Panels

GENERAL

LOWER STRUCTURE

UPPER SIDE STRUCTURE

UPPER REAR STRUCTURE

OPENINGS OTHER THAN SIDE DOORS

77 11 192 972 FEBRUARY 1997 Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes by the manufacturer in the reference numbering system is forbidden without the prior written authority of
production of the various component units and accessories from which his vehicles Renault.
are constructed".

C Renault 1997
 Bodywork

Contents

Pages

40 GENERAL 44 UPPER REAR STRUCTURE

Opening clearances 40-1 A Hydraulic pump bracket 44-1
Description of parts 40-3 B Rear wing panel 44-2
Sub-frame dimensions 40-5 C Lights bracket 44-7
Central floor 40-6 D Wing panel closing device 44-10
Main bodywork dimensions 40-7 E Right-hand wing panel trim 44-11
F Wing panel trim 44-18
G Rear lights bracket strengthener 44-21
H Wing panel drip moulding 44-23
I Rear end panel assembly 44-27
41 LOWER STRUCTURE J Interior right-hand wheel arch 44-31
K Upper rear floor extender 44-35
A Front jacking pad 41-1 L Lower rear floor extender 44-37
B Sill panel stiffener 41-2 M Rear side member extender 44-39
C Rear seat belt mounting N Hood compartment rear partition
strengthener 41-3 assembly 44-41
D Extreme rear crossmember 41-4

43 UPPER SIDE STRUCTURE

A Windscreen frame 43-1
B Frame upright trim 43-3 48 OPENINGS OTHER THAN SIDE DOORS
C "A" post assembly 43-5
D "A" post trim strengthener 43-8 Boot 48-1
E "A" post trim (scuttle side) 43-9 Hood cover 48-2
F "B" post strengthener 43-10
G "B" post trim with rear section of sill
panel 43-12
H "B" post trim only 43-15
I Wing panel upper front trim
assembly 43-17
J Partial sill panel 43-19
 GENERAL
Opening clearances 40

11632R

40-1
 GENERAL
Opening clearances 40

1 4

12488R

2 12490R

12489R

3 12487R

12491R

40-2
 GENERAL
Description of parts 40

PRS4043

1 Windscreen frame
2 Hood cover lid (composite)
3 Rear end panel assembly
4 Lights bracket
5 Rear wing panel
6 Sill panel
7 "A" post assembly
8 Front jacking pad

40-3
 GENERAL
Description of parts 40

PRS4044

9 Post finisher 19 Hydraulic pump bracket

10 Right-hand panel finisher 20 Left-hand panel finisher
11 Interior right-hand wheel arch 21 Wing panel closing device
12 Lights bracket strengthener 22 Wing panel upper finisher
13 Wing panel drip moulding 23 "B" post strengthener
14 Upper rear floor extender 24 Door sill stiffener
15 Side member extender 25 "A" post trim strengthener
16 Lower rear floor extender 26 Frame upright finisher
17 Hood compartment rear partition 27 Windscreen frame crossmember
18 Interior left-hand wheel arch 28 Seat belt mounting strengthener

40-4
 GENERAL
Sub-frame dimensions 40
DIMENS DIMENSI DIMENS
DESCRIPTION DIAMETER SLOPE
ION X ON Y ION Z

A Front sub-frame rear mounting 203 402.5 71 M 12 0

B Rear axle front mounting 1966 634.12 70 M 12 0
C Front sub-frame front mounting - 593 412 237.5 M 10 0
E Rear shock absorber upper mounting 2194 503.2 (65) 259 M 14 y: 90°
F Front shock absorber upper mounting 15.7 477.8 636.7 8.5 x: 3°45 ; y: 7°
(interior)
Front shock absorber upper mounting 5.5 610.8 654.2 8.5 x: 3°45 ; y: 7°
(exterior)
G Front side member rear end 880 369 7 18.5 x: 1°
H Front side member front end - 547.5 467.4 236.5 10.2 x 12.2 0
J Rear side member rear end G 2826 484.6 231 12.2 0
Rear side member rear end D 2788 483 231 14.5 0
L Extreme rear crossmember (skirt) G 2937 394.5 170 14.25 x: 90° ; y: 10°15
Extreme rear crossmember (skirt) D 2916 397 170 14.25 x: 90° ; y: 12°30
M Crossmember under the central floor 937 375 1.5 14.5 0
Front engine mounting 247 483.5 514 M 10 0
Rear engine mounting 113 483.5 514 M 10 0

99312R1

40-5
 GENERAL
Central floor 40
INTRODUCTION

The central floor of the E64 vehicle is identical to

that of the B64 and about the same length. The
E64 part can be obtained from the B64 part by
cutting the rear section by 112 mm as shown on
the diagram below.

The complete changing of this part is a basic ope-

ration to be carried out in the event of an impact
underneath the vehicle when coming off the
road.

PRM41201-4R
In this case, these additional parts must be orde-
red:
- the tunnel strengthener assembly,
- the instrument panel console bracket and
sheath end.

This part can be partially changed by cutting as

described in the following pages in the event of a
side impact in addition to a sill panel or an "A"
post.

COMPOSITION OF PART

1 Central floor
2 Tunnel strengthener
3 Console bracket
4 Sheath end

PRM41201-3R

40-6
 GENERAL
Main bodywork dimensions 40
NOTE: these dimensions are measured in the centreline of the various welded nuts.

PRE4001

PRE4002

40-7
 GENERAL
Main bodywork dimensions 40

11970 12034

12033 12032

40-8
 LOWER STRUCTURE
Front jacking pad 41 A
INTRODUCTION 1 CONNECTION TO THE FRONT SIDE
CROSSMEMBER
The changing of this part is an additional opera-
tion to the changing of the front side crossmem-
ber. Thickness of the panels concerned (mm)

COMPOSITION OF THE REPLACEMENT PART Front jacking pad 2.5

Side crossmember 1
Part only.

Unpicking

3 MAG weld seams

30 mm long

Welding

PRE4101

11994

41-1
 LOWER STRUCTURE
Sill panel stiffener 41 B
INTRODUCTION Welding

The changing of this part is an additional opera-

tion to the changing of an "A" post or a sill panel
in the event of a side collision.

COMPOSITION OF THE REPLACEMENT PART 12059

Complete part with reel.

NOTE: at (A), welding of 3 thicknesses.

PRE4102

1 CONNECTION TO SILL PANEL CLOSER

12058

Thickness of the panels concerned (mm)

Sill panel stiffener 1.5

Sill panel closer 1.8

Unpicking

77 spot welds on 1.5 mm thickness

41-2
 LOWER STRUCTURE
Rear seat belt mounting strengthener 41 C
INTRODUCTION Welding

The changing of this part is an additional opera-

tion to the changing of the front section of the
rear floor.

COMPOSITION OF THE REPLACEMENT PART

Part only.

12037

A = 90 mm

PRE4103

1 CONNECTION TO THE FRONT SECTION OF THE

REAR FLOOR

Thickness of the panels concerned (mm)

Mounting strengthener 2
Front section of rear floor 0.7
12036

Unpicking

4 MAG weld seams 20 mm long

2 MAG weld seams 15 mm long
3 MAG weld seams 10 mm long

41-3
 LOWER STRUCTURE
Extreme rear crossmember 41 D
INTRODUCTION

The changing of this part is an additional opera-

tion to the changing of a rear end panel assembly.

The edge of the rear panel must be folded back.

11976
COMPOSITION OF THE REPLACEMENT PART

Part only.

PRE4104

11977

41-4
 UPPER SIDE STRUCTURE
Windscreen frame 43 A
INTRODUCTION Welding

The changing of this part is a basic operation to be

carried out in the event of a side collision or rollo-
ver.

This part is partially changed in addition to chan-

ging of the "A" post.

COMPOSITION OF THE REPLACEMENT PART

12079
Part only.

PRE4301

12080
1 CONNECTION TO THE "A" POST

Thickness of the panels concerned (mm)

Frame 1.5
"A" post 1.25

Unpicking

1 MAG weld seam 90 mm long

4 MAG weld seams 30 mm long
1 MAG weld seam 20 mm long

43-1
 UPPER SIDE STRUCTURE
Windscreen frame 43 A
2 CONNECTION TO THE FRAME UPRIGHT Welding
FINISHER

Thickness of the panels concerned (mm)

Opening frame 1.5

Opening finisher 2
Strengthener securing connecting arch 1

Unpicking

112 spot welds 1.5 mm panel thickness 12081

2 MAG weld seams 45 mm long

Partial cut off

150 mm on 1.5 mm thickness

NOTE: at (A), welding of 3 thicknesses.

43-2
 UPPER SIDE STRUCTURE
Frame upright finisher 43 B
INTRODUCTION

The changing of this part is an additional opera-

tion to the changing of the "A" post and the
windscreen frame.

For safety reasons, the finisher must not be cut.

COMPOSITION OF THE REPLACEMENT PART

Part only.

PRE4302

43-3
 UPPER SIDE STRUCTURE
Frame upright finisher 43 B
1 CONNECTION TO THE OPENING LOWER 2 CONNECTION TO THE OPENING UPPER
CROSSMEMBER CROSSMEMBER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Opening finisher 2 Opening finisher 2

Lower crossmember 1.2 Upper crossmember 0.9

Unpicking Unpicking

2 MAG weld seams 30 mm long 2 spot welds on

2 MAG weld seams 20 mm long 2 mm thickness

Welding Welding

12009 12052

43-4
 UPPER SIDE STRUCTURE
"A" post assembly 43 C
INTRODUCTION 1 CONNECTION TO THE SILL PANEL CLOSING
PLATE
The replacement of this part is a basic operation
to be carried out in the event of a front side colli- Thickness of the panels concerned (mm)
sion.
Sill panel 2
It is obtained by cutting the sill panel observing Sill panel stiffener 1.5
the dimensions. Sill panel closer 1.8

For reasons of stability, the strengthener must not

be cut. Unpicking

COMPOSITION OF THE REPLACEMENT PART 14 spot welds on 2 mm thickness

Complete part including:

- "A" post,
- "A" post upper finisher, 345 mm on 2 mm thickness
- strengthener tube,
- "B" post finisher,
- sill panel,
- "B" post finisher strengthener, Welding
- sill panel blanking piece.

NOTE: it is possible to change just the "A" post .

The sill panel must be unpicked.

12050

PRE4303

NOTE: welding of 3 thicknesses.

43-5
 UPPER SIDE STRUCTURE
"A" post assembly 43 C
2 CONNECTION TO THE OPENING FINISHER

Thickness of the panels concerned (mm)

Post upper finisher 1.25

Strengthener securing connecting arch 1
Opening finisher 2

12051 Unpicking

12 spot welds on 1.25 mm thickness

4 spot welds on 1mm thickness

Welding

NOTE: welding of 3 thicknesses.

12003

NOTE: at (A), welding of 3 thicknesses.

43-6
 UPPER SIDE STRUCTURE
"A" post assembly 43 C
3 CONNECTION TO THE POST FINISHER
(SCUTTLE SIDE)

Thickness of the panels concerned (mm)

"A" post 1.5

Post finisher 1.2
Sill panel 2

12054
Unpicking

27 spot welds on 1.5mm thickness

3 MAG plug welds

Welding

12004

NOTE: at (A), welding of 3 thicknesses

at (B), welding of 4 thicknesses

43-7
 UPPER SIDE STRUCTURE
"A" post finisher strengthener 43 D
INTRODUCTION 1 CONNECTION TO THE "A" POST FINISHER
(SCUTTLE SIDE)
The changing of this part is an additional opera-
tion to the changing of the "A" post finisher. Thickness of the panels concerned (mm)

Finisher strengthener 1.5

Post finisher 1.2
COMPOSITION OF THE REPLACEMENT PART

Part only. Unpicking

11 spot welds on 1.5 mm thickness

Welding

PRE4304

11973

43-8
 UPPER SIDE STRUCTURE
"A" post finisher (scuttle side) 43 E
INTRODUCTION

The design of the vehicle is such that the scuttle

side and the "A" post finisher are in one piece.
Also, when one of these parts is changed, the part
supplied by the Parts Department has to be par-
tially cut.

The changing of this part is an additional opera-

tion to changing of the "A" post. On the right-
hand side, the scuttle side upper strengthener,
which must be ordered separately, must also be
changed.

COMPOSITION OF THE REPLACEMENT PART

1 Scuttle side ("A" post finisher)

2 Scuttle side upper strengthener

PRE4305

43-9
 UPPER SIDE STRUCTURE
"B" post strengthener 43 F
INTRODUCTION 1 CONNECTION TO THE SILL PANEL CLOSER

The changing of this part is an additional opera-

tion to the changing of the wing panel. Thickness of the panels concerned (mm)

Post finisher 1.5

Sill panel closer 1.5
COMPOSITION OF THE REPLACEMENT PART

Part only. Unpicking

6 spot welds on 1.5 mm thickness

3 MAG weld seams 20 mm long

Welding

PRE4306

12055

NOTE: welding of 3 thicknesses

43-10
 UPPER SIDE STRUCTURE
"B" post strengthener 43 F
2 CONNECTION TO THE FRONT SECTION OF THE
REAR FLOOR

Thickness of the panels concerned (mm)

Post finisher 1.5

Rear floor 0.7

12041
Unpicking

17 MAG weld seams 40 mm long

10 MAG weld seams 30 mm long
4 MAG weld seams 20 mm long
2 MAG weld seams 10 mm long

200 mm at 1.5 mm thickness

Welding

12042 12091

43-11
 UPPER SIDE STRUCTURE
"B" post finisher with sill panel rear section 43 G
INTRODUCTION

The changing of this part is an additional opera-

tion to the changing of the wing panel.

To maintain stiffness, the strengthener must not

be cut.

NOTE: the "B" post strengthener must be remo-

ved in order to gain access to the interior spot
welds.

It is possible to change just the "B" post finisher.

COMPOSITION OF THE REPLACEMENT PART

Complete part including:

- "A"post,
- "B" post finisher finisher,
- sill panel,
- "B" post finisher strengthener,
- sill panel blanking piece,
- "A" post upper finisher,
- strengthener tube.

PRE4307

43-12
 UPPER SIDE STRUCTURE
"B" post finisher with sill panel rear section 43 G
1 CONNECTION TO THE PANEL FRONT UPPER 2 CONNECTION TO THE PANEL REAR FINISHER
FINISHER ASSEMBLY

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Post finisher 1.5 Sill panel 2

Upper finisher 1.5 Rear finisher 0.9

Unpicking
Unpicking
8 spot welds on 2 mm thickness
10 spot welds on 1.5 mm thickness 1 MAG weld seam 20 mm long
1 MAG weld seam 15 mm long

Welding
Welding

12049
12075

NOTE: at (A), welding of 3 thicknesses.

43-13
 UPPER SIDE STRUCTURE
"B" post finisher with sill panel rear section 43 G
3 CONNECTION TO THE SILL PANEL STIFFENER

Thickness of the panels concerned (mm)

Sill panel 2
Sill panel stiffener 1.5
Sill panel closer 1.8

Unpicking
12043
35 spot welds on 2 mm thickness

3 spot welds on 1.5 mm thickness

345 mm at 2 mm thickness

Welding

NOTE: welding of 3 thicknesses

12048

12048

NOTE: at (A), welding of 3 thicknesses.

43-14
 UPPER SIDE STRUCTURE
"B" post finisher only 43 H
1 CONNECTION TO THE PANEL FRONT UPPER 2 CONNECTION TO SILL PANEL STIFFENER
FINISHER ASSEMBLY

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Post finisher 1.5 Post finisher 1.5

Upper finisher 1.5 Sill panel stiffener 1.5

Unpicking Unpicking

10 spot welds on 1.5 mm thickness 11 spot welds on 1.5 mm thickness

1 MAG weld seam 15 mm long

Welding Welding

12074
12075

12074
12075

NOTE: at (A), welding of 3 thicknesses.

NOTE: at (A), welding of 3 thicknesses.

43-15
 UPPER SIDE STRUCTURE
"B" post finisher only 43 H
3 CONNECTION TO THE REAR SECTION OF THE
SILL PANEL

Thickness of the panels concerned (mm)

Post finisher 1.5

Sill panel 2

Unpicking

12 spot welds on 1.5 mm thickness

Welding

12073

12073

43-16
 UPPER SIDE STRUCTURE
Wing panel front upper finisher assembly 43 I
INTRODUCTION 1 CONNECTION TO THE "B" POST FINISHER

The changing of this part is an additional opera-

tion to the changing of: Thickness of the panels concerned (mm)
- side panel,
- "B" post finisher, Upper finisher 1,5
- side panel finisher. Post finisher 1,5

COMPOSITION OF THE REPLACEMENT PART Unpicking

10 spot welds on 1.5 mm thickness
Complete part including stiffener. 1 MAG weld seam 15 mm long

Welding

PRE4308
12076

12076

43-17
 UPPER SIDE STRUCTURE
Wing panel front upper finisher assembly 43 I
2 CONNECTION TO THE PANEL REAR FINISHER

Thickness of the panels concerned (mm)

Exterior finisher panel 1,5

Interior finisher panel 1,5
Rear finisher 0,9

12077
Unpicking
16 spot welds on 1.5 mm thickness
2 MAG weld seams 20 mm long

Welding

12077

NOTE: at (A), welding of 3 thicknesses.

12078

12078

NOTE: at (A), welding of 3 thicknesses.

43-18
 UPPER SIDE STRUCTURE
Partial sill panel 43 J
INTRODUCTION

The changing of this part is a basic operation to

be carried out in the event of a side impact.

It is obtained by cutting the sill panel observing

the dimensions.

COMPOSITION OF THE REPLACEMENT PART

Part only.

PRE4309

43-19
 UPPER SIDE STRUCTURE
Partial sill panel 43 J
1 CONNECTION TO THE PARTIAL CUT OFFS 2 CONNECTION TO THE SILL PANEL CLOSER AND
STIFFENER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Sill panel 2 Sill panel 2

Sill panel closer 1.8
Sill panel stiffener 1.5

Unpicking Unpicking

27 spot welds on 2 mm thickness

2 x 345 mm at 2 mm thickness

Welding Welding

12056 12057

43-20
 UPPER REAR STRUCTURE
Hydraulic pump bracket 44 A
INTRODUCTION Welding

The replacement of this part is an additional ope-

ration to the changing of the interior wheel arch.

COMPOSITION OF THE REPLACEMENT PART

Part only.
12006

12006

PRE4401

1 CONNECTION TO THE REAR WHEEL ARCH

Thickness of the panels concerned (mm)

Hydraulic pump bracket 1.5 12005

Unpicking

10 MAG weld seams 15 mm long

12005

44-1
 UPPER REAR STRUCTURE
Rear wing panel 44 B
INTRODUCTION 1 CONNECTION TO THE "B" POST FINISHER

The replacement of this part is a basic operation

to be carried out in the event of a rear collision. Thickness of the panels concerned (mm)

Wing panel 0.8

Post finisher 1.5
COMPOSITION OF THE REPLACEMENT PART Interior finisher panel 1.5
Lower inlet side member closing
Part including: plate 1.5
- bumper support plate,
- panel stiffener.
Unpicking

19 spot welds on 0.8 mm thickness

180 mm braze

Welding

PRE4402

12177

NOTE: at (A), welding of 3 thicknesses.

44-2
 UPPER REAR STRUCTURE
Rear wing panel 44 B
2 CONNECTION TO THE LOWER EXTERIOR SIDE 3 CONNECTION TO THE REAR PANEL FINISHER
MEMBER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Wing panel 0.8 Wing panel 0.8

Sill panel 2 Panel finisher 0.9
Sill panel stiffener 1.5 Rear end panel 0.7

Unpicking Unpicking
18 spot welds on 0.8 mm thickness
1 MAG weld seam 75 mm long 38 spot welds on 0.8 mm thickness

30 mm braze
Welding

Welding

12067

12176

NOTE: at (A), welding of 3 thicknesses.

NOTE: at (A), welding of 3 thicknesses.

44-3
 UPPER REAR STRUCTURE
Rear wing panel 44 B
4 CONNECTION TO THE TANK FILLER NECK

Thickness of the panels concerned (mm)

Bracket 0.8
Wing panel 0.9

12174 Unpicking

7 spot welds on 0.8 mm thickness

Welding

12175

12173

44-4
 UPPER REAR STRUCTURE
Rear wing panel 44 B
5 CONNECTION TO THE LIGHTS BRACKET

Thickness of the panels concerned (mm)

Wing panel 0.8

Lights bracket 0.7

Unpicking 12066

8 spot welds on 0.8 mm thickness

3 spot welds on 0.7 mm thickness

Welding

12060

44-5
 UPPER REAR STRUCTURE
Rear wing panel 44 B
6 CONNECTION TO THE WING PANEL DRIP
MOULDING

Thickness of the panels concerned (mm)

Wing panel 0.8

Panel drip moulding 1.25

Unpicking 12008

6 spot welds on 0.8 mm thickness

1 70 mm braze
1 30 mm braze

Welding

12065

12011

12065

44-6
 UPPER REAR STRUCTURE
Lights bracket 44 C
INTRODUCTION 1 CONNECTION TO THE REAR END PANEL

The changing of this part is an additional opera-

tion to the changing of a wing panel or the rear Thickness of the panels concerned
end panel.
Lights bracket 0.7
Rear end panel 0.7
Lights support strengthener 1
COMPOSITION OF THE REPLACEMENT PART

Part only. Unpicking

16 spot welds on 1 mm thickness

Welding

PRE4403

12020

NOTE: at (A), welding of 3 thicknesses.

44-7
 UPPER REAR STRUCTURE
Lights bracket 44 C
2 CONNECTION TO THE WING PANEL DRIP 3 CONNECTION TO THE LIGHTS BRACKET
MOULDING STRENGTHENER
Thickness of the panels concerned (mm)
Thickness of the panels concerned (mm)
Lights bracket 0.7
Lights bracket 0.7 Lights bracket strengthener 1
Panel drip moulding 1.25 Panel drip moulding 1.25

Unpicking

Unpicking 3 spot welds on 0.7 mm thickness

2 spot welds on 0.7 mm thickness

2 spot welds on 1 mm thickness

5 spot welds on 1.25 mm thickness

A 25 mm braze

Welding
Welding

12022
12021

NOTE: at (A), welding of 3 thicknesses

44-8
 UPPER REAR STRUCTURE
Lights bracket 44 C
4 CONNECTION TO THE WING PANEL

Thickness of the panels concerned (mm)

Lights bracket 0.7

Wing panel 0.8

12066
Unpicking

8 spot welds on 0.8 mm thickness

3 spot welds on 0.7 mm thickness

Welding

12060

44-9
 UPPER REAR STRUCTURE
Wing panel closing device 44 D
INTRODUCTION 1 CONNECTION TO THE WING PANEL Finisher

The changing of this part is an additional opera-

tion to the changing of the wing panel finisher. Thickness of the panels concerned (mm)

Closing device 0.75

Panel finisher 0.9
COMPOSITION OF THE REPLACEMENT PART

Part only. Unpicking

10 spot welds on 0.75 mm thickness

1 MAG weld seam 25 mm thickness

Welding

PRE4404

12010

12010

44-10
 UPPER REAR STRUCTURE
Right-hand wing panel finisher 44 E
INTRODUCTION 1 CONNECTION TO THE FRONT UPPER FINISHER
ASSEMBLY
The changing of this part is an additional opera-
tion to the changing of a wing panel. Thickness of the panels concerned (mm)
NOTE: if the sill panel is not changed, a partial cut Panel finisher 0.9
must be made in the lower section of the exterior Upper exterior finisher 1.5
wheel arch. Upper interior finisher 1.5

Unpicking

16 spot welds on 0.9 mm thickness

COMPOSITION OF THE REPLACEMENT PART 2 MAG weld seams 20 mm long

Part only.

Welding

12038

PRE4405

44-11
 UPPER REAR STRUCTURE
Right-hand wing panel finisher 44 E
2 CONNECTION TO THE BOOT CENTRE
PARTITION STRENGTHENER

Thickness of the panels concerned (mm)

Panel finisher 0.9

Partition strengthener 0.75

11995
Unpicking

1 MAG weld seam 35 mm long

Welding

11997

11982

44-12
 UPPER REAR STRUCTURE
Right-hand wing panel finisher 44 E
3 CONNECTION TO THE REAR END PANEL 4 CONNECTION TO THE FLOOR EXTENDER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Panel finisher 0.9 Panel finisher 0.9

Rear end panel 0.7 Upper extender 1
Lower extender 1

Unpicking Unpicking

5 spot welds on 0.9 mm thickness 4 spot welds on 0.9 mm thickness

Welding Welding

12063 12062

NOTE: welding of 3 thicknesses. NOTE: welding of 3 thicknesses.

44-13
 UPPER REAR STRUCTURE
Right-hand wing panel finisher 44 E
5 CONNECTION TO THE HOOD COMPARTMENT
PARTITIONS ASSEMBLIES

Thickness of the panels concerned (mm)

Panel partition 0.9

Boot rear partition 0.7
Boot rear upper connection 1

12024
Unpicking

13 spot welds on 0.9 mm thickness

Welding

12061

11983

44-14
 UPPER REAR STRUCTURE
Right-hand wing panel finisher 44 E
Welding

12023

12064

6 CONNECTION TO THE INTERIOR WHEEL ARCH

Thickness of the panels concerned

NOTE: at (A), welding of 3 thicknesses.
Panel finisher 0.9
Interior wheel arch 0.7
Wheel arch upper section 1

Unpicking

25 spot welds on 2 mm thickness

4 MAG weld seams 35 mm long

11996
12 spot welds on 0.9 mm thickness

44-15
 UPPER REAR STRUCTURE
Right-hand wing panel finisher 44 E
Welding

11998

12040

7 CONNECTION TO THE REAR SIDE MEMBER

ASSEMBLY

Thickness of the panels concerned (mm)

Panel finisher 0.9

Rear side strengthener 0.7

Unpicking

4 spot welds on 0.9 mm thickness

2 MAG weld seams 20 mm long

11981

1 spot welds on 0.7 mm thickness

NOTE: welding of 3 thicknesses.

44-16
 UPPER REAR STRUCTURE
Right-hand wing panel finisher 44 E
8 PARTIAL CUT OFF

Thickness of the panels concerned (mm)

Panel finisher 0.9

Rear side strengthener 0.7

Unpicking

200 mm on 0.9 mm thickness

Welding

12039

44-17
 UPPER REAR STRUCTURE
Wing panel finisher 44 F
INTRODUCTION 1 CONNECTION TO THE HOOD COMPARTMENT
UPPER PARTITION
The changing of this part is an additional opera-
tion to the changing of a wing panel. Thickness of the panels concerned (mm)
NOTE: if the sill panel is not changed, a cut must Panel finisher 0.9
be made in the the lower section of the exterior Upper partition 1
wheel arch. Balancer bracket 1.5

The description of the changing of the left-hand

panel finisher only includes the connections which Unpicking
are different from the changing of the right-hand 4 spot welds on 0.9 mm thickness.
panel finisher. 1 MAG weld seam 20 mm long

1 spot weld on 1.5 mm thickness

COMPOSITION OF THE REPLACEMENT PART

Complete part including including balancer

bracket. Welding

12025

PRE4406

44-18
 UPPER REAR STRUCTURE
Wing panel finisher 44 F
Welding

11990

11988

2 CONNECTION TO THE REAR BOOT PARTITION

Thickness of the panels concerned (mm)

Panel finisher 0.9

Rear boot partition 0.7
12007

Unpicking

12 spot welds on 0.9 mm thickness

44-19
 UPPER REAR STRUCTURE
Wing panel finisher 44 F
3 CONNECTION TO THE INTERIOR WHEEL ARCH 4 CONNECTION TO THE HYDRAULIC PUMP
BRACKET

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Panel finisher 0.9 Panel finisher 0.9

Wheel arch 0.7 Pump bracket 1.5

Unpicking Unpicking

18 spot welds on 0.9 mm thickness 3 MAG weld seams 15 mm long

Welding Welding

11987 11989

44-20
 UPPER REAR STRUCTURE
Rear lights bracket strengthener 44 G
INTRODUCTION 1 CONNECTION TO THE REAR LIGHTS BRACKET

The changing of this part is an additional opera-

tion to the changing of the rear lights bracket. Thickness of the panels concerned (mm)

Rear lights strengthener 1

Rear lights bracket 0.7
Drip panel moulding 1.25
COMPOSITION OF THE REPLACEMENT PART

Part only. Unpicking

5 spot welds on 1 mm thickness

3 spot welds on 0.7 mm thickness

2 spot welds on 1.95 mm thickness

Welding

PRE4407

12085

NOTE: at (A), welding of 3 thicknesses.

44-21
 UPPER REAR STRUCTURE
Rear lights bracket strengthener 44 G
2 CONNECTION TO THE WING Drip panel
moulding

Thickness of the panels concerned (mm)

Rear lights strengthener 1

Rear lights bracket 0.7
Drip moulding panel 1.25

12017
Unpicking

12 spot welds on 1 mm thickness

Welding

12084

NOTE: at (A), welding of 3 thicknesses.

44-22
 UPPER REAR STRUCTURE
Wing Drip panel moulding 44 H
INTRODUCTION

The changing of this part is a basic operation to be

carried out in the event of a rear impact.

In addition to the changing of this part, the rear

light bracket strengthener must also be changed.

The changing of this part is an additional opera-

tion to the changing of the wing panel or a lights
bracket.

COMPOSITION OF THE REPLACEMENT PART

Part only.

PRE4408

44-23
 UPPER REAR STRUCTURE
Wing Drip panel moulding 44 H
1 CONNECTION TO THE WING PANEL 2 CONNECTION TO THE HOOD COMPARTMENT
REAR PARTITION DRIP MOULDING

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Drip panel moulding 1.25 Drip panel moulding 1.25

Wing panel 0.8 D drip moulding partition 1.25
Compartment upper partition 1
Compartment rear partition 0.7

Unpicking
Unpicking
6 spot welds on 0.8 mm thickness
6 spot welds on 1.25 mm thickness

70 mm braze
30 mm braze
3 30 mm brazes

Welding
Welding

12065
12018

NOTE: at (A), welding of 3 thicknesses.

44-24
 UPPER REAR STRUCTURE
Wing Drip panel moulding 44 H
3 CONNECTION TO THE REAR LIGHTS BRACKET
STRENGTHENER

Thickness of the panels concerned (mm)

Drip panel moulding 1.25

Rear lights bracket strengthener 1

Unpicking 11993

9 spot welds on 1.25 mm thickness

Welding

NOTE: at (A), welding of 3 thicknesses.

11992

NOTE: at (A), welding of 3 thicknesses.

44-25
 UPPER REAR STRUCTURE
Wing Drip panel moulding 44 H
4 CONNECTION TO THE REAR LIGHTS BRACKET

Thickness of the panels concerned (mm)

Drip panel moulding 1.25

Rear lights bracket 0.7

Unpicking 11991

7 spot welds on 1.25 mm thickness

25 mm brazes

12019

NOT: at (A), welding of 3 thicknesses.

NOTE: at (A), welding of 3 thicknesses.

44-26
 UPPER REAR STRUCTURE
Rear end panel assembly 44 I
INTRODUCTION 1 CONNECTION TO THE REAR FLOOR UPPER
EXTENDER
The changing of this part is a basic operation to be
carried out in the event of a rear collision. Thickness of the panels concerned (mm)

End panel 0.7

COMPOSITION OF THE REPLACEMENT PART Upper extender 1

Assembled part with:

- end panel, Unpicking
- end panel finisher.

24 spot welds on 0.7 mm thickness

Welding

12070

PRE4409

NOTE: welding of 3 thicknesses.

44-27
 UPPER REAR STRUCTURE
Rear end panel assembly 44 I
2 CONNECTION TO THE REAR FLOOR LOWER 3 CONNECTION TO THE WING PANEL FINISHER
EXTENDER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

End panel 0.7 End panel 0.7

Lower extender 1 Finisher 0.9

Unpicking Unpicking

31 spot welds on 0.7 mm thickness 4 spot welds on 0.7 mm thickness

Welding Welding

12069

12087

NOTE: welding of 3 thicknesses.

44-28
 UPPER REAR STRUCTURE
Rear end panel assembly 44 I
4 CONNECTION TO THE REAR LIGHTS BRACKET 5 CONNECTION TO THE REAR LIGHTS BRACKET
STRENGTHENER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

End panel 0.7 End panel 0.7

Rear lights bracket strengthener 1 Rear lights bracket 0.7
Rear lights bracket 0.7

Unpicking
Unpicking

9 spot welds on 0.7 mm thickness

1 spot weld on 1 mm thickness

7 spot welds on 0.7 mm thickness

Welding

Welding

12088

12086

NOTE: welding of 3 thicknesses.

44-29
 UPPER REAR STRUCTURE
Rear end panel assembly 44 I

12089

NOTE: at (A), welding of 3 thicknesses.

12068

44-30
 UPPER REAR STRUCTURE
Right-hand interior wheel arch 44 J
INTRODUCTION

The changing of this part is an additional opera-

tion to the changing of a wing panel finisher.

COMPOSITION OF THE REPLACEMENT PART

Assembled part with:

- wheel arch upper component,
- interior wheel arch.

PRE4410

44-31
 UPPER REAR STRUCTURE
Right-hand interior wheel arch 44 J
1 CONNECTION TO THE REAR PARTITION 2 CONNECTION TO THE REAR PARTITION
STRENGTHENER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Interior wheel arch 0.7 Wheel arch 0.7

Central boot partition 0.75 Rear partition strengthener 0.75

Unpicking Unpicking

7 spot welds on 0.7 mm thickness 8 spot welds on 0.7 mm thickness

Welding Welding

12098 12097

NOTE: at (A), welding of 3 thicknesses.

44-32
 UPPER REAR STRUCTURE
Right-hand interior wheel arch 44 J
3 CONNECTION TO THE REAR SECTION OF THE 4 CONNECTION TO THE REAR CROSSMEMBER
REAR FLOOR

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Interior wheel arch 0.7 Interior wheel arch 0.7

Rear section of the rear floor 0.75 Rear crossmember 0.8

Unpicking Unpicking

16 spot welds on 0.7 mm thickness 7 spot welds on 0.7 mm thickness

1 MAG spot weld Ø 8 mm
1 MAG weld seam 20 mm long

Welding

Welding

12000

11999

NOTE: at (A), welding of 3 thicknesses.

44-33
 UPPER REAR STRUCTURE
Right-hand interior wheel arch 44 J
5 CONNECTION TO THE HOOD COMPARTMENT
REAR PARTITION

Thickness of the panels concerned (mm)

Upper interior wheel arch 1

Compartment rear upper partition 1
Compartment rear partition 0.7

12096
Unpicking

4 spot welds on 1 mm thickness

9 spot welds on 0.7 mm thickness

Welding

12035

44-34
 UPPER REAR STRUCTURE
Rear floor upper extender 44 K
INTRODUCTION 1 CONNECTION TO THE WING PANEL

The changing of this part is an additional opera-

tion to the changing of a rear end panel assembly. Thickness of the panels concerned (mm)

Rear floor extender 1

Wing panel 0.9
COMPOSITION OF THE REPLACEMENT PART

Part only. Unpicking

2 spot welds on 1 mm thickness

Welding

PRE4411
12095

NOTE: welding of 3 thicknesses.

44-35
 UPPER REAR STRUCTURE
Rear floor upper extender 44 K
2 CONNECTION TO THE REAR CROSSMEMBER 3 CONNECTION TO THE REAR SIDE MEMBER
EXTENDER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Rear floor extender 1 Rear floor extender 1

Rear crossmember 0.8 Rear side member extender 1

Unpicking Unpicking

27 spot welds on 1 mm thickness 4 spot welds on 1 mm thickness

Welding Welding

12094 12093

NOTE: at (A), welding of 3 thicknesses.

44-36
 UPPER REAR STRUCTURE
Rear floor lower extender 44 L
INTRODUCTION 1 CONNECTION TO THE SIDE PANEL

The changing of this part is an additional opera-

tion to the changing of a rear end panel assembly. Thickness of the panels concerned (mm)

Rear floor extender 1

Wing panel 0.7
COMPOSITION OF THE REPLACEMENT PART

Assembled part with strengthener. Unpicking

2 spot welds on 1 mm thickness

Welding

PRE4412
12047

NOTE: welding of 3 thicknesses.

44-37
 UPPER REAR STRUCTURE
Rear floor lower extender 44 L
2 CONNECTION TO THE REAR CROSSMEMBER

Thickness of the panels concerned (mm)

Rear floor extender 1

Rear crossmember 0.8
Strengthener 2.5

12090
Unpicking

36 spot welds on 1 mm thickness

Welding

NOTE: at (A), welding of 3 thicknesses.

12092

NOTE: at (A), welding of 3 thicknesses.

44-38
 UPPER REAR STRUCTURE
Rear side member extender 44 M
INTRODUCTION

The changing of this part is an additional opera-

tion to the changing of a rear end panel assembly.

COMPOSITION OF THE REPLACEMENT PART

Part only.

PRE4413

44-39
 UPPER REAR STRUCTURE
Rear side member extender 44 M
1 CONNECTION TO THE REAR FLOOR EXTENDER 2 CONNECTION TO THE REAR CROSSMEMBER

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Rear side member extender 1 Rear side member extender 1

Rear floor extender 1 Rear crossmember 0.8

Unpicking Unpicking

4 spot welds on 1 mm thickness 7 spot welds on 1 mm thickness

Welding Welding

12046 12045

NOTE: at (A), welding of 3 thicknesses.

44-40
 UPPER REAR STRUCTURE
Hood compartment rear partition assembly 44 N
INTRODUCTION 1 CONNECTION TO THE REAR PARTITION
STRENGTHENER
The changing of this part is an additional opera-
tion to the changing of the side drip moulding or Thickness of the panels concerned (mm)
the interior wheel arch
Compartment rear partition 0.7
Rear partition strengthener 0.85

COMPOSITION OF THE REPLACEMENT PART

Unpicking
Assembled part with:
- compartment rear partition,
- compartment upper rear partition 37 spot welds on 0.7 mm thickness
- central drip moulding,
- hinge strengtheners.

1450 mm at 0.7 mm thickness

Welding

11986

PRE4414

44-41
 UPPER REAR STRUCTURE
Hood compartment rear partition assembly 44 N
Welding

12082

11984

2 CONNECTION TO THE LEFT-HAND REAR SIDE NOTE: triple layer welding (on the left-hand side
PARTITION only).

Thickness of the panels concerned (mm)

Compartment rear partition 0.7

Rear side partition 1.5
Rear partition strengthener 0.85

Unpicking

3 spot welds on 2.25 mm thickness

44-42
 UPPER REAR STRUCTURE
Hood compartment rear partition assembly 44 N
3 CONNECTION TO THE RIGHT-HAND PANEL 4 CONNECTION TO THE RIGHT-HAND INTERIOR
TRIM WHEEL ARCH (UPPER SECTION)

Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)

Compartment upper rear partition 1 Compartment upper rear partition 1

Panel trim 0.9 Wheel arch 1

Unpicking Unpicking

3 spot welds on 0.7 mm thickness 14 spot welds on 0.7 mm thickness

Welding Welding

12014 12083

NOTE: at (A), triple layer welding.

44-43
 UPPER REAR STRUCTURE
Hood compartment rear partition assembly 44 N
5 CONNECTION TO THE LEFT-HAND PANEL TRIM

Thickness of the panels concerned (mm)

Compartment upper rear partition 1

Panel trim 0.9
Balancer bracket 1.5

11979
Unpicking
17 spot welds on 0,7 mm thickness
1 MAG welds seam 20 mm long

1 spot weld on 2.2 mm thickness

Welding

11978

NOTE: at (A), triple layer welding.

44-44
 UPPER REAR STRUCTURE
Hood compartment rear partition assembly 44 N
6 CONNECTION TO THE WING PANEL

Thickness of the panels concerned (mm)

Compartment upper rear partition 1

Wing panel 0.8

Unpicking

3 spot welds on 0.8 mm thickness

Welding

11985

44-45
OPENINGS OTHER THAN SIDE DOORS
Boot 48

PRE4801

12472S

Disconnect and remove the electrical wiring.

Remove the nuts.

NOTE: the light unit must be removed in order to

gain access to the lower mounting bolts. When re-
fitting the struts, seal using preformed mastic for
detachable components.

48-1
 OPENINGS OTHER THAN SIDE DOORS
Hood cover 48

PRE4802

12473S 12474S

Disconnect the electrical wiring.

Separate the rams.

Remove the bolts.

48-2