apz mecánica automotriz renault 19 carrocería ( sheet metal work )

248
77 11 190 877 NOVEMBER 1996 Edition Anglaise Sheet metal work "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed". All copyrights reserved by Renault. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault. C Renault S.A. 1988 GENERAL LOWER STRUCTURE UPPER FRONT STRUCTURE UPPER SIDE STRUCTURE UPPER REAR STRUCTURE UPPER BODY SECTION BODY PROTECTION SIDE OPENINGS BONNET AND TAILGATE

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Page 1: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

77 11 190 877 NOVEMBER 1996 Edition Anglaise

Sheet metal work

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

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

All copyrights reserved by Renault.

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

C Renault S.A. 1988

GENERAL

LOWER STRUCTURE

UPPER FRONT STRUCTURE

UPPER SIDE STRUCTURE

UPPER REAR STRUCTURE

UPPER BODY SECTION

BODY PROTECTION

SIDE OPENINGS

BONNET AND TAILGATE

Page 2: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

EXPLODED VIEW

PRS4011

Page 3: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

Contents

GENERAL

Engine - Clutch - GearboxVehicle dimensionsLiftingDescription of parts (explodedviews)Description of symbolsOpening clearancesCollision damage assessmentDimensions of the lower structureMain bodywork dimensionsBody jig benchSpecial tools

40-140-240-7

40-1140-1840-2040-2740-3240-3440-3540-42

LOWER STRUCTURE

41-141-341-441-541-641-741-9

41-1041-1241-1341-16

41-1741-1841-2241-2341-2541-2641-28

41-2941-3041-3141-3441-36

UPPER FRONT STRUCTURE

PagesPages

40

41

42

Panels

UPPER SIDE STRUCTURE43A Complete front end cross memberB Part front end cross memberC Complete front end panelD Part front end panelE Side member closing panelF Front side member front sectionG Part front side member front sectionH Front side member rear sectionI Front side cross memberJ Front half unitK Part centre floor panelL Rear floor panel (part centre

section)M Rear floor panelN Utility vehicle floor panelO Lateral side member lower sectionP Lower side spacerQ Sill closing panel stiffenerR Front pillar lower section stiffenerS Floor and cross member side

stiffenerT Floor panel upper cross memberU Assembled rear end panelV Part rear end panel cross memberW Body

42-1

42-4

42-642-742-842-9

42-1042-14

42-1642-18

A WingB Complete radiator grille upper cross

memberC Part radiator grille upper cross

memberD Bonnet lock supportE Headlight carrier panelF Part front wing panel (front section)G Wheel arch (shock absorber turret)H Part heater bulkhead partitionI Part windscreen aperture lower

cross memberJ Front pillar upper stiffener

43-1

43-343-543-643-8

43-943-1043-1543-1943-2143-2243-2343-2743-2943-30

A Front pillar lower sectionB Front door pillar by cutting at

windscreen uprightC Door hinges (on front pillar)D Front door pillarE Front pillarF Front door pillar seal fastening

(KSM)G Centre pillarH Centre pillar liningI Sill panelJ Body sideK Part sill panelL Sill panelM Sill panel front stiffenerN Sill panel rear stiffenerO Roof arch

Page 4: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

SIDE OPENINGS

Contents

BODY PROTECTION46

48

UPPER BODY SECTION45

47

45-145-745-9

45-10

45-1145-12

A Roof panelB Windscreen surroundC Linings and stiffenersD Windscreen pillar liningE Windscreen aperture upper cross

memberF Rear roof cross member

UPPER REAR STRUCTURE44

44-144-8

44-1344-2544-2644-3244-3644-3744-3844-3944-4044-4444-4644-47 44-48

44-4944-51

44-5344-5444-5544-5644-5844-64

44-7044-7144-7344-7544-7744-79

A Complete wing panelComplete rear wing panel

B Part wing panelPart rear wing panel

C Quarter panel liningD Assembled wing panel liningE Wing panel lower front liningF Wing panel upper front liningG Wing panel rear liningH Tailgate upper rain channelI Outer wheel archJ Complete quarter panel archK Part quarter panel archL Backrest mounting stiffenerM Outer wheel arch stiffenerN Upper cross member between

wheel archesO Hood compartment base partitionP Hood compartment rear cross

memberQ Backrest mounting stiffenerR Jack support (right hand side)S Centre shelfT Half unitU Rear end panelV Rear end panel lining and

assembled end panelW Part end panel cross memberX Rear end panel extension pieceY Side rain channelZ Boot lid rain channel2A Lighting support panel

46-146-2

A Sub-frame front protectorB Wheel arch mud shield

47-147-247-447-6

A Door hingesB Front door panelC Rear door panelD Front door - rear door

BONNET AND TAILGATE

48-148-348-5

48-11

48-13

48-14

A BonnetB TailgateC Boot lidD Hood cover panelE Broken boot lid counter balance ball

jointF Roof cross member (noise

reduction)

Page 5: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALEngine - Clutch - Gearbox 40

Vehicle type

Engine

TypeCubic

capacity(cm3)

Clutch type Manual and automatic gearbox type

B530 - C530 - L530S530 C1G 1237 180 CP 3300 JB0 - JB1 - JB4 - JB5

B531 - C531 - L531 C1J 1397 180 CP 3300 JB0 - JB1 - JB4 - JB5

B53H - B53P - C53PL53H - L53P

C2J 1397 180 CP 3300 JB0 - JB1 - JB4 - JB5

B532 - C532 - L532 C3J 1390 180 CP 3300 JB0 - JB1

B53G - B537 - C537L53G - L537 - S537 E6J 1390 180 CP 3300 JB0 - JB1 - MB1

B53A - C53A - L53A E7J 1390 180 CP 3300 JB1 - MB1

B535 - C535 - L535 E7J 1390 180 CP 3300 JB1 - MB1

B53W - C53W - L53W E7F 1171 180 CP 3300 JB0 - JB1 - JB3

B53E - B53M - B533B536 - C53E - C53MC533 - L533 - L536

F2N 1721 200 CP 4000 JB0 - JB1 - JB3 - AD4

B53B - B53C - B53FC53B - C53C - C53F

D53C - L53B - L53C -L53F

F3N 1721 200 CP 4000 AD4 - JB3 - MB3

B53V - B53Y - B538C53V - C53Y - C538D53V - D53Y - L53VL53Y - L538 - 353A353C - 353D - 353F453A - 453C - 453D 453F - 453H - 553A553C - 553D - 553F553H - 853A - 853C

853F

F3P 1794 200 CP 4000 AD4 - JB3 - JC5

B53D - B539 - C53DC539 - D53D - L53D

L539F7P 1764 200 CP 4400 JB3 - JC5

B53I - B53J - B53KB53T - B53Z - B534C53I - C53J - C53KC53T - C53Z - C534L53I - L53J - L53KL53T - L53Z - L534S53I - S53J - S53K -

S534

F8Q 1870200 CPV 4600

200 CPV 3500JB1 - JB3 - JC5

40-1

Page 6: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALVehicle dimensions 40

91936R1

B53Phase I

Mark Dimensions in metres

A 2.545

B 4.155

C 1.418

D 1.416 unladen

E 1.406 to 1.417

F 1.676 or 1.694

40-2

Page 7: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERAL

Vehicle dimensions 40

95890R

B53Phase II

Mark Dimensions in metres

A 0.813

B 2.540 - 2.544 (1)

C 0.805 - 0.809 (1)

D 4.158 - 4.166 (1)

E 0.120 (2)

F 1.426

G 1.684 - 1.696 (1)

H 1.400 - 1.420 (1) - (3)

I 1.406 - 1.417 (1)

(1) Depending on version with option(2) Laden(3) Unladen

40-3

Page 8: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALVehicle dimensions 40

92866R

* Depending on version

L53 SaloonExcept Sport

Mark Dimensions in metres

A 2.545 or 2.540 *

B 4.262

C 1.412 unladen

D 1.418

E 1.406 to 1.417 *

F 1.684 or 1.694 *

40-4

Page 9: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALVehicle dimensions 40

92764R

B - C - L539Sport

Mark

Dimensions in metres

B and C L

A

B 4.150 4.259

C 1.389 1.400

D

E

F

2.540

1.429

1.406

1.684

40-5

Page 10: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALVehicle dimensions 40

94726R

D53Cabriolet

Mark Dimensions in metres

A 2.545

B 4.155

C 1.375 ± 5

D 1.418

E 1.406 to 1.417

F 1.676 or 1.694

40-6

Page 11: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALLifting 40

87709R

USING AXLE STANDS

To place the vehicle on axle stands, the standsmust be positioned under jacking points (1)provided for lifting the vehicle using the jacksupplied with the vehicle.

To position the axle stands at the rear, lift thevehicle from the side.

LIFTING USING A JACK FROM THE SIDE

Use cross piece Cha. 280-02.

Take the load under the front door sill.

Position the body sill flange correctly in the crosspiece groove.

91936G385679-1G7

40-7

Page 12: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALLifting 40

92556R

Safety symbol (special precautions to be taken while working)

ESSENTIAL SPECIAL TOOLS

Cha. 280 -02 Adjustable cross piece on trolley

jack

Cha. 408 -01

or Adjustable dowel on trolley jack

Cha. 408 -02

The vehicle must not be lifted by taking the loadunder the front suspension arms.

Depending on the type of trolley jack , use dowelsCha. 408-01 or Cha. 408-02 to fit cross piece Cha.280-02.

To lift the front or the rear, take the load underthe lifting points provided for the on-board jack.

USING A TROLLEY JACK FROM THE FRONT

Apply the handbrake or chock the rear wheels.

Use cross piece Cha. 280-02.

Take the load under the front sub-frame.

Ensure that the cross piece does not come intocontact with the gearbox or the exhaustdownpipe.

Appropriate axle stands must be used if atrolley jack is used.

For B537 and C537 type vehicles, make a clearancenotch in cross piece Cha. 280-02 to prevent it fromcoming into contact with the exhaust.

USING A TROLLEY JACK FROM THE REAR

The rear of the vehicle MUST NOT be lifted bytaking the load under the rear axle. Lift eachwheel separately taking the load at the liftingpoints provided for the on-board jack.

40-8

Page 13: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALLifting

AXLE STANDS

To place the vehicle on axle stands, the standsmust be positioned: - either under the jacking points provided for

lifting the vehicle using the on-board jack,- or under the pads located behind the stiffeners.

To position the axle stands at the rear, lift thevehicle sideways.

40

98336G85679-1G7

WHEEL FREE LIFT

SAFETY ADVICE

Several possibilities must be considered:

1 - REMOVAL OF COMPONENTS

In general, never use a two post lift when a fourpost lift is suitable.

If this is not possible, fit the lifting pads under thesill flange at the lifting points provided for the on-board jack.

98703S

FRONT

98704S

REAR

The pads must be placed to the right of thejacking points. They must be engaged in the ope-nings in the sill panel flanges.

40-9

Page 14: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALLifting 40

LASHING FOR TOWING

FOR TOWING REFER TO THE CURRENTLEGISLATION FOR EACH COUNTRY.

NEVER USE THE DRIVESHAFTS AS TIE-DOWNPOINTS.

The towing points are only to be used for towingon the road. They must never be used for pullingthe vehicle out of a ditch, for any other similaroperations or for lifting the vehicle directly or in-directly.

2 - SPECIAL CASE FOR REMOVAL - REFITTING OFTHE ENGINE AND TRANSMISSION ASSEMBLY

In this case, the vehicle body must be connected tothe arms of the two post lift using special pads.

FOG :Part number FOG 449 8111 - 449 8411

or

CHEMICO :Part number 39 2550 0001

or

SCHENCHPart number 776 684

FRONT

98705S

REAR

98702S

40-10

Page 15: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of parts (exploded views) 40

PRS4012

B53 / C53

9 Rear floor panel front section10 Rear floor panel11 Floor panel stiffener cross member12 Fuel tank mounting cross member13 Cross member under rear floor panel14 Rear side member15* Front side cross member16* Front side member rear section17 Front side member closure panel18 Front side member front section18A Part front side member19 Lower front cross member19A Part lower cross member20 Assembled front panel20A Part assembled front panel

LOWER STRUCTURE ALL TYPES

1 Sill closing panel2 Centre floor panel2A Part centre floor panel2B Part centre floor panel3 Centre floor panel cross member4 Front seat mounting cross member5 Front 1/2 unit (wheel arch)6 Rear 1/2 unit (wheel arch)7 Assembled rear floor panel with side

member8 Rear floor panel rear section8A Part rear floor panel8B Part rear floor panel

* Steel part with high degree of flexibility

40-11

Page 16: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of parts (exploded views) 40

PRS4013

B53 / C53

UPPER STRUCTURE

50 Front roof panel cross member51 Windscreen pillar lining52 B53 roof drip moulding lining53 Rear roof cross member54 Roof panel55 Centre pillar lining56 B53 quarter panel lining57 Quarter panel arch58 Rear outer wheel arch59 Quarter panel lining (C53)60 Sill panel partition (C53)61 Door pillar lining (C53)62 Body top lining (C53)63 Centre pillar lower lining64 Front wing bracket65 Front wing

66 Front wheel arch67 Front wheel arch extender68 Diesel engine mounting cup69 Headlight carrier panel70 Bonnet lock support71 Front upper cross member71A Part front upper cross member72 Inner wheel flange panel - front pillar

lining72A Part inner wheel flange panel - front

pillar lining72B Part inner wheel flange panel - front

pillar lining73 Heater bulkhead partition73A Part heater bulkhead partition74 Bulkhead75 Windscreen aperture lower cross member75A Part lower cross member76 Bonnet

40-12

Page 17: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of parts (exploded views) 40

PRS4014

B53 / C53

UPPER STRUCTURE

80 Tailgate81 Front door82 Rear door83 Rear door panel84 Front door panel85 Lighting support86 Rear end panel87 Assembled rear end panel with cross

member88 Rear end panel lining89 Sill panel (C53)90 Wing panel (C53)

90A Part wing panel in line with cross-section A90B Part wing panel in line with cross-section B91 Body top (roof drip moulding) (C53)92 Sill panel (B53)93 Body top (B53)94 Front pillar95 Body side96 Centre pillar97 Rear wing panel (B53)97A Part rear wing panel (cross-section A)97B Part rear wing panel (cross-section B)98 Wing panel upper rain channel99 Wing panel lower rain channel

40-13

Page 18: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of parts (exploded views) 40

PRS4015

1 Rear floor panel with side member

2 Part rear floor panel (rear section)

3 Rear floor pnel

4 Rear side member

5 Part rear end panel cross member

B53 / C53 / L53

LOWER STRUCTURE

40-14

Page 19: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of parts (exploded views) 40

PRS4016

L53SALOON

UPPER STRUCTURE

1 Roof panel2 Rear roof cross member3 Boot lid4 Counter balance ball joint5 Boot lid strut6 Quarter panel lining7 Quarter panel arch8 Outer wheel arch9 Wing panel side rain channel10 Wing panel

11 Rear end panel cross member12 Rear end panel cross member blanking piece13 Lighting support panel14 Assembled rear end panel15 Rear end panel side extender16 Jack support (right hand side only)17 Backrest mounting stiffener18 Rear centre shelf19 Half unit

40-15

Page 20: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of parts (exploded views) 40

PRS4017

D53CABRIOLET

1 Windscreen surround2 Rear floor panel upper cross member3 Floor panel and cross member side stiffener4 Lower side spacer5 Lateral side member lower section6 Sill panel stiffener7 Sill panel rear stiffener8 Sill panel outer panel9 Bare sill panel outer panel

10 Door panel11 Door12 Front pillar upper stiffener13 Front pillar14 Front wing15 Sill panel front stiffener16 Front pillar lower lining17 Windscreen pillar lining18 Windscreen aperture upper cross member

40-16

Page 21: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of parts (exploded views) 40

PRS4018

D53CABRIOLET

38 Lighting support component stiffener39 Rear wing panel40 Outer wheel arch stiffener41 Outer wheel arch42 Wing panel lower front lining43 Wing panel upper front lining44 Centre pillar45 Centre pillar lining46 Assembled wing panel lining47 Boot lighting support

28 Upper cross member between wheelarches

29 Hood compartment base partition30 Hood compartment rear cross member31 Boot lid rain channel32 Hood compartment cover33 Boot lid34 Hood compartment cover hinge35 Boot lid hinge36 Wing panel rear lining37 Lighting support component

40-17

Page 22: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

Cut the part by grinding the flange orgrind down the remaining bits of spotweldAngle grinder fitted with a rubberbacking pad and a 120 to 180 mm P36grade fibre disc

GENERALDescription of symbols 40

Cut using a cold chisel

Grind the weld fillet or spot weldsStraight grinding wheel fitted with a75mm diameter 1.8 to 3.2 mm thickBakelite disc.

Rotary grind the spot welds20,000 rpm straight grinding wheel witha 10 or 16mm diameter spherical cutter.

Rotary grind the spot weldsSpot weld drill. Speed of rotation 800 to1,000 rpm.

Unpick the metal strip

Clean the surfaces to be welded100 mm fibre disc

Cut using a hacksawPneumatic power hacksaw

Release brazed joint

Dimensions and types of electrodes tobe used for the operation:

MIG stitch weldingNote: for good quality welding, it isrecommended that a gas composed ofArgon + 15% CO2, which is consideredto be an active gas, is used (MIG)

Plug weldingMIG welding

Inject wax into the hollow sectionsGun under pressure fitted with aflexible end piece.

Safety symbolThis means that the welding operationin question concerns one or moreaspects of vehicle safety

Lead fillHot air gunNozzle output temperature 600° min.Palette+ 33% lead stick+ tallowNote: to a large extent, the soft solderfinish compensates for the risks ofdeformation due to welding

Application of electrically weldablemasticThis conductive mastic, insertedbetween two panels to be spot welded,seals the panels and prevents corrosionof the spot welds

Application of aluminium based paintThis must be applied to the matingsurfaces of each of the parts to be plugwelded. This paint is conductive andcan withstand high temperatures; itgives anti-corrosion protection aroundwelds.

Apply a bead of extruded mastic• gun with a manual or pneumatic

cartridge• crimping or mating mastic with one

or two parts

Apply mastic by spraying• gun under pressure• anti-chipping and anti-corrosion

mastic with two parts

L = 100

L = 100

L = 100 +flat

L = 250

L = 350 +ball joint

L = 330

40-18

Page 23: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDescription of symbols 40

LOCATION OFOPERATIONS

TYPES OF TOOL ANDORDER OF OPERATIONS

LOCATION OFOPERATIONS

TYPES OF TOOL ANDORDER OF OPERATIONS

CUTTING-UNPICKING

saw saw

or

chisel

rotarygrind

unpick clean

unpick cleangrind

rotary grind

unpick cleansand

grind

sandreleasebrazed joint

WELDING

grind leadfill

stitchweld

XL (en

mm)

1-23-4568

100100250350330electric spot welder

WELDING (cont)

plug weld

stitch weld

FINISHING

studextractor

PROTECTION OF CRIMPED WELD JOINTS

bead of mastic in cartridge

bead and spraying of mastic

ANTI-CHIPPING PROTECTION

spraying of mastic

PROTECTION OF HOLLOW SECTIONS

injection using angled nozzle

PAINTING STYLED AREAS

aerosol can

40-19

Page 24: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALOpening clearances 40

92309-1R1

B53Phases I and II

91936-4R

40-20

Page 25: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALOpening clearances 40

92309-1R2

B53Phases I and II

40-21

Page 26: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALOpening clearances 40

92866R1

NOTE: for front section parts, refer to the B53 diagrams on previous pages.

L53Saloon

93126R

40-22

Page 27: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALOpening clearances 40

94726R1

D53Cabriolet

40-23

Page 28: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALOpening clearances 40D53

Cabriolet

94772R

1

94772-2R

3

94772-3R

4

94772-4R

5

94772-1R

2

94772-5R

6

40-24

Page 29: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALOpening clearances 40

94772-8R

D53Cabriolet

94772-6R

7

94772-7R

8

94772-9R

9

10

94772-10R

11

40-25

Page 30: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALOpening clearances 40D53

Cabriolet

94772-11R

12

40-26

Page 31: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

H

GENERALCollision damage assessment 40

85591R

CHECKING THE FRONT CROSS MEMBER AND THE FRONT END PANEL SUB-FRAME MOUNTING (1)

Compare lengths:CG = DHCH = DG

If lengths (CH - DG) and diagonals (CG - DH) are not identical, point (3) on the sub-frame must be checked asshown on the following pages.

If points (1) and (2) are correct, the front axle angles must be checked and adjusted.

If the front axle cannot be adjusted, it will then be necessary to change front axle components (stub axlecarrier, etc.).

PRS4019

85593R

C

40-27

Page 32: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALCollision damage assessment 40

PRS4020

CHECKING THE CENTRE SECTION (3) OF THE SUB-FRAME

Compare lengths:EI = FJEJ = FI

If points (2) and (3) are correct, it will be possible to straighten or partially change the front section of the sidemember and refit a new cross member without having to place the vehicle on a body jig bench. Point (1) isaligned using the engine sub-frame, after having changed the sub-frame if necessary.

If all the sub-frame check points (1), (2) and (3) are correct, it will then be necessary to check and adjust thefront axle.If adjustment is not possible, front axle components must be changed (stub axle carrier, etc.).

If points (1) and (3) are not correct, the vehicle must be placed on the bench in order to change the frontsection of the side member.

85860-1R

85592S

EJ

40-28

Page 33: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALCollision damage assessment 40

92381R4

CHECKING THE LATERAL SIDE MEMBERS (6) (REAR ARM MOUNTINGS)

Compare lengths:GO = HPGP = HO

Following a side or rear impact, if there is a difference in length, the vehicle must be placed on the framebench in order to re-align the lateral side member or partially change it.

IT IS NOT NECESSARY TO REMOVE THE FRONT MECHANICAL COMPONENTS IN ORDER TO PLACE THEVEHICLE ON THE JIG BENCH FOLLOWING A REAR OR SIDE IMPACT. SUPPORTS SPECIALLY PROVIDED FOR THEPURPOSE MUST BE PLACED AT POINTS (2).

If there is no difference in length, check points (4) as shown below.

85593R

85588S

O

H40-29

Page 34: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALCollision damage assessment 40

PRS4021

CHECKING THE ENDS OF THE REAR SIDE MEMBER (4)

Compare lengths:EK = FLEL = FK

If points (4) and (6) are correct and there is no apparent distortion, repair is possible without using the benchon condition that the upper structure is not too badly damaged and not too many parts need to be changed.

If there is a difference in length (FK - EL), the method of repair to be used (on or off the bench) depends onthe number of upper structure parts to be changed.

85595R

85589S

F

K

40-30

Page 35: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALCollision damage assessment 40

PRS4022

CHECKING THE REAR ARMS (5)

Compare lengths:FM = EN

Following a rear impact or a wheel impact, it is possible to quickly check whether or not the arms aredeformed.

If the diagonals are different, change the rear arms.

This operation for checking the arms (5) must be followed by a trammel gauge check of the mounting of thearms to the lateral side members (6).

85594R

85589S

F

M

40-31

Page 36: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDimensions of the lower structure 40

PRS4023

REMINDER OF ALIGNMENT

The intersection of the three planes X - Y -Z determines initial point 0 of the vehicle and the three referencelines:

1 Dimension start line: L - D - C (position of body jig bench bracket at X, in relation to this line).

2 Body centreline: A - D - C (position of body jig bench bracket at Y, in relation to this line).

3 Base line: L - D - B (position of body jig bench bracket at Z, in relation to this line).

The bodywork repair body jig brackets and their positions on the bench are designed in accordance withthese three lines.

40-32

Page 37: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALDimensions of the lower structure 40

92381R3

ALL TYPES

40-33

Page 38: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALMain bodywork dimensions 40

NOTE: the dimensions are measured in the centreline of the various welded nuts.

D53Cabriolet

PRS4027

40-34

Page 39: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALBody jig bench 40

BRACKETS AND REFERENCE POINTS

SUB-FRAME FRONT MOUNTING

92631S

Jig used for repairing the front of the vehicle,with the front sub-frame removed.

This enables positioning of the lower crossmember and the end of the side member.

FRONT SHOCK ABSORBER UPPER MOUNTING

92632S

Jig used for repairing the front of the vehicle,front sub-frame removed.

This allows:- positioning of the wheel arch or the 1/2 unit,

- drilling of the shock absorber upper cupmounting holes.

(refer to the method described in sub-section 41)

DIESEL ENGINES UPPER MOUNTING

92662S

The jig is used to position the engine mounting se-curing cup so that it can be welded to the cowlside panel.

SUB-FRAME REAR MOUNTING

92633S

A - Repairing the front(front sub-frame removed)

The jig allows positioning of the side member orthe front 1/2 unit.

40-35

Page 40: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALBody jig bench 40

92637S

REAR AXLE MOUNTING

A - Repairing the front(rear sub-frame fitted)

The jig allows the rear of the vehicle to besupported and aligned on the bench.

B - Repairing the rear(front sub-frame fitted)

The jig allows the front of the vehicle to besupported and aligned on the bench.

92634S

FRONT SEAT CROSS MEMBER

When the jig is centred along the length of thevehicle, it enables the vehicle to be supported andaligned when major repairing is being carriedout:

Eg. : front or rear unit

It also allows alignment of the rear section of thefront side member.

92635S

B - Repairing the rear(rear sub-frame removed)

The jig allows positioning of the side member orthe rear unit.

92636S

40-36

Page 41: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALBody jig bench 40

REAR SHOCK ABSORBER UPPER MOUNTING

During repairing of the rear, with the rear sub-frame removed, the jig allows positioning of the1/2 unit (assembled wheel arch).

92638S

FUEL TANK MOUNTING CROSS MEMBER

During repairing of the rear (sub-frame removed),the jig allows positioning of the fuel tank crossmember.

92639S

92640S

REAR SIDE MEMBER REAR END PANEL

During repairing of the rear, the jig allowspositioning of the side member or the rear unit.

40-37

Page 42: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALBody jig bench 40

PRS4024

FITTING CELETTE BRACKETS

40-38

Page 43: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALBody jig bench 40

PRS4025

FITTING BLACKHAWK BRACKETS

40-39

Page 44: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALBody jig bench 40

PRS4026

FITTING CELETTE BRACKETS

D53Cabriolet

40-40

Page 45: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALBody jig bench 40

PART NUMBERS FOR SPECIAL TOOLS

Special heads for the CELETTE body jig benchMZ system

Please contact your local After Sales Office for furtherdetails.

Special heads for the BLACKHAWK body jig benchMS system

Please contact your local After Sales Office for furtherdetails.

Figure Description

92 673

92 674

40-41

Page 46: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALSpecial tools

Car. 1138-02Part number 00 00 113 802

Points (A), (B), (C) and (D) are the reference pointsfor positioning the jig on the vehicle. Before fit-ting the jig, it is necessary to ensure at damage as-sessment that the reference points are correct.

Points (E), (F), (G), (H) and (J) are mainly used formounting and positioning the replacement parts.However, if either point (A) or (B) cannot be usedas a reference point, the points on the oppositeside to the impact act as reference points.

40FRONT END PANEL JIG

92301R

40-42

Page 47: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

GENERALSpecial tools

ADJUSTING THE DOORS

40TOOL FOR REMOVING DOOR HINGE PINS

85899R

97129R

Car. 1055-02Part number 00 00 105 502

Fitted to the FENWICK REN. 1303 type slide ham-mer.

Flush fitting adjustment

This is obtained by pulling or pushing one or twohinges using tool Car. 956 fitted to impact extrac-tor M.S. 580.

Adjustment range: 3 mm

85700-2S

Tilt adjustment

It is possible to adjust the door clearances, front torear and tilt, without removing the door from thevehicle, using a claw lever on the male hinges:

Wilmonda BHA part number(Supplier: Z. INTERNATIONAL)

40-43

Page 48: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREComplete front end panel cross member

COMPOSITION OF THE REPLACEMENT PART

Assembled part with engine sub-frame mountingstiffeners.

41 A

92567S

This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.

PRS4112

BUTT WELDING JOINT ON THE SIDE MEMBER1

Thickness of panels (mm)

Cross member: 1.25Side member: 1.25Side member closure panel: 0.8

Unpicking

10 spot welds

Welding

BUTT WELDING JOINT ON THE SIDE MEMBER2

Thickness of panels (mm)

Cross member: 1.25Cowl side panel: 1

Unpicking

3 spot welds

92567-1S

40

41-1

Page 49: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREComplete front end panel cross member 41 A

92562S

BUTT WELDING JOINT ON THE HEADLIGHTCARRIER PANEL

3

Thickness of panels (mm)

Cross member: 1.25Headlight carrier panel: 0.8

Unpicking

8 spot weldsOne 15mm MAG weld fillet

Welding

BUTT WELDING JOINT ON THE LOCK SUPPORT4

Thickness of panels (mm)

Cross member: 1.25Lock support: 1.5

Unpicking

4 spot welds

Welding

92561-1S

41-2

Page 50: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREPart front end panel cross member 41 B

In order to carry out this operation on Phase I ve-hicles, the closure panel (3) above must be remo-ved from the new replacement part.

Phase II vehicles

This operation is a variation on the previous one.Therefore, only its special points are describedbelow.

It is not necessary to use the body jig bench forthis operation. Front panel jig Car. 1138 issufficient.

For this operation, lock support (2) below must beordered as well.

COMPOSITION OF THE REPLACEMENT PART

Same as previous part.

PRS4127

Phase I vehicles

PRS4113

41-3

Page 51: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREComplete front end panel 41 C

92563S

COMPOSITION OF THE REPLACEMENT PART

Special replacement part consisting of:- upper cross member- lower cross member- lock support-

PRS4128

For phase I vehicles:

At A : cut out the two phase II headlight moun-ting lugs.

At B : Add 2 washers (diameter 6 × 18) tocompensate for the enlargement of thecut-outs.

BUTT WELDING JOINT ON THE SIDE MEMBER1

Refer to the previous operation.

PANELThickness of the panels (mm)

Upper cross member: 1.2Headlight carrier panel: 0.8Lower cross member: 1.25Cowl side panel: 1

Unpicking

18 spot welds

Welding

92565-1S

92567-1S

BUTT WELDING JOINT ON THE COWL SIDEPANEL

2

41-4

Page 52: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREPart front end panel 41 D

PRS4115

This operation is a variation on the previous one.Therefore, only its special points are described be-low.

It can only be carried out on phase I vehicles whichdo not have a lower cross member closure panel(refer to the part lower cross member operation).

COMPOSITION OF THE REPLACEMENT PART

Same as previous part.

NOTE: cut (A) will only be made on the oppositeside to the impact.

Welding

92561-4S

41-5

Page 53: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURESide member closure panel 41 E

92568S

This operation is carried out in addition to:

- straightening of the front section of the sidemember following removal of the front lowercross member,

- partial replacement of the front section of theside member following removal of the frontlower cross member,

- complete replacement of the front section ofthe cross member.

COMPOSITION OF THE REPLACEMENT PART

Panel only

PRS4116

UNPICKING

- 3 spot welds on the front cross member,- 10 single layer spot welds on the side member.

+

6 two layer spot welds

2 MAG weld fillets (15 mm x 2)

Welding

41-6

Page 54: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFront side member front section 41 F

92567S

This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.

COMPOSITION OF THE REPLACEMENT PART

Part only without closure panel (the closure panelmust be ordered separately).

PRS4117

BUTT WELDING JOINT ON THE CLOSUREPANEL

1

Refer to the previous operation.

Thickness of panels (mm)

Cross member: 1.25Side member: 1.25Closure panel: 0.8

BUTT WELDING JOINT ON THE LOWER CROSSMEMBER

2

Unpicking

10 spot welds

Welding40

41-7

Page 55: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFront side member front section 41 F

92569S

BUTT WELDING JOINT ON THE WHEEL ARCH3

Thickness of panels (mm)

Side member front section: 1.25Closure panel: 0.8Wheel arch: 0.7

Unpicking

+

18 spot weldsTwo 15mm MAG weld fillets

Welding

92566-2S

BUTT WELDING JOINT ON THE REAR SECTIONOF THE SIDE MEMBER

4

Thickness of panels (mm)

Side member front section: 1.25Side member rear section: 2Wheel arch: 0.7

Unpicking

Welding

92570S

After painting and before refitting the trim,protect the hollow sections with wax.

41-8

Page 56: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREPart front side member front section 41 G

PRS4118

This operation is a variation on the previous one.Therefore, only its special points are describedbelow.

COMPOSITION OF THE REPLACEMENT PART

Same as previous part.

Welding

92571S

41-9

Page 57: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFront side member rear section 41 H

92572S

This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.

COMPOSITION OF THE REPLACEMENT PART

(1) Bare side member(2) Side cross member(3) Jack support(4) Sub-frame support (5) Stiffening plate

PRS4119

BUTT WELDING JOINT ON THE FRONT SECTION1

Refer to the previous operation.

BUTT WELDING JOINT ON THE FLOOR2

Thickness of panels (mm)

Side member rear section: 2Floor stiffener: 2Floor: 0.6

Unpicking

From inside the vehicle:

32 spot welds

Welding

After painting and before refitting the trim,protect hollow sections with wax.

40

41-10

Page 58: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFront side member rear section 41 H

92577S

BUTT WELDING JOINT ON THE INNER SILLPANEL

3

Thickness of panels (mm)

Side cross member: 1Jack support: 2Inner sill panel: 1.5Sill panel: 1

Unpicking

9 spot welds

Welding

Ø D = 6 mm

After painting and before refitting the trim,protect the hollow sections with wax.

BUTT WELDING JOINT ON THE SEAT CROSSMEMBER

4

Thickness of panel (mm)

Side member rear section: 2Seat cross member: 1.25

Unpicking

+

6 two layer spot welds

92576S

Welding

After painting and before refitting the trim,protect the hollow sections with wax.

41-11

Page 59: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFront side cross member 41 I

92574S

COMPOSITION OF THE REPLACEMENT PART

(1) Bare side cross member(2) Jack support

PRS4120

BUTT WELDING JOINT ON THE INNER SILLPANEL

1

Refer to the previous operation.

BUTT WELDING JOINT ON THE FLOOR2

Refer to the previous operation.

BUTT WELDING JOINT ON THE SIDE MEMBER3

Thickness of panels (mm)

Side cross member: 1Side member: 2

+

9 spot weldsOne 30mm MAG weld fillet

Welding

92575S

After painting and before refitting the trim,protect the hollow sections with wax.

Ø D = 5.5 mm

41-12

Page 60: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFront half unit 41 J

92567-1S

COMPOSITION OF THE REPLACEMENT PART

(1) Side member front section(2) Wheel arch(3) Shock absorber cup(4) Wheel arch extender(5) Cowl side panel(6) Side member closure panel

This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.

PRS4121

BUTT WELDING JOINT ON THE LOWER CROSSMEMBER

1

Reminder

92567S

BUTT WELDING JOINT ON THE UPPER CROSSMEMBER

2

92563S

CHAMBER

92564S

Reminder

40

Reminder

BUTT WELDING JOINT ON THE HEATERBULKHEAD PARTITION

3

41-13

Page 61: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFront half unit 41 J

92641S

BUTT WELDING JOINT ON THE BULKHEAD4

Reminder

92564-1S

BUTT WELDING JOINT ON THE SIDE MEMBERREAR SECTION

5

Reminder

92569S

92570S

COWL SIDE PANEL PARTIAL CUT6

• On the vehicle, cut the cowl side panel in linewith the dotted line on the diagram below.This line is level with the plenum chamber.

• Cut the replacement part in line with thecontinuous black line on the diagram. This lineis 60 mm from the line cut on the vehicle.

92573S

41-14

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LOWER STRUCTUREFront half unit 41 J

92632R

With the vehicle positioned on the body jig bench,after welding the wheel arch, drill the front shockabsorber upper mounting.

To do this:- fit part (1) in the diagram below,- counter bore the four holes (A) to a diameter of

8 mm.

Warning: part (1) is the same for both the rightand left hand sides, it must be pivoted through ahalf turn when changing from one side to theother.

DRILLING THE SHOCK ABSORBER UPPERMOUNTING

7 SPECIAL FEATURES OF DIESEL VEHICLES8

On these vehicles, the right hand wheel arch hasan additional support for the engine pendulummounting.

Cup (C) must be welded during repair using abody jig bench bracket supplied with the body jigcomponents.

92662R

41-15

Page 63: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREPart centre floor panel 41 K

PRS4122

Example of the front section cut:

On the vehicle, use a chisel to cut the floor panellevel with the seat cross member in line with thedotted line on the diagram below.

NOTE: if the rear section of the floor panel is to bechanged, the dotted line will be located at (C).

COMPOSITION OF THE REPLACEMENT PART

Bare floor panel (panel only).

Cutting the replacement part

Cut (A) is made 20 mm above the round surface ofthe tunnel.

Cut (B) on one side or other of the seat crossmember location, at the front if the rear sectionof the floor panel is to be re-used, at the rear ifthe front section of the floor panel is to be re-used.

92646S

41-16

Page 64: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURERear floor panel (part centre section) 41 L

PRS4123Cut the new part 20 mm beyond the cut made onthe vehicle, in order to be able to superpose byplug welding.

In addition to:UPPER REAR STRUCTURE- End panel44-U Method 3

COMPOSITION OF THE REPLACEMENT PART

Bare part

CUTTING - UNPICKING

92369S

NOTE: the general procedure for changing awelded component is described in WorkshopRepair Manual M.R. 502 section 4.

PREPARATION OF THE NEW PART

PRS4124

Welding

92369-1S

Ø D = 0.7 mm

e = 1.7 mmH = 50 mm

After painting and before refitting the trim,protect the hollow sections of the side memberswith wax.

41-17

Page 65: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURERear floor panel 41 M

PRS4125

Addition to:UPPER REAR STRUCTURE - End panel44-U Method 3

Before changing the fuel tank support crossmember and the cross member under the floor.

COMPOSITION OF THE REPLACEMENT PARTS

(1) Rear floor panel bare part

(2) Fuel tank support cross memberSpare wheel well support

(3) Cross member under the floor panelbare part

CUTTING - UNPICKING

This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.

92370S 92371S

NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4.

40

41-18

Page 66: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURERear floor panel 41 M

92374S

UNPICKING THE CROSS MEMBERS ON THE OPPOSITE SIDE TO THE IMPACT

92372S

WELDING THE CROSS MEMBERS (right hand side)PREPARATION OF THE NEW PART

PRS4126 92374-1S

Ø D = 5.5 mm

Position the cross member under the floor panel,in relation to the fuel tank support cross member,at the distance shown on the diagram.

Cut the new part 20 mm beyond the cut made onthe vehicle, in order to be able to superpose byplug welding.

41-19

Page 67: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURERear floor panel 41 M

92373S

(right hand side) (left hand side)

92372-1S

Ø D = 5 mm

WELDING THE FLOOR PANEL

92370-1S92369-2S

Ø D = 4.5 mm

41-20

Page 68: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURERear floor panel panel 41 M

92371-1S

e = 1.3 mm H = 30 mm

After painting and before refitting the trim,protect the hollow sections of the side memberswith wax.

41-21

Page 69: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREUtility vehicle floor panel panel 41 N

PRJ4019

REMOVE:- the four lashing rings and the rear floor panel carpet,- side sections (1) and (2) secured to the floor panel and the body sides.

Unpick sections (3) and (4) of the load floor panel by grinding out the stitch welds without separating the twosections.

Remove the load floor panel and load area partition assembly from the vehicle.

Re-use the 3 wheelbrace securing clips and the jack securing assembly.

REMINDER:

1/ Before starting the grinding operations, the internal surfaces of all of the windows and the dashboardmust be protected.

2/ Before fitting the rear seats, carry out a conventional paint application procedure on all of the groundsurfaces.

S53Utility

UNPICKING AND REMOVAL OF THE UTILITY VEHICLE FLOOR PANEL

41-22

Page 70: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURE

Lateral side member lower section 41 O

PRS4106

COMPOSITION OF THE REPLACEMENT PART

Bare part

JOINT WITH THE FLOOR PANEL, SILL PANELAND SILL PANEL STIFFENER

1

Thickness of panels (mm)

Lateral side member 1.5Sill panel 1.5Sill panel stiffener 1.5

Unpicking

42 spot welds on the floor panel.22 spot welds on the sill panel.

Twenty 20mm MAG weld fillets.Two 40mm weld fillets.

Photo page 41-1

Welding

Front section:

D53Cabriolet

41-23

Page 71: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURE

Lateral side member lower section 41 OD53

Cabriolet

Centre section:

Rear section:

Photo page 41-2

Photo page 41-2

Ø D = 8 mm

After painting and before refitting the trim,protect the hollow sections with wax.

41-24

Page 72: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURELower side spacer 41 P

PRS4107

D53Cabriolet

This part can only be changed after removal of thelateral side member lower section.

COMPOSITION OF THE REPLACEMENT PART

Bare part

JOINT WITH THE FLOOR PANEL AND THELATERAL SIDE MEMBER LOWER SECTION

1

Thickness of panels (mm)

Spacer 1.5Side member lower section 1.5Floor panel 0.88

Unpicking

Ten 20mm MAG weld fillets.

Welding

Photo page 41-3

After painting and before refitting the trim,protect the hollow sections with wax.

41-25

Page 73: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURESill panel stiffener 41 Q

PRS4108

D53Cabriolet

This operation can only be carried out afterremoval of the assembled sill panel.

COMPOSITION OF THE REPLACEMENT PART

Bare part

JOINT WITH THE FLOOR PANEL1

Thickness of panels (mm)

sill panel stiffener 1.5sill panel 1.5

Unpicking

41-26

Page 74: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURESill closure panel stiffener 41 Q

Welding

On the joint near the front pillar, replace the inaccessible spot welds with MIG plug welds.

D53Cabriolet

Photo page 41-5

Ø D = 8 mm

JOINT WITH THE SILL PANEL FRONT STIFFENER2

Refer to paragraphs : 43 - L - 1

41-27

Page 75: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTURE

Front pillar lower section stiffener 41 R

PRS4109

D53Cabriolet

This operation can only be carried out afterremoval of the front pillar.

COMPOSITION OF THE REPLACEMENT PART

Part only

JOINT WITH THE COWL SIDE PANEL (pillarlining) AND SILL PANEL LINING

1

Thickness of panels (mm)

Cowl side panel 0.97Pillar stiffener 1.5Sill panel lining 1.5

31 spot welds.

Welding

Ø D = 8 mm

After painting and before refitting the trim, pro-tect the hollow sections with wax.

Photo page 41-6

41-28

Page 76: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFloor panel and cross member side stiffener 41 S

PRS4110

Thirty-six 25mm weld fillets.

D53Cabriolet

COMPOSITION OF THE REPLACEMENT PART

- Floor panel stiffener.- Cross member stiffener.

JOINT WITH THE CENTRE FLOOR PANEL ANDFLOOR PANEL CROSS MEMBER

1

Thickness of panels (mm)

Stiffener 1.5Centre floor panel 0.8Cross member 1.5Centre pillar 1.5

Unpicking

Welding

Photo page 41-7

Photo page 41-7

After painting and before refitting the trim,protect the hollow sections with wax.

41-29

Page 77: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREFloor panel upper cross member 41 T

D53Cabriolet

COMPOSITION OF THE REPLACEMENT PART

Part only

PRS4111

JOINT WITH THE FLOOR PANEL AND CROSSMEMBER STIFFENER

1

Thickness of panels (mm)

Cross member 1.5Floor panel 0.88Stiffener 1.5

Thirty-three 25mm MAG weld fillets.Two 50mm weld fillets.31 spot welds.

Welding

Photo page 41-8

Photo page 41-8

Ø D = 6 mm

41-30

Page 78: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREAssembled rear end panel 41 U

93125S

L53Saloon

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:- rear end panel cross member- rear end panel- striker plate stiffener- end panel cross member

The two blanking pieces (1) must be orderedseparately.

PRS4105

Thickness of panels (mm)

Lighting support panel 0.67End panel cross member 0.67Side panel 0.67End panel extender 0.97

Unpicking

14 spot welds

JOINT WITH THE LIGHTING SUPPORT PANEL1

Welding

- 1 triple layer spot weld(cross member - panel - lighting support)

- 4 triple layer spot welds(cross member - lighting support - extender)

Special point

93124R

After welding and before protecting the crimps,fit the 2 metal blanking pieces (1) by clippingthem in place using the lugs.

41-31

Page 79: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER SECTIONAssembled rear end panel 41 U

93122S

L53Saloon

Thickness of panels (mm)

End panel cross member 0.67Rear end panel 0.67Rear end panel cross member 1.25End panel extender 0.97

Unpicking

JOINT WITH THE END PANEL EXTENDER2

24 spot welds

93123S

- 4 triple layer spot welds

Thickness of panels (mm)

Extreme rear cross member 1,25Rear side member 1,00

Unpicking

JOINT WITH THE REAR SIDE PANEL3

14 spot welds

41-32

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LOWER STRUCTUREAssembled rear end panel 41 U

L53Saloon

Thickness of panels (mm)

Extreme rear cross member 1.25Rear floor panel panel 0.60

Unpicking

JOINT WITH THE Rear floor panel panel4

Welding

93121S

41-33

Page 81: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREPart rear end panel cross member 41 V

93123-3S

- 1 triple layer spot weld

L53Saloon

COMPOSITION OF THE REPLACEMENT PART

Panel only

PRS4104

Thickness of panels (mm)

Rear end panel cross member 1.25End panel extender 0.97Rear end panel 0.67

Unpicking

JOINT WITH THE END PANEL EXTENDER1

6 spot welds

Welding

Thickness of panels (mm)

Rear end panel cross member 1.25Rear end panel 0.67

Unpicking

2 spot welds

JOINT WITH THE REAR END PANEL2

41-34

Page 82: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREPart rear end panel cross member 41 V

93120S

L53Saloon

Welding

Reminder: see 41-U-4

JOINT WITH THE REAR FLOOR PANEL3

93121S

Reminder: see 41-U-3

JOINT WITH THE REAR CROSS MEMBER4

93122S

Welding

PARTIAL CUT5

93119S

41-35

Page 83: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

LOWER STRUCTUREBody 41 W

PRS4129

When a complete body is changed on a phase I vehicle, the Parts Department will supply a phase II type body.It will therefore be necessary to carry out the following operations (the details are described in the operationsfor each modified part, see contents).

For all types:- cut out the headlight mounting lugs on the front panel upper cross member,- add washers under the bonnet lock mountings,- order a new set of sill moulding.

For vehicles fitted with rubbing strips, order special replacement adhesive clips (refer to the parts list).

For B, C and S53 type vehicles:- drill the piston switch hole in the rear end panel,- close the tailgate harness hole in the upper rain channel.

For C and S53 type vehicles, drill the centre pillar trim 17 mm higher in order to refit the original seat belts.

41-36

Page 84: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREWing

REPLACEMENT

A) Detach the bumper without removing it completely. To do this, remove:- Two T20 Torx bolts (1)- Two 10mm hexagonal bolts (2)

B) Remove the wheel arch protector- One T20 Torx bolt (3)- Three clips (4)

C) Detach the front end of the sill moulding:- One T20 Torx bolt (5)

D) Slacken the bonnet strut mountings without removing them:- Two 13mm hexagonal bolts (6)

E) Remove the wing mountings:- Six 10mm hexagonal bolts (7)- Two 11mm hexagonal nuts (8)

F) Using a hot air gun, soften the anti-chipping mastic inside the wing and then remove the wing.

42 A

92560R

ALL TYPES

42-1

Page 85: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREWing 42 A

92676R

NOTE: the strip is bonded using a bead of "paintjoint" type mastic.

When a front wing is changed on a vehicle fittedwith rubbing strips, a mounting hole must be dril-led (see diagram).

ALL TYPES

42-2

Page 86: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREFront wing 42 A

D53Cabriolet

PRS4207

Photo page 42-1

The front wing is identical to that of the basevehicle × 53, but the lower rear section of it hasbeen modified.

This section is mounted using bolt (1) (seediagram).

42-3

Page 87: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTURE

Complete radiator grille upper cross member 42 B

PRS4209

COMPOSITION OF THE REPLACEMENT PART

Refer to the diagram below.

NOTE: for phase I vehicles, cut out the headlightmounting lugs at (A).

BUTT WELDING JOINT ON THE LOCK SUPPORT1

Thickness of panels (mm)

Cross member: 1.2Lock support: 1.5

Unpicking

4 spot welds

Welding

92561S

Thickness of panels (mm)

Cross member: 1.2Cowl side panel: 1

Unpicking

3 spot welds

Welding

92563S

2 BUTT WELDING JOINT ON THE COWL SIDEPANEL

42-4

Page 88: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREComplete radiator grille upper cross member 42 B

92563-2S

BUTT WELDING JOINT ON THE HEADLIGHTCARRIER PANEL

3

Thickness of panels (mm)

Cross member: 1.2Headlight carrier panel: 0.8

Unpicking

7 spot welds

Welding

42-5

Page 89: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREPart radiator grille upper cross member 42 C

PRS4201

This operation is a variation on the previous one.Therefore, only its special points are describedbelow.

COMPOSITION OF THE REPLACEMENT PART

Identical to the previous part.

Welding

92561-2S

42-6

Page 90: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREBonnet lock support 42 D

BUTT WELDING JOINT ON THE RADIATORGRILLE UPPER CROSS MEMBER

1

Refer to the previous paragraph.

BUTT WELDING JOINT ON THE LOWER CROSSMEMBER

2

Refer to section 41-A.

42-7

Page 91: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREHeadlight carrier panel 42 E

PRS4202

COMPOSITION OF THE REPLACEMENT PART

BUTT WELDING JOINT ON THE RADIATORGRILLE UPPER CROSS MEMBER

1

Refer to the previous paragraph.

BUTT WELDING JOINT ON THE LOWER CROSSMEMBER

2

Refer to sub-section 41-A.

BUTT WELDING JOINT ON THE COWL SIDEPANEL

3

Thickness of panels (mm)

Headlight carrier panel: 0.8Cowl side panel: 1

Unpicking

4 spot welds

Welding

92565-1S

42-8

Page 92: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREPart front wing panel (front section) 42 F

PRS4203

COMPOSITION OF THE REPLACEMENT PART

Part only, see diagram.

Cutting of the new part to : X = 435 mmCutting of the part on the vehicle to : X = 415 mm

BUTT WELDING JOINT ON THE RADIATORGRILLE UPPER CROSS MEMBER

1

Refer to the relevant paragraph.

BUTT WELDING JOINT ON THE LOWER CROSSMEMBER

2

Refer to sub-section 41-A.

BUTT WELDING JOINT ON THE HEADLIGHTCARRIER PANEL

3

Refer to the relevant paragraph.

BUTT WELDING JOINT ON THE WHEEL ARCH4

Thickness of panels (mm)

Wing panel: 1Wheel arch: 0.7

Unpicking

9 spot welds

Welding

92565S

PARTIAL CUT A5

92563-1S

42-9

Page 93: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREWheel arch (shock absorber turret) 42 G

PRS4204

This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:

(1) Wheel arch(2) Wheel arch extender(3) Rubber bush support(4) Shock absorber cup

BUTT WELDING JOINT ON THE WING PANELFRONT SECTION

1

Refer to the previous paragraph.

BUTT WELDING JOINT ON THE WING PANELREAR SECTION

2

(Shock absorber cup to the cowl side panel)

Thickness of panels (mm)

Shock absorber cup: 2Wing panel: 1

Unpicking

6 spot welds

Welding

92566S

CHAMBERThickness of panels (mm)

Cup: 2Heater bulkhead partition : 0.7

Unpicking

5 spot welds

92641S

40

A - SHOCK ABSORBER CUP TO THE HEATERBULKHEAD PARTITION

BUTT WELDING JOINT ON THE HEATERBULKHEAD PARTITION

3

42-10

Page 94: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTURE

Wheel arch (shock absorber turret) 42 G

92564S

B - WHEEL ARCH TO THE HEATER BULKHEADPARTITION

Thickness of panels (mm)

Wheel arch: 0.7Heater bulkhead partition : 0.7

Unpicking

7 spot welds

Welding

BUTT WELDING JOINT ON THE BULKHEAD4

Thickness of panels (mm)

Wheel arch: 0.7Bulkhead: 0.7

Unpicking

7 spot welds

Welding

92564-1S

42-11

Page 95: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREWheel arch (shock absorber turret) 42 G

92566-1S

BUTT WELDING JOINT ON THE SIDE MEMBER5

Thickness of panels (mm)

Wheel arch: 0.7Side member front section: 1.25Side member closure panel: 0.8Side member rear section: 2

Unpicking

21 spot weldsTwo 15mm MAG weld filletsTwo 30mm MAG weld fillets

Welding

After painting and before refitting the trim,protect the hollow sections with wax.

DRILLING THE SHOCK ABSORBER UPPERMOUNTING

6

With the vehicle positioned on the body jig bench,after welding the wheel arch, drill the front shockabsorber upper mounting.

To do this:- fit part (1) in the diagram below,- counter-bore the four holes (B) to a diameter of

8 mm.

Warning: part (1) is the same for both the rightand left hand sides, it must be pivoted through ahalf turn when changing from one side to theother.

92632R1

42-12

Page 96: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREWheel arch (shock absorber turret) 42 G

92662R

SPECIAL FEATURES OF DIESEL VEHICLES7

On these vehicles, the right hand wheel arch hasan additional support for the engine pendulummounting.

Cup (C) must be welded during repair using abody jig bench bracket supplied with the body jigcomponents.

42-13

Page 97: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREPart heater bulkhead partition 42 H

PRS4205

COMPOSITION OF THE REPLACEMENT PART

Consisting of:- heater bulkhead partition- component for joint with the windscreen

aperture lower cross member(1)- battery support- windscreen wiper motor support- welded studs and nuts.

BUTT WELDING JOINT ON THE WHEEL ARCH1

Refer to the previous paragraph.

BUTT WELDING JOINT ON THE WING PANEL2

Thickness of panels (mm)

Plenum chamber: 0.7Cowl side panel: 1

Unpicking

+

8 spot welds

Welding

92573-1S

42-14

Page 98: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREPart heater bulkhead partition 42 H

92579S

BUTT WELDING JOINT ON THE BULKHEAD3

Thickness of panels (mm)

Heater bulkhead partition : 0.7Bulkhead: 0.7

Unpicking

+

12 spot welds per 1/2 partition (i.e. 24 for thecomplete part)

Welding

Drilling of the bulkhead to a diameter of 5 mmfor plug welding.

PARTIAL CUT4

92570-1S

42-15

Page 99: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREPart windscreen aperture lower cross member 42 I

PRS4206

COMPOSITION OF THE REPLACEMENT PART

Consisting of:- windscreen aperture lower cross member- steering support (1)- welded nuts and studs

Cutting of the new part to : X = 320 mmCutting of the part on the vehicle to : X = 300 mm

BUTT WELDING JOINT ON THE FRONT PANEL1

Thickness of the panels (mm)

Windscreen aperture lower cross member: 1Cowl side panel: 1

Unpicking

+

5 spot weldsTwo 30mm MAG weld fillets

Welding

92578S

The welding operation above can only be carriedout with the front pillar removed.

92573-2S

After painting and before refitting the trim,protect the hollow sections with wax.

42-16

Page 100: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREPart windscreen aperture lower cross member 42 I

92573-3S

BUTT WELDING JOINT ON THE FRONT PILLAR2

Thickness of panels (mm)

Windscreen aperture lower cross member: 1Cowl side panel: 0.7

Unpicking

10 spot welds

Welding

92579-1S

Drilling of the cross member to a diameter of 5mm for plug welding.

PARTIAL CUT3

92580S

42-17

Page 101: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER FRONT STRUCTUREFront pillar upper stiffener 42 J

PRS4208

COMPOSITION OF THE REPLACEMENT PART

Part only

JOINT WITH THE COWL SIDE PANEL AND THEFRONT PILLAR

1

Thickness of panels (mm)

Stiffener 1.5Cowl side panel 0.97Front pillar 1.25

Unpicking

11 spot welds

Seven 30mm MAG weld fillets.

Welding

Photo page 42-2

42-18

Page 102: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREFront pillar lower section 43 A

92363R

DISMANTLING

Remove:- front door,- front wing,- dashboard,- body side interior trim,- front seat.

Partially fold back the carpet.

Remove:- bonnet opening control,- electrical wiring in the pillar,- sill panel moulding.

COMPOSITION OF THE SPECIAL REPLACEMENTFRONT PILLAR

(1) Front pillar(2) Upper hinge stiffener(3) Lower hinge stiffener(4) Door stop mounting(5) Wing mounting stud(6) Welded KSM

CUTTING - UNPICKING

(7) Upper hinge(8) Lower hinge

Maximum length of the new part: 570 mm.

92629R

92630R

Remove the damaged section in line with the diagrams above (refer to the key to symbols)(A) drill right through the spot welds at the pillar - hinge stiffener - lining joints(B) unpick using a chisel

43-1

Page 103: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREFront pillar lower section 43 A

WELDING

Carry out the following:

• retaining spot welds on the lines to be buttwelded.

• the spot welds. The corresponding (e) and (H)values are given underneath each diagram.

• the MIG stitch welds.

• the MIG plug welds at the lining and hingestiffener joints.

• lead fill the butt welded sections, aftergrinding down the weld fillet.

ANTI-CORROSION PROTECTION

After painting and before refitting the trim, injecthollow section wax into the pillar.

Grind the bits of unpicked spot weld remaining onthe support panels.

Take a section of the new part which isapproximately 50 mm larger than that cut fromthe vehicle.

Position the new part on the vehicle so that it issuperposed, then secure it using a vice-gripwrench.

Cut the two layers of metal simultaneously with ahacksaw in order to facilitate the fit.

PREPARATION BEFORE WELDING

Strip the internal and external surfaces of all areasto be welded. (On the vehicle and on the newparts) .

Coat the sections to be spot welded with a beadof electro-plastic mastic. Apply aluminium paintto the sections to be plug welded.

Adjust the new part, then secure it using a vice-grip wrench.

92628-1R 92628R

e = 2.1 mmH = 65 mm

B =Ø 5 mm

43-2

Page 104: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREFront pillar by cutting at the upright 43 B

DISMANTLING

Remove:- front door,- front wing,- dashboard,- body side internal trim,- front seat.

Partially fold back the carpet.

Remove:- bonnet opening control,- electrical wiring in the pillar,- windscreen,- pillar upright seal,- sill panel moulding.

Remove the electrical wiring.

PROTECTION

Protect the interior using a cover which is resistantto welding and grinding damage.

43-3

Page 105: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREFront pillar by cutting at the upright 43 B

92627R

Define cuts (A) and (B). The working method isidentical to that for changing the lower section ofthe pillar.

Cuts (A) and (B) must be opposite an opening inorder to make it easier to protect the interior.

In order to ease cutting and unpicking, welding ofthe butt welding joints will be shown.

92627-1R

Lead fill the butt welded sections after grindingdown the weld fillet.

ANTI-CORROSION PROTECTION

After painting, inject hollow section wax into thenew part.

Original welding

Spot welding

Stitch welding

Repair welding

D = 5 mm

e = 2.1 mmH = 65 mm

43-4

Page 106: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREDoor hinges (on the front pillar) 43 C

92627-2R

B = 296 ± 1 mm (theoretical value for informa-tion)

WELDING THE DOOR HINGES TO THE FRONTPILLAR

When a front pillar is changed, the door hinges, tobe ordered separately, must be welded on.

To do this, follow the procedure below.

Temporarily spot weld the two male hinges to thepillar using the part which has been removed tomark the positions.

Fit the door, with the front wing removed, andcheck that it is adjusted correctly before perma-nently welding the hinges in place.

D53Cabriolet

92630-1R

A = 115 ± 1 mm (theoretical value for informa-tion)Ø1 = 20 mm

43-5

Page 107: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREAssembled front pillar 43 D

D53Cabriolet

This operation can only be carried out afterremoval of the upper pillar stiffener and is inaddition to the partial changing of thewindscreen frame.

COMPOSITION OF THE REPLACEMENT PART

- Bare front pillar.- Pillar stiffener tube.- Internal pillar stiffener.

PRS4301

JOINT WITH THE WINDSCREEN PILLAR LINING1

Refer to section: 45 ...

JOINT WITH THE PILLAR LINING AND SILLPANEL

2

Thickness of panels (mm)

Front pillar 1.25Pillar lining 0.97Sill panel 1.5Sill panel front stiffener 1.5

Unpicking

50 spot welds

Three 30mm MAG weld fillets.One 90mm MAG weld fillet.

Photo page 43-1

Ø D = 8 mm

43-6

Page 108: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREAssembled front pillar 43 D

D53Cabriolet

JOINT WITH THE INTERNAL PILLAR STIFFENER3

Thickness of panels (mm)

Front pillar 1.25Stiffener 1.5

Unpicking

Two 30mm MAG weld fillets.One 10mm MAG weld fillet.

Welding

Photo page 43-2

JOINT WITH THE WINDSCREEN FRAME4

Reminder: see 45-B

After painting and before refitting the trim, treatthe hollow sections with wax.

43-7

Page 109: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREFront pillar 43 E

92363R1

COMPOSITION OF THE SPECIAL REPLACEMENTFRONT PILLAR

The parts warehouse supplies the B53 front pillar(for reasons of standardisation).

When the front pillar of the C53 is changed, thesill panel section must be cut in order to hold theoriginal butt welding joint more easily.

Dimension of the cut: 345 mm

C53

Welding

92626-1G 92626G

Original welding Repair welding

Spot welding

D = 5 mm

43-8

Page 110: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREPillar upright joint mounting (KSM) 43 F

92624R

At (A) KSM type welded mounting.

The other 4 mountings are rivets:part number. 77 03 072 263

to be secured when the support is fitted.

It is essential that electro-plastic mastic is put intothe holes before riveting in order to ensuresealing and prevent corrosion.

DIMENSION OF THE KSMS WELDED TO THEUPRIGHT

43-9

Page 111: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar 43 G

DISMANTLING

Remove:- rear door,- body side trims,- front seat,- complete rear seat,

Partially fold back the carpet.

Remove:- sill panel moulding,- electrical wiring,- front door striker,- seat belt upper support,- seat belt.

COMPOSITION OF THE REPLACEMENT PART

(1) Centre pillar(2) Seat belt mounting(3) Upper hinge(4) Lower hinge(5) Hinge stiffener(6) Striker mounting retainer

Maximum length of the new part:top 840 mmbottom 1 230 mm

92363R2

43-10

Page 112: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar 43 G

92623R

CUTTING - UNPICKING

92622R

(A) and (C) are the recommended cutting areas. To make cutting and unpicking easier, the original buttwelding joints are shown above. NOTE: it is possible to make a cut at (C) to avoid having to change the part later.

Spot welding

Brazing

(B) sealing lining support.

Take a section of the new part which is approximately 50 mm larger than that cut from the vehicle.

Position the new section on the vehicle so that it is superposed, then secure it using a vice-grip wrench.

At (A) cut 15 mm longer, this section to be plug welded.

Cut the two layers of metal simultaneously with a hacksaw in order to facilitate the fit.

43-11

Page 113: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar 43 G

92621R

PREPARATION BEFORE WELDING

Strip the internal and external surfaces of all areas to be welded. (On the vehicle and on the new parts).

Coat the sections to be spot welded with a bead of electro-plastic mastic (see the key to symbols at thebeginning of the section).

Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under eachwelding diagram and coat with aluminium paint.

Adjust the new part, then secure it using a vice-grip wrench.

92622-1S

Lead fill the butt welded sections, after grinding down the weld fillet.

Repair welding

Lead fill at (A).

D = 4.5 mm

43-12

Page 114: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar 43 G

ANTI-CORROSION PROTECTION

After painting, inject hollow section wax into thenew part.

92619S

92620S

Repair anti-corrosion protection.

43-13

Page 115: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar 43 G

PRS4304

This operation can only be carried out after remo-val of the rear wing panel.

COMPOSITION OF THE REPLACEMENT PART

Part only

D53Cabriolet

JOINT WITH THE CENTRE LINING AND SILLPANEL

1

Thickness of panels (mm)

Centre pillar 1.25Lining 1.5Sill panel 1.5

Unpicking

30 spot welds

Four 25mm MAG weld fillets

15 MAG plug welds

Welding

Photo page 43-10

Ø D = 6 mm

On the front right hand section, some spot weldsare made only after the wing panel has beenrefitted.

JOINT WITH THE WING PANEL LINING2

See 44-D

43-14

Page 116: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar lining 43 H

PRS4306

COMPOSITION OF THE CENTRE PILLAR LINING

(1) Centre pillar lining, upper section(2) Seat belt mounting nut(3)

CUTTING - UNPICKING

92618S 92617S

Original welding

Stitch welding

Spot welding

NOTE: it is possible to change the complete centre pillar or make a cut at (A) to make a butt weld (if thismethod is used, the roof trim does not have to be removed).

43-15

Page 117: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar lining 43 H

92618-1R

D = 5 mm

PREPARATION BEFORE WELDING

Strip the internal and external surfaces of all of the areas to be welded. (On the vehicle and on the new parts).

Spray zinc paint on the sections to be spot welded.

Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under eachwelding diagram and coat with aluminium paint.

Adjust the new part, then secure it using a vice-grip wrench.

Repair welding

Spot weld at (A).

92617-1S

43-16

Page 118: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar lining 43 H

92616S

Repair welding

92616-1S

Original welding

D = 6 mm

43-17

Page 119: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURECentre pillar lining 43 H

This operation can only be carried out after remo-val of the wing panel lower front lining and thefloor and cross member side stiffener.

COMPOSITION OF THE REPLACEMENT PART

- Centre pillar lining.- Seat belt mounting stiffener.

D53Cabriolet

PRS4305

JOINT WITH THE FLOOR1

Thickness of panels (mm)

Pillar lining 1.5Floor 0.88

Unpicking

Seven 40mm MAG weld fillets.

Photo page 43-11

JOINT WITH THE CENTRE PILLAR2

Refer to the previous operation.

JOINT WITH THE WING PANEL LINING3

Reminder: see 44-D

43-18

Page 120: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURESill panel 43 I

92363S

The sill panel is supplied bare.

92363S1

RECOMMENDATIONS FOR REPLACEMENT

Depending on the area which is deformed, it is possible to change the sill panel at several points (seediagrams).

92363S3

92363S2

92363S4

All of the cuts must be butt welded using MIG stitch welds, then lead filled.

43-19

Page 121: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURESill panel 43 I

92615S

92622S

92615-1R

92622-1R

Original welding

Spot welding

Repair welding

H = 35 mm

(A) D = 4.5 mm(B) D = 5 mm

ANTI-CORROSION PROTECTION

After painting and before refitting the trim, inject hollow section wax.

Brazing

43-20

Page 122: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREBody side

These parts are affected by the modification tothe sill panel moulding. The Parts Department willsupply them with the two phase II type mountingrows.

When one of the parts is changed on a phase I ve-hicle, the holes of the lower row must be closedusing self-adhesive plugs before the anti-chippingmastic is applied. These plugs are available fromthe Parts Department (see PR).

NOTE: this course of action is already applied inadvance to production vehicles.

43 J

PRS4308

ALL TYPESPhase I

43-21

Page 123: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREPart sill panel 43 K

COMPOSITION OF THE REPLACEMENT PART

Bare part

Before cutting the sill panel on the vehicle, thespot welds at the joint of the sill panel with itslongitudinal partition must be unpicked.

The number of spot welds to be unpicked willdepend on the length of the partial cut.

On the new part, drill 6.5mm diameter holes atthe butt welding joint with the longitudinalpartition.

Welding

- Make the plug welds for the joint with thepartition.

- Spot welds for the joint with the inner sillpanel.

- Stitch welds at the ends of the partial cut.

For further information, refer to the previousparagraph.

Unpicking

Photo page 43-3 Photo page 43-3

D53Cabriolet

43-22

Page 124: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREAssembled sill panel 43 L

PRS4307

This operation can only be carried out after remo-val of the front pillar and the wing panel.

COMPOSITION OF THE REPLACEMENT PART

- Sill panel.-Longitudinal partition.

D53Cabriolet

JOINT WITH THE FRONT PILLAR1

Refer to section : 43 - D - 2

Note: If the front pillar has not been damaged, itis preferable cut part of the sill panel. To do this,refer to section: 43 - K.

JOINT WITH THE INNER SILL PANEL2

Thickness of panels (mm)

Sill panel 1.5Inner sill panel 1.5Inner sill panel stiffener 1.5Lateral side member 1.5

Unpicking

62 spot welds. 3 MAG spot welds

43-23

Page 125: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREAssembled sill panel 43 L

Welding

D53Cabriolet

Photo page 43-5

43-24

Page 126: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTUREAssembled sill panel 43 L

D53Cabriolet

Ø D = 8 mm

At the rear section, the sill panel lower joint ismade only after the wing panel has been refitted.

At the front section, the joint is only made afterthe pillar has been refitted.

After painting and before refitting the trim, treatthe hollow sections with wax.

Photo page 43-6

43-25

Page 127: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURESill panel 43 L

92764R1

B - C - L53Sport

Using the dimensions shown on the diagrams below, mark the location of the 4 mounting points A, B, C andD. The dimensions are identical for B, C and L53 type vehicles.

92309R

Points :

A h = 25 mm

B h = 25 mm

C h = 22 mm

D h = 11 mm

Drill the holes to Ø 6 mm.

Apply sealing mastic to the edge of the holes and fit clips (3).

43-26

Page 128: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURESill panel front stiffener 43 M

PRS4302

COMPOSITION OF THE REPLACEMENT PART

Bare part

D53Cabriolet

JOINT WITH THE FRONT PILLAR, COWL SIDEPANEL AND WHEEL ARCH

1

Thickness of panels (mm)

Stiffener 1.5Front pillar 1.25Cowl side panel 0.97Wheel arch 0.7

Unpicking

Four 20mm MAG weld fillets.Twelve 40mm MAG weld fillets.

7 MAG plug welds.

Welding

Photo page 43-7

After painting and before refitting the trim, treatthe hollow sections with wax.

Ø D = 8 mm

43-27

Page 129: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURESill panel front stiffener 43 M

D53Cabriolet

JOINT WITH THE SILL PANEL2

Thickness of panels (mm)

Stiffener 1.5Sill panel 1.5

Unpicking

7 spot welds.

7 MAG plug welds.

One 30mm MAG welds fillet.

Welding

Ø D = 8 mm

JOINT WITH THE FLOOR AND FRONT SIDEMEMBER

3

Unpicking

Six 30mm MAG weld fillets.

Welding

Photo page 43-8

Photo page 43-8

43-28

Page 130: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURESill panel rear stiffener 43 N

This operation can only be carried out after remo-val of the rear wing panel.

Refer to paragraph: 44-A

COMPOSITION OF THE REPLACEMENT PART

Bare part

D53Cabriolet

PRS4303

JOINT WITH THE SILL PANEL AND WHEELARCH

1

Thickness of panels (mm)

Stiffener 1.5Sill panel 1.5Outer wheel arch 0.88Inner wheel arch 1.2

Unpicking

16 spot welds.

Four 25mm MAG weld fillets.

Photo page 43-9

Welding

Photo page 43-9

Ø D = 8 mm

After painting and before refitting the trim, pro-tect the hollow sections with wax.

43-29

Page 131: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER SIDE STRUCTURERoof arch 43 O

PRS4309

NOTE: at (C) apply two beads of filling mastic.

ATTENTION: when fitting a sun roof as an accesso-ry, the roof arch must be cut.

The sun roof frame will then act as the stiffener.

This part can only be changed after removal ofthe roof.

COMPOSITION OF THE REPLACEMENT PART

Part only.

B53Phase II

JOINT WITH THE BODY SIDE1

Thickness of panels (mm)

Body side 0.77Stiffener 0.77

Unpicking

4 spot welds

Welding

95813R

43-30

Page 132: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete wing panel 44 A

PRS4412

This operation is carried out with the roof remo-ved.

COMPOSITION OF THE REPLACEMENT PART

Part only. The double seal support (1) must beordered separately.

JOINT WITH THE ROOF1

Thickness of panels (mm)

Wing panel 0.67Roof 0.67Body side support extender 0.67

Unpicking

One 25mm MAG weld fillet

93126R1

At (2), apply a bead of metal bonding mastic.

Welding

93118S

- 2 triple layer spot welds

L53Saloon

44-1

Page 133: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete wing panel 44 A

93116S

Thickness of panels (mm)

Wing panel 0.67Body side 1.1

Unpicking

JOINT WITH THE BODY TOP2

One 25mm MAG weld fillet

Welding

93117S

Thickness of panels (mm)

Wing panel 0.67Quarter panel lining 0.67Roof drip moulding lining 0.67Seat belt retractor support bracket 1.2Body side upper extender 0.67

Unpicking

21 spot welds

- 4 triple layer spot welds

93115S

- 3 triple layer spot welds

L53Saloon

JOINT WITH THE QUARTER PANEL LINING3

44-2

Page 134: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

Thickness of panels (mm)

Wing panel 0.67Lighting support component 0.67

Unpicking

UPPER REAR STRUCTUREComplete wing panel 44 A

93113S

L53Saloon

Thickness of panels (mm)

Wing panel 0.67Side rain channel 0.87

Unpicking

One 10mm MAG weld fillet

Welding

8 spot welds

JOINT WITH THE SIDE RAIN CHANNEL4

93114S

Welding

4 spot welds

JOINT WITH THE LIGHTING SUPPORT COMPONENT5

Depending on method: see JOINT 6

One 20mm MAG weld fillet - see JOINT note 6

44-3

Page 135: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete wing panel 44 A

93111S

L53Saloon

Thickness of panels (mm)

Wing panel 0.67End panel extender 0.97

Unpicking

NOTE: There is a spot weld located under the endpanel cross member (see welding). If the crossmember is not to be removed, a special cut mustbe made on the panel.

4 or 5 spot welds depending on themethod

JOINT WITH THE END PANEL EXTENDER6

93112S

A - With removal of the end panel cross member

One 20mm MAG weld fillet

Welding

A - With removal of the end panel cross member

93112-1S

B - Without removal of the end panel crossmember

B - Without removal of the end panel crossmember

44-4

Page 136: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete wing panel 44 A

93109S

L53Saloon

93110S

6 spot welds

Thickness of panels (mm)

Wing panel 0.67Rear floor 0.60Outer wheel arch 0.67Inner wheel arch 1.25

Unpicking

JOINT WITH THE REAR FLOOR7

Welding

- 1 four layer spot weld- 1 triple layer spot weld

19 spot welds

Thickness of panels (mm)

Wing panel 0.67Outer wheel arch 0.67Inner wheel arch 1.25Backrest mounting stiffener 1.5Side member closure panel 1.5Sill panel 1.1

Unpicking

JOINT WITH THE OUTER WHEEL ARCH8

44-5

Page 137: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete wing panel 44 A

93106S

L53Saloon

Welding

93108S

93107S

- 14 triple layer spot welds

6 spot welds

Thickness of panels (mm)

Wing panel 0.67Sill panel 1.1

Unpicking

One 25mm brazed weld fillet

Welding

One 25mm MAG weld fillet

JOINT WITH THE SILL PANEL9

44-6

Page 138: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete wing panel 44 A

93105S

L53Saloon

10

Welding

3 spot welds

Thickness of panels (mm)

Wing panel 0.67Double seal support 0.67

Unpicking

JOINT WITH THE DOUBLE SEALSUPPORT

44-7

Page 139: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete rear wing panel 44 A

COMPOSITION OF THE REPLACEMENT PART

- Bare panel.- Window frame stiffener.- Panel stiffener.- Striker stiffener.- Bumper stiffener.- Window guide upper stiffener.

D53Cabriolet

Welding

JOINT WITH THE UPPER LINING1

Thickness of panels (mm)

Wing panel 0.8Lining 1.0

Unpicking

38 spot welds.

Photo page 44-1

JOINT WITH THE BOOT LID RAIN CHANNELAND WING PANEL REAR LINING

1

Thickness of panels (mm)

Wing panel 0.8Boot lid rain channel 1.0Lining 0.88

Unpicking

23 spot welds.One 30mm MAG weld fillet.

1 brazed weld fillet.

PRS4413

44-8

Page 140: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete rear wing panel 44 A

Note: When unpicking at the joint with the bootlid rain channel, drill out the spot welds using aspot weld rotary grinder. These holes will be plug-ged again by MAG welding.

Welding

D53Cabriolet

The MAG welds shown are to be made on bothsides.

Photo page 44-2

Photo page 44-2

Photo page 44-2

JOINT WITH THE WHEEL ARCH AND SILLPANEL

1

Thickness of panels (mm)

Wing panel 0.88Sill panel 1.5Wheel arch 0.8

Unpicking

11 spot welds.

44-9

Page 141: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete rear wing panel 44 A

Preparation before welding:

D53Cabriolet

Welding

Photo page 44-3

Photo page 44-3

Photo page 44-3

Photo page 44-3

44-10

Page 142: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete rear wing panel 44 A

D53Cabriolet

JOINT WITH THE SILL PANEL AND CENTREPILLAR

4

Thickness of panels (mm)

Wing panel 0.88Sill panel 1.5

Unpicking

15 spot welds.Two 30mm MAG weld fillets.

1 brazed fillet.

Welds

Note: At the lower section of the sill panel, thespot welds must be made in the recesses to avoidwelding four overlapping panels.

Photo page 44-4

JOINT WITH THE CENTRE PILLAR5

Thickness of panels (mm)

Wing panel 0.88Centre pillar 1.25Pillar lining 1.5

Unpicking

14 spot welds.

44-11

Page 143: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete rear wing panel 44 A

D53Cabriolet

Welding

JOINT WITH THE SILL PANEL AND PANELSTIFFENER

6

Thickness of panels (mm)

Stiffener 0.6Sill panel 1.5

Unpicking

Two 10mm MAG weld fillets

Hollow section protection:

Photo page 44-5

Photo page 44-5

Photo page 44-5

Photo page 44-5

44-12

Page 144: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut A)

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:

- bumper mounting stiffener- striker stiffener

44 B

92363R7

NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 44.

92399S

CUTTING - UNPICKING

92400-1S

(End panel - wing panel joint)

44-13

Page 145: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut A) 44 B

92404S92402S

Remove the double seal support.

92403S

PREPARATION OF THE NEW PART

92363R3

Area not used

44-14

Page 146: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut A) 44 B

PRS4410

SUPERPOSED CUT

92405-1S

Welding

PRS4411

e = 1.4 mmH = 30 mm

D = 5 mm

e = 1.4 mmH = 30 mm

D = 5 mm

A :

e = 1.4 mmH = 60 mm

44-15

Page 147: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut A) 44 B

92402-1S

ANTI-CORROSION PROTECTION

92407S

e = 1.4 mmH = 60 mm

D = 5 mm

92408S

e = 1.4 mmH = 60 mm

D = 5 mm

D = 5 mm

92410S

44-16

Page 148: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut B) 44 B

92363R8

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:

- bumper mounting stiffener- striker stiffener

CUTTING - UNPICKING

92399S 92400S

(End panel - wing panel joint)

NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 44.

44-17

Page 149: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut B) 44

92404S92401S

B

(end panel - wing panel joint)

Retain the edge of panel (A) and open it slightly inorder to superpose the new part and plug weld it.See § WELDING.

PREPARATION OF THE NEW PART

92363R6

Area not used

44-18

Page 150: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut B)

SUPERPOSED CUT

44 B

92406S

92405S

Welding

92405-2S

D = 5 mm

e = 1.4 mmH = 60 mm

44-19

Page 151: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut B) 44 B

92408S

D = 5 mm

92407S

e = 1.4 mmH = 60 mm

ANTI-CORROSION PROTECTION

92409S

44-20

Page 152: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut A) 44 B

92363R9

C53

The general procedure for changing the panel isidentical to that for the B53, only the positions ofthe superposed cuts are different.

Area not used

44-21

Page 153: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut A) 44 B

PRS4436

The Parts Department only supplies phase II typeparts which only have one row of rubbing stripmounting holes. For phase I vehicles, remember toorder the adhesive clips for mounting the phase Istrip.

NOTE: as the last but one hole (A), is not used formounting the phase I strip, it must be closed toseal effectively using an adhesive plug or a smallball of mastic (see PR).

C53 / S53Phase I

44-22

Page 154: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing panel (cut AB) 44 B

PRS4414

The general procedure for changing the panel isidentical to that for the B53, only the positions ofthe superposed cuts are different.

SPECIAL POINTS

C53

Area not used

44-23

Page 155: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart wing pane (cut A) 44 B

93104S

This operation is a variation on the previous one.Therefore, only its special points are described be-low.

COMPOSITION OF THE REPLACEMENT PART

Same as the previous part.

L53Saloon

PRS4416

Welding

44-24

Page 156: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart rear wing panel (cut A) 44 B

Partially remove the damaged part following therecommendations for the previous operation.

D53Cabriolet

PARTIAL CUT1

PRS4415

X = 920 mm.

Unpicking

Length of cut: 400 mm.

After painting and before refitting the trim,protect the hollow sections with wax (innersection of the wing panel).

Photo page 44-6

44-25

Page 157: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREQuarter panel lining 44 C

PRS4445

These vehicles are fitted with an adjustable seatbelt mounting. The Parts Department only sup-plies phase II type parts to which all types of seatbelt can be fitted. Mounting hole (A) has beenmoved up 17 mm. Consequently, when either aquarter panel lining or a complete body is chan-ged on a phase I vehicle, the original hole in thepillar trim must be extended 17 mm upwards (re-fer to the paragraph on pillar trim).

All typesPhase I

44-26

Page 158: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREQuarter panel lining 44 C

PRS4418

L53Saloon

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:- quarter panel lining,- body side upper extender.

Thickness of panels (mm)

Body side upper extender 0.67Body side 1.1Roof drip moulding lining 0.67Quarter panel lining 0.67

Unpicking

8 spot welds

JOINT WITH THE BODY TOP1

5 spot welds

Special point for removal

To gain access to the body side extender spotwelds, the roof drip moulding lining must bepartially removed. Cut it to the dimensionX = 125 mm

Welding

93099S

93098S

44-27

Page 159: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREQuarter panel lining 44 C

93097S

L53Saloon

Cut a piece of the new roof drip moulding liningto the dimension Z = 145 mm.

On the diagram above, the dotted line representsthe cut carried out on the vehicle during theunpicking operation. Dimension Y = 180 mm isused to position the new part.

JOINT WITH THE REAR ROOF CROSS MEMBER2

Thickness of panels (mm)

Quarter panel lining 0.67Roof 0.67Rear roof cross member 0.67

Unpicking

4 spot welds

Welding

JOINT WITH THE OUTER WHEEL ARCH3

Thickness of panels (mm)

Quarter panel lining 0.67Outer wheel arch 0.67Quarter panel arch 0.97Side shelf 0.97Backrest mounting stiffener 1.25

Unpicking

9 spot welds

93099-1R

44-28

Page 160: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREQuarter panel lining 44 C

93096S

L53Saloon

- 3 triple layer spot welds

- 2 plug welds to be made from inside the vehicle

JOINT WITH THE SIDE SHELF5Welding

- 4 triple layer spot welds

JOINT WITH THE ROOF PANEL4

Apply a bead of metal bonding mastic.

Thickness of panels (mm)

Quarter panel lining 0.67Side shelf 0.97Quarter panel arch 0.97Outer wheel arch 0.67

Unpicking

11 spot welds

Welding

93099-4S

93095S

44-29

Page 161: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREQuarter panel lining 44 C

93094S

L53Saloon

JOINT WITH THE SIDE RAIN CHANNEL6

Thickness of panels (mm)

Quarter panel lining 0.67Side rain channel 0.97Seat belt retractor support bracket 1.20

Unpicking

2 spot welds

Welding

- 2 triple layer spot welds

JOINT WITH THE WING PANEL7

Reminder: see 44-A-3

93116S

93115S

44-30

Page 162: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREQuarter panel lining 44 C

93126R1

L53Saloon

JOINT WITH THE QUARTER PANEL ARCH8

Reminder: see 44-J-1

93093S

44-31

Page 163: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREAssembled wing panel lining 44 C

This operation can only be carried out after remo-val of the complete wing panel.

COMPOSITION OF THE REPLACEMENT PART

- Upper front lining.- Lower front lining.- Rear lining.- Outer wheel arch.- Wheel arch stiffener.- Inner wheel arch.

D53Cabriolet

PRS4417

Welding

JOINT WITH THE CENTRE PILLAR1

Thickness of panels (mm)

Panel lining 0.88Centre pillar 1.25Centre pillar lining 1.5

Unpicking

8 spot welds.Two 20mm MAG weld fillets.Two 30mm MAG weld fillets.

Photo page 44-7

Photo page 44-7

44-32

Page 164: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREAssembled wing panel lining 44 D

D53Cabriolet

Welding (cont)

Ø D = 6 mm

JOINT WITH THE SILL PANEL AND WHEELARCH

2

Thickness of panels (mm)

Panel lining 0.88Sill panel 1.5Wheel arch 0.88Sill panel stiffener 1.5Sill panel lining 1.5

Unpicking

11 spot welds.

Two 30mm MAG weld fillets.One 20mm MAG weld fillet.

Welding

Photo page 44-8

Photo page 44-8

Photo page 44-8

44-33

Page 165: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREAssembled wing panel lining 44 D

D53Cabriolet

JOINT WITH THE REAR FLOOR3

Thickness of panels (mm)

Panel lining 0.88Rear floor 0.88Wheel arch 1.2

Unpicking

25 spot welds.Two 30mm MAG weld fillets.

Welding

JOINT WITH THE LIGHTING SUPPORT PANEL1

Thickness of panels (mm)

Panel lining 0.88Lighting support 0.67

Unpicking

12 spot welds.

Photo page 44-9

Photo page 44-9

44-34

Page 166: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREAssembled wing panel lining 44 D

After painting and before refitting the trim, pro-tect the hollow sections with wax.

D53Cabriolet

Welding (cont)

Note: For welding to the rear wing panel, refer toparagraph: 44-A

JOINT WITH THE WHEEL ARCH UPPER CROSSMEMBER

5

Reminder: see 44-N

Photo page 44-10

Photo page 44-10

44-35

Page 167: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREWing panel lower front lining 44 E

PRS4419

This operation can only be carried out after remo-val of the wing panel.

COMPOSITION OF THE REPLACEMENT PART

- Bare lining.- Window winder support.

D53Cabriolet

JOINT WITH THE CENTRE PILLAR, SILL PANELAND WHEEL ARCH

1

Thickness of panels (mm)

Sill panel 1.5Inner sill panel 1.5Panel lining 0.88Centre pillar 1.25Centre pillar stiffener 1.5

Unpicking

15 spot welds.

Welding

Ø D = 8 mm

Photo page 44-11

44-36

Page 168: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREWing panel upper front lining 44 F

This operation can only be carried out after remo-val of the wing panel.

COMPOSITION OF THE REPLACEMENT PART

- Hood mounting bracket.- Stiffener.

D53Cabriolet

PRS4420

JOINT WITH THE WHEEL ARCH AND REARLINING

1

Thickness of panels (mm)

Panel lining 0.88Inner wheel arch 1.2Outer wheel arch 0.88

Unpicking

15 spot welds.

Welding

JOINT WITH THE CENTRE PILLAR2

Refer to the "Assembled wing panel lining" ope-ration: 44-D

Photo page 44-12

44-37

Page 169: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREWing panel rear lining 44 G

This operation can only be carried out after remo-val of the wing panel.

COMPOSITION OF THE REPLACEMENT PART

- Counter balance stiffener.- Counter balance joint.- Lock stiffener.

D53Cabriolet

PRS4421

Welding

Photo page 44-13

JOINT WITH THE WHEEL ARCH, BOOT LID RAINCHANNEL AND FRONT LINING

1

Thickness of panels (mm)

Rear lining 0.88Front lining 0.88Rain channel 0.88Outer wheel arch 0.88Inner wheel arch 1.2

Unpicking

A - On the wheel arch:10 spot welds

B - On the boot lid drip moulding:5 spot welds.

C - On the front section:5 spot welds.

Ø D = 6 mm

JOINT WITH THE REAR FLOOR AND LIGHTINGSUPPORT

2

Refer to section: 44-2A

44-38

Page 170: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURETailgate upper rain channel 44 H

95785R

All typesPhase I

The parts supplied by the Parts Department are ofthe phase II type. Consequently, the wiring hole inthe upper rain channel must be closed. (hole (B) on the diagram)

NOTE: For the type of blanking piece to be used,refer to the vehicle PR.

44-39

Page 171: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREOuter wheel arch 44 I

92411S

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of: - bare outer wheel arch- wheel arch stiffener

PRS4422

CUTTING - UNPICKING

92412S

NOTE: the general, procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4.

44-40

Page 172: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREOuter wheel arch 44 I

92414S

92413S

If the quarter panel arch is not to be changed,unpick it from inside the wheel arch.

92415S

Welding

92411-1S

Spot welds (A) are to be unpicked from inside thesill panel.

Joints with:Inner wheel arch

e = 2 mm H = 60 mmBackrest mounting stiffener

e = 2.2 mm H = 60 mmQuarter panel lining

e = 1.4 H = 60 mm

44-41

Page 173: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURE

Outer wheel arch 44 I

92414-1S

92412-1S

D = 5.5 mm

Joints with:Inner wheel arch

e = 2 mm H = 60 mmQuarter panel lining

e = 1.4 mm H = 60 mmQuarter panel arch

e = 1.7 mm H = 60 mmFloor

e =1.4 mm H = 60 mm

If spot welds (A) and (B) cannot be reached by thespot welder, plug weld at D = 5 mm

92415-1S

D = 5.5 mm

e = 1.8 mmH = 60 mm

44-42

Page 174: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREOuter wheel arch 44 I

D53Cabriolet

This operation can only be carried out afterremoval of the wing panel.

Reminder: see 44-A

COMPOSITION OF THE REPLACEMENT PART

- Bare wheel arch.- Stiffener.

PRS4423

JOINT WITH THE SILL PANEL AND INNERWHEEL ARCH

1

Thickness of panels (mm)

Outer wheel arch 0.88Inner wheel arch 1.2Panel lining 0.88Wheel arch stiffener 1.5

Unpicking

31 spot welds.

Welding

Photo page 44-14

Photo page 44-14

Ø D = 6 mm

44-43

Page 175: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete quarter panel arch 44 J

93093S

L53Saloon

COMPOSITION OF THE REPLACEMENT PART

Panel only.

JOINT WITH THE QUARTER PANEL LINING1

Thickness of panels (mm)

Quarter panel arch 0.97Quarter panel lining 0.67Body side upper extender 0.67Side rain channel 0.97

Unpicking

11 spot welds

Welding

- 2 triple layer spot welds

JOINT WITH THE OUTER WHEEL ARCH2

Thickness of panels (mm)

Quarter panel arch 0.97Outer wheel arch 0.67Quarter panel lining 0.67

Unpicking

9 spot welds

PRS4424

44-44

Page 176: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREComplete quarter panel arch 44 J

93093-1S

Welding

L53Saloon

44-45

Page 177: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart quarter panel arch 44 K

PRS4425

This operation is a variation on the previous one.Therefore, only its special points are describedbelow.

COMPOSITION OF THE REPLACEMENT PART

Panel only.

Welding (superposed)

93092S

L53Saloon

44-46

Page 178: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREBackrest mounting stiffener 44 L

PRS4426

L53Saloon

- 2 triple layer spot welds

COMPOSITION OF THE REPLACEMENT PART

Part only.

Thickness of panels (mm)

Stiffener 1.5Quarter panel lining 0.67Wheel arch 0.67

Unpicking

8 spot welds

Welding

93091S

44-47

Page 179: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREOuter wheel arch stiffener 44 M

D53Cabriolet

This operation can only be carried out afterremoval of the wing panel.

Reminder: see 44-A

COMPOSITION OF THE REPLACEMENT PART

- Bare part.

Welding

PRS4428

Photo page 44-15

JOINT WITH THE LIGHTING SUPPORT PANEL1

Thickness of panels (mm)

Stiffener 0.88Wheel arch 0.88Panel lining 0.88

Unpicking

8 spot welds.

44-48

Page 180: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREUpper cross member between wheel arches 44 N

D53Cabriolet

This operation can only be carried out with thehood compartment base partition removed.

COMPOSITION OF THE REPLACEMENT PART

- Cross member.- Stiffening angle brackets.- Boot partition stiffeners.- Backrest locking supports.- Seat belt supports.

PRS4429

Welding

Photo page 44-16

Photo page 44-16JOINT WITH THE WHEEL ARCHES1

Thickness of panels (mm)

Cross member 1.5Inner wheel arch 1.2Wing panel lining 0.88

Unpicking

12 spot welds.Twenty-two 30mm MAG weld fillets.

44-49

Page 181: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURE

Upper cross member between wheel arches 44 N

Note: The 12 spot welds are replaced with plugwelds.

After painting and before refitting the trim,protect the hollow sections with wax.

D53Cabriolet

Welding (cont)

Ø D = 8 mm

Photo page 44-17

44-50

Page 182: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHood compartment base partition 44 O

This operation can only be carried out after remo-val of the hood compartment rear cross memberand the boot lid rain channel.

COMPOSITION OF THE REPLACEMENT PART

- Bare partition.- Lighting support to be ordered separately.

D53Cabriolet

PRS4430

Welding

Ø D = 6 mm

Thickness of panels (mm)

Partition 0.7Cross member 1.5Wing panel lining 0.88

Unpicking

52 spot welds

Photo page 44-18

JOINT WITH THE CROSS MEMBER AND BODYSIDES

1

44-51

Page 183: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHood compartment base partition 44 O

D53Cabriolet

JOINT WITH THE WHEEL ARCHES1

Thickness of panels (mm)

Partition 0.7Wheel arch 1.2

Unpicking

Four 30mm MAG weld fillets.

Welding

PHOTO PAGE 44-19

44-52

Page 184: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHood compartment rear cross member 44 P

This operation is carried out in addition to chan-ging of the boot lid rain channel (previous opera-tion).

COMPOSITION OF THE REPLACEMENT PART

- Bare part

D53Cabriolet

PRS4431

JOINT WITH THE LIGHTING SUPPORT PANEL1

Thickness of panels (mm)

Cross member 1.5Boot partitionRain channel 1.0Wing panel rear lining 0.88

Unpicking

60 spot welds.

Welding

PHOTO PAGE 44-20

Ø D = 6 mm

44-53

Page 185: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREBackrest mounting stiffener 44 Q

PRS4426

L53Saloon

- 2 triple layer spot welds

COMPOSITION OF THE REPLACEMENT PART

Part only.

Thickness of panels (mm)

Stiffener 1.5Quarter panel lining 0.67Wheel arch 0.67

Unpicking

8 spot welds

Welding

93091S

44-54

Page 186: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREJack support (right hand side) 44 R

L53Saloon

COMPOSITION OF THE REPLACEMENT PART

Part only.

Thickness of panels (mm)

Jack support 1.2Quarter panel lining 0.67Outer wheel arch 0.67

Unpicking

3 spot welds

Welding

PRS4427

93090S

44-55

Page 187: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURECentre shelf 44 S

PRS4432

L53Saloon

Welding

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:- bare centre shelf- rear screen lower cross member.

JOINT WITH THE SIDE RAIN CHANNEL1

Reminder: see 44-Y-1

JOINT WITH THE SEAT BELT RETRACTORSUPPORT BRACKET

2

Thickness of panels (mm)

Centre shelf 0.67Rear screen lower cross member 0.67Seat belt retractor support bracket 1.2

Unpicking

4 spot welds

- 4 triple layer spot welds

93103S

93089S

44-56

Page 188: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURECentre shelf 44 S

93087S

L53Saloon

JOINT WITH THE CENTRE SHELF3

Thickness of panels (mm)

Centre shelf 0.67Side shelf 0.97Seat belt retractor support bracket 1.2

Unpicking

24 spot welds

Welding

- 6 triple layer spot welds

93088S

44-57

Page 189: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHalf unit 44 T

PRS4433

L53Saloon

- One 20mm MAG weld fillet- Two 25mm MAG weld fillets

This operation is to be carried out on a body jigbench. Refer to sub-section 40 of the basicmanual.

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:- wing panel,- assembled outer wheel arch,- assembled inner wheel arch,- quarter panel arch,- assembled quarter panel lining,- assembled side rain channel,- lighting support panel,- end panel extender,- assembled side shelf,- backrest mounting stiffener,- jack support (for right hand side only).

JOINT WITH THE SIDE MEMBER CLOSURECOMPONENT

1

Thickness of panels (mm)

Outer wheel arch 0.67Inner wheel arch 1.25Closure component 1.5

Unpicking

3 spot welds

Two 25mm MAG weld filletsFive 20mm MAG weld fillets

Welding

93085S

44-58

Page 190: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHalf unit 44 T

93084S

L53Saloon

Welding

Four 20mm MAG weld fillets

3 triple layer spot welds

JOINT WITH THE REAR FLOOR2

Thickness of panels (mm)

Inner wheel arch 1.25Wing panel 0.67Rear floor 0.60Side member booster 2.00

Unpicking

19 spot welds

Reminder: see 44-A-7

93086S

93109S

44-59

Page 191: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHalf unit 44

92415-1S

L53Saloon

(A) 1 triple layer spot weld to be unpicked usingthe spot weld drill

JOINT WITH THE SILL PANEL3

Thickness of panels (mm)

Wing panel 0.67Sill panel 1.1Outer wheel arch 0.67

Unpicking

6 spot welds

4 spot welds

1 spot weld

One 25 mm brazed weld fillet

WeldingJOINT WITH THE REAR SHELF4

Reminder: see 44-A-9 Reminder: see 44-Y-1

T

93106S 93103S

44-60

Page 192: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHalf unit 44 T

93123S

L53Saloon

Reminder: see 44-S-2

Reminder: see 44-S-3

JOINT WITH THE ASSEMBLED REAR ENDPANEL

5

Reminder: see 41-U-2

JOINT WITH THE END PANEL CROSS MEMBER6

Reminder: see 41-U-1

93089S

93088S

93087S 93125S

44-61

Page 193: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHalf unit 44 T

93097S

L53Saloon

93124S

JOINT WITH THE BODY TOP7

Reminder: see 44-C-1

93098S

93099-1S

Reminder: see 44-A-2

JOINT WITH THE REAR ROOF CROSS MEMBER8

Reminder: see 44-C-2

93117S

44-62

Page 194: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREHalf unit 44 T

93099-4S

L53Saloon

JOINT WITH THE ROOF PANEL9

Reminder: see 44-A-2

93118S

44-63

Page 195: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel 44 U

PRS4434

METHOD 1

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of: - bare end panel- side brackets- striker stiffener

CUTTING - UNPICKING

92364S 92365S

NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4

44-64

Page 196: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel 44 U

Welding

92365-1S

A =

End panel - cross member joint

e = 1.4 mmH = 60 mm

ANTI-CORROSION PROTECTION

e = 1.4 mmH = 60 mm

92364-1S

92366-2S

e = 1.9 mm

44-65

Page 197: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel 44 U

92364-2S

METHOD 2 (end panel with lining)

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of: 1 - bare end panel 2 - lining- side brackets- striker stiffener

CUTTING - UNPICKING

92365-2S

PRS4435

NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4

44-66

Page 198: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel 44 U

92366S

Welding

92367S 92365-3S

e = 1.4 mmH = 60 mm

Fit the lining and make a few retaining spotwelds.

End panel - cross member joint e = 1.9 mm

44-67

Page 199: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel 44 U

92364-3S 92366-1S

92366-2S

e = 1.4 mmH = 60 mm

e = 1.4 mmH = 60 mm

ANTI-CORROSION PROTECTION

44-68

Page 200: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel 44 U

PRS4437

NOTE: the general procedure for changing awelded component is described in WorkshopRepair Manual M.R. 502 section 4

METHOD 3(end panel with lining and lower cross member)

COMPOSITION OF THE REPLACEMENT PART

Assembled part consisting of:- bare end panel- side brackets- striker stiffener- lining- lower cross member

CUTTING - UNPICKING

WELDING

ANTI-CORROSION PROTECTION

92364-5S

92364-4S 92366-2S

44-69

Page 201: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel lining and assembled end panel 44 V

PRS4446

B - C - S53Phase I

The difference between phase I and phase II partsis that the piston switch hole (B) has beendiscontinued. The Parts Department supplies both types of part,with or without hole (B). When a complete body ischanged, the Parts Department will only supplyphase II type bodies on which it will be necessaryto cut hole (B) (see diagram below).

Hole (B), (shaded area) is cut using a powerhacksaw after making two 8mm diameter holes(C).

95788R1

44-70

Page 202: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart end panel cross member 44 W

93123-1S

L53Saloon

Welding

COMPOSITION OF THE REPLACEMENT PART

Panel only

The two blanking pieces (1) must be orderedseparately.

5 spot welds

After welding and before protecting the crimps,fit the 2 metal blanking pieces (1) clipping them inplace with the lugs.

- 1 triple layer spot weld

Special point

Reminder: see 41-U-1

Thickness of panels (mm)

End panel cross member 0.67End panel extender 0.97Rear end panel 0.67

Unpicking

JOINT WITH THE LIGHTING SUPPORT PANEL1

JOINT WITH THE END PANEL EXTENDER2

PRS4438

93125S

93124R

44-71

Page 203: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREPart end panel cross member 44 W

93100S

L53Saloon

PARTIAL CUT3

44-72

Page 204: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel extender 44 X

93123-1S

L53Saloon

Reminder: see 41-U-1

COMPOSITION OF THE REPLACEMENT PART

Panel only

Reminder: see 44-W-2

Thickness of panels (mm)

End panel extender 0.97Rear end panel 0.67

Unpicking

1 spot weld

JOINT WITH THE REAR END PANEL2

93125-1S

PRS4439

JOINT WITH THE END PANEL CROSS MEMBER1

44-73

Page 205: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURERear end panel extender 44 X

93111S

L53Saloon

Welding

Reminder: see 41-V-1

Reminder: see 44-A-6

JOINT WITH THE WING PANEL4

93123-2S

93123-3S

JOINT WITH THE EXTREME REAR CROSSMEMBER

3

44-74

Page 206: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURESide bracket 44 Y

93103S

L53 Saloonexcept Sport

WeldingCOMPOSITION OF THE REPLACEMENT PART

Panel only

Thickness of panels (mm)

Side bracket 0.87Rear screen lower cross member 0.67

Unpicking

One 20mm MAG weld fillet

1 spot weld

2 spot welds

see welding

1 triple layer plug weld after unpicking using aspot weld drill.

Thickness of panels (mm)

Side rain channel 0.87Seat belt retractor support bracket 1.2Quarter panel lining 0.67

Unpicking

11 spot welds

JOINT WITH THE REAR SHELF1

JOINT WITH THE SEAT BELT RETRACTORSUPPORT BRACKET

2

PRS4440

44-75

Page 207: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURESide rain channel 44 Y

93102S

L53 Saloonexcept Sport

3 spot welds

2 triple layer spot welds

Thickness of panels (mm)

Side rain channel 0.87Lighting support panel 0.67

Unpicking

Welding Welding

JOINT WITH THE LIGHTING SUPPORT PANEL3

93101S

44-76

Page 208: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREBoot lid rain channel 44 Z

D53Cabriolet

COMPOSITION OF THE REPLACEMENT PART

- Bare rain channel.- Hood cover lock stiffeners.- Boot lid hinge stiffeners.

PRS4441

JOINT WITH THE HOOD COMPARTMENT REARPARTITION AND BOOT PARTITION

1

Thickness of panels (mm)

Rear partition 1.5Boot base partition 0.7Rain channel 1.0

Unpicking

50 spot welds.

Welding

Photo page 44-21

44-77

Page 209: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTUREBoot lid rain channel 44 Z

D53Cabriolet

JOINT WITH THE WING PANEL AND LIGHTINGSUPPORTS

1

Thickness of the panels (mm)

Rain channel 1.0Wing panel 0.88Lighting support 0.67

Unpicking

54 spot welds.

Welding

PHOTO PAGE 44-22

44-78

Page 210: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURELighting support panel 44 2A

92368-1S

COMPOSITION OF THE REPLACEMENT PART

Bare part

CUTTING - UNPICKING

Welding

92368S

PRS4442

IMPORTANT: unpicking must be carried out fromthe inside.

e = 1.4 mmH = 60 mm

NOTE: the general procedure for changing awelded component is described in WorkshopRepair Manual M.R. 502 section 4

44-79

Page 211: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURELighting support panel 44

PRS4447

B - C - S53Phase I 2A

Hole (B) has been added on phase II vehicles forcentring the rear light. Initially, hole (A) for cen-tring the light on phase I vehicles has been retai-ned but in the future, this will be discontinued forreasons of economy. Consequently, when thephase I light is to be re-used, it will be necessary tocut the upper centring pin in order to fit it to thephase II support.

44-80

Page 212: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURELighting support panel 44D53

Cabriolet 2A

This part can only be changed with its stiffener

COMPOSITION OF THE REPLACEMENT PART

- Bare parts.

The lighting support and its stiffener must beordered at the same time, they each have aseparate part number.

PRS4443

JOINT WITH THE LIGHTING SUPPORT PANEL1

Thickness of panels mm)

Lighting support 0.7Rain channel 1.0Wing panel 0.88End panel 0.7Lighting support stiffener 1.0

Unpicking

42 spot welds.

1 brazed weld filet.

Welding

Photo page 44-23

44-81

Page 213: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURELighting support panel 44D53

Cabriolet 2A

Welding (cont)

Photo page 44-24

Photo page 44-24

44-82

Page 214: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER REAR STRUCTURELighting support panel 44

93113S

L53Saloon 2A

COMPOSITION OF THE REPLACEMENT PART

Part only

Reminder: see 44-2H-3

Reminder: see 44-C-5

Reminder: see 41-V-1

JOINT WITH THE SIDE RAIN CHANNEL1

JOINT WITH THE SIDE PANEL2

JOINT WITH THE END PANEL SIDE MEMBER3

93101S

PRS4444

93125S

44-83

Page 215: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONRoof panel

The roof panel is supplied bare, without crossmember or roof drip moulding.

CUTTING - UNPICKING

45 A

PRS4501

DISMANTLING

Remove:- seats,- interior trims,- windscreen,- tailgate.

PROTECTION

Protect the interior using a cover which is resistantto welding and grinding damage.

3 and 5 DOOR VEHICLES 5 DOOR VEHICLES

92607S 92609S

Roof: front cross member - 13 spot welds

92608-1S

Original welding

92610S

Roof: body side - 14 spot welds Roof: rear cross member - 40 spot welds

45-1

Page 216: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONRoof panel 45 A

92611-1S

3 DOOR VEHICLES

92612S

Roof: body side - 14 spot welds

Original welding

Cut B Cut CCut A

PRS4502 PRS4503 PRS4504

Spot welding

Fillet welding

Brazing

(1) Body side(2) Roof drip moulding(3) Roof panel(4) Rear cross member(5) Quarter panel top(6) Quarter panel upper stiffener(7) Structure bonding mastic (roof drip mouldings and

roof, cross members and roof joints)

45-2

Page 217: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONRoof panel 45 A

92609-1S

3 and 5 DOOR VEHICLES

Repair welding

5 DOOR VEHICLES

92607-1S

92610-1S92608S

45-3

Page 218: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

Cut A

UPPER BODY SECTIONRoof panel 45 A

92611-1S

3 DOOR VEHICLES

PRS4502

Repair welding

Cut B Cut C

PRS4503 PRS4504

D = 4.5 mm

(1) Body side(2) Roof drip moulding(3) Roof panel(4) Rear cross member(5) Quarter panel top(6) Quarter panel upper stiffener(7) Structure bonding mastic (roof drip mouldings

and roof, cross members and roof joints)

NOTE: make a brazed weld at the roof-front pillarupright joint.

92612-1S

45-4

Page 219: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONRoof panel 45 A

93118S

Only special points specific to L53 type vehicleswill be described for this operation. Refer to sec-tion 45-A for other joints.

COMPOSITION OF THE REPLACEMENT PART

Panel only

PRS4501

JOINT WITH THE WING PANEL1

Reminder:see 44-A-1

93126R1

JOINT WITH THE REAR ROOF CROSS MEMBER2

Thickness of panels (mm)

Roof 0.67Roof cross member 0.67Body side upper extender 0.67Quarter panel lining 067

Unpicking

17 spot welds

L53Saloon

45-5

Page 220: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONRoof panel 45 A

93083S

L53Saloon

Welding

- 8 triple layer spot welds

93099-2S

Apply a bead of metal bonding mastic.

45-6

Page 221: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONWindscreen surround 45 B

PRS4506

D53Cabriolet

COMPOSITION OF THE REPLACEMENT PART

- Frame.- Pillar closure panel.- Upper linings.

Welding

For fitting, refer to section 40 "Bodyworkdimensions".

Photo page 45-1

Photo page 45-1

JOINT WITH THE FRONT PILLAR1

Thickness of panels (mm)

Frame 1.0Lining 1.5Front pillar 1.25

Unpicking

98 spot welds.Four 20mm MAG weld fillets.Six 30mm MAG weld fillets.

2 brazed weld fillets.

45-7

Page 222: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONWindscreen frame 45 B

Welding (cont)

D53Cabriolet

Photo page 45-2

PARTIAL CUT2

Photo page 45-2

Photo page 45-2

45-8

Page 223: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONLinings and stiffeners 45 C

PRS4505

Original welding

Joints (1) - (2) - (3) - (4) - (5) - (6)

NOTE: Joint (6): body side roof drip moulding

The repair welding is identical to the originalwelding.

45-9

Page 224: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONWindscreen pillar lining 45 D

This operation is carried out in addition to chan-ging of the windscreen frame.

COMPOSITION OF THE REPLACEMENT PART

Part only.

D53Cabriolet

PRS4507

JOINT WITH THE FRONT PILLAR1

Thickness of panels (mm)

Lining 1.5Front pillar 1.25Frame 1.0

Unpicking

31 spot welds.

Welding

Photo page 45-3

45-10

Page 225: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTION

Windscreen aperture upper cross member 45 E

94955S

This operation is carried out in addition to chan-ging of the windscreen frame.

COMPOSITION OF THE REPLACEMENT PART

Bare part.

D53Cabriolet

Welding

PRS4508

JOINT WITH THE WINDSCREEN APERTUREFRAME

1

Thickness of panels (mm)

Cross member 1.5Pillar lining 1.5Frame 1.0

Unpicking

42 spot welds.Four 30mm MAG weld fillets.

45-11

Page 226: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

UPPER BODY SECTIONRear roof cross member 45 F

93097S

COMPOSITION OF THE REPLACEMENT PART

Panel only

L53Saloon

PRS4509

JOINT WITH THE QUARTER PANEL LINING1

Reminder: see 44-C-2

JOINT WITH THE ROOF2

Reminder : see 45-A-2

93083S

93099-2S

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BODY PROTECTIONSub-frame front protector

Remove the four bolts (1) and detach the protec-tor from the 4 lugs (2).

46 A

PRS4601

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BODY PROTECTIONWheel arch mud shield 46 B

PRS4603

FRONT REAR

PRS4602

46-2

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SIDE OPENINGSDoor hinges

Production fitting

47 A

92308R

(1) Welded hinges(B) 6 mm diameter screw pin fitted on bushes (C)(2) Torx end piece (T40)

After Sales fittingwhen changing a door

PRS4701

Special feature for the electrical wiring in thedoors: to make removal easier without having toremove the trim, there is a connection unit loca-ted in each pillar.

(B) 6 mm diameter screw pin fitted on bushes (C)(C) Special replacement bolted hinge

47-1

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SIDE OPENINGSFront door panel 47 B

PRS4702

PREPARATION BEFORE WELDING

Take a section from the new part which is approxi-mately 50mm larger then that cut from the vehi-cle.

Position the new part on the vehicle so that it issuperposed, then secure it with a vice-gripwrench.

Cut the two layers of metal simultaneously using ahacksaw to facilitate the fit.

Remove the panel and take off the surplus sectionremaining on the door.

COMPOSITION OF THE REPLACEMENT DOORPANEL

92614-1S

(1) Exterior panel(2) Panel stiffener(3) Sound proofing

CUTTING - UNPICKING

92614S

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SIDE OPENINGSFront door panel 47 B

92614-2S

Apply aluminium paint to the area which is to beplug welded.

Apply a bead of metal bonding mastic.

Fit the panel then secure it with a vice-gripwrench.

Gradually crimp the edge of the panel.

D = 4.5 mm

After painting, inject hollow section wax into thedoor, particularly in the welded areas.

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SIDE OPENINGSRear door panel 47 C

92613-1S

PREPARATION BEFORE WELDING

Take a piece from the new part which isapproximately 50mm larger then that cut fromthe vehicle.

Position the new part on the vehicle so that it issuperposed, then secure it with a vice-gripwrench.

Cut the two layers of metal simultaneously using ahacksaw to facilitate the fit.

Remove the panel and take off the surplus sectionremaining on the door.

COMPOSITION OF THE REPLACEMENT DOORPANEL

92333R

1 Exterior panel2 Panel stiffener3 Sound proofing

CUTTING - UNPICKING

92613-2S

Drill out the three resistance spot welds at (A), pa-nel - door inner panel joint.

Remove the damaged section following therecommendations of the previous diagrams (referto the key to symbols).

47-4

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SIDE OPENINGSRear door panel 47 C

92613R

Apply aluminium paint to the area which is to beplug welded.

Apply a bead of metal bonding mastic.

Fit the panel then secure it with a vice-gripwrench.

Gradually crimp the edge of the panel.

D = 4.5 mm

After painting, inject hollow section wax into thedoor, in particular in the welded areas.

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Page 234: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

SIDE OPENINGSFront door - rear door 47 D

PRS4703

The lower side rubbing strip mounting row hasbeen discontinued. Consequently, as the PartsDepartment only supplies phase II type parts, thefollowing must be ordered depending on the typeof rubbing strips in order to refit phase I type rub-bing strips:

- either self adhesive clips (A) for narrow rub-bing strips (see PR),

- or apply 6mm wide double sided adhesivetape to the lower section of wide rubbingstrips (see PR).

All typesPhase I

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Page 235: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBonnet

PARTS RE-USED

48 A

PRS4802

REMOVAL - REFITTING

The bonnet is removed via the four mounting bolts (A) on the strut.

PARTS CHANGED

PRS4803

48-1

Page 236: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBonnet 48 A

PRS4804

ADJUSTMENTS

Carry out in the following order:

1 - Adjusting via the struts

The clearance in mountings (A) allows adjustment of:- the peripheral bonnet clearances, alignment

and backward movement,- the flush fitting (height) of the rear section of

the bonnet with the front wings.

The clearance of mountings (B) allows the rearsection of the bonnet to be moved sidewayswithout altering the height.

2 - Adjusting via the lock

The clearance in lock mounting bolts (C) enablesthe flush fitting (height) of the front of thebonnet to be adjusted.

NOTE: adjustment via the lock must never beused for adjusting the alignment of the bonnetcentreline with the wings. The lock must operatewithout any lateral stress.

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BONNET AND TAILGATETailgate 48 B

92458S

Adjust the peripheral clearances with the roof andthe side panels using the mounting nuts.

REMOVAL

92459R

Remove the rear headlining.

Unclip the counter balances.

Remove the 2 nuts (1).

ADJUSTMENTS

Adjust the flush fitting with the roof using shims(2).

Adjust the flush fitting with the end panel and therear lights using the striker mounting bolts.

92459-1S

PRS4805

48-3

Page 238: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATETailgate 48 B

95787R

The phase I part supplied by the Parts Departmentconsists of a phase II type inner panel and a phaseI type panel. Consequently, for correct sealing, itwill be necessary to close holes (A) and (B) in theinner panel (refer to PR for the part numbers forthe blanking pieces)

B - C - S53Phase II

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Page 239: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBoot lid 48 C

PRS4806

Using the diagram, mark the centrelines of thespoiler mounting points starting from the edge ofthe rear screen wiper hole (A).

Drill the 4 mounting points to a diameter of 8 mm.

Apply sealing mastic to the edge of the holes andfit the spoiler.

From inside the tailgate, fit the 2 mounting stiffe-ners and secure using the 4 nuts.

FITTING THE REAR SPOILER

B - C - S53SPORT

93175R

1 Spoiler2 Mounting stiffener

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Page 240: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBoot lid 48 C

PRS4807

ADJUSTMENT

L53Saloon

(A) Adjustment of the clearances, alignment, backward movement,flush fitting

(B) Lateral adjustment of the rear section(C) Adjustment via the lock

48-6

Page 241: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBoot lid 48 C

PRS4808

On phase II vehicle the "Chamade" badge is nolonger fitted. The parts supplied by the PartsDepartment are specific to each vehicle.

L53 SaloonPhase II

48-7

Page 242: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBoot lid 48 C

L539Saloon

FITTING LIGHTING EXTENDERS AND BADGES

Using the dimensions shown on the diagram below, mark the location of the six mounting holes for the rearlighting extenders and the three mounting holes for the badges.

The holes must be drilled before painting in order to avoid any risk of corrosion.

97748R

A and B Existing holes

DIMENSIONS FOR DRILLING THE REAR LIGHT EXTENDER MOUNTING HOLES

In order to standardise, the Parts Department will only supply undrilled boot lids.

Consequently, if the boot lid is changed on Sport type vehicles (L539), the lighting extender mounting holesmust be drilled by the repairer in line with the recommendations below.

48-8

Page 243: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBoot lid 48 C

PRS4809

D53Cabriolet

94814-1R 94815R

After removing the counter balances, remove thefour bolts (A)

Different adjustments

48-9

Page 244: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBoot lid 48 C

D53Cabriolet

DIMENSIONS FOR DRILLING THE BADGE MOUNTING HOLES

In order to standardise, the Parts Department will only supply phase III boot lids.

Consequently, if the boot lid is to be changed on phase I and II D53 Sport type vehicles, themounting holes for the badges must be drilled by the repairer in line with the recommenda-tions below.

A Existing holes

Using the dimensions shown on the diagram below, mark the location of the 2 + 2 badgemounting holes.

The holes must be drilled before painting in order to avoid any risk of corrosion.

98085R

After painting and before refitting the trim, inject the hollow sections with wax.

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Page 245: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEHood cover panel 48 D

PRS4810

Remove the lock in order to unclip wire ( A )Remove the jacks.

D53Cabriolet

Removal

94793S 94794R

Disconnect the rear screen demisting harness

48-11

Page 246: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEHood cover panel 48 D

94795R

Remove mountings (B).

D53Cabriolet

48-12

Page 247: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATEBroken boot lid counter balance ball joint 48 E

93143R

NOTE: for the general procedure for fitting orchanging a tailgate or boot lid counter balanceball joint, refer to Technical Note n° 258.

L53Saloon

(1) Ball joint part number 77 00 753 309(2) Nut part number 77 01 422 012

93142R

93142-1S

Drilling for the ball joint

93143R1

Cut the ball joint thread to a length of 8 mm.

Before fitting and tightening the ball joint, coatthe thread with Loctite

- SCEL BLOC part number 77 01 394 072or

- SCEL METAL part number 77 01 421 041

48-13

Page 248: apz mecánica automotriz renault 19 carrocería ( sheet metal work )

BONNET AND TAILGATERoof cross member (noise reduction) 48 F

PRS4811

Procedure for cutting the roof noise reduction cross member if an R19 sunroof is to be fitted, for vehicles manufactured from 1st December 1991.

X53All types

1 Checking for the presence of the noise reduction cross member.(the special headlining is fitted with a boss)

2 Mark its location on the jig to be prepared when cutting the roof.

3 The roof and cross member are cut together in a single operationusing a "compass saw" type tool.

IMPORTANT : do not try to cut the roof and cross member separately or touse cross member (A) as a lever as this will deform the roof drip mouldings(B).

4 Before fitting the sun roof, it is essential to:- smooth the cuts,- reapply mastic between the roof and remaining ends of the cross

member (noise reduction function),- apply anti-corrosion protection to all cuts.

48-14