4 panelwork - jani tarvainen · pdf filemégane ii - section 4 contents page...

© Renault s.a.s. 2005

"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

NOVEMBER 2005 Edition Anglaise

X84, and B84 or C84 or G84 or S84

4 Panelwork

40A GENERAL VEHICLE INFORMATION

41A FRONT LOWER STRUCTURE

41B CENTRE LOWER STRUCTURE

41C SIDE LOWER STRUCTURE

41D REAR LOWER STRUCTURE

42A UPPER FRONT STRUCTURE

43A SIDE UPPER STRUCTURE

44A REAR UPPER STRUCTURE

45A TOP OF BODY

47A SIDE OPENING ELEMENTS

48A NON-SIDE OPENING ELEMENTS

Mégane II - Section 4

Contents

Page

Mégane II - Section 4ContentsPage

40A GENERAL VEHICLE INFORMATION

Bodywork special tooling: Use 40A-1

Sub-frame: Specifications 40A-5

Hollow body parts inserts: List and location of components 40A-9

Hollow body parts inserts: Precautions for repair 40A-14

Earths on the body: List and location of components 40A-15

Vehicle front section structure: Description 40A-18

Vehicle side section structure: Description 40A-20

Vehicle central section structure: Description 40A-25

Vehicle structure rear section: Description 40A-28

Vehicle removable section structure: Description 40A-32

Structure components to be positioned on body repair bench: Description 40A-34

Structural bodywork reference material: Use 40A-40





Front impact cross member: Removal - Refitting 41A-8

Lower front end cross member: General description 41A-9

Front end side cross member: Description 41A-10

Radiator support cross member: General description 41A-12

Radiator support cross member: Removal - Refitting 41A-13

Front side member: General description 41A-14

Front side member: Description 41A-17

Front section of front side member closure panel: General description 41A-21

Front section of front side member closure panel: Description 41A-23

Battery tray support: General description 41A-26

Battery tray support: Description 41A-27

Radiator cross member mounting: General description 41A-28

Radiator cross member support: Description 41A-29

Front mounting of front sub-frame: General description 41A-31


Contents

Front mounting of front sub-frame: Description 41A-32

Engine mounting: General description 41A-33

Engine mounting: Description 41A-34

Sub-frame rear mounting: General description 41A-35

Sub-frame rear mounting: Description 41A-36

Front half unit: General description 41A-38

Front half unit: Description 41A-39


Vehicle front section structure: Description 41B-1

Vehicle side section structure: Description 41B-3

Vehicle central section structure: Description 41B-8

Centre floor, side section: General description 41B-11

Central floor, side section: Description 41B-13

Centre floor front lateral cross member: General description 41B-16

Centre floor front lateral cross member: Description 41B-18

Tunnel: Description 41B-20

Centre floor stiffener: Description

Front cross member under front seat: General description 41B-22

Front cross member under front seat: Description 41B-23


Front seat rear mounting interior unit: Description 41B-25

Front seat rear outer mounting unit: Description 41B-26

41C SIDE LOWER STRUCTURE

Vehicle side section structure: Description 41C-1

Vehicle central section structure: Description 41C-6

Sill panel: Description 41C-9

Complete sill panel: General description 41C-16

Full inner sill panel: General description 41C-21

Rear inner sill panel: Description 41C-23

Sill panel reinforcement: General description 41C-25

Sill panel reinforcement: Description 41C-26

Sill panel rear reinforcement: Description 41C-29

Front jack support: General description 41C-31

Impact absorber unit: Description 41C-32


Vehicle central section structure: Description 41D-1

Vehicle structure rear section: Description 41D-4

Rear floor, front section: General description 41D-8

Rear floor, front section: Description 41D-10


Contents

Rear floor rear section: General description 41D-13

Rear floor rear section: Removal - Refitting 41D-14

Rear side member: General description 41D-17

Rear impact cross member mounting reinforcement: Description 41D-19

Rear side member: Description 41D-20

Rear side member closure panel, rear section: Description 41D-23

Rear floor front cross member, centre section: Description 41D-25

Rear floor centre cross member: General description 41D-27

Rear floor centre cross member: Description 41D-28

Far rear lower cross member, side section: Description 41D-29

Exhaust mounting support: Description 41D-30

Tank mounting support: Description 41D-31

Rear impact lower cross member: General description 41D-32

Rear impact lower cross member: Removal - Refitting 41D-33






Front wing: General description 42A-8

Front wing: Removal - Refitting 42A-11

Front wing: Adjusting 42A-13

Front wing lower mounting support: General description 42A-17

Front wing lower mounting support: Removal - Refitting 42A-18

Front wing upper mounting support: General description 42A-19

Front wing upper mounting support: Removal - Refitting 42A-20

Front: General description 42A-22

Front: Removal - Refitting 42A-23

Scuttle side panel: General description 42A-26

Cowl side panel: Description 42A-28

Scuttle side panel upper reinforcement: General description 42A-31

Scuttle side panel upper reinforcement: Description 42A-32

Front wheel arch: General description 42A-34

Front wheel arch: Description 42A-35

Heater bulkhead: Description 42A-38

Windscreen aperture lower cross member: General description 42A-40

Windscreen aperture lower cross member: Description 42A-41

Dashboard cross member: Removal - Refitting 42A-42

Windscreen aperture lower cross member closure panel: General description 42A-46

Windscreen aperture lower cross member closure panel: Description 42A-47


Contents

Bulkhead: Description 42A-49

Bulkhead reinforcement: Description 42A-51

Bulkhead lower cross member: General description 42A-52

Bulkhead lower cross member: Description 42A-53

Bulkhead panel: Removal - Refitting 42A-54

Bulkhead side reinforcement: General description 42A-55

Bulkhead upper cross member: General description 42A-56

Bulkhead upper cross member: Description 42A-57

Bulkhead side stiffener: Description 42A-59

Windscreen wiper mounting: Description 42A-61



A-pillar: General description 43A-6

A-pillar: Description 43A-7

A-pillar reinforcement: General description 43A-10

A-pillar reinforcement: Description 43A-11

Windscreen pillar lining: General description 43A-15

Windscreen pillar lining: Description 43A-16

B-pillar: General description 43A-18

B-pillar: Description 43A-21

B-pillar reinforcement: General description 43A-25


B-pillar reinforcement: Description 43A-26

B-pillar reinforcement stiffener: Description 43A-30

B-pillar lining: General description 43A-33

B-pillar lining: Description 43A-34

B-pillar lower lining: Description 43A-36

B-pillar upper lining: Description 43A-37

Body side front section: General description 43A-38

Body side front section: Description 43A-39

Body side front section reinforcement: Description 43A-42

Upper body panel: General description 43A-45

Upper body panel: Description 43A-47


Vehicle structure rear section: Description 44A-1

Rear wing panel: General description 44A-5

Rear wing panel: Description 44A-7

Rear wing panel rain channel: General description 44A-14

Rear wing panel rain channel: Description 44A-15

Rear lights support: General description 44A-17

Rear lights support: Description 44A-18

Lights support lining: General description 44A-20


Contents

Lights support lining: Description 44A-21

Outer rear wheel arch: General description 44A-22

Outer rear wheel arch: Description 44A-24

Inner wheel arch: General descriptions 44A-28

Inner wheel arch: Description 44A-29

Rear wheel arch closure panel: Description 44A-31

Rear wheel arch extension: Description 44A-33

Quarter panel lining: General description 44A-35

Quarter panel reinforcement: Description 44A-36

Quarter panel lining: Description 44A-37

Quarter panel upper reinforcement: Description 44A-40

Quarter panel centre reinforcement: Description 44A-43

Roof rear drip moulding lining: Description 44A-44

Rear end panel assembly: Description 44A-46

Rear end panel: General description 44A-48

Rear end panel: Description 44A-49

Rear end panel side lining: Description 44A-51

45A TOP OF BODY


Roof: General description 45A-6

Roof: Description 45A-7


Roof front section: Description 45A-9

Roof rear section: Description 45A-10

Roof front cross member: General description 45A-11

Roof front cross member: Description 45A-12

Roof centre cross member: General description 45A-13

Roof centre cross member: Description 45A-14

Roof rear cross member: General description 45A-15

Roof rear cross member: Description 45A-16



Front side door: General description 47A-3

Front side door: Removal - Refitting 47A-5

Front side door: Adjustment 47A-7

Front side door: Stripping - Restoring 47A-10

Front side door panel: Description 47A-11

Rear side door: General description 47A-16

Rear side door: Removal - Refitting 47A-18

Rear side door: Adjustment 47A-20

Rear side door: Stripping - Restoring 47A-23

Rear side door panel: Description 47A-24

45A TOP OF BODY

Contents

Fuel filler flap cover: General description 47A-26

Fuel filler flap cover: Removal - Refitting 47A-27

48A NON-SIDE OPENING ELEMENTS


Bonnet: General description 48A-3

Bonnet: Removal - Refitting 48A-5

Bonnet: Adjustment 48A-7

Tailgate: General description 48A-10

Tailgate: Removal - Refitting 48A-11

Tailgate: Adjusting 48A-13

Tailgate: Stripping-Rebuilding 48A-15


40A-1

GENERAL VEHICLE INFORMATIONBodywork special tooling: Use

B84 or C84

40AUSING THE DASHBOARD CROSS MEMBER REMOVAL TOOL Car. 1673

a Screw the rod (1) onto the body (2) as far as the stopand tighten gently.

a Insert the assembly into the A-pillar, then screw intothe beam as far as the stop.

a Firmly lock tool body (2) in the same way as a locknut against the dashboard cross member nut whileholding the hexagonal head of bolt (1) .

a Unscrew the tool as far as the stop using hexagonbolt (2) and tighten it gently (during this operation,the beam nut, which has a left-hand thread, screwsinto the beam and disengages it from the A-pillar).

a Hold the tool body and unlock rod (1) in the sameway as a lock nut.

a Unscrew dashboard cross member rod (1) to remo-ve the tool.

a Repeat the procedure for the second bolt.

This releases the dashboard cross member from theA-pillar.

101308

102527

102529

102530

40A-2


B84 or C84

40Aa To refit, screw the lock nut (left-hand thread) fully

into the beam.

a Fit the beam with the A-pillar hole.

a As for the removal operation, prepare the tool, screwit completely into the beam nut then lock the toolbody (2) against the beam nut.

a Simultaneously screw the rod (1) and the body (2) ofthe tool as far as the stop, tightening gently.

a Hold the body (2) of the tool and unscrew the rod (1)in the same way as a lock nut and then remove thetool.

USING THE DASHBOARD PROTECTION TOOL Car. 1764

a Use this tool when replacing the windscreen:

- remove the A-pillar trims,

- position the dashboard protector to prevent dama-ge.

102528

WARNING

When removing the dashboard cross member, itis possible that the lock nuts may cause the twosides to become incorrectly adjusted. In thiscase, refit the dashboard to adjust the clearanceswith the windscreen pillar trim and the door trim.

18263

40A-3


B84 or C84

40APREPARATION OF TOOL Car. 1504

40A-4


B84 or C84

40A

a (1) Mandrel mounting

- (2) Mandrels

- (3) Tightening bolt

- (4) Body

- (5) Anvils

- (6) Special nut

- (7) Nuts

- (8) Studs

- (9) Thrust nut

- Select the mandrel, anvil and insert assemblyadapted to the crimping operation to be carried out.

- Into the mandrel mounting: (1) screw the mandrel(2) (left-hand thread).

- Tighten the bolt (3) onto the body (4) until the stop(left-hand thread).

- Into the body: (4) screw the anvil (5) (left-handthread).

- Fit the assembly (1) and (2) into the body of the to-ol.

- Screw the insert (left-hand thread) onto the pullrod.

USING TOOL CAR. 1504

a Turn the bolt using a 24 spanner, holding the toolhandle manually.

111554

To fi t the special nut (6) , position the mandrelacross the crimped nut and tighten it onto thethrust nut (9) .

WARNING

Each time a panel is stripped in the workshop(e.g. when drilling), degrease and wipe the areaand then use a fine brush to apply the following:

- a pre-treatment primer,

- a two-part primer,

- paint in the vehicle body colour.

16069

WARNING

Completion of the crimping operation should befelt by the operator (increase in the tighteningeffor t). Crimping of the insert is correct when itno longer has any rotational play; this should bechecked before removing the pull rod - mandrelassembly.

40A-5

GENERAL VEHICLE INFORMATIONSub-frame: Specifications

B84 or C84

40A

DESCRIPTION DIMEN-SION X

DIMEN-SION Y

DIMEN-SION Z

DIAMETER (inmm)

ANGLE(indegrees)

A Front sub-frame rear mountingwithout mechanical components

301 305 77.8 ∅ 24.5; M12 0

Front sub-frame rear mountingwith mechanical components

301 305 6.5 M12 0

B Rear axle leader pin withoutmechanical components

2148.2 - 650.8 116 ∅ 20.5; M10 0

B1 Rear axle assembly front moun-ting without mechanical compo-nents

2040 -635 116 M10 0

Rear axle assembly front moun-ting with mechanical components

2040 -635 111 M10 0

B2 Rear axle assembly front moun-ting without mechanical compo-nents

2131 -732.2 116 M10 0

Rear axle assembly front moun-ting with mechanical components

2131 -732.2 111 M10 0

C Front sub-frame front mounting -141.5 -478 252 M10 0

C* Front sub-frame front mounting 141.4 477.9 261 M12 0

E Rear shock absorber upper moun-ting

2435 -398 262.5 ∅ 10.7; M10 90

F1 Front shock absorber upper stop -55.1 - 602.1 687.3 M8

F1* Front shock absorber upper stop 82.7 601.8 670.4 M8

F2 Front shock absorber upper stop 50.7 -529.9 672.4 M8

F2* Front shock absorber upper stop -24 530.1 681.4 M8

F3 Front shock absorber upper stop 73.3 -631.8 672.2 M8

F3* Front shock absorber upper stop -45.4 632.1 686.8 M8

F4 Front shock absorber mountingleader pin

81.4 -598.2 670.4 17.2 x 17.2

F4* Front shock absorber mountingleader pin

-53.9 597.9 687.2 17.2 x 17.2

G Front side member rear leader pin 547 -408.6 -9.8 ∅ 20.5 0

H Front side member front leaderpin, without mechanical compo-nents

-525 -476 84.5 M12 0

40A-6


B84 or C84

40A

Front side member front leaderpin, with mechanical components

-525 -476 80.7 M12 0

H* Front side member front leaderpin, without mechanical compo-nents

-525 492 84 M12 0

Front side member front leaderpin, with mechanical components

-525 492 80.2 M12 0

J Rear side member rear leader pin 3005 -563.5 235 20x20 0

J* Rear side member rear leader pin 3005 -523.5 235 20x20 0

K1 Front end cross member -552.9 -439.3 410.9 M10 90

K1* Front end cross member -552.2 447.6 409 M10 90

K2 Front end cross member -546.2 -535.1 276 M10 90

K2* Front end cross member -546.3 -533.6 276 M10 90

K3 Front panel support additionalmounting

-312.9 -737 634.5 M6 9.64

L Rear end cross member 3096.7 -515 315 M8 90

L* Rear end cross member 3096.7 572.2 315 M8 90

L1 Rear end cross member 3096.7 -612.5 217.5 M8 90

L1* Rear end cross member 3096.7 474.7 217.5 M8 90

P1 Engine mounting -309.2 507 528.9 M10 0

P2 Engine mounting -149.2 529 531.9 M10 0

R Additional engine mounting (tie-rod)

-35.6 452.6 587 ∅ 14.5; M12 0

DESCRIPTION DIMEN-SION X

DIMEN-SION Y

DIMEN-SION Z

DIAMETER (inmm)

ANGLE(indegrees)

Note:

The reference points located on the right-hand sideof the vehicle are shown by an asterisk.

40A-7


B84 or C84

40AA and B = vehicle trim height reference

40A-8


B84 or C84

40A100030

40A-9

GENERAL VEHICLE INFORMATIONHollow body parts inserts: List and location of components

B84 or C84

40A

B84

101425

40A-10


B84 or C84

40A

A-pillar insert (1) .

A-pillar reinforcement insert (2) .

C84

101424

102031

102848

40A-11


B84 or C84

40A

A-pillar insert (3) .

A-pillar lining insert (4) .

Front side member rear insert (5) .

B-pillar insert (6) .

102007

102850

102868

B84

101967

40A-12


B84 or C84

40A

B-pillar reinforcement insert (7) .

Rear wing panel lower insert (8) .

Rear wing panel upper insert (9) .

Sill panel rear insert (10) , (11) .

102851

101968

102849

C84

102581

40A-13


B84 or C84

40A

Sill panel reinforcement insert (12) .

Rear wing panel upper insert (13) .

102591

102629

40A-14

GENERAL VEHICLE INFORMATIONHollow body parts inserts: Precautions for repair

B84 or C84

40AThe expanding inserts ensure that the vehicle cavitiesare sealed and soundproofed. They react to the tempe-rature when the bodywork is immersed in the catapho-retic bath at the factory. These conditions cannot bereproduced on the bodywork.

As inserts are not recoverable, always replace expan-ding inserts.

The inserts supplied by the Parts Department areidentical to the original parts.

To obtain the same sealing and soundproofing proper-ties, carry out the following operations:

- clean the bonding surfaces with heptane.

- if necessary, seal the holes in the insert using piecescut from a soundproofing pad.

- apply a bead of preformed trim sealing mastic aroundand inside the insert holes.

- fit the insert by compressing the mastic.

In some cases, it is possible to replace the accessiblepart of the insert only, which must be cut out of the re-placement part.

WARNING

Do not refit the part after compressing the bead.

When MIG welding, protect the inserts from spatterand heat dispersion.

For example, use a heat shield.

40A-15

GENERAL VEHICLE INFORMATIONEarths on the body: List and location of components

B84 or C84

40AFor the replacement procedure for earth studs, see MR400, 40A, General information, Electrical earthscrew connections .IMPORTANT

To avoid damaging the vehicle's electric and elec-tronic components, the battery and the earths ofany wiring harness near the weld area must be dis-connected.

The earth of the welding machine must be placedas close as possible to the weld area.

115071

40A-16


B84 or C84

40ADETAILED VIEW OF THE POSITION OF EARTHS ON THE VEHICLE

Earth studs (1) on the front right-hand side member.

Earth studs (2) on the front left-hand side member andon the front end side cross member.

Earth studs (3) on the tunnel.

Left-hand side

Earths studs (4) on the rear end panel side lining.

115075

115076

115077

115101

40A-17


B84 or C84

40ARight-hand side

Earth studs (5) on the rear end panel side lining and onthe inner wheel arch.

115105

40A-18

GENERAL VEHICLE INFORMATIONVehicle front section structure: Description

B84 or C84

40AFRONT STRUCTURE

102401

Mark Description Classification Type Thickness(mm)

(1) Scuttle side panel upper reinforcement (see 42A , Upper front struc-ture, Scuttle side panel upperreinforcement: Description,page 42A-32)

- 0.9

(2) Scuttle side panel (see 42A , Upper front struc-ture, Cowl side panel: Descrip-tion, page 42A-28)

HLE/THLE

1/2.5

(3) Front end side cross member (see Front end side cross mem-ber: Description )

- 1.2

(4) Left-hand front half unit (see 41A , Front lower struc-ture, Front half unit: Descrip-tion, page 41A-39)

HLE/THLE

1.1/3

(5) Front section of front side member clo-sure panel

(see 41A , Front lower struc-ture, Front section of front sidemember closure panel: Des-cription, page 41A-23)

HLE/THLE

1.7/3

40A-19

GENERAL VEHICLE INFORMATIONVehicle front section structure: Description

B84 or C84

40A

(6) Front mounting of front sub-frame (see 41A , Front lower struc-ture, F ront mounting of frontsub-frame: Description, page41A-32)

HLE 1.2

(7) Radiator cross member support (see 41A , Front lower struc-ture, Radiator cross membersupport: Description, page 41A-29)

- 1.2/2.5

(8) Front side member (see 41A , Front lower struc-ture, Front side member: Des-cription, page 41A-17)

HLE/THLE

1.2/3

(9) Battery tray bracket (see 41A , Front lower struc-ture, Battery tray support: Des-cription, page 41A-27)

- 1.5/2

(10) Right-hand front half unit (see 41A , Front lower struc-ture, Front half unit: Descrip-tion, page 41A-39)

HLE/THLE

1.1/3


- 1.2

(12) Engine stand (see 41A , Front lower struc-ture, Engine mounting: Des-cription, page 41A-34)

HLE 1.5/2

(13) Wheel arch (see 42A , Upper front struc-ture, Front wheel arch: Descrip-tion, page 42A-35)

- 1.1/2

(14) Engine tie-bar mounting HLE 1

(15) Sub-frame rear mounting (see Sub-frame rear mounting:Description )

HLE/THLE

2/3

(16) Centre floor front side cross member (see 41B, Centre lower struc-ture, Centre floor front lateralcross member: Description,page 41B-18)

HLE/THLE

1.2/3

(17) Connecting bracket

(18) Front wheel arch (see 42A , Upper front struc-ture, Front wheel arch: Descrip-tion, page 42A-35)

HLE 1.1/2


40A-20

GENERAL VEHICLE INFORMATIONVehicle side section structure: Description

B84 or C84

40ASIDE STRUCTURE

B84

102402


(1) Front side door panel (see Front side door panel:Description )

HLE 0.7/0.95

(2) Rear side door panel (see Rear side door panel:Description )

HLE 0.7/0.95

(3) Front jack support ( (see Front jacking point:Description)

HLE 1.8

(4) Rear jack support ( (see Front jacking point:Description)

HLE 1.8

(5) Sill panel (see 41C, Side lower struc-ture, Sill panel: Description,page 41C-9)

- 0.7

(6) Upper body (see 43A, Side upper struc-ture, Upper body panel: Des-cription, page 43A-47)

- 0.7

40A-21


B84 or C84

40A

(7) Body side front section (see 43A, Side upper struc-ture, B o dy side front sec-tion: Description, page 43A-39)

- 0.7

(8) Body side front section reinforcement (see 43A, Side upper struc-ture, B o dy side front sec-t i o n r e i n f o rcement:Description, page 43A-42)

HLE 1.2/1.5

(9) Rear inner sill panel (see 41C, Side lower struc-ture, Rear inner sill panel:Description, page 41C-23)

HLE 1

(10) B-pillar reinforcement stiffener (see B-pillar reinforcementstiffener: Description )

HLE 1.5/2.2

(11) Anti-intrusion reinforcement

(12) B-pillar lower lining (see B-pillar lower lining:Description )

- 0.7

(13) B-pillar upper lining (see B-pillar upper lining:Description )

HLE 1.5

(14) Rear roof drip moulding lining ( (see Roof drip mouldinglining: Description)

- 1

(15) Roof rear cross member with sunroof (see 45A, Top of body, Roofrear cross member: Descrip-tion, page 45A-16)

HLE 0.7/0.9

(16) Roof rear cross member without sun-roof

(see 45A, Top of body, Roofrear cross member: Descrip-tion, page 45A-16)

HLE 0.7/0.9

(17) Roof middle cross member (see 45A, Top of body, Roofcentre cross member: Des-cription, page 45A-14)

HLE 1.5

(18) Front section of roof (see 45A, Top of body, Rooffront section: Description,page 45A-9)

- 0.7

(19) A-pillar lining (see 43A, Side upper struc-ture, Windscreen pillarlining: Description, page43A-16)

HLE 1.5/2

(20) Roof front cross member (see 45A, Top of body, Rooffront cross member: Des-cription, page 45A-12)

HLE 0.7


40A-22


B84 or C84

40A

(21) Roof (see 45A, Top of body, Roof:Description, page 45A-7)

- 0.7

(22) Rear section of roof (see 45A, Top of body, Roofrear section: Description,page 45A-10)

- 0.7


C84

102403



HLE 0.7/0.95


HLE 1.8


HLE 1.8

40A-23


B84 or C84

40A


- 0.7


- 0.7


- 0.7


HLE 1.2/1.5


HLE 1


(10) Quarter panel front reinforcement HLE 1.5


VHLE 1.8


HLE 1.5/2



HLE 0.7/0.9


HLE 0.7/0.9


- 0.7


- 0.7


- 0.7


40A-24


B84 or C84

40A


HLE 0.7


HLE 1.5


40A-25

GENERAL VEHICLE INFORMATIONVehicle central section structure: Description

B84 or C84

40ACENTRAL STRUCTURE

102404


(1) Bulkhead lower cross member (see 42A, Upper front struc-ture, Bulkhead lower crossmember: Description, page42A-53)

VHLE 2.5

(2) Steering column unit - 1.5

(3) Bulkhead (see 42A, Upper front struc-ture, Bulkhead: Description,page 42A-49)

- 0.9

(4) Bulkhead side reinforcement (see 42A, Upper front struc-ture, Bulkhead side stiffe-ner: Description, page 42A-59)

UHLE 1.7

(5) Bulkhead reinforcement (see 42A, Upper front struc-ture, Bulkhead reinforce-ment: Description, page42A-51)

UHLE 1.7

40A-26


B84 or C84

40A

(6) Bulkhead upper cross member (see 42A, Upper front struc-ture, Bulkhead upper crossmember: Description, page42A-57)

HLE 0.95/3

(7) Heater bulkhead (see 42A, Upper front struc-ture, Heater bulkhead: Des-cription, page 42A-38)

- 0.7/1.2

(8) Windscreen wiper mounting (see 42A, Upper front struc-ture, Windscreen wipermounting: Description, page42A-61)

- 1.2

(9) Windscreen aperture lower cross mem-ber

(see 42A, Upper front struc-ture, Windscreen aperturelower cross member: Des-cription, page 42A-41)

- 0.7

(10) Windscreen aperture lower cross mem-ber closure panel

(see 42A, Upper front struc-ture, Windscreen aperturelower cross member clo-sure panel: Description,page 42A-47)

- 0.65/1.2

(11) Front seat mounting exterior unit (see 41B , Centre lowerstructure, Front seat rearouter mounting unit: Des-cription, page 41B-26)

HLE 1.5

(12) Front seat mounting interior unit (see 41B , Centre lowerstructure, Front seat rearmounting interior unit: Des-cription, page 41B-25)

HLE 1.5/2.5

(13) Front cross member under front seat (see 41B , Centre lowerstructure, Front cross mem-ber under front seat: Des-cription, page 41B-23)

HLE 1.5

(14) Steering column mounting - 1.3

(15) Tunnel (see 41B , Centre lowerstructure, Tunnel: Descrip-tion, page 41B-20)

HLE/THLE

1/1.6

(16) Centre floor, side section (see 41B , Centre lowerstructure, Central floor, sidesection: Description, page41B-13)

VHLE 0.7/2.5

(17) Exhaust mounting support (see 41D, Rear lower struc-ture, Exhaust mounting sup-port: Description, page 41D-30)

- 1.2/2.5


40A-27


B84 or C84

40A

(18) Fuel tank mounting support (see 41D, Rear lower struc-ture, Tank mounting sup-port: Description, page 41D-31)

- 1.2

(19) Front section of rear floor (see 41D, Rear lower struc-ture, Rear floor, front sec-tion: Description, page 41D-10)

HLE/THLE

0.7/2.5

(20) Sill panel reinforcement stiffener VHLE 1.8

(21) Sill panel rear reinforcement (see 41C, Side lower struc-ture, Sill panel rear reinfor-cement: Description, page41C-29)

HLE 1.4

(22) Fuel gauge closure panel HLE 0.8

(23) Rear floor front cross member, centresection

(see 41D, Rear lower struc-ture, Rear floor front crossmember, centre section:Description, page 41D-25)

HLE 1.2/2


40A-28

GENERAL VEHICLE INFORMATIONVehicle structure rear section: Description

B84 or C84

40AREAR STRUCTURE

B84

102405


(1) Rear wing panel (see 44A, Rear upper structure, Rear wingpanel: Description, page 44A-7)

- 0.7

(2) Quarter panel lining (see 4 4 A, Rear upper structure, Quarterpanel lining: Description, page 44A-37)

- 0.6

(3) Rear quarter upper rein-forcement

(see 4 4 A, Rear upper structure, Quarterpanel upper reinforcement: Description, page44A-40)

- 0.9

(4) Far rear lower crossmember, side section

(see 4 1 D, Rear lower structure, F ar rearlower cross member, side section: Descrip-tion, page 41D-29)

- 0.95

(5) Rear wheel arch exten-der

(see 44A, Rear upper structure, Rear wheelarch extension: Description, page 44A-33)

- 0.7

(6) Tailgate stop mounting

40A-29


B84 or C84

40A

(7) Rear floor centre crossmember

(see 41D, Rear lower structure, Rear floorcentre cross member: Description, page 41D-28)

HLE 1/2.5

(8) Rear end panel assem-bly

(see 44A, Rear upper structure, Rear endpanel assembly: Description, page 44A-46)

HLE/THLE

0.65/2.5

(9) Rear end panel (see 44A, Rear upper structure, Rear endpanel: Description, page 44A-49)

- 0.65

(10) Rear side member (see 41D, Rear lower structure, Rear sidemember: Description, page 41D-20)

HLE/THLE

0.95/2

(11) Rear impact crossmember mounting stiffe-ner

(see Rear impact cross member mountingstiffener: Description )

HLE 2

(12) Rear end panel sidelining

(see 44A, Rear upper structure, Rear endpanel side lining: Description, page 44A-51)

- 0.7

(13) Rear side member clo-sure panel, rear section

(see 41D, Rear lower structure, Rear sidemember closure panel, rear section: Descrip-tion, page 41D-23)

- 0.7

(14) Light mounting lining (see 44A, Rear upper structure, Lights sup-port lining: Description, page 44A-21)

HLE 0.95

(15) Rear light mounting (see 44A, Rear upper structure, Rear lightssupport: Description, page 44A-18)

- 0.9

(16) Inner rear wheel arch (see 44A, Rear upper structure, Inner wheelarch: Description, page 44A-29)

HLE 0.7/1.5

(17) Rear wheel arch closurepanel

(see 44A, Rear upper structure, Rear wheelarch closure panel: Description, page 44A-31)

- 0.7

(18) Quarter panel stiffener (see 4 4 A, Rear upper structure, Quarterpanel reinforcement: Description, page 44A-36)

- 0.9

(19) Rear wing panel rainchannel

(see 44A, Rear upper structure, Rear wingpanel rain channel: Description, page 44A-15)

HLE 0.85/1


40A-30


B84 or C84

40A

C84

102406



- 0.7


- 0.6



- 0.9

(4) Quarter panel centrereinforcement

(see 4 4 A, Rear upper structure, Quarterpanel centre reinforcement: Description,page 44A-43)

HLE 1.5

(5) Rear roof drip mouldinglining

(see 44A, Rear upper structure, Roof reardrip moulding lining: Description, page 44A-44)

- 1/2

40A-31


B84 or C84

40A

(6) Far rear lower crossmember, side part


- 0.95



- 0.7




HLE 1/2.5



HLE/THLE

0.65/2.5


- 0.65


HLE/THLE

0.95/2



- 0.7

(14) Impact cross membermounting stiffener


HLE 2


HLE 0.95



- 0.7


- 0.9


HLE 0.7/1.5



- 0.7


- 0.9



HLE 0.85/1


40A-32

GENERAL VEHICLE INFORMATIONVehicle removable section structure: Description

B84 or C84

40ASTRUCTURE WHICH CAN BE DISMANTLED

102400

Mark Description Classification Type

(1) Frontal impact cross member (see 41A, Front lower structure,Front impact cross member:Removal - Refitting, page 41A-8)

Aluminium

(2) Radiator mounting cross member (see 41A, Front lower structure,Radiator support cross member:Removal - Refitting, page 41A-13)

(3) Front end panel centre section (see 42A, Upper front structure,Front: Removal - Refitting, page42A-23)

Steel/SMC

(4) Front end panel side section (see 42A, Upper front structure,Front: Removal - Refitting, page42A-23)

SMC

(5) Bonnet (see 48A, Non-side opening ele-ments, Bonnet: Removal - Refit-ting, page 48A-5)

Aluminium

40A-33

GENERAL VEHICLE INFORMATIONVehicle removable section structure: Description

B84 or C84

40A

(6) Front wing upper mounting support (see 42A, Upper front structure,Front wing upper mounting sup-port: Removal - Refitting, page42A-20)

(7) Front wing (see 42A, Upper front structure,Front wing: Removal - Refitting,page 42A-11)

Noryl

(8) Front wing lower mounting support (see 42A, Upper front structure,Front wing lower mounting sup-port: Removal - Refitting, page42A-18)

(9) Dashboard cross member (see 42A, Upper front structure,Dashboard cross member:Removal - Refitting, page 42A-42)

(10) Bulkhead plate (see 42A, Upper front structure,Bulkhead panel: Removal - Refit-ting, page 42A-54)

Aluminium

(11) Front side door, 3-door version (see 47A , Side opening ele-ments, Front side door: Removal- Refitting, page 47A-5)


(13) Fuel filler flap cover (see 47A , Side opening ele-ments , Fuel filler flap cover:Removal - Refitting, page 47A-27)

Noryl

(14) Rear section of rear floor ( (see Rear floor rear section:Description)

(15) Rear side door (see 47A , Side opening ele-ments, Rear side door: Removal- Refitting, page 47A-18)

(16) Rear impact lower cross member (see 41D, Rear lower structure,Rear impact lower cross mem-ber: Removal - Refitting, page41D-33)

Polypropy-lene

(17) Tailgate (see 48A, Non-side opening ele-ments, Tailgate: Removal - Refit-ting, page 48A-11)


40A-34

GENERAL VEHICLE INFORMATIONStructure components to be positioned on body repair bench: Description

B84 or C84

40APART REQUIRING REPAIRS IN BODY JIG BENCH

- (1) Engine stand.

- (2) Front wheel arch.

- (3) Front half unit.

- (4) Front side member.

- (5) Radiator cross member mounting.

- (6) Front sub-frame front mounting unit.

- (7) Front sub-frame rear mounting unit.

- (8) Rear side member.

I - PRINCIPAL REFERENCE POINTS FOR SETTING TRIM HEIGHT

1 - A - FRONT SUB-FRAME REAR MOUNTING

This is the principal front reference point for setting thetrim height.

a - Front mechanical components in place

The bracket covers the sub-frame mounting bolt (A) .

102044

101152

40A-35


B84 or C84

40ATwo possible cases can arise:

- For rebuilding the rear of the vehicle, these two pointsalone can be used to align and support the front of thevehicle.

- For a light frontal impact not requiring removal of thefront axle sub-frame.

If in doubt about the damage to one of the main refe-rence points (A or B), use the two additional points lo-cated in the area not affected by the impact to confirmthe trim height.

b - Front mechanical components removed

If replacing the sub-frame rear support, this referencepoint is replaced temporarily by point (G), located onthe rear part of the front side member, point (A) thusbeing used for positioning the replaced component.

2 - B - REAR AXLE FRONT MOUNTING

This is the principal rear reference point for setting thetrim height.

a - Rear mechanical components in place

The bracket covers the rear axle bearing mountingbolts.

Used for a frontal impact or a light rear impact.

b - Rear mechanical components removed

101091

Note:

- on the left-hand side, the hole is round;

- on the right-hand side, it is a slot.

WARNING

This point contributes to ensuring the front axlegeometry, it aligns the front axle sub-frame with thebody and directly influences all the angles of thefront axle.

101154

101092

40A-36


B84 or C84

40AThe bracket is supporting the underneath of the rearaxle assembly mounting unit and is centred in thethreaded holes of the rear axle bearing mounting.

If the complete rear side member is being replaced,this reference point is replaced by point (G) located onthe rear section of the front side member, points (B)being used to position the replaced component.

II - REFERENCE POINTS FOR POSITIONING THE PARTS REPLACED

1 - C - FRONT SUB-FRAME FRONT MOUNTING UNIT

With just the front mechanical components removed,the bracket rests under the front sub-frame front moun-ting unit and is centred in the threaded hole of the sub-frame mounting.

It is used when replacing:

- a partial or complete front side member,

- a half unit.

2 - F - FRONT SHOCK ABSORBER UPPER MOUNTING

The bracket rests under the shock absorber cup and iscentred in the shock absorber cup hole.

It is used when replacing:

- a wheel arch,

- a front half unit.

It is also used when straightening.

WARNINGThese points are used to align the rear axle with thebody and directly influence the vehicle trajectoryangle.

101090

WARNING

This point helps to maintain the front axle geometry.It directly influences the clearance in the space ofthe lower wishbone and therefore the variations incastor angle and wheel alignment.

101088

WARNING

This point helps to maintain the front axle geometry.It directly influences the camber and castor pivotangles.

40A-37


B84 or C84

40A3 - P - ENGINE MOUNTING

The bracket is positioned from above the engine moun-ting and is centred in the mounting hole of the axle.

It should be used with the mechanical components re-moved for the replacement of:


- a front wheel arch.

4 - H - END OF FRONT SIDE MEMBER

The bracket rests under the side member and is cen-tred in the threaded hole of the radiator mounting crossmember.

It should be used with the mechanical components re-moved for the replacement of:

- a side member,


- a radiator cross member mounting support.

5 - K - FRONTAL IMPACT CROSS MEMBER MOUNTING

The bracket rests vertically against the radiator crossmember mounting and is centred in the threadedmounting holes of the frontal impact cross member.

When rebuilding, points (K) are used for replacing:

- a radiator cross member mounting,

- a partial or complete front side member,

- a half unit.

101094

101090

101093

40A-38


B84 or C84

40A

They are also used as reference points for point (K3)for mounting the front wing upper support.

6 - J - REAR SIDE MEMBER END

The bracket rests under the side member and is cen-tred in the leader pin hole.

It should be used with the mechanical components inplace to realign a side member.

It is also used with the mechanical components remo-ved, in the same conditions, to replace the side mem-ber.

7 - E - REAR SHOCK ABSORBER MOUNTING

The bracket is centred and attached inside the shockabsorber shaft.

It should be used when replacing a complete rear sidemember.

8 - L - REAR END PANEL CROSS MEMBER

The bracket rests vertically against the side lining ofthe rear end panel and is centred on the rear impactcross member mounting studs.

101093

101087

101089

101095

40A-39


B84 or C84

40AThey are used when replacing:

- an impact cross member mounting stiffener,

- a partial or complete rear side member.

40A-40

GENERAL VEHICLE INFORMATIONStructural bodywork reference material: Use

B84 or C84

40AI - - CLASSIFYING INFORMATION

This information is classified in two additional docu-ments:

1 - Vehicle structure bodywork repair procedures (MR of the vehicle concerned)

This document comprises two sections:

a - Section 0:

This section does not contain repair procedures, it onlycontains descriptive information; It consists of severalsubsections:

- 01C Vehicle bodywork specifications

- 02A Lifting equipment

- 02B Bodywork innovations

- 03B Collision

- 04E Paintwork

- 05B Bodywork equipment and tooling

b - Section 4:

This section consists of several subsections:

- 40A General information

- 41A Lower front structure

- 41B Lower central structure

- 41C Lower side structure

- 41D Lower rear structure

- 42A Upper front structure

- 43A Upper side structure

- 44A Upper rear structure

- 45A Top of body

- 47A Side opening elements

- 48A Non-side opening elements

These subsections are linked to the ReplacementParts Catalogue and contain two types of information

- Part 1: General description containing information re-lating to generic structural spare parts and to their de-sign. This information may be the same for severalvehicles.

- Part 2: Description, removal and refitting, strip and re-build, and adjustment; contains information about thestructure of the replacement parts and contains spe-cial notes about the vehicle being worked on.

2 - Fundamentals of structural bodywork repair (MR 400)

This document comprises two sections:

a - Section 0:

This section does not contain any repair procedures; itonly contains descriptive information and has only onesubsection:

- 03B Collision

b - Section 4:

This section contains information for using materialsand products, and the fundamental operating rangeswhich relate to the sheet metal worker's work. This sec-tion only contains a single subsection.

- 40A Structure general information

II - INFORMATION SEARCH

WARNINGAlways read both parts in order to have all thenecessary information to repair the vehicle.

Questions Answers

Specifications of specific tools to repair a given vehi-cle.

Refer firstly to section 0 of the Vehicle's MR then referto the « special tooling catalogue » or the « garageequipment catalogue » .

Specifications of specific products to repair a givenvehicle.

Firstly refer to section 0 of the Vehicle's MR then referto the « IXELL product catalogue » .

40A-41


B84 or C84

40A

Use of a specific tool to repair a given vehicle. Firstly refer to subsection 0 of the Vehicle's MR

Using a bodywork tool. Firstly refer to subsection 40 of the Vehicle MR thenMR 400

Information concerning the replacement parts of agiven vehicle regarding:

- The replacement possibilities with the position onthe vehicle.

- A conversion before assembly.

- A cutting area with the special features of this cut.

- Special features of right-left symmetry.

- Special features of the version or equipment.

Refer to the subsection which corresponds to the partconcerned: 41 to 48 of the Vehicle MR, part 2

Information concerning the spare parts of a givenvehicle, the composition and the specifications ofeach par t it contains.

Firstly refer to the parts description exploded view insubsection 40 of the Vehicle MR.

If this is detailed in the document, refer to subsections41 to 48 of the Vehicle MR part 2 which correspondswith the part concerned.

If this does not appear in the description, refer to sub-section 41 to 48 for the part in the next level up.

Information concerning:

- Details of panel overlap on a joint.

- A procedure and an operational mode relating to anew type of assembly in Renault.

- A procedure for using a tool or a new product whichis unfamiliar in Renault.

Refer to the subsection which corresponds to the partconcerned: 41 to 48 of the Vehicle MR then subsec-tion 40 of Vehicle MR 400.

Towing and raising a vehicle after an accident. Firstly refer to subsection 40 of the Vehicle MR thenthe equipment catalogue.

Conveyance and handling of a vehicle after an acci-dent.

Firstly refer to subsection 40 of the MR 400 then theequipment catalogue.

Combination of impacts to repair a given vehicle. Refer to section 0 of the Vehicle's MR

Logic of the impact combination. Refer to section 0 of the Vehicle's MR

Fault finding on an impact for a given vehicle. Firstly refer to section 0 of the Vehicle's MR then sec-tion 0 of MR 400.

Questions Answers

40A-42


B84 or C84

40A

Logic of impact fault finding. Section 0 of MR 400.

General instructions for:

- Repair.

- Safety.

- Preparing a vehicle.

- Classification of tools.

- Precautions for repair.

Section 0 of MR 400.

Questions Answers

41A-1

FRONT LOWER STRUCTUREVehicle front section structure: Description

B84 or C84

41AFRONT STRUCTURE

102401



- 0.9


HLE/THLE

1/2.5


- 1.2


HLE/THLE

1.1/3



HLE/THLE

1.7/3

41A-2

FRONT LOWER STRUCTUREVehicle front section structure: Description

B84 or C84

41A


HLE 1.2


- 1.2/2.5


HLE/THLE

1.2/3


- 1.5/2


HLE/THLE

1.1/3


- 1.2


HLE 1.5/2


- 1.1/2



HLE/THLE

2/3


HLE/THLE

1.2/3



HLE 1.1/2


41A-3

FRONT LOWER STRUCTUREVehicle central section structure: Description

B84 or C84


102404



VHLE 2.5



- 0.9


UHLE 1.7


UHLE 1.7

41A-4


B84 or C84

41A


HLE 0.95/3


- 0.7/1.2


- 1.2



- 0.7



- 0.65/1.2


HLE 1.5


HLE 1.5/2.5


HLE 1.5



HLE/THLE

1/1.6


VHLE 0.7/2.5


- 1.2/2.5


41A-5


B84 or C84

41A


- 1.2


HLE/THLE

0.7/2.5



HLE 1.4




HLE 1.2/2


41A-6

FRONT LOWER STRUCTUREVehicle removable section structure: Description

B84 or C84


102400



Aluminium



Steel/SMC


SMC


Aluminium

41A-7

FRONT LOWER STRUCTUREVehicle removable section structure: Description

B84 or C84

41A



Noryl




Aluminium




Noryl




Polypropy-lene



41A-8

FRONT LOWER STRUCTUREFront impact cross member: Removal - Refitting

B84 or C84

41A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove:

- the front bumper( (see Front bumper: Removal -Refitting) ,

- the headlights( (see Halogen headlight: Removal- Refitting) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the side mounting bolts (1) (three on eitherside).

a Move the retaining clips on the front end panel awayusing a flat-blade screwdriver and detach the frontalimpact cross member.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the front impact cross member,

- the side mounting bolts (1) (three on each side).

a

a Tighten to torque:

- the side mounting bolts ( 44 Nm ) ,

- the unit bolts ( 35 Nm ) .

II - FINAL OPERATION

a Refit:

- Refit the headlights( (see Halogen headlight: Re-moval - Refitting) ,

- the front bumper( (see Front bumper: Removal -Refitting) .

Tightening torquesm

side mounting bolts 44 Nm

unit bolts 35 Nm

101164

Note:

Depending on the degree of impact, it may bepossible to replace the cross member via the unitbolts (2) .

101165

WARNING

The cross member contributes to the structuralrigidity of the engine compartment. For thisreason, the tightening torque must be observedfollowing any operation.

41A-9

FRONT LOWER STRUCTURELower front end cross member: General description

B84 or C84

41A

DESIGN OF THE STRUCTURAL COMPONENT

A special feature of this part is that it is bolted to theends of the front side members via the radiator crossmember mounting support.

WARNING

The information contained in the following descri-bes the general repair procedure for all vehicleshaving the same design for this part.

Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special notes will be specified if applica-ble in other parts of this subsection dealing with thepart.

Note:

For a detailed description of a particular connec-tion, see MR 400, 40A, General Information .

110517

41A-10

FRONT LOWER STRUCTUREFront end side cross member: Description

B84 or C84

41AThere is only one way of replacing this part:

- complete replacement.

I - COMPOSITION OF THE SPARE PART

Right-hand side

Left-hand side

II - PART FITTED

Right-hand side

Left-hand side

102624

101414

Mark Description Type Thickness(mm)

(1) Front end sidecross member

- 1.2

101762

101591

41A-11

FRONT LOWER STRUCTUREFront end side cross member: Description

B84 or C84

41A

WARNING

If the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,these should be replaced with plug welds afterholes have been drilled in the first panel.

41A-12

FRONT LOWER STRUCTURERadiator support cross member: General description

B84 or C84

41A


The distinctive feature of this part is that it combines two functions:

- distributing the force of frontal impacts,

- radiator mounting cross member.

WARNING



Note:


110077

41A-13

FRONT LOWER STRUCTURERadiator support cross member: Removal - Refitting

B84 or C84

41A

REMOVAL


a Remove the front bumper( (see Front bumper: Re-moval - Refitting) .

a Attach the radiator upper section.

a Remove the engine undertray.


a Remove:

- the mounting bolts (1) , (2) and (3) ,

- the radiator mounting cross member.

REFITTING


a Refit:

- the radiator mounting cross member,

- the mounting bolts (1) , (2) and (3) .


- the mounting nut (1) ( 21 Nm ) ,

- the mounting bolts (2) ( 105 Nm ) ,

- the mounting bolts (3) ( 62 Nm ) .


a Refit the engine undertray.

a Detach the radiator upper section.

a Refit the front bumper( (see Front bumper: Remo-val - Refitting) .

Tightening torquesm

the mounting nut (1) 21 Nm

the mounting bolts (2) 105 Nm

the mounting bolts (3) 62 Nm

102009

41A-14

FRONT LOWER STRUCTUREFront side member: General description

B84 or C84

41A

I - DESIGN OF THE STRUCTURAL COMPONENT

The special feature of this type of part is that it combi-nes the functions of front section and rear section ofthe front side member and that it is made of two diffe-rent kinds of panels of different thicknesses assembledby laser butt welding.

II - AREA TO BE CUT FOR PARTIAL REPLACEMENT

1 - 1- Cut 1:

This line shows the centre of the area in which it is pos-sible to carry out a partial replacement.

This operation allows you to access the inside of thehollow section of the structural component to straigh-ten it.

In this case, the side member weld line must be stag-gered from that of its closure panel.

WARNING



IMPORTANT

The straightening bench must be used.

Note:


110509

110510

Note:

For the partial replacement of parts constituting asingle structural component, it is essential to stag-ger the welds of each of the components.

1

2

41A-15


B84 or C84

41A

2 - 2 - Cut 2:

The cut is made along the butt weld.III - ASSEMBLY INSTRUCTIONS FOR A PARTIAL REPLACEMENT

Only the connecting pieces relevant to partial replace-ment by cutting are shown.

108391

108396

108392

108390

WARNING


41A-16


B84 or C84

41AIf there are other issues regarding access to mating fa-ces, the various replacement options are described inthe basic instructions for structural bodywork repair(see MR 400, 40A, General Information ).

Lines (3) and (4) of the diagram show a butt weld bycontinuous MAG welding.

Weld (4) along the butt weld line.

110511

3

4

41A-17

FRONT LOWER STRUCTUREFront side member: Description

B84 or C84

41ARight-hand side

Left-hand side

The options for replacing this part are as follows:

- partial replacement of the front section,

- partial replacement.


Right-hand side

Left-hand side

115690

115689

115114

115115

41A-18


B84 or C84

41AII - PART FITTED

1 - Partial replacement of the front section

Right-hand side

Left-hand side


(1) Front section offront side mem-ber

HLE/THLE

1.7/2.5

(2) Bulkhead crossmember right-hand bracket

- 1.5

(3) Stiffener unit forend of sidemember

VHLE 1.8

(4) Impact absorbermounting unit

HLE/THLE

1.2/3

(5) Sub-framemounting unit

HLE 1.8/3

(6) Front side mem-ber reinforce-ment

HLE 1.5

(7) Reinforcementfor gearbox onside member

- 1.5

(8) Side plate moun-ting reinforce-ment

- 1.7

101757

101756

41A-19


B84 or C84

41A2 - Partial replacement

Preparation of the replacement part

Right-hand side

To make the cut, unclip the connecting bracket (B) .

Left-hand side

III - POSITIONING OF LOCAL ELECTRICAL EARTHS

101754

Note:

When cutting, be careful not to damage the rearinner reinforcement (A) .

101758

Note:

Do not reuse the connecting bracket previouslyremoved, a new one is available from the PartsDepartment .

101755

WARNING

The position of this cut must be observed, and isdetermined according to the position of the internalreinforcements cut or the acoustic inserts.

115075

41A-20


B84 or C84

41A

115076

IMPORTANT



41A-21

FRONT LOWER STRUCTUREFront section of front side member closure panel: General description

B84 or C84

41A


The special feature of this type of part is that it combi-nes the functions of both the front section and rear sec-tion of the front side member closure panel and that itis made of two different kinds of panels of different thic-knesses assembled by laser butt welding.


1 - Cut 1:

This line shows the centre of the area in which it is pos-sible to carry out a partial replacement.


WARNING


Before reading the following general information,make sure that there are no special notes associa-ted with the vehicle. These special notes are speci-fied if necessary in other parts of the subsectiondealing with the component.

IMPORTANT


Note:


110512

Note:


101418

41A-22

FRONT LOWER STRUCTUREFront section of front side member closure panel: General description

B84 or C84

41A

2 - Cut 2:

The cut must be made on the butt weld.

III - ASSEMBLY INSTRUCTIONS FOR A PARTIAL REPLACEMENT

In this case, the side member weld line must be stag-gered from that of its closure panel.


For other issues of access to mating faces, the variousreplacement options are described in the structural bo-dywork repair basics (see MR 400, 40A, General in-formation ).

Lines (3) and (4) of the diagram show a butt weld bycontinuous MAG welding.


101596

101598

Note:


WARNING


110514

4

3

41A-23

FRONT LOWER STRUCTUREFront section of front side member closure panel: Description

B84 or C84

41ARight-hand side

Left-hand side


- partial replacement of the front section: this operationcomplements straightening the radiator cross mem-ber mounting,

- partial replacement: this operation complements thepartial replacement of the front side member,


Right-hand side

Left-hand side

115688

115687

115111

115112

41A-24


B84 or C84

41A

II - PART FITTED


2 - Partial replacement


(1) Side memberclosure panel

HEL/THLE

1.7/2.5

(2) Front assemblymounting unitclosure panelcomponent

HEL 1.8

(3) Brake hose stopbracket

- 2

(4) Additional unitinterior closurepanel compo-nent

HEL 1.2

(5) Washer fluidreservoir moun-ting

HEL 2

(6) Interior closurepanel compo-nent

HEL 1.5

(7) Front towing ring - -

101597

WARNING


101598

WARNING

Do not move the position of this weld as it is deter-mined by the position of the linings, reinforcementsor expanding inserts.

41A-25


B84 or C84

41AIII - POSITIONING OF LOCAL ELECTRICAL EARTHS

115075

115076

IMPORTANT



41A-26

FRONT LOWER STRUCTUREBattery tray support: General description

B84 or C84

41A


This part functions only as a battery tray bracket. It iswelded to the vehicle structure.

WARNING


Before reading the following general information,make sure that there are no special notes associa-ted with the vehicle. These special notes are speci-fied if necessary in other parts of the sub-sectiondealing with the component.

Note:


101415

41A-27

FRONT LOWER STRUCTUREBattery tray support: Description

B84 or C84

41A

There is only one way of replacing this part:



II - PART FITTED

Complete replacement

101415

115119


(1) Battery t rayupper section

- 2

(2) Battery t raylower section

- 1.5

(3) Air filter retai-ning bracket

- 1.2

115120

WARNING


41A-28

FRONT LOWER STRUCTURERadiator cross member mounting: General description

B84 or C84

41A


It is composed of the following components:

- cross member mounting component (1) ,

- mounting support unit (2) .

This part acts as:

- a radiator cross member support,

- front end cross member support,

- front end panel support.

WARNING



IMPORTANT


Note:


107397

2

1

41A-29

FRONT LOWER STRUCTURERadiator cross member support: Description

B84 or C84

41A

To replace this part, order an additional connectingbracket (A) .




115683

Note:

A straightening bench is essential when simulta-neously replacing the left-hand and right-handparts.

115108


(1) Radiator crossmember moun-ting unit

HEL 1.2

(2) Radiator crossmember moun-t ing c losurepanel

HEL 2.5

41A-30

FRONT LOWER STRUCTURERadiator cross member support: Description

B84 or C84

41AII - PART FITTED


III - STRAIGHTENING

101590

WARNING


101589

Note:

When straightening a radiator cross member moun-ting, the side member closure panel can be partiallyreplaced to access the damaged area.

41A-31

FRONT LOWER STRUCTUREFront mounting of front sub-frame: General description

B84 or C84

41A


This is a basic part; it functions only as a front mountingof front sub-frame.

WARNING



IMPORTANT


Note:


101422

41A-32

FRONT LOWER STRUCTUREFront mounting of front sub-frame: Description

B84 or C84




II - PART FITTED

complete replacement

Note:


101422


(1) Front mountingof front sub-frame

HEL 1.8

115110

WARNING


41A-33

FRONT LOWER STRUCTUREEngine mounting: General description

B84 or C84

41A


This is a basic part; it only functions as an enginemounting.

WARNING


Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special features will be specified if appli-cable in other parts of this sub-section dealing withthe part.

IMPORTANT


Note:


102623

41A-34

FRONT LOWER STRUCTUREEngine mounting: Description

B84 or C84

41A


- complete replacement: this operation complementsthe replacement of the scuttle panel for a frontal im-pact and the partial replacement of the front sidemember and front wheel arch for a right-hand side im-pact.


II - PART FITTED


102623

Note:


115263


(1) Engine moun-ting rear section

HEL 1.5

(2) engine moun-ting upper sec-tion

HEL 2

(3) Engine moun-t i ng he igh tadjuster reinfor-cement

- 2

(4) Engine moun-ting rear reinfor-cement

- 2

101761

WARNING


41A-35

FRONT LOWER STRUCTURESub-frame rear mounting: General description

B84 or C84

41A


This is a basic part; its only function is that of a frontsub-frame rear cross member.

WARNING



IMPORTANT


Note:


110547

41A-36

FRONT LOWER STRUCTURESub-frame rear mounting: Description

B84 or C84

41A




II - PART FITTED


101420

115121


(1) Sub-frame rearmounting

HEL 2

(2) Sub-frame rearmounting rein-forcement

THLE 3

101999

41A-37

FRONT LOWER STRUCTURESub-frame rear mounting: Description

B84 or C84

41ACut A

115123

WARNING


41A-38

FRONT LOWER STRUCTUREFront half unit: General description

B84 or C84

41A


The special feature of this type of part is that it acts si-multaneously as front side member, front wheel arch,centre floor front side cross member and front end sidecross member and is composed of several differentkinds of panels of different thicknesses.

WARNING



IMPORTANT


Note:


109546

41A-39

FRONT LOWER STRUCTUREFront half unit: Description

B84 or C84

41ARight-hand side

Left-hand side

To replace this part, order an additional engine tie-barmounting (A) or connecting bracket (B) depending onthe impact side.



101604

101603

41A-40


B84 or C84

41AI - COMPOSITION OF THE SPARE PART

Right-hand side

115124

41A-41


B84 or C84

41ALeft-hand side

II - PART FITTED


115125


(1) Front side mem-ber

HEL/THLE

1.5/3

(2) Front section offront side mem-ber c losu repanel

HEL/THLE

1.2/2.5

(3) Front wheel arch HEL 1.1/2

(4) Engine support HEL 1.5/2

(5) Front end sidecross member

HEL 1.5

(6) Sub-frame rearmounting

HEL/THLE

2/3

(7) Cent re floorfront side crossmember

HEL/THLE

1.2/3

(8) Battery t raybracket

- 1.5/2 115126

41A-42


B84 or C84

41A


IMPORTANT

For welded connections in three thicknesses, thespot welds on the part replaced should be made inthe same place as for the original joint to retain itsmechanical properties.

WARNING


115075

115076

IMPORTANT



41B-1

CENTRE LOWER STRUCTUREVehicle front section structure: Description

B84 or C84

41BFRONT STRUCTURE

102401



- 0.9


HLE/THLE

1/2.5


- 1.2


HLE/THLE

1.1/3



HLE/THLE

1.7/3

41B-2

CENTRE LOWER STRUCTUREVehicle front section structure: Description

B84 or C84

41B


HLE 1.2


- 1.2/2.5


HLE/THLE

1.2/3


- 1.5/2


HLE/THLE

1.1/3


- 1.2


HLE 1.5/2


- 1.1/2



HLE/THLE

2/3


HLE/THLE

1.2/3



HLE 1.1/2


41B-3

CENTRE LOWER STRUCTUREVehicle side section structure: Description

B84 or C84

41BSIDE STRUCTURE

B84

102402



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


HLE 1.8


- 0.7


- 0.7

41B-4


B84 or C84

41B


- 0.7


HLE 1.2/1.5


HLE 1


HLE 1.5/2.2



- 0.7


HLE 1.5


- 1


HLE 0.7/0.9



HLE 0.7/0.9


HLE 1.5


- 0.7


HLE 1.5/2


HLE 0.7


41B-5


B84 or C84

41B


- 0.7


- 0.7


C84

102403



HLE 0.7/0.95


HLE 1.8


HLE 1.8

41B-6


B84 or C84

41B


- 0.7


- 0.7


- 0.7


HLE 1.2/1.5


HLE 1




VHLE 1.8


HLE 1.5/2



HLE 0.7/0.9


HLE 0.7/0.9


- 0.7


- 0.7


- 0.7


41B-7


B84 or C84

41B


HLE 0.7


HLE 1.5


41B-8

CENTRE LOWER STRUCTUREVehicle central section structure: Description

B84 or C84

41BCENTRAL STRUCTURE

102404



VHLE 2.5



- 0.9


UHLE 1.7


UHLE 1.7

41B-9


B84 or C84

41B


HLE 0.95/3


- 0.7/1.2


- 1.2



- 0.7



- 0.65/1.2


HLE 1.5


HLE 1.5/2.5


HLE 1.5



HLE/THLE

1/1.6


VHLE 0.7/2.5


- 1.2/2.5


41B-10


B84 or C84

41B


- 1.2


HLE/THLE

0.7/2.5



HLE 1.4




HLE 1.2/2


41B-11

CENTRE LOWER STRUCTURECentre floor, side section: General description

B84 or C84

41B


The special feature of this type of part is that it is madeof two different kinds of panels of different thicknessesassembled by laser butt welding.


These cutting lines show the area in which it is possibleto carry out a partial replacement of the centre floorside section.

Cut 1, 2 and 3:

- cut (1) affects the partial replacement of the centrefloor side section.

- cuts (1) and (2) affect the partial replacement of therear section of the centre floor side section.

- cuts (1) and (3) affect the partial replacement of thefront section of the centre floor side section.



If there are other issues regarding access to mating fa-ces, the various replacement options are described inthe basic instructions for structural bodywork repair(see MR 400, 40A, General information ).

WARNING


Before reading this general information, check thatthere are no special notes associated with this vehi-cle. These special notes will be specified if applica-ble in other parts of this sub-section dealing withthe part.

Note:


110500

110501

WARNING


3

2

1

41B-12

CENTRE LOWER STRUCTURECentre floor, side section: General description

B84 or C84

41B

Line (1) in the drawing shows partial replacement anda weld by joggling with plug welds at regular intervals.

Lines (1) and (2) in the diagram show the partial rearreplacement and a weld by joggling with plug welds atregular intervals.

Lines (1) and (2) in the diagram show the partial frontreplacement and a weld by joggling with plug welds atregular intervals.

110502

110504

1

1

2

110503

1 3

41B-13

CENTRE LOWER STRUCTURECentral floor, side section: Description

B84 or C84

41B


- partial replacement of front end section: this operationcomplements the replacement of the A-pillar reinfor-cement,


- partial replacement of the rear section: this operationcomplements the replacement of the B-pillar reinfor-cement,



II - PART FITTED

1 - Partial replacement of the front end section

115691

115128


(1) Side floor - 0.7

(2) Cent re s idemember reinfor-cement

THLE 2.5

(3) Cent re s idemember

THLE 2

103089

41B-14


B84 or C84

41B2 - Partial replacement of the front section

3 - Partial replacement of the rear section

4 - Complete replacement


103088

103090

115131

WARNING


115077

41B-15


B84 or C84

41B

IMPORTANT



41B-16

CENTRE LOWER STRUCTURECentre floor front lateral cross member: General description

B84 or C84

41B


This is a basic part; it functions only as a centre floorfront side cross member.


Line (1) in the diagram shows the area in which it ispossible to carry out a partial replacement.



If there are other issues regarding access to mating fa-ces, the various replacement options are described inthe basic instructions for structural bodywork repair(see MR 400, 40A, General Information ).

WARNING



IMPORTANT

For complete replacement, the straightening benchmust be used.

Note:

For detailed instructions about a particular join, seeMR400, 40A, General information .

110598

110599

WARNING


1

41B-17

CENTRE LOWER STRUCTURECentre floor front lateral cross member: General description

B84 or C84

41B

Line (3) of the diagram shows a butt weld by conti-nuous MAG welding.

110600

3

41B-18

CENTRE LOWER STRUCTURECentre floor front lateral cross member: Description

B84 or C84

41B


- partial replacement,



II - PART FITTED

1 - Partial replacement101417

115133

Mark Description Type Thic-kness(mm)

(1) Front side crossmember

HEL 1.2

(2) Front side crossmember reinfor-cement

- 1.5

(3) Front side crossmember impactreinforcement

THLE 3

101998

Note:

The cut is made at the end of the front side mem-ber.

41B-19

CENTRE LOWER STRUCTURECentre floor front lateral cross member: Description

B84 or C84

41B2 - Complete replacement

102000

WARNING


41B-20

CENTRE LOWER STRUCTURETunnel: Description

B84 or C84

41B


- complete replacement: this operation complementsthe replacement of the complete centre floor side sec-tion for a side impact.


II - PART FITTED

Front section

(X1) = 135 mm

115692

115135


(1) Tunnel - 1

(2) Centre crossmemberbeneath tunnel

HEL 1.5

(3) Steeringcolumn crossmember moun-ting

- 1.3

(4) Steeringcolumn stayupper bracket

- 1.3

(5) Tunnel reinfor-cement

THLE 1.6

102975

Note:

For right-hand drive vehicles, observe the valueindicated before to position the steering columncross member mounting.

41B-21

CENTRE LOWER STRUCTURETunnel: Description

B84 or C84

41BRear section

102974

WARNING


41B-22

CENTRE LOWER STRUCTUREFront cross member under front seat: General description

B84 or C84

41B


This is a basic part; its function is to secure the frontsection of the front seat and to stiffen the bodywork inthe event of a side impact.

WARNING



Note:

For detailed instructions about a particular join, seeMR400, 40A, General information .

110507

41B-23

CENTRE LOWER STRUCTUREFront cross member under front seat: Description

B84 or C84

41B




II - PART FITTED


102653

115139


(1) Fron t c rossmember underfront seat

HEL 1.5

(2) Seat mountingreinforcement

HEL 1.5

WARNING


102954

41B-24

CENTRE LOWER STRUCTUREFront cross member under front seat: Description

B84 or C84

41B2 - Fitting the cross member

Left-hand side

(X1) = 335 mm

Right-hand side

(X2) = 335 mm

102952

102953

Note:

It is essential to observe the values indicatedbefore.

41B-25

CENTRE LOWER STRUCTUREFront seat rear mounting interior unit: Description

B84 or C84

41BThere is only one way of replacing this part:



II - PART FITTED

(X1) = 335 mm

102654

Number Description Type Thickness(mm)

(1) Front seat rearinner mountingunit

HEL 1.5

102952

Note:

It is necessary to respect the dimension previouslyindicated.

41B-26

CENTRE LOWER STRUCTUREFront seat rear outer mounting unit: Description

B84 or C84

41B




II - PART FITTED

(X1) = 335 mm

102652

115140


(1) Fr o n t s e a tmounting unit

HEL 1.5

(2) Fr o n t s e a tmounting rein-forcement

HEL 1.5

WARNING

If the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,they should be replaced with plug welds after holeshave been drilled in the first panel.

102953

Note:

It is necessary to respect the dimension previouslyindicated.

41C-1

SIDE LOWER STRUCTUREVehicle side section structure: Description

B84 or C84

41CSIDE STRUCTURE

B84

102402



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


HLE 1.8


- 0.7


- 0.7

41C-2


B84 or C84

41C


- 0.7


HLE 1.2/1.5


HLE 1


HLE 1.5/2.2



- 0.7


HLE 1.5


- 1


HLE 0.7/0.9



HLE 0.7/0.9


HLE 1.5


- 0.7


HLE 1.5/2


HLE 0.7


41C-3


B84 or C84

41C


- 0.7


- 0.7


C84

102403



HLE 0.7/0.95


HLE 1.8


HLE 1.8

41C-4


B84 or C84

41C


- 0.7


- 0.7


- 0.7


HLE 1.2/1.5


HLE 1




VHLE 1.8


HLE 1.5/2



HLE 0.7/0.9


HLE 0.7/0.9


- 0.7


- 0.7


- 0.7


41C-5


B84 or C84

41C


HLE 0.7


HLE 1.5


41C-6

SIDE LOWER STRUCTUREVehicle central section structure: Description

B84 or C84

41CCENTRAL STRUCTURE

102404



VHLE 2.5



- 0.9


UHLE 1.7


UHLE 1.7

41C-7


B84 or C84

41C


HLE 0.95/3


- 0.7/1.2


- 1.2



- 0.7



- 0.65/1.2


HLE 1.5


HLE 1.5/2.5


HLE 1.5



HLE/THLE

1/1.6


VHLE 0.7/2.5


- 1.2/2.5


41C-8


B84 or C84

41C


- 1.2


HLE/THLE

0.7/2.5



HLE 1.4




HLE 1.2/2


41C-9

SIDE LOWER STRUCTURESill panel: Description

B84 or C84

41C

To replace this part, order the expanding inserts cor-responding to each of the following cases.


- partial replacement of the front end section: order in-sert (A) ,

- partial replacement under door:

- partial replacement centre section: order insert (B) ,

- Complete replacement: order inserts (A) and (B) .



- partial replacement of the front end section: order in-sert (C) ,

- partial replacement under door:

- complete replacement: order inserts (C) , (D) and (E) .

For the complete replacement of the sill panel on 3-and 5-door versions, also order anti-grit protective film(F) .

B84

115662

C84

115671

41C-10


B84 or C84

41CI - COMPOSITION OF THE SPARE PART

II - PART FITTED


B84

115390


(1) Sill panel - 0.7

(2) Jacking point HEL 1.8

C84

115396


(3) Sill panel - 0.7

(4) Jacking point HEL 1.8

B84

115395

41C-11


B84 or C84

41CCut A

Cut B

Cut C115408

115418

C84

115398

115417

41C-12


B84 or C84

41C2 - Partial replacement under door 3 - Central partial replacement

Cut D

B84

115394

C84

115399

B84

115392

115410

41C-13


B84 or C84

41CCut E 4 - Complete replacement

115419

B84

115391

41C-14


B84 or C84

41CCut F Cut G

115406 115414

C84

115397

41C-15


B84 or C84

41CCut H III - ANTI-GRIT PROTECTION

To fit anti-grit protective adhesive film, see TechnicalNote 579A, Anti-grit protective adhesive film, 55A,Exterior protection, Anti-grit protective adhesivefilm .

115411

115416

WARNING

If the spot welds cannot be made as they were ori-ginally using an electric spot welding machine, theyshould be replaced with plug welds after holes havebeen drilled in the first panel.

41C-16

SIDE LOWER STRUCTUREComplete sill panel: General description

B84 or C84

41C


The special feature of this part is that its lower sectionis butt welded by laser with two different types of paneland two different thicknesses.

The special feature of this part is that its lower sectionis butt welded by laser with two different types of paneland two different thicknesses.

This is a basic part; it only functions as a sill panel.

WARNING



Note:


IMPORTANT

Before any operation, remove the front seat belts.

B84

110571

C84

113243

41C-17


B84 or C84

41CII - AREA TO BE CUT FOR COMPLETE REPLACEMENT

B84

110580

41C-18


B84 or C84

41C

Cut 1, 2 and 3:

These cut lines show the complete replacement of thesill panel.

III - AREA TO BE CUT FOR PARTIAL REPLACEMENT

C84

112727

110582

1

4

41C-19


B84 or C84

41CCut 1 and 4.

These cut lines show the partial front replacement ofthe sill panel.

Cut 3 and 5.

These cut lines show the partial rear replacement ofthe sill panel.

Cut 4 and 6.

These cut lines show the partial under door replace-ment of the sill panel.

It is possible to use cuts made previously to carry out larger partial replacements:

- front partial replacement,

- rear partial replacement.

These operations allow you to access the inside of thehollow section of the structural component to straigh-ten it.

110578

110572

5

3

6

4

110574

110576

41C-20


B84 or C84

41CIV - ASSEMBLY INSTRUCTIONS FOR A PARTIAL REPLACEMENT


If there are other issues regarding access to mating fa-ces, the various replacement options are described inthe basic instructions for structural bodywork repair(see MR 400, 40A, General information ).

Lines (1) , (2) and (5) of the diagram show a butt weldby continuous MAG welding.

All the welds described in this procedure are identical.

WARNING


110575

2

1

5

41C-21

SIDE LOWER STRUCTUREFull inner sill panel: General description

B84 or C84

41C


This is a basic part; it only functions as an inner sill pa-nel.

This is a basic part; it only functions as an inner sill pa-nel.


This part is replaced completely on this type of vehicle.

WARNING



Note:


B84

102626

C84

102627

C84, and LONG CHASSIS

41C-22

SIDE LOWER STRUCTUREFull inner sill panel: General description

B84 or C84

41C





B84

102595

WARNING


B84

102595

41C-23

SIDE LOWER STRUCTURERear inner sill panel: Description

B84 or C84

41CThe options for replacing this part are as follows:

- partial replacement (5-door version),



II - PART FITTED


B84

115946

C84

102627


(1) Rear inner sillpanel

- 1

B84

102595

41C-24

SIDE LOWER STRUCTURERear inner sill panel: Description

B84 or C84

41CSpecial note on the replacement of the rear inner sill panel


Special note on the replacement of the rear inner sill panel

102584

Note:

Make a partial cut on the outer rear wheel arch tounweld the rear inner sill panel.

B84

102583

C84

102582

102580

WARNINGIf the spot welds cannot be made as they were ori-ginally using an electric spot welding machine, theyshould be replaced with plug welds after holes havebeen drilled in the first panel.

41C-25

SIDE LOWER STRUCTURESill panel reinforcement: General description

B84 or C84

41C


The distinctive feature of this part is that it combines several functions:

- sill panel reinforcement,

- A-pillar reinforcement

- B-pillar reinforcement,

- body side front section reinforcement.


WARNING



Note:


115657

105381

41C-26

SIDE LOWER STRUCTURESill panel reinforcement: Description

B84 or C84

41C



- partial replacement of the front section: order insert(A) ,

- Complete replacement: order inserts (A) and (B) .



- partial replacement of the front section: order insert(C) ,

- Complete replacement: order inserts (C) and (D) .

B84

115661

C84

115670

41C-27


B84 or C84

41CI - COMPOSITION OF THE SPARE PART

II - PART FITTED



B84

115423

C84

115424


(1) Body side frontsection reinfor-cement

HEL 1.2/1.5

(2) Upper hingereinforcement

HEL 2

(3) Lower h ingereinforcement

VHEL 2

102039

102594

41C-28


B84 or C84

41CSpecial features of the rear cut on the 3-door version

102590

WARNING


41C-29

SIDE LOWER STRUCTURESill panel rear reinforcement: Description

B84 or C84

41C

To replace this part, also order the sill panel rear rein-forcement stiffener (A) .


- complete replacement: this operation complementsthe replacement of the rear inner sill panel.


II - PART FITTED

102663

102663


(1) Sill panel rearreinforcement

HEL 1.4

C84

102588

B84

102585

41C-30

SIDE LOWER STRUCTURESill panel rear reinforcement: Description

B84 or C84

41C

Cut A

To straighten the sill panel rear reinforcement, desol-der the sill panel rear reinforcement stiffener (2) .

102586

115432

Note:

To keep the B-pillar reinforcement if it has not beendamaged, the operation is performed from insidethe vehicle.

102587

WARNING


IMPORTANT



41C-31

SIDE LOWER STRUCTUREFront jack support: General description

B84 or C84

41C


The special feature of this part is that it combines thefunctions of front and rear jacking point.

WARNING



Note:


102619

41C-32

SIDE LOWER STRUCTUREImpact absorber unit: Description

B84

41CThere is only one way of replacing this part:

- complete replacement: this operation complementsthe replacement of the rear wing.


II - PART FITTED

Perform a dummy fitting of the sill panel and the reardoor to check the positioning of the impact absorberunit.

102814


(1) Impact absorberunit

- 1

102589

Note:

Use plug welds.

41D-1

REAR LOWER STRUCTUREVehicle central section structure: Description

B84 or C84

41DCENTRAL STRUCTURE

102404



VHLE 2.5



- 0.9


UHLE 1.7


UHLE 1.7

41D-2


B84 or C84

41D


HLE 0.95/3


- 0.7/1.2


- 1.2



- 0.7



- 0.65/1.2


HLE 1.5


HLE 1.5/2.5


HLE 1.5



HLE/THLE

1/1.6


VHLE 0.7/2.5


- 1.2/2.5


41D-3


B84 or C84

41D


- 1.2


HLE/THLE

0.7/2.5



HLE 1.4




HLE 1.2/2


41D-4

REAR LOWER STRUCTUREVehicle structure rear section: Description

B84 or C84

41DREAR STRUCTURE

B84

102405



- 0.7


- 0.6



- 0.9



- 0.95



- 0.7


41D-5


B84 or C84

41D



HLE 1/2.5



HLE/THLE

0.65/2.5


- 0.65


HLE/THLE

0.95/2



HLE 2



- 0.7



- 0.7


HLE 0.95


- 0.9


HLE 0.7/1.5



- 0.7


- 0.9



HLE 0.85/1


41D-6


B84 or C84

41D

C84

102406



- 0.7


- 0.6



- 0.9



HLE 1.5



- 1/2



- 0.95

41D-7


B84 or C84

41D



- 0.7




HLE 1/2.5



HLE/THLE

0.65/2.5


- 0.65


HLE/THLE

0.95/2



- 0.7



HLE 2


HLE 0.95



- 0.7


- 0.9


HLE 0.7/1.5



- 0.7


- 0.9



HLE 0.85/1


41D-8

REAR LOWER STRUCTURERear floor, front section: General description

B84 or C84

41D


This is a basic part; its only function is that of rear floorfront section.


Cut 1:

This line marks the area in which it is possible to per-form a partial replacement.




WARNING



Note:


115695

102976

WARNING


41D-9

REAR LOWER STRUCTURERear floor, front section: General description

B84 or C84

41D

Line (2) on the diagram marks a joggled joint connec-ted with plug welds at regular intervals.

110650

41D-10

REAR LOWER STRUCTURERear floor, front section: Description

B84 or C84

41DThe options for replacing this part are as follows:

- partial replacement: this operation complements thereplacement of the rear section of the body side aftera side impact,



115695

115250

41D-11


B84 or C84

41D

II - PART FITTED





(1) Front section ofrear floor

- 0.7

(2) Passenger retai-ning cross mem-ber

HEL 0.9

(3) Rear seat moun-ting right-handside stiffener

HEL 1.65

(4) Rear seat moun-ting left-hand sidestiffener

HEL 1.65

(5) Reservoir frontmounting stiffener

- 1.2

(6) Cable sleeve stopsupport

- 1.2

(7) Exhaust moun-ting support

- 1.2/2.5

(8) Cross memberreinforcement

HEL 0.85

102976

102973

WARNING


115077

41D-12


B84 or C84

41D

115100

IMPORTANT



41D-13

REAR LOWER STRUCTURERear floor rear section: General description

B84 or C84

41D


The special feature of this type of part is that it is affixedto the vehicle by bolts and by a cement bead.

II - ASSEMBLY INSTRUCTIONS FOR A PARTIAL REPLACEMENT



WARNING



Note:

For a detailed description of a particular connec-tion, ( see MR 400, 40A, General information ).

STANDARD CHASSIS

102666

WARNING


41D-14

REAR LOWER STRUCTURERear floor rear section: Removal - Refitting

B84 or C84

41D

REMOVAL


a Remove:

- the rear wheel arch liners( (see Rear wheel archliner: Removal - Refitting) ,

- the rear bumper( (see Rear bumper: Removal -Refitting) ,

- the luggage compartment carpet( (see Luggagecompartment carpet: Removal - Refitting) ,

- the emergency spare wheel and the jack.

a Remove the exhaust silencer mounting bolt (1) .

a Detach the exhaust silencer by pulling it downwards.

a Remove the heat shield mounting bolts (2) .

a Remove the heat shield.

a Remove:

- the two tank mounting bolts (3) ,

- the funnel lower mounting bolt (4) .

Tightening torquesm

rear floor rear sectionmounting bolts

21 Nm

101107

101108

101109

41D-15


B84 or C84

41DII - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove all the floor mountings.

a Insert a flat chisel (5) into the rear right-hand cornerof the floor.

a Use the flat chisel as a lever and carefully detach thefloor.

REFITTING

I - REFITTING PREPARATION OPERATION

1 - Preparation of the replacement part

a Remove the remaining cement bead.

a Using heptane and a lint-free cloth, clean the surfa-ces to be attached.

101114

101111

101112

Note:

During the operation, cut the mastic bead using asectioning tool if there is too much resistanceduring removal.

41D-16


B84 or C84

41D

a Apply the sealing mastic (6) .

2 - Preparing the vehicle

a Remove the remaining cement bead.

a Using heptane and a lint-free cloth, clean the surfa-ces to be attached.

a

II - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the rear floor,

- all the floor mountings.

a Tighten to torque the rear floor rear section moun-ting bolts ( 21 Nm ) .

a Check that the seal between the floor and subframeis sufficient.

III - FINAL OPERATION

a Refit:

- the lower mounting bolt (4) to the funnel,

- the two tank mounting bolts (3) ,

- the silencer heat shield,

- the bolts (2) securing the heat shield,

- the exhaust silencer,

- the silencer mounting bolt (1) ,

- the emergency spare wheel and the jack.

- the luggage compartment carpet( (see Luggagecompartment carpet: Removal - Refitting) ,


- the rear wheel arch liners( (see Rear wheel archliner: Removal - Refitting) .

101113

101110

Note:

To avoid any risk of damage to the mastic beadand to facilitate the positioning of the floor whenit is refitted, move the tank away using a woodenblock (7) .

Note:

Remove any visible excess mastic from the vehi-cle inter ior and exterior.

41D-17

REAR LOWER STRUCTURERear side member: General description

B84 or C84

41D


This is a basic part; it only functions as a rear sidemember.


Cut 1:

This line marks the area in which it is possible to per-form a partial replacement.





WARNING



IMPORTANT


Note:


115694

102668

WARNING


41D-18

REAR LOWER STRUCTURERear side member: General description

B84 or C84

41D


102970

41D-19

REAR LOWER STRUCTURERear impact cross member mounting reinforcement: Description

B84 or C84

41D


- complete replacement: this operation complementsthe replacement of the rear end panel assembly andthe rear side member closure panel.


II - PART FITTED

102661

Note:

The body jig bench must be used.

115242


(1) Rear side mem-ber c losu repanel compo-nent

VHEL 2

(2) Rear side mem-ber connectioncomponent

HEL 2

(3) Rea r t owingbushing

- -

102955

WARNING


41D-20

REAR LOWER STRUCTURERear side member: Description

B84 or C84

41D



- Complete replacement: this operation complementsthe partial replacement of the rear floor front sectionafter a rear impact.


115694

Note:


115243


(1) Rear side mem-ber

HEL 1.6/2

(2) Rea r c rossmember/rearside memberconnection com-ponent

HEL/VHEL

1.2/1.8

(3) R e a r a x l eassembly unit

HEL 1.8

(4) Sill panel rearreinforcement

HEL 1.4

(5) Rear side mem-ber assemblyunit reinforce-ment connec-tion component

VHEL 2

(6) R e a r a x l eassembly unitreinforcement

HEL 2

(7) Far rear lowercross member,side section

- 1

(8) Rear impactcross membermounting stiffe-ner

HEL/VHEL

2

41D-21


B84 or C84

41DII - PART FITTED

Front section

Rear section


102958

102957

102970

102962

Note:

If the impact does not enable the side member tobe cut at (A) , remove the connecting bracket (B)from the spare part and weld it in area (X1) on therear side member.

The cutting procedure remains the same as pre-viously.

41D-22


B84 or C84

41D2 - Complete replacement

115245

WARNING


IMPORTANT



41D-23

REAR LOWER STRUCTURERear side member closure panel, rear section: Description

B84 or C84

41DThere is only one way of replacing this part:

- complete replacement: this operation complementsthe replacement of the rear end panel and the rearside member after a rear impact.


II - PART FITTED


Cut A

115682


(1) Rear side mem-ber c losu repanel, rear sec-tion

- 0.7

102972

115249

41D-24

REAR LOWER STRUCTURERear side member closure panel, rear section: Description

B84 or C84

41DFitting the side member closure panel

102971

WARNING


IMPORTANT



41D-25

REAR LOWER STRUCTURERear floor front cross member, centre section: Description

B84 or C84

41D

there is only one way of replacing this part:

- complete replacement: this operation complementsthe replacement of the rear side member after a sideimpact.


II - PART FITTED

102669

115254


(1) Rear axle crossmember

HEL 1.2

(2) Rear left-handseat belt ancho-rage centre stif-fener

HEL 2

(3) Rear r ight-handseat belt ancho-rage centre stif-fener

HEL 1.5

102961

41D-26

REAR LOWER STRUCTURERear floor front cross member, centre section: Description

B84 or C84

41DCut A

115255

WARNING


41D-27

REAR LOWER STRUCTURERear floor centre cross member: General description

B84 or C84

41D


This is a basic part; it only fulfils the function of a rearfloor centre cross member.

WARNING



Note:


102667

41D-28

REAR LOWER STRUCTURERear floor centre cross member: Description

B84 or C84


- complete replacement: this operation supplementsthe replacement of the rear side member following arear or side collision.


II - PART FITTED


102667

Number Description Type Thic-kness(mm)

(1) Rear floor centrecross member

HEL 1

103111

WARNING


41D-29

REAR LOWER STRUCTUREFar rear lower cross member, side section: Description

B84 or C84


- complete replacement: this operation supplementsthe replacement of the rear wheel arch extension, theside lining of the rear end panel and the lower sectionof the rear wing panel rain channel.


II - PART FITTED


102645


(1) Far rear lowercross member,side section

- 1

102968

WARNING


41D-30

REAR LOWER STRUCTUREExhaust mounting support: Description

B84 or C84


- complete replacement: this operation supplementsthe replacement of the tunnel.


II - PART FITTED


102664


(1) Exhaust moun-ting support

- 1.2

102963

Note:

The angle of the exhaust mounting support can beadjusted using the two rivets which should be obtai-ned separately from the Parts Department .

WARNING


41D-31

REAR LOWER STRUCTURETank mounting support: Description

B84 or C84




II - PART FITTED


102660


(1) Fuel tank moun-ting support .

- 1.2

102956

WARNING


41D-32

REAR LOWER STRUCTURERear impact lower cross member: General description

B84 or C84

41D


This component is made from aluminium.

A feature of this component is that it is attached to theends of rear side members.

WARNING


Before reading the following general information,make sure that there are no special notes associa-ted with the vehicle. These special notes are speci-fied if necessary in other parts of the sub-sectiondealing with the part.

Note:


101411

41D-33

REAR LOWER STRUCTURERear impact lower cross member: Removal - Refitting

B84 or C84

41D

REMOVAL


a Remove:

- the rear lights( (see Rear light on wing: Removal- Refitting) ,

- the rear bumper( (see Rear bumper: Removal -Refitting) .


a Remove:

- the mounting nuts (1) ,

- the rear impact lower cross member.

REFITTING


a


a Refit:

- the rear impact lower cross member,

- the mounting nuts (1) .

a Tighten to torque the rear impact lower crossmember mounting nuts ( 21 Nm ) .


a Refit:


- the rear lights( (see Rear light on wing: Removal- Refitting) .

Tightening torquesm

rear impact lower crossmember mounting nuts

21 Nm

101178

102960

Note:

Replace the foam on the rear impact lower crossmember if it has been damaged.

42A-1

UPPER FRONT STRUCTUREVehicle front section structure: Description

B84 or C84

42AFRONT STRUCTURE

102401



- 0.9


HLE/THLE

1/2.5


- 1.2


HLE/THLE

1.1/3



HLE/THLE

1.7/3

42A-2

UPPER FRONT STRUCTUREVehicle front section structure: Description

B84 or C84

42A


HLE 1.2


- 1.2/2.5


HLE/THLE

1.2/3


- 1.5/2


HLE/THLE

1.1/3


- 1.2


HLE 1.5/2


- 1.1/2



HLE/THLE

2/3


HLE/THLE

1.2/3



HLE 1.1/2


42A-3

UPPER FRONT STRUCTUREVehicle central section structure: Description

B84 or C84


102404



VHLE 2.5



- 0.9


UHLE 1.7


UHLE 1.7

42A-4


B84 or C84

42A


HLE 0.95/3


- 0.7/1.2


- 1.2



- 0.7



- 0.65/1.2


HLE 1.5


HLE 1.5/2.5


HLE 1.5



HLE/THLE

1/1.6


VHLE 0.7/2.5


- 1.2/2.5


42A-5


B84 or C84

42A


- 1.2


HLE/THLE

0.7/2.5



HLE 1.4




HLE 1.2/2


42A-6

UPPER FRONT STRUCTUREVehicle removable section structure: Description

B84 or C84


102400



Aluminium



Steel/SMC


SMC


Aluminium

42A-7

UPPER FRONT STRUCTUREVehicle removable section structure: Description

B84 or C84

42A



Noryl




Aluminium




Noryl




Polypropy-lene



42A-8

UPPER FRONT STRUCTUREFront wing: General description

B84 or C84

42A


This type of front wing has the following specifications:

- plastic wing (NORYL),

- wing bolted to its upper mounting support.

II - REMOVAL - REFITTING

To remove or replace the front wing, remove:

- the scuttle panel grille,

- the engine side trim,

- the front wing upper trim,

- the front wheel arch liner,

- the front section of the sill panel protector,

- the front wing direction indicator,

- the front bumper,

- the front headlight.

III - ADJUSTMENT

Two main areas of adjustment may be identified:

- the adjustment of the rear area,

- the adjustment of the front area

WARNING



105225

Note:

If the component is to be removed and not repla-ced, mark the position of the mountings before uns-crewing them to avoid having making adjustmentswhen refitting the component.

Note:

The front wing is the penultimate removable compo-nent to be fitted to the vehicle body in the factory.

For final adjustment, correctly position all the othercomponents including the bumper and the headli-ghts for them to be correctly positioned.

42A-9


B84 or C84

42A1 - Adjustment of the rear area:

Adjust the shut lines and alignment with the front doorusing mountings (6) and (7) .

101224

42A-10


B84 or C84

42A2 - Adjustment of the front area:

Adjust the alignment of the front wing using mountings(15) .

101224

42A-11

UPPER FRONT STRUCTUREFront wing: Removal - Refitting

B84 or C84

42A

The front wing is a structural bodywork componentmade of thermoplastic, and can be removed.

REMOVAL


a Remove:

- the scuttle panel grille( (see Scuttle panel grille:Removal - Refitting) ,



- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting)




- the front headlight( (see Halogen headlight: Re-moval - Refitting) .


a Remove:

- the bolts (A) ,

- the nut (B) ,

- the front wing.

Tightening torquesm

bolts (A) 6.5 Nm

nut (B) 6.5 Nm

101224

42A-12

UPPER FRONT STRUCTUREFront wing: Removal - Refitting

B84 or C84

42AREFITTING


a Always replace the expanding insert (C) .


a Refit:

- the front wing,

- the nut (B) ,

- the bolts (A) .

a Adjust the shut lines and flush fitting (see Frontwing: Adjustment ).

a tighten to torque:

- the bolts (A) ( 6.5 Nm ) ,

- the nut (B) ( 6.5 Nm ) .


a Refit:

- the headlight( (see Halogen headlight: Removal -Refitting) ,




- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting)



- the scuttle panel grille( (see Scuttle panel grille:Removal - Refitting) .

103203

42A-13

UPPER FRONT STRUCTUREFront wing: Adjusting

B84 or C84

42A

ADJUSTMENT VALUESa For information on front wing adjustment values,

(see Vehicle shut lines: Adjustment value ).

ADJUSTMENT

a Observe the adjustment sequence.

I - BASIC ADJUSTMENT

a Remove:

- the front wing (see 42A, Upper front structure,Front wing: Removal - Refitting, page 42A-11) ,

- the front wing upper mounting support (see 42A,Upper front structure, Front wing upper moun-ting support: Removal - Refitting, page 42A-20),

a Detach and clean the beading (7) .

a Position the support and the wing on the vehicle.

a Finger tighten all the mountings.

Tightening torquesm

mounting bolts of thefront wing upper moun-ting support

6.5 Nm

bolts (A) 6.5 Nm

bolt (B) 6.5 Nm

nut (C) 6.5 Nm

bolts (D) 6.5 Nm

bolt (E) 6.5 Nm

101218

101220

42A-14


B84 or C84

42A

a

a Adjust the shut lines and flush fitting between thewing, the door and the bonnet.

a Remove the front wing.

a Mark the position of the upper mounting supportthen remove it.

a Reapply the cement bead using a type M.J.Pro set-ting adhesive .

a Tighten to torque the mounting bolts of the frontwing upper mounting support ( 6.5 Nm ) .

101753

Note:

Only mountings (8) are accessible when the wingis in position.

42A-15


B84 or C84

42AII - FINAL ADJUSTMENT

a Adjust the shut lines and flush fitting of area (1) .

a Tighten to torque bolts (A) ( 6.5 Nm ) .

a Adjust the shut lines and flush fitting of areas (2) and(3) .


- the bolt (B) ( 6.5 Nm ) ,

- the nut (C) ( 6.5 Nm ) .

a Adjust the shut lines and flush fitting of areas (4) and(5) .

a Tighten to torque the bolts (D) ( 6.5 Nm ) .

101224

42A-16


B84 or C84

42A

a Adjust the shut lines and flush fitting of area (6) .

a Tighten to torque the bolt (E) ( 6.5 Nm ) .

a Adjust the headlight setting if necessary.

101217

Note:

Adjustment cannot be made at the bumper, as itis fitted into the wing lower pressure piece.

42A-17

UPPER FRONT STRUCTUREFront wing lower mounting support: General description

B84 or C84

42A


This is a basic part, it fulfils the function of a front winglower mounting support and it enables the front wing tobe adjusted in the Y axis.

This part is bolted to the scuttle side panel.

WARNING



101612

42A-18

UPPER FRONT STRUCTUREFront wing lower mounting support: Removal - Refitting

B84 or C84

42A

REMOVAL


a Remove:

- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting) ,


- the front headlight( (see Halogen headlight: Re-moval - Refitting) .


a Remove the mounting bolt (1) from the front wing.

a Remove:

- the mounting nuts (2) from the support,

- the front wing lower mounting support.

REFITTING


a Refit:

- the front wing lower mounting support,

- the mounting nuts (2) from the support,

- the mounting bolt (1) from the front wing.


- the front wing lower mounting support nuts (2)( 6.5 Nm ) ,

- the front wing mounting bolt (1) ( 6.5 Nm ) .


a Refit:



- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting) .

Tightening torquesm

front wing lower moun-ting support nuts (2)

6.5 Nm

front wing mountingbolt (1)

6.5 Nm

101217

101216

42A-19

UPPER FRONT STRUCTUREFront wing upper mounting support: General description

B84 or C84

42A


This is a basic part, it fulfils the function of front wingupper mounting support and it enables the front wing tobe adjusted in the X and Y axes.

WARNING



101611

42A-20

UPPER FRONT STRUCTUREFront wing upper mounting support: Removal - Refitting

B84 or C84

42A

REMOVAL


a Remove:

- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting) ,



- the front wing (see 42A, Upper front structure,Front wing: Removal - Refitting, page 42A-11) .

a Remove:

- the mounting bolts (1) from the bonnet hinges,

- the bonnet.


a Remove the mounting bolts (2) from the support.

a Detach the cement bead (3) .

a Remove the front wing upper mounting support.

Tightening torquesm

front wing upper moun-ting support bolts

6.5 Nm

101219

101752

101220

42A-21

UPPER FRONT STRUCTUREFront wing upper mounting support: Removal - Refitting

B84 or C84

42AREFITTING


a Always replace the expanding insert (4) .

a Clean and apply a bead (3) of M.J. PRO setting ad-hesive .


a Refit:

- the front wing upper mounting support,

- the support mounting bolts (2) .

a Tighten to torque the front wing upper mountingsupport bolts ( 6.5 Nm ) .


a Refit:

- the bonnet,

- the bonnet mounting bolts (1) ,




- the front wheel arch liner( (see Front wheel archliner: Removal - Refitting) .

103205

WARNING

Before cementing the part, it is advisable to fitthe wing and the bonnet provisionally in order tomark the correct position for the front wing uppermounting support.

42A-22

UPPER FRONT STRUCTUREFront: General description

B84 or C84

42A


A special feature of this type of component is that itcomprises an upper cross member (1) made from steeland composite material and two side sections (2) madefrom a composite material, which cannot be repairedand which are bolted on the vehicle.

This part is attached to the ends of the front side mem-bers and cannot be adjusted.

WARNING



101610

101609

42A-23

UPPER FRONT STRUCTUREFront: Removal - Refitting

B84 or C84

42A

The side sections are removable structural compo-nents made of SMC type composite material.

The upper cross member is a component made up oftwo sections (steel and SMC) which are pressed to-gether.

REMOVAL

I - REMOVAL PREPARATION OPERATION FOR SIDE SECTION

a Remove:

- the front wheel arch liners( (see Front wheel archliner: Removal - Refitting) ,


- the front headlights( (see Halogen headlight: Re-moval - Refitting) ,

- the front impact cross member (see 41A, Frontlower structure, Front impact cross member:Removal - Refitting, page 41A-8) .

a Pull out the filling pipe (1) .

a Disconnect the pump pipes (2) and detach the reser-voir (3) by pulling it strongly towards the front of thevehicle.

a Drain the reservoir if necessary.

a Unclip the radiator air deflector (4) .

Tightening torquesm

front end panel sidesection mounting bolts

6.5 Nm

front end panel uppercross member moun-ting bolt

21 Nm

101168

101169

42A-24


B84 or C84

42AII - OPERATION FOR REMOVAL OF SIDE SECTION

a Remove:

- the mounting bolts (5) from the side section,

- the side sections from the front end panel.

REFITTING

I - REFITTING OPERATION FOR SIDE SECTION

a Refit:

- the side sections to the front end panel.

- the side section mounting bolts (5) .

a Tighten to torque the front end panel side sectionmounting bolts ( 6.5 Nm ) .


a Clip the radiator air deflector (4) into place.

a Refit the reservoir (3) .

a Connect the pipes (2) to the washer fluid pump.

a Refit the filler pipe (1) .

a Fill the washer fluid reservoir.

REMOVAL

I - REMOVAL PREPARATION OPERATION FOR THE UPPER CROSS MEMBER

a Unclip the upper section (6) of the plastic union anddetach the bonnet opening cable.

a Using a screwdriver, unclip the radiator indexingpins (7) .

101167

101791

101783

42A-25


B84 or C84

42A

a Disconnect the audible warning connector (8) .

a Disconnect the washer fluid pump connector (9) .

a Detach the wiring harness from the upper crossmember.

II - OPERATION FOR REMOVAL OF THE UPPER CROSS MEMBER

a Remove:

- the mounting bolts (10) from the side sections,

- the mounting bolt (11) from the upper cross mem-ber,

- the upper cross member.

REFITTING

I - REFITTING OPERATION FOR THE UPPER CROSS MEMBER

a Refit:

- the upper cross member,

- the mounting bolt (11) to the upper cross member,

- the side section mounting bolts (10) .


- the front end panel upper cross member moun-ting bolt ( 21 Nm ) ,

- the front end panel side section mounting bolts(6.5 Nm) .


a Refit the wiring harness on the upper cross member.

a Connect:

- the connector (9) to the washer fluid pump,

- the audible warning connector (8) .

a Clip the radiator indexing pins (7) into place.

a Refit the bonnet opening cable to the upper crossmember.

101789

101788

101787

42A-26

UPPER FRONT STRUCTUREScuttle side panel: General description

B84 or C84

42A



- scuttle side panel.

- A-pillar lining.


Cut line (3) marks the area in which it is possible tomake a cut.




WARNING



Note:


115794

101608

WARNING


42A-27

UPPER FRONT STRUCTUREScuttle side panel: General description

B84 or C84

42A

Line (6) in the drawing marks the partial replacementand a MAG butt weld.

Depending on the exact position of the cut, a weldmade by joggling with plug welds at regular intervalsmay also be used.

101592

42A-28

UPPER FRONT STRUCTURECowl side panel: Description

B84 or C84

42A


- partial replacement of front end section,


- partial replacement of the rear section,



II - PART FITTED


115794

115261


(1) A-pillar lining HEL 1

(2) Dashboard rein-forcement brac-ket

VHEL 2.5

(3) Dashboardmounting unitreinforcement

VHEL 2

(4) Dashboardmounting unit

HEL 1.7

(5) Driver's posi-tion mountingbracket

- 1.5

(6) Dashboardcross membermounting upperspacer

VHEL 2.5

(7) Dashboardcross membermounting lowerspacer

VHEL 2.5

101592

42A-29


B84 or C84

42AThe partial replacement of the front end section is lin-ked to the partial replacement of the upper reinforce-ment on the scuttle side panel.


3 - Partial replacement of the rear section


101764

102001

WARNING


Note:

The complete replacement of the scuttle side panelsupplements the replacement of the A-pillar reinfor-cement.

IMPORTANT


42A-30


B84 or C84


115076

IMPORTANT



42A-31

UPPER FRONT STRUCTUREScuttle side panel upper reinforcement: General description

B84 or C84

42A


This type of part fixes the bonnet hinge mounting andthe front wing upper mounting support.

WARNING



Note:


115696

42A-32

UPPER FRONT STRUCTUREScuttle side panel upper reinforcement: Description

B84 or C84

42AThe options for replacing this part are as follows:




II - PART FITTED




115696


(1) Scut t le s idepanel upperreinforcement

- 0.9

101593

101594

WARNING


115076

42A-33

UPPER FRONT STRUCTUREScuttle side panel upper reinforcement: Description

B84 or C84

42A

IMPORTANT



42A-34

UPPER FRONT STRUCTUREFront wheel arch: General description

B84 or C84

42A


This is a basic part; it only fulfils the function of a frontwheel arch.

WARNING



IMPORTANT


Note:


115796

42A-35

UPPER FRONT STRUCTUREFront wheel arch: Description

B84 or C84

42AFront right-hand wheel arch

Front left-hand wheel arch


- complete replacement : this operation supplementsthe replacement of the scuttle side panel for a side im-pact or the front side member for a frontal impact.


Front right-hand wheel arch

115795

115796

Note:


115265


(1) Shock absor-ber cup heightadjuster

- 1.1

(2) Shock absor-ber cup

HLE 2

(3) Cup reinforce-ment

- 2

(4) Engine sup-port connec-tionreinforcement

- 2

42A-36


B84 or C84

42AFront left-hand wheel arch II - PART FITTED


Do not detach the windscreen aperture lower crossmember side bracket to replace the front wheel arch.

115264


(5) Shock absor-ber cup heightadjuster

- 1.1

(6) Shock absor-ber cup

HLE 2

(7) Air filter moun-ting support

- 1.2

101765

WARNING


101766

42A-37


B84 or C84


115076

IMPORTANT



42A-38

UPPER FRONT STRUCTUREHeater bulkhead: Description

B84 or C84

42A


- complete replacement : this operation supplementsthe replacement of the front wheel arch or the winds-creen aperture lower cross member for a side impact.


II - PART FITTED



102673

115267


(1) Heater bulkhead - 0.7

(2) Heater bulk-head brackets

- 1.2

102980

WARNING


115076

42A-39

UPPER FRONT STRUCTUREHeater bulkhead: Description

B84 or C84

42A

IMPORTANT



42A-40

UPPER FRONT STRUCTUREWindscreen aperture lower cross member: General description

B84 or C84

42A


This is a basic part; it only fulfils the function of winds-creen aperture lower cross member.

WARNING



Note:


102674

42A-41

UPPER FRONT STRUCTUREWindscreen aperture lower cross member: Description

B84 or C84

42A


- complete replacement : this operation supplementsthe replacement of the windscreen aperture lowercross member closure panel.


II - PART FITTED

102674

115270


(1) Windscreenaperture lowercross member

- 0.7

(2) Wiper moun-ting reinforce-ment

- 1.2

102986

IMPORTANT

For the weld joints in three thicknesses, the spotwelds on the part replaced should be executed inthe same place as the originals to retain the mecha-nical properties of the joint.

WARNING


42A-42

UPPER FRONT STRUCTUREDashboard cross member: Removal - Refitting

B84 or C84

42A

REMOVAL


a Remove:

- the front doors (see 47A, Side opening elements,Front side door: Removal - Refitting, page 47A-5) ,

- the dashboard( (see Dashboard: Removal - Refit-ting) ,

- the steering column( (see Steering column: Re-moval - Refitting) .


a Unclip the wiring harness (1) .

a Remove the mounting bolts (2) .

a Remove the blanking covers (3) .

Special tooling required

Car. 1765 Dashboard beam playcompensation pinrepositioning bolts

Tightening torquesm

centring device (6) 8 Nm

mounting bolt (5) 21 Nm

side mounting bolts (4) 21 Nm

mounting bolts (2) 8 Nm

Note:

In the event of a front impact with triggering of air-bags, check the area of connection between bothdiameters of the beam. If there is any damage visi-ble to the naked eye, this part must be replaced. 102216

102526

42A-43


B84 or C84

42A

a Remove the side mounting bolts (4) .

a Remove the mounting bolt (5) .

a Loosen the centring device (6) in order to align theholes in the A-pillar lining with the dashboard crossmember lock nuts.

a Fit the (Car. 1765) onto body (8) as far as the stop.

a Screw the rod (7) fully into the body (8) and tightengently.

a Firmly lock the tool body (8) against the dashboardcross member nut in the same way as a lock nut,while holding the hexagon bolt (7) .

a Unscrew the tool as far as the stop using the hexa-gon bolt (8) and tighten it gently (during the opera-tion, the beam nut, which has a left-hand thread,screws into the beam and releases it from the A-pillar).

102525

102526

102527

102529

42A-44


B84 or C84

42A

a Hold tool body (8) and unlock rod (7) .

a Unscrew dashboard cross member rod (7) to remo-ve the tool.

a Remove:

- the side mounting bolts (4) from the other side ofthe vehicle,

- the dashboard cross member.

REFITTING


a Fully tighten the locking nut (left-hand thread) in thebeam.

a Refit:

- the dashboard cross member,

- the side mounting bolts (4) on the side on which thelock nut has not been loosened.

a Fit the (Car. 1765) onto body (8) as far as the stop.

a Screw the rod (7) fully into the body (8) and tightengently.

a Firmly lock tool body in the same way as a lock nutagainst the dashboard cross member nut while hol-ding the hexagon bolt.

a Simultaneously screw the rod (7) and the tool body(8) fully, tightening gently.

102530

Note:

To maintain the adjustment of the dashboardcross member and therefore make refittingeasier, only loosen the lock nut on one side.

102527

102528

42A-45


B84 or C84

42A

a Hold the tool body (8) and release the rod (7) in thesame way as a lock nut.

a Unscrew dashboard cross member rod to removethe tool.

a Tighten to torque the centring device (6) ( 8 Nm ) .

a Refit:

- the mounting bolt (5) ,

- the side mounting bolts (4) .


- the mounting bolt (5) ( 21 Nm ) ,

- the side mounting bolts (4) ( 21 Nm ) .

a Refit the blanking covers (3) .

a Refit the mounting bolts (2) .

a Tighten to torque the mounting bolts (2) ( 8 Nm ) .

a Clip the wiring harness (1) .


a Refit:

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

- the dashboard( (see Dashboard: Removal - Refit-ting) ,

- the front doors (see 47A, Side opening elements,Front side door: Removal - Refitting, page 47A-5) .

a It is possible to adjust the dashboard after it hasbeen refitted to the vehicle, by removing the dash-board side panel (9) to access the mounting bolt (5)and the dashboard cross member centring device(6) .

102530

WARNING

During removal of the dashboard cross member,the lock nuts may loosen on both sides. If thishappens, refit the dashboard to adjust its clea-rances with the windscreen pillar and door trims.

101196

42A-46

UPPER FRONT STRUCTUREWindscreen aperture lower cross member closure panel: General description

B84 or C84

42A


This is a basic part; it only fulfils the function of thewindscreen aperture lower cross member closure pa-nel.

WARNING



Note:


102675

42A-47

UPPER FRONT STRUCTUREWindscreen aperture lower cross member closure panel: Description

B84 or C84

42A


- Complete replacement: this operation supplementsthe replacement of the heater bulkhead for a side im-pact at the A-pillar.


II - PART FITTED


102675

115274


(1) Windscreenaperture lowercross memberclosure panel

- 0.7

(2) Windscreenaperture lowercross membercentre reinfor-cement

- 1.2

102987

WARNING


42A-48

UPPER FRONT STRUCTUREWindscreen aperture lower cross member closure panel: Description

B84 or C84


115076

IMPORTANT



42A-49

UPPER FRONT STRUCTUREBulkhead: Description

B84 or C84



- Complete replacement: this operation supplementsthe replacement of the bulkhead side reinforcementand the bulkhead lower cross member.


II - PART FITTED


Passenger compartment side view

Engine side view102677


(1) Bulkhead - 1

102988

102978

WARNING


42A-50

UPPER FRONT STRUCTUREBulkhead: Description

B84 or C84


115076

IMPORTANT



42A-51

UPPER FRONT STRUCTUREBulkhead reinforcement: Description

B84 or C84




II - PART FITTED


102676


(1) Bulkheadreinforcement

UHLE 1.7

102989

WARNING


115076

IMPORTANT



42A-52

UPPER FRONT STRUCTUREBulkhead lower cross member: General description

B84 or C84

42A


This is a basic part; it simply fulfils the function of abulkhead cross member.

WARNING


Note:


110640

WARNINGIf the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,these should be replaced with plug welds afterholes have been drilled in the first panel.

42A-53

UPPER FRONT STRUCTUREBulkhead lower cross member: Description

B84 or C84




II - PART FITTED


102670


(1) Bulkheadlower crossmember

THLE 2.5

102985

WARNING


42A-54

UPPER FRONT STRUCTUREBulkhead panel: Removal - Refitting

B84 or C84

42A

The removal/refitting of this part is an operation linkedto the replacement of the complete body shell.

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the mounting bolts (A) .

a Cut the cement bead using the pneumatic tool (seeTechnical Note 414 A ).

a Remove the bulkhead panel.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Refit the bulkhead panel.

a Refit the mounting bolts (A) .

a Tighten to torque the bolts (A) ( 8 Nm ) .

Tightening torquesm

bolts (A) 8 Nm

103126

Note:

Wire cutting can be difficult due to the shape ofthe surrounding components, and the bulkheadpanel mounting bolts.

Note:

To refit, the bonding procedure is identical to thatfor replacing a bonded windscreen (refer toTechnical Note 371A ).

42A-55

UPPER FRONT STRUCTUREBulkhead side reinforcement: General description

B84 or C84

42A


This is a basic part, it simply fulfils the function of bulk-head side reinforcement.


WARNING



Note:


110084

42A-56

UPPER FRONT STRUCTUREBulkhead upper cross member: General description

B84 or C84

42A


This is a basic part; it only fulfils the function of a bulk-head upper cross member.

WARNING



Note:


102672

42A-57

UPPER FRONT STRUCTUREBulkhead upper cross member: Description

B84 or C84

42A


- Complete replacement: this operation supplementsthe replacement of the A-pillar.


II - PART FITTED

102672

115276


(1) Bulkhead uppercross member

HLE 1

(2) Windscreenaperture lowercross memberleft-hand sideangle bracket

- 1.2

(3) Wiper left-handmounting pad

- 1

(4) Wiper right-handmounting pad

- 1

(5) Linkage supportreinforcementplate

HLE 2

(6) Tie-bar moun-ting

HLE 3

(7) Bulkhead uppercross memberbracket

- 2

102979

WARNING


42A-58

UPPER FRONT STRUCTUREBulkhead upper cross member: Description

B84 or C84


115076

IMPORTANT



42A-59

UPPER FRONT STRUCTUREBulkhead side stiffener: Description

B84 or C84


- Complete replacement: this operation supplementsthe replacement of the A-pillar and the A-pillar lining.


II - PART FITTED

101607


(1) Bulkhead sidereinforcement

- 1.7

101997

IMPORTANT

For the weld joints in three thicknesses, the spotwelds on the part replaced should be executed inthe same place as the originals to retain the mecha-nical properties of the joint.

WARNING


42A-60

UPPER FRONT STRUCTUREBulkhead side stiffener: Description

B84 or C84


115076

IMPORTANT



42A-61

UPPER FRONT STRUCTUREWindscreen wiper mounting: Description

B84 or C84


- Complete replacement: this operation supplementsthe replacement of the scuttle side panel and the scu-ttle side panel reinforcement


II - PART FITTED

102671


(1) Wiper mounting - 1.2

102969

IMPORTANT


WARNING


42A-62

UPPER FRONT STRUCTUREWindscreen wiper mounting: Description

B84 or C84


115076

IMPORTANT



43A-1

SIDE UPPER STRUCTUREVehicle side section structure: Description

B84 or C84

43ASIDE STRUCTURE

B84

102402



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


HLE 1.8


- 0.7


- 0.7

43A-2


B84 or C84

43A


- 0.7


HLE 1.2/1.5


HLE 1


HLE 1.5/2.2



- 0.7


HLE 1.5


- 1


HLE 0.7/0.9



HLE 0.7/0.9


HLE 1.5


- 0.7


HLE 1.5/2


HLE 0.7


43A-3


B84 or C84

43A


- 0.7


- 0.7


C84

102403



HLE 0.7/0.95


HLE 1.8


HLE 1.8

43A-4


B84 or C84

43A


- 0.7


- 0.7


- 0.7


HLE 1.2/1.5


HLE 1




VHLE 1.8


HLE 1.5/2



HLE 0.7/0.9


HLE 0.7/0.9


- 0.7


- 0.7


- 0.7


43A-5


B84 or C84

43A


HLE 0.7


HLE 1.5


43A-6

SIDE UPPER STRUCTUREA-pillar: General description

B84 or C84

43A


The A-pillar is obtained by extension from the bodyside front section.

WARNING

The following information describes the generalrepair procedure for all vehicles with the same typeof design for this part.


Note:


115660

WARNING


43A-7

SIDE UPPER STRUCTUREA-pillar: Description

B84 or C84

43A

To replace this part, also order insert (A) .



- partial central replacement: this operation is specificto the replacement of the hinge reinforcement,



II - PART FITTED


X1 = 60 mm

115660

115280


(1) Body side - 0.7

(2) Jacking pointsupport

HLE 1.8

102041

43A-8


B84 or C84

43ACut A

Make the cut in area (X2) .

Cut B

2 - Partial central replacement

For replacement of the hinge reinforcement (see 43A,Side upper structure, A-pillar reinforcement: Des-cription, page 43A-11) .

115406

102635

115283

113507

43A-9


B84 or C84

43A3 - Complete replacement

Cut C

102003

115282

Note:

Do not make the cut above this limit as the expan-ding insert could be cut.

102635

IMPORTANT


WARNING


43A-10

SIDE UPPER STRUCTUREA-pillar reinforcement: General description

B84 or C84

43A


This part's special feature is that it serves as an A-pillarreinforcement, B-pillar reinforcement, body side frontsection reinforcement and sill panel reinforcement.

This part's special feature is that it serves as an A-pillarreinforcement, B-pillar reinforcement, body side frontsection reinforcement and sill panel reinforcement.

WARNING

The following information describes the generalrepair procedure for all vehicles with the same typeof design for this part.


Note:


B84

115657

C84

115667

WARNING


43A-11

SIDE UPPER STRUCTUREA-pillar reinforcement: Description

B84 or C84

43A



- partial replacement of lower section: order insert (B)or (D) ,

- partial replacement: order inserts (A) and (B) or (C)and (D) .


B84

115659

C84

115668

B84

115423

43A-12


B84 or C84

43AII - PART FITTED

1 - Partial replacement of the lower section

Cut A

C84

115424


(1) Body side rein-forcement

HLE 1.2

(2) A-pillar upperhinge reinforce-ment

THLE 2.5

(3) A-pillar lowerhinge reinforce-ment

THLE 2.5

WARNING


102039

115288

43A-13


B84 or C84

43ACut B


Cut C

III - REPLACEMENT OF UPPER HINGE REINFORCEMENT

Unpick the welds and remove the upper hinge reinfor-cement (4) .

115289

102005

115287

WARNING

Do not alter the position of this weld; it is determi-ned by the position of the lining, reinforcements orexpanding inserts.

115024

43A-14


B84 or C84

43A

Position and weld the upper hinge reinforcement (4)with six plug welds after having drilled the replacementpart.

IV - SPECIAL NOTE FOR LOWER HINGE REINFORCEMENT

Apply two securing beads (5) of 15 mm to the lowerhinge reinforcement.

WARNING

Each time a panel is stripped in the workshop (e.g. when drilling), degrease and wipe the area and then use a fine paintbrush to apply the following:


- a two-part primer


115025

115026

43A-15

SIDE UPPER STRUCTUREWindscreen pillar lining: General description

B84 or C84

43A


This is a basic part, its only function is that of the winds-creen pillar lining.


WARNING



Note:


102613

43A-16

SIDE UPPER STRUCTUREWindscreen pillar lining: Description

B84 or C84

43ATo replace this part, order the expanding insert.




B84

102613

C84

102607


(1) Windscreenpillar lining

HLE 1.5

43A-17

SIDE UPPER STRUCTUREWindscreen pillar lining: Description

B84 or C84

43AII - PART FITTED


Apply a safety bead (A) .


102854

22362

WARNING


115076

IMPORTANT



43A-18

SIDE UPPER STRUCTUREB-pillar: General description

B84

43A


The B-pillar is obtained by extension from the front sec-tion body side.

WARNING



Note:


IMPORTANT


110591

43A-19


B84

43AII - AREA TO BE CUT FOR PARTIAL REPLACEMENT

Cut lines (1) and (2) show the area in which it is possi-ble to carry out a partial replacement.

Make the cut line (2) on the butt weld.




110592

12

43A-20


B84

43A

Lines (5) and (6) of the drawing show a butt weld bycontinuous MAG welding.


110593

5

6

WARNING


43A-21

SIDE UPPER STRUCTUREB-pillar: Description

B84

43A

To replace this part, order the expanding insert (A) .





II - PART FITTED


It is possible to cut in area (X1) .

115658

115280


(1) Body side - 0.9


HLE 1.8

102857

43A-22


B84

43ACut A

It is possible to cut along the whole length of the sill pa-nel.

Cut B

115298

101970

115283

101964

43A-23


B84

43ACut C


Cut D

115419

Note:

Make the cut outside area (X2) to avoid cutting intothe impact absorbing unit and the expanding insert.

102859

115293

102858

43A-24


B84

43ACut E

115294

101970

101964

WARNING


43A-25

SIDE UPPER STRUCTUREB-pillar reinforcement: General description

B84 or C84

43A


The special feature of this part is that it combines seve-ral functions:

- B-pillar reinforcement,

- A-pillar reinforcement

- sill panel reinforcement,

- body side front section reinforcement.

II - ASSEMBLY INSTRUCTIONS FOR A PARTIAL REPLACEMENT




WARNING



Note:


115657

WARNING


101971

43A-26

SIDE UPPER STRUCTUREB-pillar reinforcement: Description

B84 or C84

43A


To replace this part, order the expanding insert (B) .




B84

115657

C84

115667

B84

115423

43A-27


B84 or C84

43AII - PART FITTED

Partial replacement

It is possible to make the cut in area (X1) .

Cut A

C84

115424



HLE 1.2


HLE 2


THLE 2

B84

102861

115299

43A-28


B84 or C84

43A

It is possible to make the cut along the length of the sillpanel reinforcement.

Cut BIt is possible to make the cut in area (X3) .

Cut C

101971

115301

C84

102860

115300

43A-29


B84 or C84

43A

It is possible to make the cut along the length of the sillpanel reinforcement.

Cut D

102593

115302

WARNING


43A-30

SIDE UPPER STRUCTUREB-pillar reinforcement stiffener: Description

B84 or C84

43A


- complete replacement: this operation supplementsthe replacement of the B-pillar reinforcement.


B84

102614

B84

115306


(1) B-pillar impactreinforcement

HLE 2.2

(2) B-pillar reinforce-ment central stif-fener

HLE 1.5

(3) B-pillar reinforce-ment upper stif-fener

HLE 2

43A-31


B84 or C84

43AII - PART FITTED

Complete replacementC84

102609


(4) B-pillar reinforce-ment stiffener

THLE 1.8

B84

115307

C84

115308

43A-32


B84 or C84

43A

WARNING


43A-33

SIDE UPPER STRUCTUREB-pillar lining: General description

B84 or C84

43A


This is a basic part, its only function is that of the B-pillar lining.

The special feature of this part is that it is extendedfrom the rear quarter lining.

WARNING



Note:


B84

102615

C84

102659

WARNING


43A-34

SIDE UPPER STRUCTUREB-pillar lining: Description

C84

43ATo replace this part, order the complete rear quarterlining.


- partial replacement: this operation supplements thereplacement of the B-pillar reinforcement.


II - PART FITTED

102659


(1) Quarter panellining

- 0.6

WARNING


102869

102853

43A-35

SIDE UPPER STRUCTUREB-pillar lining: Description

C84

43A

102852

WARNING

The position of this cut must be observed, and isdetermined according to the position of the internalreinforcements or acoustic inserts cut.

43A-36

SIDE UPPER STRUCTUREB-pillar lower lining: Description

B84


- complete replacement: this operation supplementsthe replacement of the B-pillar reinforcement after aside impact.


II - PART FITTED


102612


(1) B-pi l lar lowerlining

- 0.7

115309

WARNING


43A-37

SIDE UPPER STRUCTUREB-pillar upper lining: Description

B84


- complete replacement: this operation supplementsthe replacement of the B-pillar reinforcement after aside impact.


II - PART FITTED


102615


(1) B-pillar upperlining

HLE 1.5

102863

WARNING


43A-38

SIDE UPPER STRUCTUREBody side front section: General description

B84 or C84

43A


This part has two special features:

- it is welded under the roof,

- it is butt welded at section (1) .

This part is obtained by removing the front section ofthe body side, 5-door version.

WARNING



Note:


110491

1

C84

110491

WARNING


43A-39

SIDE UPPER STRUCTUREBody side front section: Description

B84 or C84

43A

To replace this part, order expanding inserts (A) , (B)and (C) .


- partial replacement (3-door version),

- complete replacement (5-door version).


115655

Note:

The Parts Department only supplies the front sec-tion of the body sides for 5-door versions.

For 3-door versions, keep the section common to 5-door versions (A-pillar) and dispose of the B-pillar.

115280


(1) Body s idefront section

- 0.7


HLE 1.8

43A-40


B84 or C84

43AII - PART FITTED



Cut A

Cut B

C84

102632

115312

101970

115283

WARNING


43A-41


B84 or C84



Cut C


Cut D

B84

102858

115294

101964

115419

WARNING

The position of this cut must be observed, and isdetermined according to the position of the internalreinforcements or acoustic inserts cut.

43A-42

SIDE UPPER STRUCTUREBody side front section reinforcement: Description

B84 or C84

43A

To carry out this operation, order expanding inserts (A), (B) and (C) .

To carry out this operation, order expanding inserts (A), (B) and (D) .


- complete replacement: this operation supplementsthe replacement of the body side after a side impact.


B84

115654

C84

115664

B84

115423

43A-43


B84 or C84

43AII - PART FITTED

Complete replacementC84

115424



HLE 1.2


THLE 2.5


THLE 2.5

B84

115315

C84

115316

43A-44


B84 or C84

43A

III - REPLACEMENT OF THE UPPER HINGE REINFORCEMENT

Remove the welds from and then remove the upperhinge reinforcement (4) .

Position then weld the upper hinge reinforcement (4)with six plug welds, after drilling the replacement part.

IV - SPECIAL NOTE ON THE LOWER HINGE REINFORCEMENT

On the lower hinge reinforcement, apply two securingbeads (5) of 15 mm .

WARNING


115024

WARNING

Each time a panel is stripped in the workshop (e.g. when drilling), degrease and wipe the area and then use a fine paintbrush to apply the following:


- a two-part primer,


115025

115026

43A-45

SIDE UPPER STRUCTUREUpper body panel: General description

B84 or C84

43A


This is a basic part; its only function is that of an upperbody.


Lines (1) , (2) and (3) in the illustration show the area inwhich a partial replacement may be carried out.




WARNING



Note:


IMPORTANT


110603

B84

110604

B84

WARNING


1

2 3

43A-46

SIDE UPPER STRUCTUREUpper body panel: General description

B84 or C84

43A

Lines (4) , (5) and (6) of the drawing show a butt weldby continuous MAG welding.

Weld (6) along the butt weld.

110605

4

5

6

43A-47

SIDE UPPER STRUCTUREUpper body panel: Description

B84 or C84

43A




I - COMPOSITION OF THE SPARE PARTB84

115656

C84

115666

B84

115656

43A-48


B84 or C84

43AII - PART FITTED

Partial replacement


Cut A

C84

115666


(1) Upper body - 0.7

B84

102006

115282

43A-49


B84 or C84

43A


Cut B


Cut C

102864

115298

102858

115294

43A-50


B84 or C84

43A


Cut D


C84

102006

102630

115310

102634

43A-51


B84 or C84

43ACut E

115311

WARNING


44A-1

REAR UPPER STRUCTUREVehicle structure rear section: Description

B84 or C84

44AREAR STRUCTURE

B84

102405



- 0.7


- 0.6



- 0.9



- 0.95



- 0.7


44A-2


B84 or C84

44A



HLE 1/2.5



HLE/THLE

0.65/2.5


- 0.65


HLE/THLE

0.95/2



HLE 2



- 0.7



- 0.7


HLE 0.95


- 0.9


HLE 0.7/1.5



- 0.7


- 0.9



HLE 0.85/1


44A-3


B84 or C84

44A

C84

102406



- 0.7


- 0.6



- 0.9



HLE 1.5



- 1/2



- 0.95

44A-4


B84 or C84

44A



- 0.7




HLE 1/2.5



HLE/THLE

0.65/2.5


- 0.65


HLE/THLE

0.95/2



- 0.7



HLE 2


HLE 0.95



- 0.7


- 0.9


HLE 0.7/1.5



- 0.7


- 0.9



HLE 0.85/1


44A-5

REAR UPPER STRUCTURERear wing panel: General description

B84 or C84

44A


This part has three special features:

- it is welded under the roof,

- it is butt welded on the body side front section.

- it is supplementary to the body side front section for acomplete body side replacement.


Lines (1) and (2) of the drawing show the areas inwhich it is possible to carry out a partial replacement.

WARNING



Note:


IMPORTANT

Before any operation is carried out, remove the seatbelts and curtain airbag.

107759

B84

110611

1

2

44A-6

REAR UPPER STRUCTURERear wing panel: General description

B84 or C84

44A

Lines (3) , (4) and (5) in the drawing show the areas inwhich it is possible to carry out a partial replacement.


Only the connections relevant to partial replacement bycutting are shown.


Lines (7) in the drawing show a butt weld by continuousMAG welding.

C84

113208

WARNING


110612

44A-7

REAR UPPER STRUCTURERear wing panel: Description

B84 or C84

44A


- partial replacement: order insert (A) ,

- Complete replacement: order inserts (A) and (B) andanti-gravel protective film (C) .


- partial replacement: order inserts (E) and (F) and anti-gravel protective film (G) ,

- complete replacement: order inserts (D) , (E) and (F)and anti-gravel protective film (G) .


B84

115652

C84

115663

B84

115811


(1) Rear wingpanel

- 0.7

(2) Door strikerplate stiffener

- 1


HLE 1.8

44A-8


B84 or C84

44AII - PART FITTED


Cut H

C84

115823


(4) Rear wingpanel

- 0.7

(5) Door strikerplate stiffener

- 1


HLE 1.8

WARNING


B84

102993

115814

44A-9


B84 or C84

44A

Cut I

Cut J

101973

115821

WARNING

Do not alter the positioning of this weld; it is deter-mined by that of the linings, reinforcements orexpanding inserts.

C84

102628

115816

44A-10


B84 or C84

44A


Cut K

Cut L

102633

115817

101970

115417

44A-11


B84 or C84


Cut M

Cut N

B84

102858

115294

101972

115420

44A-12


B84 or C84

44A

Cut O

3 - Special note on replacing the rear wing panel

C84

102631

115311

101970

IMPORTANT


102992

44A-13


B84 or C84

44AThe procedure for crimping the rear wing panel is iden-tical to that for replacing a door panel.

Cut P

Use an MJ Pro type adhesive to ensure correct appea-rance and sealing after crimping of the rear wing panel.

III - ANTI-GRAVEL PROTECTION

To fit anti-gravel protective adhesive film, see Techni-cal note 579A, Anti-gravel protective adhesive film,55A, Exterior protection, Anti-gravel protective ad-hesive film .

115822

103085

Note:

Use structural adhesive on the crimping area.

44A-14

REAR UPPER STRUCTURERear wing panel rain channel: General description

B84 or C84

44A


This is a basic part; its only function is that of rear wingpanel rain channel.


WARNING



Note:


115797

44A-15

REAR UPPER STRUCTURERear wing panel rain channel: Description

B84 or C84


- partial replacement of the bottom section of the rearwing panel rain channel: this operation avoids theneed to remove the rear wing,

- replacement of the bottom section of the rain channel:this operation supplements the rear wheel arch exten-sion and the side closure of the far rear lower crossmember.

- complete replacement: this operation supplementsthe replacement of the roof, rear wing and the rearwheel arch extension.


II - PART FITTED

1 - Partial replacement of the bottom section of the rear wing panel rain channel

2 - Replacement of the bottom section of the rear wing panel rain channel

115797


(1) Rear side rainchannel

HLE 0.9/1

102637

102638

44A-16

REAR UPPER STRUCTURERear wing panel rain channel: Description

B84 or C84

44A3 - Complete replacement of the rear wing panel rain channel


102824

WARNING


115100

IMPORTANT



44A-17

REAR UPPER STRUCTURERear lights support: General description

B84 or C84

44A


This is a basic part; its only function is that of a rear li-ghts support and it is part of the rear wing panel rainchannel connection.

This is a basic part; its only function is that of a rear li-ghts support.


WARNING



Note:


101408

44A-18

REAR UPPER STRUCTURERear lights support: Description

B84 or C84

44A


- complete replacement: this operation supplementsthe replacement of the rear end panel assembly.


II - PART FITTED

115798

101408


(1) Rear lights sup-port

- 0.9

(2) Luggage com-partment l idside stop moun-ting

- 1

102639

IMPORTANTFor welded connections in three thicknesses, thespot welds on the part replaced should be made inthe same place as for the original joint to retain itsmechanical properties.

WARNING


44A-19

REAR UPPER STRUCTURERear lights support: Description

B84 or C84


115100

IMPORTANT



44A-20

REAR UPPER STRUCTURELights support lining: General description

B84 or C84

44A


This is a basic part, its only function is that of the lightmounting lining.

WARNING



Note:


102650

44A-21

REAR UPPER STRUCTURELights support lining: Description

B84 or C84


- complete replacement: this operation supplementsthe replacement of the rear end panel assembly.


II - PART FITTED


102650


(1) Lights sup-port lining

- 1

102827

WARNING


44A-22

REAR UPPER STRUCTUREOuter rear wheel arch: General description

B84 or C84

44A


The special feature of this part is its extension from thequarter panel lining to create the external rear wheelarch.


WARNING



Note:


113248

C84

110625

1

44A-23

REAR UPPER STRUCTUREOuter rear wheel arch: General description

B84 or C84

44A

The line (1) of the drawing shows the area in which it ispossible to carry out a partial replacement.




Line (2) in the drawing shows partial replacement anda weld by joggling with plug welds at regular intervals.

B84

102648

WARNING


110626

2

44A-24

REAR UPPER STRUCTUREOuter rear wheel arch: Description

B84 or C84


- partial replacement (3-door version): this operationdoes not require removal of the quarter panel centrestiffener,



B84

102647

C84

102659



HEL 0.6

44A-25


B84 or C84

44AII - PART FITTED


C84

102878

102876

102873

WARNING


44A-26


B84 or C84


B84

102816

C84

102866

102865

102872

IMPORTANT


44A-27


B84 or C84


115100

IMPORTANT



44A-28

REAR UPPER STRUCTUREInner wheel arch: General descriptions

B84 or C84

44A


This is a basic part; its only function is that of an inter-nal rear wheel arch and rear shock absorber mounting.


WARNING



IMPORTANTThe straightening bench must be used.

Note:


110624

44A-29

REAR UPPER STRUCTUREInner wheel arch: Description

B84 or C84

44A


- Complete replacement: this operation complementsthe replacement of the rear wheel arch closure panel.


II - PART FITTED

102646

115843


(1) I n n e r r e a rwheel arch

HEL 0.7

(2) Rear section ofrear wheel arch

HEL 0.7

(3) R e a r l i g h tmounting lining

HEL 1

(4) Rear seat seat-back uppe rmounting sup-port

HEL 1.5

102817

WARNINGIf the spot welds cannot be made as they were ori-ginally using an electrical spot welding machine,these should be replaced with plug welds afterholes have been drilled in the first panel.

44A-30

REAR UPPER STRUCTUREInner wheel arch: Description

B84 or C84


115100

IMPORTANT



44A-31

REAR UPPER STRUCTURERear wheel arch closure panel: Description

B84 or C84


- complete replacement: this operation complementsthe replacement of the rear outer wheel arch for aside impact.


II - PART FITTED


102601


(1) Rear wheel archclosure panel

- 0.7

102826

WARNING


44A-32

REAR UPPER STRUCTURERear wheel arch closure panel: Description

B84 or C84


115100

IMPORTANT



44A-33

REAR UPPER STRUCTURERear wheel arch extension: Description

B84 or C84




II - PART FITTED


102602


(1) Rear wheel archextender.

- 0.7

102642

WARNING


44A-34

REAR UPPER STRUCTURERear wheel arch extension: Description

B84 or C84


115100

IMPORTANT



44A-35

REAR UPPER STRUCTUREQuarter panel lining: General description

B84 or C84

44A



- quarter panel lining,

- outer rear wheel arch.


WARNING



Note:


102647

44A-36

REAR UPPER STRUCTUREQuarter panel reinforcement: Description

B84 or C84


- complete replacement: this operation complementsthe replacement of the quarter panel lining for a sideimpact.


II - PART FITTED


102603


(1) Quarter panelstiffener

- 0.9 102822

WARNING


44A-37

REAR UPPER STRUCTUREQuarter panel lining: Description

B84 or C84


- complete replacement: this operation complementsthe replacement of the rear end panel and rear sidemember for a rear impact or the rear body side andrear quarter upper reinforcement for a rear side im-pact.


B84

102647

C84

102659



- 0.6

44A-38


B84 or C84

44AII - PART FITTED


B84

102825

44A-39


B84 or C84

44A

C84

102879

WARNING


44A-40

REAR UPPER STRUCTUREQuarter panel upper reinforcement: Description

B84 or C84


- complete replacement: this operation complementsthe replacement of the complete body side or the up-per body for a side impact.


B84

102617

C84

102610


(1) Quarter panelupper reinforce-ment

- 0.9

44A-41


B84 or C84

44AII - PART FITTED


B84

102821

Note:

To replace this part, partially detach the side lining(2) from the roof rear cross member.

102820

C84

102867

Note:

The rear section of the 3-door version is identical tothe 5-door version.

44A-42


B84 or C84

44A

WARNING


44A-43

REAR UPPER STRUCTUREQuarter panel centre reinforcement: Description

C84


- complete replacement: this operation complementsthe replacement of the rear wing panel for a rear sideimpact.


II - PART FITTED


Cut A

102605


(1) Quarter panelcentre reinforce-ment

- 0.9

102819

115847

WARNING


44A-44

REAR UPPER STRUCTURERoof rear drip moulding lining: Description

B84 or C84


- complete replacement: this operation complementsthe replacement of the complete body side or the up-per body for a side impact.


II - PART FITTED

B84

102616

C84

102604


(1) Rear roof dripmoulding lining

- 0.9

B84

102818

44A-45

REAR UPPER STRUCTURERoof rear drip moulding lining: Description

B84 or C84

44A

C84

102880

WARNING


44A-46

REAR UPPER STRUCTURERear end panel assembly: Description

B84 or C84


- complete replacement: this operation complementsthe replacement of the light mounting lining for a rearimpact.


115800

115851

44A-47

REAR UPPER STRUCTURERear end panel assembly: Description

B84 or C84

44AII - PART FITTED

Complete replacementMark Description Type Thickness

(mm)

(1) Rear end panel - 0.7

(2) Rear end panellining, right-handside section

- 0.7

(3) Rear end panellining, left-handside section

- 0.7

(4) Rear end panellining reinforce-ment

VHEL 1.8

(5) Rear end panell ining, centresection

- 0.7

(6) Rear end panellining trim moun-ting bridge piece

- 1

(7) Tank mountingreinforcement

VHEL 2.5

(8) Rear floor rearright-hand sec-tion mountingreinforcement

HEL 2

(9) Rear floor rearleft-hand sectionmounting reinfor-cement

HEL 2

102881

WARNING


44A-48

REAR UPPER STRUCTURERear end panel: General description

B84 or C84

44A


This is a basic part, and its only function is that of therear end panel.


WARNING



Note:


110438

44A-49

REAR UPPER STRUCTURERear end panel: Description

B84 or C84





II - PART FITTED


2 - Complete replacement115801


(1) Rear end panel - 0.7

101995

101996

44A-50

REAR UPPER STRUCTURERear end panel: Description

B84 or C84

44ACut A


115850

WARNING


115100

IMPORTANT



44A-51

REAR UPPER STRUCTURERear end panel side lining: Description

B84 or C84




II - PART FITTED

Partial replacement

Detailed view of the cut

101412


(1) Rear end panelside lining

- 0.7

102965

102966

WARNING


45A-1

TOP OF BODYVehicle side section structure: Description

B84 or C84

45ASIDE STRUCTURE

B84

102402



HLE 0.7/0.95


HLE 0.7/0.95


HLE 1.8


HLE 1.8


- 0.7


- 0.7

45A-2


B84 or C84

45A


- 0.7


HLE 1.2/1.5


HLE 1


HLE 1.5/2.2



- 0.7


HLE 1.5


- 1


HLE 0.7/0.9



HLE 0.7/0.9


HLE 1.5


- 0.7


HLE 1.5/2


HLE 0.7


45A-3


B84 or C84

45A


- 0.7


- 0.7


C84

102403



HLE 0.7/0.95


HLE 1.8


HLE 1.8

45A-4


B84 or C84

45A


- 0.7


- 0.7


- 0.7


HLE 1.2/1.5


HLE 1




VHLE 1.8


HLE 1.5/2



HLE 0.7/0.9


HLE 0.7/0.9


- 0.7


- 0.7


- 0.7


45A-5


B84 or C84

45A


HLE 0.7


HLE 1.5


45A-6

TOP OF BODYRoof: General description

B84 or C84

45A


This is a basic part; its only function is that of a roof.

The roof is welded onto the body sides.

There are also models with an aperture for a sunroof.


WARNING



Note:


112147

45A-7

TOP OF BODYRoof: Description

B84 or C84

45A

To replace this part, also order the roof stiffener mate-rial (A) (see Parts Catalogue ).




II - PART FITTED

104573

101613


(1) Roof - 0.7

101824

101825

WARNINGIf the spot welds cannot be made as they were ori-ginally using an electric spot welding machine, theyshould be replaced with plug welds after holes havebeen drilled in the first panel.

Note:

The procedure presents no difficulties.

45A-8

TOP OF BODYRoof: Description

B84 or C84

45ABonding area

For a detailed description of a particular connection(see MR 400, 40A, General information ).

101826

101828

101829

45A-9

TOP OF BODYRoof front section: Description

B84 or C84



This operation only affects versions equipped with asunroof.


Part supplied on its own.

II - PART FITTED

101615


(1) Front section ofroof

- 0.7

101832

Note:

The procedure for replacing this part has no specialnotes, and joints can all be made as originally.

45A-10

TOP OF BODYRoof rear section: Description

B84 or C84



This operation only affects versions equipped with asunroof.



II - PART FITTED

101614


(1) Rear sectionof roof

- 0.7

101833

WARNING


45A-11

TOP OF BODYRoof front cross member: General description

B84 or C84

45A


This is a basic part; its only function is that of a rooffront cross member and roof stiffener by means of acemented connection.


WARNING



Note:


110529

45A-12

TOP OF BODYRoof front cross member: Description

B84 or C84


- Complete replacement: this operation supplementsthe replacement of the roof for the normal roof versionand the roof front section for the sunroof version.


II - PART FITTED

Standard roof version

Sunroof version

102606


(1) Roof f rontcross mem-ber

HLE 0.7

101830

101831

Note:

There is no specific procedure for replacing thispart; all connections can be made as they originallywere.

45A-13

TOP OF BODYRoof centre cross member: General description

B84 or C84

45A


This is a basic part; its only function is that of a roofcentre cross member and roof stiffener by means of acemented connection.


WARNING



Note:


112723

45A-14

TOP OF BODYRoof centre cross member: Description

B84 or C84


- Complete replacement: this operation supplementsthe replacement of the roof.



II - PART FITTED

102608


(1) Roof centrecross member

HLE 1.5

101834

Note:


45A-15

TOP OF BODYRoof rear cross member: General description

B84 or C84

45A


This is a basic part; its only function is that of roof rearcross member as well as roof stiffener by means of acemented connection.


WARNING



Note:


112721

45A-16

TOP OF BODYRoof rear cross member: Description

B84 or C84

45AStandard roof version

Sunroof version





Sunroof version

102618

102611

115143

115144

45A-17

TOP OF BODYRoof rear cross member: Description

B84 or C84

45A

II - PART FITTED


Sunroof version


(1) Roof rearcross mem-ber

- 0.7

(2) Rear crossmember sidelining

HLE 0.9

101827

101835

Note:


47A-1

SIDE OPENING ELEMENTSVehicle removable section structure: Description

B84 or C84


102400



Aluminium



Steel/SMC


SMC


Aluminium

47A-2

SIDE OPENING ELEMENTSVehicle removable section structure: Description

B84 or C84

47A



Noryl




Aluminium




Noryl




Polypropy-lene



47A-3

SIDE OPENING ELEMENTSFront side door: General description

B84 or C84

47A

I - COMPONENT DESIGN

This part has the following specifications:

- "bolted and bolted" hinges mounted vertically on theA-pillar and the door box section,

- a door check rod integrated in the lower hinge.


If the front door hinge mountings are the "bolted and bolted" type it is possible to remove the front side door, depending on the operations to be performed:

- either by unscrewing the mountings on the compo-nent in the event of replacement of the front side door,

- or with the hinges by removing the mountings on theA-pillar in the event of replacement of the body.

III - ADJUSTMENT

There are four main areas where adjustments can be made:

- adjustment of the front area,

- adjustment of the rear area,

- adjustment of the upper area,

- adjustment of the lower area.

Always begin the adjustments on the hinge side withthe lock striker plate loose and the stops in place.

1 - Adjustment of the front area:

Adjust the shut lines and alignment with the front wingusing the front door hinge mountings.

2 - Adjustment of the rear area

Adjust the shut lines and alignment with the rear doorand the closure firmness using the striker plate moun-tings.

3 - Adjustment of the upper area

Adjust the shut lines and alignment with the roof and A-pillar using the front side door hinge mountings.

WARNING



101720

Note:


Note:

The front side door is the component positionedafter the rear side door, in the order of assembly ofremovable components in the factory.

For it to be completely adjusted, position all theother components correctly.

IMPORTANT

In this case, compromise between the closure firm-ness and the rear shut lines of the front door bygiving priority to closing in such a way that the doorpresses sufficiently onto the seal to avoid floating ofthe rear of the door.

47A-4

SIDE OPENING ELEMENTSFront side door: General description

B84 or C84

47A4 - Adjustment of the lower area

Adjust the shut lines and alignment with the sill panelusing the front side door hinge mountings.

47A-5

SIDE OPENING ELEMENTSFront side door: Removal - Refitting

B84 or C84

47A

I - REMOVAL WITHOUT THE HINGES

1 - REMOVAL PREPARATION OPERATION

a Disconnect the door wiring harness supply connec-tor.

2 - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove:

- the four mounting bolts (1) from the door,

- the door.

II - REFITTING WITHOUT THE HINGES

1 - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the door,

- the door's four mounting bolts (1) .

a Adjust the door clearances and shut lines.

a Tighten to torque the door mounting bolts ( 21 Nm) .

2 - FINAL OPERATION

a Connect the door wiring harness supply connector.

III - REMOVAL WITH HINGES





a Remove:

- the door hinge mounting bolts (2) ,

- the door.

Tightening torquesm

door mounting bolts 21 Nm

door hinge mountingbolts

27 Nm

door retention device 0.8 Nm

door retention devicemounting bolts

2.1 Nm

101720

101720

47A-6

SIDE OPENING ELEMENTSFront side door: Removal - Refitting

B84 or C84

47AIV - REFITTING WITH HINGES


a Refit:

- the door,

- the door hinge mounting bolts (2) .

a Adjust the door clearances and shut lines.

a Tighten to torque the door hinge mounting bolts (27 Nm ) .

2 - FINAL OPERATION

a Connect the door's wiring harness supply connector.

a Refit the front wing.

V - PASSIVE SAFETY

a At the end of the operation, check the presence andcondition of the door retention device (3) .

a Tighten to torque the door retention device ( 0.8Nm ) .

a On 3-door models, check the presence and condi-tion of the additional door retention device (4) loca-ted on the lower section.

Tighten to torque the door retention device moun-ting bolts ( 2.1 Nm ) .

22749

Note:

The function of this part is essential in the eventof a frontal impact. The door retention devicekeeps the door in its longitudinal plane, therebyabsorbing impact energy efficiently.

101727

47A-7

SIDE OPENING ELEMENTSFront side door: Adjustment

B84 or C84

47A

ADJUSTMENT VALUESa For information on the front side door adjustment va-

lues, (see Vehicle shut lines: Adjustment value ).

ADJUSTMENTa There are two options for adjusting the door:

- by means of the mountings on the door box section(opening clearance adjustment),

- by means of the mountings on the A-pillar (shut lineadjustment):

a The front wing needs to be removed for this opera-tion.


I - REAR DOOR SHUT LINE ADJUSTMENT

a Undo the hinge mounting bolts (6) .

a Adjust the shut lines with the rear door.

a Tighten to torque the hinge mounting bolts ( 27Nm ) .

Tightening torquesm

hinge mounting bolts 27 Nm

door box section moun-ting bolts

21 Nm

striker plate bolts 21 Nm

115802

101721

47A-8


B84 or C84

47AII - ADJUSTMENT OF FLUSH FITTING WITH THE FRONT WING AND THE REAR DOOR

Special note on the hinge upper mounting

a Replace the original indexing studs (7) with bolts (8), available from the Parts Department , to enableflush fitting adjustment.

a Undo the door box section mounting bolts (9) .

a Adjust the flush fitting with the front wing.

a Tighten to torque the door box section mountingbolts ( 21 Nm ) .

101719

Note:

To increase the adjustment available, enlarge theupper holes on the original hinges.

After-Sales hinges are supplied with squareslots.

101722

47A-9


B84 or C84

47ASpecial notes on the striker plate

a The striker plate is spot-welded at (A) on the reinfor-cement inside the B-pillar.

To carry out adjustments, bend the fusible sections(B) of the plate.

This operation can only be performed by exerting arelatively strong force on the striker (e.g. by using ahammer).

a Undo the striker plate bolts (10) .

a Adjust the flush fitting with the rear door, the contactand the closure firmness.

a Tighten to torque the striker plate bolts ( 21 Nm ) .

22751

101725

47A-10

SIDE OPENING ELEMENTSFront side door: Stripping - Restoring

B84 or C84

47AThe order of the operations described applies specifi-cally to replacing the door.

STRIPPING

a Remove:

- the door mirror( (see Door mirror: Removal - Re-fitting) ,

- the sliding window( (see Sliding window in frontside door: Removal - Refitting) ,

- the interior trim( (see Front side door trim: Remo-val - Refitting) ,

- the exterior handle( (see Door exterior handle:Removal - Refitting) ,

- the door lock( (see Front side door lock: Remo-val - Refitting) .

a Remove:

- the door lower interior weatherstrip( (see Frontside door interior weatherstrip: Removal - Refit-ting) ,

- the door lower exterior weatherstrip( (see Frontdoor side exterior weather strip: Removal - Re-fitting) ,

- the exterior door frame seal( (see Front side doorframe seal: Removal - Refitting) ,

- the exterior strip( (see Front door protectivestrip: Removal - Refitting) .

REASSEMBLING

a Refit:

- the exterior strip( (see Front door protectivestrip: Removal - Refitting) .

- the exterior door frame seal( (see Front side doorframe seal: Removal - Refitting) ,

- the door lower exterior weatherstrip( (see Frontdoor side exterior weather strip: Removal - Re-fitting) ,

- the door lower interior weatherstrip( (see Frontside door interior weatherstrip: Removal - Refit-ting) ,

- the door lock( (see Front side door lock: Remo-val - Refitting) ,

- the exterior handle( (see Door exterior handle:Removal - Refitting) ,

- the interior trim( (see Front side door trim: Remo-val - Refitting) ,

- the sliding window( (see Sliding window in frontside door: Removal - Refitting) ,

- the door mirror( (see Door mirror: Removal - Re-fitting) .

Note:

It is possible to carry out the stripping operations onthe vehicle before removing the door.

WARNING

For vehicles equipped with the hands-free func-tion, remove the exterior handle and the doorlock when the door interior trim is removed andleave the lock assembly in the interior trim dur ingremoval.

47A-11

SIDE OPENING ELEMENTSFront side door panel: Description

B84 or C84

47A




Car. 1657 Door panel uncrimpingpliers.

B84

101600

C84

101616

47A-12


B84 or C84

47AI - COMPOSITION OF THE SPARE PART

II - PART FITTED


B84

115147

C84

115149


(1) Front side doorpanel

HLE 0.7

(2) Door panel rein-forcement

HLE 1.5

B84

101582

47A-13


B84 or C84

47A

Cut A

Special note for removal of the door panel

The door panel can be removed using the (Car. 1657) .

2 - Applying the structural adhesive

C84

101587

115152

22436

B84

101583

47A-14


B84 or C84

47A

Use an M. J. Pro type setting adhesive.

3 - Positioning the panel soundproofing

C84

101586

B84

101584

C84

101585

47A-15


B84 or C84

47A

Note:

If a panel straightening operation requiring evenpartial removal of soundproofing is necessary, thesoundproofing must be replaced.

47A-16

SIDE OPENING ELEMENTSRear side door: General description

B84

47A

I - COMPONENT DESIGN

This part has the following specifications:

- "bolted and bolted" hinges mounted vertically on theB-pillar and the door box section,

- a door check rod integrated in the lower hinge.


If the front side door hinge mountings are the "bolted and bolted" type it is possible to remove the rear side door, depending on the operations to be performed:

- either by unscrewing the mountings on the compo-nent in the event of replacement of the rear side door,

- or with the hinges by removing the mountings on theA-pillar in the event of replacement of the body.

III - ADJUSTMENT

There are four main areas where adjustments can be made:

- adjustment of the front area,





1 - Adjustment of the front area:

Adjust the shut lines and alignment with the front sidedoor using the rear side door hinge mountings.

2 - Adjustment of the rear area:

Adjust the shut lines and alignment with the rear wingand the closure firmness using the striker plate moun-tings.

3 - Adjustment of the upper area:

Adjust the shut lines and alignment with the roof andthe quarter panel using the rear side door hinge moun-tings.

WARNING



101730

Note:


Note:

The rear side door is the component positioned firstin the order of assembly of removable componentsin the factory.

For it to be completely adjusted, correctly positionall the other components.

IMPORTANT

In this case, compromise between the closure firm-ness and the rear shut lines of the rear side door bygiving priority to closing in such a way that the doorpresses sufficiently onto the seal to avoid floating ofthe rear of the door.

47A-17

SIDE OPENING ELEMENTSRear side door: General description

B84

47A4 - Adjustment of the lower area:

Adjust the shut lines and alignment with the sill panelusing the rear side door hinge mountings.

47A-18

SIDE OPENING ELEMENTSRear side door: Removal - Refitting

B84

47A





a Remove:

- the door mounting bolts (1) ,

- the door.

II - REFITTING WITHOUT HINGES


a Refit:

- the door,

- the door mounting bolts (1) .

a Adjust the door shut lines and flush fitting (see Vehi-cle shut lines: Adjustment value ).

a Tighten to torque the door mounting bolts ( 21 Nm) .

2 - FINAL OPERATION

a Connect the door wiring harness supply connector.





a Remove:

- the hinge mounting bolts (2) ,

- the door.

IV - REFITTING WITH HINGES


a Refit:

- the door,

- the hinge mounting bolts (2) .

Tightening torquesm

door mounting bolts 21 Nm


door retention devicemounting bolts

21 Nm

101730101730

47A-19

SIDE OPENING ELEMENTSRear side door: Removal - Refitting

B84

47Aa Adjust the door shut lines and flush fitting (see Vehi-

cle shut lines: Adjustment value ).


2 - FINAL OPERATION

a Connect the door's wiring harness supply connector.

V - PASSIVE SAFETY

a At the end of the operation, check the presence andcondition of the door retention device (3) .

a Tighten to torque the door retention device moun-ting bolts ( 21 Nm ) .

101727

REMINDER:

This part's function is essential in the event of arear collision. The door retention device keepsthe door in its longitudinal plane, thereby absor-bing impact energy efficiently.

47A-20

SIDE OPENING ELEMENTSRear side door: Adjustment

B84

47A

ADJUSTMENT VALUESa For information on the rear side door adjustment va-

lues, (see Vehicle shut lines: adjustment value ).

ADJUSTMENTa There are two options for adjusting the door:

- by means of the mountings on the door box section(opening clearance adjustment),

- by means of the mountings on the A-pillar (shut lineadjustment):


I - ADJUSTMENT OF FLUSH FITTING WITH THE FRONT DOOR AND THE REAR WING

a Undo the hinge mounting bolts (6) .

a Adjust the shut lines with the rear door.


Tightening torquesm


door box section moun-ting bolts

21 Nm

striker plate bolts 21 Nm

115803

101731

47A-21


B84

47AII - ADJUSTMENT OF FLUSH FITTING WITH THE FRONT DOOR AND THE REAR WING

Special note on the hinge upper mounting

a Replace the original indexing studs (7) with bolts (8)available from the Parts Department , to enableflush fitting adjustment.

a Undo the door box section mounting bolts (9) .

a Adjust the flush fitting with the front door and the rearwing.

a Tighten to torque the door box section mountingbolts ( 21 Nm ) .

103950

Note:

To increase the adjustment available, enlarge theupper holes on the original hinges.

After-Sales hinges are supplied with squareslots.

101729

47A-22


B84

47ASpecial notes on the striker plate

a The striker plate is spot-welded to the rear wing rein-forcement at (A) .

To carry out adjustments, bend the fusible sections(B) of the plate.

This operation can only be performed by exerting arelatively strong force on the striker (e.g. by using ahammer.

a Undo the striker plate bolts (10) .

a Adjust the flush fitting with the rear wing, the contactand the closure firmness.

a Tighten to torque the striker plate bolts ( 21 Nm ) .

103946

101728

47A-23

SIDE OPENING ELEMENTSRear side door: Stripping - Restoring

B84

47AThe order of the operations described applies specifi-cally to replacing the door.

STRIPPING

a Remove:

- the sliding window( (see Sliding window in rearside door: Removal - Refitting) ,

- the interior trim( (see Rear side door trim: Remo-val - Refitting) ,

- the exterior handle( (see Interior door handle onrear side door) ,

- the door lock( (see Rear side door lock: Removal- Refitting) .

a Remove:

- the door lower weatherstrip( (see Rear side doorinterior weather strip: Removal - Refitting) ,

- the fixed window and exterior door frame seal( (seeRear side door frame seal: Removal - Refitting),

- the exterior door moulding( (see Rear door pro-tective strip: Removal - Refitting) .

REASSEMBLINGa Refit:

- the exterior door moulding( (see Rear door pro-tective strip: Removal - Refitting) ,

- the fixed window and exterior door frame seal( (seeRear side door frame seal: Removal - Refitting),

- the door lower weatherstrip( (see Rear side doorinterior weather strip: Removal - Refitting) ,

- the door lock( (see Rear side door lock: Removal- Refitting) ,

- the exterior handle( (see Interior door handle onrear side door) ,

- the interior trim( (see Rear side door trim: Remo-val - Refitting) ,

- the sliding window( (see Sliding window in rearside door: Removal - Refitting) .

Note:

It is possible to carry out the stripping operations onthe vehicle before removing the door.

WARNING

For vehicles equipped with the hands-free func-tion, remove the exterior handle and the doorlock when the door interior trim is removed andleave the lock-exterior handle support assemblyin the trim during removal.

47A-24

SIDE OPENING ELEMENTSRear side door panel: Description

B84

47A




II - PART FITTED



Car. 1657 Door panel uncrimpingpliers.

101602

115148


(1) Rear side doorpanel

HLE 0.7

(2) Door panel rein-forcement

- 1

101579

47A-25

SIDE OPENING ELEMENTSRear side door panel: Description

B84

47ACut A

Special note for panel removal

The door panel can be removed using the (Car. 1657) .

2 - Applying the structural adhesive

Use an M. J. Pro type setting adhesive.

3 - Positioning the panel soundproofing

115152

22436

101580

101581

Note:

If a panel straightening operation requiring evenpartial removal of soundproofing is necessary, thesoundproofing must be replaced.

47A-26

SIDE OPENING ELEMENTSFuel filler flap cover: General description

B84 or C84

47A

COMPONENT DESIGN

The fuel filler flap has two special features:

- it is made of plastic (NORYL),

- it is slotted into its plastic mounting (1) .

WARNING



110629

1

47A-27

SIDE OPENING ELEMENTSFuel filler flap cover: Removal - Refitting

B84 or C84

47AREMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Press gently with your fingers to disengage the co-ver of the four clips (1) and pull the cover outwards.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Clip the fuel filler flap cover onto its mounting.

101161

101161

48A-1

NON-SIDE OPENING ELEMENTSVehicle removable section structure: Description

B84 or C84


102400



Aluminium



Steel/SMC


SMC


Aluminium

48A-2

NON-SIDE OPENING ELEMENTSVehicle removable section structure: Description

B84 or C84

48A



Noryl




Aluminium




Noryl




Polypropy-lene



48A-3

NON-SIDE OPENING ELEMENTSBonnet: General description

B84 or C84

48A


This type of bonnet has the following specifications:

- opening at the front, « bolted and bolted » , type hin-ges at the rear, mounted vertically on the bonnet hin-ge mounting and flat mounted and indexed on thebonnet lining,

- side stay mounted on the front wing mounting sup-port,

- side stops mounted with pedestrian impact absorbersbuilt into the front upper cross member,

- central lock with built-in safety retainer,

- with built-in and removable windscreen washer jets.


If the bonnet hinge mountings are of the « bolted and bolted » type, following the operations to be performed, it is possible to remove the bonnet:

- either by unscrewing the mountings on the compo-nent if the bonnet is to be replaced or removed formechanical work,

- or with the hinges by removing the mountings on theaperture if the body is to be replaced.

III - ADJUSTMENT

There are two main areas where adjustments can be made:


- adjustment of the front area.


Adjustment of the rear area:

Adjust the shut lines and alignment with the scuttleaperture and the front wings using the bonnet hingemountings.

Adjustment of the front area:

Shut lines with the wings and clearance from the bum-per and headlights are not adjustable because the bon-net stops on the front upper cross member are fixed.

Only the closure firmness is adjustable by the fittingssecuring the lock.

WARNING



112034

Note:


Note:

The bonnet is the last of the removable componentsto be fitted on the body in the factory assembly pro-cess.

For final adjustment, correctly position all the othercomponents including the bumper and the headli-ghts for them to be correctly positioned.

48A-4

NON-SIDE OPENING ELEMENTSBonnet: General description

B84 or C84

48A

Note:

In this case, compromise between the closure firm-ness and the front height of the bonnet by givingpriority to closing in such a way as to retain a mini-mum bonnet drag in the direction of the support onthe stops to avoid the front of the bonnet floating.

48A-5

NON-SIDE OPENING ELEMENTSBonnet: Removal - Refitting

B84 or C84

48A

I - REMOVAL BY MEANS OF THE BONNET BOLTS


a Remove:

- the bonnet soundproofing( (see Bonnet sound-proofing: Removal - Refitting) ,

- the tube supplying the washer jets on the bonnet.


a Remove:

- the bonnet mounting bolts (1) ,

- the bonnet.

II - REFITTING BY MEANS OF THE BONNET BOLTS


a Refit:

- the bonnet,

- the bonnet mounting bolts (1) .

a Adjust the opening clearances and shut lines (see48A, Non-side opening elements, Bonnet: Ad-justment, page 48A-7) .

a Torque tighten the bonnet mounting bolts ( 8 Nm ).

2 - FINAL OPERATION

a Refit:

- the tube supplying the washer jets on the bonnet,

- the bonnet soundproofing( (see Bonnet sound-proofing: Removal - Refitting) .

III - REMOVAL BY MEANS OF THE BONNET HINGE BOLTS


a Remove:



- the tube supplying the washer jets on the bonnet.


a Remove:

- the bonnet hinge mounting bolts (2) ,

Tightening torquesm

bonnet mounting bolts 8 Nm

bonnet hinge mountingbolts

8 Nm

101162

101163

48A-6

NON-SIDE OPENING ELEMENTSBonnet: Removal - Refitting

B84 or C84

48A- the bonnet.

IV - REFITTING BY MEANS OF THE BONNET HINGE BOLTS


a Refit:

- the bonnet,

- the bonnet hinge mounting bolts (2) .

a Adjust the opening clearances and shut lines (see48A, Non-side opening elements, Bonnet: Ad-justment, page 48A-7) .

a Torque tighten the bonnet hinge mounting bolts (8 Nm ) .

2 - FINAL OPERATION

a Refit:

- the tube supplying the washer jets on the bonnet,


- the front wing (see 42A, Upper front structure,Front wing: Removal - Refitting, page 42A-11) .

48A-7

NON-SIDE OPENING ELEMENTSBonnet: Adjustment

B84 or C84

48A

ADJUSTMENT VALUES

a For any information regarding bonnet adjustmentvalues, see Vehicle shut lines: Adjustment value .

ADJUSTMENTa There are two options for adjusting the bonnet:

- by means of the bonnet mounting bolts,

- by means of the bonnet hinge mounting bolts: thefront wing needs to be removed for this operation.

The bonnet striker must be adjusted in addition tothe bonnet adjustment.


I - ADJUSTMENT BY MEANS OF THE BONNET MOUNTING BOLTS

a Undo the bonnet mounting bolts (4) .

a Adjust the bonnet shut lines.

a Torque tighten the bonnet mounting bolts ( 8 Nm ).

Tightening torquesm

bonnet mounting bolts 8 Nm

bonnet hinge mountingbolts

8 Nm

safety catch mountingbolts

8 Nm

115806

101162

48A-8


B84 or C84

48AII - ADJUSTMENT BY MEANS OF THE BONNET HINGE MOUNTING BOLTS

a Remove the front wing (see 42A , Upper frontstructure, Front wing: Removal - Refitting, page42A-11) .

a Undo the bonnet hinge bolts (5) .

a Position the front wing on the vehicle.

a Adjust the bonnet shut lines.


a Torque tighten the bonnet hinge mounting bolts (8 Nm ) .

a Refit the front wing (see 42A, Upper front structu-re, Front wing: Removal - Refitting, page 42A-11).

III - ADJUSTMENT OF THE CLOSING PLUNGER AND SAFETY CATCH

a

a Adjust the closing plunger with the bonnet lock.

101163 101157

Note:

When adjusting the closing plunger and safetycatch, it is essential to remove the closing plun-ger and catch, and touch up the bonnet pain-twork with anti-corrosion protection.

48A-9


B84 or C84

48A

a Adjust the safety catch.

a Tighten to torque the safety catch mounting bolts( 8 Nm ) .

a

103121

Note:

It is essential to check that the safety catch ope-rates correctly following adjustment of the bonnetand lock mechanism.

101787

Note:

When in the closed position, the bonnet shouldrest on stops (6) .

48A-10

NON-SIDE OPENING ELEMENTSTailgate: General description

B84 or C84

48A


This type of tailgate has the following specifications:

- bottom opening, hinges at the top of the "bolted andbolted" type, fixed vertically on the tailgate hinge rein-forcements and flat mounted on the tailgate lining,

- side stays fixed onto the rain channels of the rearwings,

- fixed side stops built into the tailgate lining,

- central lock.


When the tailgate hinge mountings are of the "bolted and bolted" type, following the operations to be perfor-med it is possible to remove the tailgate:

- either by unscrewing the mountings on the compo-nent if the tailgate is to be replaced,

- or with the hinges by removing the mountings on theroof rear cross member if the body is to be replaced.

III - ADJUSTMENT

Two main areas of adjustment may be identified:



always begin the adjustments on the hinge side withthe lock striker plate loose and the stops in place.

Adjustment of the upper area:

Adjust the shut lines and alignment with the roof andthe rear wings using the tailgate hinge mountings.

Adjustment of the lower area:

Shut lines with the wings and clearance from the bum-per and rear lights are not adjustable because the tail-gate stops on the tailgate lining are fixed.

Only the closure firmness is adjustable by the fittingssecuring the lock.

WARNING



112177

Note:


Note:

For final adjustment, correctly position the rearlights and the bumper so that they remain correctlypositioned.

Note:

In this case, compromise between the closurelength and the lower shut lines of the tailgate bygiving priority to closing in such a way as to retainsufficient pressure by the tailgate on the stops toprevent the tailgate floating.

48A-11

NON-SIDE OPENING ELEMENTSTailgate: Removal - Refitting

B84 or C84

48A



a Remove the tailgate trim( (see Tailgate lining: Re-moval - Refitting) .

a Disconnect the electrical connectors to:

- the rear screen wiper motor,

- the tailgate lock,

- the heated rear screen.

a Remove:

- the tailgate electrical supply harness,

- the washer jet pipes,

- the tailgate gas struts.


a Remove:

- the tailgate mounting bolts (1) from each side of thevehicle.

- the tailgate.

II - REFITTING WITHOUT HINGES


a Refit:

- the tailgate,

- the tailgate mounting bolts (1) to each side of thevehicle.

a Torque tighten the tailgate mounting bolts ( 8 Nm) .

2 - FINAL OPERATION

a Refit:

- the tailgate gas struts,


- the tailgate electrical feed harness.

a Connect the electrical connectors to:

- the heated rear screen,



a Refit the tailgate trim( (see Tailgate lining: Remo-val - Refitting) .



a Remove the tailgate trim( (see Tailgate lining: Re-moval - Refitting) .

a Disconnect the electrical connectors to:



- the heated rear screen.

a Remove:

- the tailgate electrical supply harness,


- the tailgate gas struts.

Tightening torquesm

tailgate mounting bolts 8 Nm

hinge mounting bolt 21 Nm

101378

48A-12

NON-SIDE OPENING ELEMENTSTailgate: Removal - Refitting

B84 or C84

48A2 - OPERATION FOR REMOVAL OF PART CONCERNED

a Keep the headlining to one side using a wedge (2) .

a Remove:

- the hinge mounting bolt (3) from each side of thevehicle,

- the tailgate.

IV - REFITTING WITH HINGES


a Refit:

- the tailgate,

- the hinge mounting bolt (3) to each side of the ve-hicle,

a Tighten to torque the hinge mounting bolt ( 21 Nm) .

a Fit the headlining.

2 - FINAL OPERATION

a Refit:

- the tailgate gas struts,


- the tailgate electrical feed harness.

a Connect the electrical connectors to:

- the heated rear screen,



a Refit the tailgate trim( (see Tailgate lining: Remo-val - Refitting) .

101376

48A-13

NON-SIDE OPENING ELEMENTSTailgate: Adjusting

B84 or C84

48A

ADJUSTMENT VALUES

a For any information regarding tailgate adjustmentvalues, see Vehicle shut lines: Adjustment value .

ADJUSTMENTa There are two options for adjusting the tailgate:

- by means of the tailgate mounting bolts,

- by means of the tailgate hinge mounting bolts:

a The tailgate striker plate must be adjusted in addi-tion to the tailgate adjustment.


I - ADJUSTMENT BY MEANS OF THE TAILGATE MOUNTING BOLTS

a Loosen the tailgate mounting bolts (6) .

a Adjust the tailgate shut lines.

a Torque tighten the tailgate mounting bolts ( 8 Nm) .

Tightening torquesm

tailgate mounting bolts 8 Nm

tailgate hinge moun-ting bolt

21 Nm

tailgate striker platemounting bolts

21 Nm

115807

101379

48A-14

NON-SIDE OPENING ELEMENTSTailgate: Adjusting

B84 or C84

48AII - ADJUSTMENT BY MEANS OF THE TAILGATE HINGE MOUNTING BOLTS

a Keep the headlining to one side using a wedge (7) .

a Loosen the tailgate hinge mounting bolt (8) .

a Adjust the tailgate shut lines.

a Tighten to torque the tailgate hinge mounting bolt( 21 Nm ) .

a Fit the headlining.

III - TAILGATE STRIKER PLATE ADJUSTMENT

a Loosen the tailgate striker plate mounting bolts (9) .

a Adjust the tailgate lower section shut lines.

a Tighten to torque the tailgate striker plate moun-ting bolts ( 21 Nm ) .

a

101376101158

101377

Note:

When in the closed position, the stops (10)should rest on the body.

48A-15

NON-SIDE OPENING ELEMENTSTailgate: Stripping-Rebuilding

B84 or C84

48ADescribed below is a special sequence of operationsfor tailgate replacement.

STRIPPING

a Remove:

- the tailgate trim( (see Tailgate lining: Removal -Refitting) ,

- the rear screen wiper motor( (see Rear screen wi-per motor: Removal - Refitting) ,

- the tailgate lock( (see Tailgate lock: Removal -Refitting) ,

- the tailgate opening control( (see Tailgate exterioropening control: Removal - Refitting) ,

- the high level brake light( (see Third brake light:Removal - Refitting) ,

- the rear screen( (see Rear screen glass: Remo-val - Refitting) ,

- the wiring harness.

REASSEMBLING

a Refit:

- the wiring harness,

- the rear screen( (see Rear screen glass: Remo-val - Refitting) ,

- the high level brake light( (see Third brake light:Removal - Refitting) ,

- the tailgate opening control( (see Tailgate exterioropening control: Removal - Refitting) ,

- the tailgate lock( (see Tailgate lock: Removal -Refitting) ,

- the rear screen wiper motor( (see Rear screen wi-per motor: Removal - Refitting) ,

- the tailgate trim( (see Tailgate lining: Removal -Refitting) .

Note:

It is possible to carry out the trim removal opera-tions on the vehicle before removing the tailgate.

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