Technical Note586A X84, and K84 Special features of the MEGANE Sports Tourer

MEGANE Sports Tourer: KMXX

Basic manual: MR 365

Sub-sections concerned: 01C - 03B - 05B - 40A - 41C - 41D - 43A - 44A - 45A - 47A - 48A - 52A - 54A - 55A - 56A - 59A - 71A - 73A

Special bodywork features of the MEGANE Sports Tourer.

Edition 2
77 11 319 662 NOVEMBER 2005
All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

Edition Anglaise

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

Renault s.a.s. 2006

Special features of the MEGANE Sports TourerContentsPage

Special features of the MEGANE Sports Tourer

Contents
Page

01C

VEHICLE BODYWORK SPECIFICATIONS Vehicle: Specications Vehicle: Towing and lifting Vehicle clearances: Adjustment values 01C-1 01C-3 01C-4

41C

SIDE LOWER STRUCTURE Sill panel: Description Rear inner sill panel: Description 41C-1 41C-4

41D 03B IMPACT Parts to be replaced according to impact Description

REAR LOWER STRUCTURE Rear oor rear section: Removal - Retting

41D-1 41D-6 41D-8 41D-9 41D-10

03B-1

Rear side member: Description Rear end lower cross member: Description

05B

BODYWORK EQUIPMENT AND TOOLING Body jig bench: Description 05B-1

Far rear lower cross member, side section: Description Rear impact lower cross member: Removal - Retting

40A

GENERAL VEHICLE INFORMATION Sub-frame: Specications Earths on the body: List and location of components Vehicle side section structure: Description Rear structure: Parts description Vehicle removable section structure: Description 40A-1 40A-4 40A-5 40A-6 40A-7 43A SIDE UPPER STRUCTURE Upper body panel: Description Rear roof drip moulding reinforcement: Removal Retting Roof drip moulding lining: Description

43A-1

43A-3 43A-4

Contents

44A

REAR UPPER STRUCTURE Rear wing panel: Description Lights support lining: Description C-pillar closure panel: Description Outer rear wheel arch: Description Rear wheel arch closure panel, front section: Description Rear wheel arch closure panel, rear section: Description Quarter panel lining: Description Quarter panel reinforcement: Description Rear end panel assembly: Description Rear end panel: Description 44A-1 44A-4 44A-5 44A-6

52A

NON-SIDE OPENING ELEMENT MECHANISMS Tailgate lock: Removal Retting Tailgate exterior opening control: Removal - Retting 52A-1 52A-2

54A

WINDOWS Rear quarter panel window: Removal - Retting Rear screen glass: Removal - Retting

44A-8

54A-1 54A-2 54A-4

44A-9 44A-10 44A-12 44A-13 44A-14 55A

Opening rear screen glass: Removal - Retting

EXTERIOR PROTECTION Rear bumper: Removal Retting Rear bumper: StrippingRebuilding Tailgate strip: Removal Retting

55A-1 55A-3 55A-5 55A-6

45A

TOP OF BODY Roof: Description Roof panel arch: Description Roof rear cross member: Description 45A-1 45A-3 45A-4

Roof protective strip: Removal - Retting

56A

EXTERIOR ACCESSORIES Tailgate spoiler: Removal Retting

48A

NON-SIDE OPENING ELEMENTS Tailgate: Adjusting Tailgate: StrippingRebuilding Tailgate: Removal - Retting Fuel ller ap: Removal Retting 48A-1 59A 48A-2 48A-7 48A-9

56A-1

SAFETY ACCESSORIES Rear seat belt: Removal Retting

59A-1

Contents

71A

BODY INTERIOR TRIM Luggage compartment carpet: Removal - Retting Rear wheel arch lining: Removal - Retting C-pillar upper trim: Removal - Retting Rear quarter panel trim: Removal - Retting Rear end panel lining: Removal - Retting

71A-1 71A-2 71A-5 71A-7 71A-8

73A

NON-SIDE OPENING ELEMENT LINING Tailgate lining: Removal Retting

73A-1

VEHICLE BODYWORK SPECIFICATIONS Vehicle: Specifications

01C

103483

Dimensions in metres : (A) (B) (C) (D) (E ) (F) (unladen) (G) (H) 0.842 2.686 0.972 4.500 1.518 1.467 1.514 1.777

Engine Vehicle type Type KM0B KM0H K4J 730 K4J 730 Cubic capacity (cc) 1390 1390 JH3 JH3 Gearbox

01C-1

VEHICLE BODYWORK SPECIFICATIONS Vehicle: Specifications

Engine Vehicle type Type KM0C KM0J KM0J KM0F KM02 KM0U KM0U KM0G KM00 VEHICLE IDENTIFICATION Example: KM0F K : Body type (estate) M : Project code 0F : Engine suffix K4M760 K4M760 K4M761 K9K 722 K9K 728 F4R 770 F4R 771 F9Q 800 F9Q 808 Cubic capacity (cc) 1598 1598 1598 1461 1461 1998 1998 1870 1870 JH3 JH3 DP0 JR5 JR5 ND0 DP0 ND0 ND0 Gearbox

01C

01C-2

VEHICLE BODYWORK SPECIFICATIONS Vehicle: Towing and lifting

REAR Equipment required diagnostic tool

01C

WARNING - See the current towing regulations in each country. - Never use the drive shafts as attachment points. - The towing points may only be used for towing on the road. - Never use the towing points for removing the vehicle from a ditch or to lift the vehicle, either directly or indirectly. Vehicles tted with automatic transmission: - The vehicle should preferably be towed on a platform or by raising the front wheels. If this is not possible, the vehicle may as an exception be towed at a speed below 20 km/h for a maximum distance of 30 km/h (gear selector in N position). Vehicle equipped with RENAULT card: - If the vehicle battery is at, the steering column remains locked. In this event, t a new battery or connect to an electrical supply to lock the airbag computer using the diagnostic tool (see 88C, Airbags and pretensioners, Airbag computer locking procedure ), which unlocks the steering column. If it is not possible to unlock the airbag computer, the front of the vehicle must be lifted.

105148

FRONT

100567

01C-3

VEHICLE BODYWORK SPECIFICATIONS Vehicle clearances: Adjustment values

01C

Section 1 WARNING The clearance values are given for information purposes. When adjusting, certain rules have to be followed: - maintain symmetry with respect to the opposite side, - ensure the ush tting is correct, - check correct operation of the opening, and water/ air-tightness.

115070

105497

(X1) = 4.5 mm

01C-4

VEHICLE BODYWORK SPECIFICATIONS Vehicle clearances: Adjustment values

Section 2 Section 4

01C

105499

(X4) = 1.5 mm Section 5

105496

(X2) = 5.6 mm Section 3

105494

(X5) = 3mm

105495

(X3) = 1.5 mm

01C-5

VEHICLE BODYWORK SPECIFICATIONS Vehicle clearances: Adjustment values

Section 6 Section 8

01C

105500

(X8) = 2.5mm Section 9

105502

(X6) = 4.5mm Section 7

105501

(X9) = 4mm

105498

(X7) = 3mm

01C-6

VEHICLE BODYWORK SPECIFICATIONS Vehicle clearances: Adjustment values

Section 10

01C

105493

(X10) = 4.5mm

01C-7

IMPACT Parts to be replaced according to impact Description

REAR IMPACT 2nd Degree

03B

105843

1st Degree

105846

Rear screen lower cross member Rear lights support Rear outer wheel arch Rear end lower cross member side closure panel Rear impact cross member mounting reinforcement Rear side member closure panel, rear section Sill panel reinforcement, rear section Rear floor, front section with supports 3rd Degree

105844

Rear end panel Rear end panel assembly Rear wing panel

105845

Quarter panel lining

03B-1

IMPACT Parts to be replaced according to impact Description

Rear wing panel rain channel Rear wheel arch closure panel, rear section Rear wheel arch closure panel, front section Inner rear wheel arch Rear side member Rear side member closure panel Centre cross member

03B

03B-2

BODYWORK EQUIPMENT AND TOOLING Body jig bench: Description

05B

105074

05B-1

BODYWORK EQUIPMENT AND TOOLING Body jig bench: Description

05B

105071

05B-2

BODYWORK EQUIPMENT AND TOOLING Body jig bench: Description

05B

105077

05B-3

BODYWORK EQUIPMENT AND TOOLING Body jig bench: Description

05B

102454

CELETTE Special heads for Sytme MZ Order from: CELETTE S.A B.P 38026 VIENNA Montage de base complet pour MEGANE : 896.309

05B-4

GENERAL VEHICLE INFORMATION Sub-frame: Specifications

A et B = rfrentiel de mise en assiette Description A Front sub-frame rear mounting without mechanical components Front sub-frame rear mounting with mechanical components B B1 Rear axle leader pin without mechanical components Rear axle assembly front mounting, without mechanical components Rear axle assembly front mounting, with mechanical components B2 Rear axle assembly front mounting, without mechanical components Rear axle assembly front mounting, with mechanical components C C* E F1 F1* F2 F2* F3 F3* F4 F4* G H Front sub-frame front mounting Front sub-frame front mounting Rear shock absorber upper mounting Front shock absorber upper stop Front shock absorber upper stop Front shock absorber upper stop Front shock absorber upper stop Front shock absorber upper stop Front shock absorber upper stop Front shock absorber mounting leader pin Front shock absorber mounting leader pin Front side member rear leader pin Front side member front leader pin without mechanical components Front side member front leader pin with mechanical parts H* Front side member front leader pin without mechanical components Front side member front leader pin with mechanical parts X 301 301 2208.2 2100 2100 2191 2191 -141.5 141.4 2494 -55.1 82.7 50.7 -24 73.3 -45.4 81.4 -53.9 547 -525 -525 -525 -525 Dimension Y 305 305 -650.8 -635 -635 -732.2 -732.2 -478 477.9 -398 -602.1 601.8 -529.9 530.1 -631.8 632.1 -598.2 597.9 -408.6 -476 -476 492 492 Dimension Z 77.8 6.5 116 116 111 116 111 252 261 262.5 687.3 670.4 672.4 681.4 672.2 686.8 670.4 687.2 -9.8 84.5 80.7 84 80.2 Diameter

40A
Angle % 0 0 0 0 0 0 0 0 0 90 24.5; 12 M12 20.5; 10 M10 M10 M10 M10 M12 M12 10.7; 10 M8 M8 M8 M8 M8 M8 17.2 x 17.2 17.2 x 17.2 20.5 M12 M12 M12 M12 0 0 0 0 0 -

40A-1

GENERAL VEHICLE INFORMATION Sub-frame: Specifications

Description J J* K1 K1* K2 K2* K3 L L* L1 L1* P1 P2 R Rear side member rear leader pin Rear side member rear leader pin Front end cross member Front end cross member Front end cross member Front end cross member Front panel support additional mounting Rear end cross member Rear end cross member Rear end cross member Rear end cross member Engine mounting Engine mounting Additional engine mounting (tie-rod) X 3065 3065 -552.9 -552.2 -546.2 -546-3 -312.9 3363.2 3363.2 3363.2 3363.2 -309.9 -147.9 -35.6 Dimension Y -563.5 563.5 -439.3 447.6 -535.1 533.6 -737 -515 572.2 -612.5 474.7 507 529 452.6 Dimension Z 235 235 410.9 409 276 276 634.5 295 295 197.5 197.5 528.9 531.9 587 Diameter 20x20 20x20 M10 M10 M10 M10 M6 M8 M8 M8 M8 M10 M10

40A
Angle % 0 0 90 90 90 90 9.64 90 90 90 90 0 0 0

14.5; 12

Note: The reference points located on the right-hand side of the vehicle are shown by an asterisk.

40A-2

GENERAL VEHICLE INFORMATION Sub-frame: Specifications

40A

100030

40A-3

GENERAL VEHICLE INFORMATION Earths on the body: List and location of components
IMPORTANT

40A

To avoid damaging the vehicle's electric and electronic components, the battery and the earths of any wiring harness near the weld area must be disconnected. The earth of the welding machine must be placed as close as possible to the weld area. B-GROUND

105466

40A-4

GENERAL VEHICLE INFORMATION Vehicle side section structure: Description

SIDE STRUCTURE

40A

105841

(1 ) : rear door panel (2 ) : Sill panel ( 41C, Lower side structure, Rear door panel ) (3 ) : Upper body ( 43A, Upper side structure, Upper body ) (4 ) : Body side front section ( 5) : Rear roof drip moulding lining ( 43A, Upper side structure, Rear roof drip moulding lining ) (6 ) : Roof panel arch ( 45A, Top of body, Roof panel arch ) ( 7 ) : Roof rear cross member ( 45A, Top of body, Roof rear cross member ) (8 ) : Roof front section (9 ) : Roof ( 45A, Top of body, Roof ) (10) : Rear section of roof ( 45A, Top of body, Rear section of roof )

40A-5

GENERAL VEHICLE INFORMATION Rear structure: Parts description

REAR STRUCTURE

40A

106124

( 1 ) : Rear wing panel ( 44A, Upper rear structure, Rear wing panel ) ( 2) : Far rear lower cross member side section ( 41D, Upper rear structure, Far rear lower cross member side section ) (3 ) : Outer rear wheel arch ( 44A, Upper rear structure, Outer rear wheel arch ) (4 ) : Seatbelt reinforcement (5 ) : Rear quarter upper reinforcement ( 44A, Upper rear structure, Rear quarter upper reinforcement ) (6 ) : Far rear lower cross member (7 ) : Rear end panel assembly ( 44A, Upper rear structure, Rear end panel assembly ) (8 ) : Rear end panel ( 44A, Upper rear structure, Rear end panel ) (9 ) : Rear roof drip moulding reinforcement ( 43A, Upper side structure, Rear roof drip moulding reinforcement ) (10) : Light mounting lining ( 44A, Upper rear structure, Light mounting lining ) (11) : Rear quarter lining mounting

(12) : Rear floor centre cross member (13) : Rear quarter lining ( 44A, Upper rear structure, Rear quarter lining ) (14) : Inner C-pillar ( 44A, upper rear structure, Inner C-pillar ) (15 ) : Rear light mounting ( 44A, Upper rear structure, Rear light mounting ) (16) : Rear side member ( 41D, Upper rear structure, Rear side member ) (17) : Rear side member closure panel, rear section (18) : Rear wheel arch closure panel, front section ( 44A, Upper rear structure, Rear wheel arch closure panel, front section ) (19) : Inner rear wheel arch (20) : Rear wheel arch closure panel, rear section( 44A, Upper rear structure, Rear wheel arch closure panel, rear section )

40A-6

GENERAL VEHICLE INFORMATION Vehicle removable section structure: Description

REMINDER All the relevant sections are indicated opposite each part, to make it easier and quicker to find and consult them. REMOVABLE STRUCTURAL COMPONENTS

40A

105840

(1 ) : Rear side door (see: 47A, Side doors, Rear side door ) ( 2 ) : Rear floor rear section (see: 41D, Rear Lower structure, Rear floor rear section (3 ) : Rear impact cross member (see: 41D, Rear lower structure, Rear impact cross member (4 ) : Tailgate (see: 48A, Non-side doors, Tailgate

40A-7

SIDE LOWER STRUCTURE Sill panel: Description

The replacement of this part is a basic operation for a side impact.

41C

PARTS CONCERNED (thickness in mm): 1 Sill panel 0.9 2 Front jacking point mounting 1.8 3 Rear jacking point mounting 1.8 Order the inserts according to the cuts selected. II - VIEW OF THE POSITION OF THE EXPANDING INSERTS A-pillar

WARNING The information which follows concerns only the descriptions and connections which are specic to the part concerned. The information on the additional parts will be dealt with in the appropriate sections.

Note: In order to carry out this operation, order expanding inserts. The positions of the cuts given in the procedure can be modified according to the severity of impact. Replacement is made by combining cuts (a, b, and c).

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel.

I - COMPOSITION OF THE SPARE PART Assembled part, with: - Rear jacking point - Front jacking point B-pillar
102031

101433

101967

41C-1

SIDE LOWER STRUCTURE Sill panel: Description

Detail of the cut on A-pillar Details of the cut under the door

41C

102033

Note: Make a partial replacement in the area X1 for a localised impact the cut is made in front of the jacking point. This procedure can also be carried out underneath the rear side door. WARNING Beyond this limit, complete coverage by the replacement part is not guaranteed. Detail of the B-pillar cut

102041

Upper cut (A).

101966

102030

WARNING When performing the cutting operation, protect the B-pillar reinforcement and the lining.

Lower cut (B).

Note: Make the cut (B) below this limit to avoid cutting the expanding insert.

41C-2

SIDE LOWER STRUCTURE Sill panel: Description

41C

Partial replacement below front door using cuts ( 3 ,4) WARNING Do not make the cut beyond this limit to avoid damaging the expanding insert during welding. Detail of the rear cut

102033

Note: This procedure can also be carried out underneath the rear side door.
101964

WARNING Avoid making the cut beyond this limit as the impact absorber unit and the expanding insert may be damaged. EXAMPLE OF CUT COMBINATIONS Partial replacement of front using cuts ( 1 , 2 )

Partial rear replacement using cuts ( 5 , 6 , 7 )

101965

WARNING When making the cut, protect the B-pillar reinforcement at ( 6) .

102032

41C-3

SIDE LOWER STRUCTURE Rear inner sill panel: Description

The replacement of this part is linked to the replacement of the sill panel rear reinforcement. The options for replacing this part are as follows: - complete: additional operation to the partial replacement of the lower rear wheel arch and the partial replacement of the B-pillar reinforcement (specific cuts for this operation), - partial: at the rear section along cut (A) in addition to the partial replacement of the lower rear wheel arch (specific cut for this operation). Part in position

41C

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel.

105048

Special note on the replacement of the rear inner sill panel

COMPOSITION OF THE REPLACEMENT PART Part supplied on its own

105047

Note: Make a cut on the outer rear wheel arch to unweld the rear inner sill panel.

Detailed view of cut (a)

105212

Pieces concernes (paisseur en mm) : - 1 Rear inner sill panel 1 - 2 Body side reinforcement front ring 1.2 - 3 Rear quarter lining 0.7 - 4 Centre floor side section 1.2 - 5 Rear sill panel reinforcement 1.4 - 6 B-pillar lower lining 0.7
105046

41C-4

SIDE LOWER STRUCTURE Rear inner sill panel: Description

41C

14580-1

41C-5

REAR LOWER STRUCTURE Rear floor rear section: Removal - Refitting

41D

III - REMOVAL PREPARATION OPERATION Tightening torques m oor mounting bolts 21 Nm Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ).

Note: The replacement of this part is a supplementary operation to the replacement of the end panel for a rear impact, the part should be removed and retted in the event of a fault (e.g. a leak). It is a removable component made from sheetmoulded compound polyester composite material (SMC). In the procedure described below, you will nd details of the operations to be carried out for a complete replacement. For the bonding zones, use preformed sealant mastic (part no.: 77 01 423 330 ). Information on any additional parts will be provided in the respective sections (see contents).

104272

I - REPAIR For repairs to the external panel and box see ( MR 502 ).

II - COMPOSITION OF THE SPARE PART

104273

Remove the lower bolts ( 1) .

102666

Part supplied on its own.

41D-1

REAR LOWER STRUCTURE Rear floor rear section: Removal - Refitting

41D

101171

105349

Remove the bolts (2) . Move the wheel arch liner to one side. Remove the bumper mounting bolt (3) .

Remove the bolts (5 ) .

105348

Unclip the bumper at the side section ( 6) .

105352

Disconnect the rear light connector. Remove: - the nuts ( 4) , - the rear lights.

Remove the bumper (this operation requires two people). Remove: - the luggage compartment carpet, - the emergency spare wheel and the jack.

41D-2

REAR LOWER STRUCTURE Rear floor rear section: Removal - Refitting

41D

101109

Remove: - the fuel tank mounting bolts (9) , - the funnel lower mounting bolt (10 ) .
101107

Remove the mounting bolt (7) and lower the silencer.

IV - OPERATION FOR REMOVAL OF PART CONCERNED

101108

101114

Remove the heat shield mounting bolts (8) . Remove the heat shield.

Remove the floor mounting bolts (11) .

41D-3

REAR LOWER STRUCTURE Rear floor rear section: Removal - Refitting

REFITTING

41D

I - REFITTING PREPARATION OPERATION Preparation of the replacement part

105964

Insert a flat chisel into the rear right-hand corner of the floor.

101113

Remove the remaining cement bead. Using a lint free cloth, clean the surfaces to be bonded with heptane. Apply the sealant mastic as shown in the diagram.
105965

Using the flat chisel carefully lever off the floor.

41D-4

REAR LOWER STRUCTURE Rear floor rear section: Removal - Refitting

Preparing the vehicle

41D

101110

Remove the remaining cement bead. Using a lint free cloth, clean the surfaces to be bonded with heptane.
105349

Note: T o avoid any damage to the mastic bead and to facilitate the positioning of the oor when it is retted, keep the tank away using a wooden block. II - REFITTING OPERATION FOR PART CONCERNED Refit the rear floor rear section (this operation requires two people). Torque tighten the floor mounting bolts ( 21 Nm ) . Note: Remove any visible excess mastic from the vehicle interior and exterior. III - FINAL OPERATION Refit: - the fuel tank mounting bolts, - the funnel lower mounting bolt, - the heat shield, - the heat shield mounting bolts, - the silencer, - the emergency spare wheel and the jack. - the luggage compartment carpet, - the rear bumper (this operation requires two people).

Remove: - the bolts (12) , - the rear lights, - the bumper mounting bolts, - the wheel arch covers. Check that the seal between the floor and subframe is sufficient.

41D-5

REAR LOWER STRUCTURE Rear side member: Description

The replacement of this part is a supplementary operation to the partial replacement of the rear section of the rear floor following a rear impact. In the procedure described below, you will find only the descriptions and connections which are specific to the part concerned. Information on any additional parts will be provided in the respective sections (see contents).

41D

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. The body jig bench must be used. COMPOSITION OF THE SPARE PART Part supplied with: - Rear side member - Bare rear side member-impact cross member connecting component - Rear side member-rear cross member mounting connecting component - Rear cross member-rear side member connecting component - Rear side member connecting component rear reinforcement - Rear end lower cross member - Rear side member reinforcement - Rear side member unit reinforcement connecting component - Rear axle assembly unit - Rear axle mounting reinforcement - Rear axle mounting support - Rear sill lining - Rear sill lining reinforcement - Rear sill - Rear cross member-rear side member connecting component - Rear side member-rear cross member connecting component reinforcement - Rear cups - Rear shock absorber mounting cup - Rear shock absorber mounting reinforcement. PARTS CONCERNED (thickness in mm): 1 Rear inner sill panel 1 2 Quarter panel lining 0.7 3 Inner rear wheel arch 0.7 4 Rear side member closure panel component 0.7 5 Quarter panel lining lower section mounting 0.6 6 Rear cross member 0.7 7 Centre cross member 1 8 Rear axle cross member 1.2 9 Rear floor front section 0.7 10 Seat hinge side mounting reinforcement member 1.65 11 Bead reinforcement 0.9 12 Rear inner wheel arch extension 0.7
102668

41D-6

REAR LOWER STRUCTURE Rear side member: Description

PART IN POSITION

41D

The cutting procedure remains the same as the previous cut.

WARNING On the left-hand side, the cut is made on the original butt welding line.

105052

Complete replacement

102962

105051

Detailed view of cut A

105050

Note: If the impact prevents the side member from being cut at the point shown below, remove the connecting bracket B from the replacement part and weld it in area X1 on the side member (shown below).

41D-7

REAR LOWER STRUCTURE Rear end lower cross member: Description

this part may only be replaced in one way: The complete replacement is a supplementary operation to the replacement of the rear end panel assembly. COMPOSITION OF THE SPARE PART Part supplied on its own

41D

14579

105227

PARTS CONCERNED (thickness in mm): 1 Far rear lower cross member 0.7 2 Far rear lower cross member mounting 0.7 Complete replacement

106267

41D-8

REAR LOWER STRUCTURE

Far rear lower cross member, side section: Description
The replacement of this part is an additional operation to the replacement of the rear end panel assembly. In the procedure described below, you will find only the descriptions and connections which are specific to the part concerned. Information on any additional parts will be provided in the respective sections (see contents). PART IN POSITION

41D

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel.

105049

COMPOSITION OF THE REPLACEMENT PART Part supplied with: - Crimped nut M8

102645

PARTS CONCERNED (thickness in mm): 1 Far rear lower cross member 1 2 Rear quarter lining 0.7 3 Rear inner wheel arch extension 0.7 4 Rear side member 2 5 End panel lining 0.8 6 Rear side member reinforcement 1.5

41D-9

REAR LOWER STRUCTURE

Rear impact lower cross member: Removal - Refitting

41D

Tightening torques m mounting unit mounting bolts cross member xing bolts 35 Nm 21 Nm

Note: The replacement of this part is a basic operation for a rear impact. It is a removable aluminium structural component. In the procedure described below, you will nd only the descriptions and connections which are specic to the part concerned. Information on any supplementary parts will be provided in the respective sections (see contents). Note:
105204

REMOVAL
I - COMPOSITION OF THE SPARE PART Assembled part, with: - Rear end cross member, - Spacer, - Side mounting units, - Bolts, - Nuts.

The cross member contributes to the strength of the structure in the event of an impact. For this reason, it is essential to observe the correct tightening torque after any work on the cross member. II - REMOVAL PREPARATION OPERATION Remove: - the front wheel arch liners (see MR 365 Bodywork, 55A Exterior protection, Wheel arch liner: Removal - Refitting ), - the rear bumper (see MR 365 Bodywork, 55A Exterior protection, Rear bumper: Removal - Refitting ).

41D-10

REAR LOWER STRUCTURE

Rear impact lower cross member: Removal - Refitting
III - OPERATION FOR REMOVAL OF PART CONCERNED

41D

REFITTING
I - REFITTING PREPARATION OPERATION

105345

Remove mounting nuts (1) .

102960

Note: After all interventions necessitating the removal of the mounting units, check the condition of the cross member foam and replace if necessary. Torque tighten the mounting unit mounting bolts ( 35 Nm ) .

105346

II - REFITTING OPERATION FOR PART CONCERNED Refit the rear impact cross member.

Note: Depending on the severity of the impact, it is possible to replace the cross member without removing the mounting units.

Torque tighten the cross member fixing bolts ( 21 Nm ) .

III - FINAL OPERATION Refit: - the rear bumper (see MR 365 Bodywork, 55A Exterior protection, Rear bumper: Removal - Refitting ), - the front wheel arch liners (see MR 365 Bodywork, 55A Exterior protection, Wheel arch liner: Removal - Refitting ).

41D-11

SIDE UPPER STRUCTURE Upper body panel: Description

The options for replacing this part are as follows: - Complete: basic operation for a side impact, - partial: with cuts (A), (B) and (C), basic operation for a side impact. The combination of cuts will be selected according to the deformation (you will find examples at the end of the section). In the procedure described below, you will find only the descriptions and connections which are specific to the part concerned. Information on any supplementary parts will be provided in the respective sections (see contents). Detailed view of cut (a)

43A

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. Note: COMPOSITION OF THE REPLACEMENT PART Make cut (A) in zone (X1). Do not make the cut on the position of the expanding insert.

102006

105205

Part supplied on its own. PARTS CONCERNED (thickness in mm): - 1 Upper body 0.9 - 2 Body side reinforcement front ring 1.2 - 3 B-pillar upper lining 1.5 - 4 Rear roof drip moulding reinforcement 1 - 5 Rear roof drip moulding lining 1 Note: The expanding inserts must be replaced. A-pillar upper expanding insert (B ).
102007

43A-1

SIDE UPPER STRUCTURE Upper body panel: Description

Detailed view of cut (B)

43A

104876

Note: Make cut (B) in zone (X2). Detail of cut (C)

104877

Note: Make cut (C) in zone (X3).

43A-2

SIDE UPPER STRUCTURE

Rear roof drip moulding reinforcement: Removal - Refitting
The replacement of this part is a supplementary operation to replacing the whole body side or upperbody for a side impact or overturning. Information on any supplementary parts will be provided in the respective sections (see contents).

43A

Note: The operation presents no particular difculties.

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel.
104879

Part in position

COMPOSITION OF THE REPLACEMENT PART

105209

Part supplied assembled with captive nut M10 PARTS CONCERNED (thickness in mm): - 1 Body side 0.7 - 2 Body side reinforcement front ring 1.2 - 3 Seatbelt reinforcement 1 - 4 Quarter panel rear reinforcement 1.2 - 5 Quarter panel lining 0.7 - 6 Rear roof drip moulding lining 1 - 7 B-pillar upper lining 1.5

43A-3

SIDE UPPER STRUCTURE Roof drip moulding lining: Description

The replacement of this part is a supplementary operation to replacing the whole body side or upperbody for a side impact or overturning. Information on any supplementary parts will be provided in the respective sections (see contents). PART IN POSITION

43A

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART

104880

105210

Part supplied on its own.

Note: The roof bar mounting housings should be protected during the operation. PARTS CONCERNED (thickness in mm) : - 1 Rear roof drip moulding lining 1 - 2 Rear roof drip moulding reinforcement 1 - 3 B-pillar upper lining 1.5 - 4 Quarter panel lining 0.7

43A-4

REAR UPPER STRUCTURE Rear wing panel: Description

The replacement of this part is a basic operation for a rear side impact. In the procedure described below, you will find only the descriptions and connections which are specific to the part concerned. Information on any additional parts will be provided in the respective sections (see Contents). several locations for cutting are possible: - cut (A) requires removal of the roof, - cuts (B), (D) and (E) avoid the need to reapply the sill panel anti-gravel protection or avoid having to remove the roof, - cut (C) requires reapplying the anti-gravel protection. The combination of cutting points are selected according to the damage.

44A

COMPOSITION OF THE REPLACEMENT PART

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. For the bonded sections, use a structural adhesive of type MCT 514 (part no.: 77 11 172 674 ). Assembled part with door striker plate stiffener PARTS CONCERNED (thickness in mm): - 1 Rear wing panel 0.7 - 2 Rain channel 0.8 - 3 Lights support 0.8 WARNING The wiring harness earths near the weld zone must be disconnected to avoid damaging the electrical and electronic components of the vehicle. The welding machine earth must be placed as close as possible to the weld zone. - 4 Far rear lower cross member 1 - 5 C-pillar closure panel 0.7 - 6 Quarter panel lining 0.7 - 7 Interior quarter panel rear reinforcement 1.2 - 8 Rear roof drip moulding stiffener 1 - 9 Rear roof drip moulding lining 1 - 10 Shoulder harness reinforcement 1 - 11 Sill panel closure panel 1 - 12 Sill panel reinforcement 1.4

105206

Order the expanding inserts according to the cuts selected: - Left-hand side: Expanding insert in quarter panel lining area: 82 00 21 43 98 Expanding insert in quarter panel lining area: 82 00 17 61 52 - Right-hand side: Expanding insert in quarter panel lining area: 82 00 26 27 36 Expanding insert in quarter panel lining area: 82 00 17 61 52

44A-1

REAR UPPER STRUCTURE Rear wing panel: Description

COMPLETE REPLACEMENT

44A

105045

104430

Order the inserts according to the cuts selected. Note: The expanding inserts must be replaced. Detailed view of the expanding insert position Details concerning cut (B)

105042

Details concerning cut (C)

104429

105044

44A-2

REAR UPPER STRUCTURE Rear wing panel: Description

Special note on replacing the rear wing panel

44A

105043

Note: Use a structural adhesive (part no.: 77 11 219 885 ) for the crimping area. Use an M.J.Pro type adhesive to ensure that the seal and fitting of the rear wing panel are correct after crimping.

44A-3

REAR UPPER STRUCTURE Lights support lining: Description

The replacement of this part is a supplementary operation to the replacement of the rear wing panel and the rear lights support following a rear side impact. In the procedure described below, you will find only the descriptions and connections which are specific to the part concerned. Information on any additional parts will be provided in the respective sections (see Contents). The operation presents no particular difficulties.

44A

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.

104868

105216

PARTS CONCERNED (thickness in mm) : - lights support lining 1 , - lights support 0.8 , - C-pillar closure panel 0.7 , - interior quarter panel rear reinforcement 1.2 , - quarter panel lining 0.7 . PART IN POSITION

44A-4

REAR UPPER STRUCTURE C-pillar closure panel: Description

The replacement of this part is a supplementary operation to the replacement of the rear end panel and rear light support following a rear impact. Information on any additional parts will be provided in the respective sections (see contents).

44A

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.

104878

105215

PARTS CONCERNED (thickness in mm) : - C-pillar closure panel 0.7 , - quarter panel lining 0.7 , - interior quarter panel rear reinforcement 1.2 , - lights support lining 1 , - lights support 0.8 , - lower section quarter panel lining support 0.7 , - far rear lower cross member 1 . PART IN POSITION

44A-5

REAR UPPER STRUCTURE Outer rear wheel arch: Description

The options for replacing this part are as follows: - complete, cut (a) additional to the rear wing panel, - partial, cut (b) additional to the sill panel. Detailed view of cut (a)

44A

Note: When replacing this part, it is necessary to order the quarter panel lining and remove the outer rear wheel arch.

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. Information on any additional parts will be provided in the respective sections (see contents). COMPOSITION OF THE REPLACEMENT PART Part supplied with: - the rear parcel shelf bridge piece.

104869

14579

105969

PARTS CONCERNED (thickness in mm): - exterior rear wheel arch (0.7) , - quarter panel lining (0.7) .

44A-6

REAR UPPER STRUCTURE Outer rear wheel arch: Description

Detailed view of cut (b)

44A

104870

Spacing between the spot welds 60 mm . Apply a mastic bead in the corner to perform sealing. Use M.J.Pro mastic (part number: 77 11 172 676 ).

44A-7

REAR UPPER STRUCTURE

Rear wheel arch closure panel, front section: Description
The replacement of this part is a supplementary operation to the partial replacement of the outer wheel arch for a rear side impact. Information on any additional parts will be provided in the respective sections (see contents).

44A

Note: The operations in the procedure are carried out on the left-hand part. The right-hand side of the vehicle has a slightly different shape due to the fuel ller neck, but the replacement method is the same.

105040

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.

105213

PARTS CONCERNED (thickness in mm) : - front section of the rear wheel arch closure panel 0.7 , - rear section of the rear wheel arch closure panel 0.7 , - quarter panel lining 0.7 , - rear wheel arch connecting piece reinforcement 0.7 , - rear side roller mounting interior support 2 , - interior roller support reinforcement 0.7 . PART IN POSITION

44A-8

REAR UPPER STRUCTURE

Rear wheel arch closure panel, rear section: Description
The replacement of this part is a supplementary operation to the partial replacement of the outer wheel arch for a rear side impact. Information on any additional parts will be provided in the respective sections (see contents). PART IN POSITION

44A

Note: The operations in the procedure are carried out on the left-hand part. The right-hand side of the vehicle has a slightly different shape due to the fuel reservoir ller neck, but the replacement procedure is the same.

105041

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.

105214

PARTS CONCERNED (thickness in mm) : - rear section of the rear wheel arch closure panel 0.7 , - front section of the rear wheel arch closure panel 0.7 , - interior rear wheel arch 0.7 , - quarter panel lining 0.7 , - wheel arch extension 0.7 , - rear wheel arch connecting piece reinforcement 0.7 .

44A-9

REAR UPPER STRUCTURE Quarter panel lining: Description

The replacement of this part is supplementary to the replacement of the rear wing panel and the roof panel following a rear side collision. Information on any additional parts will be provided in the respective sections (see contents).

44A

- front section of the rear wheel arch closure panel 0.7 , - rear section of the rear wheel arch closure panel 0.7 , - interior quarter panel rear reinforcement 1.2 , - rear wheel arch connecting piece reinforcement 0.7 , - body side 0.7 ,

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied with: - rear roof drip moulding trim, - rear section body side closure piece, - rear shoulder harness reinforcement, - rear inner/outer wheel arch connecting piece, - rear inner/outer wheel arch rear section connecting piece, - side roller mounting interior support, - rear wheel arch connecting piece reinforcement, - bridge piece for attaching rear side torso airbag, - bare side plate for attaching airbag, - rear centre linkage attachment reinforcement.

- C-pillar closure panel 0.7 , - lights support lining 1 , - rear roof drip moulding stiffener 1 , - rear roof drip moulding lining 1 , - sill panel closure panel 1 , - roof rear arch 0.7 , - far rear lower cross member 1 . PART IN POSITION

104872

Detailed view of the expanding insert position

Note: The expanding inserts must be replaced.

105969

PARTS CONCERNED (thickness in mm) : - quarter panel lining 0.7 , - shoulder harness reinforcement 1 ,

44A-10

REAR UPPER STRUCTURE Quarter panel lining: Description

44A

104432

44A-11

REAR UPPER STRUCTURE Quarter panel reinforcement: Description

The replacement of this part is a complementary operation to the replacement of the light support for a rear impact and the roof panel for overturning. The information on the additional parts will be provided in the corresponding sections (refer to contents).

44A

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied with: - roof bar mounting support, - rear light support lining.
104871

Detailed view of the position of the expanding inserts

Note: The expanding inserts must be replaced.

105211

PARTS CONCERNED (thickness in mm): - interior quarter panel rear reinforcement 1.2 , - roof bar mounting support 2 , - rear light support lining 1 , - rear side rain channel 1.2 , - roof rear cross member 0.8 , - quarter panel lining 0.6 , - rear light support 0.8 . PART IN POSITION
104431

44A-12

REAR UPPER STRUCTURE Rear end panel assembly: Description

The replacement of this part is a basic operation for a rear impact. Information on any additional parts will be provided in the respective sections (see Contents). This operation is complementary to the rear lights support. - light support 0.8 , - light support lining 1 , - rear end cross member 0.7 ,

44A

- rear cross member closure piece 0.7 , - rear side member 1.6 , - rear side member closure panel 0.7 .

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied with: - plain rear end panel, - rear end panel lining, - rear section rear floor mounting reinforcement, - rear cross member closure piece, - rear section quarter panel lining support, - luggage compartment lid striker panel reinforcement, - nut for welding, - M8 captive nut.

PART IN POSITION

104873

REMOVAL

105202

PARTS CONCERNED (thickness in mm) : - rear end panel 0.7 ,

104875

- quarter panel lining support 0.7 , - rear wing panel 0.7 ,

For replacement of the rear end panel assembly, remove the two quarter panel lining supports, rear section.

44A-13

REAR UPPER STRUCTURE Rear end panel: Description

The replacement of this part is a basic operation for a rear impact. Information on any additional parts will be provided in the respective sections (see Contents). PART IN POSITION

44A

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.

104874

105203

PARTS CONCERNED (thickness in mm) : - rear end panel 0.7 , - rear end panel lining 0.8 .

44A-14

TOP OF BODY Roof: Description

The replacement of this part is a basic operation. The procedure presents no particular difficulties. PART IN POSITION

45A

WARNING If the spot welds cannot be made as they were originally using an electrical spot welding machine, these should be replaced with plug welds after holes have been drilled in the rst panel. For bonding areas, use a setting adhesive of type M.J.Pro (part no.: 77 11 172 676 ). In the procedure described below, you will find only the descriptions and connections which are specific to the part concerned.
105055

COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.

105946

To perform this operation, order the roof stiffener cardboard as a supplement. Bonding area

101613

PARTS CONCERNED (thickness in mm): - roof 0.7 , - body side 0.7 , - body side reinforcement front ring 1.2 , - B-pillar upper lining 1.5 , - rear roof drip moulding lining 1 , - rear roof drip moulding stiffener 1 , - quarter panel lining 0.7 , - interior quarter panel rear reinforcement 1.2 , - roof rear cross member 0.8 , - roof front cross member 0.7 .
105053

45A-1

TOP OF BODY Roof: Description

45A

105054

105056

Roof stiffener cardboard

105946

Place the roof stiffener cardboard between the roof centre cross member and the roof arch.

45A-2

TOP OF BODY Roof panel arch: Description

The replacement of this part is a supplementary operation to the roof. PART IN POSITION

45A

Note: The procedure for replacing this part has no specic notes, and joints can all be made as originally. For information purposes, there is a diagram of the part fitted to the vehicle in the procedure. Information on any additional parts will be provided in the respective sections (see Contents). COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.
105059

105207

PARTS CONCERNED (thickness in mm) : - roof arch 0.7 , - quarter panel lining 0.7 , - shoulder harness reinforcement 1 .

45A-3

TOP OF BODY Roof rear cross member: Description

The replacement of this part is a supplementary operation to the roof. PART IN POSITION

45A

Note: The procedure for replacing this part has no specic notes, and joints can all be made as originally. For information purposes, there is a diagram of the part fitted to the vehicle in the procedure. Information on any additional parts will be provided in the respective sections (see Contents). COMPOSITION OF THE REPLACEMENT PART Part supplied with: - plain roof rear cross member, - rear cross member left-hand side lining, - rear cross member right-hand side lining, - two nuts for welding.
105058

105208

PARTS CONCERNED (thickness in mm) : - roof rear cross member 0.8 , - interior quarter panel rear reinforcement 1.2 .

45A-4

NON-SIDE OPENING ELEMENTS Tailgate: Adjusting

Adjustment areas

48A

103921 105968

PRE-ASSEMBLY PREPARATION On the vehicle: Remove: - the end panel interior trim, - the headlining (partially), - the tailgate striker plate. Fit the rear lights. On the replacement tailgate: Fit: - the lock, - the side centre lining stops, - the fuse strip. FITTING THE COMPONENT
103919

Note: Before nal retting, re-seal between the hinges and the tailgate with ller mastic. Finger tighten all the attachments. This operation requires two people. Adjustment procedure

48A-1

NON-SIDE OPENING ELEMENTS Tailgate: Stripping-Rebuilding

Special tooling required Car. 1363 Door mirror removal tool. glass

48A

The replacement of this part is a basic operation for a rear impact. Note: Order an additional set of clips, available from the Par ts Department. For information on the replacement of each component attached to the tailgate, refer to their corresponding sections (see Contents). Two operators are required to hold the tailgate. Details of shut lines can be found in section 01C . Note: Before nal retting, re-seal the hinge support area with ller mastic. COMPOSITION OF THE REPLACEMENT PART Part supplied on its own.

22815

Note: In the event of an electrical fault, open the tailgate manually. Unlock the tailgate lock by pushing lug (1) with a screwdriver. This operation is performed from inside the vehicle. Disconnect the battery.

105201

OPENING DURING A FAULT

105157

Unclip the upper trim by pulling it.

48A-2

NON-SIDE OPENING ELEMENTS Tailgate: Stripping-Rebuilding

48A

105150

Release the lock trim piece.

106029

Unclip the opening rear screen strut (if fitted to the vehicle) by pulling and turning the strut, taking care not to touch the opening panel.

105155

Remove the bolts (2 ) .

105158

Unclip the side trims.

105154

Remove the spoiler mounting bolts (3 ) .

48A-3

NON-SIDE OPENING ELEMENTS Tailgate: Stripping-Rebuilding

48A

105159

Unclip the spoiler upwards. Disconnect the connector from the 3rdbrake light.

106102

Disconnect the hands-free opening button connector (if fitted to the vehicle).

105172

Remove: - the two bolts, - the two clips (4 ) . Unclip the jet. Remove: - the jet, - the 3rd brake light.
105173

Disconnect the de-icer connector ( 5) .

48A-4

NON-SIDE OPENING ELEMENTS Tailgate: Stripping-Rebuilding

48A

105171

103917

Disconnect the connector (6) from the wiper motor (if fitted to the vehicle). Disconnect the connector on the tailgate trim.

Remove the badge using the (Car. 1363)

105156

Remove the tailgate harness and the rear screen washer hose.
104449

Press the hands-free opening button tabs (if fitted to the vehicle).

48A-5

NON-SIDE OPENING ELEMENTS Tailgate: Stripping-Rebuilding

48A

105152

Remove the number plate light mounting. Remove the rear screen glass (see 54A, Windows, Rear screen glass: Removal - Refitting or Opening rear screen glass: Removal - Refitting ).
106102

Remove the hands-free opening button (if fitted to the vehicle).

Remove the tailgate lock (see 52A, Non-side opening element mechanisms, Tailgate lock: Removal - Refitting ).

105151

Remove the mounting bolts (7) from the number plate light mounting.

48A-6

NON-SIDE OPENING ELEMENTS Tailgate: Removal - Refitting

OPENING DURING A FAULT Tightening torques m tailgate mounting bolts 10 Nm

48A

The removal and refitting of this component is a supplementary operation to the replacement of the bodywork or an entire rear wing panel. Note: Order an additional set of clips, available from the Par ts Department. For information on the replacement of each component attached to the tailgate, refer to their corresponding sections (see Contents). Two operators are required to hold the tailgate. Details of shut lines can be found in section 01C .
22815

Note: Before nal retting, re-seal the hinge support area with ller mastic. Note: In the event of an electrical fault, open the tailgate manually. Unlock the tailgate lock by pushing lug (A) with a screwdriver. This operation is performed from inside the vehicle.

REMOVAL
Disconnect the different electrical supply connectors.

48A-7

NON-SIDE OPENING ELEMENTS Tailgate: Removal - Refitting

48A

105173

Remove the tailgate struts (B) .

103920

Remove the tailgate by means of the upper hinge mounting bolts (C) .

REFITTING
Screw on the bolts (C) without tightening them and refit the tailgate (use the former paint and screw marks on the hinges to help you). Torque tighten the tailgate mounting bolts ( 10 Nm ). Connect the different electrical connectors.

48A-8

NON-SIDE OPENING ELEMENTS Fuel filler flap: Removal - Refitting

The replacement of this part is a basic operation for a rear side impact. In the procedure described below, you will only find descriptions of the connections which are specific to the part concerned. Information on any additional parts will be provided in the respective sections (see Contents). It is a removable plastic component. COMPOSITION OF THE REPLACEMENT PART Part supplied on its own (pre-primed).

48A

105967

REPAIR The flap is made from NORYL GTX; for paint products, refer to Technical Note 592A . Note: The fuel ller ap cannot be adjusted during retting; the bolts (B) are simply for removing the fuel ller neck.
105966

REMOVAL
Press gently on the flap with your fingers to release it from the 4 clips (A) and pull it outwards.

REFITTING
Clip the fuel filler flap into place.

48A-9

NON-SIDE OPENING ELEMENT MECHANISMS Tailgate lock: Removal - Refitting

REMOVAL

52A

105170 22815

Remove the bolts (2 ) . Press on the clip (3 ) .

Note: If there is an electrical fault, open the tailgate manually . Unlock the tailgate lock by pushing lug (1) with a screwdriver. This operation is performed from inside the vehicle. Remove the tailgate trim (see 73A, Non-side opening elements trim, Tailgate trim, Removal - Refitting ).

Remove the lock. Disconnect the connector from the lock.

REFITTING
Connect the lock connector. Refit: - the lock, - the tailgate trim (see 73A, Non-side opening elements trim, Tailgate trim, Removal - Refitting ).

52A-1

NON-SIDE OPENING ELEMENT MECHANISMS Tailgate exterior opening control: Removal - Refitting
REMOVAL
Note: It is not necessary to remove the tailgate strip to perform this operation.

52A

105153

Protect the edge of the opening control with masking tape. Unclip the control using a flat-blade screwdriver. Disconnect the connector.

REFITTING
Reconnect the connector. Clip on the tailgate opening control.

52A-2

WINDOWS Rear quarter panel window: Removal - Refitting

REMOVAL
Remove: - the wheel arch trim (see 71A, Body internal trim, Wheel arch trim: Removal - Refitting ). - the rear quarter panel trim (see 71A, Body internal trim, Rear quarter panel trim: Removal - Refitting ).

54A

105567

Position the shims ( 1) . Bond the rear quarter glass. Balance up the clearances and shut lines. Refit: - the rear quarter panel trim (see 71A, Body internal trim, Rear quarter panel trim: Removal - Refitting ). - the wheel arch trim (see 71A, Body internal trim, Wheel arch trim: Removal - Refitting ).

105566

Protect the edge of the quarter panel window using masking tape. Cut the cement bead (this operation requires two people).

Note: Protect the rear quarter glass preformed seal when cutting a cement bead for a bodywork operation. If replacement is required, the rear quarter glass comes supplied with a prefor med seal.

REFITTING
For preparation and bonding, refer to Technical Note 560A, General bonding procedures for windows and sunroof .

WARNING It is essential to use high modulus adhesive to bond the windows.

54A-1

WINDOWS Rear screen glass: Removal - Refitting

REMOVAL
Remove: - the tailgate trim (see 73A, Non-side opening elements trim, Tailgate trim: Removal - Refitting ). - the tailgate spoiler (see 56A, Exterior equipment, Tailgate spoiler: Removal - Refitting ). - the rear screen wiper motor (see Technical Note 3690A, 85A, Washing - Wiping, Rear screen wiper ).

54A

105568

Protect the rear screen surround with masking tape. Cut the cement bead; this operation requires two people.

REFITTING
For preparation and bonding (see Technical Note 560 A, General bonding procedure for windows and sunroof ).

105173

Disconnect the two rear screen de-icing supply terminals (1) . Position the heating circuit strips against the rear screen (to avoid damaging them when cutting the cement bead).

105569

Always replace the shims. Bond the rear screen glass (this operation requires two people).

54A-2

WINDOWS Rear screen glass: Removal - Refitting

54A

105568

Equal out the shut lines and flush-fittings: - rear screen - roof, - rear screen - quarter panel. Refit: - the rear screen wiper motor (see Technical Note 3690A, 85A, Washing - Wiping, Rear screen wiper ), - the tailgate spoiler (see 56A, Exterior equipment, Tailgate spoiler: Removal - Refitting ). - the tailgate trim (see 73A, Non-side opening elements trim, Tailgate trim: Removal - Refitting ).

54A-3

WINDOWS Opening rear screen glass: Removal - Refitting

REMOVAL
Remove the tailgate trim (see 73A, Non-side opening elements trim, Tailgate trim: Removal - Refitting ).

54A

105159

Close the tailgate again. Detach the spoiler upwards. Disconnect: - the high level brake light connector, - the jet pipe.

100077

Remove: - the rear screen wiper arm (see Technical Note 3690A, 85A, Wiping - Washing, Rear screen wiper ), - the nut ( 1) .

106019

Open the tailgate. Disconnect the connector (3 ) .

106218

Open the rear screen. Remove the spoiler mounting bolts (2) .

54A-4

WINDOWS Opening rear screen glass: Removal - Refitting

54A

106217

Disconnect the de-icing supply terminals from the rear screen. Unclip the blanking covers (4) . Separate the tailgate harness. Remove the struts ( 7) .
106030

106020

Remove: - the nut ( 5) , - the windscreen wiper mechanism, - the bolts (6 ) , - the striker plate. Remove: - the bolts (8 ) , - the opening rear screen window (this operation requires two people).
106216

54A-5

WINDOWS Opening rear screen glass: Removal - Refitting

54A

105568

Equal out the shut lines and shut lines. Tighten the opening rear screen bolts. Adjust the rear screen mechanism (see Technical Note 3690A, 85A, Wiping - Washing, Rear screen wiper motor mechanism ). Refit the tailgate trim (see 73A, Non-side opening elements trim, Tailgate trim: Removal - Refitting ).

106214

Mark the position of the stops before removing them. Remove: - the bolts (9 ) , - the stops.

REFITTING

106213

Check that the seals are present before refitting the opening rear screen onto the tailgate.

54A-6

EXTERIOR PROTECTION Rear bumper: Removal - Refitting

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ).

55A

101171

Remove the bolts (3 ) from the wheel arch liner. Pull away the wheel arch liners.
104272

Remove the bumper mounting bolts ( 4) .

104273

Remove the lower bolts (1) and (2) .

105352

Remove: - the rear light mounting bolts, - the rear lights. Disconnect the connectors.

55A-1

EXTERIOR PROTECTION Rear bumper: Removal - Refitting

55A

105349

105349

Remove the bolts (5) .

Refit: - the bolts (7 ) , - the rear lights, - the rear light mounting bolts.

105348

Unclip the bumper at the side section (6) . Remove the bumper (this operation requires two people).
101171

REFITTING
Clip the bumper back in place.

Refit: - the mounting bolts (8) , - the wheel arch liner, - the bolts (9 ) , - the lower mounting bolts.

55A-2

EXTERIOR PROTECTION Rear bumper: Stripping-Rebuilding

STRIPPING
Remove the rear bumper (see 55A, Exterior protection, Rear bumper: Removal - Refitting ). I - SPECIAL NOTE ON REMOVING THE EXTERIOR BUMPER IMPACT STRIP

55A

II - SPECIAL NOTE ON REMOVING THE IMPACT ABSORBERS

105345

Remove: - the rear cross member nut (1) , - the rear cross member.
105347

Detach the clips. Remove: - the exterior strip, - the centre strip.

105346

Remove: - the rivets, - the centre mounting.

55A-3

EXTERIOR PROTECTION Rear bumper: Stripping-Rebuilding

55A

105344

Remove the rivets (2) . Unclip the side mounting.

REASSEMBLING
I - SPECIAL NOTE ON REFITTING THE EXTERIOR BUMPER IMPACT STRIP Clip the impact strips back in place. Refit the rear bumper (see 55A, Exterior protection, Rear bumper: Removal - Refitting )

II - # SPECIAL NOTE ON REFITTING THE IMPACT ABSORBERS Refit: - the side support, - the rivets - the centre support, - the rivets, - the rear cross member, - the rear cross member nut, - the rear bumper (see 55A, Exterior protection, Rear bumper: Removal - Refitting )

55A-4

EXTERIOR PROTECTION Tailgate strip: Removal - Refitting

REMOVAL
Remove the tailgate trim (see 55A, Non-side opening elements trim, Tailgate trim: Removal - Refitting ).

55A

105151

Disconnect the strip wiring harness connector (1) . Remove the nuts (2) . Unclip the strip (3) .

REFITTING
Clip the panel. Fit the mounting nuts. Connect the wiring harness. Refit the tailgate trim (see 55A, Non-side opening elements trim, Tailgate trim: Removal - Refitting ).

55A-5

EXTERIOR PROTECTION Roof protective strip: Removal - Refitting

REMOVAL
Note: The roof trim strips vary, depending on equipment level (sunroof). Removal is the same for both versions.

55A

104318

105353

Note: The roof bar mounting access panels may be replaced and are available individually from the Parts Department .

Remove: - the blanking covers (1) , - the mounting bolts, - the roof bars (depending on the equipment level).

105354

Unclip the roof trim strip ( 2 ) and (3) .

55A-6

EXTERIOR PROTECTION Roof protective strip: Removal - Refitting

55A

105356

Note: The trim strip retaining clips may be replaced and are available individually from the Parts Department .

REFITTING

105355

Position the trim strip at the rear. Insert the front section of the trim strip under the windscreen seal. Clip the trim strip along its whole length. Refit: - the roof bars (depending on the equipment level), - the mounting bolts.

55A-7

EXTERIOR ACCESSORIES Tailgate spoiler: Removal - Refitting

REMOVAL

56A

II - SPECIAL NOTE ON REMOVING THE SPOILER ON VERSIONS WITH OPENING REAR SCREEN

105157

Unclip the centre trim. I - SPECIAL NOTE ON REMOVING THE SPOILER ON VERSIONS WITH FIXED REAR SCREEN
106029

Remove the rear screen struts, starting at section (1) .

105158

Unclip the side trim panels.

105158

Unclip the side trim panels.

105154

Remove the spoiler mounting bolts.

56A-1

EXTERIOR ACCESSORIES Tailgate spoiler: Removal - Refitting

56A

106218

105172

Open the rear screen. Remove the bolts (2) . Note: The remainder of the removal procedure is identical for both versions.

Remove: - the bolts, - the clips (3) . Unclip the jet pipe. Remove: - the jet, - the high level brake light.

REFITTING
Clip the high level brake light onto the spoiler. Refit: - the jet, - the jet pipe, - the high level brake light mounting bolts. Connect the high level brake light connector. Clip the spoiler onto the vehicle.
105159

Refit: - the spoiler mounting bolts, - the side trim panels, - the struts (depending on the equipment level), - the centre trim.

Detach the spoiler upwards. Disconnect the high level brake light connector.

56A-2

SAFETY ACCESSORIES Rear seat belt: Removal - Refitting

59A

Equipment required diagnostic tool

Tightening torques m inertia reel mounting bolt seat belt mounting bolts 21 Nm 21 Nm

REMOVAL

IMPORTANT Before carrying out any work on or near safety system components, it is essential to lock the airbag computer using the diagnostic tool. When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel is lit continuously (ignition on).

101345

Unclip the upper section of the trim ( 1) . Remove the trim ( 2) .

IMPORTANT Handling pyrotechnic systems (airbags or pretensioners) near to a source of heat or ame is forbidden: there is a risk of triggering the airbags or pretensioners.

IMPORTANT After a pyrotechnic component has been triggered, certain parts must be replaced (see 88C Airbags and pretensioners, Airbags and pretensioners: Precautions during repair). Lock the airbag computer using the diagnostic tool (see 88C, Airbags and pretensioners, Airbag computer locking procedure ). Disconnect the battery starting with the positive terminal (see 80A, Battery: Removal - Refitting ). Move the front seat as far forward as possible. Remove the bench seat base Unclip: - the clip (3) using an unclipping tool - the trim at ( 4) and (5 ) .
101347

59A-1

SAFETY ACCESSORIES Rear seat belt: Removal - Refitting

59A

105163

105164

Unclip trim (6) .

Remove: - the bolt (8 ) , - the seat belt guide. Partially remove the door seal.

101338

Remove the seat belt lower mounting bolt (7) .

105165

Unclip the C-pillar trim ( 9) and (10) .

59A-2

SAFETY ACCESSORIES Rear seat belt: Removal - Refitting

59A

105166

105168

Partially remove the luggage compartment seal. Unclip the rear quarter panel trim (11) .

Pull the inner trim off the wheel arch.

105167

Unclip the luggage compartment light. Disconnect the luggage compartment lighting connector. Remove the bolts (12) . Release the rear parcel shelf trim.
105169

Disconnect the connector (13) . Remove: - the inertia reel bolt (14) , - the inertia reel.

REFITTING
Refit the inertia reel. Tighten to torque the inertia reel mounting bolt ( 21 Nm ) .

59A-3

SAFETY ACCESSORIES Rear seat belt: Removal - Refitting

Refit: - the connector on the inertia reel, - the rear parcel shelf trim, - the bolts, - the luggage compartment light connector, - the rear quarter panel trim, - the luggage compartment seal, - the C-pillar trim, - the seat belt guide, - the seat belt lower mounting. Torque tighten the seat belt mounting bolts ( 21 Nm ) . Refit: - the rear door sill upper trim, - the rear door sill trim, - the rear bench seat base. - the B-pillar lower trim. Connect the battery, starting with the positive terminal (see 80A, Battery: Removal - Refitting ). Unlock the airbag computer using the diagnostic tool (see 88C, Airbags and pretensioners, Airbag computer locking procedure ).

59A

59A-4

BODY INTERIOR TRIM Luggage compartment carpet: Removal - Refitting

REMOVAL

71A

105160

Remove: - the velcro strip, - the christmas tree clips, - the luggage compartment carpet.

REFITTING
Remove: - the luggage compartment carpet, - the velcro strip, - the christmas tree clips.

71A-1

BODY INTERIOR TRIM Rear wheel arch lining: Removal - Refitting

71A

Equipment required diagnostic tool

Tightening torques m seat belt mounting bolts 21 Nm

REMOVAL

IMPORTANT Before carrying out any work on or near a safety system component, lock the airbag computer using the diagnostic tool . When this function is activated, all the trigger lines are disabled and the airbag instrument panel warning light is lit when the ignition is switched on. Unclip the upper section of the trim ( 1) . IMPORTANT Handling the pyrotechnic systems (airbags or pretensioners) near to a heat source or ame is prohibited: there is a risk of triggering the airbags or pretensioners. Lock the airbag computer using the diagnostic tool (see 88C, Airbags and pretensioners, Airbag computer locking procedure ). Disconnect the battery starting with the positive terminal (see 80A, Battery: Removal - Refitting ). Move the front seat as far forward as possible. Remove the trim ( 2) .

101345

101347

Remove the bench seat base. Unclip: - the clip (3) using an unclipping tool, - the trim at ( 4) and (5 ) .

71A-2

BODY INTERIOR TRIM Rear wheel arch lining: Removal - Refitting

71A

105163

105164

Unclip the trim at (6) .

Remove: - the bolt (8 ) , - the seat belt guide. Partially remove the door seal.

101338

Remove the seat belt lower mounting bolt (7) .

105165

Unclip the C-pillar trim ( 9) and (10) .

71A-3

BODY INTERIOR TRIM Rear wheel arch lining: Removal - Refitting

71A

105166

105168

Partially remove the luggage compartment seal. Unclip the rear quarter panel trim (11) .

Remove the rear wheel arch trim.

REFITTING
Refit: - the rear parcel shelf trim, - the bolts, - the luggage compartment light connector, - the luggage compartment light, - the rear quarter panel trim, - the luggage compartment seal, - the C-pillar trim,
105167

- the seat belt guide, - the seat belt lower mounting. Torque tighten the seat belt mounting bolts ( 21 Nm ) . Refit: - the rear door sill upper trim, - the rear door sill trim, - the rear bench seat base, - the B-pillar lower trim. Connect the battery, starting with the positive terminal (see 80A, Battery: Removal - Refitting ). Unlock the airbag computer using the diagnostic tool (see 88C, Airbags and pretensioners, Airbag computer locking procedure ).

Unclip the luggage compartment light. Disconnect the luggage compartment lighting connector. Remove the bolts (12) . Release the rear parcel shelf trim.

71A-4

BODY INTERIOR TRIM C-pillar upper trim: Removal - Refitting

71A

Equipment required diagnostic tool

Tightening torques m seat belt mounting bolts 21 Nm

REMOVAL

IMPORTANT Before carrying out any work on or near a safety system component, it is essential to lock the airbag computer using the diagnostic tool . When this function is activated, all the trigger lines are disabled and the airbag instrument panel warning light is lit when the ignition is switched on. Lock the airbag computer using the diagnostic tool (see 88C, Airbags and pretensioners, Airbag computer locking procedure ). Disconnect the battery starting with the positive terminal (see 80A, Battery: Removal - Refitting ). Move the front seat as far forward as possible.

101347

Remove the bench seat base. Unclip: - the clip (3) using an unclipping tool, - the trim at ( 4) and (5 ) .

105163

Unclip the trim at (6 ) .

101345

Unclip the upper section of the trim (1) . Remove the trim (2) .

71A-5

BODY INTERIOR TRIM C-pillar upper trim: Removal - Refitting

71A

101338

105165

Remove the seat belt lower mounting bolt (7) .

Unclip the C-pillar trim ( 9) and (10) .

REFITTING
Refit: - the C-pillar trim, - the seat belt guide, - the seat belt lower mounting. Torque tighten the seat belt mounting bolts ( 21 Nm ) . Refit: - the rear door sill upper trim, - the rear door sill trim, - the rear bench seat base, - the B-pillar lower trim. Connect the battery, starting with the positive terminal (see 80A, Battery: Removal - Refitting ).
105164

Remove: - the bolt (8 ) , - the seat belt guide. Partially remove the door seal.

Unlock the airbag computer using the diagnostic tool (see 88C, Airbags and pretensioners, Airbag computer locking procedure ).

71A-6

BODY INTERIOR TRIM Rear quarter panel trim: Removal - Refitting

REMOVAL

71A

105166

Partially remove the luggage compartment seal. Unclip the rear quarter panel trim (1) .

REFITTING
Clip the rear quarter panel trim. Refit the luggage compartment seal.

71A-7

BODY INTERIOR TRIM Rear end panel lining: Removal - Refitting

REMOVAL

71A

105162

Remove: - The blanking covers ( 1) , - the bolts, - the striker panel trim piece (2) , - the luggage compartment seal partially.

105161

Unclip the rear end panel trim by pressing the clips (3) .

REFITTING
Reattach the trim. Refit: - the bolts, - the blanking covers, - the luggage compartment seal.

71A-8

NON-SIDE OPENING ELEMENT LINING Tailgate lining: Removal - Refitting

REMOVAL

73A

105157

Release the central trim.

106022

Unclip the side trim panels.

105150 106029

Unclip the lock trim piece.

Note the struts' direction of fitting. Remove the struts (depending on the equipment level), starting at (1) .

73A-1

NON-SIDE OPENING ELEMENT LINING Tailgate lining: Removal - Refitting

73A

106024

Remove the trim mounting bolts (2) . Remove the tailgate trim.

REFITTING
Refit: - the tailgate trim, - the trim bolts, - the lock trim piece, - the side trim panels, - the struts (depending on the equipment level), - the centre trim.

73A-2