillar lining) 1.2
concerned.
Information concerning other parts will be dealt

with in the respective section (see contents).

DEPARTMENT
1 - Part only (right hand side).
2 - Part only (left hand side).
PRB4212
or
42-19
B
5 4
CAQ11697R5
13009R
A C
2 6
5 3 4
CAR11700R5 CAI11550-2R5
42-20
E
1
4
CAS13028R1
12903R2
or
D
5
5 1
CAS13028R8
42-21
G
7
CAC11541R7a
13010R1
F H
1
4
2 1
CAB11540R1a CAS13028R2
42-22
13005R3
I 2
CAP11696-1R4
42-23
Wheel arch 42 I
INTRODUCTION

operation to the replacement of the cowl side pa-
nel (pillar lining) for a frontal impact.
It also requires the replacement of the cowl side

panel upper reinforcements (pillar lining), and
the use of the repair bench.

concerned.


DEPARTMENT
PRB4213
- engine mounting height adjuster (right hand PARTS CONCERNED (thickness in mm):
side),
- engine support plate (right hand side), 1 Shock absorber cup height adjuster 1.5
- wheel arch , 2 Engine mounting height adjuster 1.8
- shock absorber cup , 3 Engine mounting reinforcement 1.5
- shock absorber cup height adjuster , 4 Shock absorber cup 2
- ABS mounting (right hand side), 5 Side plenum chamber 1
- injection unit and impact sensor mounting 6 Side member closure panel 1.2
(left hand side). 7 Front side member, front section 1.5
9 Front wheel arch 0.8
10 Front end cross member 1.8
11 Shock absorber cup height
adjuster / plenum chamber joining
component 1.5
42-24
Wheel arch 42 I
B
9 7
CAQ11697R5
13009R
A C
9 10
9 6 7
CAR11700R5 CAI11550-2R5
42-25
Wheel arch 42 I
E
1
CAA11538-1R3
12895R1
D F
1
2
3
8
CAA11536-1R8a CAS13029R1
42-26
Wheel arch 42 I
G
1 8
CAA11536R5
13005R1
H1
G1 1 6
1 8
CAA11537-2R2
CAA11536-4R5
H
1 6
CAA11537-1R2
42-27
Wheel arch 42 I
K
9
7
CAS13028R1
13005R5
I L 3
2
1
CAT13324R8
CAB11539-1R8
J L1
1
3
6
7
CAE11546R7 CAA11536-1R3
42-28
Wheel arch 42 I
13007R 13000R
M N
4
CAA11536R8 CAS13024-1R3
42-29
Wheel arch 42 I
P
9
7
CAS13028R2
13010R2
O
5
11
CAA11538R8
42-30
Side plenum chamber 42 J
The replacement of this part is a complementary 1 Central plenum chamber 1

operation to the replacement of the front half 2 Side plenum chamber 1
unit. 3 Bulkhead 0.7
4 Windscreen wiper plate
In the operation described below there are only centre reinforcement 1.2
descriptions of the joints specific to the part 5 Pedal plate reinforcement 1
concerned.

with in the respective sections (see contents).

DEPARTMENT

- nut to be welded,
- shaft to be welded.
PRH4210
42-31
Side plenum chamber 42 J
C
3
652j1-14426
CAA11538R8
A
1 5
D
CAA11537-1R2 5
CAG11548-2R4
B
E
3 4 1
1 2
3
CAN11690R1
CAI11550-2R1
42-32
Bulkhead 42 K
INTRODUCTION

operation to the replacement of the front pillar
for a front side impact.

concerned.

NOTE : for vehicles not fitted with air conditio-

ning, the blanking cover (2) will also have to be
ordered, which will be mounted at its lower sec-
tion by two rivets whose sealing will be ensured
by a paint sealing mastic.
For driving school vehicles, parts (3 and 4) will PRH4211

have to be ordered separately, and the specific
pedal mounting will have to be used as a drilling
or
template.
COMPOSITION OF THE PART FROM THE PARTS PARTS CONCERNED (thickness in mm):
DEPARTMENT
1 Bulkhead 0.7
1 - Bulkhead : Part assembled with welded studs. 2 Central plenum chamber 1
2 - Blanking cover : part only. 4 Windscreen wiper plate
centre reinforcement 1.2
3 and 4 - Pedal reinforcement : Part assembled 5 Pedal plate reinforcement 1
with welded bolt. 6 Centre floor 0.7
7 Windscreen aperture lower cross
member 1.2
8 Steering mounting unit, upper section 2
42-33
Bulkhead 42 K
1 3 2
652k1-14424 CAN11690-2R1
or
A C
2
3
1
1
CAA11538-1R4
CAA11538-1R4
5
1
CAG11548R4
42-34
Bulkhead 42 K
E H
1
1
4 1
CAI11550R1 CAS13030-1R4
F I
1
2
1 1
CAW13605-4R6 CAT13319-1R7
G J 5
1 1
1
CAA11536-3R1 CAS13030R4
42-35
Bulkhead 42 K
L 7
652k2-14430 CAT13321-2R3
K
1 7
CAA11536R5
1 8
CAA11536-1R5a
42-36
Windscreen wiper mounting plate 42 L
The replacement of this part is a complementary 1 Windscreen wiper plate

operation to the replacement of the windscreen centre reinforcement 1.2
aperture lower cross member for a frontal impact. 2 Windscreen aperture lower cross
member 1.2
In the operation described below there are only 3 Bulkhead 0.7
descriptions of the joints specific to the part 4 Central plenum chamber 1
concerned.


DEPARTMENT
Part assembled with upper and lower section with

welded nuts.
PRH4212
42-37
Windscreen wiper mounting plate 42 L
B
3 1 4
CAI11550-1R1
652l1-14432
2 1
652L2-14431
CAA11536-2R5
1 2 3
CAD11545R5
42-38
Windscreen aperture lower cross member 42 M
The replacement of this part is a complementary 1 Windscreen aperture lower cross

operation to the replacement of the front pillar li- member 1.2
ning for a front side impact. 2 Steering mounting unit, upper section 2
3 Front pillar
In the operation described below there are only 4 Bulkhead 0.7
descriptions of the joints specific to the part 5 Cowl side panel pillar lining 1.2
concerned. 6 Bonnet hinge mounting 1.2


DEPARTMENT
Part assembled with steering column mountings

and dashboard mountings.
PRH4213
42-39
B 1
CAD11545-1R3
652m2-14428
C
A
1
2 1
CAA11536-2R4
CAA11536-1R1a
5
1
CAA11538R6
42-40
3 6 1
CAS13025-1R2
652m1-14429
1 3 6
CAX13968-1R6
42-41
Steering column lower mounting 42 N
The replacement of this part is a basic operation 1 Steering mounting unit, upper section 2
for damage to the steering column when the vehi- 2 Steering mounting unit, lower section 2
cle has been stolen. 3 Bulkhead 0.7

concerned.


DEPARTMENT
Part assembled with welded nuts.
PRH4214
42-42
Steering column lower mounting 42 N
B
3 1
652n1-14427 CAR11700R1
2 1
CAB11540-1R2
42-43
Front pillar 43 A
INTRODUCTION

The front pillar is removed for replacement by cut-

ting the assembled body side, front section, from
which the windscreen aperture pillar double seal
mounting must be unclipped.
The cowl side panel reinforcement, rear section,

will have to be ordered separately.

concerned.

PRH4308
DEPARTMENT
or
1 - Front pillar
- front pillar reinforcement , PARTS CONCERNED (thickness in mm) :
- windscreen aperture pillar double seal
mounting, 1 Front pillar 1.2
- welded nuts, 2 Front pillar reinforcement 1
- wing mounting bracket, 3 Windscreen aperture pillar
- cowl side panel upper reinforcement, double seal mounting 0.7
- welded stud, 4 Bulkhead 0.7
- door hinge. 5 Windscreen aperture lower cross
member 1.2
2 - Cowl side panel reinforcement, rear section 6 Sill panel closure panel 1
Part only 7 Sill panel reinforcement 1
3 - Windscreen aperture pillar double seal joint 9 Windscreen aperture pillar lining 1.2
mounting 10 Cowl side panel pillar lining 1.2
Part only 11 Bonnet hinge mounting 1.2
43-1
Front pillar 43 A
B 4 10
CAY14351-4R2
653a1-14377
A
C
10
2
6
1 2
CAN11690-3R4
CAN11690-3R4
D
6 7 1
CAW13602R1
43-2
Front pillar 43 A
E G
1 7 6 8
1 7 6
CAY14350-3R5 CAI11550-2R5
F H
1 1
10
2
CAN11690-3R3 CAS13033R5
43-3
Front pillar 43 A
653a2-14378 653a3-14357
I 3 J
1 1
CAR11700-1R8 CAS13033R5
43-4
Front pillar 43 A
K N
9 1
1 11 5
CAV13465R6 CAP11696R6
L O
10
2
10 9 1
1
CAJ11551R1 CAN11690-3R4
M P 10 4
2
1 11 10
1
CAW13602R5 CAY14351-4R2
43-5
Front pillar 43 A
Q S
9
10
1
2 1
CAE11546-5R1 CAQ11697R3
1 10 9
CAL11554-2R2
43-6
Front pillar lining (cowl side panel) 43 B
The replacement of this part is a basic operation 1 Cowl side panel pillar lining 1.2
for a front side impact. 2 Side plenum chamber 1
3 Bulkhead 0.7
In the operation described below there are only 4 Windscreen aperture lower cross
descriptions of the joints specific to the part member 1.2
concerned. 5 Windscreen aperture pillar lining 1.2
6 Bonnet hinge mounting 1.2
Information concerning other parts will be dealt 7 Sill panel closure panel 1
with in the respective section (see contents). 8 Sill panel reinforcement 1

DEPARTMENT
Part only
PRH4309
or
43-7
B
1
CAA11538-1R3
653b1-14375
A C
2
1
1 1
CAS13028R7 CAA11538-1R4
43-8
D F
3 1 6 4
CAA11538-1R1 CAX13938-4R6
E
5 1
CAN11689R1a
43-9
H
8 1
CAN11689R1a
653b2-14358
G I
1 3
7
CAE11546-1R4 CAC11541-1R2
43-10
Windscreen aperture pillar lining 43 C
The replacement of this part is a complementary 1 Windscreen aperture pillar lining 1.2
operation to the replacement of the front pillar 2 Body side lining 0.7
for a front side impact. 3 Roof front cross member 1.2
The Parts Department part is identical for the two 5 Centre pillar reinforcement 1
versions, BUT, for version B it must be cut as
shown below.

concerned.


DEPARTMENT

- windscreen aperture pillar lining,
- windscreen aperture pillar reinforcement.
PRH4310
* Cut for version B (140 mm)
or
43-11
Windscreen aperture pillar lining 43 C
C
653c1-14359 CAE11546-1R4
A
3 1
CAA11536-3R1
B 653c2-14360
D
4 1
2
CAB11539-1R3
CAN11689R1a
43-12
Centre pillar 43 D
The replacement of this part is a basic operation 1 Centre pillar 1.2

for a side impact. 2 Centre pillar closure panel 0.7
3 Centre pillar reinforcement 1
The centre pillar is removed for replacement by 4 Seat belt mounting centre pillar
cutting the assembled front section of the body upper reinforcement 1.2
side. 5 Sill panel reinforcement 1
concerned.


DEPARTMENT
Three parts assembled with :

- front pillar reinforcement ,
- windscreen aperture double seal mounting,
- welded nuts,
- wing mounting bracket,
- cowl side panel upper reinforcement,
- welded stud,
- door hinge.
PRH4311
or
43-13
Centre pillar 43 D
B
6
5
1
CAI11550R5
653d1-14379
A
1 1
C
1
3
CAS13033R6 2
CAE11546-2R4
43-14
Centre pillar 43 D
D F
6 6
5 5
1 1
CAI11550R5 CAI11550R5
E G
1 1
5
2
1
CAS13033R5 CAE11546-8R1
43-15
Centre pillar 43 D
I 4 2
CAL11554-3R2
653d2-14361
H J 2 4
1
1 1
CAS13033R7 CAL11554-3R1
43-16
Centre pillar 43 D
K M 4 2
2 3
3
1
1
CAE11546-8R2 CAL11554-3R2
L N
2 2
3 3
1 1
CAE11546-8R1 CAE11546-8R2
43-17
Centre pillar 43 D
653d3-14379
CAN11689-1R4
43-18
Centre pillar lining 43 E
The replacement of this part is a complementary 1 Centre pillar lining 1

operation to the centre pillar for version B, the 2 Centre pillar closure panel 0.7
rear wing panel for version C for a side impact. 3 Seat belt mounting centre
pillar upper reinforcement 1.2
In the operation described below there are only 4 Sill panel closure panel 1
descriptions of the joints specific to the part 5 Sill panel reinforcement 1
concerned.


DEPARTMENT
VERSION B (1)
- lock striker plate reinforcement,

- seat belt mounting upper reinforcement,
- nuts to be welded.
VERSION C (2)
- lock striker plate reinforcement,

- seat belt mounting upper reinforcement,
PRH4312
43-19
VERSION B
B
CAN11689R3
653e1-14362 C
1
A 5
4
1 2
CAE11546R8
CAB11539R6
43-20
1 3 2
CAE11546-2R1
653e2-14363
F
1
D
1
CAS13033R7
1 2
CAB11539R6
43-21
VERSION C
H
2
CAQ11697R3
653e3-14364
CAA11536R8
43-22
2 1
CAB11539-1R1
653e4-14365
2 1
I
1
CAB11539R5
1 L
CAS13033R3
1 3 2
CAE11546-2R5
43-23
Centre pillar reinforcement 43 F
INTRODUCTION VERSION C (2)
The replacement of this part is a complementary - quarter panel lower reinforcement,

operation to the centre pillar for version B, the - quarter panel upper reinforcement,
rear wing panel for C, for a side impact. - inflating insert,
- quarter panel lining,
In the operation described below there are only - seat belt mounting nuts,
descriptions of the joints specific to the part - stretcher extension.
concerned.


DEPARTMENT
VERSION B (1)
- quarter panel lower reinforcement,

- quarter panel upper reinforcement,
- inflating insert,
- quarter panel lining, PRH4314
- seat belt mounting nuts.

2 Centre pillar lining 0.7
3 Seat belt mounting centre
pillar upper reinforcement 1.2
6 Windscreen aperture pillar lining 1.2
PRH4313
43-24
VERSION B
653f2-14367
653f1-14366
B
A
1 1 2
4
2
CAB11539-1R2
CAF11547R3
43-25
C E
1 6
2 1
CAA11537-1R2 CAC11541R5
D F
1 1
CAB11539-1R3 CAA11536-3R1
43-26
VERSION C
653f3-14368
653f5-14380
G
FA 1 1
1 1
CAA11536-3R2
CAA11536-3R1
2 1
CAB11539R5
43-27
I K
2 3 1 2
CAE11546-2R2 CAB11539-1R3
J L
2
6
2 1
CAB11539R5 CAE11546R4
43-28
CAB11539R4
653f4-14376
M O
1 1
1 1
CAS13033R6 CAA11536-2R5
43-29
4
5
CAE11546R3
Q
1
CAA11536-1R8a
43-30
Body side, front section 43 G
INTRODUCTION


concerned.


DEPARTMENT
1 - Cowl side panel upper reinforcement, rear

section
Part only.
PRH4315
2 - Body side, front section
- front pillar reinforcement, NOTE : for replacing this part, refer to operations
- windscreen aperture pillar double seal 43A and 43D.
mounting,
- welded nuts,
- welded stud,
- door hinge.
43-31
Sill panel 43 H
The replacement of this part is a complementary 1 Sill panel 1.2

operation to the base reinforcement for a side im- 2 Sill panel closure panel 1
pact. 3 Sill panel reinforcement 1
This operation is carried out partially for version B 5 Centre pillar reinforcement 1
and completely for version C. 6 Centre pillar closure panel 0.7

concerned.


DEPARTMENT
VERSION B (1)
Part assembled with welded stud.
VERSION C (2)
Part assembled with welded stud.
PRH4316
or
43-32
Sill panel 43 H
VERSION C
B
1 3 2
CAI11550-2R5
653h1-14381
C
1 3 2
A
1 1
CAI11550-2R2
D
CAS13033R5
1 3 2
CAI11550-2R2
43-33
Sill panel 43 H
E VERSION B
1 3 2
CAI11550-2R5
F 653h3-14382
1 1
G
CAS13033R6
1 1
CAS13033R6
43-34
Sill panel 43 H
H J
1
1 5 3
CAS13033R8 CAE11546-2R1
I K
2 3 1
1 5 6
CAE11546-2R1 CAT13326-1R1
43-35
Sill panel 43 H
M
1 4 2
CAY14355R3
653h2-14369
1
3
4
L
CAE11546-2R3
1 3 2 O
1
CAI11550-2R5
CAS13033R8
43-36
Sill panel 43 H
P
1 3 2
CAE11546-2R1
Q
2
CAE11546-2R7
43-37
Sill panel reinforcement 43 I
INTRODUCTION

operation to the sill panel .

concerned.


DEPARTMENT
Part only.
PRH4317

2 Body side lining 0.7
43-38
4 3 1
CAS13025-1R2
653i1-14370
A C
1 4 1 3
CAN11689R5 CAN11689R5
43-39
CAA11536R7
653i2-14371
D
F
3
1
3 1
2
CAS13025-3R8
CAA11536-1R6
1 3 5
CAS13025-2R5
43-40
Sill panel closure panel 43 J
INTRODUCTION

operation to the sill panel reinforcement for a
side impact (versions B and C).

concerned.


DEPARTMENT

- reinforcement plate,
PRH4319

4 Rear floor 0.7
5 Cross member of rear floor cross
member 1.5
6 Cross member under front seat 1
8 Centre floor 1.47
43-41
B
1
653j1-14372 CAA11538-1R3
A
3
C
1
6
1
CAA11536-2R8
CAA11538-1R3
1 6 8
CAF11547R1
43-42
5 1
653j2-14373
CAB11540-1R2
E
G
1
5 4 1
CAA11538-1R5
CAT13325-2R2
4 1
CAB11540-1R2
43-43
653j4-14383
J
9
653j3-14374
1
I
1
CAA11536R4
CAA11538-1R5
43-44
Complete body side 43 K
INTRODUCTION
The replacement of this part is a complementary operation to the replacement of the

roof for a front side impact.
In the operation described below there are only descriptions of the joints specific to
the part concerned.
Information concerning other parts will be dealt with in the respective section (see
contents).
COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT
1 - Upper reinforcement of cowl side panel, rear section

Part only
2 - Body side, front section

- front pillar reinforcement,
- windscreen aperture pillar double seal mounting,
- welded nuts,
- welded stud,
- door hinge.
3 - Rear wing panel

Part assembled with striker plate reinforcement.
PRH4318
NOTE 1 : to replace these parts, refer to operations 43A, 43D and 44A.
NOTE 2 : sections A and B of part 3 are big enough to be cut where they overlap
with the sections corresponding to part 2.
43-45
VERSIONS
B/C Rear wing panel, complete and part section 44 A
INTRODUCTION

for a rear side impact.
It will be replaced partially.
For version B : along cut A, diagram below (the

double seal mounting will have to be ordered se-
parately).
For version C : along cut B.
NOTE : complete replacement will be complemen-

tary to the roof.

concerned.
PRH4425

DEPARTMENT
VERSION B (1)
- bumper reinforcement,
- door striker plate reinforcement,
- striker plate reinforcement plate,
- double seal mounting (part 3) (to be ordered
separately for version B).
VERSION C (2)
- stiffener,
- adjustable seal, PRH4432
- bumper reinforcement.
or
44-1
VERSIONS
1 Rear wing panel 0.8

2 Quarter panel double seal mounting 0.7
3 Rear quarter panel upper rear
reinforcement 1.2
4 Rear quarter panel lower rear
reinforcement 1.2
6 Door striker plate reinforcement 1.2
9 Seat belt mounting centre pillar
upper reinforcement 1.2
11 Upper rear side rain channel 1
12 Lower rear side rain channel 0.7
654a6-14298
CAA11536R8
44-2
VERSIONS
C
654a7-14299 CAJ11551-1R4
B
1 5
4
1
CAE11546-8R2
CAS13033R7
44-3
VERSIONS
(with removal of roof) F
1 1
CAS13033R1
G
654a8-14300 5
1 3
CAE11546-8R8
CAB11539R3
44-4
VERSIONS
H
CAJ11551-1R4
654a9-14301
5
4
1 J
CAE11546-8R2
1
6
CAE11546-2R3
44-5
VERSIONS
K N
5
1 1
CAB11539R4 CAS13033R2
L O
8
1
1
5
CAE11546-2R3 CAE11546-2R8
1
7
CAE11546-2R3
44-6
VERSIONS
Q
1 5
CAV13463R5
654a1-14295
P R
8
5 1
CAO11694R6 CAE11546-2R7
44-7
VERSIONS
SPECIAL NOTE FOR VERSION C
T 5
CAT13326-1R4
654a4-14296
U 5
S
CAT13326-1R4
1 1
CAS13033R1
44-8
VERSIONS
W
1
11
CAB11540-1R3
654a5-14297
V X
1 1
1
12
11
CAS13033R6 CAT13325-2R3
44-9
VERSIONS
Z
5
9 10 1
CAT13329-2R6
654a3-14314
AA
5 10 1
Y
1 CAE11546R6
1
AB
CAS13033R4
1
10
CAJ11551-1R4
44-10
VERSIONS
AD
7
10
1
CAE11546-8R2
654a2-14315
AE
AC
5 1 5 8
10
1
CAI11550-2R5
CAE11546-8R2
AF
1 1
CAS13033R6
44-11
Upper side rain channel 44 B
INTRODUCTION

operation to the roof and to the rear wing panel.

concerned.


DEPARTMENT
Part only.
PRH4426
1 Rear upper side rain channel 1

2 Rear lower side rain channel 0.7
reinforcement 1.2
reinforcement 1.2
44-12
Upper side rain channel 44 B
B
1 2 3
CAJ11551-1R1
654b1-14302
C
4 1
A
5 2 1
CAO11694-1R1a
CAS13024R5
D 1
CAS13024-1R3
44-13
Tailgate balancing ball joint 44 C
INTRODUCTION

for cases where the ball joint breaks.

concerned.


DEPARTMENT
Part only.
654c1-14303
A
1
2
PRH4433
PARTS CONCERNED (thickness in mm): CAA11538R4
1 Tailgate balancing ball joint 1.5

2 Rear lower side rain channel 0.7
44-14
Outer wheel arch 44 D
The replacement of this part is a complementary - rear quarter panel lower reinforcement,
operation to the rear wing panel and lights moun- - rear quarter panel upper reinforcement,
ting panel. - inflatable insert,
- rear quarter panel lining,
This operation is carried out partially (see cut and - seat belt mounting nuts,
method below). - stretcher extension.

concerned.


DEPARTMENT
VERSION B (1)
- rear quarter panel lower reinforcement, PRH4428

- rear quarter panel upper reinforcement,
- inflatable insert,
- rear quarter panel lining, PARTS CONCERNED (thickness in mm):
reinforcement 1.2
PRH4427
44-15
Outer wheel arch 44 D
B
1 1 3
CAT13320-1R2
654d1-14304
or
C
2 1
1 1
CAA11536-1R1a
CAC11541-1R2
NOTE : plug weld under the rear quarter panel

lower reinforcement.
44-16
Inner wheel arch 44 E
The replacement of this part is a complementary 1 Rear inner wheel arch 0.8
operation to the body side lining, rear section and 2 Rear floor 0.7
the lights mounting for a rear side impact. 3 Rear axle assembly mounting unit 1
concerned.


DEPARTMENT

- shock absorber mounting cup,
- shock absorber mounting cup reinforcement,
- parcel shelf side mounting,
- shock absorber cup height adjuster,
- rear seat mounting hook,
- rear seat mounting.
PRH4429
44-17
Inner wheel arch 44 E
B
1
2
654e1-14305 CAS13028R2
A
1
C
1 1
CAA11536-3R4
CAC11541-1R7
44-18
Body side lining 44 F
The replacement of this part is a complementary - rear quarter panel lower reinforcement,
operation to the rear wing panel. - rear quarter panel upper reinforcement,
This operation is carried out partially (see cut and - rear quarter panel lining,
method below). - seat belt mounting nuts,
- stretcher extension.
The method below deals with the special features
of versions B and C. In both cases, the upper rain
channel will have to be ordered separately.

concerned.


DEPARTMENT

PRH4428
VERSION B (1)
Upper rain channel
- rear quarter panel lower reinforcement,
- rear quarter panel upper reinforcement, Part only.
- rear quarter panel lining,
PRH4426

3 Rear inner wheel arch 0.8
PRH4427
5 Rear upper side rain channel 1
reinforcement 1.2
reinforcement 1.2
8 Roof rear cross member 1
44-19
B 1 1 2
CAG11548-2R1
654f1-14306
or C
1 3 2
A 1 1 2
CAS13024-1R6
CAG11548-2R1
44-20
C1 E
1 4
1
CAA11536-2R3 CAR11700-1R1
D F
1 2
1 4 3
CAQ11697R5a CAT13326-1R7
44-21
H
7 8
CAA11536-3R2
654f2-14307
I
or
G
8 7
7 1 1
CAX13938R5
CAA11536R6
J
1 1
CAA11537R2
44-22
K M 7
5 1 6
CAA11536-1R1a CAJ11551-2R7
L
1 7 5
CAS13024-3R6
44-23
SPECIAL FEATURES OF VERSION C
O
1 1
CAA11536-2R6
654f3-14308 P
1
or
2
9
N
1 2 9 1
CAW13602R7
CAY14292-4R1
44-24
1 1
CAA11536-2R6
654f5-14310
or
or
1 7 1
CAP11696-4R5
or
44-25
654f4-14309
S
1 1
CAS13033R6
44-26
Rear end panel 44 G
The replacement of this part is a basic operation 1 Rear end panel 1

for a rear impact. 2 Rear floor 0.7
3 Rear end panel lining 0.7
In the operation described below there are only 4 Absorber mounting 1.2
descriptions of the joints specific to the part 5 Rear side member 1.2
concerned. 6 Lights mounting 1


DEPARTMENT

- rear end panel lining,
- rear end panel striker plate reinforcement,
- bumper support corner plate,
- absorber mounting,
- bumper mounting support corner plate
PRH4430
44-27
Rear end panel 44 G
B
3 2 1
CAG11548-8R5
654g1-14311
C
A 2
2
1 4
CAT13324-3R6
CAT13319-1R2
D
1 4 5
CAS13024-2R2
44-28
Rear end panel 44 G
E G 6
1
6
1 3
CAA11536-1R4 CAS13029-2R1
F H
1
1
2
CAA11538-1R8 CAA11538R3
44-29
Rear lights mounting 44 H
The replacement of this part is a complementary 1 Lights mounting 1

operation : 2 Rear lower side rain channel 0.7
3 Parcel shelf lower mounting 1
- to the rear end panel for a rear impact, for 4 Rear wing panel 0.8
this operation, the rain channel on the Parts 5 Wheel arch 0.8
Department part will have to be removed, 6 Absorber mounting 1.2
7 Rear bumper mounting side
- to the wing panel for a rear side impact. reinforcement 1.2
8 Rear quarter panel lining 0.7
This operation is carried out partially (see method 9 Rear floor 0.7
below). 10 Rear quarter panel lower rear
reinforcement 1.2
For the complementary operation to the rear end 11 Rear upper side rain channel 1
panel, the lower rear side rain channel will have
to be removed according to (X) below, keeping
the lower parcel shelf mounting.
X
COMPOSITION OF THE PART FROM THE PARTS 2
DEPARTMENT

- rear lower side rain channel,
1
- parcel shelf lower mounting,
- balancing reinforcement (ball joint mounting
support),
- balancing ball joint.
CAA11536-3R3
PRH4431
44-30
B
CAS13024-1R7
654h1-14312
C
A 5
2 1
1 CAA11538-1R2
CAS13025R7
CAS13025-1R8
44-31
E G
4
4 1
CAA11536-3R6 CAE11546-2R7
F H
1
7
4 9
CAT13328-1R7 CAA11538-1R3
44-32
J 11
2
10
CAY14294R7
654h2-14313
I K
11
11 10 2
CAA11537-1R4 CAJ11551-5R6
44-33
TOP OF BODY
Roof 45 A
INTRODUCTION
The replacement of this part is a basic operation.

concerned.


DEPARTMENT

- soundproofing,
- earthing washer.
PRH4517
1 Roof 0.7
2 Roof front cross member 1.2
4 Front pillar 1.2
5 Body side, front section 1.2
6 Rear wing panel 0.8
reinforcement 1.2
11 Upper side rain channel 0.7
45-1
TOP OF BODY
Roof 45 A
C
1
3
655a4-14253 CAT13326-1R5
A
1
D
5
1
CAQ11697R7
CAA11538R8
B
1
3
CAT13326-1R5
45-2
TOP OF BODY
Roof 45 A
F
6
CAA11538R8
655a3-14248
7 1
CAF11547-2R7
45-3
TOP OF BODY
Roof 45 A
H
1
6 9
CAF11547-2R5
655a1-14252
G
1
6 8
CAF11547-2R5
45-4
TOP OF BODY
Roof 45 A
J
8 10 1
CAS13024R5
655a2-14250
I K
10 1
8 11 8
CAN11689R1a CAS13024-1R1
45-5
TOP OF BODY
Roof 45 A
VERSION B SUNROOF VERSION
When replacing the body or roof of a vehicle fit-

ted with a sunroof, the roof will have to be cut to
the following dimensions.
655a5-14258 655a6-14249
L NOTE : a radius of 73 mm on the four corners

must be respected.
8 6 1
CAS13024-1R5
45-6
TOP OF BODY
Roof front cross member 45 B
INTRODUCTION

operation to the roof.

concerned.


DEPARTMENT
Part assembled with roof cross member closure

panel.
655b1-14254
A
2 1
PRH4518 CAA11536-2R2

2 Windscreen aperture pillar lining 1.2 B
CAO11694R4
45-7
TOP OF BODY
Roof centre cross member 45 C
INTRODUCTION


concerned.


655c1-14256
DEPARTMENT
Part assembled with an acoustic weight.

A 1 2 3
CAS13028R4
PRH4519

45-8
TOP OF BODY
Roof rear cross member 45 D
INTRODUCTION


concerned.


DEPARTMENT
Part only.
655d1-14246
2 1
PRH4520
CAA11536R1

reinforcement 1.2
B
1 2
CAA11536-1R5
45-9
TOP OF BODY
Top of body 45 E
INTRODUCTION VERSION C

This operation is carried or partially (see cut and

method for versions B and C below).

concerned.


DEPARTMENT
Part only.
VERSION B
PRH4522
or
1 Top of body 1.2

3 Windscreen aperture pillar
upper reinforcement 1
6 Body side upper stretcher
(version C) 1
7 Centre pillar 1.2
8 Seat belt mounting centre pillar
upper reinforcement 1.2
PRH4521 reinforcement 1.2
reinforcement 1.2
or
45-10
TOP OF BODY
Top of body 45 E
1 2
CAB11539-1R5
655e1-14255
C
or
2
A
1
CAQ11697R3
1 1
CAS13033R1 D
1 2
CAB11539-1R5
45-11
TOP OF BODY
Top of body 45 E
E H
2 1 2
CAA11536R1 CAB11539R4
F I
2
1
1
3
CAE11546-2R3 CAB11539R7
G
2
CAE11546-2R8
45-12
TOP OF BODY
Top of body 45 E
VERSION C
K
5
4 1
CAN11690R5
L
655e2-14247
or
J 1 2
CAQ11697R2
M
CAB11539R4 4 3
CAT13326-3R1
45-13
TOP OF BODY
Top of body 45 E
N Q 5
1 8 7
1
CAA11536-1R8 CAY14261R7
O R
8
5
1
6
CAA11538R2 CAI11550R8
P S
5 1
6
CAE11546-2R8 CAS13033R4
45-14
TOP OF BODY
Top of body 45 E
VERSION C
U
1 10
CAB11539R1
655e3-14251
or
T V
5
1 1
CAE11546-2R8 CAS13033R1
45-15
TOP OF BODY
Top of body 45 E
VERSION B
X
3
CAB11539R7
655e4-14257
or
Y
5
W
1 4
2 CAE11546-8R8
CAB11539R4
Z
5
4 1
CAN11690R5
45-16
TOP OF BODY
Top of body 45 E
AA AD
5 1
4
4
1
CAE11546-8R2 CAV13466R7
AB AE
1 5 1
CAS13033R8 CAO11694-1R1a
AC AF
1
1 8 5
CAE11546-2R1 CAA11538R4
45-17
TOP OF BODY
Top of body 45 E
AG VERSION B
CAB11539R7
655e5-14259
or
AH
1 4
CAE11546-8R3
45-18
TOP OF BODY
Top of body 45 E
AI AK
5
5
1
1 4
CAE11546-8R8 CAB11539R7
AJ AL
5
1 1
CAB11539R4 CAS13033R2
45-19
Front and rear doors 47 A
PRH4704
REMOVAL
13021R 13021R1
Fit the door support tool (see section 50B). Remove the door hinge pins using tool Car. 1415
(see section 50B).
Disconnect the door wiring by pushing the clip up-
wards. NOTE : tool Car. 1415 has to be modified (see fol-
lowing page).
Remove the bolt on the door support bar (A).
47-1
MODIFYING THE TOOL FOR REMOVING THE REFITTING AND ADJUSTING
HINGE PINS
14244R PRH5001
Using a flat file and a round file, file the end of Refitting is the opposite of removal. Refer to the
the tool blade and the bottom of the neck to section "Opening clearances" to make adjus-
obtain the precise dimensions indicated on the tments.
diagram below.
NOTE : when changing the door or when
Following this modification, it is also possible to changing the body but replacing original opening
remove the pins on the X65 (B) and the pins on elements, the correct type of after sales bolted
the MEGANE (C). hinges will have to be used which ensure the
correct height adjustment of the door.
Use the Parts Department kit, part number 77 01

468 331.
47-2
85700-2R
Adjusting the doors by tilting
Use special tool, WILMONDA, part number BHA

(Supplier Z. INTERNATIONAL).
This tool allows position "X" of the welded hinge

to be modified on the front pillar or the centre pil-
lar.
85899R1
Flush fitting adjustment of the doors
Adjustment range : 3 mm.
47-3
Front door panel 47 B
INTRODUCTION

for a side impact.
This part can be replaced partially (see cut and

method below).

DEPARTMENT

- upper reinforcement of door trim,
- soundproofing pads,
- vertical stiffener (version B).
PRH4705
1 Door panel 0.7

2 Door box section 0.7
3 Door frame 0.8
47-4
B
2 1
2
CAT13318R1
1
PRH4707
2
or
A C
1
1 3
2
1
CAS13033R8 CAT13318R2
47-5
1 3
CAB11539-1R2
PRH4708
E or
2 1
2
1 F
1
CAT13318R1
1
1
CAS13033R8
47-6
G
1 3
2
1
CAT13318R2
H
1 3 2 3
CAT13318R2
47-7
Rear door panel 47 C
INTRODUCTION

for a side impact.
This part can be replaced partially (see cut and

method below).

DEPARTMENT

- soundproofing pads,
- stiffener.
PRH4706
1 Door panel 0.7

2 Door box section 0.7
3 Door frame 0.8
47-8
B
1 2
1
2
CAT13318R2
1
PRH4709
2
or
A C
1
2
1
CAS13033R8 CAB11539R3
47-9
E
1 2
4
1
2 3
CAT13318R2
1
PRH4710
2
D
1
3
CAS13033R8
47-10
Tailgate 48 A
PRH4805 13972R1
Pull the spoiler upwards to unclip it (B).

REMOVAL
Disconnect the third stop light (C).
Remove the supply pipe from the rear screen jet

(D).
13973R
Remove the spoiler on the tailgate (mounting

bolt (A)).
14161R1
Remove the mounting bolt (E).
Unclip the trim using the unpicking pliers (clips

(F)).
Remove the tailgate trim.
48-1
Tailgate 48 A
REMOVING THE HINGES
14160R
Disconnect: 13991R2
- the supply connectors from the screen wiper
and tailgate lock motors,
- the supply terminals from the screen de-icing Partially pull back the luggage compartment seal
network. in the area which comes into contact with the
upper section of the side parcel shelf (H).
Remove:
- the wiring loom from the tailgate box section Using a flat blade screwdriver, remove the
and the screen jet supply pipe, headlining retaining clips (I).
13972R2
- the tailgate balancers and the mounting nuts

(G),
- the tailgate .
48-2
Tailgate 48 A
REFITTING
PRM9402
13992R
IMPORTANT
Unclip and pull the trim to one side. When refitting the hinges, do not forget to en-
sure the seal between them and the roof panel.
Fit an open wrench between the lining and the
headlining to hold the headlining to one side To do this, use the mastic sealing bead, part num-
while the hinges are being removed. ber 77 11 170 230 (refer to the Technical Note
396A).
Carefully pull the headlining to one side as indica-
ted below to gain access to the hinge mounting To adjust the tailgate and the tailgate lock after
nuts (J) ( 13 mm hexagonal nuts). refitting, respect the opening clearances in sec-
tion 40.
Adjustments must be made when the tailgate is

fully refitted.
48-3
Bonnet 48 B
PRH4806
48-4
Bonnet 48 B
REMOVAL REFITTING
14072R1 13974R2
Disconnect the supply pipe from the nozzles fitted To correctly adjust the bonnet, move the lock and
on the bonnet. the bonnet struts to ensure the opening
clearances specified in section 40.
Remove:
- the mounting nuts (A) of the bonnet struts,
- the bonnet (two people).
48-5

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Sheet Metalwork

UPPER FRONT STRUCTURE

UPPER SIDE STRUCTURE

UPPER REAR STRUCTURE

SIDE OPENING ELEMENTS

NON-SIDE OPENING ELEMENTS

BB0A - BB0C - BB0D - BB0E - CB0A - CB0C - CB0D - CB0E

77 11 197 393 DECEMBER 1997 Edition Anglaise

40 GENERAL 42 UPPER FRONT STRUCTURE

44 UPPER REAR STRUCTURE

47 SIDE OPENING ELEMENTS

B/C B0A D7F 1149 180 CP 3300

B/C B0C E7J 1390 180 CP 3300

B/C B0E F8Q 1870 200 CPOV 3250

B : Bodywork type (5-door)

SPECIAL TOOLING REQUIRED

Cha. 280 -02 Adaptable cross piece for trolley

If a trolley jack is used, appropriate axle AXLE STANDS

To lift at the front or rear, take the weight under

LIFTING FROM THE SIDE WITH A TROLLEY JACK

Use cross piece Cha. 280-02.

Take the weight under the valance at the front

Position the flange correctly in the cross member

There are several examples to consider :

1 - WHEN REMOVING COMPONENTS

Generally speaking, never use a 2-post lift if a

If this is not possible, position the lifting pads

2 - SPECIAL CASE OF THE REMOVAL - REFITTING 98703S

In this specific case, the body of the vehicle MUST

These MUST be placed to the right of the jacking

NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS

The black part is the one which will be

are the part numbers corresponding to

are the thicknesses (in mm) of the

This arrow on the diagram designates

The above diagram shows the part on the vehicle

This dashed line shows the centre of

place of operation and logical sequence

This letter designates the diagram

site of operation and logical sequence

1st opera- unpicking apply weld

In this example, there is no direct access for remo-

In this particular case, the arrow indicates that

This arrow indicates that the part which

The references which follow indicate different 10349R

Grind back beads or spot welds Crimping of exterior door panels.

Drill spot welds Body solder - lead fill.

Clean the surfaces to be welded Application of weldable mastic.

- Cutting out part by grinding off flange Application of aluminium paint.

*60 Headlight carrier panel 81BB Centre pillar lining (version B)

Section view of sun roof

• INSPECTION USING TRAMMEL GAUGE

• INSPECTION OF AXLE ASSEMBLY GEOMETRY

Front end of front side member.

Rear mounting of front sub-frame.

The starting point for a rear impact.

Right hand side

The starting point for a frontal impact.

Right hand side Right hand side

Left hand side Left hand side

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

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

Left hand front mounting of front sub- 10×10

Right hand front mounting of front sub- 10×10