77 11 190 877 NOVEMBER 1996 Edition Anglaise
Sheet metal work
"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.
The methods may be modified as a result of changes by the manufacturer in theproduction of the various component units and accessories from which his vehiclesare constructed".
All copyrights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority ofRenault.
C Renault S.A. 1988
GENERAL
LOWER STRUCTURE
UPPER FRONT STRUCTURE
UPPER SIDE STRUCTURE
UPPER REAR STRUCTURE
UPPER BODY SECTION
BODY PROTECTION
SIDE OPENINGS
BONNET AND TAILGATE
EXPLODED VIEW
PRS4011
Contents
GENERAL
Engine - Clutch - GearboxVehicle dimensionsLiftingDescription of parts (explodedviews)Description of symbolsOpening clearancesCollision damage assessmentDimensions of the lower structureMain bodywork dimensionsBody jig benchSpecial tools
40-140-240-7
40-1140-1840-2040-2740-3240-3440-3540-42
LOWER STRUCTURE
41-141-341-441-541-641-741-9
41-1041-1241-1341-16
41-1741-1841-2241-2341-2541-2641-28
41-2941-3041-3141-3441-36
UPPER FRONT STRUCTURE
PagesPages
40
41
42
Panels
UPPER SIDE STRUCTURE43A Complete front end cross memberB Part front end cross memberC Complete front end panelD Part front end panelE Side member closing panelF Front side member front sectionG Part front side member front sectionH Front side member rear sectionI Front side cross memberJ Front half unitK Part centre floor panelL Rear floor panel (part centre
section)M Rear floor panelN Utility vehicle floor panelO Lateral side member lower sectionP Lower side spacerQ Sill closing panel stiffenerR Front pillar lower section stiffenerS Floor and cross member side
stiffenerT Floor panel upper cross memberU Assembled rear end panelV Part rear end panel cross memberW Body
42-1
42-4
42-642-742-842-9
42-1042-14
42-1642-18
A WingB Complete radiator grille upper cross
memberC Part radiator grille upper cross
memberD Bonnet lock supportE Headlight carrier panelF Part front wing panel (front section)G Wheel arch (shock absorber turret)H Part heater bulkhead partitionI Part windscreen aperture lower
cross memberJ Front pillar upper stiffener
43-1
43-343-543-643-8
43-943-1043-1543-1943-2143-2243-2343-2743-2943-30
A Front pillar lower sectionB Front door pillar by cutting at
windscreen uprightC Door hinges (on front pillar)D Front door pillarE Front pillarF Front door pillar seal fastening
(KSM)G Centre pillarH Centre pillar liningI Sill panelJ Body sideK Part sill panelL Sill panelM Sill panel front stiffenerN Sill panel rear stiffenerO Roof arch
SIDE OPENINGS
Contents
BODY PROTECTION46
48
UPPER BODY SECTION45
47
45-145-745-9
45-10
45-1145-12
A Roof panelB Windscreen surroundC Linings and stiffenersD Windscreen pillar liningE Windscreen aperture upper cross
memberF Rear roof cross member
UPPER REAR STRUCTURE44
44-144-8
44-1344-2544-2644-3244-3644-3744-3844-3944-4044-4444-4644-47 44-48
44-4944-51
44-5344-5444-5544-5644-5844-64
44-7044-7144-7344-7544-7744-79
A Complete wing panelComplete rear wing panel
B Part wing panelPart rear wing panel
C Quarter panel liningD Assembled wing panel liningE Wing panel lower front liningF Wing panel upper front liningG Wing panel rear liningH Tailgate upper rain channelI Outer wheel archJ Complete quarter panel archK Part quarter panel archL Backrest mounting stiffenerM Outer wheel arch stiffenerN Upper cross member between
wheel archesO Hood compartment base partitionP Hood compartment rear cross
memberQ Backrest mounting stiffenerR Jack support (right hand side)S Centre shelfT Half unitU Rear end panelV Rear end panel lining and
assembled end panelW Part end panel cross memberX Rear end panel extension pieceY Side rain channelZ Boot lid rain channel2A Lighting support panel
46-146-2
A Sub-frame front protectorB Wheel arch mud shield
47-147-247-447-6
A Door hingesB Front door panelC Rear door panelD Front door - rear door
BONNET AND TAILGATE
48-148-348-5
48-11
48-13
48-14
A BonnetB TailgateC Boot lidD Hood cover panelE Broken boot lid counter balance ball
jointF Roof cross member (noise
reduction)
GENERALEngine - Clutch - Gearbox 40
Vehicle type
Engine
TypeCubic
capacity(cm3)
Clutch type Manual and automatic gearbox type
B530 - C530 - L530S530 C1G 1237 180 CP 3300 JB0 - JB1 - JB4 - JB5
B531 - C531 - L531 C1J 1397 180 CP 3300 JB0 - JB1 - JB4 - JB5
B53H - B53P - C53PL53H - L53P
C2J 1397 180 CP 3300 JB0 - JB1 - JB4 - JB5
B532 - C532 - L532 C3J 1390 180 CP 3300 JB0 - JB1
B53G - B537 - C537L53G - L537 - S537 E6J 1390 180 CP 3300 JB0 - JB1 - MB1
B53A - C53A - L53A E7J 1390 180 CP 3300 JB1 - MB1
B535 - C535 - L535 E7J 1390 180 CP 3300 JB1 - MB1
B53W - C53W - L53W E7F 1171 180 CP 3300 JB0 - JB1 - JB3
B53E - B53M - B533B536 - C53E - C53MC533 - L533 - L536
F2N 1721 200 CP 4000 JB0 - JB1 - JB3 - AD4
B53B - B53C - B53FC53B - C53C - C53F
D53C - L53B - L53C -L53F
F3N 1721 200 CP 4000 AD4 - JB3 - MB3
B53V - B53Y - B538C53V - C53Y - C538D53V - D53Y - L53VL53Y - L538 - 353A353C - 353D - 353F453A - 453C - 453D 453F - 453H - 553A553C - 553D - 553F553H - 853A - 853C
853F
F3P 1794 200 CP 4000 AD4 - JB3 - JC5
B53D - B539 - C53DC539 - D53D - L53D
L539F7P 1764 200 CP 4400 JB3 - JC5
B53I - B53J - B53KB53T - B53Z - B534C53I - C53J - C53KC53T - C53Z - C534L53I - L53J - L53KL53T - L53Z - L534S53I - S53J - S53K -
S534
F8Q 1870200 CPV 4600
200 CPV 3500JB1 - JB3 - JC5
40-1
GENERALVehicle dimensions 40
91936R1
B53Phase I
Mark Dimensions in metres
A 2.545
B 4.155
C 1.418
D 1.416 unladen
E 1.406 to 1.417
F 1.676 or 1.694
40-2
GENERAL
Vehicle dimensions 40
95890R
B53Phase II
Mark Dimensions in metres
A 0.813
B 2.540 - 2.544 (1)
C 0.805 - 0.809 (1)
D 4.158 - 4.166 (1)
E 0.120 (2)
F 1.426
G 1.684 - 1.696 (1)
H 1.400 - 1.420 (1) - (3)
I 1.406 - 1.417 (1)
(1) Depending on version with option(2) Laden(3) Unladen
40-3
GENERALVehicle dimensions 40
92866R
* Depending on version
L53 SaloonExcept Sport
Mark Dimensions in metres
A 2.545 or 2.540 *
B 4.262
C 1.412 unladen
D 1.418
E 1.406 to 1.417 *
F 1.684 or 1.694 *
40-4
GENERALVehicle dimensions 40
92764R
B - C - L539Sport
Mark
Dimensions in metres
B and C L
A
B 4.150 4.259
C 1.389 1.400
D
E
F
2.540
1.429
1.406
1.684
40-5
GENERALVehicle dimensions 40
94726R
D53Cabriolet
Mark Dimensions in metres
A 2.545
B 4.155
C 1.375 ± 5
D 1.418
E 1.406 to 1.417
F 1.676 or 1.694
40-6
GENERALLifting 40
87709R
USING AXLE STANDS
To place the vehicle on axle stands, the standsmust be positioned under jacking points (1)provided for lifting the vehicle using the jacksupplied with the vehicle.
To position the axle stands at the rear, lift thevehicle from the side.
LIFTING USING A JACK FROM THE SIDE
Use cross piece Cha. 280-02.
Take the load under the front door sill.
Position the body sill flange correctly in the crosspiece groove.
91936G385679-1G7
40-7
GENERALLifting 40
92556R
Safety symbol (special precautions to be taken while working)
ESSENTIAL SPECIAL TOOLS
Cha. 280 -02 Adjustable cross piece on trolley
jack
Cha. 408 -01
or Adjustable dowel on trolley jack
Cha. 408 -02
The vehicle must not be lifted by taking the loadunder the front suspension arms.
Depending on the type of trolley jack , use dowelsCha. 408-01 or Cha. 408-02 to fit cross piece Cha.280-02.
To lift the front or the rear, take the load underthe lifting points provided for the on-board jack.
USING A TROLLEY JACK FROM THE FRONT
Apply the handbrake or chock the rear wheels.
Use cross piece Cha. 280-02.
Take the load under the front sub-frame.
Ensure that the cross piece does not come intocontact with the gearbox or the exhaustdownpipe.
Appropriate axle stands must be used if atrolley jack is used.
For B537 and C537 type vehicles, make a clearancenotch in cross piece Cha. 280-02 to prevent it fromcoming into contact with the exhaust.
USING A TROLLEY JACK FROM THE REAR
The rear of the vehicle MUST NOT be lifted bytaking the load under the rear axle. Lift eachwheel separately taking the load at the liftingpoints provided for the on-board jack.
40-8
GENERALLifting
AXLE STANDS
To place the vehicle on axle stands, the standsmust be positioned: - either under the jacking points provided for
lifting the vehicle using the on-board jack,- or under the pads located behind the stiffeners.
To position the axle stands at the rear, lift thevehicle sideways.
40
98336G85679-1G7
WHEEL FREE LIFT
SAFETY ADVICE
Several possibilities must be considered:
1 - REMOVAL OF COMPONENTS
In general, never use a two post lift when a fourpost lift is suitable.
If this is not possible, fit the lifting pads under thesill flange at the lifting points provided for the on-board jack.
98703S
FRONT
98704S
REAR
The pads must be placed to the right of thejacking points. They must be engaged in the ope-nings in the sill panel flanges.
40-9
GENERALLifting 40
LASHING FOR TOWING
FOR TOWING REFER TO THE CURRENTLEGISLATION FOR EACH COUNTRY.
NEVER USE THE DRIVESHAFTS AS TIE-DOWNPOINTS.
The towing points are only to be used for towingon the road. They must never be used for pullingthe vehicle out of a ditch, for any other similaroperations or for lifting the vehicle directly or in-directly.
2 - SPECIAL CASE FOR REMOVAL - REFITTING OFTHE ENGINE AND TRANSMISSION ASSEMBLY
In this case, the vehicle body must be connected tothe arms of the two post lift using special pads.
FOG :Part number FOG 449 8111 - 449 8411
or
CHEMICO :Part number 39 2550 0001
or
SCHENCHPart number 776 684
FRONT
98705S
REAR
98702S
40-10
GENERALDescription of parts (exploded views) 40
PRS4012
B53 / C53
9 Rear floor panel front section10 Rear floor panel11 Floor panel stiffener cross member12 Fuel tank mounting cross member13 Cross member under rear floor panel14 Rear side member15* Front side cross member16* Front side member rear section17 Front side member closure panel18 Front side member front section18A Part front side member19 Lower front cross member19A Part lower cross member20 Assembled front panel20A Part assembled front panel
LOWER STRUCTURE ALL TYPES
1 Sill closing panel2 Centre floor panel2A Part centre floor panel2B Part centre floor panel3 Centre floor panel cross member4 Front seat mounting cross member5 Front 1/2 unit (wheel arch)6 Rear 1/2 unit (wheel arch)7 Assembled rear floor panel with side
member8 Rear floor panel rear section8A Part rear floor panel8B Part rear floor panel
* Steel part with high degree of flexibility
40-11
GENERALDescription of parts (exploded views) 40
PRS4013
B53 / C53
UPPER STRUCTURE
50 Front roof panel cross member51 Windscreen pillar lining52 B53 roof drip moulding lining53 Rear roof cross member54 Roof panel55 Centre pillar lining56 B53 quarter panel lining57 Quarter panel arch58 Rear outer wheel arch59 Quarter panel lining (C53)60 Sill panel partition (C53)61 Door pillar lining (C53)62 Body top lining (C53)63 Centre pillar lower lining64 Front wing bracket65 Front wing
66 Front wheel arch67 Front wheel arch extender68 Diesel engine mounting cup69 Headlight carrier panel70 Bonnet lock support71 Front upper cross member71A Part front upper cross member72 Inner wheel flange panel - front pillar
lining72A Part inner wheel flange panel - front
pillar lining72B Part inner wheel flange panel - front
pillar lining73 Heater bulkhead partition73A Part heater bulkhead partition74 Bulkhead75 Windscreen aperture lower cross member75A Part lower cross member76 Bonnet
40-12
GENERALDescription of parts (exploded views) 40
PRS4014
B53 / C53
UPPER STRUCTURE
80 Tailgate81 Front door82 Rear door83 Rear door panel84 Front door panel85 Lighting support86 Rear end panel87 Assembled rear end panel with cross
member88 Rear end panel lining89 Sill panel (C53)90 Wing panel (C53)
90A Part wing panel in line with cross-section A90B Part wing panel in line with cross-section B91 Body top (roof drip moulding) (C53)92 Sill panel (B53)93 Body top (B53)94 Front pillar95 Body side96 Centre pillar97 Rear wing panel (B53)97A Part rear wing panel (cross-section A)97B Part rear wing panel (cross-section B)98 Wing panel upper rain channel99 Wing panel lower rain channel
40-13
GENERALDescription of parts (exploded views) 40
PRS4015
1 Rear floor panel with side member
2 Part rear floor panel (rear section)
3 Rear floor pnel
4 Rear side member
5 Part rear end panel cross member
B53 / C53 / L53
LOWER STRUCTURE
40-14
GENERALDescription of parts (exploded views) 40
PRS4016
L53SALOON
UPPER STRUCTURE
1 Roof panel2 Rear roof cross member3 Boot lid4 Counter balance ball joint5 Boot lid strut6 Quarter panel lining7 Quarter panel arch8 Outer wheel arch9 Wing panel side rain channel10 Wing panel
11 Rear end panel cross member12 Rear end panel cross member blanking piece13 Lighting support panel14 Assembled rear end panel15 Rear end panel side extender16 Jack support (right hand side only)17 Backrest mounting stiffener18 Rear centre shelf19 Half unit
40-15
GENERALDescription of parts (exploded views) 40
PRS4017
D53CABRIOLET
1 Windscreen surround2 Rear floor panel upper cross member3 Floor panel and cross member side stiffener4 Lower side spacer5 Lateral side member lower section6 Sill panel stiffener7 Sill panel rear stiffener8 Sill panel outer panel9 Bare sill panel outer panel
10 Door panel11 Door12 Front pillar upper stiffener13 Front pillar14 Front wing15 Sill panel front stiffener16 Front pillar lower lining17 Windscreen pillar lining18 Windscreen aperture upper cross member
40-16
GENERALDescription of parts (exploded views) 40
PRS4018
D53CABRIOLET
38 Lighting support component stiffener39 Rear wing panel40 Outer wheel arch stiffener41 Outer wheel arch42 Wing panel lower front lining43 Wing panel upper front lining44 Centre pillar45 Centre pillar lining46 Assembled wing panel lining47 Boot lighting support
28 Upper cross member between wheelarches
29 Hood compartment base partition30 Hood compartment rear cross member31 Boot lid rain channel32 Hood compartment cover33 Boot lid34 Hood compartment cover hinge35 Boot lid hinge36 Wing panel rear lining37 Lighting support component
40-17
Cut the part by grinding the flange orgrind down the remaining bits of spotweldAngle grinder fitted with a rubberbacking pad and a 120 to 180 mm P36grade fibre disc
GENERALDescription of symbols 40
Cut using a cold chisel
Grind the weld fillet or spot weldsStraight grinding wheel fitted with a75mm diameter 1.8 to 3.2 mm thickBakelite disc.
Rotary grind the spot welds20,000 rpm straight grinding wheel witha 10 or 16mm diameter spherical cutter.
Rotary grind the spot weldsSpot weld drill. Speed of rotation 800 to1,000 rpm.
Unpick the metal strip
Clean the surfaces to be welded100 mm fibre disc
Cut using a hacksawPneumatic power hacksaw
Release brazed joint
Dimensions and types of electrodes tobe used for the operation:
MIG stitch weldingNote: for good quality welding, it isrecommended that a gas composed ofArgon + 15% CO2, which is consideredto be an active gas, is used (MIG)
Plug weldingMIG welding
Inject wax into the hollow sectionsGun under pressure fitted with aflexible end piece.
Safety symbolThis means that the welding operationin question concerns one or moreaspects of vehicle safety
Lead fillHot air gunNozzle output temperature 600° min.Palette+ 33% lead stick+ tallowNote: to a large extent, the soft solderfinish compensates for the risks ofdeformation due to welding
Application of electrically weldablemasticThis conductive mastic, insertedbetween two panels to be spot welded,seals the panels and prevents corrosionof the spot welds
Application of aluminium based paintThis must be applied to the matingsurfaces of each of the parts to be plugwelded. This paint is conductive andcan withstand high temperatures; itgives anti-corrosion protection aroundwelds.
Apply a bead of extruded mastic• gun with a manual or pneumatic
cartridge• crimping or mating mastic with one
or two parts
Apply mastic by spraying• gun under pressure• anti-chipping and anti-corrosion
mastic with two parts
L = 100
L = 100
L = 100 +flat
L = 250
L = 350 +ball joint
L = 330
40-18
GENERALDescription of symbols 40
LOCATION OFOPERATIONS
TYPES OF TOOL ANDORDER OF OPERATIONS
LOCATION OFOPERATIONS
TYPES OF TOOL ANDORDER OF OPERATIONS
CUTTING-UNPICKING
saw saw
or
chisel
rotarygrind
unpick clean
unpick cleangrind
rotary grind
unpick cleansand
grind
sandreleasebrazed joint
WELDING
grind leadfill
stitchweld
XL (en
mm)
1-23-4568
100100250350330electric spot welder
WELDING (cont)
plug weld
stitch weld
FINISHING
studextractor
PROTECTION OF CRIMPED WELD JOINTS
bead of mastic in cartridge
bead and spraying of mastic
ANTI-CHIPPING PROTECTION
spraying of mastic
PROTECTION OF HOLLOW SECTIONS
injection using angled nozzle
PAINTING STYLED AREAS
aerosol can
40-19
GENERALOpening clearances 40
92309-1R1
B53Phases I and II
91936-4R
40-20
GENERALOpening clearances 40
92309-1R2
B53Phases I and II
40-21
GENERALOpening clearances 40
92866R1
NOTE: for front section parts, refer to the B53 diagrams on previous pages.
L53Saloon
93126R
40-22
GENERALOpening clearances 40
94726R1
D53Cabriolet
40-23
GENERALOpening clearances 40D53
Cabriolet
94772R
1
94772-2R
3
94772-3R
4
94772-4R
5
94772-1R
2
94772-5R
6
40-24
GENERALOpening clearances 40
94772-8R
D53Cabriolet
94772-6R
7
94772-7R
8
94772-9R
9
10
94772-10R
11
40-25
GENERALOpening clearances 40D53
Cabriolet
94772-11R
12
40-26
H
GENERALCollision damage assessment 40
85591R
CHECKING THE FRONT CROSS MEMBER AND THE FRONT END PANEL SUB-FRAME MOUNTING (1)
Compare lengths:CG = DHCH = DG
If lengths (CH - DG) and diagonals (CG - DH) are not identical, point (3) on the sub-frame must be checked asshown on the following pages.
If points (1) and (2) are correct, the front axle angles must be checked and adjusted.
If the front axle cannot be adjusted, it will then be necessary to change front axle components (stub axlecarrier, etc.).
PRS4019
85593R
C
40-27
GENERALCollision damage assessment 40
PRS4020
CHECKING THE CENTRE SECTION (3) OF THE SUB-FRAME
Compare lengths:EI = FJEJ = FI
If points (2) and (3) are correct, it will be possible to straighten or partially change the front section of the sidemember and refit a new cross member without having to place the vehicle on a body jig bench. Point (1) isaligned using the engine sub-frame, after having changed the sub-frame if necessary.
If all the sub-frame check points (1), (2) and (3) are correct, it will then be necessary to check and adjust thefront axle.If adjustment is not possible, front axle components must be changed (stub axle carrier, etc.).
If points (1) and (3) are not correct, the vehicle must be placed on the bench in order to change the frontsection of the side member.
85860-1R
85592S
EJ
40-28
GENERALCollision damage assessment 40
92381R4
CHECKING THE LATERAL SIDE MEMBERS (6) (REAR ARM MOUNTINGS)
Compare lengths:GO = HPGP = HO
Following a side or rear impact, if there is a difference in length, the vehicle must be placed on the framebench in order to re-align the lateral side member or partially change it.
IT IS NOT NECESSARY TO REMOVE THE FRONT MECHANICAL COMPONENTS IN ORDER TO PLACE THEVEHICLE ON THE JIG BENCH FOLLOWING A REAR OR SIDE IMPACT. SUPPORTS SPECIALLY PROVIDED FOR THEPURPOSE MUST BE PLACED AT POINTS (2).
If there is no difference in length, check points (4) as shown below.
85593R
85588S
O
H40-29
GENERALCollision damage assessment 40
PRS4021
CHECKING THE ENDS OF THE REAR SIDE MEMBER (4)
Compare lengths:EK = FLEL = FK
If points (4) and (6) are correct and there is no apparent distortion, repair is possible without using the benchon condition that the upper structure is not too badly damaged and not too many parts need to be changed.
If there is a difference in length (FK - EL), the method of repair to be used (on or off the bench) depends onthe number of upper structure parts to be changed.
85595R
85589S
F
K
40-30
GENERALCollision damage assessment 40
PRS4022
CHECKING THE REAR ARMS (5)
Compare lengths:FM = EN
Following a rear impact or a wheel impact, it is possible to quickly check whether or not the arms aredeformed.
If the diagonals are different, change the rear arms.
This operation for checking the arms (5) must be followed by a trammel gauge check of the mounting of thearms to the lateral side members (6).
85594R
85589S
F
M
40-31
GENERALDimensions of the lower structure 40
PRS4023
REMINDER OF ALIGNMENT
The intersection of the three planes X - Y -Z determines initial point 0 of the vehicle and the three referencelines:
1 Dimension start line: L - D - C (position of body jig bench bracket at X, in relation to this line).
2 Body centreline: A - D - C (position of body jig bench bracket at Y, in relation to this line).
3 Base line: L - D - B (position of body jig bench bracket at Z, in relation to this line).
The bodywork repair body jig brackets and their positions on the bench are designed in accordance withthese three lines.
40-32
GENERALDimensions of the lower structure 40
92381R3
ALL TYPES
40-33
GENERALMain bodywork dimensions 40
NOTE: the dimensions are measured in the centreline of the various welded nuts.
D53Cabriolet
PRS4027
40-34
GENERALBody jig bench 40
BRACKETS AND REFERENCE POINTS
SUB-FRAME FRONT MOUNTING
92631S
Jig used for repairing the front of the vehicle,with the front sub-frame removed.
This enables positioning of the lower crossmember and the end of the side member.
FRONT SHOCK ABSORBER UPPER MOUNTING
92632S
Jig used for repairing the front of the vehicle,front sub-frame removed.
This allows:- positioning of the wheel arch or the 1/2 unit,
- drilling of the shock absorber upper cupmounting holes.
(refer to the method described in sub-section 41)
DIESEL ENGINES UPPER MOUNTING
92662S
The jig is used to position the engine mounting se-curing cup so that it can be welded to the cowlside panel.
SUB-FRAME REAR MOUNTING
92633S
A - Repairing the front(front sub-frame removed)
The jig allows positioning of the side member orthe front 1/2 unit.
40-35
GENERALBody jig bench 40
92637S
REAR AXLE MOUNTING
A - Repairing the front(rear sub-frame fitted)
The jig allows the rear of the vehicle to besupported and aligned on the bench.
B - Repairing the rear(front sub-frame fitted)
The jig allows the front of the vehicle to besupported and aligned on the bench.
92634S
FRONT SEAT CROSS MEMBER
When the jig is centred along the length of thevehicle, it enables the vehicle to be supported andaligned when major repairing is being carriedout:
Eg. : front or rear unit
It also allows alignment of the rear section of thefront side member.
92635S
B - Repairing the rear(rear sub-frame removed)
The jig allows positioning of the side member orthe rear unit.
92636S
40-36
GENERALBody jig bench 40
REAR SHOCK ABSORBER UPPER MOUNTING
During repairing of the rear, with the rear sub-frame removed, the jig allows positioning of the1/2 unit (assembled wheel arch).
92638S
FUEL TANK MOUNTING CROSS MEMBER
During repairing of the rear (sub-frame removed),the jig allows positioning of the fuel tank crossmember.
92639S
92640S
REAR SIDE MEMBER REAR END PANEL
During repairing of the rear, the jig allowspositioning of the side member or the rear unit.
40-37
GENERALBody jig bench 40
PRS4024
FITTING CELETTE BRACKETS
40-38
GENERALBody jig bench 40
PRS4025
FITTING BLACKHAWK BRACKETS
40-39
GENERALBody jig bench 40
PRS4026
FITTING CELETTE BRACKETS
D53Cabriolet
40-40
GENERALBody jig bench 40
PART NUMBERS FOR SPECIAL TOOLS
Special heads for the CELETTE body jig benchMZ system
Please contact your local After Sales Office for furtherdetails.
Special heads for the BLACKHAWK body jig benchMS system
Please contact your local After Sales Office for furtherdetails.
Figure Description
92 673
92 674
40-41
GENERALSpecial tools
Car. 1138-02Part number 00 00 113 802
Points (A), (B), (C) and (D) are the reference pointsfor positioning the jig on the vehicle. Before fit-ting the jig, it is necessary to ensure at damage as-sessment that the reference points are correct.
Points (E), (F), (G), (H) and (J) are mainly used formounting and positioning the replacement parts.However, if either point (A) or (B) cannot be usedas a reference point, the points on the oppositeside to the impact act as reference points.
40FRONT END PANEL JIG
92301R
40-42
GENERALSpecial tools
ADJUSTING THE DOORS
40TOOL FOR REMOVING DOOR HINGE PINS
85899R
97129R
Car. 1055-02Part number 00 00 105 502
Fitted to the FENWICK REN. 1303 type slide ham-mer.
Flush fitting adjustment
This is obtained by pulling or pushing one or twohinges using tool Car. 956 fitted to impact extrac-tor M.S. 580.
Adjustment range: 3 mm
85700-2S
Tilt adjustment
It is possible to adjust the door clearances, front torear and tilt, without removing the door from thevehicle, using a claw lever on the male hinges:
Wilmonda BHA part number(Supplier: Z. INTERNATIONAL)
40-43
LOWER STRUCTUREComplete front end panel cross member
COMPOSITION OF THE REPLACEMENT PART
Assembled part with engine sub-frame mountingstiffeners.
41 A
92567S
This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.
PRS4112
BUTT WELDING JOINT ON THE SIDE MEMBER1
Thickness of panels (mm)
Cross member: 1.25Side member: 1.25Side member closure panel: 0.8
Unpicking
10 spot welds
Welding
BUTT WELDING JOINT ON THE SIDE MEMBER2
Thickness of panels (mm)
Cross member: 1.25Cowl side panel: 1
Unpicking
3 spot welds
92567-1S
40
41-1
LOWER STRUCTUREComplete front end panel cross member 41 A
92562S
BUTT WELDING JOINT ON THE HEADLIGHTCARRIER PANEL
3
Thickness of panels (mm)
Cross member: 1.25Headlight carrier panel: 0.8
Unpicking
8 spot weldsOne 15mm MAG weld fillet
Welding
BUTT WELDING JOINT ON THE LOCK SUPPORT4
Thickness of panels (mm)
Cross member: 1.25Lock support: 1.5
Unpicking
4 spot welds
Welding
92561-1S
41-2
LOWER STRUCTUREPart front end panel cross member 41 B
In order to carry out this operation on Phase I ve-hicles, the closure panel (3) above must be remo-ved from the new replacement part.
Phase II vehicles
This operation is a variation on the previous one.Therefore, only its special points are describedbelow.
It is not necessary to use the body jig bench forthis operation. Front panel jig Car. 1138 issufficient.
For this operation, lock support (2) below must beordered as well.
COMPOSITION OF THE REPLACEMENT PART
Same as previous part.
PRS4127
Phase I vehicles
PRS4113
41-3
LOWER STRUCTUREComplete front end panel 41 C
92563S
COMPOSITION OF THE REPLACEMENT PART
Special replacement part consisting of:- upper cross member- lower cross member- lock support-
PRS4128
For phase I vehicles:
At A : cut out the two phase II headlight moun-ting lugs.
At B : Add 2 washers (diameter 6 × 18) tocompensate for the enlargement of thecut-outs.
BUTT WELDING JOINT ON THE SIDE MEMBER1
Refer to the previous operation.
PANELThickness of the panels (mm)
Upper cross member: 1.2Headlight carrier panel: 0.8Lower cross member: 1.25Cowl side panel: 1
Unpicking
18 spot welds
Welding
92565-1S
92567-1S
BUTT WELDING JOINT ON THE COWL SIDEPANEL
2
41-4
LOWER STRUCTUREPart front end panel 41 D
PRS4115
This operation is a variation on the previous one.Therefore, only its special points are described be-low.
It can only be carried out on phase I vehicles whichdo not have a lower cross member closure panel(refer to the part lower cross member operation).
COMPOSITION OF THE REPLACEMENT PART
Same as previous part.
NOTE: cut (A) will only be made on the oppositeside to the impact.
Welding
92561-4S
41-5
LOWER STRUCTURESide member closure panel 41 E
92568S
This operation is carried out in addition to:
- straightening of the front section of the sidemember following removal of the front lowercross member,
- partial replacement of the front section of theside member following removal of the frontlower cross member,
- complete replacement of the front section ofthe cross member.
COMPOSITION OF THE REPLACEMENT PART
Panel only
PRS4116
UNPICKING
- 3 spot welds on the front cross member,- 10 single layer spot welds on the side member.
+
6 two layer spot welds
2 MAG weld fillets (15 mm x 2)
Welding
41-6
LOWER STRUCTUREFront side member front section 41 F
92567S
This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.
COMPOSITION OF THE REPLACEMENT PART
Part only without closure panel (the closure panelmust be ordered separately).
PRS4117
BUTT WELDING JOINT ON THE CLOSUREPANEL
1
Refer to the previous operation.
Thickness of panels (mm)
Cross member: 1.25Side member: 1.25Closure panel: 0.8
BUTT WELDING JOINT ON THE LOWER CROSSMEMBER
2
Unpicking
10 spot welds
Welding40
41-7
LOWER STRUCTUREFront side member front section 41 F
92569S
BUTT WELDING JOINT ON THE WHEEL ARCH3
Thickness of panels (mm)
Side member front section: 1.25Closure panel: 0.8Wheel arch: 0.7
Unpicking
+
18 spot weldsTwo 15mm MAG weld fillets
Welding
92566-2S
BUTT WELDING JOINT ON THE REAR SECTIONOF THE SIDE MEMBER
4
Thickness of panels (mm)
Side member front section: 1.25Side member rear section: 2Wheel arch: 0.7
Unpicking
Welding
92570S
After painting and before refitting the trim,protect the hollow sections with wax.
41-8
LOWER STRUCTUREPart front side member front section 41 G
PRS4118
This operation is a variation on the previous one.Therefore, only its special points are describedbelow.
COMPOSITION OF THE REPLACEMENT PART
Same as previous part.
Welding
92571S
41-9
LOWER STRUCTUREFront side member rear section 41 H
92572S
This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.
COMPOSITION OF THE REPLACEMENT PART
(1) Bare side member(2) Side cross member(3) Jack support(4) Sub-frame support (5) Stiffening plate
PRS4119
BUTT WELDING JOINT ON THE FRONT SECTION1
Refer to the previous operation.
BUTT WELDING JOINT ON THE FLOOR2
Thickness of panels (mm)
Side member rear section: 2Floor stiffener: 2Floor: 0.6
Unpicking
From inside the vehicle:
32 spot welds
Welding
After painting and before refitting the trim,protect hollow sections with wax.
40
41-10
LOWER STRUCTUREFront side member rear section 41 H
92577S
BUTT WELDING JOINT ON THE INNER SILLPANEL
3
Thickness of panels (mm)
Side cross member: 1Jack support: 2Inner sill panel: 1.5Sill panel: 1
Unpicking
9 spot welds
Welding
Ø D = 6 mm
After painting and before refitting the trim,protect the hollow sections with wax.
BUTT WELDING JOINT ON THE SEAT CROSSMEMBER
4
Thickness of panel (mm)
Side member rear section: 2Seat cross member: 1.25
Unpicking
+
6 two layer spot welds
92576S
Welding
After painting and before refitting the trim,protect the hollow sections with wax.
41-11
LOWER STRUCTUREFront side cross member 41 I
92574S
COMPOSITION OF THE REPLACEMENT PART
(1) Bare side cross member(2) Jack support
PRS4120
BUTT WELDING JOINT ON THE INNER SILLPANEL
1
Refer to the previous operation.
BUTT WELDING JOINT ON THE FLOOR2
Refer to the previous operation.
BUTT WELDING JOINT ON THE SIDE MEMBER3
Thickness of panels (mm)
Side cross member: 1Side member: 2
+
9 spot weldsOne 30mm MAG weld fillet
Welding
92575S
After painting and before refitting the trim,protect the hollow sections with wax.
Ø D = 5.5 mm
41-12
LOWER STRUCTUREFront half unit 41 J
92567-1S
COMPOSITION OF THE REPLACEMENT PART
(1) Side member front section(2) Wheel arch(3) Shock absorber cup(4) Wheel arch extender(5) Cowl side panel(6) Side member closure panel
This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.
PRS4121
BUTT WELDING JOINT ON THE LOWER CROSSMEMBER
1
Reminder
92567S
BUTT WELDING JOINT ON THE UPPER CROSSMEMBER
2
92563S
CHAMBER
92564S
Reminder
40
Reminder
BUTT WELDING JOINT ON THE HEATERBULKHEAD PARTITION
3
41-13
LOWER STRUCTUREFront half unit 41 J
92641S
BUTT WELDING JOINT ON THE BULKHEAD4
Reminder
92564-1S
BUTT WELDING JOINT ON THE SIDE MEMBERREAR SECTION
5
Reminder
92569S
92570S
COWL SIDE PANEL PARTIAL CUT6
• On the vehicle, cut the cowl side panel in linewith the dotted line on the diagram below.This line is level with the plenum chamber.
• Cut the replacement part in line with thecontinuous black line on the diagram. This lineis 60 mm from the line cut on the vehicle.
92573S
41-14
LOWER STRUCTUREFront half unit 41 J
92632R
With the vehicle positioned on the body jig bench,after welding the wheel arch, drill the front shockabsorber upper mounting.
To do this:- fit part (1) in the diagram below,- counter bore the four holes (A) to a diameter of
8 mm.
Warning: part (1) is the same for both the rightand left hand sides, it must be pivoted through ahalf turn when changing from one side to theother.
DRILLING THE SHOCK ABSORBER UPPERMOUNTING
7 SPECIAL FEATURES OF DIESEL VEHICLES8
On these vehicles, the right hand wheel arch hasan additional support for the engine pendulummounting.
Cup (C) must be welded during repair using abody jig bench bracket supplied with the body jigcomponents.
92662R
41-15
LOWER STRUCTUREPart centre floor panel 41 K
PRS4122
Example of the front section cut:
On the vehicle, use a chisel to cut the floor panellevel with the seat cross member in line with thedotted line on the diagram below.
NOTE: if the rear section of the floor panel is to bechanged, the dotted line will be located at (C).
COMPOSITION OF THE REPLACEMENT PART
Bare floor panel (panel only).
Cutting the replacement part
Cut (A) is made 20 mm above the round surface ofthe tunnel.
Cut (B) on one side or other of the seat crossmember location, at the front if the rear sectionof the floor panel is to be re-used, at the rear ifthe front section of the floor panel is to be re-used.
92646S
41-16
LOWER STRUCTURERear floor panel (part centre section) 41 L
PRS4123Cut the new part 20 mm beyond the cut made onthe vehicle, in order to be able to superpose byplug welding.
In addition to:UPPER REAR STRUCTURE- End panel44-U Method 3
COMPOSITION OF THE REPLACEMENT PART
Bare part
CUTTING - UNPICKING
92369S
NOTE: the general procedure for changing awelded component is described in WorkshopRepair Manual M.R. 502 section 4.
PREPARATION OF THE NEW PART
PRS4124
Welding
92369-1S
Ø D = 0.7 mm
e = 1.7 mmH = 50 mm
After painting and before refitting the trim,protect the hollow sections of the side memberswith wax.
41-17
LOWER STRUCTURERear floor panel 41 M
PRS4125
Addition to:UPPER REAR STRUCTURE - End panel44-U Method 3
Before changing the fuel tank support crossmember and the cross member under the floor.
COMPOSITION OF THE REPLACEMENT PARTS
(1) Rear floor panel bare part
(2) Fuel tank support cross memberSpare wheel well support
(3) Cross member under the floor panelbare part
CUTTING - UNPICKING
This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.
92370S 92371S
NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4.
40
41-18
LOWER STRUCTURERear floor panel 41 M
92374S
UNPICKING THE CROSS MEMBERS ON THE OPPOSITE SIDE TO THE IMPACT
92372S
WELDING THE CROSS MEMBERS (right hand side)PREPARATION OF THE NEW PART
PRS4126 92374-1S
Ø D = 5.5 mm
Position the cross member under the floor panel,in relation to the fuel tank support cross member,at the distance shown on the diagram.
Cut the new part 20 mm beyond the cut made onthe vehicle, in order to be able to superpose byplug welding.
41-19
LOWER STRUCTURERear floor panel 41 M
92373S
(right hand side) (left hand side)
92372-1S
Ø D = 5 mm
WELDING THE FLOOR PANEL
92370-1S92369-2S
Ø D = 4.5 mm
41-20
LOWER STRUCTURERear floor panel panel 41 M
92371-1S
e = 1.3 mm H = 30 mm
After painting and before refitting the trim,protect the hollow sections of the side memberswith wax.
41-21
LOWER STRUCTUREUtility vehicle floor panel panel 41 N
PRJ4019
REMOVE:- the four lashing rings and the rear floor panel carpet,- side sections (1) and (2) secured to the floor panel and the body sides.
Unpick sections (3) and (4) of the load floor panel by grinding out the stitch welds without separating the twosections.
Remove the load floor panel and load area partition assembly from the vehicle.
Re-use the 3 wheelbrace securing clips and the jack securing assembly.
REMINDER:
1/ Before starting the grinding operations, the internal surfaces of all of the windows and the dashboardmust be protected.
2/ Before fitting the rear seats, carry out a conventional paint application procedure on all of the groundsurfaces.
S53Utility
UNPICKING AND REMOVAL OF THE UTILITY VEHICLE FLOOR PANEL
41-22
LOWER STRUCTURE
Lateral side member lower section 41 O
PRS4106
COMPOSITION OF THE REPLACEMENT PART
Bare part
JOINT WITH THE FLOOR PANEL, SILL PANELAND SILL PANEL STIFFENER
1
Thickness of panels (mm)
Lateral side member 1.5Sill panel 1.5Sill panel stiffener 1.5
Unpicking
42 spot welds on the floor panel.22 spot welds on the sill panel.
Twenty 20mm MAG weld fillets.Two 40mm weld fillets.
Photo page 41-1
Welding
Front section:
D53Cabriolet
41-23
LOWER STRUCTURE
Lateral side member lower section 41 OD53
Cabriolet
Centre section:
Rear section:
Photo page 41-2
Photo page 41-2
Ø D = 8 mm
After painting and before refitting the trim,protect the hollow sections with wax.
41-24
LOWER STRUCTURELower side spacer 41 P
PRS4107
D53Cabriolet
This part can only be changed after removal of thelateral side member lower section.
COMPOSITION OF THE REPLACEMENT PART
Bare part
JOINT WITH THE FLOOR PANEL AND THELATERAL SIDE MEMBER LOWER SECTION
1
Thickness of panels (mm)
Spacer 1.5Side member lower section 1.5Floor panel 0.88
Unpicking
Ten 20mm MAG weld fillets.
Welding
Photo page 41-3
After painting and before refitting the trim,protect the hollow sections with wax.
41-25
LOWER STRUCTURESill panel stiffener 41 Q
PRS4108
D53Cabriolet
This operation can only be carried out afterremoval of the assembled sill panel.
COMPOSITION OF THE REPLACEMENT PART
Bare part
JOINT WITH THE FLOOR PANEL1
Thickness of panels (mm)
sill panel stiffener 1.5sill panel 1.5
Unpicking
41-26
LOWER STRUCTURESill closure panel stiffener 41 Q
Welding
On the joint near the front pillar, replace the inaccessible spot welds with MIG plug welds.
D53Cabriolet
Photo page 41-5
Ø D = 8 mm
JOINT WITH THE SILL PANEL FRONT STIFFENER2
Refer to paragraphs : 43 - L - 1
41-27
LOWER STRUCTURE
Front pillar lower section stiffener 41 R
PRS4109
D53Cabriolet
This operation can only be carried out afterremoval of the front pillar.
COMPOSITION OF THE REPLACEMENT PART
Part only
JOINT WITH THE COWL SIDE PANEL (pillarlining) AND SILL PANEL LINING
1
Thickness of panels (mm)
Cowl side panel 0.97Pillar stiffener 1.5Sill panel lining 1.5
31 spot welds.
Welding
Ø D = 8 mm
After painting and before refitting the trim, pro-tect the hollow sections with wax.
Photo page 41-6
41-28
LOWER STRUCTUREFloor panel and cross member side stiffener 41 S
PRS4110
Thirty-six 25mm weld fillets.
D53Cabriolet
COMPOSITION OF THE REPLACEMENT PART
- Floor panel stiffener.- Cross member stiffener.
JOINT WITH THE CENTRE FLOOR PANEL ANDFLOOR PANEL CROSS MEMBER
1
Thickness of panels (mm)
Stiffener 1.5Centre floor panel 0.8Cross member 1.5Centre pillar 1.5
Unpicking
Welding
Photo page 41-7
Photo page 41-7
After painting and before refitting the trim,protect the hollow sections with wax.
41-29
LOWER STRUCTUREFloor panel upper cross member 41 T
D53Cabriolet
COMPOSITION OF THE REPLACEMENT PART
Part only
PRS4111
JOINT WITH THE FLOOR PANEL AND CROSSMEMBER STIFFENER
1
Thickness of panels (mm)
Cross member 1.5Floor panel 0.88Stiffener 1.5
Thirty-three 25mm MAG weld fillets.Two 50mm weld fillets.31 spot welds.
Welding
Photo page 41-8
Photo page 41-8
Ø D = 6 mm
41-30
LOWER STRUCTUREAssembled rear end panel 41 U
93125S
L53Saloon
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:- rear end panel cross member- rear end panel- striker plate stiffener- end panel cross member
The two blanking pieces (1) must be orderedseparately.
PRS4105
Thickness of panels (mm)
Lighting support panel 0.67End panel cross member 0.67Side panel 0.67End panel extender 0.97
Unpicking
14 spot welds
JOINT WITH THE LIGHTING SUPPORT PANEL1
Welding
- 1 triple layer spot weld(cross member - panel - lighting support)
- 4 triple layer spot welds(cross member - lighting support - extender)
Special point
93124R
After welding and before protecting the crimps,fit the 2 metal blanking pieces (1) by clippingthem in place using the lugs.
41-31
LOWER SECTIONAssembled rear end panel 41 U
93122S
L53Saloon
Thickness of panels (mm)
End panel cross member 0.67Rear end panel 0.67Rear end panel cross member 1.25End panel extender 0.97
Unpicking
JOINT WITH THE END PANEL EXTENDER2
24 spot welds
93123S
- 4 triple layer spot welds
Thickness of panels (mm)
Extreme rear cross member 1,25Rear side member 1,00
Unpicking
JOINT WITH THE REAR SIDE PANEL3
14 spot welds
41-32
LOWER STRUCTUREAssembled rear end panel 41 U
L53Saloon
Thickness of panels (mm)
Extreme rear cross member 1.25Rear floor panel panel 0.60
Unpicking
JOINT WITH THE Rear floor panel panel4
Welding
93121S
41-33
LOWER STRUCTUREPart rear end panel cross member 41 V
93123-3S
- 1 triple layer spot weld
L53Saloon
COMPOSITION OF THE REPLACEMENT PART
Panel only
PRS4104
Thickness of panels (mm)
Rear end panel cross member 1.25End panel extender 0.97Rear end panel 0.67
Unpicking
JOINT WITH THE END PANEL EXTENDER1
6 spot welds
Welding
Thickness of panels (mm)
Rear end panel cross member 1.25Rear end panel 0.67
Unpicking
2 spot welds
JOINT WITH THE REAR END PANEL2
41-34
LOWER STRUCTUREPart rear end panel cross member 41 V
93120S
L53Saloon
Welding
Reminder: see 41-U-4
JOINT WITH THE REAR FLOOR PANEL3
93121S
Reminder: see 41-U-3
JOINT WITH THE REAR CROSS MEMBER4
93122S
Welding
PARTIAL CUT5
93119S
41-35
LOWER STRUCTUREBody 41 W
PRS4129
When a complete body is changed on a phase I vehicle, the Parts Department will supply a phase II type body.It will therefore be necessary to carry out the following operations (the details are described in the operationsfor each modified part, see contents).
For all types:- cut out the headlight mounting lugs on the front panel upper cross member,- add washers under the bonnet lock mountings,- order a new set of sill moulding.
For vehicles fitted with rubbing strips, order special replacement adhesive clips (refer to the parts list).
For B, C and S53 type vehicles:- drill the piston switch hole in the rear end panel,- close the tailgate harness hole in the upper rain channel.
For C and S53 type vehicles, drill the centre pillar trim 17 mm higher in order to refit the original seat belts.
41-36
UPPER FRONT STRUCTUREWing
REPLACEMENT
A) Detach the bumper without removing it completely. To do this, remove:- Two T20 Torx bolts (1)- Two 10mm hexagonal bolts (2)
B) Remove the wheel arch protector- One T20 Torx bolt (3)- Three clips (4)
C) Detach the front end of the sill moulding:- One T20 Torx bolt (5)
D) Slacken the bonnet strut mountings without removing them:- Two 13mm hexagonal bolts (6)
E) Remove the wing mountings:- Six 10mm hexagonal bolts (7)- Two 11mm hexagonal nuts (8)
F) Using a hot air gun, soften the anti-chipping mastic inside the wing and then remove the wing.
42 A
92560R
ALL TYPES
42-1
UPPER FRONT STRUCTUREWing 42 A
92676R
NOTE: the strip is bonded using a bead of "paintjoint" type mastic.
When a front wing is changed on a vehicle fittedwith rubbing strips, a mounting hole must be dril-led (see diagram).
ALL TYPES
42-2
UPPER FRONT STRUCTUREFront wing 42 A
D53Cabriolet
PRS4207
Photo page 42-1
The front wing is identical to that of the basevehicle × 53, but the lower rear section of it hasbeen modified.
This section is mounted using bolt (1) (seediagram).
42-3
UPPER FRONT STRUCTURE
Complete radiator grille upper cross member 42 B
PRS4209
COMPOSITION OF THE REPLACEMENT PART
Refer to the diagram below.
NOTE: for phase I vehicles, cut out the headlightmounting lugs at (A).
BUTT WELDING JOINT ON THE LOCK SUPPORT1
Thickness of panels (mm)
Cross member: 1.2Lock support: 1.5
Unpicking
4 spot welds
Welding
92561S
Thickness of panels (mm)
Cross member: 1.2Cowl side panel: 1
Unpicking
3 spot welds
Welding
92563S
2 BUTT WELDING JOINT ON THE COWL SIDEPANEL
42-4
UPPER FRONT STRUCTUREComplete radiator grille upper cross member 42 B
92563-2S
BUTT WELDING JOINT ON THE HEADLIGHTCARRIER PANEL
3
Thickness of panels (mm)
Cross member: 1.2Headlight carrier panel: 0.8
Unpicking
7 spot welds
Welding
42-5
UPPER FRONT STRUCTUREPart radiator grille upper cross member 42 C
PRS4201
This operation is a variation on the previous one.Therefore, only its special points are describedbelow.
COMPOSITION OF THE REPLACEMENT PART
Identical to the previous part.
Welding
92561-2S
42-6
UPPER FRONT STRUCTUREBonnet lock support 42 D
BUTT WELDING JOINT ON THE RADIATORGRILLE UPPER CROSS MEMBER
1
Refer to the previous paragraph.
BUTT WELDING JOINT ON THE LOWER CROSSMEMBER
2
Refer to section 41-A.
42-7
UPPER FRONT STRUCTUREHeadlight carrier panel 42 E
PRS4202
COMPOSITION OF THE REPLACEMENT PART
BUTT WELDING JOINT ON THE RADIATORGRILLE UPPER CROSS MEMBER
1
Refer to the previous paragraph.
BUTT WELDING JOINT ON THE LOWER CROSSMEMBER
2
Refer to sub-section 41-A.
BUTT WELDING JOINT ON THE COWL SIDEPANEL
3
Thickness of panels (mm)
Headlight carrier panel: 0.8Cowl side panel: 1
Unpicking
4 spot welds
Welding
92565-1S
42-8
UPPER FRONT STRUCTUREPart front wing panel (front section) 42 F
PRS4203
COMPOSITION OF THE REPLACEMENT PART
Part only, see diagram.
Cutting of the new part to : X = 435 mmCutting of the part on the vehicle to : X = 415 mm
BUTT WELDING JOINT ON THE RADIATORGRILLE UPPER CROSS MEMBER
1
Refer to the relevant paragraph.
BUTT WELDING JOINT ON THE LOWER CROSSMEMBER
2
Refer to sub-section 41-A.
BUTT WELDING JOINT ON THE HEADLIGHTCARRIER PANEL
3
Refer to the relevant paragraph.
BUTT WELDING JOINT ON THE WHEEL ARCH4
Thickness of panels (mm)
Wing panel: 1Wheel arch: 0.7
Unpicking
9 spot welds
Welding
92565S
PARTIAL CUT A5
92563-1S
42-9
UPPER FRONT STRUCTUREWheel arch (shock absorber turret) 42 G
PRS4204
This operation is to be carried out on a body jigbench. Refer to sub-section for instructionson fitting the components.
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:
(1) Wheel arch(2) Wheel arch extender(3) Rubber bush support(4) Shock absorber cup
BUTT WELDING JOINT ON THE WING PANELFRONT SECTION
1
Refer to the previous paragraph.
BUTT WELDING JOINT ON THE WING PANELREAR SECTION
2
(Shock absorber cup to the cowl side panel)
Thickness of panels (mm)
Shock absorber cup: 2Wing panel: 1
Unpicking
6 spot welds
Welding
92566S
CHAMBERThickness of panels (mm)
Cup: 2Heater bulkhead partition : 0.7
Unpicking
5 spot welds
92641S
40
A - SHOCK ABSORBER CUP TO THE HEATERBULKHEAD PARTITION
BUTT WELDING JOINT ON THE HEATERBULKHEAD PARTITION
3
42-10
UPPER FRONT STRUCTURE
Wheel arch (shock absorber turret) 42 G
92564S
B - WHEEL ARCH TO THE HEATER BULKHEADPARTITION
Thickness of panels (mm)
Wheel arch: 0.7Heater bulkhead partition : 0.7
Unpicking
7 spot welds
Welding
BUTT WELDING JOINT ON THE BULKHEAD4
Thickness of panels (mm)
Wheel arch: 0.7Bulkhead: 0.7
Unpicking
7 spot welds
Welding
92564-1S
42-11
UPPER FRONT STRUCTUREWheel arch (shock absorber turret) 42 G
92566-1S
BUTT WELDING JOINT ON THE SIDE MEMBER5
Thickness of panels (mm)
Wheel arch: 0.7Side member front section: 1.25Side member closure panel: 0.8Side member rear section: 2
Unpicking
21 spot weldsTwo 15mm MAG weld filletsTwo 30mm MAG weld fillets
Welding
After painting and before refitting the trim,protect the hollow sections with wax.
DRILLING THE SHOCK ABSORBER UPPERMOUNTING
6
With the vehicle positioned on the body jig bench,after welding the wheel arch, drill the front shockabsorber upper mounting.
To do this:- fit part (1) in the diagram below,- counter-bore the four holes (B) to a diameter of
8 mm.
Warning: part (1) is the same for both the rightand left hand sides, it must be pivoted through ahalf turn when changing from one side to theother.
92632R1
42-12
UPPER FRONT STRUCTUREWheel arch (shock absorber turret) 42 G
92662R
SPECIAL FEATURES OF DIESEL VEHICLES7
On these vehicles, the right hand wheel arch hasan additional support for the engine pendulummounting.
Cup (C) must be welded during repair using abody jig bench bracket supplied with the body jigcomponents.
42-13
UPPER FRONT STRUCTUREPart heater bulkhead partition 42 H
PRS4205
COMPOSITION OF THE REPLACEMENT PART
Consisting of:- heater bulkhead partition- component for joint with the windscreen
aperture lower cross member(1)- battery support- windscreen wiper motor support- welded studs and nuts.
BUTT WELDING JOINT ON THE WHEEL ARCH1
Refer to the previous paragraph.
BUTT WELDING JOINT ON THE WING PANEL2
Thickness of panels (mm)
Plenum chamber: 0.7Cowl side panel: 1
Unpicking
+
8 spot welds
Welding
92573-1S
42-14
UPPER FRONT STRUCTUREPart heater bulkhead partition 42 H
92579S
BUTT WELDING JOINT ON THE BULKHEAD3
Thickness of panels (mm)
Heater bulkhead partition : 0.7Bulkhead: 0.7
Unpicking
+
12 spot welds per 1/2 partition (i.e. 24 for thecomplete part)
Welding
Drilling of the bulkhead to a diameter of 5 mmfor plug welding.
PARTIAL CUT4
92570-1S
42-15
UPPER FRONT STRUCTUREPart windscreen aperture lower cross member 42 I
PRS4206
COMPOSITION OF THE REPLACEMENT PART
Consisting of:- windscreen aperture lower cross member- steering support (1)- welded nuts and studs
Cutting of the new part to : X = 320 mmCutting of the part on the vehicle to : X = 300 mm
BUTT WELDING JOINT ON THE FRONT PANEL1
Thickness of the panels (mm)
Windscreen aperture lower cross member: 1Cowl side panel: 1
Unpicking
+
5 spot weldsTwo 30mm MAG weld fillets
Welding
92578S
The welding operation above can only be carriedout with the front pillar removed.
92573-2S
After painting and before refitting the trim,protect the hollow sections with wax.
42-16
UPPER FRONT STRUCTUREPart windscreen aperture lower cross member 42 I
92573-3S
BUTT WELDING JOINT ON THE FRONT PILLAR2
Thickness of panels (mm)
Windscreen aperture lower cross member: 1Cowl side panel: 0.7
Unpicking
10 spot welds
Welding
92579-1S
Drilling of the cross member to a diameter of 5mm for plug welding.
PARTIAL CUT3
92580S
42-17
UPPER FRONT STRUCTUREFront pillar upper stiffener 42 J
PRS4208
COMPOSITION OF THE REPLACEMENT PART
Part only
JOINT WITH THE COWL SIDE PANEL AND THEFRONT PILLAR
1
Thickness of panels (mm)
Stiffener 1.5Cowl side panel 0.97Front pillar 1.25
Unpicking
11 spot welds
Seven 30mm MAG weld fillets.
Welding
Photo page 42-2
42-18
UPPER SIDE STRUCTUREFront pillar lower section 43 A
92363R
DISMANTLING
Remove:- front door,- front wing,- dashboard,- body side interior trim,- front seat.
Partially fold back the carpet.
Remove:- bonnet opening control,- electrical wiring in the pillar,- sill panel moulding.
COMPOSITION OF THE SPECIAL REPLACEMENTFRONT PILLAR
(1) Front pillar(2) Upper hinge stiffener(3) Lower hinge stiffener(4) Door stop mounting(5) Wing mounting stud(6) Welded KSM
CUTTING - UNPICKING
(7) Upper hinge(8) Lower hinge
Maximum length of the new part: 570 mm.
92629R
92630R
Remove the damaged section in line with the diagrams above (refer to the key to symbols)(A) drill right through the spot welds at the pillar - hinge stiffener - lining joints(B) unpick using a chisel
43-1
UPPER SIDE STRUCTUREFront pillar lower section 43 A
WELDING
Carry out the following:
• retaining spot welds on the lines to be buttwelded.
• the spot welds. The corresponding (e) and (H)values are given underneath each diagram.
• the MIG stitch welds.
• the MIG plug welds at the lining and hingestiffener joints.
• lead fill the butt welded sections, aftergrinding down the weld fillet.
ANTI-CORROSION PROTECTION
After painting and before refitting the trim, injecthollow section wax into the pillar.
Grind the bits of unpicked spot weld remaining onthe support panels.
Take a section of the new part which isapproximately 50 mm larger than that cut fromthe vehicle.
Position the new part on the vehicle so that it issuperposed, then secure it using a vice-gripwrench.
Cut the two layers of metal simultaneously with ahacksaw in order to facilitate the fit.
PREPARATION BEFORE WELDING
Strip the internal and external surfaces of all areasto be welded. (On the vehicle and on the newparts) .
Coat the sections to be spot welded with a beadof electro-plastic mastic. Apply aluminium paintto the sections to be plug welded.
Adjust the new part, then secure it using a vice-grip wrench.
92628-1R 92628R
e = 2.1 mmH = 65 mm
B =Ø 5 mm
43-2
UPPER SIDE STRUCTUREFront pillar by cutting at the upright 43 B
DISMANTLING
Remove:- front door,- front wing,- dashboard,- body side internal trim,- front seat.
Partially fold back the carpet.
Remove:- bonnet opening control,- electrical wiring in the pillar,- windscreen,- pillar upright seal,- sill panel moulding.
Remove the electrical wiring.
PROTECTION
Protect the interior using a cover which is resistantto welding and grinding damage.
43-3
UPPER SIDE STRUCTUREFront pillar by cutting at the upright 43 B
92627R
Define cuts (A) and (B). The working method isidentical to that for changing the lower section ofthe pillar.
Cuts (A) and (B) must be opposite an opening inorder to make it easier to protect the interior.
In order to ease cutting and unpicking, welding ofthe butt welding joints will be shown.
92627-1R
Lead fill the butt welded sections after grindingdown the weld fillet.
ANTI-CORROSION PROTECTION
After painting, inject hollow section wax into thenew part.
Original welding
Spot welding
Stitch welding
Repair welding
D = 5 mm
e = 2.1 mmH = 65 mm
43-4
UPPER SIDE STRUCTUREDoor hinges (on the front pillar) 43 C
92627-2R
B = 296 ± 1 mm (theoretical value for informa-tion)
WELDING THE DOOR HINGES TO THE FRONTPILLAR
When a front pillar is changed, the door hinges, tobe ordered separately, must be welded on.
To do this, follow the procedure below.
Temporarily spot weld the two male hinges to thepillar using the part which has been removed tomark the positions.
Fit the door, with the front wing removed, andcheck that it is adjusted correctly before perma-nently welding the hinges in place.
D53Cabriolet
92630-1R
A = 115 ± 1 mm (theoretical value for informa-tion)Ø1 = 20 mm
43-5
UPPER SIDE STRUCTUREAssembled front pillar 43 D
D53Cabriolet
This operation can only be carried out afterremoval of the upper pillar stiffener and is inaddition to the partial changing of thewindscreen frame.
COMPOSITION OF THE REPLACEMENT PART
- Bare front pillar.- Pillar stiffener tube.- Internal pillar stiffener.
PRS4301
JOINT WITH THE WINDSCREEN PILLAR LINING1
Refer to section: 45 ...
JOINT WITH THE PILLAR LINING AND SILLPANEL
2
Thickness of panels (mm)
Front pillar 1.25Pillar lining 0.97Sill panel 1.5Sill panel front stiffener 1.5
Unpicking
50 spot welds
Three 30mm MAG weld fillets.One 90mm MAG weld fillet.
Photo page 43-1
Ø D = 8 mm
43-6
UPPER SIDE STRUCTUREAssembled front pillar 43 D
D53Cabriolet
JOINT WITH THE INTERNAL PILLAR STIFFENER3
Thickness of panels (mm)
Front pillar 1.25Stiffener 1.5
Unpicking
Two 30mm MAG weld fillets.One 10mm MAG weld fillet.
Welding
Photo page 43-2
JOINT WITH THE WINDSCREEN FRAME4
Reminder: see 45-B
After painting and before refitting the trim, treatthe hollow sections with wax.
43-7
UPPER SIDE STRUCTUREFront pillar 43 E
92363R1
COMPOSITION OF THE SPECIAL REPLACEMENTFRONT PILLAR
The parts warehouse supplies the B53 front pillar(for reasons of standardisation).
When the front pillar of the C53 is changed, thesill panel section must be cut in order to hold theoriginal butt welding joint more easily.
Dimension of the cut: 345 mm
C53
Welding
92626-1G 92626G
Original welding Repair welding
Spot welding
D = 5 mm
43-8
UPPER SIDE STRUCTUREPillar upright joint mounting (KSM) 43 F
92624R
At (A) KSM type welded mounting.
The other 4 mountings are rivets:part number. 77 03 072 263
to be secured when the support is fitted.
It is essential that electro-plastic mastic is put intothe holes before riveting in order to ensuresealing and prevent corrosion.
DIMENSION OF THE KSMS WELDED TO THEUPRIGHT
43-9
UPPER SIDE STRUCTURECentre pillar 43 G
DISMANTLING
Remove:- rear door,- body side trims,- front seat,- complete rear seat,
Partially fold back the carpet.
Remove:- sill panel moulding,- electrical wiring,- front door striker,- seat belt upper support,- seat belt.
COMPOSITION OF THE REPLACEMENT PART
(1) Centre pillar(2) Seat belt mounting(3) Upper hinge(4) Lower hinge(5) Hinge stiffener(6) Striker mounting retainer
Maximum length of the new part:top 840 mmbottom 1 230 mm
92363R2
43-10
UPPER SIDE STRUCTURECentre pillar 43 G
92623R
CUTTING - UNPICKING
92622R
(A) and (C) are the recommended cutting areas. To make cutting and unpicking easier, the original buttwelding joints are shown above. NOTE: it is possible to make a cut at (C) to avoid having to change the part later.
Spot welding
Brazing
(B) sealing lining support.
Take a section of the new part which is approximately 50 mm larger than that cut from the vehicle.
Position the new section on the vehicle so that it is superposed, then secure it using a vice-grip wrench.
At (A) cut 15 mm longer, this section to be plug welded.
Cut the two layers of metal simultaneously with a hacksaw in order to facilitate the fit.
43-11
UPPER SIDE STRUCTURECentre pillar 43 G
92621R
PREPARATION BEFORE WELDING
Strip the internal and external surfaces of all areas to be welded. (On the vehicle and on the new parts).
Coat the sections to be spot welded with a bead of electro-plastic mastic (see the key to symbols at thebeginning of the section).
Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under eachwelding diagram and coat with aluminium paint.
Adjust the new part, then secure it using a vice-grip wrench.
92622-1S
Lead fill the butt welded sections, after grinding down the weld fillet.
Repair welding
Lead fill at (A).
D = 4.5 mm
43-12
UPPER SIDE STRUCTURECentre pillar 43 G
ANTI-CORROSION PROTECTION
After painting, inject hollow section wax into thenew part.
92619S
92620S
Repair anti-corrosion protection.
43-13
UPPER SIDE STRUCTURECentre pillar 43 G
PRS4304
This operation can only be carried out after remo-val of the rear wing panel.
COMPOSITION OF THE REPLACEMENT PART
Part only
D53Cabriolet
JOINT WITH THE CENTRE LINING AND SILLPANEL
1
Thickness of panels (mm)
Centre pillar 1.25Lining 1.5Sill panel 1.5
Unpicking
30 spot welds
Four 25mm MAG weld fillets
15 MAG plug welds
Welding
Photo page 43-10
Ø D = 6 mm
On the front right hand section, some spot weldsare made only after the wing panel has beenrefitted.
JOINT WITH THE WING PANEL LINING2
See 44-D
43-14
UPPER SIDE STRUCTURECentre pillar lining 43 H
PRS4306
COMPOSITION OF THE CENTRE PILLAR LINING
(1) Centre pillar lining, upper section(2) Seat belt mounting nut(3)
CUTTING - UNPICKING
92618S 92617S
Original welding
Stitch welding
Spot welding
NOTE: it is possible to change the complete centre pillar or make a cut at (A) to make a butt weld (if thismethod is used, the roof trim does not have to be removed).
43-15
UPPER SIDE STRUCTURECentre pillar lining 43 H
92618-1R
D = 5 mm
PREPARATION BEFORE WELDING
Strip the internal and external surfaces of all of the areas to be welded. (On the vehicle and on the new parts).
Spray zinc paint on the sections to be spot welded.
Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under eachwelding diagram and coat with aluminium paint.
Adjust the new part, then secure it using a vice-grip wrench.
Repair welding
Spot weld at (A).
92617-1S
43-16
UPPER SIDE STRUCTURECentre pillar lining 43 H
92616S
Repair welding
92616-1S
Original welding
D = 6 mm
43-17
UPPER SIDE STRUCTURECentre pillar lining 43 H
This operation can only be carried out after remo-val of the wing panel lower front lining and thefloor and cross member side stiffener.
COMPOSITION OF THE REPLACEMENT PART
- Centre pillar lining.- Seat belt mounting stiffener.
D53Cabriolet
PRS4305
JOINT WITH THE FLOOR1
Thickness of panels (mm)
Pillar lining 1.5Floor 0.88
Unpicking
Seven 40mm MAG weld fillets.
Photo page 43-11
JOINT WITH THE CENTRE PILLAR2
Refer to the previous operation.
JOINT WITH THE WING PANEL LINING3
Reminder: see 44-D
43-18
UPPER SIDE STRUCTURESill panel 43 I
92363S
The sill panel is supplied bare.
92363S1
RECOMMENDATIONS FOR REPLACEMENT
Depending on the area which is deformed, it is possible to change the sill panel at several points (seediagrams).
92363S3
92363S2
92363S4
All of the cuts must be butt welded using MIG stitch welds, then lead filled.
43-19
UPPER SIDE STRUCTURESill panel 43 I
92615S
92622S
92615-1R
92622-1R
Original welding
Spot welding
Repair welding
H = 35 mm
(A) D = 4.5 mm(B) D = 5 mm
ANTI-CORROSION PROTECTION
After painting and before refitting the trim, inject hollow section wax.
Brazing
43-20
UPPER SIDE STRUCTUREBody side
These parts are affected by the modification tothe sill panel moulding. The Parts Department willsupply them with the two phase II type mountingrows.
When one of the parts is changed on a phase I ve-hicle, the holes of the lower row must be closedusing self-adhesive plugs before the anti-chippingmastic is applied. These plugs are available fromthe Parts Department (see PR).
NOTE: this course of action is already applied inadvance to production vehicles.
43 J
PRS4308
ALL TYPESPhase I
43-21
UPPER SIDE STRUCTUREPart sill panel 43 K
COMPOSITION OF THE REPLACEMENT PART
Bare part
Before cutting the sill panel on the vehicle, thespot welds at the joint of the sill panel with itslongitudinal partition must be unpicked.
The number of spot welds to be unpicked willdepend on the length of the partial cut.
On the new part, drill 6.5mm diameter holes atthe butt welding joint with the longitudinalpartition.
Welding
- Make the plug welds for the joint with thepartition.
- Spot welds for the joint with the inner sillpanel.
- Stitch welds at the ends of the partial cut.
For further information, refer to the previousparagraph.
Unpicking
Photo page 43-3 Photo page 43-3
D53Cabriolet
43-22
UPPER SIDE STRUCTUREAssembled sill panel 43 L
PRS4307
This operation can only be carried out after remo-val of the front pillar and the wing panel.
COMPOSITION OF THE REPLACEMENT PART
- Sill panel.-Longitudinal partition.
D53Cabriolet
JOINT WITH THE FRONT PILLAR1
Refer to section : 43 - D - 2
Note: If the front pillar has not been damaged, itis preferable cut part of the sill panel. To do this,refer to section: 43 - K.
JOINT WITH THE INNER SILL PANEL2
Thickness of panels (mm)
Sill panel 1.5Inner sill panel 1.5Inner sill panel stiffener 1.5Lateral side member 1.5
Unpicking
62 spot welds. 3 MAG spot welds
43-23
UPPER SIDE STRUCTUREAssembled sill panel 43 L
Welding
D53Cabriolet
Photo page 43-5
43-24
UPPER SIDE STRUCTUREAssembled sill panel 43 L
D53Cabriolet
Ø D = 8 mm
At the rear section, the sill panel lower joint ismade only after the wing panel has been refitted.
At the front section, the joint is only made afterthe pillar has been refitted.
After painting and before refitting the trim, treatthe hollow sections with wax.
Photo page 43-6
43-25
UPPER SIDE STRUCTURESill panel 43 L
92764R1
B - C - L53Sport
Using the dimensions shown on the diagrams below, mark the location of the 4 mounting points A, B, C andD. The dimensions are identical for B, C and L53 type vehicles.
92309R
Points :
A h = 25 mm
B h = 25 mm
C h = 22 mm
D h = 11 mm
Drill the holes to Ø 6 mm.
Apply sealing mastic to the edge of the holes and fit clips (3).
43-26
UPPER SIDE STRUCTURESill panel front stiffener 43 M
PRS4302
COMPOSITION OF THE REPLACEMENT PART
Bare part
D53Cabriolet
JOINT WITH THE FRONT PILLAR, COWL SIDEPANEL AND WHEEL ARCH
1
Thickness of panels (mm)
Stiffener 1.5Front pillar 1.25Cowl side panel 0.97Wheel arch 0.7
Unpicking
Four 20mm MAG weld fillets.Twelve 40mm MAG weld fillets.
7 MAG plug welds.
Welding
Photo page 43-7
After painting and before refitting the trim, treatthe hollow sections with wax.
Ø D = 8 mm
43-27
UPPER SIDE STRUCTURESill panel front stiffener 43 M
D53Cabriolet
JOINT WITH THE SILL PANEL2
Thickness of panels (mm)
Stiffener 1.5Sill panel 1.5
Unpicking
7 spot welds.
7 MAG plug welds.
One 30mm MAG welds fillet.
Welding
Ø D = 8 mm
JOINT WITH THE FLOOR AND FRONT SIDEMEMBER
3
Unpicking
Six 30mm MAG weld fillets.
Welding
Photo page 43-8
Photo page 43-8
43-28
UPPER SIDE STRUCTURESill panel rear stiffener 43 N
This operation can only be carried out after remo-val of the rear wing panel.
Refer to paragraph: 44-A
COMPOSITION OF THE REPLACEMENT PART
Bare part
D53Cabriolet
PRS4303
JOINT WITH THE SILL PANEL AND WHEELARCH
1
Thickness of panels (mm)
Stiffener 1.5Sill panel 1.5Outer wheel arch 0.88Inner wheel arch 1.2
Unpicking
16 spot welds.
Four 25mm MAG weld fillets.
Photo page 43-9
Welding
Photo page 43-9
Ø D = 8 mm
After painting and before refitting the trim, pro-tect the hollow sections with wax.
43-29
UPPER SIDE STRUCTURERoof arch 43 O
PRS4309
NOTE: at (C) apply two beads of filling mastic.
ATTENTION: when fitting a sun roof as an accesso-ry, the roof arch must be cut.
The sun roof frame will then act as the stiffener.
This part can only be changed after removal ofthe roof.
COMPOSITION OF THE REPLACEMENT PART
Part only.
B53Phase II
JOINT WITH THE BODY SIDE1
Thickness of panels (mm)
Body side 0.77Stiffener 0.77
Unpicking
4 spot welds
Welding
95813R
43-30
UPPER REAR STRUCTUREComplete wing panel 44 A
PRS4412
This operation is carried out with the roof remo-ved.
COMPOSITION OF THE REPLACEMENT PART
Part only. The double seal support (1) must beordered separately.
JOINT WITH THE ROOF1
Thickness of panels (mm)
Wing panel 0.67Roof 0.67Body side support extender 0.67
Unpicking
One 25mm MAG weld fillet
93126R1
At (2), apply a bead of metal bonding mastic.
Welding
93118S
- 2 triple layer spot welds
L53Saloon
44-1
UPPER REAR STRUCTUREComplete wing panel 44 A
93116S
Thickness of panels (mm)
Wing panel 0.67Body side 1.1
Unpicking
JOINT WITH THE BODY TOP2
One 25mm MAG weld fillet
Welding
93117S
Thickness of panels (mm)
Wing panel 0.67Quarter panel lining 0.67Roof drip moulding lining 0.67Seat belt retractor support bracket 1.2Body side upper extender 0.67
Unpicking
21 spot welds
- 4 triple layer spot welds
93115S
- 3 triple layer spot welds
L53Saloon
JOINT WITH THE QUARTER PANEL LINING3
44-2
Thickness of panels (mm)
Wing panel 0.67Lighting support component 0.67
Unpicking
UPPER REAR STRUCTUREComplete wing panel 44 A
93113S
L53Saloon
Thickness of panels (mm)
Wing panel 0.67Side rain channel 0.87
Unpicking
One 10mm MAG weld fillet
Welding
8 spot welds
JOINT WITH THE SIDE RAIN CHANNEL4
93114S
Welding
4 spot welds
JOINT WITH THE LIGHTING SUPPORT COMPONENT5
Depending on method: see JOINT 6
One 20mm MAG weld fillet - see JOINT note 6
44-3
UPPER REAR STRUCTUREComplete wing panel 44 A
93111S
L53Saloon
Thickness of panels (mm)
Wing panel 0.67End panel extender 0.97
Unpicking
NOTE: There is a spot weld located under the endpanel cross member (see welding). If the crossmember is not to be removed, a special cut mustbe made on the panel.
4 or 5 spot welds depending on themethod
JOINT WITH THE END PANEL EXTENDER6
93112S
A - With removal of the end panel cross member
One 20mm MAG weld fillet
Welding
A - With removal of the end panel cross member
93112-1S
B - Without removal of the end panel crossmember
B - Without removal of the end panel crossmember
44-4
UPPER REAR STRUCTUREComplete wing panel 44 A
93109S
L53Saloon
93110S
6 spot welds
Thickness of panels (mm)
Wing panel 0.67Rear floor 0.60Outer wheel arch 0.67Inner wheel arch 1.25
Unpicking
JOINT WITH THE REAR FLOOR7
Welding
- 1 four layer spot weld- 1 triple layer spot weld
19 spot welds
Thickness of panels (mm)
Wing panel 0.67Outer wheel arch 0.67Inner wheel arch 1.25Backrest mounting stiffener 1.5Side member closure panel 1.5Sill panel 1.1
Unpicking
JOINT WITH THE OUTER WHEEL ARCH8
44-5
UPPER REAR STRUCTUREComplete wing panel 44 A
93106S
L53Saloon
Welding
93108S
93107S
- 14 triple layer spot welds
6 spot welds
Thickness of panels (mm)
Wing panel 0.67Sill panel 1.1
Unpicking
One 25mm brazed weld fillet
Welding
One 25mm MAG weld fillet
JOINT WITH THE SILL PANEL9
44-6
UPPER REAR STRUCTUREComplete wing panel 44 A
93105S
L53Saloon
10
Welding
3 spot welds
Thickness of panels (mm)
Wing panel 0.67Double seal support 0.67
Unpicking
JOINT WITH THE DOUBLE SEALSUPPORT
44-7
UPPER REAR STRUCTUREComplete rear wing panel 44 A
COMPOSITION OF THE REPLACEMENT PART
- Bare panel.- Window frame stiffener.- Panel stiffener.- Striker stiffener.- Bumper stiffener.- Window guide upper stiffener.
D53Cabriolet
Welding
JOINT WITH THE UPPER LINING1
Thickness of panels (mm)
Wing panel 0.8Lining 1.0
Unpicking
38 spot welds.
Photo page 44-1
JOINT WITH THE BOOT LID RAIN CHANNELAND WING PANEL REAR LINING
1
Thickness of panels (mm)
Wing panel 0.8Boot lid rain channel 1.0Lining 0.88
Unpicking
23 spot welds.One 30mm MAG weld fillet.
1 brazed weld fillet.
PRS4413
44-8
UPPER REAR STRUCTUREComplete rear wing panel 44 A
Note: When unpicking at the joint with the bootlid rain channel, drill out the spot welds using aspot weld rotary grinder. These holes will be plug-ged again by MAG welding.
Welding
D53Cabriolet
The MAG welds shown are to be made on bothsides.
Photo page 44-2
Photo page 44-2
Photo page 44-2
JOINT WITH THE WHEEL ARCH AND SILLPANEL
1
Thickness of panels (mm)
Wing panel 0.88Sill panel 1.5Wheel arch 0.8
Unpicking
11 spot welds.
44-9
UPPER REAR STRUCTUREComplete rear wing panel 44 A
Preparation before welding:
D53Cabriolet
Welding
Photo page 44-3
Photo page 44-3
Photo page 44-3
Photo page 44-3
44-10
UPPER REAR STRUCTUREComplete rear wing panel 44 A
D53Cabriolet
JOINT WITH THE SILL PANEL AND CENTREPILLAR
4
Thickness of panels (mm)
Wing panel 0.88Sill panel 1.5
Unpicking
15 spot welds.Two 30mm MAG weld fillets.
1 brazed fillet.
Welds
Note: At the lower section of the sill panel, thespot welds must be made in the recesses to avoidwelding four overlapping panels.
Photo page 44-4
JOINT WITH THE CENTRE PILLAR5
Thickness of panels (mm)
Wing panel 0.88Centre pillar 1.25Pillar lining 1.5
Unpicking
14 spot welds.
44-11
UPPER REAR STRUCTUREComplete rear wing panel 44 A
D53Cabriolet
Welding
JOINT WITH THE SILL PANEL AND PANELSTIFFENER
6
Thickness of panels (mm)
Stiffener 0.6Sill panel 1.5
Unpicking
Two 10mm MAG weld fillets
Hollow section protection:
Photo page 44-5
Photo page 44-5
Photo page 44-5
Photo page 44-5
44-12
UPPER REAR STRUCTUREPart wing panel (cut A)
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:
- bumper mounting stiffener- striker stiffener
44 B
92363R7
NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 44.
92399S
CUTTING - UNPICKING
92400-1S
(End panel - wing panel joint)
44-13
UPPER REAR STRUCTUREPart wing panel (cut A) 44 B
92404S92402S
Remove the double seal support.
92403S
PREPARATION OF THE NEW PART
92363R3
Area not used
44-14
UPPER REAR STRUCTUREPart wing panel (cut A) 44 B
PRS4410
SUPERPOSED CUT
92405-1S
Welding
PRS4411
e = 1.4 mmH = 30 mm
D = 5 mm
e = 1.4 mmH = 30 mm
D = 5 mm
A :
e = 1.4 mmH = 60 mm
44-15
UPPER REAR STRUCTUREPart wing panel (cut A) 44 B
92402-1S
ANTI-CORROSION PROTECTION
92407S
e = 1.4 mmH = 60 mm
D = 5 mm
92408S
e = 1.4 mmH = 60 mm
D = 5 mm
D = 5 mm
92410S
44-16
UPPER REAR STRUCTUREPart wing panel (cut B) 44 B
92363R8
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:
- bumper mounting stiffener- striker stiffener
CUTTING - UNPICKING
92399S 92400S
(End panel - wing panel joint)
NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 44.
44-17
UPPER REAR STRUCTUREPart wing panel (cut B) 44
92404S92401S
B
(end panel - wing panel joint)
Retain the edge of panel (A) and open it slightly inorder to superpose the new part and plug weld it.See § WELDING.
PREPARATION OF THE NEW PART
92363R6
Area not used
44-18
UPPER REAR STRUCTUREPart wing panel (cut B)
SUPERPOSED CUT
44 B
92406S
92405S
Welding
92405-2S
D = 5 mm
e = 1.4 mmH = 60 mm
44-19
UPPER REAR STRUCTUREPart wing panel (cut B) 44 B
92408S
D = 5 mm
92407S
e = 1.4 mmH = 60 mm
ANTI-CORROSION PROTECTION
92409S
44-20
UPPER REAR STRUCTUREPart wing panel (cut A) 44 B
92363R9
C53
The general procedure for changing the panel isidentical to that for the B53, only the positions ofthe superposed cuts are different.
Area not used
44-21
UPPER REAR STRUCTUREPart wing panel (cut A) 44 B
PRS4436
The Parts Department only supplies phase II typeparts which only have one row of rubbing stripmounting holes. For phase I vehicles, remember toorder the adhesive clips for mounting the phase Istrip.
NOTE: as the last but one hole (A), is not used formounting the phase I strip, it must be closed toseal effectively using an adhesive plug or a smallball of mastic (see PR).
C53 / S53Phase I
44-22
UPPER REAR STRUCTUREPart wing panel (cut AB) 44 B
PRS4414
The general procedure for changing the panel isidentical to that for the B53, only the positions ofthe superposed cuts are different.
SPECIAL POINTS
C53
Area not used
44-23
UPPER REAR STRUCTUREPart wing pane (cut A) 44 B
93104S
This operation is a variation on the previous one.Therefore, only its special points are described be-low.
COMPOSITION OF THE REPLACEMENT PART
Same as the previous part.
L53Saloon
PRS4416
Welding
44-24
UPPER REAR STRUCTUREPart rear wing panel (cut A) 44 B
Partially remove the damaged part following therecommendations for the previous operation.
D53Cabriolet
PARTIAL CUT1
PRS4415
X = 920 mm.
Unpicking
Length of cut: 400 mm.
After painting and before refitting the trim,protect the hollow sections with wax (innersection of the wing panel).
Photo page 44-6
44-25
UPPER REAR STRUCTUREQuarter panel lining 44 C
PRS4445
These vehicles are fitted with an adjustable seatbelt mounting. The Parts Department only sup-plies phase II type parts to which all types of seatbelt can be fitted. Mounting hole (A) has beenmoved up 17 mm. Consequently, when either aquarter panel lining or a complete body is chan-ged on a phase I vehicle, the original hole in thepillar trim must be extended 17 mm upwards (re-fer to the paragraph on pillar trim).
All typesPhase I
44-26
UPPER REAR STRUCTUREQuarter panel lining 44 C
PRS4418
L53Saloon
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:- quarter panel lining,- body side upper extender.
Thickness of panels (mm)
Body side upper extender 0.67Body side 1.1Roof drip moulding lining 0.67Quarter panel lining 0.67
Unpicking
8 spot welds
JOINT WITH THE BODY TOP1
5 spot welds
Special point for removal
To gain access to the body side extender spotwelds, the roof drip moulding lining must bepartially removed. Cut it to the dimensionX = 125 mm
Welding
93099S
93098S
44-27
UPPER REAR STRUCTUREQuarter panel lining 44 C
93097S
L53Saloon
Cut a piece of the new roof drip moulding liningto the dimension Z = 145 mm.
On the diagram above, the dotted line representsthe cut carried out on the vehicle during theunpicking operation. Dimension Y = 180 mm isused to position the new part.
JOINT WITH THE REAR ROOF CROSS MEMBER2
Thickness of panels (mm)
Quarter panel lining 0.67Roof 0.67Rear roof cross member 0.67
Unpicking
4 spot welds
Welding
JOINT WITH THE OUTER WHEEL ARCH3
Thickness of panels (mm)
Quarter panel lining 0.67Outer wheel arch 0.67Quarter panel arch 0.97Side shelf 0.97Backrest mounting stiffener 1.25
Unpicking
9 spot welds
93099-1R
44-28
UPPER REAR STRUCTUREQuarter panel lining 44 C
93096S
L53Saloon
- 3 triple layer spot welds
- 2 plug welds to be made from inside the vehicle
JOINT WITH THE SIDE SHELF5Welding
- 4 triple layer spot welds
JOINT WITH THE ROOF PANEL4
Apply a bead of metal bonding mastic.
Thickness of panels (mm)
Quarter panel lining 0.67Side shelf 0.97Quarter panel arch 0.97Outer wheel arch 0.67
Unpicking
11 spot welds
Welding
93099-4S
93095S
44-29
UPPER REAR STRUCTUREQuarter panel lining 44 C
93094S
L53Saloon
JOINT WITH THE SIDE RAIN CHANNEL6
Thickness of panels (mm)
Quarter panel lining 0.67Side rain channel 0.97Seat belt retractor support bracket 1.20
Unpicking
2 spot welds
Welding
- 2 triple layer spot welds
JOINT WITH THE WING PANEL7
Reminder: see 44-A-3
93116S
93115S
44-30
UPPER REAR STRUCTUREQuarter panel lining 44 C
93126R1
L53Saloon
JOINT WITH THE QUARTER PANEL ARCH8
Reminder: see 44-J-1
93093S
44-31
UPPER REAR STRUCTUREAssembled wing panel lining 44 C
This operation can only be carried out after remo-val of the complete wing panel.
COMPOSITION OF THE REPLACEMENT PART
- Upper front lining.- Lower front lining.- Rear lining.- Outer wheel arch.- Wheel arch stiffener.- Inner wheel arch.
D53Cabriolet
PRS4417
Welding
JOINT WITH THE CENTRE PILLAR1
Thickness of panels (mm)
Panel lining 0.88Centre pillar 1.25Centre pillar lining 1.5
Unpicking
8 spot welds.Two 20mm MAG weld fillets.Two 30mm MAG weld fillets.
Photo page 44-7
Photo page 44-7
44-32
UPPER REAR STRUCTUREAssembled wing panel lining 44 D
D53Cabriolet
Welding (cont)
Ø D = 6 mm
JOINT WITH THE SILL PANEL AND WHEELARCH
2
Thickness of panels (mm)
Panel lining 0.88Sill panel 1.5Wheel arch 0.88Sill panel stiffener 1.5Sill panel lining 1.5
Unpicking
11 spot welds.
Two 30mm MAG weld fillets.One 20mm MAG weld fillet.
Welding
Photo page 44-8
Photo page 44-8
Photo page 44-8
44-33
UPPER REAR STRUCTUREAssembled wing panel lining 44 D
D53Cabriolet
JOINT WITH THE REAR FLOOR3
Thickness of panels (mm)
Panel lining 0.88Rear floor 0.88Wheel arch 1.2
Unpicking
25 spot welds.Two 30mm MAG weld fillets.
Welding
JOINT WITH THE LIGHTING SUPPORT PANEL1
Thickness of panels (mm)
Panel lining 0.88Lighting support 0.67
Unpicking
12 spot welds.
Photo page 44-9
Photo page 44-9
44-34
UPPER REAR STRUCTUREAssembled wing panel lining 44 D
After painting and before refitting the trim, pro-tect the hollow sections with wax.
D53Cabriolet
Welding (cont)
Note: For welding to the rear wing panel, refer toparagraph: 44-A
JOINT WITH THE WHEEL ARCH UPPER CROSSMEMBER
5
Reminder: see 44-N
Photo page 44-10
Photo page 44-10
44-35
UPPER REAR STRUCTUREWing panel lower front lining 44 E
PRS4419
This operation can only be carried out after remo-val of the wing panel.
COMPOSITION OF THE REPLACEMENT PART
- Bare lining.- Window winder support.
D53Cabriolet
JOINT WITH THE CENTRE PILLAR, SILL PANELAND WHEEL ARCH
1
Thickness of panels (mm)
Sill panel 1.5Inner sill panel 1.5Panel lining 0.88Centre pillar 1.25Centre pillar stiffener 1.5
Unpicking
15 spot welds.
Welding
Ø D = 8 mm
Photo page 44-11
44-36
UPPER REAR STRUCTUREWing panel upper front lining 44 F
This operation can only be carried out after remo-val of the wing panel.
COMPOSITION OF THE REPLACEMENT PART
- Hood mounting bracket.- Stiffener.
D53Cabriolet
PRS4420
JOINT WITH THE WHEEL ARCH AND REARLINING
1
Thickness of panels (mm)
Panel lining 0.88Inner wheel arch 1.2Outer wheel arch 0.88
Unpicking
15 spot welds.
Welding
JOINT WITH THE CENTRE PILLAR2
Refer to the "Assembled wing panel lining" ope-ration: 44-D
Photo page 44-12
44-37
UPPER REAR STRUCTUREWing panel rear lining 44 G
This operation can only be carried out after remo-val of the wing panel.
COMPOSITION OF THE REPLACEMENT PART
- Counter balance stiffener.- Counter balance joint.- Lock stiffener.
D53Cabriolet
PRS4421
Welding
Photo page 44-13
JOINT WITH THE WHEEL ARCH, BOOT LID RAINCHANNEL AND FRONT LINING
1
Thickness of panels (mm)
Rear lining 0.88Front lining 0.88Rain channel 0.88Outer wheel arch 0.88Inner wheel arch 1.2
Unpicking
A - On the wheel arch:10 spot welds
B - On the boot lid drip moulding:5 spot welds.
C - On the front section:5 spot welds.
Ø D = 6 mm
JOINT WITH THE REAR FLOOR AND LIGHTINGSUPPORT
2
Refer to section: 44-2A
44-38
UPPER REAR STRUCTURETailgate upper rain channel 44 H
95785R
All typesPhase I
The parts supplied by the Parts Department are ofthe phase II type. Consequently, the wiring hole inthe upper rain channel must be closed. (hole (B) on the diagram)
NOTE: For the type of blanking piece to be used,refer to the vehicle PR.
44-39
UPPER REAR STRUCTUREOuter wheel arch 44 I
92411S
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of: - bare outer wheel arch- wheel arch stiffener
PRS4422
CUTTING - UNPICKING
92412S
NOTE: the general, procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4.
44-40
UPPER REAR STRUCTUREOuter wheel arch 44 I
92414S
92413S
If the quarter panel arch is not to be changed,unpick it from inside the wheel arch.
92415S
Welding
92411-1S
Spot welds (A) are to be unpicked from inside thesill panel.
Joints with:Inner wheel arch
e = 2 mm H = 60 mmBackrest mounting stiffener
e = 2.2 mm H = 60 mmQuarter panel lining
e = 1.4 H = 60 mm
44-41
UPPER REAR STRUCTURE
Outer wheel arch 44 I
92414-1S
92412-1S
D = 5.5 mm
Joints with:Inner wheel arch
e = 2 mm H = 60 mmQuarter panel lining
e = 1.4 mm H = 60 mmQuarter panel arch
e = 1.7 mm H = 60 mmFloor
e =1.4 mm H = 60 mm
If spot welds (A) and (B) cannot be reached by thespot welder, plug weld at D = 5 mm
92415-1S
D = 5.5 mm
e = 1.8 mmH = 60 mm
44-42
UPPER REAR STRUCTUREOuter wheel arch 44 I
D53Cabriolet
This operation can only be carried out afterremoval of the wing panel.
Reminder: see 44-A
COMPOSITION OF THE REPLACEMENT PART
- Bare wheel arch.- Stiffener.
PRS4423
JOINT WITH THE SILL PANEL AND INNERWHEEL ARCH
1
Thickness of panels (mm)
Outer wheel arch 0.88Inner wheel arch 1.2Panel lining 0.88Wheel arch stiffener 1.5
Unpicking
31 spot welds.
Welding
Photo page 44-14
Photo page 44-14
Ø D = 6 mm
44-43
UPPER REAR STRUCTUREComplete quarter panel arch 44 J
93093S
L53Saloon
COMPOSITION OF THE REPLACEMENT PART
Panel only.
JOINT WITH THE QUARTER PANEL LINING1
Thickness of panels (mm)
Quarter panel arch 0.97Quarter panel lining 0.67Body side upper extender 0.67Side rain channel 0.97
Unpicking
11 spot welds
Welding
- 2 triple layer spot welds
JOINT WITH THE OUTER WHEEL ARCH2
Thickness of panels (mm)
Quarter panel arch 0.97Outer wheel arch 0.67Quarter panel lining 0.67
Unpicking
9 spot welds
PRS4424
44-44
UPPER REAR STRUCTUREComplete quarter panel arch 44 J
93093-1S
Welding
L53Saloon
44-45
UPPER REAR STRUCTUREPart quarter panel arch 44 K
PRS4425
This operation is a variation on the previous one.Therefore, only its special points are describedbelow.
COMPOSITION OF THE REPLACEMENT PART
Panel only.
Welding (superposed)
93092S
L53Saloon
44-46
UPPER REAR STRUCTUREBackrest mounting stiffener 44 L
PRS4426
L53Saloon
- 2 triple layer spot welds
COMPOSITION OF THE REPLACEMENT PART
Part only.
Thickness of panels (mm)
Stiffener 1.5Quarter panel lining 0.67Wheel arch 0.67
Unpicking
8 spot welds
Welding
93091S
44-47
UPPER REAR STRUCTUREOuter wheel arch stiffener 44 M
D53Cabriolet
This operation can only be carried out afterremoval of the wing panel.
Reminder: see 44-A
COMPOSITION OF THE REPLACEMENT PART
- Bare part.
Welding
PRS4428
Photo page 44-15
JOINT WITH THE LIGHTING SUPPORT PANEL1
Thickness of panels (mm)
Stiffener 0.88Wheel arch 0.88Panel lining 0.88
Unpicking
8 spot welds.
44-48
UPPER REAR STRUCTUREUpper cross member between wheel arches 44 N
D53Cabriolet
This operation can only be carried out with thehood compartment base partition removed.
COMPOSITION OF THE REPLACEMENT PART
- Cross member.- Stiffening angle brackets.- Boot partition stiffeners.- Backrest locking supports.- Seat belt supports.
PRS4429
Welding
Photo page 44-16
Photo page 44-16JOINT WITH THE WHEEL ARCHES1
Thickness of panels (mm)
Cross member 1.5Inner wheel arch 1.2Wing panel lining 0.88
Unpicking
12 spot welds.Twenty-two 30mm MAG weld fillets.
44-49
UPPER REAR STRUCTURE
Upper cross member between wheel arches 44 N
Note: The 12 spot welds are replaced with plugwelds.
After painting and before refitting the trim,protect the hollow sections with wax.
D53Cabriolet
Welding (cont)
Ø D = 8 mm
Photo page 44-17
44-50
UPPER REAR STRUCTUREHood compartment base partition 44 O
This operation can only be carried out after remo-val of the hood compartment rear cross memberand the boot lid rain channel.
COMPOSITION OF THE REPLACEMENT PART
- Bare partition.- Lighting support to be ordered separately.
D53Cabriolet
PRS4430
Welding
Ø D = 6 mm
Thickness of panels (mm)
Partition 0.7Cross member 1.5Wing panel lining 0.88
Unpicking
52 spot welds
Photo page 44-18
JOINT WITH THE CROSS MEMBER AND BODYSIDES
1
44-51
UPPER REAR STRUCTUREHood compartment base partition 44 O
D53Cabriolet
JOINT WITH THE WHEEL ARCHES1
Thickness of panels (mm)
Partition 0.7Wheel arch 1.2
Unpicking
Four 30mm MAG weld fillets.
Welding
PHOTO PAGE 44-19
44-52
UPPER REAR STRUCTUREHood compartment rear cross member 44 P
This operation is carried out in addition to chan-ging of the boot lid rain channel (previous opera-tion).
COMPOSITION OF THE REPLACEMENT PART
- Bare part
D53Cabriolet
PRS4431
JOINT WITH THE LIGHTING SUPPORT PANEL1
Thickness of panels (mm)
Cross member 1.5Boot partitionRain channel 1.0Wing panel rear lining 0.88
Unpicking
60 spot welds.
Welding
PHOTO PAGE 44-20
Ø D = 6 mm
44-53
UPPER REAR STRUCTUREBackrest mounting stiffener 44 Q
PRS4426
L53Saloon
- 2 triple layer spot welds
COMPOSITION OF THE REPLACEMENT PART
Part only.
Thickness of panels (mm)
Stiffener 1.5Quarter panel lining 0.67Wheel arch 0.67
Unpicking
8 spot welds
Welding
93091S
44-54
UPPER REAR STRUCTUREJack support (right hand side) 44 R
L53Saloon
COMPOSITION OF THE REPLACEMENT PART
Part only.
Thickness of panels (mm)
Jack support 1.2Quarter panel lining 0.67Outer wheel arch 0.67
Unpicking
3 spot welds
Welding
PRS4427
93090S
44-55
UPPER REAR STRUCTURECentre shelf 44 S
PRS4432
L53Saloon
Welding
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:- bare centre shelf- rear screen lower cross member.
JOINT WITH THE SIDE RAIN CHANNEL1
Reminder: see 44-Y-1
JOINT WITH THE SEAT BELT RETRACTORSUPPORT BRACKET
2
Thickness of panels (mm)
Centre shelf 0.67Rear screen lower cross member 0.67Seat belt retractor support bracket 1.2
Unpicking
4 spot welds
- 4 triple layer spot welds
93103S
93089S
44-56
UPPER REAR STRUCTURECentre shelf 44 S
93087S
L53Saloon
JOINT WITH THE CENTRE SHELF3
Thickness of panels (mm)
Centre shelf 0.67Side shelf 0.97Seat belt retractor support bracket 1.2
Unpicking
24 spot welds
Welding
- 6 triple layer spot welds
93088S
44-57
UPPER REAR STRUCTUREHalf unit 44 T
PRS4433
L53Saloon
- One 20mm MAG weld fillet- Two 25mm MAG weld fillets
This operation is to be carried out on a body jigbench. Refer to sub-section 40 of the basicmanual.
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:- wing panel,- assembled outer wheel arch,- assembled inner wheel arch,- quarter panel arch,- assembled quarter panel lining,- assembled side rain channel,- lighting support panel,- end panel extender,- assembled side shelf,- backrest mounting stiffener,- jack support (for right hand side only).
JOINT WITH THE SIDE MEMBER CLOSURECOMPONENT
1
Thickness of panels (mm)
Outer wheel arch 0.67Inner wheel arch 1.25Closure component 1.5
Unpicking
3 spot welds
Two 25mm MAG weld filletsFive 20mm MAG weld fillets
Welding
93085S
44-58
UPPER REAR STRUCTUREHalf unit 44 T
93084S
L53Saloon
Welding
Four 20mm MAG weld fillets
3 triple layer spot welds
JOINT WITH THE REAR FLOOR2
Thickness of panels (mm)
Inner wheel arch 1.25Wing panel 0.67Rear floor 0.60Side member booster 2.00
Unpicking
19 spot welds
Reminder: see 44-A-7
93086S
93109S
44-59
UPPER REAR STRUCTUREHalf unit 44
92415-1S
L53Saloon
(A) 1 triple layer spot weld to be unpicked usingthe spot weld drill
JOINT WITH THE SILL PANEL3
Thickness of panels (mm)
Wing panel 0.67Sill panel 1.1Outer wheel arch 0.67
Unpicking
6 spot welds
4 spot welds
1 spot weld
One 25 mm brazed weld fillet
WeldingJOINT WITH THE REAR SHELF4
Reminder: see 44-A-9 Reminder: see 44-Y-1
T
93106S 93103S
44-60
UPPER REAR STRUCTUREHalf unit 44 T
93123S
L53Saloon
Reminder: see 44-S-2
Reminder: see 44-S-3
JOINT WITH THE ASSEMBLED REAR ENDPANEL
5
Reminder: see 41-U-2
JOINT WITH THE END PANEL CROSS MEMBER6
Reminder: see 41-U-1
93089S
93088S
93087S 93125S
44-61
UPPER REAR STRUCTUREHalf unit 44 T
93097S
L53Saloon
93124S
JOINT WITH THE BODY TOP7
Reminder: see 44-C-1
93098S
93099-1S
Reminder: see 44-A-2
JOINT WITH THE REAR ROOF CROSS MEMBER8
Reminder: see 44-C-2
93117S
44-62
UPPER REAR STRUCTUREHalf unit 44 T
93099-4S
L53Saloon
JOINT WITH THE ROOF PANEL9
Reminder: see 44-A-2
93118S
44-63
UPPER REAR STRUCTURERear end panel 44 U
PRS4434
METHOD 1
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of: - bare end panel- side brackets- striker stiffener
CUTTING - UNPICKING
92364S 92365S
NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4
44-64
UPPER REAR STRUCTURERear end panel 44 U
Welding
92365-1S
A =
End panel - cross member joint
e = 1.4 mmH = 60 mm
ANTI-CORROSION PROTECTION
e = 1.4 mmH = 60 mm
92364-1S
92366-2S
e = 1.9 mm
44-65
UPPER REAR STRUCTURERear end panel 44 U
92364-2S
METHOD 2 (end panel with lining)
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of: 1 - bare end panel 2 - lining- side brackets- striker stiffener
CUTTING - UNPICKING
92365-2S
PRS4435
NOTE: the general procedure for changing a welded component is described in Workshop Repair ManualM.R. 502 section 4
44-66
UPPER REAR STRUCTURERear end panel 44 U
92366S
Welding
92367S 92365-3S
e = 1.4 mmH = 60 mm
Fit the lining and make a few retaining spotwelds.
End panel - cross member joint e = 1.9 mm
44-67
UPPER REAR STRUCTURERear end panel 44 U
92364-3S 92366-1S
92366-2S
e = 1.4 mmH = 60 mm
e = 1.4 mmH = 60 mm
ANTI-CORROSION PROTECTION
44-68
UPPER REAR STRUCTURERear end panel 44 U
PRS4437
NOTE: the general procedure for changing awelded component is described in WorkshopRepair Manual M.R. 502 section 4
METHOD 3(end panel with lining and lower cross member)
COMPOSITION OF THE REPLACEMENT PART
Assembled part consisting of:- bare end panel- side brackets- striker stiffener- lining- lower cross member
CUTTING - UNPICKING
WELDING
ANTI-CORROSION PROTECTION
92364-5S
92364-4S 92366-2S
44-69
UPPER REAR STRUCTURERear end panel lining and assembled end panel 44 V
PRS4446
B - C - S53Phase I
The difference between phase I and phase II partsis that the piston switch hole (B) has beendiscontinued. The Parts Department supplies both types of part,with or without hole (B). When a complete body ischanged, the Parts Department will only supplyphase II type bodies on which it will be necessaryto cut hole (B) (see diagram below).
Hole (B), (shaded area) is cut using a powerhacksaw after making two 8mm diameter holes(C).
95788R1
44-70
UPPER REAR STRUCTUREPart end panel cross member 44 W
93123-1S
L53Saloon
Welding
COMPOSITION OF THE REPLACEMENT PART
Panel only
The two blanking pieces (1) must be orderedseparately.
5 spot welds
After welding and before protecting the crimps,fit the 2 metal blanking pieces (1) clipping them inplace with the lugs.
- 1 triple layer spot weld
Special point
Reminder: see 41-U-1
Thickness of panels (mm)
End panel cross member 0.67End panel extender 0.97Rear end panel 0.67
Unpicking
JOINT WITH THE LIGHTING SUPPORT PANEL1
JOINT WITH THE END PANEL EXTENDER2
PRS4438
93125S
93124R
44-71
UPPER REAR STRUCTUREPart end panel cross member 44 W
93100S
L53Saloon
PARTIAL CUT3
44-72
UPPER REAR STRUCTURERear end panel extender 44 X
93123-1S
L53Saloon
Reminder: see 41-U-1
COMPOSITION OF THE REPLACEMENT PART
Panel only
Reminder: see 44-W-2
Thickness of panels (mm)
End panel extender 0.97Rear end panel 0.67
Unpicking
1 spot weld
JOINT WITH THE REAR END PANEL2
93125-1S
PRS4439
JOINT WITH THE END PANEL CROSS MEMBER1
44-73
UPPER REAR STRUCTURERear end panel extender 44 X
93111S
L53Saloon
Welding
Reminder: see 41-V-1
Reminder: see 44-A-6
JOINT WITH THE WING PANEL4
93123-2S
93123-3S
JOINT WITH THE EXTREME REAR CROSSMEMBER
3
44-74
UPPER REAR STRUCTURESide bracket 44 Y
93103S
L53 Saloonexcept Sport
WeldingCOMPOSITION OF THE REPLACEMENT PART
Panel only
Thickness of panels (mm)
Side bracket 0.87Rear screen lower cross member 0.67
Unpicking
One 20mm MAG weld fillet
1 spot weld
2 spot welds
see welding
1 triple layer plug weld after unpicking using aspot weld drill.
Thickness of panels (mm)
Side rain channel 0.87Seat belt retractor support bracket 1.2Quarter panel lining 0.67
Unpicking
11 spot welds
JOINT WITH THE REAR SHELF1
JOINT WITH THE SEAT BELT RETRACTORSUPPORT BRACKET
2
PRS4440
44-75
UPPER REAR STRUCTURESide rain channel 44 Y
93102S
L53 Saloonexcept Sport
3 spot welds
2 triple layer spot welds
Thickness of panels (mm)
Side rain channel 0.87Lighting support panel 0.67
Unpicking
Welding Welding
JOINT WITH THE LIGHTING SUPPORT PANEL3
93101S
44-76
UPPER REAR STRUCTUREBoot lid rain channel 44 Z
D53Cabriolet
COMPOSITION OF THE REPLACEMENT PART
- Bare rain channel.- Hood cover lock stiffeners.- Boot lid hinge stiffeners.
PRS4441
JOINT WITH THE HOOD COMPARTMENT REARPARTITION AND BOOT PARTITION
1
Thickness of panels (mm)
Rear partition 1.5Boot base partition 0.7Rain channel 1.0
Unpicking
50 spot welds.
Welding
Photo page 44-21
44-77
UPPER REAR STRUCTUREBoot lid rain channel 44 Z
D53Cabriolet
JOINT WITH THE WING PANEL AND LIGHTINGSUPPORTS
1
Thickness of the panels (mm)
Rain channel 1.0Wing panel 0.88Lighting support 0.67
Unpicking
54 spot welds.
Welding
PHOTO PAGE 44-22
44-78
UPPER REAR STRUCTURELighting support panel 44 2A
92368-1S
COMPOSITION OF THE REPLACEMENT PART
Bare part
CUTTING - UNPICKING
Welding
92368S
PRS4442
IMPORTANT: unpicking must be carried out fromthe inside.
e = 1.4 mmH = 60 mm
NOTE: the general procedure for changing awelded component is described in WorkshopRepair Manual M.R. 502 section 4
44-79
UPPER REAR STRUCTURELighting support panel 44
PRS4447
B - C - S53Phase I 2A
Hole (B) has been added on phase II vehicles forcentring the rear light. Initially, hole (A) for cen-tring the light on phase I vehicles has been retai-ned but in the future, this will be discontinued forreasons of economy. Consequently, when thephase I light is to be re-used, it will be necessary tocut the upper centring pin in order to fit it to thephase II support.
44-80
UPPER REAR STRUCTURELighting support panel 44D53
Cabriolet 2A
This part can only be changed with its stiffener
COMPOSITION OF THE REPLACEMENT PART
- Bare parts.
The lighting support and its stiffener must beordered at the same time, they each have aseparate part number.
PRS4443
JOINT WITH THE LIGHTING SUPPORT PANEL1
Thickness of panels mm)
Lighting support 0.7Rain channel 1.0Wing panel 0.88End panel 0.7Lighting support stiffener 1.0
Unpicking
42 spot welds.
1 brazed weld filet.
Welding
Photo page 44-23
44-81
UPPER REAR STRUCTURELighting support panel 44D53
Cabriolet 2A
Welding (cont)
Photo page 44-24
Photo page 44-24
44-82
UPPER REAR STRUCTURELighting support panel 44
93113S
L53Saloon 2A
COMPOSITION OF THE REPLACEMENT PART
Part only
Reminder: see 44-2H-3
Reminder: see 44-C-5
Reminder: see 41-V-1
JOINT WITH THE SIDE RAIN CHANNEL1
JOINT WITH THE SIDE PANEL2
JOINT WITH THE END PANEL SIDE MEMBER3
93101S
PRS4444
93125S
44-83
UPPER BODY SECTIONRoof panel
The roof panel is supplied bare, without crossmember or roof drip moulding.
CUTTING - UNPICKING
45 A
PRS4501
DISMANTLING
Remove:- seats,- interior trims,- windscreen,- tailgate.
PROTECTION
Protect the interior using a cover which is resistantto welding and grinding damage.
3 and 5 DOOR VEHICLES 5 DOOR VEHICLES
92607S 92609S
Roof: front cross member - 13 spot welds
92608-1S
Original welding
92610S
Roof: body side - 14 spot welds Roof: rear cross member - 40 spot welds
45-1
UPPER BODY SECTIONRoof panel 45 A
92611-1S
3 DOOR VEHICLES
92612S
Roof: body side - 14 spot welds
Original welding
Cut B Cut CCut A
PRS4502 PRS4503 PRS4504
Spot welding
Fillet welding
Brazing
(1) Body side(2) Roof drip moulding(3) Roof panel(4) Rear cross member(5) Quarter panel top(6) Quarter panel upper stiffener(7) Structure bonding mastic (roof drip mouldings and
roof, cross members and roof joints)
45-2
UPPER BODY SECTIONRoof panel 45 A
92609-1S
3 and 5 DOOR VEHICLES
Repair welding
5 DOOR VEHICLES
92607-1S
92610-1S92608S
45-3
Cut A
UPPER BODY SECTIONRoof panel 45 A
92611-1S
3 DOOR VEHICLES
PRS4502
Repair welding
Cut B Cut C
PRS4503 PRS4504
D = 4.5 mm
(1) Body side(2) Roof drip moulding(3) Roof panel(4) Rear cross member(5) Quarter panel top(6) Quarter panel upper stiffener(7) Structure bonding mastic (roof drip mouldings
and roof, cross members and roof joints)
NOTE: make a brazed weld at the roof-front pillarupright joint.
92612-1S
45-4
UPPER BODY SECTIONRoof panel 45 A
93118S
Only special points specific to L53 type vehicleswill be described for this operation. Refer to sec-tion 45-A for other joints.
COMPOSITION OF THE REPLACEMENT PART
Panel only
PRS4501
JOINT WITH THE WING PANEL1
Reminder:see 44-A-1
93126R1
JOINT WITH THE REAR ROOF CROSS MEMBER2
Thickness of panels (mm)
Roof 0.67Roof cross member 0.67Body side upper extender 0.67Quarter panel lining 067
Unpicking
17 spot welds
L53Saloon
45-5
UPPER BODY SECTIONRoof panel 45 A
93083S
L53Saloon
Welding
- 8 triple layer spot welds
93099-2S
Apply a bead of metal bonding mastic.
45-6
UPPER BODY SECTIONWindscreen surround 45 B
PRS4506
D53Cabriolet
COMPOSITION OF THE REPLACEMENT PART
- Frame.- Pillar closure panel.- Upper linings.
Welding
For fitting, refer to section 40 "Bodyworkdimensions".
Photo page 45-1
Photo page 45-1
JOINT WITH THE FRONT PILLAR1
Thickness of panels (mm)
Frame 1.0Lining 1.5Front pillar 1.25
Unpicking
98 spot welds.Four 20mm MAG weld fillets.Six 30mm MAG weld fillets.
2 brazed weld fillets.
45-7
UPPER BODY SECTIONWindscreen frame 45 B
Welding (cont)
D53Cabriolet
Photo page 45-2
PARTIAL CUT2
Photo page 45-2
Photo page 45-2
45-8
UPPER BODY SECTIONLinings and stiffeners 45 C
PRS4505
Original welding
Joints (1) - (2) - (3) - (4) - (5) - (6)
NOTE: Joint (6): body side roof drip moulding
The repair welding is identical to the originalwelding.
45-9
UPPER BODY SECTIONWindscreen pillar lining 45 D
This operation is carried out in addition to chan-ging of the windscreen frame.
COMPOSITION OF THE REPLACEMENT PART
Part only.
D53Cabriolet
PRS4507
JOINT WITH THE FRONT PILLAR1
Thickness of panels (mm)
Lining 1.5Front pillar 1.25Frame 1.0
Unpicking
31 spot welds.
Welding
Photo page 45-3
45-10
UPPER BODY SECTION
Windscreen aperture upper cross member 45 E
94955S
This operation is carried out in addition to chan-ging of the windscreen frame.
COMPOSITION OF THE REPLACEMENT PART
Bare part.
D53Cabriolet
Welding
PRS4508
JOINT WITH THE WINDSCREEN APERTUREFRAME
1
Thickness of panels (mm)
Cross member 1.5Pillar lining 1.5Frame 1.0
Unpicking
42 spot welds.Four 30mm MAG weld fillets.
45-11
UPPER BODY SECTIONRear roof cross member 45 F
93097S
COMPOSITION OF THE REPLACEMENT PART
Panel only
L53Saloon
PRS4509
JOINT WITH THE QUARTER PANEL LINING1
Reminder: see 44-C-2
JOINT WITH THE ROOF2
Reminder : see 45-A-2
93083S
93099-2S
45-12
BODY PROTECTIONSub-frame front protector
Remove the four bolts (1) and detach the protec-tor from the 4 lugs (2).
46 A
PRS4601
46-1
BODY PROTECTIONWheel arch mud shield 46 B
PRS4603
FRONT REAR
PRS4602
46-2
SIDE OPENINGSDoor hinges
Production fitting
47 A
92308R
(1) Welded hinges(B) 6 mm diameter screw pin fitted on bushes (C)(2) Torx end piece (T40)
After Sales fittingwhen changing a door
PRS4701
Special feature for the electrical wiring in thedoors: to make removal easier without having toremove the trim, there is a connection unit loca-ted in each pillar.
(B) 6 mm diameter screw pin fitted on bushes (C)(C) Special replacement bolted hinge
47-1
SIDE OPENINGSFront door panel 47 B
PRS4702
PREPARATION BEFORE WELDING
Take a section from the new part which is approxi-mately 50mm larger then that cut from the vehi-cle.
Position the new part on the vehicle so that it issuperposed, then secure it with a vice-gripwrench.
Cut the two layers of metal simultaneously using ahacksaw to facilitate the fit.
Remove the panel and take off the surplus sectionremaining on the door.
COMPOSITION OF THE REPLACEMENT DOORPANEL
92614-1S
(1) Exterior panel(2) Panel stiffener(3) Sound proofing
CUTTING - UNPICKING
92614S
47-2
SIDE OPENINGSFront door panel 47 B
92614-2S
Apply aluminium paint to the area which is to beplug welded.
Apply a bead of metal bonding mastic.
Fit the panel then secure it with a vice-gripwrench.
Gradually crimp the edge of the panel.
D = 4.5 mm
After painting, inject hollow section wax into thedoor, particularly in the welded areas.
47-3
SIDE OPENINGSRear door panel 47 C
92613-1S
PREPARATION BEFORE WELDING
Take a piece from the new part which isapproximately 50mm larger then that cut fromthe vehicle.
Position the new part on the vehicle so that it issuperposed, then secure it with a vice-gripwrench.
Cut the two layers of metal simultaneously using ahacksaw to facilitate the fit.
Remove the panel and take off the surplus sectionremaining on the door.
COMPOSITION OF THE REPLACEMENT DOORPANEL
92333R
1 Exterior panel2 Panel stiffener3 Sound proofing
CUTTING - UNPICKING
92613-2S
Drill out the three resistance spot welds at (A), pa-nel - door inner panel joint.
Remove the damaged section following therecommendations of the previous diagrams (referto the key to symbols).
47-4
SIDE OPENINGSRear door panel 47 C
92613R
Apply aluminium paint to the area which is to beplug welded.
Apply a bead of metal bonding mastic.
Fit the panel then secure it with a vice-gripwrench.
Gradually crimp the edge of the panel.
D = 4.5 mm
After painting, inject hollow section wax into thedoor, in particular in the welded areas.
47-5
SIDE OPENINGSFront door - rear door 47 D
PRS4703
The lower side rubbing strip mounting row hasbeen discontinued. Consequently, as the PartsDepartment only supplies phase II type parts, thefollowing must be ordered depending on the typeof rubbing strips in order to refit phase I type rub-bing strips:
- either self adhesive clips (A) for narrow rub-bing strips (see PR),
- or apply 6mm wide double sided adhesivetape to the lower section of wide rubbingstrips (see PR).
All typesPhase I
47-6
BONNET AND TAILGATEBonnet
PARTS RE-USED
48 A
PRS4802
REMOVAL - REFITTING
The bonnet is removed via the four mounting bolts (A) on the strut.
PARTS CHANGED
PRS4803
48-1
BONNET AND TAILGATEBonnet 48 A
PRS4804
ADJUSTMENTS
Carry out in the following order:
1 - Adjusting via the struts
The clearance in mountings (A) allows adjustment of:- the peripheral bonnet clearances, alignment
and backward movement,- the flush fitting (height) of the rear section of
the bonnet with the front wings.
The clearance of mountings (B) allows the rearsection of the bonnet to be moved sidewayswithout altering the height.
2 - Adjusting via the lock
The clearance in lock mounting bolts (C) enablesthe flush fitting (height) of the front of thebonnet to be adjusted.
NOTE: adjustment via the lock must never beused for adjusting the alignment of the bonnetcentreline with the wings. The lock must operatewithout any lateral stress.
48-2
BONNET AND TAILGATETailgate 48 B
92458S
Adjust the peripheral clearances with the roof andthe side panels using the mounting nuts.
REMOVAL
92459R
Remove the rear headlining.
Unclip the counter balances.
Remove the 2 nuts (1).
ADJUSTMENTS
Adjust the flush fitting with the roof using shims(2).
Adjust the flush fitting with the end panel and therear lights using the striker mounting bolts.
92459-1S
PRS4805
48-3
BONNET AND TAILGATETailgate 48 B
95787R
The phase I part supplied by the Parts Departmentconsists of a phase II type inner panel and a phaseI type panel. Consequently, for correct sealing, itwill be necessary to close holes (A) and (B) in theinner panel (refer to PR for the part numbers forthe blanking pieces)
B - C - S53Phase II
48-4
BONNET AND TAILGATEBoot lid 48 C
PRS4806
Using the diagram, mark the centrelines of thespoiler mounting points starting from the edge ofthe rear screen wiper hole (A).
Drill the 4 mounting points to a diameter of 8 mm.
Apply sealing mastic to the edge of the holes andfit the spoiler.
From inside the tailgate, fit the 2 mounting stiffe-ners and secure using the 4 nuts.
FITTING THE REAR SPOILER
B - C - S53SPORT
93175R
1 Spoiler2 Mounting stiffener
48-5
BONNET AND TAILGATEBoot lid 48 C
PRS4807
ADJUSTMENT
L53Saloon
(A) Adjustment of the clearances, alignment, backward movement,flush fitting
(B) Lateral adjustment of the rear section(C) Adjustment via the lock
48-6
BONNET AND TAILGATEBoot lid 48 C
PRS4808
On phase II vehicle the "Chamade" badge is nolonger fitted. The parts supplied by the PartsDepartment are specific to each vehicle.
L53 SaloonPhase II
48-7
BONNET AND TAILGATEBoot lid 48 C
L539Saloon
FITTING LIGHTING EXTENDERS AND BADGES
Using the dimensions shown on the diagram below, mark the location of the six mounting holes for the rearlighting extenders and the three mounting holes for the badges.
The holes must be drilled before painting in order to avoid any risk of corrosion.
97748R
A and B Existing holes
DIMENSIONS FOR DRILLING THE REAR LIGHT EXTENDER MOUNTING HOLES
In order to standardise, the Parts Department will only supply undrilled boot lids.
Consequently, if the boot lid is changed on Sport type vehicles (L539), the lighting extender mounting holesmust be drilled by the repairer in line with the recommendations below.
48-8
BONNET AND TAILGATEBoot lid 48 C
PRS4809
D53Cabriolet
94814-1R 94815R
After removing the counter balances, remove thefour bolts (A)
Different adjustments
48-9
BONNET AND TAILGATEBoot lid 48 C
D53Cabriolet
DIMENSIONS FOR DRILLING THE BADGE MOUNTING HOLES
In order to standardise, the Parts Department will only supply phase III boot lids.
Consequently, if the boot lid is to be changed on phase I and II D53 Sport type vehicles, themounting holes for the badges must be drilled by the repairer in line with the recommenda-tions below.
A Existing holes
Using the dimensions shown on the diagram below, mark the location of the 2 + 2 badgemounting holes.
The holes must be drilled before painting in order to avoid any risk of corrosion.
98085R
After painting and before refitting the trim, inject the hollow sections with wax.
48-10
BONNET AND TAILGATEHood cover panel 48 D
PRS4810
Remove the lock in order to unclip wire ( A )Remove the jacks.
D53Cabriolet
Removal
94793S 94794R
Disconnect the rear screen demisting harness
48-11
BONNET AND TAILGATEHood cover panel 48 D
94795R
Remove mountings (B).
D53Cabriolet
48-12
BONNET AND TAILGATEBroken boot lid counter balance ball joint 48 E
93143R
NOTE: for the general procedure for fitting orchanging a tailgate or boot lid counter balanceball joint, refer to Technical Note n° 258.
L53Saloon
(1) Ball joint part number 77 00 753 309(2) Nut part number 77 01 422 012
93142R
93142-1S
Drilling for the ball joint
93143R1
Cut the ball joint thread to a length of 8 mm.
Before fitting and tightening the ball joint, coatthe thread with Loctite
- SCEL BLOC part number 77 01 394 072or
- SCEL METAL part number 77 01 421 041
48-13
BONNET AND TAILGATERoof cross member (noise reduction) 48 F
PRS4811
Procedure for cutting the roof noise reduction cross member if an R19 sunroof is to be fitted, for vehicles manufactured from 1st December 1991.
X53All types
1 Checking for the presence of the noise reduction cross member.(the special headlining is fitted with a boss)
2 Mark its location on the jig to be prepared when cutting the roof.
3 The roof and cross member are cut together in a single operationusing a "compass saw" type tool.
IMPORTANT : do not try to cut the roof and cross member separately or touse cross member (A) as a lever as this will deform the roof drip mouldings(B).
4 Before fitting the sun roof, it is essential to:- smooth the cuts,- reapply mastic between the roof and remaining ends of the cross
member (noise reduction function),- apply anti-corrosion protection to all cuts.
48-14
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