Elemente Caroserie Duster

8/12/2019 Elemente Caroserie Duster

1/136

Renault s.a.s 2007

"The repair procedures given by the manufacturer in this document are based on the

technical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".

All rights reserved by Renault.

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

NOVEMBER2009 EDITION ANGLAISE

X79

4 Panelwork

40A GENERAL INFORMATION

41A FRONT LOWER STRUCTURE

41B CENTRE LOWER STRUCTURE

41C SIDE LOWER STRUCTURE

41D REAR LOWER STRUCTURE

42A FRONT UPPER STRUCTURE

43A SIDE UPPER STRUCTURE

44A REAR UPPER STRUCTURE

45A TOP OF BODY

47A SIDE OPENING ELEMENTS

48A NON-SIDE OPENING ELEMENTS


2/136

DUSTER - Chapitre 4

Contents

Pages

DUSTER - Chapitre 4ContentsPages

40A GENERAL INFORMATION

Subframe: Specifications 40A-1

Earths on body: List andlocation of components 40A-5

Vehicle structure, sidesection: Description 40A-8

Vehicle structure, centresection: Description 40A-10

Vehicle structure, rearsection: Description 40A-12

Vehicle structure, removablesection: Description 40A-14


Front end lower crossmember: Replacement 41A-1

Front end side crossmember: Replacement 41A-2

Front side member, frontsection: Replacement 41A-3

Front section of front sidemember closure panel:Replacement 41A-7

Battery tray mounting:Replacement 41A-9

Engine mounting:Replacement 41A-10

Front subframe frontmounting unit: Replacement 41A-11

Front half-unit: Replacement 41A-12

41B CENTRE LOWER STRUCTURE

Centre floor, side section:Replacement 41B-1

Centre side member:Replacement 41B-5

41C SIDE LOWER STRUCTURE

Sill panel: Replacement 41C-1

Sill panel closure panel:Replacement 41C-6

Sill panel reinforcement:Replacement 41C-10

Sill panel stiffener:Replacement 41C-14

Sill panel rear reinforcement:Replacement 41C-18



3/136

Contents

41D REAR LOWER STRUCTURE

Rear floor reinforcement:Replacement 41D-1

Rear floor, front section:Replacement 41D-2

Rear side member assembly:Replacement 41D-4

Rear side member:Replacement 41D-6

Front upper cross member:Replacement 41D-7

Rear floor front cross

member: Replacement 41D-8

Rear floor centre crossmember: Replacement 41D-10

Rear floor, rear section:Replacement 41D-11

Rear floor, rear side section:Replacement 41D-14

Rear towing eye:Replacement 41D-15

Exhaust mounting support:Replacement 41D-16


Front panel: Replacement 42A-1

Front wing: Removal -Refitting 42A-2

Scuttle side panel:Replacement 42A-4

Scuttle side panel upperreinforcement: Replacement 42A-6

Front wheel arch, frontsection: Replacement 42A-7

Heater bulkhead:Replacement 42A-8

Windscreen aperture lowercross member: Replacement 42A-10

Dashboard cross member:Removal - Refitting 42A-11

Headlight carrier panel:Replacement 42A-15

43A SIDE UPPER STRUCTURE

A-pillar reinforcement:Replacement 43A-1

Windscreen pillar lining:

Replacement 43A-3

B-pillar reinforcement:Replacement 43A-4

B-pillar lining: Replacement 43A-5

B-pillar lower lining:Replacement 43A-6

Body side, front section:Replacement 43A-7

Roof bar mounting:

Replacement 43A-12

44A REAR UPPER STRUCTURE

Rear wing panel:Replacement 44A-1

Rear light mounting:Replacement 44A-6

Light mounting lining:

Replacement 44A-7

Quarter panel lining:Replacement 44A-8

Rear half-unit: Replacement 44A-9

Rear end panel:Replacement 44A-11

Rear end panel lining:Replacement 44A-12



4/136

Contents

45A TOP OF BODY

Roof: Replacement 45A-1

Roof front cross member:Replacement 45A-3

Roof centre cross member:Replacement 45A-4

Roof panel arch:Replacement 45A-5

47A SIDE OPENING ELEMENTS

Front side door: Removal -Refitting 47A-1

Front side door: Stripping -rebuilding 47A-3

Front side door: Adjustment 47A-4

Rear side door: Removal -Refitting 47A-6

Rear side door: Stripping -rebuilding 47A-8

Rear side door: Adjustment 47A-9

Fuel filler flap cover:Removal - Refitting 47A-11

48A NON-SIDE OPENING ELEMENTS

Bonnet: Removal - Refitting 48A-1

Bonnet: Stripping -

Rebuilding 48A-2

Bonnet: Adjustment 48A-3

Tailgate: Removal - Refitting 48A-5

Tailgate: Stripping -Rebuilding 48A-7

Tailgate: Adjustment 48A-8


5/13640A-1

GENERAL INFORMATION

Subframe: Specifications 40A

145388


6/13640A-2

GENERAL INFORMATION


145387


7/13640A-3

GENERAL INFORMATION


4x2 version

145386

No. Description Dimen-sion X(mm)

Dimen-sion Y(mm)

Dimen-sion Z(mm)

Diameter(mm)

Angle

A Left front subframe rear mounting with-out mechanical components

301 305 78 24.7-M12 0

Ao Right front subframe rear mountingwithout mechanical components

301 305 78 24.7x29.6-M12

0

A Left front subframe rear mounting withmechanical components

301 305 -28 Bolt head 0

Ao Right front subframe rear mounting withmechanical components

301 305 -28 Bolt head 0

B Rear side member front leader pin 1838 622 74 30x30 0

B1 Left-hand rear axle fixing leader pinwithout mechanical components

2200 600 118.5 16.2 0

B1o Right-hand rear axle fixing leader pin

without mechanical components

2200 600 118.5 16.2x24.2 0

B2 Rear axle rear mounting withoutmechanical components

2230 516 114.5 Bolt head 0


8/13640A-4

GENERAL INFORMATION


A and B = vehicle trim height reference

C Left front subframe front mounting with-out mechanical components

-502 476 82 M12 0

Co Right front subframe front mountingwithout mechanical components

-525 492 82 M12 0

C Left front subframe front mounting withmechanical components

-502 476 -5.5 Bolt head 0

Co Right front subframe front mountingwith mechanical components

-525 492 -5.5 Bolt head 0

E Rear shock absorber upper mounting 2672.25 562.5 532.5 18.2 X: 8

Y: 0

F Front shock absorber upper mounting -3 583.5 683 48 x: 035

y: 340

G Front side member rear leader pin, cen-tre section

721 409 -8.5 20x50 0

J Rear side member rear leader pin 2809 485.5 259.5 16.2x32.2 0

K Front left end lower cross member -698 565.5 314.75 14.5 90

Ko Front right lower end cross member -698 566.5 314.75 12.2x16.2 90

K1 Front upper cross member -504 555 656 10.2x12.2 0

K2 Bumper mountings -421 732 403 12x12 0

K3 Headlight mounting 581.5 420.5 458.3 8.2x16.2 90

L Rear left rear end cross member 3300 580 325 20.5 90

LO Rear right rear end cross member 3300 580 325 20x50 90

P1 Engine mountings 1 -310 492.5 491.5 M10 180

P2 Engine mountings 2 -150 514.5 491.5 M10 180

Q1 Gearbox mountings 1 -283 429.5 368 M10 X: 0

y: 90

Z: 4

Q2 Gearbox mountings 2 -254 427.3 320.5 M10 X: 0

y: 90

Z: 4

No. Description Dimen-sion X(mm)

Dimen-sion Y(mm)

Dimen-sion Z(mm)

Diameter(mm)

Angle


9/13640A-5

GENERAL INFORMATION

Earths on body: List and location of components 40AFor the earth stud fitting procedure (see ) (MR400,40H, Bolted connections).

145384


10/13640A-6

GENERAL INFORMATION

Earths on body: List and location of components 40A

DETAILED VIEW OF THE EARTH POSITIONS ONTHE VEHICLE

Earth studs on:

- the front left-hand end side cross member (1) ,

- the front end panel upper cross member mounting (2),

- the battery tray bracket (3) ,

- the left-hand shock absorber cup height adjuster (4) .

145385

145380

145379


11/13640A-7

GENERAL INFORMATION

Earths on body: List and location of components 40AEarth studs on:

- the right-hand shock absorber cup height adjuster (5),

- the front right-hand end side cross member (6) .

Earth stud on the tunnel (7) .

Earth stud on left-hand light mounting lining (8) .

Earth stud on right-hand light mounting lining (9) .

145383

145382

145381


12/13640A-8

GENERAL INFORMATION

Vehicle structure, side section: Description 40A

145372

No. Description Reference

(1) Sill panel (see 41C, Side lower structure, Sill panel: Replacement, page41C-1)

(2) Body side, front section (see 43A, Side upper structure, Body side, front section:Replacement, page 43A-7)

(3) Sill panel reinforcement (see 41C, Side lower structure, Sill panel reinforcement:Replacement, page 41C-10)

(4) Sill panel rear reinforce-ment

(see 41C, Side lower structure, Sill panel rear reinforcement:Replacement, page 41C-18)

(5) B-pillar reinforcement (see 43A, Side upper structure, B-pillar reinforcement:Replacement, page 43A-4)

(6) Sill pane stiffener (see 41C, Side lower structure, Sill panel stiffener: Replace-ment, page 41C-14)

(7) A-pillar reinforcement (see 43A, Side upper structure, A-pillar reinforcement:Replacement, page 43A-1)

(8) Double seal mounting (see 43A, Side upper structure, Body side, front section:

Replacement, page 43A-7)


13/13640A-9

GENERAL INFORMATION

Vehicle structure, side section: Description 40A

(9) Windscreen pillar lining (see 43A, Side upper structure, Windscreen pillar lining:Replacement, page 43A-3)

(10) B-pillar lining (see 43A, Side upper structure, B-pillar lining: Replacement,page 43A-5)

(11) B-pillar lower lining (see 43A, Side upper structure, B-pillar lower lining: Replace-ment, page 43A-6)

(12) Roof bar mounting (see 43A, Side upper structure, Roof bar mounting: Replace-ment, page 43A-12)

(13) Roof rear cross member (see )

(14) Roof panel arch (see 45A, Top of body, Roof panel arch: Replacement, page45A-5)

(15) Roof centre cross member (see 45A, Top of body, Roof centre cross member: Replace-ment, page 45A-4)

(16) Roof front cross member (see 45A, Top of body, Roof front cross member: Replace-ment, page 45A-3)

(17) Roof (see 45A, Top of body, Roof: Replacement, page 45A-1)



14/13640A-10

GENERAL INFORMATION

Vehicle structure, centre section: Description 40A

145374


(1) Sill panel closure panel (see 41C, Side lower structure, Sill panel closure panel:Replacement, page 41C-6)

(2) Centre floor, side section (see 41B, Centre lower structure, Centre floor, side section:Replacement, page 41B-1)

(3) Centre side member (see 41B, Centre lower structure, Centre side member:Replacement, page 41B-5)

(4) Front cross member under frontseat

(see )

(5) Front seat rear mounting sup-port

(see )

(6) Front section of rear floor sidereinforcement

(see 41D, Rear lower structure, Rear floor, front section:Replacement, page 41D-2)

(7) Rear floor, front section (see 41D, Rear lower structure, Rear floor, front section:Replacement, page 41D-2)

(8) Rear floor front cross member (see 41D, Rear lower structure, Rear floor front cross mem-ber: Replacement, page 41D-8)


15/13640A-11

GENERAL INFORMATION

Vehicle structure, centre section: Description 40A

(9) Centre floor reinforcement (see )

(10) Windscreen aperture lower

cross member

(see 42A, Front upper structure, Windscreen aperture lower

cross member: Replacement, page 42A-10)

(11) Heater bulkhead (see 42A, Front upper structure, Heater bulkhead: Replace-ment, page 42A-8)



16/13640A-12

GENERAL INFORMATION

Vehicle structure, rear section: Description 40A4x2 version

145376


(1) Rear wing panel (see 44A, Rear upper structure, Rear wing panel: Replace-ment, page 44A-1)

(2) Rear half unit (see 44A, Rear upper structure, Rear half-unit: Replacement,page 44A-9)

(3) Rear floor, side section (see 41D, Rear lower structure, Rear floor, rear side section:Replacement, page 41D-14)

(4) Exhaust mounting support (see 41D, Rear lower structure, Exhaust mounting support:Replacement, page 41D-16)

(5) Rear side member (see 41D, Rear lower structure, Rear side member: Replace-ment, page 41D-6)

(6) Rear side member assem-bly

(see 41D, Rear lower structure, Rear side member assembly:Replacement, page 41D-4)

(7) Rear towing eye (see 41D, Rear lower structure, Rear towing eye: Replace-ment, page 41D-15)

(8) Quarter panel lining (see 44A, Rear upper structure, Quarter panel lining:

Replacement, page 44A-8)


17/13640A-13

GENERAL INFORMATION

Vehicle structure, rear section: Description 40A

(9) Light mounting lining (see 44A, Rear upper structure, Light mounting lining:Replacement, page 44A-7)

(10) Rear light mounting (see 44A, Rear upper structure, Rear light mounting:Replacement, page 44A-6)

(11) Rear end panel (see 44A, Rear upper structure, Rear end panel: Replace-ment, page 44A-11)

(12) Rear end panel lining (see 44A, Rear upper structure, Rear end panel lining:Replacement, page 44A-12)

(13) Rear floor, rear section (see 41D, Rear lower structure, Rear floor, rear section:Replacement, page 41D-11)

(14) Rear floor reinforcement (see 41D, Rear lower structure, Rear floor reinforcement:

Replacement, page 41D-1)

(15) Rear floor centre crossmember

(see 41D, Rear lower structure, Rear floor centre cross mem-ber: Replacement, page 41D-10)



18/13640A-14

GENERAL INFORMATION

Vehicle structure, removable section: Description 40A

145373


(1) Bonnet (see 48A, Non-side opening elements, Bonnet:Removal - Refitting, page 48A-1)

(2) Front wing (see 42A, Front upper structure, Front wing:Removal - Refitting, page 42A-2)

(3) Dashboard cross member centre plate (see 42A, Front upper structure, Dashboardcross member: Removal - Refitting, page 42A-

11)

(4) Dashboard cross member (see 42A, Front upper structure, Dashboardcross member: Removal - Refitting, page 42A-11)

(5) Front side door (see 47A , Side opening elements, Front sidedoor: Removal - Refitting, page 47A-1)

(6) Rear side door (see 47A, Side opening elements, Rear sidedoor: Removal - Refitting, page 47A-6)

(7) Fuel filler flap cover (see 47A, Side opening elements, Fuel filler

flap cover: Removal - Refitting, page 47A-11)

(8) Tailgate (see 48A, Non-side opening elements, Tail-gate: Removal - Refitting, page 48A-5)


19/13641A-1

FRONT LOWER STRUCTURE

Front end lower cross member: Replacement 41AI - COMPOSITION OF THE SPARE PART

II - IN THE EVENT OF REPLACEMENT

There is only one way of replacing this part:

- complete replacement.

Locate the earths located near to the weld area (see40A, General information, Earths on body: List andlocation of components, page 40A-5) .

Complete replacement

Part in positionNo. Description Thickness

(mm)

(1) Front end lower crossmember

1.45

WARNING

If the mating faces of the parts to be welded are notaccessible, use a GMAW plug weld in place of theoriginal electrical resistance weld (see ) (MR 400,40C, Gas metal arc welded connections (GMAW)).

WARNING

To avoid damaging the vehicles electric and elec-tronic components, the earths of any wiring harnessnear the weld area must be disconnected.

Position the earth of the welding machine as close

as possible to the weld area (see ) (MR 400, 40H,Bolted connections).

144792


20/13641A-2


Front end side cross member: Replacement 41AI - COMPOSITION OF THE SPARE PART






Part in position

Left-hand side

Right-hand side

No. Description Thickness(mm)

(1) Front end side crossmember

1.20

WARNING


WARNING




144794

144793


21/13641A-3


Front side member, front section: Replacement 41AI - COMPOSITION OF THE SPARE PART

Left-hand side

Right-hand side


The options for replacing this part are as follows:

- Complete replacement

- partial replacement section A-B.

144786


(1) Front side member front

section

1.25

(2) Engine - gearbox assem-bly suspension rear rein-forcement on body

2.5

(3) Engine - gearbox assem-bly suspension front rein-forcement on body

2.5

(4) Front subframe mount-ing support plate

3

(5) Front sub-frame frontmounting unit

1.2

144781


(6) Front side member frontsection

1.25

(7) Front sub-frame frontmounting unit 1.2


3

(9) Front tow hitch support 2.5


22/13641A-4


Front side member, front section: Replacement 41ALeft-hand side

Right-hand side


1 - Complete replacement

Part in position

Left-hand side

144783

144779

WARNING

If the mating faces of the parts to be welded are not

accessible, use a GMAW plug weld in place of theoriginal electrical resistance weld (see ) (MR 400,40C, Gas metal arc welded connections (GMAW)).

WARNING

To avoid damaging the vehicles electric and elec-tronic components, the earths of any wiring harness

near the weld area must be disconnected.

Position the earth of the welding machine as closeas possible to the weld area (see ) (MR 400, 40H,Bolted connections).

IMPORTANT

Use a repair bench to ensure the positioning of thepoints and the geometry of the axle assemblies.

144782


23/13641A-5


Front side member, front section: Replacement 41ARight-hand side

2 - Partial replacement section A-B

Part in position

Left-hand side

Detailed view of cut B

Right-hand side

144778

IMPORTANT


144785

144784

144780


24/13641A-6


Front side member, front section: Replacement 41ADetailed view of cut B

144777


25/13641A-7


Front section of front side member closure panel: Replacement 41AI - COMPOSITION OF THE SPARE PART




- partial replacement section A-B.

Locate the earths located near to the weld area (see40A, General information, Earths on body: List and

location of components, page 40A-5) .

144775


(1) Front closure panel com-ponent of front section

front side member

1.25

(2) Front subframe mount-ing front unit component

1.2

(3) Brake hose stop bracket 2

144772

WARNING


WARNING




26/13641A-8


Front section of front side member closure panel: Replacement 41A1 - Complete replacement

Part in position

2 - Partial replacement section A-B

Part in position

Detailed view of cut B

144771

144774

144773


27/13641A-9


Battery tray mounting: Replacement 41AI - COMPOSITION OF THE SPARE PART






Part in position

144789


(1) Battery tray bracket 1.45

(2) Computer mounting 0.95

WARNING

If the mating faces of the parts to be welded are notaccessible, use a GMAW plug weld in place of the

original electrical resistance weld (see ) (MR 400,40C, Gas metal arc welded connections (GMAW)).

WARNING

To avoid damaging the vehicles electric and elec-

tronic components, the earths of any wiring harnessnear the weld area must be disconnected.


144788


28/13641A-10


Engine mounting: Replacement 41AI - COMPOSITION OF THE SPARE PART






Part in position

144791


(1) Right-han d mountingplate for engine - gear-

box assembly support onbody

2.5

(2) Right-hand engine -gearbox assembly sus-pension support on body

2.5

WARNING


WARNING




144790


29/13641A-11


Front subframe front mounting unit: Replacement 41AI - COMPOSITION OF THE SPARE PART






Part in position

144766


(1) Front subframe frontmounting unit

1.2

(2) Front towing eye mount-ing reinforcement

2.5


3

WARNING


WARNING




144767


30/13641A-12


Front half-unit: Replacement 41AI - COMPOSITION OF THE SPARE PART

Left-hand side

Right-hand side

144770


(1) Front section of front side

member closure panel

1.2/1.25

(2) Front left-hand sidemember

1.2/3

(3) Battery tray bracket onbody

1.8

(4) Computer mounting 0.95

(5) Gas tank mountingimpact reinforcement

1.5

(6) Gas tank mounting onsubframe

1.4

(7) Bonnet left-hand strutmounting reinforcement

1.5

(8) Front left-hand shockabsorber cup

2.5

(9) Front left-hand shockabsorber cup heightadjuster

1.2

(10) Rear left-hand unit offront subframe mounting

1.95

(11) Centre floor front left-hand rear mounting rein-forcement

0.95

(12) Centre floor front left-hand side cross member

0.95

(13) Rear exterior unit of frontaxle subframe mounting

1.7


1.2

144769


(15) Engine stand 2.5

(16) Front right-hand sidemember

1.2/3

(17) Front section of front sidemember closure panel

1.2/1.25


1.2

(19) Front wheel arch 1.2

(20) Front shock absorber cupheight adjuster

2.5



31/13641A-13


Front half-unit: Replacement 41A




Locate the earths located near to the weld area (see

40A, General information, Earths on body: List andlocation of components, page 40A-5) .


Part in position

Left-hand side

Right-hand side

(21) Front shock absorber cup 2.5

(22) Centre floor front right-hand side cross member

0.95

(23) Rear exterior unit of frontaxle subframe mounting

1.7

(24) Front subframe rearright-hand mounting rein-forcement

0.95

(25) Rear right-hand unit offront subframe mounting

1.95

WARNING


WARNING



IMPORTANT



144776

144768


32/13641B-1

CENTRE LOWER STRUCTURE

Centre floor, side section: Replacement 41BI - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT



- partial replacement along cut A,

- partial replacement along cut B.

Locate the earths located near to the weld area (see

40A, General information, Earths on body: List andlocation of components, page 40A-5) .


(1) Centre floor, side sec-tion

0.6

144922

WARNING



WARNING




33/13641B-2


Centre floor, side section: Replacement 41B1 - Complete replacement

Part in position

144923


34/13641B-3


Centre floor, side section: Replacement 41B2 - Partial replacement along cut A

Part in position

Detailed view A

144924

144925


35/13641B-4


Centre floor, side section: Replacement 41B3 - Partial replacement along cut B

Part in position

Detailed view B

144927

144926


36/13641B-5


Centre side member: Replacement 41BI - COMPOSITION OF THE SPARE PART



- complete replacement.Locate the earths located near to the weld area (see

40A, General information, Earths on body: List and



Part in position


(1) Centre side member 1.95

WARNING


WARNING




144917


37/13641C-1

SIDE LOWER STRUCTURE

Sill panel: Replacement 41CI - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT


- complete replacement A-D-E,

- partial replacement of front end section A-C,

- partial replacement under door B-C,

- partial replacement B-D-E.



No. Description Thickness

(mm)

(1) Sill panel 0.95

144870

WARNING


WARNING




38/13641C-2


Sill panel: Replacement 41C1 - Complete replacement A-D-E

Part in position

Detailed view A Detailed view D

144869

144876 144877


39/13641C-3


Sill panel: Replacement 41C2 - Partial replacement of front end section A-C

Part in position

Detailed view A

Detailed view C

3 - Partial replacement section under door B-C

Part in position

144875

144876

144872

144871


40/13641C-4


Sill panel: Replacement 41CDetailed view B

Detailed view C

4 - Partial replacement B-D-E

Part in position

Detailed view B

144873

144872

144874

144873


41/13641C-5


Sill panel: Replacement 41CDetailed view D

144877


42/13641C-6


Sill panel closure panel: Replacement 41CI - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT


- complete replacement A-D,

- front section partial replacement A-C,

- rear section partial replacement B-D.



(mm)

(1) Sill panel closure panel 1.3

144879

WARNING



WARNING


Position the earth of the welding machine as closeas possible to the weld area (see ) (MR 400, 40H,

Bolted connections).


43/13641C-7


Sill panel closure panel: Replacement 41C1 - Complete replacement A-D

Part in position

144878


44/13641C-8


Sill panel closure panel: Replacement 41C2 - Front section partial replacement A-C

Part in position

Detailed view C

144880

144883


45/13641C-9


Sill panel closure panel: Replacement 41C3 - Rear section partial replacement B-D

Part in position

Detailed view B

144881

144882


46/13641C-10


Sill panel reinforcement: Replacement 41CI - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT







(mm)

(1) Sill panel reinforcement 1.2

144903

WARNING



WARNING





47/13641C-11


Sill panel reinforcement: Replacement 41C1 - Complete replacement A-D

Part in position

144902


48/13641C-12


Sill panel reinforcement: Replacement 41C2 - Front section partial replacement A-C

Part in position

Detailed view C

144895

144892


49/13641C-13


Sill panel reinforcement: Replacement 41C3 - Rear section partial replacement B-D

Part in position

Detailed view B

144901

144894


50/13641C-14


Sill panel stiffener: Replacement 41CI - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT







(mm)

(1) Sill pane stiffener 2

144885

WARNING



WARNING





51/13641C-15


Sill panel stiffener: Replacement 41C1 - Complete replacement A-D

Part in position

144884


52/13641C-16


Sill panel stiffener: Replacement 41C2 - Front section partial replacement A-C

Part in position

Detailed view C

144887

144888


53/13641C-17


Sill panel stiffener: Replacement 41C3 - Rear section partial replacement B-D

Part in position

Detailed view B

144886

144889


54/13641C-18


Sill panel rear reinforcement: Replacement 41CI - COMPOSITION OF THE SPARE PART






Part in position

144890


(mm)

(1) Lower connection com-ponent for front section

inner rear wheel arch

0.95

(2) Lower connection com-ponent for rear sectioninner rear wheel arch

0.95

WARNING


WARNING




144891


55/13641D-1

REAR LOWER STRUCTURE

Rear floor reinforcement: Replacement 41DI - COMPOSITION OF THE SPARE PART







(mm)

(1) Rear floor reinforce-ment

0.8

WARNING


WARNING




144957


56/13641D-2


Rear floor, front section: Replacement 41DI - COMPOSITION OF THE SPARE PART




- partial replacement along cut A.



144953


(1) Rear floor, front section 0.65

(2) Impact retaining com-ponent under secondrow front seat

1.95

(3) Front section of rearfloor reinforcement

1.8

(4) Centre attachmen treinforcement for childseat on second row

1.8

144954

WARNING


WARNING




57/13641D-3


Rear floor, front section: Replacement 41D1 - Complete replacement

Part in position

2 - Partial replacement along cut A

Part in position

Detailed view A

144950

144951

144952


58/13641D-4


Rear side member assembly: Replacement 41DI - COMPOSITION OF THE SPARE PART

145102


(1) Rear side member 1.45

(2) Rear support for retain-ing the fuel tank on thebody

1.5

(3) Interior reinforcementof rear axle mountingside member

2

(4) Connection compo-nent between rear sidemember and inner rearwheel arch

1.45

(5) Exhaust rear supporton subframe

2.5

(6) Subframe side closurepanel component

0.65

(7) Rear suspens ionspring support rein-forcement

2

(8) Rear axle rear mount-ing reinforcement

3.5

(9) Rear upper spring sup-

port

2

(10) Side rear cross mem-ber

1.9

(11) Rear support reinforce-ment for jack

3

(12) Rear axle mountingbracket on body

2

(13) Rear axle assemblymounting unit

1.9



59/13641D-5


Rear side member assembly: Replacement 41DII - IN THE EVENT OF REPLACEMENT





Part in position

WARNING


WARNING




IMPORTANT


144942


60/13641D-6


Rear side member: Replacement 41DI - COMPOSITION OF THE SPARE PART





Partial replacement along cut A

Part in position

Detailed view A


(1) Rear side member 1.45

WARNING


WARNING




IMPORTANT


144944

144945


61/13641D-7


Front upper cross member: Replacement 41DI - COMPOSITION OF THE SPARE PART







(mm)

(1) Front upper cross mem-ber

0.95

WARNING


WARNING




145070


62/13641D-8


Rear floor front cross member: Replacement 41DI - COMPOSITION OF THE SPARE PART







144959


(1) Rear floor front crossmember

1.2

(2) Attachment support forsecond row seat

0.95

(3) Front support reinforce-ment for retaining thefuel tank on the body

1.5

144960

WARNING


WARNING




63/13641D-9


Rear floor front cross member: Replacement 41D1 - Complete replacement

Part in position


Part in position

Detailed view A

144961

144963

144962


64/13641D-10


Rear floor centre cross member: Replacement 41DI - COMPOSITION OF THE SPARE PART






Part in position

144964


(1) Rear floor rear centrecross member

1.2

(2) Brake limiter mountingsupport

1.95

(3) Emergency sparewheel subframe jointsupport

2

(4) Mounting bracket ofsecond row seat

2

(5) Second row anchor-age centre reinforce-

ment

1.95

(6) Fuel tank rear mount-ing reinforcement

1.5

WARNING



WARNING



IMPORTANT


144965


65/13641D-11


Rear floor, rear section: Replacement 41DI - COMPOSITION OF THE SPARE PART II - IN THE EVENT OF REPLACEMENT






(1) Rear floor, rear section 0.7

144947

WARNING



WARNING




66/13641D-12


Rear floor, rear section: Replacement 41D1 - Complete replacement

Part in position


Part in position

144946

144948


67/13641D-13


Rear floor, rear section: Replacement 41DDetailed view A

144949


68/13641D-14


Rear floor, rear side section: Replacement 41DI - COMPOSITION OF THE SPARE PART







(mm)

(1) Rear floor, rear sidesection

0.65

WARNING


WARNING




144955


69/13641D-15


Rear towing eye: Replacement 41DI - COMPOSITION OF THE SPARE PART






Part in position

144941


(1) Rear towing eye 14

(2) Rear side member clo-sure panel component

0.95

(3) Rea r towing eyemounting

3

WARNING


WARNING



144940


70/136


71/13642A-1

FRONT UPPER STRUCTURE

Front panel: Replacement 42AI - COMPOSITION OF THE SPARE PART






Part in position

145060


(mm)

(1) Front end panel upper

cross member centremounting

1.4

(2) Lock mounting crossmember reinforcement

1.2

(3) Right-hand headlight car-rier panel

1

(4) Front end panel uppercross member

0.95

(5) Left-hand headlight car-

rier panel

1

WARNING


WARNING




145061


72/13642A-2


Front wing: Removal - Refitting 42ALocation and specifications (tightening torques, partsalways to be replaced, etc.) (see Exterior body fronttrim assembly: Exploded view) .

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).

a Remove (see Exterior body front trim assembly:Exploded view) (55A, Exterior protection):

- the scuttle panel grille side blanking cover,

- the front wheel arch liner,

- the front section of the sill panel extender,

- the front bumper (see Front bumper assembly:Exploded view) .

a Remove:

- the side indicator (see Side indicator: Removal -Refitting) ,

- the headlight (see Headlight assembly: Explod-ed view) (80B, Headlight).


73/13642A-3


Front wing: Removal - Refitting 42AII - REMOVAL OPERATION

a Remove:

- the bolts (1) ,

- the nuts (2) ,

- the front wing.

REFITTING

a Proceed in the reverse order to removal.

a Adjust the clearances and flush fitting (see Vehiclepanel gaps: Adjustment value) (01C, Vehiclebodywork specifications).

145098

145100

145099


74/13642A-4


Scuttle side panel: Replacement 42AI - COMPOSITION OF THE SPARE PART



- complete replacement A-C,

- front section partial replacement A-B.



145059


(mm)

(1) A-pillar lining impact rein-forcement

1.95

(2) A-pillar lining 0.9

(3) Mounting plate nut 0.9

(4) Mounting support forupper section of driver'sseat cross member

1.95

145056

WARNING


WARNING




75/13642A-5


Scuttle side panel: Replacement 42A1 - Complete replacement A-C

Part in position

2 - Front section partial replacement A-B

Part in position

Detailed view B

145055

145058

145057


76/13642A-6


Scuttle side panel upper reinforcement: Replacement 42AI - COMPOSITION OF THE SPARE PART







(mm)

(1) Scuttle side panel upperreinforcement

0.95

WARNING


WARNING




145065


77/13642A-7


Front wheel arch, front section: Replacement 42AI - COMPOSITION OF THE SPARE PART







(mm)

(1) Front wheel arch, frontsection

1.2

WARNING


WARNING




145062


78/13642A-8


Heater bulkhead: Replacement 42AI - COMPOSITION OF THE SPARE PART



- complete replacement A-C,

- partial replacement B-C.



145054


(mm)

(1) Lower section of wind-screen aperture lower

cross member

0.95

(2) Winds cree n aper turelower cross member cen-tre reinforcement

0.95

(3) Reinforcement of wind-screen wiper shaft left-hand mounting

1.45

(4) Windscreen wiper platemounting bridge

1.5

145051

WARNING


WARNING




79/13642A-9


Heater bulkhead: Replacement 42A1 - Complete replacement A-C

Part in position

2 - Partial replacement B-C

Part in position

Detailed view B

145050

145053

145052


80/13642A-10


Windscreen aperture lower cross member: Replacement 42AI - COMPOSITION OF THE SPARE PART






Part in position

145068


(mm)

(1) Central mount ing rein-forcement of windscreen

wiper output shaft

1.45

(2) Upper section of wind-screen aperture lowercross member

0.65

(3) Dashboard retainingbridge piece on subframe

0.95

(4) Reinforcement on bon-net left-hand hinge sub-frame

1.9

WARNING


WARNING




145069


81/13642A-11


Dashboard cross member: Removal - Refitting 42A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Lock the airbag computer using theDiagnostic tool(seeFault finding - Replacement of components)(88C, Airbag and pretensioners).

a Disconnect the battery (see Battery: Removal - Re-fitting) (80A, Battery).

a Remove:

- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (88C, Airbags and pre-tensioners),

- the steering wheel (see Steering wheel: Removal- Refitting) (36A, Steering assembly),

- the steering column switch assembly (see Steer-

ing column switch assembly: Removal - Refit-ting) (84A, Control - Signals),

- the instrument panel (see Instrument panel: Re-moval - Refitting) (83A, Instrument panel),

- the radio (see Radio: Removal - Refitting) (86A,Radio),

- the dashboard (see Dashboard: Removal - Refit-ting) (57A, Interior equipment),

- the front air distribution ducts (see Front air distri-bution duct: Removal - Refitting) ,

- the steering column (see Steering column: Re-moval - Refitting) (36A, Steering assembly).

a Unclip:

- the wiring harness at (1) ,

- the electrical harness at (2) .

a Unclip the wiring harness on the distribution unit at(3) .

a Unclip the ignition switch connector (4) from its

mounting.

Equipment required

Diagnostic tool

Tightening torquesm

dashboard cross mem-ber bolts

21 N.m

dashboard cross mem-ber strut mountings

21 N.m

IMPORTANT

To avoid any risk of triggering when working on ornear a pyrotechnic component (airbags or preten-sioners), lock the airbag computer using the diag-nostic tool.

When this function is activated, all the trigger linesare inhibited and the airbag warning light on theinstrument panel lights up continuously (ignitionon).

IMPORTANT

Never handle the pyrotechnic systems (pretension-ers or airbags) near to a source of heat or nakedflame - they may be triggered.

117093

LEFT-HAND DRIVE


82/13642A-12



a Remove:

- the heating resistor relay mounting bolt (5) ,

- the heating resistor relay mounting.

aDisconnect the connector (6) from the heating resis-tor unit.

a Partially lift the floor carpet to access the strutmounting bolt.

a Mark the position of the strut on the body before re-moving it.

a Remove:

- the two upper nuts (7) from the strut,

- the two lower bolts (8) from the strut,

- stay.

a Disconnect:

- the air conditioning control panel connector,

- the passenger compartment fan assembly connec-tor,

- the passenger compartment fan assembly resistorunit connector.

K9K

24757

LEFT-HAND DRIVE

108102


83/13642A-13



a Remove:

- the bolts (12) from the air distribution unit,

- the wiring harness on the dashboard cross mem-ber.

II - OPERATION FOR REMOVAL OF PARTCONCERNED

a Mark the position of the dashboard cross memberon the body before removing it.

a Remove the dashboard cross member bolts (13)from both sides of the vehicle.

REFITTING

I - REFITTING OPERATION FOR PARTCONCERNED

a Refit the dashboard cross member bolts on both

sides of the vehicle, respecting the marking madebefore the removal operation.

a Torque tighten the dashboard cross memberbolts (21 N.m).

II - FINAL OPERATION

a Refit:

- the wiring harness on the dashboard cross mem-ber,

- the bolts on the air distribution unit,

- the bolts on the steering column.

a Reconnect:

- the passenger compartment fan assembly resistorunit connector,

- the passenger compartment fan assembly connec-tor,

- the air conditioning control panel connector.

a Refit:

- the strut, by positioning the strut bracket (14) in the

distribution unit hole (15) ,- the two lower bolts on the strut, respecting the

marking made during the removal operation,

- the two upper nuts to the strut.

a Torque tighten thedashboard cross member strutmountings (21 N.m).

a Refit the floor carpet.

a Reconnect heating resistor unit connector.

a Refit:

- the heating resistor relay mounting.

108098

108100

117092

K9K


84/13642A-14


Dashboard cross member: Removal - Refitting 42A- the heating resistor relay mounting bolt.

a Clip on:

- the starter switch connector on its mounting.

- the wiring harness on the strut.

a Clip:

- the wiring harness on the distribution unit,

- the wiring harness on the strut.

a Refit:

- the steering column (see Steering column: Re-moval - Refitting) (36A, Steering assembly).

- the front air distribution ducts (see Front air distri-bution duct: Removal - Refitting) ,

- the dashboard (see Dashboard: Removal - Refit-ting) (57A, Interior equipment),

- the radio (see Radio: Removal - Refitting) (86A,Radio),

- the instrument panel (see Instrument panel: Re-moval - Refitting) (83A, Instrument panel),

- the steering column switch assembly (see Steer-ing column switch assembly: Removal - Refit-ting) (84A, Control - Signals),

- the steering wheel (see Steering wheel: Removal- Refitting) (36A, Steering assembly),

- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (88C, Airbags and seatbelt pretensioners).

a Connect the battery (see Battery: Removal - Refit-ting) (80A, Battery).

a Unlock the airbag computer using theDiagnostictool (seeFault finding - Replacement of compo-nents) (88C, Airbags and pretensioners).


85/13642A-15


Headlight carrier panel: Replacement 42AI - COMPOSITION OF THE SPARE PART







(mm)

(1) Headlight carrier panel 1

WARNING



WARNING




145067


86/13643A-1

SIDE UPPER STRUCTURE

A-pillar reinforcement: Replacement 43AI - COMPOSITION OF THE SPARE PART







144855


(1) A-pillar reinforcement 1.2

(2) Upper hinge reinforce-ment of front side dooron body

2

(3) Lower hinge reinforce-ment of front side dooron body

2

144854

WARNING


WARNING




87/13643A-2


A-pillar reinforcement: Replacement 43A1 - Complete replacement

Part in position

2 - Partial replacement A

Part in position

Detailed view A

144853

144856

144859


88/13643A-3


Windscreen pillar lining: Replacement 43AI - COMPOSITION OF THE SPARE PART







(mm)

(1) Windscreen pillar lining 1.15

WARNING


WARNING




144847


89/13643A-4


B-pillar reinforcement: Replacement 43AI - COMPOSITION OF THE SPARE PART






Part in position

144858


(1) B-pillar impact rein-

forcement

1.5

(2) B-pillar impact rein-forcement component

1.8

(3) Upper hinge reinforce-ment of rear side dooron body

1.2

(4) Sensor mount ingbridge for side airbag

1.5

(5) Lower hinge reinforce-

ment of rear side dooron body

1.2

WARNING


WARNING




144857


90/13643A-5


B-pillar lining: Replacement 43AI - COMPOSITION OF THE SPARE PART






Part in position

144849


(1) B-pillar lining 1.15

(2) Anchorage reinforce-ment for first row seatbelt

1.5

WARNING


WARNING



144848


91/13643A-6


B-pillar lower lining: Replacement 43AI - COMPOSITION OF THE SPARE PART







(mm)

(1) B-pillar lower lining 0.95

WARNING


WARNING




144850


92/13643A-7


Body side, front section: Replacement 43AI - COMPOSITION OF THE SPARE PART




- partial replacement A-B,

- partial replacement B-D-C,

- partial replacement low section A-D.

125999


(1) Body side, front section 0.95

(2) Double seal support 0.65

144840


93/13643A-8


Body side, front section: Replacement 43ALocate the earths located near to the weld area (see40A, General information, Earths on body: List andlocation of components, page 40A-5) .

1 - Complete replacement

Part in position

2 - Partial replacement A-B

Part in position

WARNING



WARNING



Note:

To replace the body side front section, also orderthe double seal mounting(2) .

144839

Note:

To partially replace the body side front section

along cut A-B, also order the double seal mounting(2) .


94/136


95/136


96/13643A-11


Body side, front section: Replacement 43A

Detailed view A Detailed view D

144841

144845 144846


97/13643A-12


Roof bar mounting: Replacement 43AI - COMPOSITION OF THE SPARE PART






Part in position

Front roof bar mounting

Rear roof bar mounting


(1) Front roof bar mounting 2

(2) Rear roof bar mounting 2

WARNING


WARNING



144852

144851


98/13644A-1

REAR UPPER STRUCTURE

Rear wing panel: Replacement 44AI - COMPOSITION OF THE SPARE PART



- complete replacement A-E,

- partial replacement B-C-E,

- partial replacement B-C-D.

145014


(1) Rear wing panel 0.65

(2) Rear door striker platereinforcement,

1.2

145008


99/13644A-2


Rear wing panel: Replacement 44ALocate the earths located near to the weld area (see40A, General information, Earths on body: List andlocation of components, page 40A-5) .

1 - Complete replacement A-E

a - Part in position

b - Irremovable bodywork components - structuresto be removed in order to carry out thereplacement operation

Remove the roof (see 45A, Top of body, Roof: Re-

placement, page 45A-1) .

WARNING



WARNING



145007


100/13644A-3


Rear wing panel: Replacement 44A2 - Partial replacement B-C-E

Part in position

Detailed view B Detailed view C

145013

145011 145010


101/13644A-4


Rear wing panel: Replacement 44A3 - Partial replacement B-C-D

Part in position

Detailed view B Detailed view C

145012

145011 145010


102/13644A-5


Rear wing panel: Replacement 44ADetailed view D

145009


103/13644A-6


Rear light mounting: Replacement 44AI - COMPOSITION OF THE SPARE PART






Part in position

145015


(1) Rear side rain channel 0.85

(2) Strut mounting rein-forcement

2

(3) Closure panel compo-nent of rear lightmounting

0.95

(4) Rear light mounting 0.95

Note:

It is preferable to unclip the rear side rain channel ifit has not been affect by the impact.

WARNING


WARNING




145016


104/13644A-7


Light mounting lining: Replacement 44AI - COMPOSITION OF THE SPARE PART







(mm)

(1) Rear light mountinglining

0.65

WARNING


WARNING




145005


105/13644A-8


Quarter panel lining: Replacement 44AI - COMPOSITION OF THE SPARE PART



- complete replacement.Locate the earths located near to the weld area (see

40A, General information, Earths on body: List and



Part in position


(1) Quarter panel lining 0.65

WARNING


WARNING




145001


106/13644A-9


Rear half-unit: Replacement 44AI - COMPOSITION OF THE SPARE PART

145097


(1) Rear door striker platereinforcement,

1.2

(2) Rear wing panel 0.65

(3) Rear light mountinglining

0.65

(4) Rear light mounting 0.85/2

(5) Quarter panel lining 0.65

(6) Quarter panel lining,upper section

0.65/1.4

(7) Rear shock absorbercup reinforcement

2.5

(8) Rear shock absorbermounting reinforce-

ment

2

(9) Lower con nec tio ncomponent of rearinner wheel arch

0.95

(10) Rear inner wheel arch 0.8

(11) Support re in fo rce -ment for locking sec-

ond row seat

1.2

(12) Rear reinforcement ofquarter panel lowersection

1.2

(13) Rear reinforcement ofrear inner wheel arch

1.7

(14) Side rear parcel shelfstructure

1.2

(15) Front reinforcement of

rear inner wheel arch

Date post:	03-Jun-2018
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