Professional Documents
Culture Documents
Special Features of The MEGANE Sports Tourer
Special Features of The MEGANE Sports Tourer
Sub-sections concerned: 01C - 03B - 05B - 40A - 41C - 41D - 43A - 44A - 45A - 47A - 48A - 52A - 54A - 55A - 56A - 59A - 71A - 73A
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."
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
03B-1
Rear side member: Description Rear end lower cross member: Description
05B
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
EXTERIOR PROTECTION Rear bumper: Removal Retting Rear bumper: StrippingRebuilding Tailgate strip: Removal Retting
45A
TOP OF BODY Roof: Description Roof panel arch: Description Roof rear cross member: Description 45A-1 45A-3 45A-4
56A
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
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
73A
73A-1
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
01C
01C-2
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
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
01C
105499
105494
(X5) = 3mm
105495
(X3) = 1.5 mm
01C-5
01C
105500
105501
(X9) = 4mm
105498
(X7) = 3mm
01C-6
01C
105493
(X10) = 4.5mm
01C-7
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
03B-1
03B
03B-2
05B
105074
05B-1
05B
105071
05B-2
05B
105077
05B-3
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
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
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
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
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
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
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
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
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
101966
102030
WARNING When performing the cutting operation, protect the B-pillar reinforcement and the lining.
Note: Make the cut (B) below this limit to avoid cutting the expanding insert.
41C-2
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 )
101965
102032
41C-3
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
105047
Note: Make a cut on the outer rear wheel arch to unweld the rear inner sill panel.
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
41C
14580-1
41C-5
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 ).
104273
102666
41D-1
41D
101171
105349
Remove the bolts (2) . Move the wheel arch liner to one side. Remove the bumper mounting bolt (3) .
105348
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
41D
101109
Remove: - the fuel tank mounting bolts (9) , - the funnel lower mounting bolt (10 ) .
101107
101108
101114
Remove the heat shield mounting bolts (8) . Remove the heat shield.
41D-3
41D
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
41D-4
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
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
41D
WARNING On the left-hand side, the cut is made on the original butt welding line.
105052
Complete replacement
102962
105051
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
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
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
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
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
41D
REFITTING
I - REFITTING PREPARATION OPERATION
105345
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.
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
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
43A
104876
104877
43A-2
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.
104879
Part in position
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
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
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
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. 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
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
104429
105044
44A-2
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
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
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
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
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
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
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
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
105969
PARTS CONCERNED (thickness in mm) : - quarter panel lining 0.7 , - shoulder harness reinforcement 1 ,
44A-10
44A
104432
44A-11
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
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
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
For replacement of the rear end panel assembly, remove the two quarter panel lining supports, rear section.
44A-13
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
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
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
45A
105054
105056
105946
Place the roof stiffener cardboard between the roof centre cross member and the roof arch.
45A-2
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
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
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
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
105157
48A-2
48A
105150
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
105158
105154
48A-3
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
48A-4
48A
105171
103917
Disconnect the connector (6) from the wiper motor (if fitted to the vehicle). Disconnect the connector on the tailgate trim.
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
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 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
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
48A
105173
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
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
52A
105170 22815
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 ).
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
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 .
54A-1
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
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
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
106218
Open the rear screen. Remove the spoiler mounting bolts (2) .
54A-4
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
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
55A
101171
Remove the bolts (3 ) from the wheel arch liner. Pull away the wheel arch liners.
104272
104273
105352
Remove: - the rear light mounting bolts, - the rear lights. Disconnect the connectors.
55A-1
55A
105349
105349
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
55A
105345
Remove: - the rear cross member nut (1) , - the rear cross member.
105347
Detach the clips. Remove: - the exterior strip, - the centre strip.
105346
55A-3
55A
105344
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
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
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
55A-6
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
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
105158
105154
56A-1
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
59A
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
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
59A
105163
105164
Remove: - the bolt (8 ) , - the seat belt guide. Partially remove the door seal.
101338
105165
59A-2
59A
105166
105168
Partially remove the luggage compartment seal. Unclip the rear quarter panel trim (11) .
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
59A
59A-4
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
71A
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
71A
105163
105164
Remove: - the bolt (8 ) , - the seat belt guide. Partially remove the door seal.
101338
105165
71A-3
71A
105166
105168
Partially remove the luggage compartment seal. Unclip the rear quarter panel trim (11) .
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
71A
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
101345
Unclip the upper section of the trim (1) . Remove the trim (2) .
71A-5
71A
101338
105165
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
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
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
73A
105157
106022
105150 106029
Note the struts' direction of fitting. Remove the struts (depending on the equipment level), starting at (1) .
73A-1
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