VNX - Su Kangoo 2 BRM PDF

0
General vehicle information

01A
VEHICLE MECHANICAL SPECIFICATIONS
01C
VEHICLE BODYWORK SPECIFICATIONS
01D
MECHANICAL INTRODUCTION
02A
LIFTING EQUIPMENT
03B
COLLISION
04B
CONSUMABLES - PRODUCTS
04E
PAINT
X61
DECEMBER 2008
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
Renault s.a.s 2008
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KANGOO II - Section 0
KANGOO II - Section 0 ContentsPage
Contents
Page
01A

Vehicle: Specifications
01C
03B
01A-1

Vehicle: Identification
01C-1
Vehicle clearances:
Adjustment values
01C-3
04B
COLLISION
Vehicle damaged at side:
Description
03B-5
Vehicle damaged at rear:

Description
03B-9
Vehicle: Parts and
ingredients for the repairwork
01D
Vehicle: Precautions for
repair
Tightening torques: General
information
02A
04E
PAINT
01D-1
Colour code: Specifications
01D-3
LIFTING EQUIPMENT
Vehicle: Towing and lifting
03B
04B-1
02A-1
COLLISION
Damaged vehicle: Collision
fault finding
03B-1
Vehicle damaged at front:

Description
03B-3
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04E-1

01A
125086
Dimensions in metres:
Van
(A)
0.807
(B)
2.697
(C)
0.709
(D)
4.213
(E)
1.521
(F) (unladen)
1.839
(F) (laden)
1.751
(G)
1.533
(H)
2.133
Short van
(A)
0.807
(B)
2.313
01A-1
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(C)
0.709
(D)
3.829
(E)
1.519
(F) (unladen)
1.800
(F) (laden)
1.772
(G)
1.533
(H)
2.133
01A
Combi
Standard payload
Increased payload
(A)
0.807
(B)
2.697
(C)
0.709
(D)
4.213
(E)
1.521
(F) (unladen)
1.842
1.844
(F) (laden)
1.747
1.746
(G)
1.533
(H)
2.133
Engine
Vehicle type
Engine type
Engine suffix
Gearbox
Cubic capacity(cc)
01A-2
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Gearbox
type
Gearbox
suffix
Emissions
standard

831
FW0D
KW0D
K4M
FW0W
830
DP0
106
172
1598
834
01A
JR5
153
JH3
171
KW0W
FW0A
800
KW0A
154
802
FW0B
JR5
155
156
KW0B
KW0V
FW0C
804
KW0C
FW0F
K9K
806
1461
TL4
000
KW0F
EURO 4
FW0G
808
KW0G
812
FW0K
JR5
KW0K
155
156
FW0L
KW0L
KW0E
JH3
170
JR5
152
KW0Y
FW0E
FW0N
K7M
750
1598
FW0P
FW0Y
KW0N
KW0P
DETAILS OF VEHICLE TYPE
Example: KT01
K: Body type (five-door estate)
T: Project code
01: Engine code
01A-3
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168

01C
III - DETAILED VIEW OF THE VEHICLE

IDENTIFICATION PLATE
I - LOCATION OF VEHICLE IDENTIFICATION

PLATE (A)
Plate (A)
125689
19031
II - LOCATION OF THE VEHICLE IDENTIFICATION

NUMBER (B)
125690
01C-1
(1)
Vehicle type mine and type number; this information also

appears on marking (B)
(2)
MGVW (Maximum Gross Vehicle Weight)
(3)
GTW (Gross train weight, vehicle under load with trailer)
(4)
Maximum permissible front axle

load
(5)
Maximum permissible rear axle

load
(6)
Vehicle technical specifications
(7)
Paintwork reference number
(8)
Equipment level
(9)
Vehicle type
(10)
Upholstery code
(11)
Additional equipment details
(12)
Fabrication number
(13)
Interior trim code
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IV - COLD-MARKING OF THE BODY
Marking (C)
125555
Note:
If the complete body is being replaced, it must be
marked in compliance with the current regulations.
01C-2
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01C

Vehicle clearances: Adjustment values
01C
Section 1
127159
127197
(X1) = 7 mm 1.5
WARNING
The clearance values are given for information
purposes.
Section 2
When adjusting clearances, certain rules have to be

followed:
- maintain symmetry with respect to the opposite
side,
- ensure the flush fitting is correct,
- check correct operation of the opening, and water/
air-tightness.
All values are given in millimetres.
127193
(X2) = 3.5 mm 2
01C-3
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01C
Section 5
Section 3
127194
127195
(X3) = 3 mm 2
(X5) = 4 mm 2
Section 4
Section 6
127196
127199
(X6) = 4 mm 1
(X4) = 1 mm 1
01C-4
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Section 7
01C
Section 8
127200
127198
(X7) = 5 mm 1.5
(X8) = 4 mm 1.5
Section 9
127160
127201
(X9) = 4 mm 1.5
01C-5
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01C
Section 12
Section 10
127168
127202
(X10) = 3 mm 1.5
(X12) = 4 mm 1.5
Section 11
Section 13
127204
127203
(X13) = 4.5 mm 2
(X11) = 4 mm 1.5
01C-6
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01C
Section 16
K61
Section 14
127166
(X16) = 4.5 mm 1.5
127164
Section 17
(X14) = 4 mm 1.5
Section 15
127165
(X17) = 4.5 mm 2
127167
(X15) = 4 mm 1.5
01C-7
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01C
Section 20
Section 18
127169
127171
(X20) = 2 mm 1.8
(X18) = 5 mm 1.5
Section 19
F61
127170
(X19) = 4 mm 2
127161
01C-8
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01C
Section 23
Section 21
127173
127172
(X23) = 4 mm 2
(X21) = 4 mm 1.2
Section 22
Section 24
127174
(X22) = 4 mm 2
127176
(X24) = 3.3 mm 1 (without blocker) / 3.7 mm 1

(with blocker)
01C-9
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Section 25
01C
Section 26
127175
(X25) = 3.5 mm 1
127181
(X26) = 8 mm 3
Section 27
F61 or K61
127187
127163
(X27) = 4 mm 2
01C-10
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Section 30
Section 28
127188
127192
(X28) = 4 mm 2
(X30) = 4 mm 2
Section 29
Section 31
127191
(X29) = 4 mm 2
01C
127190
(X31) = 4 mm 2
01C-11
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Section 32
01C
Section 33
127189
(X32) = 7.2 mm 3
127186
(X33) = 8 mm 2
Section 34
K61
127182
(X34) = 4 mm 2
127162
01C-12
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01C
Section 37 / 37a
Section 35
127184
127177
(X37) = 4 mm 2
(X35) = 4 mm 2
(X37a) = 2 mm 1.5
Section 36
Section 38
127183
(X36) = 4 mm 2
127179
(X38) = 1.5 mm 1
01C-13
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01C
Section 41
Section 39
127178
127185
(X41) = 7.2 mm 3
(X39) = 4 mm 2
Section 40
K61, and SHORT CHASSIS
127180
(X40) = 1.5 mm 1.5

141251
01C-14
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Section 44
Section 42
127184
127178
(X42) = 4 mm 2
(X44) = 4 mm 2
Section 43
Section 45
127177
(X43a) = 2 mm 1.5
01C
127185
(X45) = 7.2 mm 3
(X43b) = 4 mm 2
01C-15
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Section 46
127192
(X46) = 4 mm 2
01C-16
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01C
Vehicle: Precautions for repair
GENERAL INFORMATION
All information contained in these manuals is intended
exclusively for automotive industry professionals.
The documentation is intended to cover all vehicles in
the RENAULT range throughout the world, but may not
cover equipment designed for use in specific countries.
The procedures and fault finding procedures recommended and described in this manual have been designed by automotive industry repair professionals.
1 - General recommendations
Observe basic principles of vehicle repair.
The quality of repair depends first and foremost on the
care exercised by the person in carrying it out.
To ensure good repair:
- protect the sensitive areas of the vehicle (seats, steering wheel, wings, etc.),
- disconnect the battery wherever possible (prevents
short circuits, erratic starting of the windscreen wiper
motor, etc.),
- when welding on the vehicle, it is advisable to remove
or disconnect components near the repair area that
could be affected by the heat,
- use recommended professional products and original
parts,
- observe the tightening torques,
01D
- protect the accessories and timing belts, the electrical

accessories (starter, blanking cover, electric power
assisted steering pump) and the mating face to prevent diesel fuel spilling onto the clutch friction plate.
The design quality of our vehicles demands that nothing is left to chance in making a good repair, and it is
essential to refit parts or components exactly as they
were originally (for instance: heat shields, wiring routing, pipe routing, particularly in the area of the exhaust
pipe).
Do not blow away asbestos particles or dust (brakes,
clutch, etc.), vacuum them up or clean the component
with a cleaning agent (such as a brake cleaning product).
Use professional products and apply them with care,
for example do not apply too much sealing paste to the
sealing surface.
Exhaust gases (petrol and diesel) are pollutants. Operate engines with care and always use exhaust gas extractors.
Ensure that there is no risk of a short circuit occurring
when the electrical connections are reconnected (e.g.
starter, alternator, etc.). Some points need greasing,
others do not, therefore particular attention should be
paid during refitting operations to ensure that they work
properly under all conditions.
2 - Special tooling - ease of use
- replace roll pins, self-locking or bonded nuts or bolts

every time they are removed,
- take care with electrical and electronic components
which cannot withstand excess voltage and improper
handling; replace any electrical and electronic components which have experienced a voltage drop,
- make sure that the connectors are correctly clipped,
The repair procedures have been designed using special tools; they must therefore be carried out using these tools to ensure a high degree of working safety and
quality of repair.
The equipment we have approved has undergone careful research and testing, and must be used and maintained with care.
- do not pull on the wiring,

- check for the sealing plugs on the connectors,
3 - Reliability - updating
- do not splash any liquid on the electrical and electronic components (computers, sensors, etc.),
- do not just replace parts one after the other, carry out
detailed fault finding beforehand,
- carry out a final check before returning the vehicle to
the customer (set the clock, check the alarm operation, check the lights and indicators etc.),
- clean and degrease the sections to be bonded
(threads, stub axle splines) to ensure proper adherence,
New repair procedures are constantly being developed

in the interests of repair quality, either with new products (emission control, injection, electronics, etc.), or
in fault finding. Be sure to consult the Workshop Repair
Manuals or Technical Notes or fault finding summaries
before any servicing operation.
Since vehicle specifications are subject to change during their commercial life, it is essential to check
whether there are any updated Technical Notes when
seeking information.
01D-1
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Vehicle: Precautions for repair
01D
4 - Safety
5 - Conclusion
Operations on certain equipment and certain parts (for

instance: spring-shock absorber assembly, automatic
transmission, brake system, ABS, airbag, common rail
diesel injection, LPG, etc.) require particular attention
to be paid to safety, cleanliness and care.
The procedures contained in this document merit your

attention. Please read them carefully in order to reduce
the risk of injury, and avoid using incorrect procedures
that could damage the vehicle or make it dangerous in
use.
The safety symbol used in this manual indicates that

special attention must be paid to the procedure or the
tightening torque values.
Following the recommended procedures will help you

to provide a quality of service which will ensure the vehicles achieve the highest levels of performance and
reliability.
Working safely:
- use suitable tools which are in good condition (use of
multi-purpose tools, such as adjustable pliers,
etc., should be avoided wherever possible),
Maintenance and repair operations must be carried out

under the proper conditions to ensure that our vehicles
run safely and reliably.
- use supports and adopt a correct posture when performing heavy work or raising loads,
- make sure that the procedure used is not dangerous,
- Do not wear any jewellery or other small objects during an operation,
- use personal protection (gloves, safety glasses, work
shoes, masks, skin barrier creams, etc.),
- always follow the safety instructions associated with
the operation to be performed,
- do not smoke when working on vehicles,
- use smoke extractors (welding, exhaust gases, etc.),
- do not use harmful products in unventilated rooms,
- do not overstrain yourself or attempt inappropriate
work operations,
- use axle stands when working under a vehicle raised
on a jack,
- do not ingest any chemicals (brake fluid, coolant,
etc.),
- do not open the cooling circuit when it is hot and pressurised,
- take care with components that are liable to start up
suddenly (engine cooling fan, etc.).
Respecting the environment:
- do not allow waste refrigerants to escape into the atmosphere,
- do not dispose of waste vehicle fluids (oil, brake fluid,
etc.) in drains,
- do not burn discarded products (tyres, etc.).
01D-2
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Tightening torques: General information
I - TABLE OF STANDARD TORQUES
01D
The property class is indicated on the bolt (1) or (2) .

II - FUNCTION OF A BOLTED ASSEMBLY
Fastenings
Diameter
Property
class
Standard
tightening
torque
(N.m)
M6 *
8.8
10
M8 *
8.8
25
M10 *
8.8
50
M10
10.9
62
M12
10.9
105
M14
10.9
180
M16
10.9
280
M18
10.9
400
The bolting system connects parts of an assembly to

prevent their separation or sliding when submitted to
exterior forces.
Exterior forces
* Special notes on the electrical earths

Fastenings
Diameter
Standard
tightening
torque
(N.m)
M6
M8
21
M10
44
120737
The assembly is submitted to forces that are:

- static and / or dynamic,
- simple (e.g. simple traction),
- multiple (traction + flexion + torsion).
120736
01D-3
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01D
Customer complaints resulting from incorrect tightening may be, following assembly, a safety issue (fire,
loss of control of the vehicle etc.), an immobilising fault
or a noise.
Creating tension (or preload) F0
III - TIGHTENING PROCEDURES

The two controlled tightening procedures adapted to
automotive repairs because of their low cost and simple operation are torque tightening and angle tightening (also called torque and angle).
1 - Torque tightening
This is the most commonly used procedure. Is consists
of tightening until a given resisting torque is reached,
known as tightening torque.
The tightening torque is distributed in a large part as
friction torque (under the head and in the thread) and in
a small part as useful torque (to create the tension).
120738
The assembly is held together by the tension created in

the bolt when it is tightened.
A reliable assembly is only possible if the correct tension is used:
This practise spreads the tension significantly due to

the variation in the friction coefficients from one assembly to another and the uncertainty of the tightening procedures and methods.
2 - Angle tightening
- insufficient tension: risk of loosening,

- too much tension: risk of deformation of the parts to
be assembled, or shearing of the bolt.
The principle consists of putting the parts of the assembly in contact using a mating torque (approximately 25
to 30% of the final torque) then to tighten to a determined angle.
This method, which is not dependent on the friction of
the tightened assembly, gives more precise results
than torque tightening.
IV - OBSERVING THE TIGHTENING TORQUES AND
ANGLES
Bolted assemblies whose tightening torques and angles are explicitly specified in the removal / refitting
procedures must be observed using the appropriate tools (torque wrench, angle measuring disc). Failure to
observe this can lead to safety risks, immobilising
faults or unwanted noises.
120739
(3)
Bolt
(4)
Assembled components
(5)
Extension of the bolt
(6)
Non-tightened assembly
(7)
(X1)
Tightened assembly
compression of the assembly
(Fo)
tension
(C)
tightening torque
For other bolted assemblies, non-measured tightening

(using standard spanners) is acceptable. Nevertheless, the corresponding tightening torque is indicated in
the table of standard tightening torques.
V - RECOMMENDED TIGHTENING TOOLS
For measured tightening, the repairer must have
available torque wrenches to tighten from 4 to 400 N.m
as well as an angle measuring disc.
The torque wrenches used may be click type or electronic.
01D-4
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01D
For example:
- 1 torque wrench 4 - 40 N.m,
- 1 angle measurement disc.
The torque wrenches used must comply with the ISO
6789 standard. They must be calibrated regularly following the supplier's recommendations using the appropriate procedures.
120741
VI - PRECAUTIONS WHEN USING A CLICK TYPE

TORQUE WRENCH
A click type torque wrench is a manual tightening tool.
The trigger mechanism causes a break or disengagement of the wrench past a force threshold.
This threshold depends on the setting of the wrench
but also depends on the way the wrench is handled.
- Pull the wrench gently and steadily, without applying

any torsion. Excessive tightening speed as well as jerkiness are major causes of overtightening. Any torsion
applied to the wrench will alter the trigger threshold.
- Hold the wrench on the bolt using a minimum of effort.
Any effort applied to the wrench head will alter the trigger threshold.
When used following best practises, the accuracy of

the tightness when using a click type torque wrench is
15%.
The instructions to be observed are:
120742
- Apply the tightening effort perpendicular to the mounting observing a tolerance of 15 relative to the perpendicularity. If the wrench is not perpendicular to the
mounting axis, this will result in insufficient tightening.
120740
(6)
- Stop tightening as soon as the wrench is triggered.

Continued tightening after the wrench is triggered will
lead to overtightening.
lever arm
- Place the hand in the centre of the handle. An incorrectly positioned hand on the handle will alter the trigger threshold.
01D-5
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01D
It is advisable to handle the wrench with care and to

stop tightening when the required value is displayed on
the wrench.
120743
If the length of the wrench is modified (extending the

handle, adapting an end piece) it is essential to recalibrate the wrench to its new configuration.
Modifying the length of the wrench will modify its trigger
threshold.
Use the formula: C1 = CO x L2 / (L1+L2)
- CO: torque to apply,
- C1: adjustment torque to be displayed on the wrench,
- L1: length of the extension,
- L2: length of the wrench.
Unless there are special instructions in the repair
method, a universal joint (CARDAN joint type) should
be used for measured tightening. Using a universal
joint will result in a difference between the set torque of
the wrench and the actual torque applied.
Before storing the wrench, loosen the adjustment
spring completely. A wrench stored with a spring under
tension will lose its tightening accuracy.
VII - PRECAUTIONS WHEN USING ELECTRONIC
TORQUE WRENCHES
An electronic torque wrench is a manual tightening tool. The tightening torque and, depending on the model,
the angle is read directly.
When used following best practises, the accuracy of
the tightness when using an electronic torque wrench
is 5%.
Electronic torque wrenches are not affected by the position of the operator's hand.
01D-6
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LIFTING EQUIPMENT
02A
2 - Position of rear attachment point

Essential equipment
safety strap(s)
I - TOWING
WARNING
See the current towing regulations in each country.
Never use the driveshafts, axle assembly components or suspension components as attachment
points.
Always fully tighten and lock the towing ring before
use.
Always pull in the direction of the rod's length in
order to avoid breaking it.
Vehicles fitted with automatic transmission:
- The vehicle should preferably be transported on a
platform or towed by lifting the front wheels. As an
exception, the vehicle may be towed with the
wheels on the ground but at a speed below 12
mph (20km/h) and over a maximum distance of 18
miles (30 km) (with the gear lever in neutral).
125855
II - LIFTING POINT USING A TROLLEY JACK
IMPORTANT
To prevent any accidents, the trolley jack must only
be used to lift and/or move the vehicle. The vehicle
height must be maintained with axle stands which
are strong enough to support the weight of the vehicle.
1 - Position of front attachment point
WARNING
To avoid any damage to the original protection, use
equipment fitted with rubber pads to prevent the
equipment coming into direct contact with the vehicle.
To avoid any damage to the axle assemblies, the
vehicle must not be raised using the front suspension arms for support or under the rear axle.
125856
02A-1
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LIFTING EQUIPMENT
02A
III - LIFTING POINT USING A VEHICLE LIFT

1 - Safety advice reminder
127407
14894
Safety advice reminder:

If it is necessary to remove heavy components from the
vehicle, it is preferable to use a four-post lift.
There is a danger that the vehicle will tilt on a two-post
lift after certain components have been removed (e.g.
engine and transmission assembly, rear axle, gearbox). Fit the safety strap(s) available from the Parts
Department.
127408
To place the vehicle on axle stands:

- front:
raise the vehicle under the front side cross member
at (1) and place the axle stand under the jacking
point at (2) ,
- rear:
raise the vehicle under the rear floor front cross
member at (3) and place the axle stand under the
jacking point at (4) ,
02A-2
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LIFTING EQUIPMENT
02A
3 - Permitted lifting points
2 - Fitting the straps
IMPORTANT
Only the jacking points described in this section
allow the vehicle to be raised in complete safety.
Do not raise the vehicle using points other than
those described in this section.
To raise the vehicle, position the pads of the lift arms
as indicated below. Be sure to retract the pads far
enough to avoid damaging the underside of the sill panel (5) (6) .
Front lifting points
14893
Fitting the straps:

For safety reasons, the straps must be in perfect condition; replace them if they are damaged.
When fitting the straps, check that the seats and fragile
parts of the vehicle are correctly protected.
a - Tilting towards the front
Pass the strap under the rear right-hand arm of the lift.
Pass the strap through the inside of the vehicle.
Pass the strap under the rear left-hand arm of the lift.
125852
Pass the belt through the inside of the vehicle again.
Fit the lift arm pads under the front jacking points (3) .
Tighten the strap.

b - Tilting towards the rear
Pass the strap under the front right-hand arm of the lift.
Pass the strap through the inside of the vehicle.
Pass the strap under the front left-hand arm of the lift.
Pass the belt through the inside of the vehicle again.
Tighten the strap.
02A-3
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LIFTING EQUIPMENT
Rear lifting points
125853
Fit the lift arm pads under the rear jacking points (4) .
Note:
If it is necessary to disengage the jacking points,
follow the instructions for lifting using a trolley jack
(for example, fit anchoring clamps if placing on a
body jig bench for bodywork rebuilding).
02A-4
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02A
COLLISION
Damaged vehicle: Collision fault finding
03B
I - CHECKING THE SUBFRAME
126949
a Chronological order of checks:

Front impact:
- (Gg) - (Bd) = (Gd) - (Bg) ,
- (Hg) - (Gd) = (Hd) - (Gg) .
Rear impact:
- (Bg) - (B1d) = (Bd) - (B1g) ,
- (Bg) - (Ld) = (Bd) - (Lg) .
03B-1
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COLLISION
Damaged vehicle: Collision fault finding
03B
B, B1 points: rear axle leader pin
II - DETAILED VIEW OF INSPECTION POINTS

G points: front side member rear mounting
127210
127208
L points: rear side member rear leader pin
H points: front side member front mounting
127211
a
127209
03B-2
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COLLISION
Vehicle damaged at front: Description
03B
COMBINATIONS FOR REPLACING WELDED

STRUCTURAL PARTS IN ACCORDANCE WITH
IMPACT SUSTAINED
127207
- (2) front side member front section,
1st degree
- (3) front side member front closure panel,

- (4) front end side cross member.
126940
- (1) radiator cross member mounting,
03B-3
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COLLISION
Vehicle damaged at front: Description
- (14) front half-unit.
2nd degree
126941
- (5) front side member rear section,

- (6) complete front side member closure panel,
- (7) battery tray mounting,
- (8) front sub-frame front mounting,
- (9) engine stand,
- (10) scuttle side panel,
- (11) scuttle side panel upper reinforcement,
- (12) front wheel arch.
3rd degree
126942
- (13) front sub-frame rear mounting,
03B-4
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03B
COLLISION
Vehicle damaged at side: Description
03B
127205
03B-5
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COLLISION
03B
1st degree
126946
- (1) sill panel,

- (2) A-pillar,
- (3) rear right-hand section, body side,
- (4) rear left-hand section, body side.
03B-6
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COLLISION
03B
2nd degree
126947
- (5) sill panel reinforcement.

- (6) rear sill panel reinforcement,
- (7) sill panel clousre panel,
- (8) sill panel closure panel, rear section,
- (9) sill panel stiffener,
- (10) A-pillar reinforcement
- (11) scuttle side panel,
- (12) B-pillar reinforcement,
- (13) windscreen pillar trim stiffener,
- (14) windscreen pillar lining,
- (15) lining of plated rear side panel, front section,
- (16) lining of glazed rear side panel, front section.
03B-7
http://vnx.su
COLLISION
03B
3rd degree
126948
- (17) front sub-frame rear mounting,

- (18) centre floor, side section,
- (19) centre floor front side cross member,
- (20) centre floor reinforcement,
- (21) windscreen aperture lower cross member,
- roof (22) ,
- (23) roof front cross member,
- (24) roof centre cross member,
- (25) roof panel arch,
- (26) roof rear cross member.
03B-8
http://vnx.su
COLLISION
Vehicle damaged at rear: Description
03B
127206
03B-9
http://vnx.su
COLLISION
03B
1st degree
126943
- (1) rear end panel,

- (2) rear end lower cross member,
- (3) rear end lower cross member, side section,
- (4) rear side panel rain channel.
03B-10
http://vnx.su
COLLISION
03B
2nd degree
126944
- (5) complete rear floor,

- (6) rear side member, rear cut,
- (7) rear impact cross member mounting reinforcement,
- (8) rear floor stiffener,
- (9) lining of glazed rear side panel, rear section,
- (10) lining of plated rear side panel, rear section,
- (11) rear end pillar.
03B-11
http://vnx.su
COLLISION
03B
2nd degree
126945
- (12) rear floor, front section,

- (13) complete rear side member,
- (14) tank mounting support,
- (15) rear floor centre cross member,
- (16) front cross member under rear seat,
- (17) rear left-hand wheel arch,
- (18) lining of glazed side panel,
- (19) lining of plated side panel.
03B-12
http://vnx.su
Vehicle: Parts and ingredients for the repairwork
Consumables for mechanical repair:
DEFINITION
PACKAGING
PART NUMBER
MECHANICAL SEALANTS
SILICOR
85 g tube
77 11 236 470
100 g tube
77 11 236 172
Kit
77 11 237 896
100 g cartridge
77 11 227 484
TRANSPARENT SEALING MASTIC
45 g tube
77 11 223 369
SILICOJOINT
90 g tube
77 11 236 469
LOCTITE ADHESIVE 597
Cartridge
77 11 219 705
25 ml tube
77 11 237 640
1.5 kg tin
77 01 421 161
400 ml aerosol
77 11 236 176
sealing paste
MASTIXO
Joint face seal
BEARING SEALING KIT
For crankshaft bearing cap side
sealing
SILICONE ADHESIVE SEAL
Engine and gearbox sealing paste
Sealing paste forPXXgearboxes

RESIN ADHESIVE or SEALING
RESIN
Sealing resin for engine and gearbox covers
EXHAUST MASTIC
For exhaust pipe union seals
LEAK DETECTOR
ADHESIVES
FRENETANCHE
50 ml bottle
77 11 236 471
50 ml bottle
77 11 230 112
50 ml bottle
77 11 236 472
Sealing the threading at low and

medium pressure
HIGH-STRENGTH THREADLOCK
For locking bolts
SEALING RESIN
For locking the bearings
LUBRICANT CLEANERS
NTELEC
150 ml aerosol
Avoid bad contacts in electrical circuits
04B-1
http://vnx.su
77 11 225 871
04B
INJECTOR CLEANER
355 ml container
CLOTH FOR INJECTION SYSTEM
77 11 224 188 or 77 11 225 539

77 11 211 707
SUPER RELEASING AGENT
500 ml aerosol
77 11 236 166
SUPER RELEASING AGENT
250 ml aerosol
77 11 420 439
SUPER CLEANER FOR JOINT

FACES
300 ml aerosol
77 11 238 181
SURFACE CLEANER
5 L container
77 01 404 178
SILICONE LUBRICANT
400 ml aerosol
77 11 236 168
SILICONE-FREE LUBRICANT
400 ml aerosol
77 11 236 167
600 ml aerosol
77 11 422 413
150 ml aerosol
77 11 422 414
AIR CONDITIONING CLEANER
250 ml aerosol
77 11 230 498
CARBURETTOR CLEANER
Aerosol
77 11 236 177
For cleaning joint faces
BRAKE CLEANER
GREASE
BR2+ GREASE
1 kg pack
77 01 421 145
100 g tube
77 11 419 216
85 g tube
77 11 236 173
500 ml aerosol
77 11 236 169
180 g sachets
77 11 420 011
400 ml aerosol
77 11 236 174
For:
- the lower arm bearings,
- the anti-roll bar grooves,
- the driveshaft splines.
SILICONE GREASE
For:
- the tubular rear axle bushes,
- the anti-roll bar bushes.
COPPER ANTI-SEIZE GREASE
Grease for turbochargers (high
temperature)
COPPER-ALUMINIUM LUBRICANT
Grease for turbochargers (high
temperature)
GREASE
For driveshaft seals
WHITE GREASE
For wheel sensors
04B-2
http://vnx.su
04B
500 ml aerosol
77 11 236 170
250 ml aerosol
77 11 236 171
100 g tube
82 00 168 855
04B
MULTIPURPOSE GREASE
FLUORSTAR 2L
Silicone-free electric sealing grease
LACQUER
JELT ARGENT
5 g bottle
77 11 230 111
Varnish for repairing heated rear

screens
BRAKE
0.5 L container
77 11 218 589
5 L container
77 11 238 318
25 L container
77 11 238 319
0.5 L container
77 11 172 381
5 L container
77 01 395 503
25 L container
77 11 171 926
DOT 4
0.5 L container
86 71 000 000
Authorised for vehicles without

ESP, without clutch with hydraulic
tappet
5 L container
86 71 014 277
25 L container
86 71 014 278
DOT 4, ISO CLASS 6, RENAULT

STANDARD: 03-50-006,
For vehicles with and without electronic stability program (ESP)
DOT 4, ISO CLASS 4, RENAULT
STANDARD: 03-50-005
Authorised for vehicles without ESP
COOLING SYSTEM
ANTIFREEZE (TYPE D)
COOLANT (TYPE D)
1 L container
77 11 170 548
1 L container
77 11 171 589
2 L container
77 11 170 545
5 L container
77 11 170 546
OIL
ENGINE OIL
(see Engine oil: Specifications) (Technical Note 6013A, 04A, Lubricants)

(see Manual gearbox oil: Specifications) (Technical Note 6012A, 04A,
Lubricants)
GEARBOX OIL
(see Automatic gearbox oil: Specifications) (Technical Note 6012A,

04A, Lubricants)
(see Sequential gearbox oil: Specifications) (Technical Note 6012A,
04A, Lubricants)
AXLE OIL
(see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubricants)
04B-3
http://vnx.su
ELF RENAULT MATIC D2
2 L container
77 01 402 037
Oil for power-assisted steering:

Pump connected, pump assembly
(except Laguna III)
TOTAL POWER-ASSISTED STEERING FLUID
1 L container
Oil for power-assisted steering:

Pump assembly (Laguna III)
PLANETELF PAG 488
SANDEN SP 10
77 11 172 668
250 ml container
77 01 419 313
Oil for air conditioning compressor

TYRES
1 kg pack
77 11 223 052
5 kg pack
77 11 223 053
400 ml tube
77 11 221 296
300 ml tube
77 11 222 802
TYRE PASTE
TYRE REPAIR AGENT

BLANKING PLUG
Engine type
Injection type
Part no.
F5R
77 01 206 382
F8Q
77 01 206 340
F9Q
77 01 208 229
G9T AND G9U
77 01 208 229
K9K
DELPHI
77 01 206 804
K9K
SIEMENS
77 01 476 857
M9R
77 01 209 062
P9X
77 01 474 730
ZD3
77 01 208 229
MISCELLANEOUS
GREY ABRASIVE PAD
77 01 405 943
Consumables for bodywork repair:

HOLLOW SECTION WAX
SPR CC
1 L container
77 11 172 672
SPR CC SPRAY
500 ml aerosol
77 11 211 654
04B-4
http://vnx.su
04B
STRUCTURAL ADHESIVE
STRUCTURAL ADHESIVE
Kit =2 80 ml cartridges
77 11 219 885
HIGH PERFORMANCE STRUCTURAL ADHESIVE
1 195 ml cartridge
77 11 419 113
GLAZING PRODUCTS AND ADHESIVES

MONOPAC EVOLUTION ADHESIVE KIT
310 ml cartridge
77 11 421 430
MONOPAC EVOLUTION ADDITIONAL CARTRIDGE + NOZZLE
310 ml cartridge
77 11 421 431
S-P KIT ADHESIVE KIT
310 ml cartridge
77 11 421 432
ADDITIONAL S-P KIT CARTRIDGE + NOZZLE
310 ml cartridge
77 11 421 433
BIPAC EVOLUTION ADHESIVE

KIT
2 225 ml cartridges
77 11 421 434
LINT-FREE CLOTH
Box of 340 cloths
77 11 237 262
METAL PRIMER
Bottle
77 11 419 599
WINDOW SEALING MASTIC
310 ml cartridge
77 11 170 222
SPECIAL ADHESIVE FOR WINDOWS

ADHESION PROMOTER
77 11 425 759
Cloth
77 11 423 222
For bonding double-sided adhesive

tape to windows
MISCELLANEOUS
DOUBLE-SIDED ADHESIVE
20 m roll
77 11 226 308
FRENETANCHE
50 ml bottle
77 11 236 471
ADHESIVE PATCH
82 00 043 181
ADHESIVE PAD
77 05 042 163
SEALS
BLACK MJ PRO (Electroweldable)
310 ml cartridge
77 11 172 676
WHITE MJ PRO (Electroweldable)
310 ml cartridge
77 11 172 677
PREFORMED SEALING MASTIC

BEAD
2.6 m roll
77 01 423 330
BRUSH MASTIC
1 kg pack
77 11 228 113
FILLER MASTIC
60 beads 6 mm by 0.3 m
77 11 170 230
GREASE
04B-5
http://vnx.su
04B
CLEAN GREASE
300 ml aerosol
77 11 236 174
OPENING ELEMENT MECHANISM GREASE
20 g sachets
77 11 419 865
SOUNDPROOFING
SPR GREY EVOLUTION
1 l cartridge
77 11 419 114
SPR GREY EVOLUTION SPRAY
400 ml aerosol
77 11 419 116
SPR BLACK EVOLUTION II
1 l cartridge
77 11 419 115
SOUNDPROOFING PAD (3.5 Kg/

m)
Pack of 10
77 01 423 546
SOUNDPROOFING PAD (6.5 Kg/

m)
Pack of 5
77 01 423 269
POLISHING
POLISHING LIQUID
1 L container
77 11 420 288
FINISHING LIQUID
1 L container
77 11 420 289
MASTIC
Universal mastic
GALAXI
2.5 kg pack
77 11 172 238
OPTIMAX
1.23 l cartridge
77 11 172 239
EXCELLENCE +
960 g cartridge
77 11 423 539
For finishing plastic repair
1 kg pack
77 11 423 540
Plugging mastic
XFIBRE FIBREGLASS MASTIC
975 kg pack
77 11 172 235
STANDARD BASIX POLYESTER

MASTIC
1.975 kg pack
77 11 172 234
ALUX ALUMINIUM MASTIC
975 kg pack
77 11 172 236
Sprayable mastic
PIXTO SPRAYABLE POLYESTER
MASTIC
1.5 kg tin
77 11 172 237
Finishing mastic
IXTRA POLYESTER MASTIC
1.625 kg pack
77 11 172 233
Anti-grit mastic
MAG PRO 1
310 ml cartridge
77 11 172 679
MAG PRO 3 (Dual component)
1.5 kg tin
77 11 218 364
SURFACE CLEANER
04B-6
http://vnx.su
04B
HEPTANE
500 ml container
77 11 170 064
SOLVENT SURFACE CLEANER
5 L container
77 01 404 178
WATER-BASED SURFACE CLEANER
5 L container
77 11 421 337
ANTISTATIC THINNER (for plastic

materials)
400 ml aerosol
77 01 408 493
04B
COMPOSITE MATERIAL REPAIR BY BONDING

PLASTIC REPAIR KIT
77 11 170 064
NOZZLE FOR PLASTIC REPAIR

KIT
77 11 423 523
PLASTIC REPAIR CLEANER
1 L container
77 11 423 517
PLASTIC REPAIR PRIMER
150 ml bottle
77 11 423 518
PLASTIC REPAIR ADHESIVE
2 x 25 ml bicomponent cartridge
77 11 423 519
PLASTIC REPAIR CLOTH
90 m roller
77 11 423 520
PLASTIC REPAIR NOZZLES
12 nozzles
77 11 423 522
COMPOSITE MATERIAL REPAIR BY WELDING

PLASTIC WELD REPAIR SET
77 11 425 742
PROTECTIVE STRIPS
Bag of 10 protective strips
77 11 425 744
STAINLESS STEEL MESH
Bag of 2 meshes
77 11 425 743
COOLER
400 ml aerosol
77 11 425 745
BRUSH
Box of 10 brushes
77 11 237 793
WINDOW MASKING TAPE

10 MM WINDSCREEN TAPE
77 11 171 708
20 MM WINDSCREEN TAPE
77 11 171 709
PROTECTIVE WELDING
ANTI-SPLASH SPRAY
400 ml aerosol
77 11 218 270
SPECIFIED UNDERCOAT
PRE-TREATMENT
PRIMER
WITHOUT ZINC CHROMATE (IAlpha) + THINNER
1 L container
I-PREMIA REACTIVE PRIMER (do

not use on aluminium)
3.5 l container
I-PREMIA REACTIVE PRIMER (do

not use on aluminium)
77 11 420 027 (Primer)

77 11 420 028 (Thinner)
77 11 239 243 (Primer)
77 11 228 654 (Thinner)
400 ml aerosol
04B-7
http://vnx.su
77 11 419 416
ADHRA SPRAY (adhesion promoter for thermoplastics)
400 ml aerosol
04B
77 11 423 734
77 11 423 735
PRIMARA BLACK (adhesion promoter/primer for thermoplastics)
1 L container
PRIMARA (adhesion promoter/primer for thermoplastics)
1 L container
77 11 171 514 (Activator)

77 11 171 513
77 11 171 514 (Activator)
UNDERCOAT
LEVIA
3.5 l container
77 11 228 651
FORTIA
3.5 l container
77 11 228 650
04B-8
http://vnx.su
PAINT
Colour code: Specifications
04E
Colour description
Colour Code
Satin textured code
Glacier White
O389
220 112
Bright red
O719
230 103
Beige Grey
TEC66
205 296
Jaune Etincelle (not available in

UK)
TEENC
230 109
Island Blue
TERNP
Vert Printemps (not available in UK)
TEDNK
Mint Blue
TEJ42
Emerald Grey
OKNF
Poppy Red
TENNG
230 110
Shiny grey
TEB64
205 262
Citrus Fruit Yellow
OENG
Volga Blue
ORNQ
Metallic Black
TEGND
215 145
205 316
04E-1
http://vnx.su
Mechanisms and accessories

50A
GENERAL INFORMATION
51A
SIDE OPENING ELEMENT MECHANISMS
52A
NON-SIDE OPENING ELEMENT MECHANISMS
54A
WINDOWS
55A
EXTERIOR PROTECTION
56A
EXTERIOR EQUIPMENT
57A
INTERIOR EQUIPMENT
59A
SAFETY ACCESSORIES
X61
MARCH 2009
constructed."
Edition Anglaise

consent of Renault.
Renault s.a.s 2008
http://vnx.su
Contents
Page
50A
Pair of unclipping pliers: Use
51A
51A
GENERAL INFORMATION
50A-1

Front side door lock:
Removal - Refitting
Front side door lock barrel:
Removal - Refitting
Door exterior handle:
Removal - Refitting
Front side door electric
window mechanism:
Removal - Refitting
Rear side door electric
window mechanism:
Removal - Refitting
Front side door manual
window winder mechanism:
Removal - Refitting

Sliding side door opening
controls: Removal - Refitting
51A-21
Fuel filling compartment

mechanism: Removal Refitting
51A-24
51A-1
52A
51A-3
51A-4
51A-6
51A-8
51A-9
NON-SIDE OPENING ELEMENT

MECHANISMS
Bonnet release handle:
Removal - Refitting
52A-1
Bonnet latch: Removal Refitting
52A-2
Loading door lock: Removal Refitting
52A-3
Rear loading door exterior

handle: Removal - Refitting
52A-8
Tailgate lock: Removal Refitting
52A-10
Upper rear opening element

lock: Removal - Refitting
52A-11
52A-13
Sliding side door tracks:

Removal - Refitting
51A-11
Sliding side door carriage:

Removal - Refitting
51A-16

Sliding side door lock:

Removal - Refitting
51A-19

rail: Removal - Refitting
52A-19
Tailgate balancer: Removal Refitting
52A-21

strut: Removal - Refitting
52A-22
http://vnx.su
Contents
52A
54A
NON-SIDE OPENING ELEMENT

MECHANISMS
55A
Rear opening element

electric window mechanism:
Removal - Refitting
52A-24
Tailgate exterior opening

control: Removal - Refitting
52A-26
Sunroof opening control:

Removal - Refitting
52A-27
Rear loading door stop:

Removal - Refitting
52A-28
Sunroof operating
Sunroof moving panel:
Removal - Refitting
Sliding window in front side

door: Removal - Refitting
55A-1
Front bumper: Stripping Rebuilding
55A-3
Rear bumper: Removal Refitting
55A-7
Rear bumper: StrippingRebuilding
55A-9
55A-12
52A-29
Rear side door strip:

Removal - Refitting
55A-14
52A-32
Rear loading door strip:

Removal - Refitting
55A-15
Front side door moulding:

Removal - Refitting
55A-17
Rear wing protective strip:

Removal - Refitting
55A-18
Front wheel arch liner:

Removal - Refitting
55A-19
Rear side door moulding:

Removal - Refitting
55A-20
Rear wheel arch liner:

Removal - Refitting
55A-21
54A-1
54A-3
Sliding window in rear side

door: Removal - Refitting
54A-5
Quarter panel light
54A-6
Rear side door fixed window:

Removal - Refitting
54A-7
Sliding side door window:

Removal - Refitting
Front bumper: Removal Refitting
Front side door strip:

Removal - Refitting
WINDOWS
Windscreen: Removal Refitting
EXTERIOR PROTECTION
56A
54A-9
Rear screen: Removal Refitting
54A-10
Opening rear screen:

Adjusting
54A-11
Rear loading door window:

Removal - Refitting
54A-13
Fixed roof window: Removal

- Refitting
54A-18
http://vnx.su
EXTERIOR EQUIPMENT
Scuttle panel grille: Removal
- Refitting
56A-1
Scoop under scuttle panel

grille: Removal - Refitting
56A-2
Door mirror: Removal Refitting
56A-4
Door mirror casing: Removal

- Refitting
56A-5
Door mirror glass: Removal Refitting
56A-6
Rear badges: Removal Refitting
56A-7
Contents
56A
EXTERIOR EQUIPMENT
Roof rack bar: Removal Refitting
strip: Removal - Refitting
57A
59A
56A-9
56A-11
INTERIOR EQUIPMENT
Dashboard: Removal Refitting
57A-1
Lower section of dashboard

trim: Removal - Refitting
57A-4
Dashboard air vent: Removal

- Refitting
57A-6
Centre front panel: Removal

- Refitting
57A-7
Glovebox: Removal Refitting
57A-9
Dashboard glovebox:
Removal - Refitting
57A-11
Centre console: Removal Refitting
57A-13
Floor flap and storage:

Removal - Refitting
57A-15
Interior rear-view mirror

Removal - Refitting
57A-16
Sun visor: Removal Refitting
57A-18
Grab handle: Removal Refitting
57A-19
Front storage compartment

under roof: Removal Refitting
57A-20
Rear storage compartment:

Removal - Refitting
57A-21
Separating components:
Removal - Refitting
57A-22
http://vnx.su
SAFETY ACCESSORIES
Belt height adjustment
system: Removal - Refitting
59A-1
GENERAL INFORMATION
50A
99799
a Unclipping tool (part no. 77 11 171 249) for removing

retaining clips, interior trim clips and door trim clips.
a Its flat, bevel edged tip provides easy access underneath clips and clip heads without damaging or altering the clip, the majority of which can therefore be
re-used during refitting.
121062
a Removal of clips from vehicle wheel arch liners.
121060
a Removal of clips from roof lining, carpets and vehicle soundproofing.
121061
a Removal of door window glass handles.

Note:
Place a protective cloth between the trim and the
fixed fork of the pliers so as not to damage the
trim when removing the handle.
50A-1
http://vnx.su
GENERAL INFORMATION
107941
a Removing a door trim.
50A-2
http://vnx.su
50A

Front side door lock: Removal - Refitting
51A
II - OPERATION FOR REMOVAL OF PART

CONCERNED
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Raise the window fully.
a Disconnect the front side door connector.
a Remove:
- the front side door trim (see Front side door trim:
Removal - Refitting) (72A, Side opening element
trim),
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing),
- the front side door lock barrel (see 51A, Side opening element mechanisms, Front side door lock
barrel: Removal - Refitting, page 51A-3) ,
- the exterior door handle (see 51A, Side opening
element mechanisms, Door exterior handle:
Removal - Refitting, page 51A-4) .
126869
a Remove the bolts (3) .

a Unclip the front side door interior opening control cable.
a Remove the front side door lock - exterior door
handle module assembly.
a Disconnect the connector (4) .
a Unclip the front side door lock cable from the front
side exterior door handle module.
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the front side door module rivet (1) .
108049
a Drill out the rivet (1) .
II - REFITTING OPERATION FOR PART

CONCERNED
a Clip on the front side door locking cable for the front
side exterior door handle module.
WARNING
To avoid any risk of corrosion after the localised
stripping of the panel, reapply the protective coating (see Technical Note 0592A).
a Connect the connector (4) .

a Refit the front side door lock - exterior door handle
module assembly.
a Unclip the exterior door handle module for the front

side door at (2) .
a Clip on the front side door interior opening control

cable.
51A-1
http://vnx.su

Front side door lock: Removal - Refitting
III - FINAL OPERATION.
a Clip on the front side door exterior handle module.
a Refit:
- a new rivet (1) ,
Removal - Refitting, page 51A-4) ,
barrel: Removal - Refitting, page 51A-3) ,
- a new door sealing film (see Door sealing film:
Removal - Refitting) (65A, Opening element sealing).
a Carry out a sealing test (see Technical Note 653A).
a Refit:
trim).
a Connect the front side door connector.
a Carry out a function test on all functions.
51A-2
http://vnx.su
51A

Front side door lock barrel: Removal - Refitting
Tightening torquesm
lock barrel bolt
2 Nm
REMOVAL
a Unclip the cover to access the front side door lock
barrel release mechanism.
CONCERNED
108047
a Loosen the locking bolt completely without removing

it.
a Remove the front side door lock barrel.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a Position the front side door lock barrel.
a Torque tighten the lock barrel bolt (2 Nm).
II - FINAL OPERATION.
a Clip on the blanking cover.
a Carry out a function test.
51A-3
http://vnx.su
51A

Door exterior handle: Removal - Refitting
51A
REMOVAL
a Remove:
trim),
barrel: Removal - Refitting, page 51A-3) .
108046

CONCERNED
a Remove the exterior door handle at (2) and (3) .
Exterior handle module (view from inside door box

section)
REFITTING
127455
a Pull the exterior door handle.

a Press on the lever (1) .
108048
a Check the presence and condition of the seal (4) .
51A-4
http://vnx.su

Door exterior handle: Removal - Refitting
51A

CONCERNED
a Refit the front side door lock barrel (see 51A, Side
opening element mechanisms, Front side door
lock barrel: Removal - Refitting, page 51A-3) .
a Refit new door sealing film (see Door sealing film:
a Carry out a sealing test (see Technical Note 0653).
a Refit:
trim).
127457
a Activate the door exterior handle locking mechanism

(5) .
a Lock the locking mechanism by pressing on the lever (6) .
127456
a Refit the exterior door handle at (7) and at (8) .
51A-5
http://vnx.su

Front side door electric window mechanism: Removal - Refitting
51A
PAS ELEC ONE-TCH WIND SW
REMOVAL

CONCERNED

a Open the window halfway.
a Remove:
trim),
- the door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing).
126868
a Disconnect the connector for the front side door

electric window motor (2) .
a Remove:
- the bolts (3) ,
- the front side door electric window winder mechanism.
126915
a Remove the bolts (1) from the front side door sliding
window glass.
a Secure the window in the raised position using masking tape.
51A-6
http://vnx.su

Front side door electric window mechanism: Removal - Refitting
REFITTING
CONCERNED
126868
a Refit:
- the front side door electric window winder mechanism,
- the bolts in the sequence (1) , (2) , (3) , (4) and (5) .
a Connect the connector for the front side door electric
window motor (2) .
a Refit the front side door sliding window glass.
a Refit:
trim).
51A-7
http://vnx.su
51A

Rear side door electric window mechanism: Removal - Refitting
51A
LEFT SLIDING + OPENING WINDOW, and R SLID+OPENING WINDOW, and ELEC. REAR WINDOW SW.
REMOVAL

CONCERNED

a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
a Remove:
- the sliding side door trim (see Sliding side door
trim: Removal - Refitting) (72A, Side opening element trim),
126867

a Remove:
- the bolts (3) ,
- the rear side door electric window mechanism (4) .
REFITTING
CONCERNED
127454
a Remove the bolt (1) .

a Refit the rear side door electric window mechanism

(4) .
a Refit the bolt (1) .
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
a Refit the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening
element trim).
51A-8
http://vnx.su

Front side door manual window winder mechanism: Removal - Refitting
51A
MAN. FRONT WINDOW WINDER
REMOVAL

CONCERNED

a Remove:
trim),
132061
a Remove:
- the bolts (2) ,
- the front side door manual window winder mechanism.
132062
a Remove the bolts (1) from the front side sliding door
window.
51A-9
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Front side door manual window winder mechanism: Removal - Refitting
REFITTING
CONCERNED
132061
a Refit:
- the front side door manual window winder mechanism,
- the bolts in the sequence (1) , (2) , (3) , (4) and (5) .
a Refit the front side door sliding window glass.
a Refit the door sealing film (see Door sealing film:
a Refit:
trim).
51A-10
http://vnx.su
51A

Sliding side door tracks: Removal - Refitting
51A
L SLIDING PANEL or LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and R
SLIDING PANEL or RIGHT SLIDING + FIXED WINDOW or R SLID+OPENING WINDOW
2 - Sliding side door intermediate runner
Essential equipment
K61
diagnostic tool
a Remove:
- the rear wing light (see Rear light on wing: Removal - Refitting) (81A, Rear lighting),
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
- the rear wheel arch trim (see Rear wheel arch

lining: Removal - Refitting) (71A, Body interior
trim).
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
a Remove the sliding side door intermediate drive mechanism (see 51A, Side opening element mechanisms, Sliding side door carriage: Removal Refitting, page 51A-16) .
When this function is activated, all the trigger lines

are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
3 - Sliding side door lower runner

a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(88C, Airbags and pretensioners).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
a Remove:
- the sliding side door lower drive mechanism (see
51A, Side opening element mechanisms, Sliding side door carriage: Removal - Refitting,
page 51A-16) ,
Note:
- the complete front seat (see Complete front seat:

Removal - Refitting) (75A, Front seat frames and
runners),
For partial removal of the runners, it is not necessary to remove the sliding side door.
- the B-pillar lower trims (see B-pillar lower trim:

Removal - Refitting) (71A, Body internal trim),
REMOVAL
K61

a Remove the rear side door (see Rear side door:
Removal - Refitting) (47A, Side opening elements).
a Remove:
1 - Sliding side door upper runner

a Remove the sliding side door upper drive mechanism (see 51A, Side opening element mechanisms, Sliding side door carriage: Removal Refitting, page 51A-16) .
- the centre console (see 57A, Interior equipment,

Centre console: Removal - Refitting, page 57A13) ,
- the centre front panel (see 57A, Interior equipment, Centre front panel: Removal - Refitting,
page 57A-7) ,
- the flaps and floor panel storage compartments
(see 57A, Interior equipment, Floor flap and storage: Removal - Refitting, page 57A-15) ,
- the floor carpet (see Floor carpet: Removal - Refitting) (71A, Body interior trim).
51A-11
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51A
F61
126861
a Remove:
127582
- the bolts (1) ,

- the rear section false floor panel.
a Partially lift the floor carpet.

a Remove the soundproofing (2) .
51A-12
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51A
CONCERNED
126864
a Remove:
- the nut (5) ,
126862
- the sliding side door intermediate runner.
a Remove:
- the bolts (3) ,
- the sliding side door upper runner.
126863
51A-13
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51A
REFITTING

CONCERNED
a Refit the sliding side door upper runner.
a Refit the sliding side door intermediary runner.
a Refit the sliding side door lower runner.
126865
a Refit the sliding side door upper drive mechanism

(see 51A, Side opening element mechanisms,
Sliding side door carriage: Removal - Refitting,
page 51A-16) .
a Remove the sliding side door intermediate drive mechanism (see 51A, Side opening element mechanisms, Sliding side door carriage: Removal Refitting, page 51A-16) .
K61
a Remove:
lining: Removal - Refitting) (71A, Body interior
trim).
126866
a Remove:
- the bolts (6) ,
- the nut (6) ,
- the sliding side door lower runner.

K61
a Remove:
- the rear section false floor panel,
- the floor carpet (see Floor carpet: Removal - Refitting) (71A, Body internal trim),
51A-14
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51A
- the flaps and floor panel storage compartments
(see 57A, Interior equipment, Floor flap and storage: Removal - Refitting, page 57A-15) ,
page 57A-7) ,
- the centre console (see 57A, Interior equipment,
Centre console: Removal - Refitting, page 57A13) .
F61
a Refit:
- the soundproofing (2) ,
- the floor carpet.
a Remove:
- the B-pillar lower trims (see B-pillar lower trim:
- the complete front seat (see Complete front seat:
Removal - Refitting) (75A, Front seat frames and
runners),
- the sliding side door lower drive mechanism (see
51A, Side opening element mechanisms, Sliding side door carriage: Removal - Refitting,
page 51A-16) .
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (88C, Airbags and pretensioners).
a Refit the rear side door (see Rear side door: Removal - Refitting) (47A, Side opening elements).
51A-15
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Sliding side door carriage: Removal - Refitting
51A
Note:
For partial removal of the sliding side door drive
mechanisms, it is not necessary to remove the sliding side door.
REMOVAL
a Remove the rear side door (see Rear side door:
Removal - Refitting) (47A, Side opening elements).
1 - Sliding side door upper drive mechanism
127427
127429
a Remove the sliding side door upper runner stop (1) .

2 - Sliding side door intermediate drive mechanism
127430
a Remove:
K61
a Remove the rear wing light (see Rear light on wing:
Removal - Refitting) (81A, Rear lighting).
51A-16
- the bolts (2) ,

- the intermediate runner trim at (3) .
http://vnx.su

51A
- the sliding side door intermediate runner stop.
3 - Sliding side door lower drive mechanism
127449
a Remove:
- the bolt (4) ,
- the sliding side door intermediate runner stop (5) .
127428
a Remove:
- the bolts (7) ,
F61
- the sliding side door lower runner stop.
127450
a Remove:
- the bolt (6) ,
51A-17
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51A
REFITTING

CONCERNED

CONCERNED
a Refit the sliding side door upper drive mechanism.
a Refit the sliding side door intermediary drive mechanism.
a Refit the sliding side door lower drive mechanism.
126917
a Refit the sliding side door upper runner stop.


a Remove:
K61
- the bolts (8) ,
a Refit:
- the sliding side door upper drive mechanism.
- the sliding side door intermediate runner stop (5) ,

- the intermediate runner trim,
- the rear wing light (see Rear light on wing: Removal - Refitting) (81A, Rear lighting).
a Remove:
- the bolts (9) ,
- the sliding side door intermediate drive mechanism.
a Remove:
F61
a Refit the sliding side door intermediate runner stop.
- the bolts (10) ,

- the sliding side door lower drive mechanism.
a Refit the sliding side door lower runner stop.
a Refit the rear side door (see Rear side door: Removal - Refitting) (47A, Side opening elements).
a Adjust the rear side door (see Rear side door: Adjustment) (47A, Side opening elements).
51A-18
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Sliding side door lock: Removal - Refitting
51A
REMOVAL

CONCERNED

ELEC. REAR WINDOW SW.
a Remove:
127451
a Remove:
- the bolts (1) ,
a Remove the rear sliding side door electric window

mechanism (see 51A, Side opening element mechanisms, Rear side door electric window mechanism: Removal - Refitting, page 51A-8) .
- partially remove the sliding side door lock.
127452
51A-19
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Sliding side door lock: Removal - Refitting
51A
REFITTING
CONCERNED
a Clip on the sliding side door lock control cable for the
sliding side door exterior door handle module.
a Refit the sliding side door lock - exterior door handle module assembly
a Clip on the sliding side door interior and exterior
opening control cables.
a Refit the sliding side door exterior door handle module.
a Refit the sliding side door lock.
127453
a Remove the sliding side door exterior door handle

module.

a Refit the rear sliding side door electric window mechanism (see 51A, Side opening element mechanisms, Rear side door electric window
mechanism: Removal - Refitting, page 51A-8) .
WARNING
a Unclip the sliding side door interior and exterior opening control cables.
a Remove the sliding side door lock - exterior door
handle module assembly.
a Unclip the sliding side door lock control cable from
the sliding side door exterior door handle module.
a Refit the door exterior handle (see 51A, Side opening element mechanisms, Door exterior handle:
element trim).

51A-20
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Sliding side door opening controls: Removal - Refitting
51A
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING + FIXED
WINDOW or R SLID+OPENING WINDOW
REMOVAL
Sliding side door exterior handle:
a Remove:
- the dummy lock.
CONCERNED
127459
1 - Sliding side door exterior handle:

Exterior handle module (view from inside door box
section)
a Remove the sliding side door exterior handle at (2)

and at (3) .
2 - Sliding side door interior handle:
127455
a Pull the sliding side door exterior handle.

126456
a Unclip the trim (4) .

a Unclip:
- the sliding side door interior handle,
- the sliding side door interior door handle cable.
51A-21
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51A
REFITTING

CONCERNED

1 - Sliding side door exterior handle:
127457
127453
a Check the presence and condition of seal (5) .
a Activate the sliding side door exterior handle locking

mechanism.
a Lock the sliding side door exterior handle locking
mechanism by pressing on the lever (7) .
127456
a Refit the sliding side door exterior handle at (8) and

at (9) .
51A-22
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51A
2 - Sliding side door interior handle:
a Clip:
- the sliding side door interior door handle cable,
- the sliding side door interior handle,
- the trim (4) .
a Fit the dummy lock.
a Carry out a sealing test (see Technical Note
0653A).
element trim).
51A-23
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Fuel filling compartment mechanism: Removal - Refitting
51A

CONCERNED
REMOVAL
126859
126826
a Remove:
- the fuel filler cap,
- the bolts (1) ,
- the bolt (2) ,
- the fuel filler flap,
lining: Removal - Refitting) (71A, Bodywork interior trim),
- the sliding side door intermediate drive mechanism
page 51A-16) ,
- the sliding side door intermediate runner (see 51A,
Side opening element mechanisms, Sliding
side door tracks: Removal - Refitting, page 51A11) .
126858
a Remove:
- clip (4) ,
- the fuel filler flap mechanism.
51A-24
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Fuel filling compartment mechanism: Removal - Refitting
REFITTING
CONCERNED
a Refit:
- the fuel filler flap mechanism,
- the clip (4) .
a Refit:
- the sliding side door intermediate runner (see 51A,
Side opening element mechanisms, Sliding
side door tracks: Removal - Refitting, page 51A11) ,
- the sliding side door intermediate drive mechanism
page 51A-16) ,
lining: Removal - Refitting) (71A, Bodywork interior trim),
- the fuel filler flap,
- the fuel filler cap.
51A-25
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51A

Bonnet release handle: Removal - Refitting
52A
REMOVAL
a Remove:
- the battery (see Battery : Removal - Refitting)
(80A, Battery)
- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),
- the air filter unit (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
- the bonnet catch (see 52A, Non-side opening element mechanisms, Bonnet latch: Removal - Refitting, page 52A-2) .
CONCERNED
126888
a Unclip the bonnet opening control (2) at (3) using a

flat screwdriver.
a Note the routing of the bonnet opening control cable.
a Remove the bonnet opening control cable from inside the vehicle.
REFITTING
CONCERNED
a Refit the bonnet opening control cable.
a Refit the bonnet opening control (2) .
126319
a Remove the access flap (1) to the passenger compartment fuses and relay.
a Refit the bonnet catch (see 52A, Non-side opening
element mechanisms, Bonnet latch: Removal Refitting, page 52A-2) .
a Refit:
- the access flap (1) to the passenger compartment
fuses and relays,
- the air filter unit (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),
- the battery (see Battery : Removal - Refitting)
(80A, Battery).
52A-1
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Bonnet latch: Removal - Refitting
52A
Tightening torquesm
bonnet catch bolts
21 Nm
REMOVAL
OPERATION FOR REMOVAL OF PART
CONCERNED
126887
a Unclip the bonnet opening release cable (2) .

a Remove the bonnet catch.
REFITTING
REFITTING OPERATION FOR PART CONCERNED
a Clip on the bonnet opening release cable (2) .
126886
a Refit:
a Remove the bonnet catch bolts (1) .
- the bonnet catch,

- the bolts (1) (without tightening them).
a Adjust the clearances and flush fitting (see Vehicle
clearances: Adjustment values) (01C, Vehicle bodywork specifications).
a Torque tighten the bonnet catch bolts (21 Nm) (1) .
52A-2
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Loading door lock: Removal - Refitting
52A
F61
REMOVAL
2 - Rear right-hand loading door lock

a
Note:
The upper and lower locks of the rear right-hand
loading door are removed independently.
1 - Rear left-hand loading door lock

a Remove:
- the rear left-hand loading door trim (see Left-hand
rear loading door trim: Removal - Refitting)
(73A, Non-side opening elements trim),
- the loading door exterior handle (see 52A, Nonside opening element mechanisms, Rear loading door exterior handle: Removal - Refitting,
page 52A-8) .
a Remove the rear right-hand loading door trim (see

Right-hand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim).
CONCERNED
142574
142575

a Unclip the loading door interior opening control cable.
WARNING
To prevent any risk of corrosion after stripping
the panel, reapply the anticorrosion protection
(see Technical Note 0592A).
a Unclip the loading door exterior handle module at (2)

.
a Remove the lock - exterior handle module assembly from the front side door box section.
a Unclip the loading door locking cable from the loading door exterior handle module.
52A-3
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52A
F61
CONCERNED

a Clip on the loading door locking cable for the loading
door exterior handle module.
a Refit the lock - exterior handle module assembly
for the front side door box section.
a Clip on the loading door interior opening control cable.
a - Loading door upper lock
a Refit the loading door upper lock (8) .
126885
b - Loading door lower lock
a Unclip the locking cables for the upper lock (5) and
the lower lock (6) .
a Refit the loading door lower lock (10) .
a - Loading door upper lock
a Clip on the locking cables for the upper lock (5) and
the lower lock (6) .
a Remove:
- the bolts (7) ,
III - FINAL OPERATION
- the loading door upper lock (8) .

b - Loading door lower lock
a Clip on the loading door exterior handle module.
a Remove:
a Refit:
- the bolts (9) ,
- a new rivet (1) ,
- the loading door lower lock (10) .
- the loading door exterior handle (see 52A, Nonside opening element mechanisms, Rear loading door exterior handle: Removal - Refitting,
page 52A-8) ,

a Always replace the loading door module rivet (1) .
- a new piece of trim to the rear left-hand loading

door (see Left-hand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim).
a Refit a new piece of trim to the rear right-hand loading door (see Right-hand rear loading door trim:
Removal - Refitting) (73A, Non-side opening elements trim).
52A-4
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52A
REMOVAL
a
Note:
In the event of an electric fault, it is possible to
open the loading door manually.
This operation is performed from inside the vehicle.
141002
a Unlock the loading door lock by pulling on the cable

at (2) .
a Remove:
- the tailgate trim (see Tailgate lining: Removal Refitting) (73A, Non-side opening elements trim),
141001
a Unclip blanking cover (1) .

a Open the upper rear opening element from inside
the vehicle.
52A-5
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52A

CONCERNED
140636
140635
a Remove the loading door lock bolts (5) .
a Disconnect the connector (3) from the loading door

lock.
140637
a Remove the loading door lock at (6) .

140638
a Unclip the cable stop from its housing at (4) .

a Extract the cable from the lock actuator.
52A-6
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REFITTING
CONCERNED
140639
a Refit:
- the loading door lock onto its index (7) ,
- the loading door lock bolts (5) ,
- the cable in the lock actuator.
a Clip the cable stop in its housing.
a Connect the loading door lock connector (3) .
II - FINAL OPERATION
a Refit:
- the tailgate trim (see Tailgate lining: Removal Refitting) (73A, Non-side opening elements trim).
52A-7
http://vnx.su
52A

Rear loading door exterior handle: Removal - Refitting
52A
REMOVAL
a Remove:
- the dummy lock.
CONCERNED
Rear loading door exterior handle module (viewed
from inside the door box section)
142572
a Remove the rear loading door exterior handle at (2)

and at (3) .
REFITTING
127455
a Pull the rear loading door exterior handle.

142573
a Check the presence and condition of seal (4) .
52A-8
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Rear loading door exterior handle: Removal - Refitting
52A

CONCERNED
a Refit a new piece of trim to the rear left-hand loading

door (see Left-hand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim).
127457
a Activate the rear loading door exterior handle locking mechanism (5) .
a Lock the locking mechanism by pressing on the lever (6) .
127456
a Refit:
- the rear loading door exterior handle at (7) and at
(8) ,
- the dummy lock.
52A-9
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Tailgate lock: Removal - Refitting
K61
REMOVAL
a Remove the tailgate trim (see Tailgate lining: Removal - Refitting) (73A, Non-side opening elements trim).

CONCERNED
126473

a Remove the tailgate lock.
a Disconnect the tailgate lock connector (2) .
REFITTING
CONCERNED
a Connect the tailgate lock connector (2) .
a Refit the tailgate lock.
a Refit the tailgate trim (see Tailgate lining: Removal
- Refitting) (73A, Non-side opening elements trim).
52A-10
http://vnx.su
52A

Upper rear opening element lock: Removal - Refitting
PLASTIC ROOF FLAP or TINTED WINDOW ROOF FLAP
Tightening torquesm
lock bolts
2.5 N.m
REMOVAL
a Open the panel of the upper rear opening element.
CONCERNED
138562
a Remove:
- the bolts (1) ,
- the lock of the upper rear opening element (2) .
REFITTING
CONCERNED
a Refit:
- the lock of the upper rear opening element (2) ,
- the bolts (1) .
a Torque tighten the lock bolts (2.5 N.m).
52A-11
http://vnx.su
52A

Upper rear opening element lock: Removal - Refitting
52A
ROOF FLAP or PLASTIC ROOF FLAP or TINTED WINDOW ROOF FLAP, and HORIZONTAL OPENING DOOR
REMOVAL
CONCERNED
140631
a Remove:
- the bolts (1) ,
- the upper rear opening element locks (2) .
REFITTING
CONCERNED
a Refit:
- the upper rear opening element locks (2) ,
- the bolts (1) .
52A-12
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Upper rear opening element mechanism: Removal - Refitting
52A
ROOF FLAP or PLASTIC ROOF FLAP or TINTED WINDOW ROOF FLAP
STANDARD CHASSIS
Tightening torquesm
upper bolt of the rear
side seat belt
21 N.m
Note:
If it is necessary to remove the guide slide supports, make a mark before removing them.
REMOVAL
1 - Guide bar
SHORT CHASSIS
a Remove:
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim),
138563
a Remove the quarter panel upper trim (1) .
- the rear wheel arch trims (see Rear wheel arch

lining: Removal - Refitting) (71A, Body internal
trim).
SHORT CHASSIS
141078
a Remove the quarter panel upper trim at (1) .
52A-13
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52A
141079
141081
a Unclip the upper trim from the rear wheel arch (4) .
STANDARD CHASSIS
141080
a Remove:
- the rear side seat belt upper bolt (3) ,
- the rear seat belt return mechanism.
138584
a Remove:
- the bolts (5) ,
- the thread supports.
52A-14
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52A

2 - Guide slide
138583
a Remove the rear centre trim (6) .
140904
a Unclip the blanking covers (8) .

a Remove the bolts (9) from the upper rear opening
element rail trims.
138582
a Remove:
- the clips (7) ,
140903
- the roof rear side trim.
a Remove the upper rear opening element rail trims at

(10) .
52A-15
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52A
138581
a Remove the bearing bolts (12) .
140902
a Separate the upper rear opening element guide bar

from the upper rear opening element panel by sliding it towards the front of the vehicle.
a Open the upper rear opening element panel midway and extract the upper rear opening element rails
at (11) .
a Support the upper rear opening element panel using
a block.
CONCERNED
1 - Guide bar
a Remove the struts of the upper rear opening element (see 52A, Non-side opening element mechanisms, Upper rear opening element strut:
138580
a Loosen the upper rear opening guide bar bolts (13) .
138580
a Remove the upper rear opening element guide bar

at (14) .
52A-16
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52A

- the bolts (15) .
2 - Guide slide
1 - Guide bar
a Refit:
- the roof rear side trim,
- the clips (7) ,
- the rear centre trim (6) .
STANDARD CHASSIS
a Refit:
- the net supports,
141000
- the bolts (5) ,
a Remove:
- the quarter panel upper trim.
- the bolts (15) ,

- the guide slides.
REFITTING
SHORT CHASSIS
CONCERNED
a Clip on the rear wheel arch upper trim (4) .

a Refit:
1 - Guide bar
a Refit the upper rear opening element mechanism.
- the rear seat belt return mechanism,
a Tighten the bolts (13) of the upper rear opening element mechanism.
- the rear side seat belt upper bolt (3) .
a Refit:
a Torque tighten the upper bolt of the rear side seat

belt (21 N.m).
- the upper rear opening element panel on the upper

rear opening element mechanism,
a Clip on the blanking cover (2) .
- the bearing bolts (12) .
a Refit:
a Close the upper rear opening element panel.
- the quarter panel upper trim,
a Refit the struts of the upper rear opening element

(see 5 2 A , Non-side opening element mechanisms, Upper rear opening element strut: Removal - Refitting, page 52A-22) .

trim),
2 - Guide slide
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim).
a Refit:
- the guide slides,
52A-17
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2 - Guide slide
a Remove the block.
a Fit the upper rear opening element panel.
a Refit:
- the upper rear opening element rail trims,
- the bolts (9) for the upper rear opening element rail
trims.
a Clip on the blanking covers (8) .
52A-18
http://vnx.su
52A

Upper rear opening element rail: Removal - Refitting
52A
REMOVAL
140902
140904

element rail trims.
at (4) .
a block.
CONCERNED
140903

(3) .
140901
a Remove:
- the nuts (5) from the upper rear opening element
rails,
52A-19
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Upper rear opening element rail: Removal - Refitting
- the upper rear opening element rails.
REFITTING
140925
a Check the condition of the sealing components (6)

and replace them if necessary.
CONCERNED
a Refit:
- the upper rear opening element rails,
- the nuts (5) of the upper rear opening element rails.
a Remove the block.
a Fit the upper rear opening element panel.
a Refit:
trims.
52A-20
http://vnx.su
52A

Tailgate balancer: Removal - Refitting
52A
REMOVAL
a
WARNING
The strut is fitted in such a way as to prevent
leaks. Note the strut's direction of fitting (position
of the body and cylinder rod) before removing it,
in order to refit the strut identically.
CONCERNED
126471
a Remove the tailgate strut (2) whilst supporting the

tailgate.
REFITTING
a Position the clips (1) on the tailgate strut.
CONCERNED
a Refit the tailgate strut (2) .
90920
a Unclip the clips (1) without removing them.
52A-21
http://vnx.su

Upper rear opening element strut: Removal - Refitting
52A
REMOVAL
CONCERNED
138560
a Remove the struts (2) of the upper rear opening element.
REFITTING
138559
a Unclip the upper clips (1) without removing them.

a Remove the upper sections of the struts.
a Unclip the lower clips.
a Clip on the clips (1) .

CONCERNED
a Refit the lower section of the struts of the upper rear
opening element.
a Put the panel of the upper rear opening element in
the high position.
52A-22
http://vnx.su

Upper rear opening element strut: Removal - Refitting
138561
a Hold the strut of the upper rear opening element at

(3) .
a Refit the upper section of the struts of the upper rear
opening element using a screwdriver (4) .
52A-23
http://vnx.su
52A

Rear opening element electric window mechanism: Removal - Refitting
52A
REMOVAL

CONCERNED

a Remove:
- the rear loading door window (see 54A, Windows,
Rear loading door window: Removal - Refitting,
page 54A-13) .
140212
a Remove:
- the blanking covers (2) ,
- the nuts (3) ,
- the bolts (4) .
140216
a Disconnect the connector (1) from the rear opening

element window winder motor.
140214
a Remove the rear section and then the front section

of the rear opening element window winder mechanism from the door box.
52A-24
http://vnx.su

Rear opening element electric window mechanism: Removal - Refitting
52A
REFITTING
CONCERNED
140213
a Refit:
- the rear lower section at (5) and then the rear upper
section of the rear opening element window winder
mechanism,
140218
a Refit:
- the bolt (4) ,
- the front lower section and then the front upper

section of the rear opening element window winder
mechanism,
- the nut (3) .

a Tighten:
- the bolt (4) without tightening it,
- the bolts (4) ,
- the nut (3) without tightening it.
- the nuts (3) .

a Refit the blanking covers (2) .
a Connect the connector (1) for the rear opening element window winder motor.
a Refit:
- the rear loading door window (see 54A, Windows,
Rear loading door window: Removal - Refitting,
page 54A-13) ,
52A-25
http://vnx.su

Tailgate exterior opening control: Removal - Refitting
REMOVAL
CONCERNED
126472

a Remove the tailgate exterior opening control.
REFITTING
CONCERNED
a Refit the tailgate exterior opening control.
52A-26
http://vnx.su
52A

Sunroof opening control: Removal - Refitting
52A
K61
REMOVAL
a Remove the sunroof mobile panel (see 52A, Nonside opening element mechanisms, Sunroof moving panel: Removal - Refitting, page 52A-32) .
CONCERNED
140915
a Remove the sealing pins (2) .
REFITTING
CONCERNED
a Refit:
- the sealing pins (2) ,
140913
a Remove:
- the sunroof opening control,
- the bolts (1) ,
- the bolts (1) .
- the sunroof opening control.

a Refit the mobile panel to the sunroof (see 52A, Nonside opening element mechanisms, Sunroof moving panel: Removal - Refitting, page 52A-32) .
52A-27
http://vnx.su

Rear loading door stop: Removal - Refitting
52A
F61
REMOVAL
REFITTING

CONCERNED
a Remove the rear left-hand loading door trim (see

Left-hand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim) or
the rear right-hand loading door trim (see Righthand rear loading door trim: Removal - Refitting)
(73A, Non-side opening elements trim).

CONCERNED
1 - Rear loading door stop mechanism

a Refit the rear loading door stop mechanism (2) .
2 - Rear loading door check strap
a Refit the rear loading door check strap (4) .
a Refit a new piece of trim to the rear left-hand loading
door (see Left-hand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim) or a new piece of trim to the rear righthand loading door (see Right-hand rear loading
door trim: Removal - Refitting) (73A, Non-side
opening elements trim).
126883
1 - Rear loading door stop mechanism

a Remove:
- the nuts (1) ,
- the rear loading door stop mechanism (2) .
2 - Rear loading door check strap

a Remove:
- the bolts (3) ,
- the rear loading door check strap (4) .
52A-28
http://vnx.su

Sunroof operating mechanism: Removal - Refitting
52A
K61
Essential equipment
diagnostic tool
cutting wire insertion tool
IMPORTANT
IMPORTANT
140922
a Protect the edge of the sunroof operating mechanism using 20 MM WINDSCREEN TAPE (see Vehicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products).

IMPORTANT
REMOVAL
(88C, Airbag and pretensioners).
a Remove:
- the front section of the headlining (see Headlining:
- the sunroof mobile panels (see 52A, Non-side
opening element mechanisms, Sunroof moving
panel: Removal - Refitting, page 52A-32) .
a Protect the vehicle interior.
52A-29
http://vnx.su

52A
K61
CONCERNED
140986
140923
a Fit the cutting handles on the two sections of the cutting wire inside the vehicle.
a Cut the cement bead and leave the other handle in
place until it is needed.
a Insert:
- the cutting wire insertion tool at one end,
Note:
- the cutting wire in the cutting wire insertion tool

from the outside towards the inside and leave it until it is needed.
Reduce the length of the cutting wire as you cut.

a Remove the sunroof operating mechanism.
Note:
Be careful to pass the cutting wire correctly

between the roof and the roof fixed window
frame.
a For preparation and bonding (see Technical Note

560A).
a Slide the cutting wire around the edge between the

fixed window frame and the roof.
a parts always to be replaced: Roof opening element adjusting shim (50,04,22,03).

CONCERNED
a Cut a sufficient length of cutting wire.
a Bond the sunroof operating mechanism (this operation requires two people).
Note:
a Adjust the clearance and for flush fitting.
When routing the cutting wire into the vehicle

interior, be careful not to cross the two wires, as
this would make cutting the seal impossible.
a Insert:
- the cutting wire insertion tool alongside the cutting wire already present,
towards the vehicle interior.
52A-30
http://vnx.su

K61
a Refit:
- the sunroof mobile panels (see 52A, Non-side
opening element mechanisms, Sunroof moving
panel: Removal - Refitting, page 52A-32) ,
- the front section headlining (see Headlining: Removal - Refitting) (71A, Body internal trim).
52A-31
http://vnx.su
52A

Sunroof moving panel: Removal - Refitting
52A
K61
REMOVAL
CONCERNED
138610
a Remove:
- the bolts (4) ,
- the hinge supports (5) .
140910
REFITTING
a Open the sunroof mobile panel at (1) .

a Refit:
- the hinge supports (5) ,
- the bolts (4) ,
- the sunroof mobile panel.
a Lock the sunroof opening control.
a Close the sunroof mobile panel.
140909
a Press the locking button (2) and pull the sunroof mobile panel at (3) .
a Remove the sunroof mobile panel by opening it
completely.
52A-32
http://vnx.su
WINDOWS
Windscreen: Removal - Refitting
54A
Essential special tooling

Car. 1847
Universal protector
REMOVAL
a Remove:
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing),
- the scuttle panel grille (see 56A, Exterior equipment, Scuttle panel grille: Removal - Refitting,
page 56A-1) ,
- the interior rear-view mirror (see 57A, Interior
equipment, Interior rear-view mirror Removal Refitting, page 57A-16) ,
- the rain and light sensor (see Rain and light sensor: Removal - Refitting) (85A, Wipers Washing),
108156
a
WARNING
When cutting the cement bead, take care not to
cut the wiring harness.
- the windscreen pillar trims (see A-pillar trim: Removal - Refitting) (71A, Body internal trim).
a Protect around the windscreen using masking tape.
Note:
When cutting the cement seal, protect the dashboard using the tool (Car. 1847).

CONCERNED
a Cut the cement bead (see Technical Note 560A).

a Bond the windscreen (this operation requires two
people).
REFITTING
a Always replace:
- the shims,
- the rain and light sensor adhesive base (see Rain
and light sensor: Removal - Refitting) (85C, Wipers - Washing),
- the windscreen seal (1) .
126909
a Remove the windscreen seal (1) .

560A).
54A-1
http://vnx.su
WINDOWS
Windscreen: Removal - Refitting
CONCERNED
a Bond the windscreen (this operation requires two
people).
a Respect the following clearances and shut lines:
- windscreen - roof ,
- windscreen - A-pillar .
a Refit:
- the windscreen pillar trims (see A-pillar trim: Removal - Refitting) (71A, Body internal trim),
- the rain and light sensor (see Rain and light sensor: Removal - Refitting) (85A, Wipers Washing),
- the interior rear-view mirror (see 57A, Interior
equipment, Interior rear-view mirror Removal Refitting, page 57A-16) ,
page 56A-1) ,
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing).
54A-2
http://vnx.su
54A
WINDOWS
Sliding window in front side door: Removal - Refitting
54A
REMOVAL
a Remove:
trim),
- the front side door exterior weatherstrip (see Front
door side exterior weather strip: Removal - Refitting) (66A, Window sealing),
- the front side door interior weatherstrip.
126916
a Remove the window at (2) .
REFITTING

CONCERNED
a Refit the window.
CONCERNED

a Refit:
- new door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening element sealing).
126915
a Refit:
a Unclip the window.
54A-3
http://vnx.su
WINDOWS
Sliding window in front side door: Removal - Refitting
trim).
54A-4
http://vnx.su
54A
WINDOWS
Sliding window in rear side door: Removal - Refitting
54A
LEFT SLIDING + OPENING WINDOW, and R SLID+OPENING WINDOW, and ELEC. REAR WINDOW SW.
REMOVAL
REFITTING

CONCERNED
a Refit the sliding window in the rear side door.
a Remove:
a Refit:

- the fixed rear side door window (see 54A, Windows, Rear side door fixed window: Removal Refitting, page 54A-7) ,
- the window lift mechanism (see 51A, Side opening element mechanisms, Rear side door electric window mechanism: Removal - Refitting,
page 51A-8) ,


door side exterior weather strip: Removal - Refitting) (66A, Window sealing).
- the window lift mechanism (see 51A, Side opening element mechanisms, Rear side door electric window mechanism: Removal - Refitting,
page 51A-8) ,
- the fixed rear side door window (see 54A, Windows, Rear side door fixed window: Removal Refitting, page 54A-7) .

element trim).

CONCERNED
126913
a Remove the sliding window from the rear side door

at (1) .
54A-5
http://vnx.su
WINDOWS
Quarter panel light
54A
K61
REMOVAL

CONCERNED
a Bond the rear quarter panel window.
a Adjust the clearance and for flush fitting.
a Remove:
trim),

a Refit:
- the rear quarter panel trim (see Rear quarter panel trim: Removal - Refitting) (71A, Body internal
trim).
a Protect the body around the rear quarter panel window using masking tape.
- the rear quarter panel trim (see Rear quarter panel trim: Removal - Refitting) (71A, Body internal
trim).
trim).

CONCERNED
126911

a Remove the rear quarter panel window.
REFITTING
a Always replace the shims.
560A).
54A-6
http://vnx.su
WINDOWS
Rear side door fixed window: Removal - Refitting
54A
REMOVAL
a Remove:
- the rear side door exterior weatherstrip (see Rear
side door exterior weather strip: Removal - Refitting) (66A, Window sealing),
126912
- the interior weatherstrip,

- the rear side door electric window mechanism (see
51A, Side opening element mechanisms, Rear
side door electric window mechanism: Removal - Refitting, page 51A-8) .
a Remove:
- the bolts (2) ,
- the fixed window pillar from the rear side door (3) .

CONCERNED
126914
a Remove the rear side door fixed window (4) .
127454

a Unclip the sliding window from the rear side door.
a Wind the rear side door sliding window down to the
bottom of the door box section.
54A-7
http://vnx.su
WINDOWS
Rear side door fixed window: Removal - Refitting
REFITTING
CONCERNED
a Refit:
- the fixed rear side door window (4) ,
- the fixed window pillar on the rear side door (3) .
a Clip the sliding window on the rear side door.
a Refit:
- the rear side door electric window lift mechanism
Rear side door electric window mechanism:
- the interior weatherstrip,
side door exterior weather strip: Removal - Refitting) (66A, Window sealing).
element trim).
54A-8
http://vnx.su
54A
WINDOWS
Sliding side door window: Removal - Refitting
WITHOUT REAR WINDOW WINDER
REMOVAL
CONCERNED
127440
a Remove:
- the bolts (1) ,
- the sliding side door glass.
REFITTING
a Refit the sliding side door glass.
54A-9
http://vnx.su
54A
WINDOWS
Rear screen: Removal - Refitting
54A
K61
REMOVAL
REFITTING

a Remove:
- the rear screen wiper arm (see Rear screen wiper
arm: Removal - Refitting) (85A, Washing - Wiping),
- the rear screen wiper motor (see Rear screen wiper motor: Removal - Refitting) (85A, Wiping Washing).

560A).
a Refit the rear screen wiper motor (see Rear screen
wiper motor: Removal - Refitting) (85A, Wiping Washing).
CONCERNED
a Bond the rear screen (two people are required for
this operation).
a Equal out the clearances and shut lines.
HEATED REAR SCREEN

a Disconnect the heated rear screen harness connectors.

HEATED REAR SCREEN
a Protect the bodywork around the rear screen using

masking tape.
a Connect the heated rear screen harness connectors.
a Refit:

CONCERNED
- the rear screen wiper arm (see Rear screen wiper

arm: Removal - Refitting) (85A, Washing - Wiping),
126910

a Remove the rear screen (two people are required for
this operation).
54A-10
http://vnx.su
WINDOWS
Opening rear screen: Adjusting
54A
Tightening torquesm
bolts on the rear loading door sliding window
8 N.m
Note:
Perform all manoeuvres on the rear loading door
sliding window with the vehicle engine running.
Note:
Close the rear loading door each time an adjustment is made to check the result.
140208
REMOVAL
a Loosen the bolts (1) of the rear loading door sliding

window.
I - ADJUSTMENT PREPARATION OPERATION

a Remove:
141948
a Open the rear loading door.

a Place three pieces of masking tape on the rear loading door sliding window and draw two lines 15 and
19mm from the top edge of the sliding window.
a Position a suction cup on the rear loading door sliding window.
a Unlock the rear loading door lock using the exterior
door handle (check that the window lowers).
a Close the rear loading door with an operator inside
the vehicle and another outside the vehicle.
140996
a Manually lock the rear loading door lock (check that

the window is raised).
54A-11
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WINDOWS
Opening rear screen: Adjusting
54A
141949
140218
a Place the rear loading door sliding window at the dimensions shown: (X1) = 4.5 + /- 1.5 mm
a Adjust the bolts (3) using a 20 TORX wrench, after

having completely lowered the rear loading door sliding window.
a Check the alignment of the rear loading door sliding

window in relation to the side trim (2) .
II - NEXT SIMULTANEOUSLY ADJUST THE Z AXIS
OF THE REAR LOADING DOOR
a Check that none of these actions causes the rear

loading door sliding window to become misaligned in
relation to the side trim:
- Window too high towards the front: Turn the bolt
anti-clockwise (1 turn = 1 mm).
a Place the rear loading door sliding screen at the dimensions shown. Once adjusted it must be located
in the adjustment range between 15 and 19 mm in
relation to the roof flap seal.
- Window too low towards the front: Turn the bolt

clockwise (1 turn = 1 mm).
- Window too high towards the back: Turn the bolt
anti-clockwise (1 turn = 1 mm).
a Torque tighten the bolts on the rear loading door

sliding window (8 N.m).
- Window too low towards the back: Turn the bolt

clockwise (1 turn = 1 mm).
a Remove:
a Check that the rear loading door sliding window

works by raising and lowering the window completely in one-touch mode.
- the suction cup,

- the masking tape.
a Raise the rear loading door sliding window fully.
III - FINE ADJUSTMENT OF "Z" WITHOUT

REMOVING THE DOOR TRIM.
a Close the rear loading door.
a Place three pieces of masking tape on the rear loading door sliding window and draw two lines 15 and
19mm from the top edge of the sliding window.
a Check that the rear loading door sliding window is in

the correct position.
a Refit:
- the door sealing film should always be replaced
(see Door sealing film: Removal - Refitting)
(65A, Opening element sealing).
trim),
54A-12
http://vnx.su
WINDOWS
Rear loading door window: Removal - Refitting
54A
F61
REMOVAL

CONCERNED

a Protect the edges of the loading door window with
masking tape.
rear left-hand loading door window
REAR LEFT-HAND LOADING DOOR

a Remove the rear screen wiper arm (see R e a r
screen wiper arm: Removal - Refitting) (85A,
Washing - Wiping).
a Disconnect the connectors from the rear loading
door heated window wiring.
132064
rear right-hand loading door window
132063

a Remove the rear loading door window.
54A-13
http://vnx.su
WINDOWS
F61
REFITTING
560A).
CONCERNED
a Bond the rear loading door window.
REAR LEFT-HAND LOADING DOOR
a Connect the connectors for the rear loading door
heated window wiring.
a Refit the rear screen wiper arm (see Rear screen
wiper arm: Removal - Refitting) (85A, Washing Wiping).
54A-14
http://vnx.su
54A
WINDOWS
54A

Car. 1363
Set of trim removal levers.
REMOVAL
a Remove:
a Lower the rear loading door window.
140205
a Partially remove the interior weatherstrip from the

rear loading door at (4) .
140203
a Remove the exterior weatherstrip from the rear loading door at (2) using the tool (Car. 1363) and at (3) .
140206
a Hold the interior weatherstrip of the loading door in

place using MASKING TAPE (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consumables - Products).
54A-15
http://vnx.su
WINDOWS
54A

CONCERNED
140207
a Disconnect the connector (5) from the rear loading

door window de-icing module.
a Unclip the de-icing wiring.
a Raise the rear loading door window.
140208
a Remove the bolts (6) from the rear loading door window.
140209
140996
a Manually lock the rear loading door lock (check that

the window is raised).
a Remove the rear loading door window.
54A-16
http://vnx.su
WINDOWS
REFITTING
140210
a Check the condition of the rear loading door window

pads (7) and replace them if necessary.
a If removing the pads, mark their direction of fitting.
CONCERNED
a Refit:
- the rear loading door window,
- the bolts (6) of the rear loading door window.
a Unlock the rear loading door lock.
a Lower the rear loading door window.
a Clip on the de-icing wiring.
a Connect the connector (5) for the rear loading door
window de-icing module.
a Refit the interior weatherstrip for the rear loading
door.
a Adjust the rear loading door window at X and at Z
(see 54A, Windows, Opening rear screen: Adjusting, page 54A-11)
a Refit:
54A-17
http://vnx.su
54A
WINDOWS
Fixed roof window: Removal - Refitting
54A
K61, and STANDARD CHASSIS

- the frame of the sunroof operating mechanism
using 20 MM WINDSCREEN TAPE (see Vehicle:
Parts and ingredients for the repairwork) (04B,
Consumables - Products).
Essential equipment
diagnostic tool
cutting wire insertion tool

CONCERNED
IMPORTANT
IMPORTANT
140999
a Insert:
- the cutting wire insertion tool at one end,
IMPORTANT

from the outside towards the inside and leave it until it is needed.
Note:
Be careful to pass the cutting wire correctly
between the roof and the roof fixed window
frame.
Note:
The Parts Department sells the roof fixed window
assembled with its frame.
a Slide the cutting wire around the edge between the

fixed window frame and the roof.
REMOVAL
a Cut a sufficient length of cutting wire.

Note:
When routing the cutting wire into the vehicle
interior, be careful not to cross the two wires, as
this would make cutting the seal impossible.

a Remove the front section headlining (see Headlining: Removal - Refitting) (71A, Body internal
trim).
a Insert:
a Protect:
- the cutting wire insertion tool alongside the cutting wire already present,
towards the vehicle interior.
- the vehicle interior,
54A-18
http://vnx.su
WINDOWS
54A
K61, and STANDARD CHASSIS
REFITTING
560A).
a Always replace the positioning shims.
CONCERNED
a Bond the fixed glass - fixed roof window frame
assembly(this operation requires two people).
a Adjust the clearances and flush fitting.
a Remove:
- the protection from the frame of the sunroof operating mechanism,
140997
a Fit the cutting handles on the two sections of the cutting wire inside the vehicle.
a Cut the cement bead and leave the other handle in
place until it is needed.
- the protection from the vehicle interior.

a Refit the front section headlining (see Headlining:
Removal - Refitting) (71A, Body internal trim).
Note:
Reduce the length of the cutting wire as you cut.
138607
a Remove the fixed window - roof fixed window

frame assembly using special supports:
- Support: PARV 202,
- set of arch supports: APARV 200 ESP.
54A-19
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WINDOWS
54A
REMOVAL

CONCERNED
140953
140926
a Mark the positioning of the finishing seal (1) .

a Remove the finishing seal.
a Protect the edge of the fixed roof glass using 20 MM
WINDSCREEN TAPE (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables
- Products).
140987
a
Note:
When removing and refitting the fixed roof glass,
avoid cutting the indexing pins (2) which are used
to correctly position the fixed roof glass.
a Cut the cement bead; (see Technical Note 560A)
(this operation requires two people).
a Remove the fixed roof glass.
REFITTING
560A).
54A-20
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WINDOWS
CONCERNED
a Bond the fixed roof glass.
a Remove the 20 MM WINDSCREEN TAPE.
a Refit the finishing seal.
54A-21
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54A
EXTERIOR PROTECTION
Front bumper: Removal - Refitting
55A

a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
FOG LIGHT
a Disconnect the fog light connector (4) .

CONCERNED
126428
a Unclip the radiator grille at (1) and at (2) .

a Remove the front wheel arch liners, front part (see
55A, Exterior protection, Front wheel arch liner:
126426
126427
a Unclip the pipe (3) .
55A-1
http://vnx.su
EXTERIOR PROTECTION
Front bumper: Removal - Refitting
126429

a Unclip the front bumper at (7) .
a Remove the front bumper (this operation requires
two people).
REFITTING
CONCERNED
a Refit the front bumper (this operation requires two
people).
a Clip on the front bumper.
a Clip on the pipe (3) .
FOG LIGHT
a Connect the fog light connector (4) .
Carry out a function test.
a Refit the front wheel arch liners, front part (see 55A,
Exterior protection, Front wheel arch liner: Removal - Refitting, page 55A-19) .
a Clip on the radiator grille.
55A-2
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55A
EXTERIOR PROTECTION
Front bumper: Stripping - Rebuilding
55A
STRIPPING
K61
I - STRIPPING PREPARATION OPERATION
a Remove:
- the front wheel arch liners, front part (see 55A, Exterior protection, Front wheel arch liner: Removal - Refitting, page 55A-19) ,
- the front bumper (see 55A, Exterior protection,
Front bumper: Removal - Refitting, page 55A-1)
.
FOG LIGHT
a Remove:
- the front bumper wiring (see Front bumper wiring: Removal - Refitting) (88A, Wiring),
- the front fog lights (see Front fog light: Removal Refitting) (80B, Headlights).
126434
a Unclip the impact strips at (2) .
II - STRIPPING OPERATION FOR PART

CONCERNED
126430
a Remove:
- the bolts (3) ,
- the diffuser.
126431
a Unclip the absorber at (1) .
55A-3
http://vnx.su
EXTERIOR PROTECTION
K61, and SHORT CHASSIS, and OFF-ROAD
55A
ENVIRONMENTAL CONSTRAINT: INTERNATIONAL 1 or ENVIRONMENTAL CONSTRAINT:

INTERNATIONAL 2 or ENVIRONMENTAL CONSTRAINT: INTERNATIONAL 3 or ENVIRONMENTAL CONSTRAINT: INTERNATIONAL 4 or
INTERNATIONAL 9
141226
a Drill out the rivets (3) .

a Remove the diffuser.
132046
a Unclip the stone guard grille at (4) .
141227
a Unclip the centre grille.
55A-4
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EXTERIOR PROTECTION
55A
141230
a Unclip the strip .
141228
REASSEMBLING
I - REBUILDING PREPARATION OPERATION
a parts always to be replaced: front bumper rivet
(50,05,02,18).
II - REBUILDING OPERATION FOR PART
CONCERNED

a Clip the panel.
a Refit new rivets.
a Clip on the centre grille.
141229

INTERNATIONAL 2 or ENVIRONMENTAL CONSTRAINT: INTERNATIONAL 3 or ENVIRONMENTAL CONSTRAINT: INTERNATIONAL 4 or
INTERNATIONAL 9
a Clip on the stone guard grille at (4) .
55A-5
http://vnx.su
EXTERIOR PROTECTION

a Refit:
- the diffuser,
- new rivets.
K61
a Refit:
- the diffuser,
- the bolts (3) .
a Clip:
- the impact strips (2) ,
- the absorber (1) .

FOG LIGHT
a Refit:
- the front fog lights (see Front fog light: Removal Refitting) (80B, Headlights).
- the front bumper wiring (see Front bumper wiring: Removal - Refitting) (88A, Wiring).
a Refit the front bumper (see 55A, Exterior protection, Front bumper: Removal - Refitting, page
55A-1) .
a Refit the front wheel arch liners, front part (see 55A,
Exterior protection, Front wheel arch liner: Removal - Refitting, page 55A-19) .
55A-6
http://vnx.su
55A
EXTERIOR PROTECTION
Rear bumper: Removal - Refitting
55A

CONCERNED
REMOVAL
a Remove the rear wing lights (see Rear light on
wing: Removal - Refitting) (81A, Rear lighting).
126438
126436

a Unclip the rear bumper extensions.
126446
126438
a Disconnect the connectors (2) (depending on equipment level).
55A-7
http://vnx.su
EXTERIOR PROTECTION
Rear bumper: Removal - Refitting
55A
132067
a Remove bolts (5) and (6) .
132066
a Unclip the rear bumper at (8) using a small flat-blade

screwdriver.
a Remove the rear bumper(this operation requires two
people).
REFITTING
a Always replace the rear bumper extension clips.

CONCERNED
a Refit the rear bumper (this operation requires two
people).
132065
a Unclip the end of the rear bumper at (7) .
a Clip the rear bumper into place.

a Connect the connectors (2) (depending on equipment level).

a Clip on the rear bumper extensions.
a Refit the rear wing lights (see Rear light on wing:
55A-8
http://vnx.su
EXTERIOR PROTECTION
Rear bumper: Stripping-Rebuilding
55A
STRIPPING
F61 or K61, and LONG CHASSIS or STANDARD
CHASSIS
I - STRIPPING PREPARATION OPERATION

a Remove:
- the rear wing lights (see Rear light on wing: Removal - Refitting) (81A, Rear lighting),
- the rear bumper (see 55A, Exterior protection,
Rear bumper: Removal - Refitting, page 55A-7) .
II - STRIPPING OPERATION FOR PART
CONCERNED
PROXIMITY RADAR
a Remove the proximity radars (see Proximity radar
Removal - Refitting) (87F, Parking distance control).
126475
a Unclip the centre impact strip at (2) .
a Remove:
- the rear fog light (see Rear fog lights: Removal Refitting) (81A, Rear lighting),
- the rear bumper wiring (see Rear bumper wiring:
Removal - Refitting) (88A, Wiring).
126476
a Unclip the side trims at (3) .
126474
a Remove:
- the bolts (1) ,
- the reflector.
55A-9
http://vnx.su
EXTERIOR PROTECTION
55A
REASSEMBLING

a parts always to be replaced: rear bumper rivet
(50,05,04,14).

CONCERNED
140988

a Clip on the central trim.
a Refit new rivets.
F61 or K61, and LONG CHASSIS or STANDARD

CHASSIS
a Clip:
- the side trims (3) ,
- the centre impact strip (2) .
140989
a Refit:
a Unclip the central trim (5) .
- the reflector,
- the rear fog light (see Rear fog lights: Removal Refitting) (81A, Rear lighting),
- the rear bumper wiring (see Rear bumper wiring:
Removal - Refitting) (88A, Wiring).
PROXIMITY RADAR
a Refit the proximity radars (see Proximity radar Removal - Refitting) (87F, Parking distance control).
55A-10
http://vnx.su
EXTERIOR PROTECTION
a Refit:
- the rear bumper (see 55A, Exterior protection,
Rear bumper: Removal - Refitting, page 55A-7) ,
- the rear wing lights (see Rear light on wing: Removal - Refitting) (81A, Rear lighting).
55A-11
http://vnx.su
55A
EXTERIOR PROTECTION
Front side door strip: Removal - Refitting
55A

CONCERNED

Car. 1363
REMOVAL
140948
140947
a Remove:
- the blanking cover (1) ,
- the bolt (2) .
140950
a Unclip the front side door strip using the tool (Car.
1363).
a Detach the front side door strip.
a The front side door strip must always be replaced.
55A-12
http://vnx.su
EXTERIOR PROTECTION
Front side door strip: Removal - Refitting
REFITTING
140949
a Clean the bonding area of the front side door strip

using a LINT-FREE CLOTH soaked in HEPTANE
(see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products).
a Use a clean, dry LINT-FREE CLOTH (see Vehicle:
Parts and ingredients for the repairwork) (04B,
Consumables - Products) to wipe the bonding area
of the front side door strip.
CONCERNED
a Clip on the front side door strip.
a Bond the front side door strip.
a Refit:
- the bolt (2) ,
- the blanking cover (1) .
55A-13
http://vnx.su
55A
EXTERIOR PROTECTION
Rear side door strip: Removal - Refitting
55A
REFITTING

Car. 1363

a Clip on the rear side door strip.
REMOVAL
CONCERNED
140951
140952
a Unclip the rear side door strip using the tool (Car.
1363).
55A-14
http://vnx.su
EXTERIOR PROTECTION
Rear loading door strip: Removal - Refitting
55A

Ele. 1841
Tool for removing wiper arms
REMOVAL
a Open the rear loading door.
140628
a Remove:
- the rear screen wiper arm nut,
- the rear screen wiper arm using the tool (Ele.
1841).
a Disconnect the screen washer pipe from the rear
loading door, marking the direction of the T union.
140629

CONCERNED
140630
a Unclip the rear loading door strip at (3) .
55A-15
http://vnx.su
EXTERIOR PROTECTION
Rear loading door strip: Removal - Refitting
140616
a Disconnect:
- the number plate light connectors (4) ,
- the brake lights connector (5) .
a Unclip the wiring from the rear loading door strip.
a Remove the rear loading door strip.
REFITTING
CONCERNED
a Clip the wiring onto the rear loading door strip.
a Connect:
- the brake lights connector (5) ,
- the number plate light connectors (4) .
a Clip on the rear loading door strip.
a Refit:
- the screen washer pipe for the rear loading door,
- the rear screen wiper arm,
- the rear screen wiper arm nut (2) .
55A-16
http://vnx.su
55A
EXTERIOR PROTECTION
Front side door moulding: Removal - Refitting
55A
REMOVAL
126441
a Unclip the front side door protective strip (3) at (4) .

126439
a Remove the blanking cover (1) .
REFITTING
CONCERNED

CONCERNED
a Clip on the front side door protective strip (3) .

a Refit the blanking cover (1) .
126440
55A-17
http://vnx.su
EXTERIOR PROTECTION
Rear wing protective strip: Removal - Refitting
F61
REMOVAL
CONCERNED
126477
a Unclip the rear wing protective strip (1) at (2) and at

(3) .
REFITTING
a Clip on the rear wing protective strip (1) .
55A-18
http://vnx.su
55A
EXTERIOR PROTECTION
Front wheel arch liner: Removal - Refitting
55A
2 - Front wheel arch liner, rear section
REMOVAL
Note:
It is not necessary to remove the front wheel to
remove the front wheel arch liner.
Note:
The front and rear parts of the front wheel arch
liner can be removed independently.
CONCERNED
126444
1 - Front wheel arch liner, front section
a Remove:
- the clips (3) ,
- front wheel arch liner, rear section.
REFITTING
1 - Front wheel arch liner, front section
a Refit the front wheel arch liner, rear section.
2 - Front wheel arch liner, rear section
a Refit the front wheel arch liner in the rear section.
126443
a Remove:
- the bolt (1) ,
- the clips (2) ,
- front wheel arch liner, front section.
55A-19
http://vnx.su
EXTERIOR PROTECTION
Rear side door moulding: Removal - Refitting
REMOVAL
CONCERNED
126442
a Unclip the rear side door protective strip (1) at (2)

and at (3) .
REFITTING
a Clip on the rear side door protective strip (1) .
55A-20
http://vnx.su
55A
EXTERIOR PROTECTION
Rear wheel arch liner: Removal - Refitting
55A

Note:
It is not necessary to remove the rear wheel to
remove the rear wheel arch liner.
CONCERNED
126446
a Remove:
- the bolts (2) ,
- the rear wheel arch liner.
REFITTING
a Refit the rear wheel arch liner.
126445
a Remove clips (1) .
55A-21
http://vnx.su
EXTERIOR EQUIPMENT
Scuttle panel grille: Removal - Refitting
56A

CONCERNED
REMOVAL
126448
126447
a remove:
a Remove:
- the nuts (3) ,
- the trims (1) ,
- the scuttle panel grille (4) .
- the seal (2) .

a Remove the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping - Washing).
REFITTING
a Check the cleanliness of the windscreen and the
scuttle panel grille before refitting the scuttle panel
grille.
CONCERNED
a Refit the scuttle panel grille (4) .
a Refit the windscreen wiper arms (see Windscreen
wiper arm: Removal - Refitting) (85A, Wiping Washing).
a Refit:
- the seal (2) ,
- the trims (1) .
56A-1
http://vnx.su
EXTERIOR EQUIPMENT
Scoop under scuttle panel grille: Removal - Refitting
56A
2 - Scoops under the side part of the scuttle panel

grille
REMOVAL
a Remove:
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing),
page 56A-1) ,
- the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing).

CONCERNED
126450
a Remove:
1 - Scoop under the central part of the scuttle panel

grille
- the bolts (4) ,

- the nuts (5) ,
- the windscreen wiper motor wiring (6) ,
- the scoops under the side part of the scuttle panel
grille (7) .
REFITTING
CONCERNED
1 - Scoops under the side part of the scuttle panel

grille
a Refit:
- the scoops under the side part of the scuttle panel
grille (7) ,
126449
a Remove:
- the windscreen wiper motor connector (6) .
- the nut (1) ,

- the bolts (2) ,
2 - Scoop under the central part of the scuttle panel

grille
- the scoop under the central part of the scuttle panel

grille (3) .
a Refit the scoop under the central part of the scuttle

panel grille (3) .
56A-2
http://vnx.su
EXTERIOR EQUIPMENT
Scoop under scuttle panel grille: Removal - Refitting
a Refit:
- the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing).
page 56A-1) ,
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing).
56A-3
http://vnx.su
56A
EXTERIOR EQUIPMENT
Door mirror: Removal - Refitting
56A

CONCERNED
REMOVAL
126479
126478
a Remove:
a Remove the trim (1) .
- the bolts (3) ,

- the door mirror (4) .
REFITTING
CONCERNED
a Refit the door mirror (4) .
a Connect the connector (2) (depending on equipment
level).
a Refit the trim (1) .
126479
a Disconnect the connector (2) (depending on equipment level).
56A-4
http://vnx.su
EXTERIOR EQUIPMENT
Door mirror casing: Removal - Refitting
REMOVAL
a Remove the door mirror glass (see 56A, Exterior
equipment, Door mirror glass: Removal - Refitting, page 56A-6) .
CONCERNED
126451
a Unclip the door mirror casing at (1) .
REFITTING
CONCERNED
a Clip on the door mirror casing.
a Refit the door mirror glass (see 56A, Exterior equipment, Door mirror glass: Removal - Refitting,
page 56A-6) .
56A-5
http://vnx.su
56A
EXTERIOR EQUIPMENT
Door mirror glass: Removal - Refitting
REFITTING

Car. 1363
56A

CONCERNED
a Connect the connectors (2) (depending on equipment level).
REMOVAL
a Clip the exterior door mirror glass into place.

CONCERNED
126452
a Unclip the door mirror glass at (1) using the tool

(Car. 1363).
126453
a Disconnect the connectors (2) (depending on equipment level).
56A-6
http://vnx.su
EXTERIOR EQUIPMENT
Rear badges: Removal - Refitting
2 - Fitting

Car. 1363
56A
"KANGOO" badge
I - CONSTRUCTOR BADGE
1 - Removal
126877
a Remove the protective paper from the back of the

vehicle badge.
a Position the vehicle badge:
- (X1) : 83 mm,
126480
a Unclip the manufacturer's badge (1) using the tool

(Car. 1363).
- (X2) : 467 mm.

a Stick on the vehicle badge.
2 - Refitting
a Clip on the manufacturer's badge (1) .
II - VEHICLE BADGE
1 - Refitting preparation operation
a Clean the adhesive surface of the vehicle badge
using a LINT-FREE CLOTH soaked in HEPTANE
(see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products).
a Wipe the adhesive surface of the vehicle badge with
a clean, dry LINT-FREE CLOTH.
56A-7
http://vnx.su
EXTERIOR EQUIPMENT
Rear badges: Removal - Refitting
F61
"RENAULT" badge
126878
a Remove the protective paper from the back of the

vehicle badge.
a Position the vehicle badge:
- (X1) : 86 mm,
- (X2) : 249 mm.
a Stick on the vehicle badge.
56A-8
http://vnx.su
56A
EXTERIOR EQUIPMENT
Roof rack bar: Removal - Refitting
56A
K61
Roof bar front trim

Car. 1363
Tightening torquesm
roof bar bolts
21 N.m
REMOVAL
a Put the roof bars in the transverse position.
132068
Roof bar rear trim
132069
a Unclip the roof bar trims using the tool (Car. 1363) at
(1) and (2) .
a Put the roof bars in the longitudinal position.
56A-9
http://vnx.su
EXTERIOR EQUIPMENT
Roof rack bar: Removal - Refitting
56A
K61
Roof bar front trim

CONCERNED
132070
126455
Roof bar rear trim
a Remove:
- the bolts (3) ,
- the roof bar (4) .
REFITTING
a Check the condition and cleanliness of:
- the roof bar,
- the roof,
- the support plates of the roof bar (replace them if
necessary).
132071
a Clip on the roof bar trims at (5) and (6) .

CONCERNED
a Refit the roof bar (4) .
a Torque tighten the roof bar bolts (21 N.m).

a Put the roof bars in the transverse position.
56A-10
http://vnx.su
EXTERIOR EQUIPMENT
Upper rear opening element strip: Removal - Refitting
56A
Car. 1363
REMOVAL
CONCERNED
140905
a Unclip the rear section of the upper rear opening element strip using the tool (Car. 1363).
140907
56A-11
http://vnx.su
EXTERIOR EQUIPMENT
Upper rear opening element strip: Removal - Refitting
56A
140906
140908
a Remove the upper rear opening element strip at (2) .
REFITTING
CONCERNED
a Refit the upper rear opening element strip.
a Clip on the rear section of the upper rear opening
element strip.
a Refit the bolts (1) .
56A-12
http://vnx.su
INTERIOR EQUIPMENT
Dashboard: Removal - Refitting
57A
page 57A-7) ,
Essential equipment
diagnostic tool
- the display or the central glovebox (see Display:

Removal - Refitting) (86A, Radio) (depending on
equipment level),
IMPORTANT
- the control panel (see Control panel: Removal Refitting) (61A, Heating),
- the lower dashboard trim (see 57A, Interior equipment, Lower section of dashboard trim: Removal - Refitting, page 57A-4) (71A, Body internal
trim),
IMPORTANT
- the tweeters (see Tweeter: Removal - Refitting)

(86A, Radio),
- the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners),

- the glovebox (see 57A, Interior equipment, Glovebox: Removal - Refitting, page 57A-9) .
IMPORTANT
REMOVAL
a Disconnect the battery (see Battery: Removal - Refitting) (81A, Battery).
a Remove:
- the driver's front airbag (see Driver's front airbag:
Removal - Refitting) (88C, Airbags and pretensioners),
- the steering wheel (see Steering wheel: Removal
- Refitting) (36A, Steering assembly),
- the steering column switch assembly (see Steering wheel controls assembly: Removal - Refitting) (84A, Control - Signals),
- the instrument panel (see Instrument panel: Removal - Refitting) (83A, Instrument panel),
- the radio (see Car radio: Removal - Refitting)
(86A, Radio) (depending on equipment level),
57A-1
http://vnx.su
INTERIOR EQUIPMENT
57A

CONCERNED
126857
126857
Detailed view (1)

a Remove:
- the bolts (4) ,
- the dashboard partially,
- the various wiring harnesses.
Note:
Mark the positions of the various wiring harnesses before removing the dashboard.
a Remove the dashboard (this operation requires two
people).
REFITTING
126497

CONCERNED
a Refit:
a Remove the passenger airbag bolt (2) .

a Disconnect the passenger airbag connector (3) .
- the various cable harnesses,

- the dashboard (this operation requires two people).
a Connect the passenger airbag connector (3) .
a Refit:
- the passenger airbag (2) ,
- the glovebox (see 57A, Interior equipment, Glovebox: Removal - Refitting, page 57A-9) ,
- the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners),
- the tweeters (see Tweeter: Removal - Refitting)
(86A, Radio) (depending on equipment level),
57A-2
http://vnx.su
INTERIOR EQUIPMENT
- the lower dashboard trim (see 57A, Interior equipment, Lower section of dashboard trim: Removal - Refitting, page 57A-4) (71A, Body internal
trim),
- the control panel (see Control panel: Removal Refitting) (61A, Heating),
- the display or the central glovebox (see Display:
Removal - Refitting) (86A, Radio) (depending on
equipment level),
page 57A-7) ,
(86A, Radio),
- the instrument panel (see Instrument panel: Removal - Refitting) (83A, Instrument panel),
- the steering column switch assembly (see Steering wheel controls assembly: Removal - Refitting) (84A, Control - Signals),
- the steering wheel (see Steering wheel: Removal
- Refitting) (36A, Steering assembly),
- the driver's airbag (see Driver's front airbag: Removal - Refitting) (88C, Airbags and pretensioners).
a Connect the battery (see Battery: Removal - Refitting) (81A, Battery).
57A-3
http://vnx.su
57A
INTERIOR EQUIPMENT
Lower section of dashboard trim: Removal - Refitting
57A
REMOVAL
LEFT-HAND DRIVE
a Remove:
(86A, Radio),
page 57A-7) ,
- the front side door seal partially.
126849
a Unclip the dashboard side face (3) .
126179
a Remove:
- the cover bolts (1) under the steering wheel,
- the covers under the steering wheel by pressing on
the clips (2) .
RIGHT-HAND DRIVE
a Remove the inhibitor switch (see Inhibitor switch:
Removal - Refitting) (88C, Airbags and pretensioners).
126830
a Remove:
- the bolts (4) ,
- the radio mounting.
57A-4
http://vnx.su
INTERIOR EQUIPMENT
Lower section of dashboard trim: Removal - Refitting
CONCERNED
57A
RIGHT-HAND DRIVE
a Refit the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners).
a Refit:
- the cowlings under the steering wheel,
- the front side door seal,
page 57A-7) ,
(86A, Radio).
126831

a Unclip the lower trim of the dashboard at (6) .
a Disconnect the connectors (depending on equipment level).
a Remove the dashboard lower trim.
REFITTING
CONCERNED
a Connect the connectors (depending on equipment
level).
a Clip on the dashboard lower trim.
a Refit the radio mounting.
LEFT-HAND DRIVE
a Clip on the dashboard side panel (3) .
57A-5
http://vnx.su
INTERIOR EQUIPMENT
Dashboard air vent: Removal - Refitting
57A
2 - Dashboard side air vent
REMOVAL
a Protect the dashboard around the air vents using
masking tape.
CONCERNED
1 - Dashboard centre air vent
126855
a Unclip the side dashboard air vent (2) using flatnosed pliers protected by masking tape.
REFITTING
CONCERNED
126856
a Unclip the centre dashboard air vent (1) using flatnosed pliers protected by masking tape.
1 - Dashboard centre air vent

a Clip the centre air vent back onto the dashboard (1) .
2 - Dashboard side air vent
a Clip the side air vent back onto the dashboard (2) .
a Remove the masking tape from the dashboard.
57A-6
http://vnx.su
INTERIOR EQUIPMENT
Centre front panel: Removal - Refitting
57A
REMOVAL
126853
126851
a Unclip the gear lever gaiter (1) .

CONCERNED
126854

a Unclip the lower part of the centre front panel at (7) .
REFITTING
126852

CONCERNED
a Unclip the upper part of the centre front panel (2) at

(3) and (4) .
a Clip on the lower part of the centre front panel.
a Disconnect the connectors.
a Refit the upper part of the centre front panel (2) .
a Connect the connectors.
57A-7
http://vnx.su
INTERIOR EQUIPMENT
Centre front panel: Removal - Refitting
a Clip on the gear lever gaiter (1) .
57A-8
http://vnx.su
57A
INTERIOR EQUIPMENT
Glovebox: Removal - Refitting
57A

CONCERNED
REMOVAL
a Remove:
- the front side door seal partially,
page 57A-7) .
LEFT-HAND DRIVE
RIGHT-HAND DRIVE
126850
a Remove:
- the bolts (2) ,
- the glovebox (3) .
REFITTING
CONCERNED
a Refit the glovebox (3) .
126849
LEFT-HAND DRIVE
RIGHT-HAND DRIVE
57A-9
http://vnx.su
INTERIOR EQUIPMENT
Glovebox: Removal - Refitting
a Refit:
page 57A-7) ,
- the front side door seal.
57A-10
http://vnx.su
57A
INTERIOR EQUIPMENT
Dashboard glovebox: Removal - Refitting
57A
F61
REMOVAL

CONCERNED

a Remove:
- the front side door seal partially,
page 57A-7) .
LEFT-HAND DRIVE, and AIRBAG 01
RIGHT-HAND DRIVE
132047
a Unclip the lower trim partially at (2) .
126849

132048
a Remove:
- the bolts (3) ,
- the dashboard storage compartment.
57A-11
http://vnx.su
INTERIOR EQUIPMENT
Dashboard glovebox: Removal - Refitting
F61
REFITTING
CONCERNED
a Refit the dashboard glovebox.
a Clip on the lower trim at (2) .
LEFT-HAND DRIVE, and AIRBAG 01
RIGHT-HAND DRIVE
a Refit:
page 57A-7) ,
57A-12
http://vnx.su
57A
INTERIOR EQUIPMENT
Centre console: Removal - Refitting
57A

CONCERNED
REMOVAL
a Move the front seats forward.
126846
126847
a Remove:
- the bolts (1) ,
- the central armrest at (2) and at (3) (depending on
equipment level).
126848
a Unclip the trims (2) (depending on equipment level).

a Remove the nuts (3) .
a Lift the handbrake.
a Partially remove the centre console.
a Disconnect the connectors (depending on equipment level).
a Remove the central console towards the rear.
57A-13
http://vnx.su
INTERIOR EQUIPMENT
Centre console: Removal - Refitting
REFITTING
CONCERNED
a Refit the centre console.
a Connect the connectors (depending on equipment
level).
a Refit the trims (2) (depending on equipment level).
a Refit the central armrest (depending on equipment
level).
57A-14
http://vnx.su
57A
INTERIOR EQUIPMENT
Floor flap and storage: Removal - Refitting
K61
REMOVAL
CONCERNED
126841
a Unclip the storage flap on the floor at (1) .
REFITTING
a Clip on the floor storage flap.
57A-15
http://vnx.su
57A
INTERIOR EQUIPMENT
Interior rear-view mirror Removal - Refitting
57A
REMOVAL
a Unclip the small additional interior rear view mirror.
127387
a Unclip the lower casing (3) .
127386
a Slide the wire cover (1) .
a Remove the rain and light sensor (see Rain and light sensor: Removal - Refitting) (85A, Wiping Washing) (depending on equipment level).
CONCERNED
127388
a Unclip the upper cover (2) .
126837
a Unclip the interior rear view mirror at (4) .
57A-16
http://vnx.su
INTERIOR EQUIPMENT
Interior rear-view mirror Removal - Refitting
REFITTING
CONCERNED
126836
a Clip on the interior rear view mirror at (5) .

a Refit the rain and light sensor (see Rain and light
sensor: Removal - Refitting) (85A, Wiping Washing) (depending on equipment level).
a Clip:
- the lower cover (3) ,
- the upper cover (2) .
a Slide the wire cover (1) under the headlining.
57A-17
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57A
INTERIOR EQUIPMENT
Sun visor: Removal - Refitting
57A
REMOVAL
REFITTING

CONCERNED

a Refit the sun visor (3) .
a Clip on the sun visor.
126834
a Unclip the sun visor at (1) .
126835
a Remove:
- the bolt (2) ,
- the sun visor (3) .
57A-18
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INTERIOR EQUIPMENT
Grab handle: Removal - Refitting

CONCERNED

Car. 1363
57A
REMOVAL
126833
a Unclip at (2) using the tool (Car. 1363).
REFITTING
126832

CONCERNED
a Clip on the grab handle.
a Clip the trim piece in place (1) .
57A-19
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INTERIOR EQUIPMENT
Front storage compartment under roof: Removal - Refitting
57A

CONCERNED
REMOVAL
a Remove the sun visors (see 57A, Interior equipment, Sun visor: Removal - Refitting, page 57A18) .
126829
a Unclip the front storage compartment under the roof

at (3) and at (4) .
117839
REFITTING
a Remove:
CONCERNED
- the bolts (1) ,

- the sun visor mountings (2) .
a Unclip the additional rear view mirror (depending on
equipment level).
a Remove the headlining light (see Headlining light:
Removal - Refitting) (81B, Interior lighting).
a Clip the front storage compartment under the roof.

a Refit:
- the headlining light (see Headlining light: Removal - Refitting) (81B, Interior lighting),
- the sun visor mountings (2) ,
- the sun visors (see 57A, Interior equipment, Sun
visor: Removal - Refitting, page 57A-18) .
57A-20
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INTERIOR EQUIPMENT
Rear storage compartment: Removal - Refitting
57A
REMOVAL
REFITTING

CONCERNED
126827
126827
a Remove:
a Refit the rear storage compartment at (3) .

a Clip on the rear storage compartment.
- the trims (1) ,
a Refit the trim pieces (1) .
- the bolts (1) .
126828
a Unclip the rear storage compartment at (2) .
57A-21
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INTERIOR EQUIPMENT
Separating components: Removal - Refitting
57A
F61
REMOVAL
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or PIVOTING PARTITION or

1/3 STEEL PARTITION
a Remove the B-pillar lower trim (see B-pillar lower
trim: Removal - Refitting) (71A, Body internal trim).
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or PIVOTING PARTITION

a Remove the B-pillar upper trim (see B-pillar upper
132050
a Remove:
- the bolts (2) ,
- the nuts (3) ,
- the separation component (4) .

CONCERNED
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW
132058
a Remove the spacers (5) .
132049
a Remove nuts (1) .
57A-22
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INTERIOR EQUIPMENT
57A
F61
- the connection component (11) .
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or 1/3 STEEL PARTITION
PIVOTING PARTITION
132051
a Remove:
119772
- the bolts (6) ,
a Remove the mobile separation component (12) in

the direction of (13) and (14) .
- the nuts (7) .

a Detach the separation component (8) at (9) .
132053

132052
a Remove:
- the bolts (10) ,
57A-23
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INTERIOR EQUIPMENT
57A
F61
TUBULAR PARTITION
132054
a Remove:
132055
- the bolt (16) ,

- the nuts (17) ,

- the separation components (18) .
132056
132059
a Remove:
- the nut (21) ,
a Remove the spacers (19) .
- the separation component (22) .
57A-24
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INTERIOR EQUIPMENT
57A
F61
132057
132060
a Clean the bonding area (24) on the cross member

and the separation component with HEPTANE (see
Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) and wipe
using a LINT-FREE CLOTH (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consumables - Products).
a Remove the spacer (23) .
REFITTING
Note:
Always use STRUCTURAL ADHESIVE (see
Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products).
REFITTING PREPARATION OPERATION

a Check the condition of the separation component
and replace it if necessary.
a Clean the adhesive residues on the cross member
and the separation component.
WARNING
a Apply the activator on the bonding area on the cross

member and the separation component, using the
pad provided in the bonding kit.
a Apply STRUCTURAL ADHESIVE at (24) .
a Refit the separation component (8) .
a Refit:
- the bolts (6) ,
- the nuts (7) .

CONCERNED
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW
a Refit the connection component (11) .
57A-25
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INTERIOR EQUIPMENT
F61
PIVOTING PARTITION
a Refit:
- the separation components (18) ,
- the mobile separation component (12) .
TUBULAR PARTITION
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or PIVOTING PARTITION
a Refit the B-pillar upper trim (see B-pillar upper
FULL METAL BULKHEAD or COMPLETE BULKHEAD WITH WINDOW or PIVOTING PARTITION or

1/3 STEEL PARTITION
a Refit the B-pillar lower trim (see B-pillar lower trim:
57A-26
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57A
SAFETY ACCESSORIES
Belt height adjustment system: Removal - Refitting
59A
a Refit:
Tightening torquesm
seatbelt height adjustment system bolt
- the B-pillar upper trim (see B-pillar upper trim:

21 Nm
- the B-pillar lower trim (see B-pillar lower trim: Removal - Refitting) (71A, Body internal trim).
REMOVAL
a Remove:
- the B-pillar lower trim (see B-pillar lower trim: Removal - Refitting) (71A, Body internal trim),
- the B-pillar upper trim (see B-pillar upper trim:
CONCERNED
127511
a Remove the bolt (1) from the seat belt height adjustment system.
a Remove (2) the seat belt height adjustment system.
REFITTING
CONCERNED
a Remove the seat belt height adjustment system.
a Torque tighten the seatbelt height adjustment
system bolt (21 Nm).
59A-1
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Panelwork
40A
GENERAL INFORMATION
41A
FRONT LOWER STRUCTURE
41B
CENTRE LOWER STRUCTURE
41C
SIDE LOWER STRUCTURE
41D
REAR LOWER STRUCTURE
42A
FRONT UPPER STRUCTURE
43A
SIDE UPPER STRUCTURE
44A
REAR UPPER STRUCTURE
45A
TOP OF BODY
47A
SIDE OPENING ELEMENTS
48A
NON-SIDE OPENING ELEMENTS

X61
MARCH 2009
constructed."
Edition Anglaise

consent of Renault.
Renault s.a.s 2008
http://vnx.su
Contents
Page
40A
Vehicle on repair bench:

Description
40A-1
Sub-frame: Specifications
40A-4
Hollow body parts inserts:

List and location of
components
40A-9

Radiator support cross
member: General description
41A-3
Radiator support cross

member: Removal - Refitting
41A-4
Radiator cross member

support: Description
41A-6
41A-8
Earths on the body: List and

location of components
40A-12
Front side member: General

description
Vehicle front section

structure: Description
40A-15
Front side member:

Description
41A-11
Vehicle side section

40A-17
Front side member closure

panel: General description
41A-15
Vehicle central section

40A-19
Front side member closure

panel: Description
41A-17
Vehicle structure rear

section: Description
40A-20
Battery tray support: General

description
41A-20
Vehicle removable section

40A-22
Battery tray support:

Description
41A-21
Front mounting of front subframe: General description
41A-23
Front mounting of front subframe: Description
41A-24
Sub-frame rear mounting:

General description
41A-26
Sub-frame rear mounting:

Description
41A-27
Engine mounting: General

description
41A-29
Structure components to be
positioned on body repair
bench: Description
41A
41A
GENERAL INFORMATION
40A-24

Front impact cross member:
General description
Front impact cross member:
Removal - Refitting
41A-1
41A-2
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Contents
41A
41B

Engine mounting:
Description
41A-30
Front half unit: General

description
41A-32
Front half unit: Description
41A-33

Rear floor: General
description
41D-1
Rear floor: Description
41D-2
Rear floor, front section:

General description
41D-4
Rear floor, front section:

Description
41D-6
Rear floor stiffener:

Description
41D-8
Centre floor, side section:

General description
41B-1
Rear side member: General

description
41D-10
Central floor, side section:

Description
41B-3
Rear side member:

Description
41D-13
Centre floor reinforcement:

Description
41B-6
Rear impact cross member

mounting reinforcement:
Description
41D-16
Rear floor centre cross

member: Description
41D-17
Rear end lower cross

member: Description
41D-18
Far rear lower cross member,

side section: Description
41D-20
Front cross member under

rear seat: Description
41D-21
Centre floor front lateral

cross member: Description
41C
41D
41B-8

Sill panel: General
description
41C-1
Sill panel: Description
41C-4
Sill panel closure panel:

General description
41C-15
Tank mounting support:

Description
41D-22
Sill panel closure panel, front

section: Description
41C-16
Rear impact lower cross

member: General description
41D-23
Inner sill panel rear section:

Description
41C-22
Rear impact lower cross

member: Removal - Refitting
41D-24
Sill panel reinforcement:

Description
41C-24
Sill panel rear reinforcement:

Description
41C-28
Sill pane stiffener:

Description
41C-30
42A
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Front wing: General
description
42A-1
Front wing: Removal Refitting
42A-3
Front wing: Adjusting
42A-5
Front: General description
42A-8
Contents
42A

Front: Removal - Refitting
44A
42A-9
Rear side panel: General

description
44A-1
44A-2
Scuttle side panel: General

description
42A-10
Rear side panel: Description
Cowl side panel: Description
42A-12
Rear section of rear side

panel: Description
44A-28
Scuttle side panel upper

reinforcement: General
description
42A-15
Rear side panel rain channel:

General description
44A-34
Scuttle side panel upper

reinforcement: Description
42A-16
Rear side panel rain channel:

Description
44A-35
Front wheel arch: General

description
42A-18
Far rear pillar: General

description
44A-38
Front wheel arch: Description
42A-19
Far rear pillar: Description
44A-39
Inner wheel arch: Description
44A-42
Windscreen aperture lower

cross member: General
description
42A-21
Body side rear lining:

Description
44A-44
Windscreen aperture lower

cross member: Description
42A-22
Rear end panel: Description
44A-62
Dashboard cross member:

Removal - Refitting
42A-23
45A
43A
TOP OF BODY
Roof: General description
45A-1
Roof: Description
45A-2
Roof front section:

Description
45A-5
Roof rear section:

Description
45A-6
Roof front cross member:

Description
45A-7
Roof centre cross member:

Description
45A-8
Roof panel arch: Description
45A-9

A-pillar: Description
A-pillar reinforcement:
Description
Windscreen pillar lining:
Description
43A-1
43A-5
43A-7
A-pillar lining stiffener:

Description
43A-8
B-pillar: Description
43A-9
B-pillar reinforcement:
General description
43A-15
B-pillar reinforcement:
Description
43A-16
Body side: General

description
43A-20
Body side: Description
43A-22
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Roof rear cross member:

Description
45A-10
Contents
47A
48A

Front side door: Removal Refitting
47A-1
Front side door: Stripping Restoring
47A-4
Front side door: Adjustment
47A-6
Rear side door: Removal Refitting
47A-8
Rear side door: Stripping Restoring
47A-12
Rear side door: Adjustment
47A-14

Bonnet: Removal - Refitting
48A-1
Bonnet: Stripping Rebuilding
48A-3
Bonnet: Adjustment
48A-4
Tailgate: Removal - Refitting
48A-7
Tailgate: StrippingRebuilding
48A-10
Tailgate: Adjusting
48A-11
Rear loading door: Removal

- Refitting
48A-14
Rear loading door: Stripping

- Rebuilding
48A-20
Rear loading door:

Adjustment
48A-26
Upper rear opening element:

Stripping - Rebuilding
48A-34
Upper rear opening element:

Removal - Refitting
48A-36
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GENERAL INFORMATION
Vehicle on repair bench: Description
40A
2 - Front mechanical components removed
I - PRINCIPAL REFERENCE POINTS FOR SETTING

VEHICLE TRIM LEVEL
1 - Front mechanical components in place
127213
The jig rests under the subframe mounting unit and is

centred in the threaded hole (A) .
127208
The jig covers the rear bolt of the front subframe (A) .
Use this situation for a front impact requiring removal of

the front subframe.
This could be used in two cases:

- if the rear of the vehicle is being rebuilt, these two
points alone may be used to align and support the
front of the vehicle.
- for a light frontal impact not requiring removal of the
front axle sub-frame.
40A-1
Note:
If it is suspected that one of these points may be
deformed, use two additional points located in an
area not affected by the impact in order to confirm
trim-setting.
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GENERAL INFORMATION
40A
III - MAIN REAR TRIM-SETTING REFERENCE

POINTS
II - SECONDARY FRONT TRIM-SETTING

REFERENCE POINT
1 - Rear mechanical components in place
127213
The jig rests under the front side member and is centred on the hole (C) .
127210
Use this situation for a major front impact requiring replacement of the front subframe rear mounting unit.
The jig rests under the rear axle fork and is centred on
the rear axle assembly pilot hole (B) .
It is also used to confirm the vehicle level if deformation

of a main front reference point is suspected.
This could be used in two cases:

- if the front of the vehicle is being rebuilt, these two
points alone may be used to align and support the
front of the vehicle.
- for a light rear impact not requiring removal of the rear
axle.
40A-2
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GENERAL INFORMATION
40A
IV - SECONDARY REAR TRIM-SETTING

REFERENCE POINT
2 - Rear mechanical components removed
127217
The jig rests under the rear side member and is centred on tapped hole (B1) .
Use this situation for a rear impact with removal of the
mechanical components.
127217
The jig rests under the front side member rear section
and is positioned in the hole (M) .
Use this situation for a major rear impact when replacing the rear side member assembly.
It is also used to confirm the vehicle level if deformation
of a main rear reference point is suspected.
Note:
If it is suspected that one of these points may be
deformed, use two additional points located in an
area not affected by the impact in order to confirm
trim-setting.
40A-3
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GENERAL INFORMATION
40A
STANDARD CHASSIS
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(Ag)
Front subframe rear mounting, without

mechanical components
301
-305
77.8
24.5/M12
(Ad)

301
-305
77.8
24.5 x 29/M12
(B)
Rear axle guide
1952
-580.6
110
30
(B1)
Rear axle assembly front mounting,

without mechanical components
2204.8
-522.4
110
M14 x 1.5
(B1)
Rear axle assembly front mounting, with

2204.8
-522.4
104
M14 x 1.5
(Cg)
Front sub-frame front mounting
-141.5
-478
252
16.5/M12
(Cd)
-141.4
478
261
16.5/M12
(E)
Front section of rear shock absorber

upper mounting
2368.5
-534.6
252
15
(F1g)
Front shock absorber upper stop
-53.5
-602
702.2
15.5
(F1d)
-44
632.14
701.7
15.5
(F2g)
52.5
-529.7
687.2
15.5
(F2d)
-22.4
530
696.35
15.5
(F3g)
75.1
-632
687.1
15.5
(F3d)
84.4
601.8
685.29
15.5
(G)
Front side member rear leader pin
547.5
-408.7
-9.8
20.5
(Hg)
Front side member front leader pin
-531
-475.5
50
M12
(Hd)
-531
492
50
M12
(J)
Rear side member rear leader pin
2891
-570.2
220.3
20 x 25
(K1g)
Front panel mounting on side member
-553.7
-535.1
414.7
M10
(K1d)
-553.15
-542.5
414.8
M10
(K2g)
-557.6
-478.8
267.11
M10
(K2d)
-557.25
483.91
267.11
M10
(Lg)
Rear end cross member
3133
-565.22
155.1
M10
(Lg)
3133
575.22
155.1
40A-4
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Angle
()
6.27
GENERAL INFORMATION
40A
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(L1)
3172.2
-513
225
M8
(L2)
3173.2
-570.67
135.08
M8
(M)
Leader pin under centre floor
1772.6
171.6
(P1)
Engine mounting
-309.6
507
531.9
M10
(P2)
Engine mounting
-149.2
529
531.9
M10
(Q1)
Gearbox mounting
-238.4
-429.4
378
M10
(Q2)
Gearbox mounting
-118
-417.8
319.2
M10
Angle
()
20.5
SHORT CHASSIS
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(Ag)

301
-305
77.8
24.5/M12
(Ad)

301
-305
77.8
24.5 x 29/M12
(B)
Rear axle guide
1952
-580.6
110
30
(B1)
Rear axle assembly front mounting,

without mechanical components
1820.8
-522.4
110
M14 x 1.5
(B1)
Rear axle assembly front mounting, with

1820.8
-522.4
104
M14 x 1.5
(Cg)
-141.5
-478
252
16.5/M12
(Cd)
-141.4
478
261
16.5/M12
(E)
Front section of rear shock absorber

upper mounting
1984.5
-534.6
252
15
(F1g)
-53.5
-602
702.2
15.5
(F1d)
-44
632.14
701.7
15.5
(F2g)
52.5
-529.7
687.2
15.5
(F2d)
-22.4
530
696.35
15.5
(F3g)
75.1
-632
687.1
15.5
(F3d)
84.4
601.8
685.29
15.5
(G)
Front side member rear leader pin
547.5
-408.7
-9.8
20.5
40A-5
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Angle
()
6.27
GENERAL INFORMATION
40A
Description
Dimension X
(mm)
Dimension Y
(mm)
Dimension Z
(mm)
Diameter (mm)
(Hg)
-531
-475.5
50
M12
(Hd)
-531
492
50
M12
(J)
Rear side member rear leader pin
2507
-570.2
220.3
20 x 25
(K1g)
-553.7
-535.1
414.7
M10
(K1d)
-553.15
-542.5
414.8
M10
(K2g)
-557.6
-478.8
267.11
M10
(K2d)
-557.25
483.91
267.11
M10
(Lg)
2949
-565.22
155.1
M10
(Lg)
2949
575.22
155.1
(L1)
2788.2
-513
225
M8
(L2)
2789.2
-570.67
135.08
M8
(M)
Leader pin under centre floor
1388.6
171.6
(P1)
Engine mounting
-309.6
507
531.9
M10
(P2)
Engine mounting
-149.2
529
531.9
M10
(Q1)
Gearbox mounting
-238.4
-429.4
378
M10
(Q2)
Gearbox mounting
-118
-417.8
319.2
M10
40A-6
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20.5
Angle
()
GENERAL INFORMATION
40A
126949
40A-7
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GENERAL INFORMATION
40A
126950
40A-8
http://vnx.su
GENERAL INFORMATION
Hollow body parts inserts: List and location of components
40A
126951
126953
B-pillar lining insert (1) .
126954
A-pillar reinforcement insert (2) .
40A-9
http://vnx.su
GENERAL INFORMATION
126955
A-pillar lining insert (3) .
126959
B-pillar reinforcement insert (5) .
126958
Tunnel insert (4) .
40A
126957
Rear wheel arch lining insert (6) .
40A-10
http://vnx.su
GENERAL INFORMATION
126956
Sill panel rear reinforcement insert (7) .
40A-11
http://vnx.su
40A
GENERAL INFORMATION
Earths on the body: List and location of components
40A
For the earth stud fitting procedure, (see MR 400).
126951
40A-12
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GENERAL INFORMATION
40A
126952
DETAILED VIEWS OF THE POSITION OF EARTHS

ON THE VEHICLE
126961
Earth studs on the front right-hand side member (2) .

126960
Earth studs on the front left-hand side member (1) .
40A-13
http://vnx.su
GENERAL INFORMATION
126964
Earth studs on the right-hand rear wheel arch (3) .
126962
Earth studs on the cross member under front seat (5) .
126963
Earth studs on the left-hand rear wheel arch (4) .
40A
126962
Earth studs on the tunnel (6) .
40A-14
http://vnx.su
GENERAL INFORMATION
Vehicle front section structure: Description
40A
126966
No.
Description
Classification
Type
Thickness
(mm)
(1)
Front end side cross member
HLE
1.2
(2)
Radiator cross member support
(3)
Front side member
(see 41A, Front lower structure, Front side member: Description, page 41A-11)
(4)
Front side member closure panel
(see 41A, Front lower structure, Front side member closure panel: Description, page 41A-17)
(5)
Battery tray support
(see 41A, Front lower structure, Battery tray support: General description, page 41A-20)
(6)
Front mounting of front sub-frame
(see 41A, Front lower structure, Front mounting of

front sub-frame: General description, page 41A-23)
(7)
Engine stand
(see 41A, Front lower structure, Engine mounting:

Description, page 41A-30)
(8)
Sub-frame rear mounting
(see 41A, Front lower structure, Radiator cross

member support: Description, page 41A-6)
(see 41A, Front lower structure, Sub-frame rear

mounting: General description, page 41A-26)
40A-15
http://vnx.su
GENERAL INFORMATION
Vehicle front section structure: Description
Classification
Type
40A
No.
Description
Thickness
(mm)
(9)
Front half-unit
(10)
Scuttle side panel
(11)
Scuttle side panel upper reinforcement
(see 42A, Front upper structure, Scuttle side panel

upper reinforcement: Description, page 42A-16)
(12)
Front wheel arch
(see 42A, Front upper structure, Front wheel arch:

(13)
Windscreen aperture lower cross member
(see 42A, Front upper structure, Windscreen aperture lower cross member: Description, page 42A22)
(see 41A, Front lower structure, Front half unit:

General description, page 41A-32)
(see 42A, Front upper structure, Cowl side panel:
40A-16
http://vnx.su
GENERAL INFORMATION
Vehicle side section structure: Description
40A
126968
No.
Description
Classification
(1)
Sill panel with sliding side door
(see 41C, Side lower structure, Sill panel: Description, page 41C-4)
(2)
Reinforcement for sill panel with sliding

side door
(see 41C, Side lower structure, Sill panel reinforcement: Description, page 41C-24)
(3)
Sill panel closure panel front section
(see 41C, Side lower structure, Sill panel closure

panel, front section: Description, page 41C-16)
(4)
Sill pane stiffener
(see 41C, Side lower structure, Sill pane stiffener:

Description, page 41C-30)
(5)
Reinforcement for sill panel without sliding

side door
(see 41C, Side lower structure, Sill panel reinforcement: Description, page 41C-24)
(6)
Sill panel without sliding side door
(see 41C, Side lower structure, Sill panel: Description, page 41C-4)
(7)
Sill panel rear reinforcement
(see 41C, Side lower structure, Sill panel rear reinforcement: Description, page 41C-28)
(8)
Sill panel closure panel rear section
(see 41C, Side lower structure, Inner sill panel rear

section: Description, page 41C-22)
40A-17
http://vnx.su
Type
Thickness
(mm)
GENERAL INFORMATION
Vehicle side section structure: Description
Classification
No.
Description
(9)
A-pillar reinforcement
(see 43A, Side upper structure, A-pillar reinforcement: Description, page 43A-5)
(10)
Windscreen pillar lining
(see 43A, Side upper structure, Windscreen pillar

lining: Description, page 43A-7)
(11)
Windscreen pillar lining reinforcement
(see 43A, Side upper structure, A-pillar lining stiffener: Description, page 43A-8)
(12)
A-pillar
(see 43A, Side upper structure, A-pillar: Description, page 43A-1)
(13)
(see 43A, Side upper structure, A-pillar reinforcement: Description, page 43A-5)
40A-18
http://vnx.su
Type
40A
Thickness
(mm)
GENERAL INFORMATION
Vehicle central section structure: Description
40A
126967
No.
Description
Classification
Type
Thickness
(mm)
(1)
Centre floor front side cross member
(see 41B, Centre lower structure, Centre floor front

lateral cross member: Description, page 41B-8)
(2)
Centre floor, side section
(3)
Central floor reinforcement
(4)
Roof
(5)
Roof front cross member
(6)
Roof centre cross member
(7)
Roof panel arch
(see 45A, Top of body, Roof panel arch: Description, page 45A-9)
(8)
Roof rear cross member
(see 45A, Top of body, Roof rear cross member:

(see 41B, Centre lower structure, Central floor,

side section: Description, page 41B-3)
(see 41B, Centre lower structure, Centre floor reinforcement: Description, page 41B-6)
(see 45A, Top of body, Roof: Description, page
45A-2)
(see 45A, Top of body, Roof front cross member:
(see 45A, Top of body, Roof centre cross member:
40A-19
http://vnx.su
GENERAL INFORMATION
Vehicle structure rear section: Description
40A
126969
No.
Description
Classification
Type
Thickness
(mm)
(1)
Rear floor
(see 41D, Rear lower structure, Rear floor: Description, page 41D-2)
(2)
Front section of rear floor
(see 41D, Rear lower structure, Rear floor, front

section: Description, page 41D-6)
(3)
Rear floor stiffener
(see 41D, Rear lower structure, Rear floor stiffener: Description, page 41D-8)
(4)
Front cross member under rear seat
(5)
Rear side member
(6)
Rear floor centre cross member
(7)
Rear end lower cross member
(see 41D, Rear lower structure, Rear end lower

cross member: Description, page 41D-18)
(8)
Far rear lower cross member, side part
(see 41D, Rear lower structure, Far rear lower

cross member, side section: Description, page
41D-20)
(see 41D, Rear lower structure, Front cross member under rear seat: Description, page 41D-21)
(see 41D, Rear lower structure, Rear side member:
Description, page 41D-13)
(see 41D, Rear lower structure, Rear floor centre
cross member: Description, page 41D-17)
40A-20
http://vnx.su
GENERAL INFORMATION
Vehicle structure rear section: Description
Classification
Type
40A
No.
Description
Thickness
(mm)
(9)
Fuel tank mounting support .
(10)
Rear impact cross member mounting reinforcement
(11)
Rear end panel
(see 44A, Rear upper structure, Rear end panel:

(12)
Rear end pillar
(see 44A, Rear upper structure, Far rear pillar:

(13)
Rear side panel rain channel
(14)
Left-hand inner rear wheel arch
(see 44A, Rear upper structure, Inner wheel arch:

(15)
Right-hand inner rear wheel arch
(see 44A, Rear upper structure, Inner wheel arch:

(16)
Left-hand body side rear lining
(see 44A, Rear upper structure, Body side rear

(17)
Right-hand body side rear lining
(see 44A, Rear upper structure, Body side rear

(18)
Rear section of rear side panel
(see 44A, Rear upper structure, Rear section of

rear side panel: Description, page 44A-28)
(19)
Lower section of rear side panel
(see 44A, Rear upper structure, Rear side panel:

(20)
B-pillar
(see 43A, Side upper structure, B-pillar: Description, page 43A-9)
(21)
Upper section of rear side panel

(see 41D, Rear lower structure, Tank mounting

support: Description, page 41D-22)
(see 41D, Rear lower structure, Rear impact cross
member mounting reinforcement: Description,
page 41D-16)
(see 44A, Rear upper structure, Rear side panel

rain channel: Description, page 44A-35)
40A-21
http://vnx.su
GENERAL INFORMATION
Vehicle removable section structure: Description
40A
126965
No.
Description
Classification
Type
Thickness
(mm)
(1)
Frontal impact cross member
(2)
Rear impact lower cross member
(3)
Front wing
(4)
Front end panel
(5)
Dashboard cross member
(6)
Front side door
(see 47A, Side opening elements, Front side door:

Removal - Refitting, page 47A-1)
(7)
Rear side door
(see 47A, Side opening elements, Rear side door:

(8)
Bonnet
(see 41A, Front lower structure, Front impact

cross member: Removal - Refitting, page 41A-2)
(see 41D, Rear lower structure, Rear impact lower
cross member: Removal - Refitting, page 41D-24)
(see 42A, Front upper structure, Front wing:
(see 42A, Front upper structure, Front: Removal Refitting, page 42A-9)
(see Dashboard cross member: Description)
(see 48A, Non-side opening elements, Bonnet:

40A-22
http://vnx.su
GENERAL INFORMATION
Vehicle removable section structure: Description
Classification
No.
Description
(9)
Tailgate
(see 48A, Non-side opening elements, Tailgate:

(10)
Rear loading door
(see 48A, Non-side opening elements, Rear loading door: Removal - Refitting, page 48A-14)
40A-23
http://vnx.su
Type
40A
Thickness
(mm)
GENERAL INFORMATION
Structure components to be positioned on body repair bench: Description
40A
I - PARTS REQUIRING THE USE OF A BODY JIG

BENCH
127212
(1) Engine stand

(2) Front wheel arch
(3) Front half-unit
(4) Front side member
(5) Radiator cross member support
(6) Front subframe front mounting unit
(7) Front sub-frame rear mounting unit
(8) Rear side member
(9) Rear end panel
40A-24
http://vnx.su
GENERAL INFORMATION
II - PRINCIPAL REFERENCE POINTS FOR SETTING

VEHICLE TRIM LEVEL
40A
2 - Front subframe rear mounting
1 - Front subframe front mounting
127213
The jig rests against the rear section of the side member and is centred in the sub-frame rear mounting hole.
127214
The jig supports the underneath of the front sub-frame

mounting and is centred on tapped hole (C) .
The jig is used to replace:

- a complete front half unit,
- a front subframe rear mounting unit.

- a complete front side member,
IMPORTANT
This/these point/s help(s) to ensure axle geometry.
- a front half unit.
IMPORTANT
3 - Front impact cross member mounting
127214
40A-25
http://vnx.su
GENERAL INFORMATION
The jig rests against the front impact cross member

mounting reinforcement and is centred on the mounting holes (K1) and (K2) .
40A
5 - Gearbox mounting

- the front impact cross member mounting,
- the front side member, completely or partially.
4 - Engine mounting
127214
The jig rests laterally against the side member and is

centred on the tapped holes (Q1) and (Q2)
6 - Front shock absorber upper mounting
127216
The jig rests on the engine and is centred on the engine mounting holes (P1) and (P2) .
The jig is used with the subframe removed for the replacement of:
- the engine mounting.
127215
The jig rests under the shock absorber cup and is centred on the shock absorber head mounting holes (F) .
- a wheel arch,
40A-26
http://vnx.su
GENERAL INFORMATION
The jig is also used during front straightening to keep

the shock absorber cup in position.
40A
8 - End of rear side member
IMPORTANT
7 - Rear axle assembly front mounting
127218
The jig rests under the rear side member and is centred on the hole (J) .
The jig is used:
- to realign a rear side member with the mechanical
components in place,
127217
The jig rests under the rear axle assembly mounting

unit and is centred on the tapped hole (B) of the rear
axle bearing mounting.
- to replace the complete rear side member with the

mechanical components removed, under the same
conditions.
The jig is used for replacing a rear side member assembly.
9 - Rear impact lower cross member mounting
IMPORTANT
127218
40A-27
http://vnx.su
GENERAL INFORMATION
The jig rests vertically against the side lining of the rear
end panel and is centred on the rear impact lower
cross member mounting holes (L1) and (L2) and under
the cross member mounting reinforcements. (L)
The jig is used to replace the rear end panel and the
rear impact cross member mounting reinforcement.
40A-28
http://vnx.su
40A

Front impact cross member: General description
Note:
The information contained in the following describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated with the vehicle. These special notes are specified if necessary in other parts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connection, see MR 400.
DESIGN OF THE STRUCTURAL COMPONENT
110517
This part has three distinct components: two impact

absorber units bolted onto the ends of the front side
members, and the impact cross member itself, which
bolts onto these units. The assembly is made of aluminium.
41A-1
http://vnx.su
41A

Front impact cross member: Removal - Refitting
41A
REMOVAL
a Refit:
I - REMOVAL PREPARATION
a Partially remove the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting) (55A,
Exterior protection).
a Remove:
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),
- the headlights (see Front headlight: Removal Refitting) (80B, Headlights),
- the front of the vehicle (see 42A, Front upper

structure, Front: Removal - Refitting, page 42A9) .
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection).
- the front of the vehicle (see 42A, Front upper

structure, Front: Removal - Refitting, page 42A9) .
II - REMOVAL
127529
a Remove:
- the bolts (1) ,
- the front impact cross member (2) .
REFITTING
I - REFITTING
a Refit:
- the front impact cross member,
- the bolts (1) .
41A-2
http://vnx.su

Radiator support cross member: General description
Note:
Before reading this general information, check that
there are no special notes associated with this vehicle. These special notes will be specified if applicable in other parts of this subsection dealing with the
part.
Note:
110077
This steel part, which bolts onto the front axle subframe, combines two functions:
- distribution of front impact forces,
- radiator support cross member.
41A-3
http://vnx.su
41A

Radiator support cross member: Removal - Refitting
41A
II - REMOVAL
Tightening torquesm
F61, and K4M or K7M or K9K
radiator mounting cross
member nut
21 Nm
side stiffener bolts
62 Nm

member bolts
106 Nm

member bolts
106 Nm
REMOVAL
a Remove:
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
liner: Removal - Refitting) (55A, Exterior protection),
127760
a Remove:
- the radiator mounting cross member bolts (1) ,

- the radiator mounting cross member.
- the engine undertray.

a Attach the radiator upper section.
41A-4
http://vnx.su

Radiator support cross member: Removal - Refitting
41A
- the radiator mounting cross member nut (5) .

K61 F61, and K9K, and 806
REFITTING
I - REFITTING
K61 F61, and K9K, and 806

a Torque tighten the radiator mounting cross member nut (21 Nm) (5) .
a Refit the side stiffeners (4) .
a Tighten:
- to torque the side stiffener bolts (62 Nm) (3) ,
- to torque the radiator mounting cross member
bolts (106 Nm) (2) .
127650
a Remove:
- the radiator mounting cross member bolts (2) ,
- the radiator mounting cross member.
F61, and K4M or K7M or K9K
a Refit the radiator mounting cross member.
a Torque tighten the radiator mounting cross member bolts (106 Nm) (1) .
a Detach the radiator.
a Refit:
- the engine undertray,
127652
a Remove:

- the side stiffener bolts (3) ,

- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).
- the side stiffeners (4) ,
41A-5
http://vnx.su

Radiator cross member support: Description
41A
I - COMPOSITION OF THE SPARE PART
128606
126971
To carry out this operation, order separately:

- the radiator cross member support unit (1)
- the front impact cross member mounting unit closure
panel (2)
- the radiator cross member support internal closure
panel (3)
IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometry of the axle assemblies.
41A-6
No.
Description
Type
Thickness
(mm)
(1)
Radiator cross
member mounting unit
HLE
1.2
(2)
Closure panel of
the front impact
cross member
mounting unit
THLE
2.5
(3)
Interior closure
panel of radiator
cross member
mounting
HLE
1.2
http://vnx.su

Radiator cross member support: Description
41A
II - PART FITTED
WARNING
To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).
126970
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
126960
41A-7
http://vnx.su

Front side member: General description
41A
II - AREA TO BE CUT FOR PARTIAL

REPLACEMENT
IMPORTANT
Note:
Note:
110510
1 - Cut 1:
I - DESIGN OF THE STRUCTURAL COMPONENT
This line shows the centre of the area in which it is possible to carry out a partial replacement.
This operation allows you to access the inside of the
hollow section of the structural element to straighten it.
Note:
For the partial replacement of parts constituting a
single structural component, it is essential to stagger the welds of each of the components.
In this case, the side member weld line must be staggered from that of its closure panel.
110509
The special feature of this type of part is that it combines the functions of front section and rear section of
the front side member and that it is made of two different kinds of panels of different thicknesses assembled
by laser butt welding.
41A-8
http://vnx.su

2 - Cut 2:
The cut is made along the butt weld.
41A
130093
130095
130094
130096
III - ASSEMBLY METHOD FOR A PARTIAL

REPLACEMENT
Only the connections which are specific to the partial
replacement by cutting are indicated.
WARNING
41A-9
http://vnx.su

If there are other issues regarding access to mating faces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400).
110511
Lines (3) and (4) on the diagram show a butt weld by

continuous EGW welding.
Weld (4) along the butt weld line.
41A-10
http://vnx.su
41A

Front side member: Description
41A
Right-hand side
Left side
127236
Left side
126972
No.
Description
Type
Thickness
(mm)
(1)
Front side member
HLE/
THLE
1.67/2.5
(2)
Mild
steel
1.5/2
(3)
Front mounting of
front sub-frame
HLE
1.2
(4)
Front subframe
rear mounting
HLE
(5)
Interior closure
panel component of radiator
cross member
mounting
HLE
1.2
(6)
Closure panel
component of
front
impact
cross member
mounting unit
VHEL
2.5
127237
The options for replacing this part are as follows:

- partial replacement of front end section,
- partial replacement of the front section.
IMPORTANT
41A-11
http://vnx.su

Right-hand side
41A
II - PART FITTED
1 - Partial replacement of the front end section
126978
No.
Description
Type
Thickness
(mm)
126976
Cut
(1)
Front side member
HLE/
THLE
1.67/2.5
(3)
Front mounting of
front sub-frame
HLE
1.2
(4)
Front subframe
rear mounting
HLE
(5)
Interior closure
cross member
mounting
HLE
1.2
(6)
Closure panel
component of
front
impact
cross member
mounting unit
VHEL
2.5
(7)
Bulkhead cross
member righthand bracket
Mild
steel
1.47
(8)
Engine stand
HLE/
Mild
steel
1.47/2
126977
41A-12
http://vnx.su

41A
Preparation of the replacement part
2 - Partial replacement of the front section

Right-hand side
126975
126979
Note:
When cutting, do not damage the rear reinforcement (A) .
Left side
Note:
For a detailed description of the welded connections, see MR 400.
126973
41A-13
http://vnx.su

EARTHS
126960
126961
WARNING
To avoid damaging the vehicle's electrical and electronic components, disconnect the earths of any
wiring near the weld area.
Position the welding machine earth as close as
possible to the weld zone (see MR 400).
41A-14
http://vnx.su
41A

Front side member closure panel: General description
41A

REPLACEMENT
IMPORTANT
Note:
For the replacement of parts constituting a single
structural component, it is essential to stagger the
welds of each of the components
Note:
make sure that there are no special notes relating
to the vehicle. These special notes are specified if
applicable in other parts of this subsection dealing
with the component.
Note:
For a description of a particular connection, see MR
400.
Left side
127234
1 - Cut 1:
127234
The special feature of this part is that it combines the

functions of both the front section and rear section of
the front side member closure panel and is made of
two different kinds of panels of different thicknesses
assembled by laser butt welding.
126980
The cut must be made on the splice
41A-15
http://vnx.su

Front side member closure panel: General description
2 - Cut 2:
126982
This line shows the centre of the area in which it is possible to carry out a partial replacement.
hollow section of the structural component to straighten it.
41A-16
http://vnx.su
41A

Front side member closure panel: Description
41A
Right-hand side
127235
115111
Left side
No.
Description
Type
Thickness
(mm)
(1)
Front side member closure panel
HLE/
THLE
1.7/2.5
(2)
Interior closure
panel of radiator
cross member
mounting
HLE
1.2
(3)
Front subframe
front mounting
unit
HLE
1,7
(4)
Reinforcement
bracket
Mild
steel
1.2
(5)
Front subframe
front mounting
support
Mild
steel
127234

- partial replacement of the front section,
- partial replacement of front end section.
IMPORTANT
41A-17
http://vnx.su

41A
Complete replacement
II - PART FITTED
Partial replacement of the front section
126980
126982
Cut
Cut
126981
126983
Note:
41A-18
http://vnx.su

WARNING
Respect the position of this cut which has been
determined in accordance with the position of the
inner stiffeners or acoustic inserts, in order to prevent damaging the parts (inner stiffener and/or
acoustic insert).
EARTHS
126960
WARNING
41A-19
http://vnx.su
41A

Battery tray support: General description
Note:
having the same design for this part. Before reading
the following general information, make sure that
there are no special notes associated with the vehicle. These special notes are specified if necessary
in other parts of the sub-section dealing with the
component.
Note:
101415
This part functions only as a battery tray bracket. It is

welded to the vehicle structure.
41A-20
http://vnx.su
41A

Battery tray support: Description
41A
No.
Description
Type
Thickness
(mm)
(1)
Battery tray support upper section
Mild
steel
1.5
(2)
Battery tray support lower section
Mild
steel
(3)
Air filter retaining

bracket
Mild
steel
1.2
II - PART FITTED
101415
There is only one way of replacing this part:

- complete replacement.
128394
WARNING
accessible, use GMAW plug welds in place of the
original electrical resistance welds (see MR 400).
128395
41A-21
http://vnx.su

Battery tray support: Description
EARTHS
126960
WARNING
41A-22
http://vnx.su
41A

Front mounting of front sub-frame: General description
IMPORTANT
Note:
Note:
101422
This is a basic part; it functions only as a front mounting

of front subframe.
41A-23
http://vnx.su
41A

Front mounting of front sub-frame: Description
41A
No.
Description
Type
Thickness
(mm)
(1)
Front support of
front subframe
HLE
1.5
(2)
Front support
reinforcement of
front subframe
HLE
2.5
II - PART FITTED
128393
To carry out this operation, also order the front support

reinforcement of the front subframe (2)
IMPORTANT
128392
WARNING
128393
41A-24
http://vnx.su

Front mounting of front sub-frame: Description
EARTHS
Left-hand side
126960
Right-hand side
126961
WARNING
41A-25
http://vnx.su
41A

Sub-frame rear mounting: General description
IMPORTANT
41A
Note:
Note:
part.
110489
The front sub-frame rear mounting (1) is welded to the

front half unit.
41A-26
http://vnx.su

Sub-frame rear mounting: Description
41A
No.
Description
Type
Thickness
(mm)
(1)
Sub-frame rear
mounting reinforcement
Very
high
yield
strengt
h
(2)
Sub-frame
mounting
HEL
rear
II - PART FITTED
127238

IMPORTANT
128390
WARNING
128391
41A-27
http://vnx.su

Sub-frame rear mounting: Description
EARTHS
Right-hand side
126961
Left-hand side
126960
WARNING
41A-28
http://vnx.su
41A

Engine mounting: General description
IMPORTANT
Note:
part.
Note:
102623
This is a basic part; it only functions as an engine

mounting.
41A-29
http://vnx.su
41A

Engine mounting: Description
41A
No.
Description
Type
Thickness
(mm)
(1)
Engine mounting
rear section
HLE
1.5
(2)
Engine mounting
upper section
HLE
(3)
Engine mounting
height adjuster
reinforcement
Mild
steel
1.97
(4)
Engine mounting
rear reinforcement
HLE
II - PART FITTED
127240

IMPORTANT
127530
Note:
127531
41A-30
http://vnx.su

Engine mounting: Description
EARTHS
126961
WARNING
41A-31
http://vnx.su
41A

Front half unit: General description
IMPORTANT
Note:
Note:
127232
The special feature of this type of part is that it combines the functions of front side member, front wheel
arch, centre floor front side cross member and front
end side cross member, and is made up of several panels of different types and thicknesses.
41A-32
http://vnx.su
41A

41A
Right-hand side
Right-hand side
127232
Left-hand side
126984
No.
Description
Type
Thickness
(mm)
(1)
Front subframe
front
s u p p o rt
reinforcement
HLE
2.5
(2)
Exterior closure
cross member
mounting
HLE
1.2
(3)
Front right-hand
side member closure panel
HLE THLE
1.7/2.5
(4)
Closure panel
component of
front
impact
cross member
mounting unit
Very
high
yield
strengt
h
2.5
(5)
Engine stand
HLE Mild
steel
1.47/2
(6)
Front right-hand
side member
HLE THLE
1.67/2.5
127233

41A-33
http://vnx.su

41A
No.
Description
Type
Thickness
(mm)
No.
Description
Type
Thickness
(mm)
(7)
Radiator cross
member support
unit
HLE
1.2
(3)
Front right-hand
side member closure panel
HLE THLE
1.7/2.5
(8)
Front mounting of
front sub-frame
HLE
1.2
(4)
THLE
2.5
(9)
Front subframe
rear mounting
HLE
Closure panel
component of
front
impact
cross member
mounting unit
(10)
Bulkhead cross
member righthand bracket
Mild
steel
1.47
(6)
Front left-hand
side member
HLE THLE
1.67/2.5
(7)
Radiator cross
member support
unit
HLE
1.2
(8)
Front mounting of
front sub-frame
HLE
1.2
(9)
Front subframe
rear mounting
HLE
(11)
Mild
steel
1.5/2
Left-hand side
II - PART FITTED
Left-hand side
126986
No.
Description
Type
Thickness
(mm)
(1)
Front subframe
front
s u p p o rt
reinforcement
HLE
2.5
(2)
Exterior closure
cross member
mounting
HLE
1.2
126985
41A-34
http://vnx.su

41A

EARTHS
WARNING
Left-hand side for replacement of the front righthand half unit

126960
Right-hand side for replacement of the front lefthand half unit
126961
41A-35
http://vnx.su

Centre floor, side section: General description
41B

REPLACEMENT
WARNING
part.
Note:
For a detailed description of a particular connection, (see MR 400).
110541
This cutting line (4) affects the option of partially replacing the centre floor side section.
REPLACEMENT
WARNING
If the spot welds cannot be made as they were originally using an electrical spot welding machine,
they should be replaced with plug welds after holes
have been drilled in the first panel.
110540
This is a basic part; its only function is that of centre

floor side section.
(see MR 400, 40A, General Information).
41B-1
http://vnx.su

Centre floor, side section: General description
110542
Weld line (4) on the diagram shows the partial front or

rear replacement and a weld by joggling with plug
welds at regular intervals.
41B-2
http://vnx.su
41B

Central floor, side section: Description
41B
II - PART FITTED
127242

127080

Partial replacement of the front section as seen

from below
No.
Description
Type
Thickness
(mm)
(1)
Centre floor, side

section
HLE
0.7
127082
41B-3
http://vnx.su

41B

EARTHS
127079
Note:
For a detailed description of the welded connections, see (MR 400).
126962
41B-4
http://vnx.su

WARNING
41B-5
http://vnx.su
41B

Centre floor reinforcement: Description
127243
No.
Description
Type
Thickness
(mm)
(1)
Front seat front

mounting support reinforcement
HLE
1.5
(2)
Front seat rear

mounting support reinforcement
HLE
1.5
(3)
Front seat front

mounting support
HLE
1.5
(4)
Front seat rear

mounting support
HLE
1.5
(5)
Front seat front

cross member
HLE
(6)
Front seat rear

cross member
HLE
(7)
Front seat mounting reinforcement
HLE
1.5
(8)
Front seat mounting reinforcement
HLE
1.5
(9)
Centre
member
side
VHEL
(10)
Centre
side
member reinforcement
UHLE
2.5

- partial replacement,
127084
41B-6
41B
http://vnx.su

Centre floor reinforcement: Description
41B

EARTHS
II - PART FITTED
Partial replacement
126962
127085
WARNING
127083
Note:
For a detailed description of the welded connections, (see MR 400).
41B-7
http://vnx.su

Centre floor front lateral cross member: Description
41B
No.
Description
Type
Thickness
(mm)
(1)
Front side cross

member
HLE
1.17
(2)
Front side cross

member reinforcement
1.47
(3)
Front cross member impact reinforcement
VHEL
(4)
Jacking
support
HLE
1.8
point
II - PART FITTED
127244
Partial replacement

IMPORTANT
127086
Note:
The cut is made at the end of the front side member.
127087
41B-8
http://vnx.su

Centre floor front lateral cross member: Description
102000
Note:
41B-9
http://vnx.su
41B

Sill panel: General description
41C
II - AREA TO BE CUT FOR COMPLETE

REPLACEMENT
Note:
there are no special notes associated with this vehicle. These special notes are specified if necessary
in other parts of the sub-section dealing with the
component.
Note:
110580
The lines (1) , (2) and (3) mark the cutting areas for the
complete replacement of the sill panel.
III - AREA TO BE CUT FOR PARTIAL
REPLACEMENT
122757
This part is removed by cutting into the complete body

side. This part fulfils the basic function of the sill panel.
It can be replaced partially by following the cuts described as follows.
110582
The lines (1) and (4) mark the areas for the partial replacement of the front of the sill panel.
41C-1
http://vnx.su

41C
110578
110574
The lines (3) and (5) mark the cutting areas for the partial replacement of the rear of the sill panel.
110576
110572
The lines (4) and (8) mark the cutting areas for the partial replacement of the sill panel section under the door.
Previous cuts can be used to carry out more extensive

partial replacements:
- front partial replacement, cut (1) , (2) and (5)
- Rear partial replacement, cut (2) , (3) and (4) .
These operations allow you to access the inside of the
hollow section of the structural element to straighten it.
IV - ASSEMBLY INSTRUCTIONS FOR A PARTIAL
REPLACEMENT
41C-2
http://vnx.su

WARNING
(see MR 400).
110575
Lines (1) , (2) and (5) on the drawing show a butt weld
by continuous EGW welding.
The welds described in this procedure are all identical.
41C-3
http://vnx.su
41C

41C
127245
When replacing this part, also order the B-pillar reinforcement insert, A-pillar reinforcement insert and the sill
panel rear reinforcement insert (see 40A, General information, Hollow body parts inserts: List and location of components, page 40A-9) .
127088
No.
Description
Type
Thickness
(mm)
(1)
Sill panel
Mild
steel
0.75
(2)
Mounting reinforcement for bottom rail end piece
Mild
steel
(3)
Upper closure
panel for bottom
rail unit
Mild
steel
0.75
(4)
Lower closure
panel for bottom
rail unit
Mild
steel
0.75

- partial replacement of the rear section,
41C-4
http://vnx.su

41C
II - PART FITTED
127093
Cut A
Cut B
127092
41C-5
http://vnx.su
127094

41C
2 - Rear section replacement
127095
Cut C
Cut D
127097
41C-6
http://vnx.su
127096

41C
Cut E
3 - Complete replacement
127091
127089
41C-7
http://vnx.su

41C
Note:
41C-8
http://vnx.su

41C
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW, and R SIDE
PANEL or R SIDE SCREEN+FIXED WINDOW or R SIDE SCREEN+OPENING WINDOW
127246
When replacing this part, also order the B-pillar reinforcement insert, A-pillar reinforcement insert, and the sill
panel rear reinforcement insert (see 40A, General information, Hollow body parts inserts: List and location of components, page 40A-9) .
- partial replacement under door:
No.
Description
Type
Thickness
(mm)
(1)
Sill panel
Mild
steel
0.75
41C-9
http://vnx.su

41C
II - PART FITTED
1 - Partial replacement under door
127105
Cut A
Cut B
127104
41C-10
http://vnx.su
127102

41C
127101
Cut C
127100
41C-11
http://vnx.su

41C
3 - Partial replacement of the rear section
127103
41C-12
http://vnx.su

41C
Cut F
127099
Special notes on weld joints

When welding, make the connection by superimposition beneath the section covered by the trim strip, finished off at both ends with continuous butt welding.
Note:
41C-13
http://vnx.su

41C
127098
Note:
41C-14
http://vnx.su

Sill panel closure panel: General description
Note:
part.
Note:
124602
This is a basic part; its only function is that of a sill panel closure panel.
II - ASSEMBLY METHOD FOR A PARTIAL

REPLACEMENT
WARNING
If there are other issues regarding access to mating faces, the various options are described in the basic instructions for structural bodywork repair (see MR 400).
41C-15
http://vnx.su
41C

Sill panel closure panel, front section: Description
41C
127350

- complete replacement
No.
Description
Type
Thickness
(mm)
(1)
Sill panel closure

panel front section
HLE
0.9
41C-16
http://vnx.su

41C
II - PART FITTED
127106
Detailed view A
Detailed view B
127108
41C-17
http://vnx.su
127107

41C
127109
Detailed view C
127110
Note:
41C-18
http://vnx.su

41C
127248

- complete replacement
No.
Description
Type
Thickness
(mm)
(1)
Sill panel closure

panel front section
HLE
0.9
41C-19
http://vnx.su

41C
II - PART FITTED
127111
Detailed view A
Detailed view B
127112
41C-20
http://vnx.su
127113

41C
III - POSITION OF LOCAL ELECTRICAL EARTHS
127114
126962
Detailed view C
Disconnect the electrical earth (2) on the rear cross

member, front seat.
WARNING
127115
Note:
41C-21
http://vnx.su

Inner sill panel rear section: Description
41C
II - PART FITTED
127247

127403
No.
Description
Type
Thickness
(mm)
(1)
Sill panel closure

panel rear section
HLE
1.2
Note:
126962

member, front seat.
41C-22
http://vnx.su

Inner sill panel rear section: Description
WARNING
41C-23
http://vnx.su
41C

Sill panel reinforcement: Description
41C
II - PART FITTED
127250

127120

Detailed view A
No.
Description
Type
Thickness
(mm)
(1)
Sill panel reinforcement
VHEL
0.9
127119
41C-24
http://vnx.su

41C
Detailed view B
127121
Partial replacement of the rear section
127118
41C-25
http://vnx.su

41C
Detailed view C
127123
127122
41C-26
http://vnx.su

Note:
126962

member, front seat.
WARNING
41C-27
http://vnx.su
41C

Sill panel rear reinforcement: Description
41C
II - PART FITTED
127251
If replacing this part, also order the rear wheel arch

lining insert and the sill panel rear reinforcement insert
(see 40A, General information, Hollow body parts
inserts: List and location of components, page
40A-9) .
127124
Note:
No.
Description
Type
Thickness
(mm)
(1)
Sill panel rear

reinforcement
Mild
steel
0.9

EARTHS
126964
Disconnect the electrical earth (2) from the front section of the rear wheel arch liner.
41C-28
http://vnx.su

Sill panel rear reinforcement: Description
WARNING
41C-29
http://vnx.su
41C

Sill pane stiffener: Description
41C
II - PART FITTED
127249

127116
No.
Description
Type
Thickness
(mm)
(1)
Sill pane stiffener
HLE
1.2
Detailed view A
127117
Note:
41C-30
http://vnx.su

Sill pane stiffener: Description
EARTHS
126962
Disconnect the electrical earth (2) from the rear cross

member, front seat.
WARNING
41C-31
http://vnx.su
41C

Rear floor: General description
Note:
Before reading the following information, make sure
that there are no special notes associated with the
vehicle. These special notes are specified if necessary in other parts of the sub-section dealing with
the component.
Note:
For a detailed description of welded connections,
see MR 400.
127254
This part is one of the main functions, and does not

function as the front and rear sections of the rear floor.
41D-1
http://vnx.su
41D

41D
II - PART FITTED
Partial replacement
127254

127126
Cut
No.
Description
Type
Thickness
(mm)
(1)
Rear floor
HLE
0.75
127127
41D-2
http://vnx.su

41D
127125
Note:
126964
WARNING
For a description of the welded connections, see

MR 400


EARTHS
126963
41D-3
http://vnx.su

Rear floor, front section: General description
41D
This is a basic part for commercial vehicles (vans), its

only function is that of a rear over floor, front section.
WARNING
III - ASSEMBLY INSTRUCTIONS FOR A PARTIAL
REPLACEMENT


WARNING
Note:
(see MR 400).

REPLACEMENT
Cut 1:
This line marks the area in which it is possible to make
a partial replacement.
F61
127255
41D-4
http://vnx.su

Rear floor, front section: General description
41D
110650
Line (2) on the diagram shows a joint made by joggling

connected with plug welds at regular intervals.
41D-5
http://vnx.su

Rear floor, front section: Description
41D
F61
(2)
Rear floor front

reinforcement
HLE
0.8
(3)
Rear floor cross

member mounting
HLE
0.8
II - PART IN POSITION
127255

127128
Note:
127129
No.
Description
Type
Thickness
(mm)
(1)
Front section of
rear floor
HLE
0.75
41D-6
http://vnx.su

Rear floor, front section: Description
F61
EARTHS
126962
WARNING
41D-7
http://vnx.su
41D

Rear floor stiffener: Description
41D
II - PART FITTED
127256
127130

Note:
No.
(1)
Description
Rear floor stiffener
Type
VHEL
Thickness
(mm)

EARTHS
0.8
126963
41D-8
http://vnx.su

Rear floor stiffener: Description
126964
WARNING
41D-9
http://vnx.su
41D

Rear side member: General description
IMPORTANT
41D
Note:
Note:
part.
110631
This is a basic part; it simply fulfils the function of a rear

side member.
41D-10
http://vnx.su

41D

REPLACEMENT
110632
Cut 1:
This line marks the area in which it is possible to make
a partial replacement.
III - ASSEMBLY INSTRUCTIONS FOR A PARTIAL
REPLACEMENT
WARNING
(see MR 400).
41D-11
http://vnx.su

41D
110633
The line (2) on the drawing shows a butt weld made by

continuous GMAW welding.
41D-12
http://vnx.su

Rear side member: Description
41D
127252
127136

IMPORTANT
No.
Description
Type
Thickness
(mm)
(1)
Rear
shock
absorber spacer
(2)
Rear
shock
absorber spacer
support
VHEL
1.8
(3)
Rear side member
HLE
1.5
(4)
Rear side member rear reinforcement
HLE
1.2
(5)
Rear
impact
cross member
VHEL
1,7
Note:
If replacing the complete rear side member, do not
damage the rear axle mounting reinforcement.
41D-13
http://vnx.su

41D
II - PART FITTED
127133
127137
Detailed view A
Cut
127134
127138
41D-14
http://vnx.su

Detailed view B
127135
Note:
If replacing the complete rear side member, do not
damage the rear axle mounting reinforcement.
Note:
41D-15
http://vnx.su
41D

Rear impact cross member mounting reinforcement: Description
41D
II - PART FITTED
127253

127145
No.
Description
Type
Thickness
(mm)
(1)
Rear
impact
cross member
VHEL
1.5
Note:
41D-16
http://vnx.su

Rear floor centre cross member: Description
41D
II - PART FITTED
127259

127139
No.
Description
Type
Thickness
(mm)
(1)
Rear floor centre

cross member
HLE
Note:
41D-17
http://vnx.su

Rear end lower cross member: Description
41D
II - PART FITTED
127261

127140
No.
(1)
Description
Rear end lower

cross member
Type
HLE
Thickness
(mm)
1.5
Note:
EARTHS
126963
41D-18
http://vnx.su

Rear end lower cross member: Description
WARNING
41D-19
http://vnx.su
41D

Far rear lower cross member, side section: Description
41D
II - PART FITTED
127262
127141

Note:
No.
Description
Type
Thickness
(mm)
(1)
Far rear lower

cross member,
side part
HLE
1.5
41D-20
http://vnx.su

Front cross member under rear seat: Description
No.
Description
Type
Thickness
(mm)
(1)
Front cross member under rear

seat
VHEL
(2)
Rear bench seat

mounting bracket
HLE
(3)
Rear bench seat

central mounting
bracket
HLE
(4)
Rear bench seat

central mounting
bracket
HLE
(5)
Rear bench seat

lock mounting
reinforcement
HLE
(6)
Rear bench seat

lock mounting
support
HLE
127258

41D
II - PART FITTED
127132
127131
Note:
41D-21
http://vnx.su

Tank mounting support: Description
41D
No.
Description
Type
Thickness
(mm)
(1)
Fuel tank rear

mounting support
HLE
(2)
Fuel tank rear

HLE
1.2
(3)
Fuel tank rear

HLE
1.2
II - PART FITTED
127257

127142
Note:
127143
41D-22
http://vnx.su

Rear impact lower cross member: General description
Note:
Note:
101411
This component cannot be repaired. It is a removable

component consisting of a cross member and two absorber units, and is made of aluminium or steel.
The assembly is attached to the ends of the rear side
members.
41D-23
http://vnx.su
41D

Rear impact lower cross member: Removal - Refitting
41D
REMOVAL
a Refit:
- the rear bumper (see Rear bumper: Removal Refitting) (55A, Exterior protection),
- the rear wing lights (see Rear light on wing: Removal - Refitting) (81A, Rear lighting).
a Remove:
- the rear wing lights (see Rear light on wing: Removal - Refitting) (81A, Rear lighting),
- the rear bumper (see Rear bumper: Removal Refitting) (55A, Exterior protection).

CONCERNED
127144
a Remove:
- the bolts (1) ,
- the rear impact lower cross member (2) .
REFITTING
CONCERNED
a Refit:
- the rear impact lower cross member (2) ,
- the bolts (1) .
41D-24
http://vnx.su

Front wing: General description
42A
- the impact absorber,

- the headlight.
Note:
III - ADJUSTMENT

Note:
The front wing is the penultimate removable component to be fitted to the vehicle body in the factory.
For final adjustment, correctly position all the other
components including the bumper and the headlights for them to be correctly positioned.

Two main areas of adjustment may be identified:
- the adjustment of the rear area,
- the adjustment of the front area
1 - Adjustment of the rear area:
112606
This type of front wing has the following characteristics:

- plastic wing (NORYL),
- wing bolted to its upper mounting bracket.
112042
II - REMOVAL - REFITTING
Note:
In all cases of removal of a component without its
replacement with a new one, mark the position of
the mountings before removing the mountings to
avoid adjustments during refitting.
To remove or replace the front wing, remove:
- the windscreen lower trim piece,
- the radiator grille,
- the front bumper,
42A-1
http://vnx.su

Front wing: General description
42A
112041
127225
Adjust the flush fitting and alignment with the front door
using mountings (4) and (5) .
Adjust the alignment of the wing using mountings (22)

and (23) .
127224
42A-2
http://vnx.su

Front wing: Removal - Refitting
42A
II - REMOVAL
REMOVAL
a Remove:
- the headlight (see Front headlight: Removal Refitting) (80B, Headlight),
- the front wheel arch liner (see Front wheel arch
- the side indicator (see Side indicator: Removal Refitting) (80A, Headlight).
127220
127219
a Remove the windscreen lower trim piece (1) .
127221
42A-3
http://vnx.su

Front wing: Removal - Refitting
42A
- the bolts (5) , (4) , (3) , (2) , (1) .

a Refit:
- the side indicator (see Side indicator: Removal Refitting) (80A, Headlight),
- the headlight (see Front headlight: Removal Refitting) (80B, Headlight),
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection).
127222
127223
a Remove:
- the bolts (5) ,
- the front wing.
REFITTING
I - REFITTING
a Refit:
- the front wing,
42A-4
http://vnx.su

42A
ADJUSTMENT VALUES
a For all information regarding wing adjustment values, (see Vehicle clearances: Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are three possible front wing adjustments:
- Adjustment with the front door
- Adjustment with the bonnet
- Adjustment with the headlight and bumper
109496
a Symbols A, B, C, and D show the adjustment options.

The black dot in the centre represents the body of
the bolt.
The grey section represents the component to be
adjusted.
The white section represents the adjustment area.
127159
I - ADJUSTMENT WITH THE DOOR AND SILL

PANEL
a Make these adjustments in the following order:

- Rear zone adjustments (1) , (2) and (3)
- Adjustment with the bonnet (4)
- Adjustment with the bumper and headlight (5)
127227
a Adjust the panel gaps with the front door.
42A-5
http://vnx.su

42A
127226
127224
a Adjust the panel gaps with the front door and the sill
panel.
a Remove the windscreen lower trim piece (see Scuttle panel grille: Removal - Refitting)
a Adjust the clearances with the door and A-pillar
II - ADJUSTMENT WITH BONNET
a Refit the windscreen lower trim piece.
a
Note:
Adjust the front wing with bonnet during reinstallation of the front wing upper mounting support.
III - ADJUSTMENT WITH THE BUMPER AND

HEADLIGHT
a Remove:
42A-6
http://vnx.su

127225
a Adjust the shut lines with the front bumper and the
headlight.
a Refit:
liner: Removal - Refitting)
- the front bumper (see Front bumper: Removal Refitting)
42A-7
http://vnx.su
42A

Front: General description
42A

Note:
110082
A special feature of this part is that it is made out of

composite materials; it cannot be repaired and is bolted onto the vehicle.
This part is attached to the ends of the front side member and cannot be adjusted.
42A-8
http://vnx.su

Front: Removal - Refitting
REMOVAL
REFITTING
I - REFITTING
42A
a Refit the front end panel.
a Remove:
- the radiator grille,
a Refit the bonnet lock (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).
a Connect:
- the various connectors,
- the windscreen washer fluid pipe.
- the front impact cross member (see 41A, Front

lower structure, Front impact cross member:
a Refit:
a Disconnect:
- the front impact cross member (see 41A, Front

lower structure, Front impact cross member:
- the windscreen washer fluid pipe,
- the various connectors.

a Remove the bonnet lock (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mechanisms).
- the radiator grille.
II - REMOVAL
127228
a Remove:
- the bolts (4) ,
- the front of the vehicle.
42A-9
http://vnx.su

Scuttle side panel: General description
42A

REPLACEMENT
Note:
Note:
110638
Cutting line (1) shows the area in which it is possible to

make a cut.
hollow section.
REPLACEMENT
WARNING
112703
The special feature of this part it that it concurrently

serves two functions:
(see MR 400).
- scuttle side panel,

- A-pillar lining.
42A-10
http://vnx.su

Scuttle side panel: General description
110639
Line (5) on the diagram shows partial replacement and

a weld by joggling with plug welds at regular intervals.
Depending on the exact position of the cut, EGW butt
welding may also be used.
42A-11
http://vnx.su
42A

No.
Description
Type
Thickness
(mm)
(1)
Dashboard
mounting interior
unit
HEL
2.5
(2)
A-pillar lining
HEL
(3)
A-pillar lining side

reinforcement
Mild
steel
0.77
(4)
Exterior unit rear

reinforcement
Very
high
yield
strengt
h
(5)
Left-hand exterior unit (commercial vehicle)
Very
high
yield
strengt
h
1.8
(6)
Left-hand exterior unit
Very
high
yield
strengt
h
1.8
(7)
A-pillar impact
upper reinforcement
(8)
A-pillar impact
lower reinforcement
HEL
1.2
127264

- front section replacement,
127526
42A-12
42A
http://vnx.su

42A
Detailed view A
II - PART FITTED
1 - Front section replacement
130524
130522
Cut
130525
130523
Note:
see MR 400.
42A-13
http://vnx.su

EARTHS
126960
WARNING
42A-14
http://vnx.su
42A

Scuttle side panel upper reinforcement: General description
Note:
Note:
112704
This type of part secures the front panel and the front
wing upper mounting support.
42A-15
http://vnx.su
42A

Scuttle side panel upper reinforcement: Description
42A
No.
Description
Type
Thickness
(mm)
(1)
Front wing support front mounting

reinforcement
HEL
1.2
(2)
Bonnet hinge
HEL
2.5
(3)
Scuttle
side
panel upper reinforcement
HEL
1.2
II - PART FITTED
127267

130529
Note:
see MR 400.
128388
42A-16
http://vnx.su

Scuttle side panel upper reinforcement: Description
EARTHS
126960
WARNING
42A-17
http://vnx.su
42A

Front wheel arch: General description
42A
Right-hand side
IMPORTANT
Note:
Note:
110634
Two wheel arches are available, depending on the vehicle engine type:
- with windscreen wiper mechanism mounting (1) ,

- with engine tie-rod attachment.

Left side
110635
This is a basic part; it serves only as the front wheel

arch.
42A-18
http://vnx.su

No.
Description
Type
Thickness
(mm)
(1)
Windscreen
aperture lower
cross member
side angle bracket
Mild
steel
1.2
(2)
Shock absorber
cup reinforcement
Very
high
yield
strengt
h
(3)
Shock absorber
cup
HEL
(4)
Shock absorber
cup reinforcement
Very
high
yield
strengt
h
(5)
Shock absorber
cup height adjuster
Mild
steel
1.12
(6)
Air filter mounting support
Mild
steel
1.2
127266

IMPORTANT
42A

II - PART FITTED
130528
130527
42A-19
http://vnx.su

Note:
42A
WARNING

see MR 400.


EARTHS
Left-hand side
126960
Right-hand side
126961
42A-20
http://vnx.su

Windscreen aperture lower cross member: General description
42A
Note:
Note:
104570
This is a basic part; it serves only as the windscreen

aperture lower cross member.
Its replacement allows access to the interior of the
aperture cross member for straightening.
It can be replaced partially from the left-hand side (1) .
102674
42A-21
http://vnx.su

Windscreen aperture lower cross member: Description
42A
II - PART FITTED
127269
130530

Note:
No.
Description
Type
Thickness
(mm)
(1)
Windscreen
aperture lower
cross member
Mild
steel
0.75

see MR 400.
42A-22
http://vnx.su

Dashboard cross member: Removal - Refitting
REMOVAL

Car. 1765
42A
Bolt for repositioning the play

compensation bushes of the
dashboard cross member
Essential equipment

diagnostic tool
a Remove:
Tightening torquesm
centring nut of the dashboard cross member
6 N.m
dashboard cross member side bolts
8 N.m
dashboard cross member bolts
21 N.m
dashboard cross member tie-rod bolt8
N.m
- the front side doors (see 47A, Side opening elements, Front side door: Removal - Refitting,
page 47A-1) (47A, Side opening elements),
- the dashboard (see Dashboard: Removal - Refitting) (57A, Interior equipment),
- the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit).
a Partially remove:
- the steering column (see Steering column: Removal - Refitting) (36A, Steering assembly),
- the dashboard wiring (see Dashboard wiring harness: Removal - Refitting) (88A, Wiring).
IMPORTANT
IMPORTANT
IMPORTANT
128641
a Remove:
- the bolts (1) ,
- the dashboard flange (2) .
a Unclip the passenger compartment fuse box.
42A-23
http://vnx.su

42A

CONCERNED
128640
a Remove the distribution unit bolts (3) .
128642
128639
a Remove:
- the dashboard cross member tie-rod bolts (4) ,
- the bolts (5) from the dashboard cross member,
- the blanking covers (6) .
42A-24
http://vnx.su

42A
a Refit:
- the passenger compartment fuse and relay box (2)
,
- the dashboard flange.
a Refit:
- the dashboard wiring (see Dashboard wiring harness: Removal - Refitting) (88A, Wiring),
- the steering column (see Steering column: Removal - Refitting) (36A, Steering assembly),
- the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit),
- the dashboard (see Dashboard: Removal - Refitting) (57A, Interior equipment),
128638
a Remove the side bolt (7) from the dashboard cross

member.
a Loosen the centring nut of the dashboard cross
member using the tool (Car. 1765).
- the front side doors (see 47A, Side opening elements, Front side door: Removal - Refitting,
page 47A-1) (47A, Side opening elements).
a Remove:
- the dashboard cross member side bolt (8) ,
- the dashboard cross member (this operation requires two people).
REFITTING
CONCERNED
a Refit the dashboard cross member (this operation
requires two people).
a Tighten to torque:
- the centring nut of the dashboard cross member (6 N.m) using the tool (Car. 1765),
- the dashboard cross member side bolts (8 N.m)
(7) and (8) ,
- the dashboard cross member bolts (21 N.m) (5)
,
- the dashboard cross member tie-rod bolt8
(N.m) (4) ,
a Refit the blanking covers (6) .
42A-25
http://vnx.su

43A
When replacing this component, also order the exterior

and interior A-pillar inserts (see 40A, General information, Hollow body parts inserts: List and location of components, page 40A-9) .
- upper section replacement,
- lower section replacement.
127272
No.
Description
Type
Thickness
(mm)
(1)
A-pillar
Mild
steel
0.75
Upper section replacement
126992
43A-1
http://vnx.su

43A
Cut
126993
Detailed view A
Detailed view B
126994
126995
This cut allows replacement of the A-pillar lining reinforcement (see 43A, Side upper structure, A-pillar
lining stiffener: Description, page 43A-8)
43A-2
http://vnx.su

43A
Lower section replacement
126996
43A-3
http://vnx.su

43A
Cut
126997
Note:
43A-4
http://vnx.su

A-pillar reinforcement: Description
43A
No.
Description
Type
Thickness
(mm)
(1)
HLE
1.2
(2)
Upper hinge reinforcement
VHEL
(3)
Lower hinge reinforcement
VHEL
127274
When replacing this part, also order the A-pillar reinforcement insert and the A-pillar lining insert (see 40A,
General information, Hollow body parts inserts:
List and location of components, page 40A-9) .
- lower section replacement,
127056
127055
43A-5
http://vnx.su

A-pillar reinforcement: Description
Cut A
127057
This cut allows complete replacement of the sill panel

reinforcement (see 41C, Side lower structure, Sill
panel reinforcement: Description, page 41C-24)
127054
Note:
43A-6
http://vnx.su
43A

Windscreen pillar lining: Description
43A
128607

126987
No.
Description
Type
Thickness
(mm)
(1)
Windscreen pillar
lining
HEL
0.8
Detailed view A
126988
Note:
see MR 400.
43A-7
http://vnx.su

A-pillar lining stiffener: Description
43A
127273

126989
No.
Description
Type
Thickness
(mm)
(1)
Windscreen pillar
lining reinforcement
HLE
Detailed view A
126990
This operation supplements the replacement of the Apillar upper section (see 43A, Side upper structure,
A-pillar: Description, page 43A-1)
Note:
43A-8
http://vnx.su

43A
- Complete replacement
- partial replacement of the lower section.
141249
141250
43A-9
http://vnx.su

43A
No.
(1)
Description
Thickness
(mm)
Mild
steel
0.75
Upper
runner
Mild
steel
(3)
Upper
runner
Mild
steel
(4)
Upper runner unit

upper section
Mild
steel
0.75
(2)
B-pillar
Type
No.
Description
Type
Thickness
(mm)
(5)
Upper runner unit

lower section
Mild
steel
0.75
(6)
Lower runner unit

upper section
Mild
steel
0.75
(7)
Lower runner unit

upper section
Mild
steel
0.75
(8)
Lowe r
runner
stop mounting
reinforcement
Mild
steel
127014
43A-10
http://vnx.su

43A
Cut
127015
Detailed view A
Detailed view B
127016
43A-11
http://vnx.su
127017

43A
Detailed view C
Detailed view A and D: Welding
127004
Detailed view D
127007
43A-12
http://vnx.su
127024

43A
Partial replacement of the lower section
127019
43A-13
http://vnx.su

43A
Cut
127020
Detailed view E
Note:
For a detailed description of the welded connections (see MR 400).
EARTHS
WARNING
127012
Locate the earths located near to the weld area (see

40A, General information, Earths on the body: List
and location of components, page 40A-12) .
43A-14
http://vnx.su

B-pillar reinforcement: General description
Note:
43A
WARNING
If there are other issues regarding access to mating faces, the various options are described in the basic instructions for structural bodywork repair (see MR 400).
Note:
101971
Line (2) on the drawing shows a butt weld by continuous EGW welding.
110565
This is a basic part, its only function is that of a B-pillar

reinforcement.

REPLACEMENT

REPLACEMENT
43A-15
http://vnx.su

B-pillar reinforcement: Description
No.
Description
Type
Thickness
(mm)
(1)
B-pillar reinforcement
VHEL
1.8
(2)
B-pillar centre
reinforcement
VHEL
1.5
(3)
Collapsible
mounting pad of
door striker panel
HLE
2.5
127275
There are three options for replacing this part:

- Partial replacement of the lower section.
- Partial replacement of the lower end
- Complete replacement
127059
43A-16
43A
http://vnx.su

43A
127060
Cut
Detailed view A
127061
43A-17
http://vnx.su
127062

Replacement of the lower end
43A
Detailed view B
127063
127508
This cut allows replacement of the sill panel reinforcement (see 41C, Side lower structure, Sill panel reinforcement: Description, page 41C-24)
Cut
127509
43A-18
http://vnx.su

43A
127058
Note:
43A-19
http://vnx.su

Body side: General description
43A
L SIDE SCREEN+FIXED WINDOW or L SIDE

SCREEN+OPENING WINDOW, and R SIDE
SCREEN+FIXED WINDOW or R SIDE
SCREEN+OPENING WINDOW
Note:
Note:
For a detailed description of a particular connection (see MR 400).
The three parts must be welded at the joint (1) and (2)
or (1) and (3) and butt welded by continuous EGW welding.
141322
127272
43A-20
http://vnx.su

Body side: General description
LEFT SLIDING + FIXED WINDOW or LEFT SLIDING + OPENING WINDOW, and RIGHT SLIDING
+ FIXED WINDOW or R SLID+OPENING WINDOW
141324
(see MR 400).
WARNING
The body side is achieved by welding the rear wing and
the body side front section.
43A-21
http://vnx.su
43A

43A
Note:
POSITIONING OF LOCAL ELECTRICAL EARTHS
127271
126963
127272
If replacing the complete body side, order a rear side

panel (1) and an A-pillar (2) .
For details of the procedures, (see 43A, Side upper
structure, A-pillar: Description, page 43A-1) and
Description, page 44A-2) .
126964
The parts supplied are long enough to cover and be

butt welded.
Order also the A-pillar reinforcement insert and the Apillar lining insert (see 40A, General information, Hollow body parts inserts: List and location of components, page 40A-9) .
43A-22
http://vnx.su

WARNING
43A-23
http://vnx.su
43A

Rear side panel: General description
44A
Several replacement options are possible (see 44A,

Rear upper structure, Rear section of rear side panel: Description, page 44A-28) .
Note:
L SIDE PANEL or L SIDE SCREEN+FIXED WINDOW or L SIDE SCREEN+OPENING WINDOW,

and R SIDE PANEL or R SIDE SCREEN+FIXED
WINDOW or R SIDE SCREEN+OPENING WINDOW
Note:
For a detailed description of a particular connection (see MR 400).
L SLIDING PANEL or LEFT SLIDING + FIXED
WINDOW or LEFT SLIDING + OPENING WINDOW, and R SLIDING PANEL or RIGHT SLIDING
+ FIXED WINDOW or R SLID+OPENING WINDOW
141322
This part has the following specifications:

- The body side is welded underneath the roof,
- It varies between panel and glazed versions.
- To make up the complete body side, order the rear
side panel lower section and the rear side panel upper section which can be butt welded due to a 100
mm coverage of the two parts. (see 43A, Side upper
structure, Body side: General description, page
43A-20)
141324
Several replacement options are possible: (see 44A,

Rear upper structure, Rear side panel: Description,
page 44A-2) .
This part has the following specifications:

- The body side is welded underneath the roof,
- It varies between panel and glazed versions.
- To make up the complete body side, order the B-pillar
and the rear side panel rear section which can be butt
welded due to a 100 mm coverage of the two parts.
(see 43A, Side upper structure, Body side: General description, page 43A-20)
44A-1
http://vnx.su

44A
- complete replacement with roof.
In both cases, order parts (1) + (2) and solder them together.
141324

- complete replacement without roof,
141247
44A-2
http://vnx.su

44A
No.
Description
Type
Thickness
(mm)
(1)
Rear side panel
Mild
steel
0.75
(2)
B-pillar
Mild
steel
0.75
(3)
Upper
runner
Mild
steel
(4)
Upper runner unit

upper section
Mild
steel
0.75
(5)
Upper runner unit

lower section
Mild
steel
0.75
(6)
Lower runner unit

upper section
Mild
steel
0.75
(7)
Lower runner unit

upper section
Mild
steel
0.75
(8)
Lowe r
runner
stop mounting
reinforcement
Mild
steel
(9)
Striker plate reinforcement
HLE
1.2
(10)
Central
unit
runner
Mild
steel
1.5
(11)
Central runner
unit upper closure panel
Mild
steel
0.75
(12)
Central runner
unit lower closure panel
Mild
steel
0.75
44A-3
http://vnx.su

44A
Complete replacement without roof
141283
44A-4
http://vnx.su

44A
Cut
127000
Detailed view A
Detailed view B
127001
44A-5
http://vnx.su
127004

44A
Complete replacement with roof
141284
44A-6
http://vnx.su

44A
Cut
127006
Detailed view C
Detailed view C: Welding
127008
44A-7
http://vnx.su
127009

44A
Note:
EARTHS
WARNING
44A-8
http://vnx.su

44A
L SIDE PANEL, and R SIDE PANEL

141462
141322

- upper section replacement,
- lower section replacement,
- complete replacement without roof,
- complete replacement with roof.
For both complete replacement operations on glazed
versions, order parts (1) + (2) and solder them together.
44A-9
http://vnx.su

44A
127066
No.
Description
Type
Thickness
(mm)
(1)
Rear side panel
Mild
steel
0.75
(2)
Fuel filler flap

striker plate reinforcement
HLE
1.2
44A-10
http://vnx.su

44A
141293
No.
Description
Type
Thickness
(mm)
(1)
Rear side panel
Mild
steel
0.75
(2)
Fuel filler flap

HLE
1.2
44A-11
http://vnx.su

44A
Replacement of the upper section
127044
44A-12
http://vnx.su

44A
Cut
127045
Detailed view A
Detailed view B
127046
44A-13
http://vnx.su
127047

44A
Detailed view C
Detailed view D
127048
127037
127049
44A-14
http://vnx.su

44A
Cut
127050
Detailed view E
Detailed view F
127038
44A-15
http://vnx.su
127051

44A
Detailed view G
127052
Detailed view H
127053
44A-16
http://vnx.su

44A

Complete replacement without roof
141295
44A-17
http://vnx.su

44A
141292
44A-18
http://vnx.su

44A
Cut
127036
44A-19
http://vnx.su

44A

Complete replacement with roof
141294
44A-20
http://vnx.su

44A
141291
44A-21
http://vnx.su

44A
Cut
127040
Detailed view I
Detailed view I: Welding
127042
44A-22
http://vnx.su
127043

44A
Note:
EARTHS
WARNING
44A-23
http://vnx.su

44A
SHORT CHASSIS
The options for replacing this part are as follows, lower
section replacement.
141460
141248
44A-24
http://vnx.su

44A
SHORT CHASSIS
II - PART FITTED
No.
Description
Type
Thickness
(mm)
(1)
Rear side panel
Mild
steel
0.75
(2)
Fuel filler flap

HLE
1.2
141287
44A-25
http://vnx.su

44A
SHORT CHASSIS
Cut
141286
Detailed view A
Detailed view B
141290
44A-26
http://vnx.su
141289

SHORT CHASSIS
Detailed view C
141288
Note:
EARTHS
WARNING
44A-27
http://vnx.su
44A

Rear section of rear side panel: Description
44A
No.
Description
Type
Thickness
(mm)
(1)
Rear side panel
Mild
steel
0.75
(2)
Central runner
unit upper closure
Mild
steel
0.75
(3)
Central
unit
runner
Mild
steel
1.5
(4)
Central runner
unit lower closure
Mild
steel
0.75
(5)
Striker plate reinforcement
HLE
1.2
141461

- Partial replacement of the lower section
141282
44A-28
http://vnx.su

44A
127021
44A-29
http://vnx.su

44A
Cut
127022
Detailed view A
Detailed view A
127026
44A-30
http://vnx.su
127023

44A
Detailed view A: Welding
Detailed view G
127024
127025
Partial replacement of the lower rear section
127027
44A-31
http://vnx.su

44A
Cut
127028
Detailed view C
Detailed view D
127029
44A-32
http://vnx.su
127018

44A
Detailed view E
127013
Note:
II - POSITIONING OF LOCAL ELECTRICAL EARTHS
WARNING
44A-33
http://vnx.su

Rear side panel rain channel: General description
Note:
Note:
127277
This is a basic part; it serves as rear side panel rain

channel and rear end pillar closure. (see 44A, Rear
upper structure, Far rear pillar: General description, page 44A-38)
It may be replaced partially in several ways according
to requirements of the impact combined with the rear
end pillar.
44A-34
http://vnx.su
44A

Rear side panel rain channel: Description
44A
No.
Description
Type
Thickness
(mm)
(1)
Rear side panel

rain channel
Mild
steel
0.8
(2)
Rear
loading
door hinge upper
stiffener
HLE
1.8
(3)
Rear
loading
door hinge lower
stiffener
HLE
1.8
127277

127069
127068
44A-35
http://vnx.su

44A
Cut
127070
127067
44A-36
http://vnx.su

Note:
44A
WARNING


EARTHS
126964
126963
Note:
Only disconnect the earths on the side corresponding to the repaired side
44A-37
http://vnx.su

Far rear pillar: General description
Note:
Note:
127280
This is a basic part; it serves as a rear end pillar and its

closure is normally referred to as the rear side panel
rain channel (see 44A, Rear upper structure, Rear
side panel rain channel: General description, page
44A-34) .
It may be replaced partially in several ways according
to the requirements of the impact combined with the
rear side panel rain channel.
44A-38
http://vnx.su
44A

44A
No.
Description
Type
Thickness
(mm)
(1)
Rear end pillar
HLE
1.5
(2)
Rear end pillar

lower reinforcement
HLE
1.5
(3)
Mobile anchoring reinforcement
HLE
1.5
Replacement of the lower section
127280

127073
127072
44A-39
http://vnx.su

44A
Cut
127074
127071
44A-40
http://vnx.su

Note:
44A
WARNING


EARTHS
126964
126963
Note:
Only disconnect the earths on the side corresponding to the repaired side
44A-41
http://vnx.su

127279
44A
No.
Description
Type
Thickness
(mm)
(1)
Inner rear wheel

arch
HLE
0.85
(2)
Rear trim lower

mounting plate
Mild
steel
0.7
(3)
Filler pipe mounting bridge piece
Mild
steel
(4)
Rear trim upper

mounting
Mild
steel
1.2
(5)
Rear seat back

left-hand upper
mounting
HLE
1.2
(6)
Inertia reel mounting reinforcement
HLE
1.8

IMPORTANT
127075
127076
44A-42
http://vnx.su

44A
Detailed view A
127077
126964
Note:
Note:
Only disconnect the earth corresponding to the side

of the vehicle being repaired.

EARTHS
WARNING
126963
44A-43
http://vnx.su

Body side rear lining: Description
44A

127276
If replacing this part, also order the B-pillar lining insert,

the rear wheel arch lining insert and the sill panel rear
reinforcement insert (see 40A, General information,
Hollow body parts inserts: List and location of
components, page 40A-9) .
127590
No.
Description
Type
Thickness
(mm)
(1)
Body side rear

lining
Mild
steel
0.7
(2)
Roof cross member mountings
Mild
steel
0.85
(3)
Upper mobile
anchoring reinforcements
Mild
steel
1.5
(4)
Fuel filler flap

reinforcement
Mild
steel
0.7
(5)
Lowe r
mobile
Mild
steel
1.5
(6)
Rear side panel

tensioner
Mild
steel
0.8
(7)
HLE
1.5

- partial replacement of the upper section
- partial replacement of lower section,
- partial replacement of lower rear section,
- partial replacement of outside wheel arch,
- partial replacement of rear section,
44A-44
http://vnx.su

44A

II - PART FITTED
Partial replacement of the upper section
127539
44A-45
http://vnx.su

44A

Cut
127540
Detailed view A
Detailed view B
127541
44A-46
http://vnx.su
127542

44A

127543
44A-47
http://vnx.su

44A

Cut
127544
Detailed view C
Detailed view D
127562
44A-48
http://vnx.su
127563

44A

Partial replacement of lower rear section
Detailed view E
127558
Cut
127560
Detailed view E: Welding
127559
44A-49
http://vnx.su
127564

44A

Detailed view F
Cut
127561
Partial replacement of outside wheel arch
127565
Detailed view G: Welding
127545
44A-50
http://vnx.su
127546

44A

127537
44A-51
http://vnx.su

44A

Cut
127538
44A-52
http://vnx.su

44A

127534
Detailed view H
Detailed view I
127535
44A-53
http://vnx.su
127536

44A

EARTHS
WARNING
126964
126963
Note:
Only disconnect the earth on the repaired side of
the vehicle.
44A-54
http://vnx.su

44A
L SLIDING PANEL, and R SLIDING PANEL
No.
Description
Type
Thickness
(mm)
(1)
Body side rear

lining
Mild
steel
0.7
(2)
Roof cross member mountings
Mild
steel
0.85
(3)
Upper mobile
Mild
steel
1.5
(4)
Front seat belt

reinforcement
HLE
1.5
(5)
Lowe r
mobile
anchoring reinforcement
Mild
steel
1.5
(6)
C-pillar lower
connecting bracket
Mild
steel
(7)
HLE
1.5
127276
If replacing this part, also order the B-pillar lining insert,

the rear wheel arch lining insert and the sill panel rear
reinforcement insert (see 40A, General information,
Hollow body parts inserts: List and location of
components, page 40A-9) .
- partial replacement of the central section,
- partial replacement of lower rear section.
127547
44A-55
http://vnx.su

44A

II - PART FITTED
Central section replacement
127548
44A-56
http://vnx.su

44A

Cut
127549
Detailed view A
Detailed view B: Welding
127550
44A-57
http://vnx.su
127551

44A

Partial replacement of lower rear section
127552
44A-58
http://vnx.su

44A

Cut
127553
Detailed view C
Detailed view C: Welding
127554
44A-59
http://vnx.su
127557

44A

Detailed view D

EARTHS
127555
126964
Detailed view E
127556
126963
Note:
Only disconnect the earth on the repaired side of
the vehicle.
44A-60
http://vnx.su

WARNING
44A-61
http://vnx.su
44A

Rear end panel: Description
44A
Note:
127278

No.
Description
Type
Thickness
(mm)
(1)
Rear end panel
HLE
1.2
127078
44A-62
http://vnx.su
TOP OF BODY
Roof: General description
Note:
Note:
127283
This is a basic part; its only function is that of a roof.

The roof is welded onto the body sides.
(see MR 400).
45A-1
http://vnx.su
45A
TOP OF BODY
Roof: Description
45A
127283
127283
MANUAL SUNROOF
No.
Description
Type
Thickness
(mm)
(1)
Roof
Mild
steel
0.65
MANUAL SUNROOF
128608

130521
45A-2
http://vnx.su
TOP OF BODY
Roof: Description
No.
Description
Type
Thickness
(mm)
(2)
Roof front reinforcement
HEL
0.8
(3)
Rear extension of
roof centre cross
member
HEL
(4)
Roof centre cross

member
Mild
steel
0.65
45A
MANUAL SUNROOF
II - PART FITTED
130520
Bonding area
Front section
127147
127148
45A-3
http://vnx.su
TOP OF BODY
Roof: Description
Rear section
127149
Note:
For a detailed description of the special connections, see MR 400.
45A-4
http://vnx.su
45A
TOP OF BODY
Roof front section: Description
45A
K61, and STANDARD CHASSIS, and MANUAL SUNROOF

II - PART FITTED
128609

130517
No.
(1)
Description
Front section of
roof
Type
Mild
steel
Thickness
(mm)
Note:
see MR 400.
Bonding area
0.65
127148
45A-5
http://vnx.su
TOP OF BODY
Roof rear section: Description
45A
K61, and STANDARD CHASSIS, and MANUAL SUNROOF

131165

130516
No.
(1)
Description
Roof rear section
Type
Mild
steel
Thickness
(mm)
Note:
see MR 400.
Bonding area
0.65
127149
45A-6
http://vnx.su
TOP OF BODY
Roof front cross member: Description
45A
No.
Description
Type
Thickness
(mm)
(1)
Roof front cross

member
Mild
steel
0.75
(2)
Roof front cross

member closure
panel
Mild
steel
0.75
127284

127150
Note:
127151
45A-7
http://vnx.su
TOP OF BODY
Roof centre cross member: Description
45A
127285
127152

Note:
No.
Description
Type
Thickness
(mm)
(1)
Roof centre cross

member
HLE
0.8
45A-8
http://vnx.su
TOP OF BODY
Roof panel arch: Description
45A
127281
127154

Note:
No.
Description
Type
Thickness
(mm)
(1)
Roof panel arch
Mild
steel
0.8
45A-9
http://vnx.su
TOP OF BODY
Roof rear cross member: Description
127670
45A
No.
Description
Type
Thickness
(mm)
(1)
Roof rear cross

member
Mild
steel
(2)
Hinge mounting
reinforcement
HLE
1.5
(3)
Roof bar mounting reinforcement
HLE
1.5
2 180 HINGED DOORS or 2 180 HINGED DOORS

WITH WINDOW

TAILGATE WINDOW
127156
127158
45A-10
http://vnx.su
TOP OF BODY
Roof rear cross member: Description
No.
Description
Type
Thickness
(mm)
(1)
Roof rear cross

member
Mild
steel
(3)
Roof bar mounting reinforcement
HLE
1.5
(4)
Door stop
HLE
1.5
45A
2 180 HINGED DOORS or 2 180 HINGED DOORS

WITH WINDOW
TAILGATE WINDOW
127155
Note:
127157
45A-11
http://vnx.su

Front side door: Removal - Refitting
47A
There are two possible methods for this operation:

- Removal with hinges: allows the initial adjustments to
be kept,
- Removal without hinges: used when replacing the
door.
I - REMOVAL WITHOUT HINGES
1 - REMOVAL PREPARATION
a Disconnect the front side door wiring connector.
2 - REMOVAL
127287
a Remove:
- the nuts (2) ,
- the front side door (this operation requires two people).
II - REFITTING WITHOUT HINGES
1 - REFITTING
a Refit:
- the front side door (this operation requires two people),
126467
a Remove the front side door check strap bolt (1) .
- the front side door check strap bolt (1) .

a Adjust the front side door clearances and flush fittings (see 47A, Side opening elements, Front side
door: Adjustment, page 47A-6) .
2 - FINAL OPERATION
a Connect the front side door wiring connector.
47A-1
http://vnx.su

47A
2 - REMOVAL
III - REMOVAL WITH HINGES

a Disconnect the front side door wiring connector.
a Remove:
- the headlight (see Front headlight: Removal Refitting) (80B, Headlights),
- the front wing (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) .
127286
a Remove:
- the bolts (4) ,
- the front side door (this operation requires two people).
IV - REFITTING WITH HINGES
1 - REFITTING
a Refit:
- the front side door (this operation requires two people),
- the front side door check strap bolt (3) .
126467
a Remove the front side door check strap bolt (3) .
a Adjust the front side door clearances and flush fittings (see 47A, Side opening elements, Front side
door: Adjustment, page 47A-6) .
47A-2
http://vnx.su

2 - FINAL OPERATION
a Remove:
- the front wing (see 42A, Front upper structure,
Front wing: Removal - Refitting, page 42A-3) ,
- the headlight (see Front headlight: Removal Refitting) (80B, Headlights),
47A-3
http://vnx.su
47A

Front side door: Stripping - Restoring
47A
- the front side door protective strip (see Front side

door moulding: Removal - Refitting) (55A, Exterior protection),
Note:
- the front side door check strap.
The order of the operations described below is specific to the front side door replacement.
The following procedure applies to the front side
door on the vehicle.
REASSEMBLING
REFITTING
a Refit:
STRIPPING
- the front side door check strap,

DISMANTLING
- the front side door protective strip (see Front side

door moulding: Removal - Refitting) (55A, Exterior protection),
a Remove:
- the door mirror (see Door mirror: Removal - Refitting) (56A, Exterior equipment),
trim),
- the speaker (see Front speakers: Removal - Refitting) (86A, Radio),
- the front side door sealing film (see Door sealing
film: Removal - Refitting) (65A, Door sealing),
- the driver's front side door wiring (see Driver's

front side door wiring: Removal - Refitting) or
the passenger's front side door wiring (see Passenger's front side door wiring: Removal - Refitting) (88A, Wiring),
- the front side door lock (see Front side door lock:
mechanisms),
- the front side exterior door handle (see Door exterior handle: Removal - Refitting) (51A, Side opening element mechanisms),
- the front side door electric window mechanism (see
Front side door electric window mechanism:
Removal - Refitting) or the front side door manual
- the front side door glass run channel (see Front

side door glass run channel: Removal - Refitting) (66A, Window sealing),
- the front side door sliding window (see Sliding
window in front side door: Removal - Refitting)
(54A, Windows),
- the front side door electric window mechanism (see
Front side door electric window mechanism:
Removal - Refitting) or the front side door manual
window mechanism (see Front side door manual
window winder mechanism: Removal - Refitting) (51A, Side opening element mechanism),
- the front side exterior door handle (see Door exterior handle: Removal - Refitting) (51A, Side opening element mechanisms),
- the front side door lock (see Front side door lock:
mechanisms),
- the driver's front side door wiring (see Driver's
front side door wiring: Removal - Refitting) or
the passenger's front side door wiring (see Passenger's front side door wiring: Removal - Refitting) (88A, Wiring).
47A-4
http://vnx.su

Front side door: Stripping - Restoring
window mechanism (see Front side door manual
window winder mechanism: Removal - Refitting) (51A, Side opening element mechanism),
a Refit:
- the front side door sliding window (see Sliding
window in front side door: Removal - Refitting)
(54A, Windows)
- the front side door glass run channel (see Front
side door glass run channel: Removal - Refitting) (66A, Window sealing),
door side exterior weather strip: Removal - Refitting) (66A, Window sealing).
a Refit:
- a new front side door sealing film (see Door sealing film: Removal - Refitting) (65A, Opening elements sealing),
- the speaker (see Front speakers: Removal - Refitting) (86A, Radio),
0653A).
a Refit:
trim),
- the door mirror (see Door mirror: Removal - Refitting) (56A, Exterior equipment).
47A-5
http://vnx.su
47A

47A
ADJUSTMENT VALUES
a For information on the front side door adjustment values, (see Vehicle clearances: Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are three options for adjusting the door:
- by means of the mountings on the door box section
(opening clearance adjustment),
- by means of the mountings on the A-pillar (panel
gaps adjustment); this operation requires the removal of the front wing,
- the striker panel.
109496
a
Note:
Symbols A, B, C, D represent the adjustment
options.
The black dot in the centre represents the body
of the bolt.
adjusted.
The white section represents the adjustment
area.
127160
a Observe the adjustment sequence: (1) , (2) , (3) , (4)

, (5) .
47A-6
http://vnx.su

47A
ADJUSTMENT OF THE FLUSH FITTING WITH THE

FRONT WING AND THE REAR DOOR OR THE
REAR SIDE PANEL (DEPENDING ON VERSION)
127288
a Undo the front side door hinge bolts.

127289
a Adjust the rear side door clearances.

a Tighten the front side door hinge bolts.
a Undo the front side door box section nuts.

a Adjust the clearances and the flush fittings with the
front wing.
a Tighten the front side door box section nuts.
127290
a Undo the front side door striker plate bolts.

a Adjust the flush fitting with the rear door or the rear
side panel (depending on version).
a Tighten the front side door striker plate bolts.
47A-7
http://vnx.su

Rear side door: Removal - Refitting
47A
Two removal options:

- Removal with slides: allows the initial adjustments to
be kept
- Removal without slides: used to replace the door.
127448
a Remove:
- the bolts (1) ,
20625
- the intermediate runner trim (2) .
This operation can be carried out by one person using

the DOOR SUPPORT tool. Otherwise this work requires two people.
Number of Renault agreement: 661000
Supplier: Z INTERNATIONAL
Part no.: SUP 01
I - REMOVAL WITH THE SLIDES
K61
a Remove the rear wing light (see Rear light on wing:
127450
a Remove:
- the bolt (3)
- the intermediate runner stop (4) .
47A-8
http://vnx.su

47A
2 - REMOVAL
127429
a Remove the upper runner stop (5) .
127291
a Remove the rear side door by moving the upper runner roller aside. (This operation requires two people).
II - REFITTING WITH THE SLIDES
1 - REFITTING
a Refit the rear side door (If a door support tool is not
used this operation requires two people).
2 - FINAL OPERATION
a Refit:
- the lower runner stop (7) ,
- the bolts (6) ,
- the upper runner stop (5) ,
- the intermediate runner stop (4) ,
127292
a Remove:
- bolt (3) .
- the bolts (6) ,

K61
- the lower runner stop (7) .
a Refit:
- the intermediate runner trim (2) ,
- the bolts (1) .
47A-9
http://vnx.su

47A
III - REMOVAL WITHOUT THE SLIDES

REMOVAL
127294
127296
127293
a Remove the bolts (9) and (10) .
47A-10
http://vnx.su

127295
a Remove:
- the bolts (11)
- the rear side door (this operation requires two people).
IV - REFITTING WITHOUT THE SLIDES
1 - REFITTING
a Refit:
- the rear side door,
- bolts (11) , (10) , (9) and (8) .
2 - FINAL OPERATION
47A-11
http://vnx.su
47A

Rear side door: Stripping - Restoring
47A
- the sliding side door wiring (see Rear right-hand

side door wiring: Removal - Refitting) or (see
Rear left-hand side door wiring: Removal - Refitting) (88A, Wiring),
Note:
The order of the operations described below
applies specifically to replacing the rear side door.
- the centring guides of the sliding side door.
The following procedure applies to the rear side

door on the vehicle.
REASSEMBLING
REBUILDING
STRIPPING
a Refit:
DISMANTLING
- the centring guides of the sliding side door,
a Remove:
- the sliding side door wiring (see Rear right-hand

side door wiring: Removal - Refitting) or (see
Rear left-hand side door wiring: Removal - Refitting) (88A, Wiring),
- the rear side door seals,

- the rear side door trim (see Sliding side door
- the sliding side door lock (see Sliding side door

lock: Removal - Refitting) (51A, Side opening
element mechanisms),
- the sliding side door exterior handle (see Sliding

side door opening controls: Removal - Refitting) (51A, Side opening element mechanisms),

- the grab handle (see Grab handle: Removal - Refitting) (57A, Interior accessories),
- the rear side door electric window winder mechanism (see Rear side door electric window mechanism: Removal - Refitting) (51A, Side
opening element mechanisms) (depending on
equipment level),
- the window seal of the sliding side door (see Sliding side door window seal: Removal - Refitting) (66A, Window sealing),
- the sliding window of the rear side door (see Sliding window in rear side door: Removal - Refitting) (54A, Windows) (depending on equipment
level),
- the fixed window of the rear side door (see Rear

side door fixed window: Removal - Refitting)
(54A, Windows) (depending on equipment level),
- the sliding side door window (see Sliding side

door window: Removal - Refitting) (54A, Windows) (depending on equipment level),
- the sliding side door window (see Sliding side

door window: Removal - Refitting) (54A, Windows) (depending on equipment level),
- the fixed window of the rear side door (see Rear

(54A, Windows) (depending on equipment level),
- the sliding window of the rear side door (see Sliding window in rear side door: Removal - Refitting) (54A, Windows) (depending on equipment
level),
- the rear side door electric window winder mechanism (see Rear side door electric window mechanism: Removal - Refitting) (51A, side
opening element mechanism),
- the window seal of the sliding side door (see Sliding side door window seal: Removal - Refitting) (66A, Window sealing),

- the grab handle (see Grab handle: Removal - Refitting) (57A, Interior accessories),
- the sliding side door exterior handle (see Sliding
side door opening controls: Removal - Refitting) (51A, Side opening element mechanisms),
- the sliding side door lock (see Sliding side door
lock: Removal - Refitting) (51A, Side opening
element mechanisms),

0653A).
47A-12
http://vnx.su

Rear side door: Stripping - Restoring
a Refit:
- the rear side door trim (see Sliding side door
- the rear side door seals.
47A-13
http://vnx.su
47A

47A
ADJUSTMENT VALUES
a For information on the rear side door adjustment values (see Vehicle clearances: Adjustment values)
(01C, Vehicle bodywork specifications).
ADJUSTMENT
a There are three options for adjusting the rear side
door:
- using the rear side door mountings,
- using the centring devices,
- the striker panel.
109496
a
Note:
Symbols A, B, C and D show the adjustment
options.
of the bolt.
adjusted.
area.
127160
a Observe the adjustment sequence (1) , (2) , (3) , (4) .
I - ADJUSTING THE REAR SIDE DOOR FLUSH

FITTING WITH THE FRONT DOOR
a
Note:
The adjustment is done first on the upper centring device and then on the lower centring
device following the same process.
Note:
It is not possible to adjust the female centring
devices on the door.
Note:
The centring devices must interlock completely
(auto centring), as exterior touching could cause
the door to come out of position.
47A-14
http://vnx.su

127300
a Undo the centring device bolts.

a Adjust the rear side door flush fitting with the front
side door.
a Tighten the centring device bolts.
II - FLUSH FITTING THE REAR SIDE DOOR WITH
THE REAR SIDE PANEL
127299
a Undo the striker plate bolts.

a Adjust the rear side door flush fitting with the rear
side panel.
a Tighten the striker plate bolts.
47A-15
http://vnx.su
47A

47A
III - ADJUSTING THE REAR SIDE DOOR PANEL

GAPS
127297
127295
127298
127296
a Undo the sliding side door mountings.

a Adjust the flush fitting.
a Tighten the sliding side door mountings.
47A-16
http://vnx.su

48A
This operation can be carried out in two ways:
2 - FINAL OPERATION
- Removal without the hinges: used for replacing the

bonnet
a Clip on the windscreen washer jet pipe.
- Removal with the hinges: allows the initial adjustments to be kept and avoids the original paintwork
from coming off between the hinge and the bonnet
lining.
a Connect the windscreen washer jet pipe.

III - REMOVE WITH BONNET HINGES
1 - PREPARATION FOR REMOVAL
I - REMOVE WITHOUT THE BONNET HINGES

a Remove:
a Disconnect the windscreen washer jet pipe.

a Unclip the windscreen washer jet pipe.

2 - REMOVAL
- the headlights (see Front headlight: Removal Refitting) (MR 417, 80B, Headlights),
- the front wings (see 42A, Front upper structure,
a Disconnect the windscreen washer jet pipe.
a Unclip the windscreen washer jet pipe.
2 - REMOVAL
127306
a Remove:
- the nuts (1) ,
- the bonnet. This operation requires two people.
II - REFIT WITHOUT BONNET HINGES
1 - REFITTING
127305
a Refit the bonnet. This operation requires two people.
a Remove:
a Adjust the opening clearances and flush fitting (see

48A, Non-side opening elements, Bonnet: Adjustment, page 48A-4) .
48A-1
- the bolts (2) ,

- the bonnet. This operation requires two people.
http://vnx.su

IV - REFIT WITH BONNET HINGES
1 - REFITTING
a Refit the bonnet. This operation requires two people.
a Adjust the clearance and for flush fitting (see 48A,
Non-side opening elements, Bonnet: Adjustment, page 48A-4)
2 - FINAL OPERATION
a Clip on the windscreen washer jet pipe.
a Connect the windscreen washer jet pipe.
a Refit:
48A-2
http://vnx.su
48A

Bonnet: Stripping - Rebuilding
Note:
Described below is a special sequence of operations for bonnet replacement.
The procedure described below applies to the bonnet on the vehicle.
STRIPPING
a Remove the bonnet soundproofing (see Bonnet

soundproofing: Removal - Refitting) (68A, Soundproofing).
a Unclip:
- the windscreen washer jet pipe,
- the windscreen washer jets.
a Remove the different blanking covers from the bonnet.
REASSEMBLING
a Refit the different blanking covers on the bonnet.

a Clip:
- the windscreen washer jets,
- the windscreen washer jet pipe.
a Refit the bonnet soundproofing (see Bonnet soundproofing: Removal - Refitting) (68A, Soundproofing).
48A-3
http://vnx.su
48A

Bonnet: Adjustment
48A
Tightening torquesm
bonnet catch bolts
21 N.m
ADJUSTMENT VALUES
a For information on the bonnet adjustment values,
(see Vehicle clearances: Adjustment values)
ADJUSTMENT
a There are two options for adjusting the bonnet:
- Flat adjustment using the bonnet hinge bolts in
areas (1) and (2) . This operation requires the removal of the front wing (see 42A, Front upper
structure, Front wing: Removal - Refitting, page
42A-3) ,
109496
a Symbols A, B, C and D show the adjustment options.

the bolt.
- Height adjustment using the lock mountings for the

front part of the bonnet, zone (3) and the bonnet
closure mountings.

adjusted.
Note:
It is not possible to adjust the height of the rear
section of the bonnet.
I - ADJUSTMENT USING THE BONNET NUTS

ADJUSTMENT PREPARATION STAGE
a Remove the bonnet (see 48A, Non-side opening
elements, Bonnet: Removal - Refitting, page
48A-1) .
127159
a Observe the adjustment sequence (1) , (2) , (3) .
48A-4
http://vnx.su

Bonnet: Adjustment
48A
128485
127306
a Carry out a countersinking procedure at (4) .

Note:
During factory fitting, the hinges are mounted
with no possibility of adjustment (A), it is necessary to countersink holes to make adjustments
(B).
WARNING
a Refit the bonnet (see 48A, Non-side opening elements, Bonnet: Removal - Refitting, page 48A-1)
.
a Adjust the panel gaps and flush fittings on the bonnet.
a Tighten the bonnet nuts.
a Carry out the anti-corrosion protection operations
(see Anti-corrosion protection products after assembly: Use) (04E, Paint).
II - ADJUSTMENT USING THE BONNET HINGE
BOLTS ON THE BODY
1 - ADJUSTMENT PREPARATION STAGE
a Raise the vehicle (see Vehicle: Towing and lifting)
(02A, Lifting equipment).
a Remove:
48A-5
http://vnx.su

Bonnet: Adjustment
48A
III - ADJUSTMENT USING THE BONNET CATCH
2 - ADJUSTMENT
127308
a Undo the bonnet hinge bolts.

a Refit the front wings (see 42A, Front upper structure, Front wing: Removal - Refitting, page 42A-3) .
a Adjust the bonnet panel gaps.
a Remove the front wings (see 42A, Front upper
structure, Front wing: Removal - Refitting, page
42A-3) .
126886
a Undo the bonnet catch bolts.

a Adjust the bonnet flush fitting with the headlights and
the radiator grille.
a Torque tighten the bonnet catch bolts (21 N.m).
a Tighten the bonnet hinge bolts.

3 - FINAL OPERATION
a Refit:
48A-6
http://vnx.su

48A
2 - REMOVAL

- Removal without hinges: used for replacing the tailgate
be kept.
I - REMOVAL WITHOUT THE HINGES
a Disconnect the following connectors :
- the rear screen wiper motor,
- the tailgate lock,
- for the boot lid opening control,
- the heated rear screen,
127309
- the number plate light,
a Remove:
- high level brake light.
- the tailgate bolts (1) (this operation requires two

people),
a Remove:
- the tailgate wiring,
- the tailgate (this operation requires two people).
- the tailgate washer jet tube,

- the tailgate gas struts (see Tailgate balancer: Removal - Refitting) (52A, Non-side opening element mechanisms).

1 - REFITTING
a Refit the tailgate (this operation requires two people).
a Adjust the panel gaps and flush fittings (see 48A,
Non-side opening elements, Tailgate: Adjusting,
page 48A-11) .
2 - FINAL OPERATION
a Refit:
- the tailgate wiring.
48A-7
http://vnx.su

a Connect the connectors:
48A
2 - REMOVAL
- the high level brake light,

- the rear screen wiper motor.
127310

a Remove:

- the tailgate hinge nuts (2) (this operation requires

two people),
- the tailgate (this operation requires two people).

- high level brake light.
a Remove:
1 - REFITTING

a Remove the rear section headlining (see Headlining: Removal - Refitting) (71A, Body internal
trim).
a Refit the tailgate (this operation requires two people).

Non-side opening elements, Tailgate: Adjusting,
page 48A-11) .
2 - FINAL OPERATION
a Refit:
- the tailgate wiring.
48A-8
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a Connect the connectors:
a Refit:
- the rear section headlining (see Headlining: Removal - Refitting) (71A, Body internal trim).
a Reseal the headlining rain channel around the hinge
using extruded mastic (see Anti-corrosion protection products after assembly: Use)
48A-9
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48A

Tailgate: Stripping-Rebuilding
48A

- the rear screen (see Rear screen: Removal - Refitting) (54A, Windows),
Note:
Described below is a special sequence of operations for tailgate replacement.
- the license plate light (see Number plate light:

Removal - Refitting) (81A, Rear lighting),
The procedure described below applies to the tailgate on the vehicle.
- the high level brake light (see 3rd brake light: Removal - Refitting) (81A, Rear lighting).
- the tailgate exterior opening control (see Tailgate
exterior opening control: Removal - Refitting)
(52A, Non-side opening element mechanisms),
STRIPPING
- the tailgate lock (see Tailgate lock: Removal - Refitting) (52A, Non-side opening element mechanisms),
a Remove:
- the rear screen wiper motor (see Rear screen wiper motor: Removal - Refitting) (85A, Washing Wiping),
- the tailgate lock (see Tailgate lock: Removal - Refitting) (52A, Non-side opening element mechanisms),
- the rear screen wiper motor (see Rear screen wiper motor: Removal - Refitting) (85A, Washing Wiping).
- the tailgate exterior opening control (see Tailgate

exterior opening control: Removal - Refitting)
(52A, Non-side opening element mechanisms),
- the high level brake light (see 3rd brake light: Removal - Refitting) (81A, Rear lighting),
- the number plate light (see Number plate light:
- the rear screen (see Rear screen: Removal - Refitting) (54A, Windows),
- the blanking covers,
- the rear badge (see Rear badges: Removal - Refitting) (56A, Exterior accessories).
REASSEMBLING
a Refit:
- a new rear badge (see Rear badges: Removal Refitting) (56A, Exterior accessories),
- the tailgate gas struts (see Tailgate balancer: Removal - Refitting) (52A, Non-side opening element mechanisms),
48A-10
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Tailgate: Adjusting
48A
ADJUSTMENT VALUES
a For information on the tailgate adjustment values
(see Vehicle clearances: Adjustment values)
ADJUSTMENT
a There are three options for adjusting the tailgate:
- Adjustment of areas (1) and (2) using hinge attachments,
- Adjustment of area (3) using the tailgate striker plate,
- Adjustment of the side stops (4) ,
109496
a
Note:
Symbols A, B, C and D show the adjustment
options.
of the bolt.
adjusted.
area.
127162
a Observe the adjustment sequence (1) , (2) , (3) , (4) .
48A-11
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Tailgate: Adjusting
48A
Adjustment using the hinge nuts on the tailgate
I - ADJUSTMENT OF THE CLEARANCES AND

FLUSH FITTING USING THE HINGE NUTS ON THE
BODY AND ON THE TAILGATE
Adjustment using the hinge nuts on the body
128485
a
Note:
with no possibility of adjustment (A), it is necessar y to countersink the holes to make adjustments (B).
127312
a Remove the rear section headlining (see Headlining: Removal - Refitting) (71A, Body internal
trim).
a Undo the tailgate hinge nuts.
a Adjust the panel gaps and flush fittings on the tailgate.
WARNING
a Tighten the tailgate hinge nuts.

a Refit the rear section headlining (see Headlining:
a Reseal the tailgate rain channel around the hinge
using extruded mastic (see Anti-corrosion protection products after assembly: Use) (04B, Consumables - Products).
a Remove the tailgate (see 48A, Non-side opening

elements, Tailgate: Removal - Refitting, page
48A-7) .
48A-12
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Tailgate: Adjusting
48A
II - ADJUSTMENT USING THE TAILGATE STRIKER

PLATE
127309
127314
a Undo the tailgate striker plate bolts.

a Adjust the tailgate flush fittings.
a Tighten the tailgate striker plate bolts.
III - ADJUSTMENT OF THE SIDE STOPS
127311

a Refit the tailgate (see 48A, Non-side opening elements, Tailgate: Removal - Refitting, page 48A-7)
.
a Adjust the panel gaps and flush fittings on the tailgate.
127313
a Tighten the tailgate hinge nuts.

(see Anti-corrosion protection products after assembly: Use) (04E, Paint).
48A-13
Note:
The stops (6) should be supported by the tailgate
side stops.
http://vnx.su

Rear loading door: Removal - Refitting
48A
F61 or K61, and LONG CHASSIS or STANDARD CHASSIS

- the rear loading door (this operation requires two
people).

- Removal without hinges: used for replacing the relevant door
be kept (e.g. for body replacement).

1 - Refitting
a Refit the rear loading door (this operation requires
two people).

1 - Preparation for removal
a Remove the rear left-hand loading door trim (see
Left-hand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim).
a Disconnect the connectors for (depending on equipment level):

Non-side opening elements, Rear loading door:
Adjustment, page 48A-26) .
2 - final operation
a Refit:
- the rear loading door wiring harness
- the rear screen jet pipe.
- the rear loading door lock,
a Connect the connectors of:
- the number plate light.
a Remove (depending on equipment level):
- the rear screen jet pipe,

- the rear loading door wiring.
a Fit a new trim on the rear left-hand loading door (see

2 - Removal

a Remove:
- the rear bumper extension,
(73A, Non-side opening element trim).
a Disconnect the connectors for (depending on equipment level):
127316
a Remove:

- the number plate light.
- the bolts (1) ,
48A-14
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48A

a Remove (depending on equipment level):

- the rear screen jet pipe,
a Refit:
2 - Removal
- a new trim on the rear left-hand loading door (see

- the rear bumper extension,
- the rear wing light (see Rear light on wing: Removal - Refitting) (81A, Rear lighting).
a Reseal the side rain channel around the hinges
using an extruded mastic (see Anti-corrosion protection products after assembly: Use) .
127700
a Remove:
- the bolts (2) ,
people).
1 - Refitting
two people).
2 - final operation
a Refit:
- the rear loading door wiring,
- the rear screen jet pipe.
48A-15
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48A

- Removal without hinges: used for replacing the relevant door,
be kept (e.g. for body replacement).
a Remove:
- the rear loading door trim (55A, Exterior protection). (see Tailgate lining: Removal - Refitting)
- the rear loading door window (see Rear loading
door window: Removal - Refitting)
- the rear loading door strip (see Rear loading door
strip: Removal - Refitting) (55A, Exterior protection).
141076
a Remove:
- the rear loading door electric window motor,
- the jet pipe for the rear loading door window,
- the central door locking switch module,
- the electric window motor.
- the opening control for the rear loading door,
- the door lock (see Loading door lock: Removal Refitting)

- the rear loading door wiper motor.
a Unlock the clips on the rear loading door strut using

a flat-blade screwdriver.
Remove the rear loading door strut.
48A-16
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48A

2 - Removal
141077
141075
a Remove:
a Refit the rear loading door strut.

a Lock the strut clips using a flat-blade screwdriver.
- the bolts (1) ,

people).
2 - Final operation
a Refit:
- the jet pipe for the rear loading door window.

1 - Refitting
- the electric window motor

two people).
- the sliding window

- the door lock.
- the rear loading door wiper motor,
- the central door locking switch module,
- the rear loading door electric window motor.
48A-17
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48A

a Refit:
strip: Removal - Refitting) (55A, Exterior protection),
a Remove:
- the rear left-hand wing light (see Rear light on
wing: Removal - Refitting) (81A, Rear lighting),
- the rear left-hand bumper extension (see Rear
bumper: Removal - Refitting) ,
- the internal trim on the rear left-hand body side
(see Rear quarter panel trim: Removal - Refitting)
a Disconnect:
141076
a Unlock the clips on the rear loading door strut using

a flat-blade screwdriver.
a Remove the rear loading door strut.
2 - Removal
- the connectors of the rear loading door electric wiring harness.

- the earth wire on the body of the rear loading door
electric wiring harness
141082
a Remove:
- the nuts (2) ,
- the bolt (3) ,
people).
48A-18
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1 - Refitting
two people).
141077
a Refit the rear loading door strut.

a Lock the strut clips using a flat-blade screwdriver.
2 - Final operation
a Reconnect:
- the connectors of the rear loading door electric wiring harness.
- the earth wire on the body of the rear loading door
electric wiring harness
a Refit:
- the body side rear internal trim
- the rear bumper extension
- the rear light
48A-19
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48A

Rear loading door: Stripping - Rebuilding
48A

- the rear loading door stop (see Rear loading door
stop: Removal - Refitting) (52A, Non-side opening element mechanisms),
Note:
The order of the operations described below
applies specifically to replacing the rear loading
door.

The method described below applies to rear loading

doors fitted on the vehicle.
REASSEMBLING
STRIPPING
I - REAR LEFT-HAND LOADING DOOR

a Refit:
I - REAR LEFT-HAND LOADING DOOR
- a new rear badge (see Rear badges: Removal Refitting) (56A, Exterior accessories),
a Remove:

- the exterior handle of the rear loading door (see

Rear loading door exterior handle: Removal Refitting) (52A, Non-side opening element mechanisms),
- the centring device,

- the rear loading door lock (see Loading door lock:

Removal - Refitting) (52A, Non-side opening element mechanisms),
- the license plate light (see Number plate light:


- the number plate light (see Number plate light:

Removal - Refitting) (81A, Rear lighting)
- the exterior handle of the rear loading door (see

Rear loading door exterior handle: Removal Refitting) (52A, Non-side opening element mechanisms).
- the centring device,


a Refit:
- a new trim on the rear left-hand loading door (see
II - REAR RIGHT-HAND LOADING DOOR
II - REAR RIGHT-HAND LOADING DOOR
a Remove:
a Refit:
- the rear loading door seal,
- the rear right-hand loading door trim (see Righthand rear loading door trim: Removal - Refitting) (73A, Non-side opening elements trim),



48A-20
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- a new trim on the rear right-hand loading door (see
Right-hand rear loading door trim: Removal Refitting) (73A, Non-side opening elements trim).
a Refit:
- the rear loading door seal,
- a new rear badge (see Rear badges: Removal Refitting) (56A, Exterior accessories).
48A-21
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48A

48A
STRIPPING
STRIPPING OPERATION FOR PART CONCERNED
a Remove:
- the tailgate trim (see Tailgate lining: Removal Refitting) (71A, Body internal trim),
door window: Removal - Refitting) (54A, Windows),
- the rear opening element window winder mechanism (see Rear opening element electric window mechanism: Removal - Refitting) (52A,
Non-side opening element mechanisms),
140946
- the loading door lock (see Loading door lock: Removal - Refitting) (52A, Non-side opening element mechanisms),
a Unclip the rear loading door trim.

- the lock actuator.
141003
a Remove:
- the clip (2) ,
- the interior weatherstrip of the rear loading door.
140945
48A-22
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48A
141004
a Remove:
- the bolts (3) ,
- the rear loading door window guide.
141006
a Remove:
- the connector (6)
- the bolts (7) ,
- the opening control for the rear loading door.
141007
a Remove:
- the bolts (4) ,
141005
a Remove:
- the centring device striker plate,
- the clip (8) ,
- the stop (5) .
- the rear loading door channel.
48A-23
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48A
141076
141077
a Unclip the rear loading door wiring.
a Refit the rear loading door jack.
a Unlock the clips on the jack of the rear loading door

using a flat-blade screwdriver.
a Lock the clips on the jack of the rear loading door

using a flat-blade screwdriver.
a Remove the rear loading door jack.
a Refit:
- the rear loading door channel,
REASSEMBLING
- the clip (8) ,
a Always replace:
- the bolts (7) ,
- the sealing film,
- the connector (6) ,
- the sealing foam.
- the stop (5) ,
a Order a door fitting kit in addition.
- the centring device striker plate,

- the bolts (4) ,

CONCERNED
- the rear loading door window guide,
a Clip on the rear loading door wiring.
- the bolts (3) without tightening them.

a Raise and lower the window of the rear loading door
twice.
a Tighten the bolts (3) .
a Refit:
- the interior weatherstrip of the rear loading door,
- the clip (2) .
a Clip on the rear loading door trim.
a Refit:
- the bolt (1) ,
- the lock actuator,
48A-24
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- the loading door lock (see Loading door lock: Removal - Refitting) (52A, Non-side opening element mechanisms),
- the rear opening element window winder mechanism (see Rear opening element electric window mechanism: Removal - Refitting) (52A,
Non-side opening element mechanisms),
- the tailgate trim (see Tailgate lining: Removal Refitting) (71A, Body internal trim).
48A-25
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48A

Rear loading door: Adjustment
48A
ADJUSTMENT VALUES
a For all information regarding the adjustment values
for the rear loading doors, (see Vehicle clearances:
Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a The options for adjusting the rear loading door are
as follows:
-Adjustment using the lower and upper striker plate
bolts,
-Adjustment using the lock bolts,
-Adjustment using the centring device bolts,
-Adjustment using the hinge nuts on the body and on
the door box section.
109496
a Symbols A, B, C, D represent the adjustment options.

the bolt.
adjusted.
127163
a Adjust both rear doors starting with the right-hand

one and observe the following adjustment sequence: (1) , (2) , (3) , (4) , (5) , (6) , (7) , (8) , (9)
48A-26
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48A

Lower striker plate
I - ADJUSTMENT USING LOWER AND UPPER

STRIKER PLATE BOLTS
Upper striker plate
127323
a Remove the loading door sill (see Loading door

sill: Removal - Refitting) (71A, Body internal trim).
127304
a Remove the upper striker plate cover

a Undo the upper striker plate bolts
a Adjust the panel gaps and flush fittings (1) .
a Tighten the bolts.
a Undo the lower striker plate bolts.

a Adjust the clearances and flush fitting (3) .
a Tighten the lower striker plate bolts.
a Refit the loading door sill (see Loading door sill:
a Refit the upper striker plate cover
48A-27
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48A

II - ADJUSTMENT USING THE LOCK BOLTS
Central striker plate
Upper lock
127321
a Undo the central striker plate bolts.

a Adjust the doors until they are flush with one another
(9) .
a Tighten the central striker plate bolts.
127322
Lower lock
127320
a Undo the upper and lower lock bolts

a Adjust the centring and touching when closing.
a Tighten the upper and lower lock bolts
48A-28
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48A

III - ADJUSTMENT USING THE CENTRING DEVICE
BOLTS
IV - ADJUSTMENT USING THE HINGE NUTS ON

THE BODY AND ON THE DOOR BOX SECTION
127317
128485
a Undo the centring device bolts

a Adjust the flush fitting but so that the doors do not
touch when closing.
Note:
with no possibility of adjustment (A), it is necessar y to countersink the holes to make adjustments (B).
a Tighten the centring device bolts.
WARNING
the panel, re-apply the anticorrosion protection
a Remove the rear loading door (see 48A, Non-side
opening elements, Rear loading door: Removal Refitting, page 48A-14) .
48A-29
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48A

Adjustment using the hinge nuts on the door box
section
Adjustment using the hinge nuts on the body
127301
127316
127303
127302
a Refit the rear loading door (see 48A, Non-side opening elements, Rear loading door: Removal - Refitting, page 48A-14) .
a Adjust the panel gaps and flush fitting of the rear loading door.
a Adjust the panel gaps and flush fitting of the rear loading door.
a Tighten the rear loading door hinge nuts.
a Tighten the rear loading door hinge nuts.

(see Soundproofing products after assembly:
Use) (04E, Paint).

Use) (04E, Paint).
48A-30
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48A
ADJUSTMENT VALUES
a For all information regarding the adjustment values
for the rear loading doors, (see Vehicle clearances:
Adjustment values) (01C, Vehicle bodywork specifications).
ADJUSTMENT
a The rear loading door is adjusted in the following order:
- adjustment of the shut lines of areas (1) , (2) , (3)
and adjustment of the flush fitting of area (1) using
the hinge nuts on the body and on the door box
section,
- adjustment of the flush fitting of area (3) using the
bolts of the striker plate and centring device.
109496
a Symbols A, B, C, D represent the adjustment options.

a The black dot in the centre represents the body of
the bolt.
a The grey section represents the component to be
adjusted.
a The white section represents the adjustment area.
141251
a Observe the adjustment sequence.
48A-31
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48A

I - ADJUSTMENT USING THE HINGE NUTS ON THE
BODY AND ON THE DOOR BOX SECTION
1 - Adjustment using the hinge nuts on the door
box section
128485
a
Note:
with no possibility of adjustment (A) , it is necessary to countersink the holes to make adjustments (B) .
141075
a Adjust the height and flush fitting using the nuts (1)
2 - Adjustment using the hinge nuts on the body
WARNING
a Remove the rear loading door (see 48A, Non-side
opening elements, Rear loading door: Removal Refitting, page 48A-14) .
a Remove the door hinges.
a Enlarge the holes on the hinges using a step milling
cutter (3 mm maximum).
a Refit the hinges on the door box section.
a Adjust the clearances and flush fitting of the rear loading door.
141082
a Adjust the centring and tilt using the nuts (2)

Use) (04E, Paint).
48A-32
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II - ADJUSTMENT OF THE CENTRING DEVICE AND
STRIKER PANEL
141285
a Release then tighten slightly the bolts of the striker

panel and the centring device.
a Adjust in order:
- the centring device so it does not jam
- the striker panel so it does not jam and closes properly
a Tighten the bolts of the striker panel and the centring
device (indicative torque: 15 N.m).
48A-33
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48A

Upper rear opening element: Stripping - Rebuilding
48A

2 - Guide slide
Tightening torquesm
drive bar bolts
2.5 N.m
guide slide bolts

handle bolts
6 N.m
2.5 N.m
Note:
If it is necessary to remove the guide slide supports, make a mark before removing them.
REMOVAL
a (see 48A, Non-side opening elements, Upper
rear opening element: Removal - Refitting, page
48A-36)
142576
a Remove:
- the bolts (2) ,

CONCERNED
- the guide slides.

3 - Handle
1 - Guide bar
108739
142576
a Remove:
- the bolts (1) ,
- the drive bar of the upper rear opening element.
48A-34
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Upper rear opening element: Stripping - Rebuilding
48A

4 - Upper rear opening element lock
a (see Upper rear opening element lock: Removal
- Refitting)
5 - upper rear opening element strip
a (see Upper rear opening element strip: Removal
- Refitting)
108738
a Remove:
- the bolts (4) ,
- the handle.
4 - Upper rear opening element lock
a (see Upper rear opening element lock: Removal
- Refitting)
5 - upper rear opening element strip
a (see Upper rear opening element strip: Removal
- Refitting)
REFITTING
1 - Guide bar
a Refit the drive bar of the upper rear opening element.
a Torque tighten the drive bar bolts (2.5 N.m)
2 - Guide slide
a When refitting, check that the guide slides are parallel with the frame of the upper rear opening element
a Refit the guide slides of the upper rear opening element.
a Torque tighten the guide slide bolts (6 N.m)
3 - Handle
a Refit the handle of the upper rear opening element.
a Torque tighten the handle bolts (2.5 N.m)
48A-35
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Upper rear opening element: Removal - Refitting
48A
SHORT CHASSIS
Tightening torquesm
upper bolt of the rear
side seat belt
21 N.m
REMOVAL
SHORT CHASSIS
a Remove:
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim),
trim).
141078
a Remove the quarter panel upper trim at (2) .
STANDARD CHASSIS
SHORT CHASSIS
138563
a Remove the quarter panel upper trim (1) .
141079
48A-36
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48A
SHORT CHASSIS
SHORT CHASSIS
141080
a Remove:
141081
a Unclip the upper trim from the rear wheel arch (5) .
- the rear side seat belt upper bolt (4) ,

- the rear seat belt return mechanism.
STANDARD CHASSIS
138584
a Remove:
- the bolts (6) ,
48A-37
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48A

- the thread supports.
140904

138583

element rail trims.
a Remove the rear centre trim (7) .
140903
138582
a Remove:

(11) .
- the clips (8) ,

- the roof rear side trim.
48A-38
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48A
138580
a Remove:
- the upper rear opening element drive bar at (14) ,
- the upper rear opening element.
140902
at (12) .
a block.
CONCERNED
a this operation requires two people
REFITTING
CONCERNED
a Refit the upper rear opening element in the rails of
the upper rear opening element at (12) .
a this operation requires two people

a Refit the upper rear opening element drive bar at
(14)
a Tighten the bolts (13) of the upper rear opening element mechanism.
a Refit:
- the roof rear side trim,
- the clips (8) ,
138580
a Loosen the bolts (13) of the upper rear opening element drive bar.
- the rear centre trim (7) .
STANDARD CHASSIS
a Refit:
- the net supports,
- the bolts (6) ,
48A-39
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- the quarter panel upper trim (5) .
SHORT CHASSIS
a Clip on the rear wheel arch upper trim.
a Refit:
- the rear seat belt return mechanism,
- the rear side seat belt upper bolt (4) .
a Torque tighten the upper bolt of the rear side seat
belt (21 N.m).
a Clip on the blanking cover.
a Refit:
- the quarter panel upper trim,
trim),
- the rear panel trims (see Rear panel trim: Removal - Refitting) (71A, Body internal trim).
a Remove the block.

a Refit:
trims.
48A-40
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48A
Sealing and soundproofing

65A
OPENING ELEMENT SEALING
66A
WINDOW SEALING
68A
SOUNDPROOFING
X61
DECEMBER 2008
constructed."
Edition Anglaise

consent of Renault.
Renault s.a.s 2008
http://vnx.su
Contents
Page
65A
66A
68A

Door sealing film: Removal Refitting
65A-1
Sunroof seal: Removal Refitting
65A-3
Tailgate seal: Removal Refitting
65A-4
WINDOW SEALING
Front side door glass run
channel: Removal - Refitting
66A-1
Front door side exterior

weather strip: Removal Refitting
66A-3
Rear side door exterior

weather strip: Removal Refitting
66A-4
Sliding side door window

seal: Removal - Refitting
66A-5
SOUNDPROOFING
Bonnet soundproofing:
Removal - Refitting
68A-1
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Door sealing film: Removal - Refitting
65A
REMOVAL
Note:
Remove the adhesive residue from the inner

door panel by sticking wide masking tape over
the adhesive residue. Pull gently on the masking
tape to remove any adhesive residue.
a Remove:
Removal - Refitting) (72A, Side opening elements
trim) or the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening elements trim),
- the front speaker (see Front speakers: Removal Refitting) (86A, Radio).

CONCERNED
Clean the door box section with HEPTANE using

a dry, lint-free cloth.
WARNING
To ensure the sealing film adheres correctly:
- The door must be clean (free of dust, grease
and anti-adhesive products), with no trace of
impurities and no condensation,
- The area of the door box section where the film
is to be applied must be painted completely,
- There must be a minimum temperature of 15
on the surfaces which are to be bonded.
1 - PROCEDURE ONE
a Strip off the sealing film using a heat stripper set to
approximately 100. Hold the heat stripper at a distance of approximately 20 cm, directing the hot air
flow onto the edge of the sealing film.
a Start by stripping off a corner of the sealing film.
a Carefully strip off the sealing film taking care not to
tear it.
2 - PROCEDURE TWO
a Remove the sealing film using a syringe filled with
HEPTANE (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Products).
a Start with the upper section of the sealing film.
a Remove the HEPTANE in small amounts between
the sealing film and the inner door panel as the sealing film peels away (pull slowly on the sealing film).
a Carefully strip off the sealing film taking care not to
tear it.
REFITTING
a Always replace the door sealing film.
65A-1
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Door sealing film: Removal - Refitting
65A
Removal - Refitting) (72A, Side opening elements
trim) or the sliding side door trim (see Sliding side
door trim: Removal - Refitting) (72A, Side opening elements trim).

CONCERNED
Front side door
126824
Sliding side door
126825
a Position the sealing film using the guide points (1) .

a Pass through the interior door handle cable.
a Firmly apply the sealing film around its entire edge.
a Refit:
65A-2
http://vnx.su

Sunroof seal: Removal - Refitting
K61
REMOVAL
a Remove the mobile sunroof panel (see Sunroof
moving panel: Removal - Refitting) (52A, Nonside opening element mechanisms).
CONCERNED
140924
a Mark the position of the join of the sunroof seal (1) .

a Remove the sunroof seal.
REFITTING
CONCERNED
a Refit the sunroof seal.
a Refit the mobile sunroof panel (see Sunroof moving panel: Removal - Refitting) (52A, Non-side
opening element mechanisms).
65A-3
http://vnx.su
65A

Tailgate seal: Removal - Refitting
65A

CONCERNED

Car. 1363
REMOVAL
140627
a Remove the tailgate seal starting at (2) .
REFITTING
CONCERNED
140622
a Remove the bolts (1) from the rear loading door sill.
140625
a Index the tailgate seal at (3) .
65A-4
http://vnx.su

Tailgate seal: Removal - Refitting
65A
140626
140623
a Refit the lower section of the tailgate seal by raising

the loading door sill slightly.
a Fit the tailgate sail at (4) .
a Refit the bolts (1) of the rear loading door sill.
140624
a Refit:
- the tailgate seal using the tool (Car. 1363) along
the rear light,
- the tailgate seal around the outside edge.
65A-5
http://vnx.su
WINDOW SEALING
Front side door glass run channel: Removal - Refitting
66A
REMOVAL
a Lower the front side door sliding window.
a Remove:
trim),
- the front side door exterior weatherstrip (see 66A,
Window sealing, Front door side exterior weather strip: Removal - Refitting, page 66A-3) .
- the door mirror (see Door mirror: Removal - Refitting) (56A, Exterior equipment).
CONCERNED
126893
a Remove the front side door window run channel (2) .
REFITTING
CONCERNED
126892
a Partially remove the front side door window run

channel at (1) .
126894
a Refit the front door window glass run channel starting with the top section (3) .
66A-1
http://vnx.su
WINDOW SEALING
Front side door glass run channel: Removal - Refitting
a Refit:
- the door mirror (see Door mirror: Removal - Refitting) (56A, Exterior equipment),
- the front side door exterior weatherstrip (see 66A,
Window sealing, Front door side exterior weather strip: Removal - Refitting, page 66A-3) .
trim).
66A-2
http://vnx.su
66A
WINDOW SEALING
Front door side exterior weather strip: Removal - Refitting
REFITTING

Car. 1363
66A
REMOVAL
a Lower the front side door sliding window.
CONCERNED
126891
a Refit the front side door exterior weatherstrip at (3)

and (4) .
126461
a Carefully remove the front side door exterior weatherstrip at (1) and (2) using the tool (Car. 1363).
66A-3
http://vnx.su
WINDOW SEALING
Rear side door exterior weather strip: Removal - Refitting
K61
Car. 1363
REMOVAL
a Lower the rear side door's sliding window.
CONCERNED
126462
a Carefully remove the rear side door exterior weatherstrip (1) using the tool (Car. 1363).
REFITTING
a Refit the rear side door exterior weatherstrip (1) .
66A-4
http://vnx.su
66A
WINDOW SEALING
Sliding side door window seal: Removal - Refitting
66A
REMOVAL

CONCERNED

a Remove the sliding side door trim (see Sliding side

element trim).

a Remove:
- the door sealing film (see 65A, Opening element
sealing, Door sealing film: Removal - Refitting,
page 65A-1) ,
126463
a Remove the sliding side door window seal (1) .
- the rear side door exterior weatherstrip (see 66A,

Window sealing, Rear side door exterior weather strip: Removal - Refitting, page 66A-4) ,
- the rear side door sliding window (see Sliding side
- the rear side door fixed window (see Rear side
door fixed window: Removal - Refitting) (54A,
Windows),

a Remove the rear side door fixed window (see Rear
(54A, Windows).
66A-5
http://vnx.su
WINDOW SEALING
66A
126890
a Remove the sliding side door window seal (2) .
126890
a Refit the sliding side door window seal (2) .

Note:
Position the sliding side door window seal joint at
the lower section (3) .
REFITTING
CONCERNED
a Refit the sliding side door window seal (1) .

a Refit:
- the rear side door fixed window (see Rear side
Windows),
- the rear side door sliding window (see Sliding side
- the rear side door exterior weatherstrip (see 66A,
Window sealing, Rear side door exterior weather strip: Removal - Refitting, page 66A-4) ,
66A-6
http://vnx.su
WINDOW SEALING
66A
- a new door sealing film (see 65A, Opening element sealing, Door sealing film: Removal - Refitting, page 65A-1) .

a Refit the rear side door fixed window (see Rear side
Windows).

element trim).
66A-7
http://vnx.su
SOUNDPROOFING
Bonnet soundproofing: Removal - Refitting
REMOVAL
CONCERNED
126460
a Remove:
- the clips (1) ,
- the bonnet soundproofing (2) .
REFITTING
a Refit the bonnet soundproofing (2) .
68A-1
http://vnx.su
68A
Trim and upholstery

71A
BODY INTERNAL TRIM
72A
SIDE OPENING ELEMENT TRIM
73A
NON-SIDE OPENING ELEMENTS TRIM
75A
FRONT SEAT FRAMES AND MECHANISMS
76A
REAR SEAT FRAMES AND MECHANISMS
77A
FRONT SEAT TRIM
78A
REAR SEAT TRIM
79A
SEAT COMPONENTS
X61
MARCH 2009
constructed."
Edition Anglaise

consent of Renault.
Renault s.a.s 2008
http://vnx.su
Contents
Page
71A
BODY INTERNAL TRIM
72A
Floor carpet: Removal Refitting
71A-1
Front side door trim:

Removal - Refitting
72A-1
Luggage compartment
carpet: Removal - Refitting
71A-5
Sliding side door trim:

Removal - Refitting
72A-3
Headlining: Removal Refitting
71A-7
Cab headlining: Removal Refitting

B-pillar lower trim: Removal Refitting
Rear wheel arch lining:
Removal - Refitting
73A
71A-12
71A-14
71A-15
A-pillar trim: Removal Refitting
71A-18
B-pillar upper trim: Removal Refitting
71A-19
75A
Rear quarter panel trim:

Removal - Refitting
71A-21
Rear panel trim: Removal Refitting
71A-22
Rear side door sill: Removal

- Refitting
71A-24
Loading door sill: Removal Refitting
71A-25
http://vnx.su
Tailgate lining: Removal Refitting
73A-1
Right-hand rear loading door

73A-4
Left-hand rear loading door

73A-5
FRONT SEAT FRAMES AND

MECHANISMS
Front seat frame:
Precautions for repair
75A-1
Front seat frame: Removal Refitting
75A-2
Front seat base frame:

Removal - Refitting
75A-5
Front seatback frame:

Removal - Refitting
75A-7
Front seat runner: Removal Refitting
75A-9
Contents
75A
76A
FRONT SEAT FRAMES AND

MECHANISMS
Rear seat access
mechanisms: Removal Refitting
75A-11
Complete front seat:

Removal - Refitting
75A-13
1/3 and 2/3 rear bench seat

78A-6
1/3 and 2/3 rear bench seat

seatback trim: Removal Refitting
78A-8
SEAT COMPONENTS
76A-1
Front headrest: Removal Refitting
79A-1
Rear seat runner: Removal Refitting
76A-2
Front seat headrest guide:

Removal - Refitting
79A-4
Complete rear bench seat:

Removal - Refitting
76A-4
Rear headrest: Removal Refitting
79A-6
Rear seat headrest guide:

Removal - Refitting
79A-7
Rear bench seatback frame

1/3 and 2/3: Removal Refitting
76A-7
Rear bench seat base frame:

Removal - Refitting
76A-8
76A-10
FRONT SEAT TRIM

Front seat base trim:
Removal - Refitting
77A-1
Front seatback trim: Removal

- Refitting
77A-8
Front seat lower cover:

Removal - Refitting
78A
79A
REAR SEAT TRIM
Rear seat frame: Removal Refitting
Rear bench seat

77A
78A
77A-16
REAR SEAT TRIM

Rear seat base trim:
Removal - Refitting
78A-1
Rear seatback trim: Removal

- Refitting
78A-4
http://vnx.su
BODY INTERNAL TRIM

Floor carpet: Removal - Refitting
71A
K61
- the B-pillar lower trims (see 71A, Body internal
trim, B-pillar lower trim: Removal - Refitting,
page 71A-14) .
Essential equipment
diagnostic tool

CONCERNED
IMPORTANT
IMPORTANT
IMPORTANT
126546
a Remove:
- the clips (1) ,
- the trims (1) ,
REMOVAL
- the floor carpet.
REFITTING
a Partially remove the side door seals.


CONCERNED
a Refit:

a Remove:
- the floor carpet,

- the trims (1) .
- the front seats completely (see 75A, Front seat

frames and mechanisms, Complete front seat:
- the central console (see Centre console: Removal - Refitting) (57A, Interior equipment),
- the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment),
- the floor storage compartments and flaps (see
Floor flap and storage: Removal - Refitting)
(57A, Interior equipment),
71A-1
http://vnx.su
BODY INTERNAL TRIM

K61
a Refit:
page 71A-14) ,
- the floor storage compartments and flaps (see
Floor flap and storage: Removal - Refitting)
(57A, Interior equipment),
a Refit the side door seals.
71A-2
http://vnx.su
71A
BODY INTERNAL TRIM

71A
F61
CONCERNED
Essential equipment
diagnostic tool
IMPORTANT
IMPORTANT
126906
a Remove:
- the clips (1) ,
IMPORTANT
- the floor carpet.
REFITTING
CONCERNED
REMOVAL
a Refit the floor carpet.

a Remove:
- the front side door seals,
page 71A-14) .
71A-3
http://vnx.su
BODY INTERNAL TRIM

F61
a Refit:
page 71A-14) ,
- the front side door seals.
a Unlock the computer using the diagnostic tool (see
Fault finding - Replacement of components)
71A-4
http://vnx.su
71A
BODY INTERNAL TRIM

Luggage compartment carpet: Removal - Refitting
K61
REMOVAL
a Remove:
- the loading door sill (see 71A, Body internal trim,
Loading door sill: Removal - Refitting, page
71A-25) ,
- the rear wheel arch trims (see 71A, Body internal
trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) ,
- the complete rear bench seat (see 76A, Rear seat
frames and mechanisms, Complete rear bench
seat: Removal - Refitting, page 76A-4) .
CONCERNED
a Remove the luggage compartment carpet.
REFITTING
CONCERNED
a Refit the luggage compartment carpet.
a Refit:
71A-25) .
71A-5
http://vnx.su
71A
BODY INTERNAL TRIM

Luggage compartment carpet: Removal - Refitting
71A
F61
REMOVAL
a Refit:
- the trim (2) ,
a Remove:

- the rear sliding side door sill (see 71A, Body internal trim, Rear side door sill: Removal - Refitting, page 71A-24) ,
71A-25) ,
trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) .

71A-25) ,
- the rear side door sill (see 71A, Body internal
trim, Rear side door sill: Removal - Refitting,
page 71A-24) .
126905
a Remove:
- the bolts (1) ,
- the trim (2) .
CONCERNED
a Remove the luggage compartment carpet.
REFITTING
CONCERNED
a Refit the luggage compartment carpet.
71A-6
http://vnx.su
BODY INTERNAL TRIM

Headlining: Removal - Refitting
71A

Essential equipment
diagnostic tool
K61
a Partially remove the side door seals and tailgate

seal.
a
IMPORTANT
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
F61
a Partially remove the front side door seals.
IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the
diagnostic tool.
When this function is activated, all the trigger
lines are inhibited and the airbag warning light on
the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or
naked flame - they may be triggered.
126903
a Remove:
REMOVAL
- the clips (1) ,

- the headlining trims (2) .
K61
a
K61
Note:
The front and rear parts of the headlining are
removed independently.
Headlining front section
a Remove:
- the windscreen pillar trims (see 71A, Body internal trim, A-pillar trim: Removal - Refitting, page
71A-18) ,
71A-7
http://vnx.su
BODY INTERNAL TRIM

- the sun visors (see Sun visor: Removal - Refitting) (57A, Interior equipment),
- the headlining light (see Headlining light: Removal - Refitting) (81B, Interior lighting).
Headlining rear section

a Remove:
- the rear wheel arch trim (see 71A, Body internal
ROOF STORAGE
- the rear quarter panel trim (see 71A, Body internal trim, Rear quarter panel trim: Removal - Refitting, page 71A-21) .
a Remove the front storage compartment under the

roof (see Front storage compartment under roof:
Removal - Refitting) (57A, Interior equipment).
a Remove:
page 71A-14) ,
71A

CONCERNED
K61
- the B-pillar upper trims (see 71A, Body internal

trim, B-pillar upper trim: Removal - Refitting,
page 71A-19) .
K61
a Remove the rear storage compartment under the
roof (see Rear storage compartment: Removal Refitting) (depending on the equipment level).
126879
a Remove:
- the bolts (4) ,
- the thread supports (5) .
1 - Headlining front section
127505
a Unclip the upper storage compartment support trims

(6) in the roof.
a Remove:
- the upper storage compartment supports (7) in the
roof,
- the clips (8) .
a Remove the front section of the headlining.
71A-8
http://vnx.su
BODY INTERNAL TRIM

2 - Headlining rear section
a Remove:
- the clips (8) and (9) ,
- the rear section of the headlining.
F61
126904
a Unclip the upper storage compartment support trims

(10) in the roof.
a Remove:
- the upper storage compartment supports (11) in
the roof,
- the clips (12) ,
- the cab headlining partially.
71A-9
http://vnx.su
71A
BODY INTERNAL TRIM

71A
a Refit new double-sided adhesive foam (14) .
REFITTING
K61
REFITTING PREPARATION OPERATION

CONCERNED

K61
1 - Headlining front section
a Refit:
- the front section of the headlining,
- the upper storage compartment supports (7) in the
roof,
2 - Headlining rear section
a Refit:
- the headlining rear section,
126881
F61
a Refit:
- the cabin headlining.
- the upper storage compartment supports (11) in
the roof,
K61
126882
a Remove the double-sided adhesive foam.

a Degrease the zone (13) using ALINT-FREE CLOTH
soaked in HEPTANE (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables
- Products).

a Refit the rear storage compartment under the roof
(see Rear storage compartment: Removal - Refitting) (depending on the equipment level).
71A-10
http://vnx.su
BODY INTERNAL TRIM

71A
a Refit:
page 71A-19) ,
page 71A-14) .
K61
a Refit the side door seals and tailgate seal.
tool (see Fault finding - Replacement of components)(88C, Airbags and pretensioners).
ROOF STORAGE
a Refit the front storage compartment under the roof
(see Front storage compartment under roof: Removal - Refitting) (57A, Interior equipment).
a Refit:
71A-18) .
K61
Headlining rear section
a Refit:
- the rear quarter panel trim (see 71A, Body internal trim, Rear quarter panel trim: Removal - Refitting, page 71A-21) ,
F61
a Refit the headlining trims (2) .
a Refit the front side door seals.
71A-11
http://vnx.su
BODY INTERNAL TRIM

Cab headlining: Removal - Refitting
71A
F61
REMOVAL

CONCERNED

a Partially remove the front side door seals.
126904
a Unclip covers (3) .

126903
a Remove:
a Remove:
- the clips (4) ,

- the front storage compartment supports under the
roof (5) ,
- the clips (1) ,

- the headlining trims (2) ,
- the cabin headlining.

page 71A-14) ,
REFITTING

page 71A-19) ,

CONCERNED
71A-18) ,
a Refit:
- the cabin headlining,
- the front storage compartment supports under the
roof (5) .
- the headlining light (see Headlining light: Removal - Refitting) (81B, Interior lighting).
ROOF STORAGE
ROOF STORAGE
a Remove the front storage compartment under the
roof (see Front storage compartment under roof:
Removal - Refitting) (57A, Interior equipment).
a Refit the front storage compartment under the roof

(see Front storage compartment under roof: Removal - Refitting) (57A, Interior equipment).
71A-12
http://vnx.su
BODY INTERNAL TRIM

Cab headlining: Removal - Refitting
F61
a Refit:
71A-18) ,
page 71A-19) ,
page 71A-14) ,
- the headlining trims (2) ,
- the front side door seals.
71A-13
http://vnx.su
71A
BODY INTERNAL TRIM

B-pillar lower trim: Removal - Refitting
71A

CONCERNED
REMOVAL
a Clip on the B-pillar lower trim.
a Partially remove the side door seals.
a Move the front seat forward.
a Refit the side door seals.

a Put the front seat into its initial position.

CONCERNED
126845
a Unclip the B-pillar lower trim at (1) and (2) .

a Disconnect the connector.
a Remove the B-pillar lower trim.
REFITTING

a Connect the connector.
71A-14
http://vnx.su
BODY INTERNAL TRIM

Rear wheel arch lining: Removal - Refitting
K61
REMOVAL
a Tilt the rear bench seat.
a Remove the rear parcel shelf.
CONCERNED
126899

a Unclip the trim from the rear wheel arch.
REFITTING
CONCERNED
a Refit the rear wheel arch trim.
a Refit the rear parcel shelf.
a Tilt the rear bench seat back to its initial position.
71A-15
http://vnx.su
71A
BODY INTERNAL TRIM

71A
F61
REMOVAL
2 - Second fitting

First fitting
a Remove the jack.
CONCERNED
1 - First fitting
126898

a Unclip the rear wheel arch lining at (3) .
REFITTING
CONCERNED
1 - First fitting
126897
a Clip on the rear wheel arch lining.

2 - Second fitting
a Refit the rear wheel arch trim.
First fitting
a Refit the jack.
71A-16
http://vnx.su
BODY INTERNAL TRIM

71A
REMOVAL
REFITTING

CONCERNED
a Remove the rear panel trim (see 71A, Body internal trim, Rear panel trim: Removal - Refitting,
page 71A-22) .
a Clip on the rear wheel arch lining.

a Refit the rear panel trim (see 71A, Body internal
trim, Rear panel trim: Removal - Refitting, page
71A-22) .

CONCERNED
140621
140620
71A-17
http://vnx.su
BODY INTERNAL TRIM

A-pillar trim: Removal - Refitting
REMOVAL
a Partially remove the front side door seal.
CONCERNED
126896
a Unclip the windscreen pillar trim at (1) .

a Keep the upper section held away by sliding the
windscreen pillar trim at (2) .
WARNING
Take care not to damage the headlining when
removing the A-pillar trims.
REFITTING
CONCERNED
a Refit the windscreen pillar trim.
a Refit the front side door seal.
71A-18
http://vnx.su
71A
BODY INTERNAL TRIM

B-pillar upper trim: Removal - Refitting
71A
REMOVAL
a Remove:
- the seals of the front and rear side doors partially,
- the B-pillar lower trim (see 71A, Body internal
page 71A-14) .
126843
a Remove:
- the front seat belt return mechanism bolt (3) ,
- the front seat belt return mechanism.
CONCERNED
126842
a Unclip the trim from the front seatbelt return mechanism (1) at (2) .
126844
a Unclip:
- the B-pillar upper trim at (5) and (6) .
71A-19
http://vnx.su
BODY INTERNAL TRIM

B-pillar upper trim: Removal - Refitting
REFITTING
CONCERNED
a Refit the B-pillar upper trim.
a Refit:
- the front seat belt return mechanism,
- the seat belt return mechanism trim,
- the B-pillar lower trim (see 71A, Body internal
page 71A-14) ,
- the seals of the front and rear side doors.
71A-20
http://vnx.su
71A
BODY INTERNAL TRIM

Rear quarter panel trim: Removal - Refitting
71A
K61
REMOVAL

CONCERNED

a Remove the rear wheel arch trim (see 71A, Body internal trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) .
126902
a Unclip the rear quarter panel trim (3) .
REFITTING
126901
a Remove:
- the trim (1) ,
- the bolt (1) ,
- the rear side seatbelt return mechanism (2) .

CONCERNED
a Clip the rear quarter panel trim (3) .
a Refit:
- the rear side seatbelt return mechanism,
- the trim (1) ,
71A-21
http://vnx.su
BODY INTERNAL TRIM

Rear panel trim: Removal - Refitting
71A
REMOVAL
a Partially remove the front side door seal.
a Move the entire front seat forward.
a Remove the rear seat.
a Open the upper storage compartment in the rear
wheel arch trim.
a Remove the rear seat belt from its housing.
CONCERNED
140619
140617
a Unclip the clips (1) .
140618
REFITTING
CONCERNED
a Clip on:
- the rear wheel arch trim,
- the clips (1) .
a Fit the rear seat belt in its housing.
a Close the upper storage compartment in the rear
wheel arch trim.
71A-22
http://vnx.su
BODY INTERNAL TRIM

Rear panel trim: Removal - Refitting
a Refit:
- the rear seat,
71A-23
http://vnx.su
71A
BODY INTERNAL TRIM

Rear side door sill: Removal - Refitting
F61
REMOVAL
CONCERNED
126895
a Remove:
- the bolts (1) ,
- the rear side door seal (2) .
REFITTING
a Refit the rear side door sill (2) .
71A-24
http://vnx.su
71A
BODY INTERNAL TRIM

Loading door sill: Removal - Refitting
REMOVAL
a remove the rear wheel arch trims (see 71A, Body
internal trim, Rear wheel arch lining: Removal Refitting, page 71A-15)
CONCERNED
127506
a Remove:
- the bolts (1) ,
- the loading door sill (2) .
REFITTING
a Refit the rear wheel arch trims (see 71A, Body internal trim, Rear wheel arch lining: Removal - Refitting, page 71A-15) .
a Refit the loading door sill (2) .
71A-25
http://vnx.su
71A

Front side door trim: Removal - Refitting
72A

CONCERNED
REMOVAL
a Unclip the manual window winder control.
126468
a Remove the bolts (3) , (4) and (5) .
126467
a Remove the trims (2) .
126469
a Unclip:
- the front side door trim at (5) and (6) .
- the front side door interior opening release cable.
72A-1
http://vnx.su

Front side door trim: Removal - Refitting
72A

a Refit the trim pieces (2) .

a Disconnect the connectors from the front window
winder switch plate.

a Clip on the manual window winder control.
a Remove the front side door trim.
REFITTING
126470
a Always replace:
- the bracket (7) ,
- the front side door trim clips.
CONCERNED
a Connect the front window winder switch plate connectors.
a Clip on the front side door interior opening control

cable.
a Refit the front side door trim.
72A-2
http://vnx.su

Sliding side door trim: Removal - Refitting
72A

CONCERNED
REMOVAL
K61
K61
126458
126456

a Remove the bolts.
a Partially unclip the sliding side door trim at (2) and at

(3) .
a Unclip the sliding side door opening release cable.
a Remove the sliding side door trim.
72A-3
http://vnx.su

Sliding side door trim: Removal - Refitting
72A

CONCERNED
F61
K61
a Clip on the sliding side door opening release cable.
a Refit the sliding side door trim with new clips.
F61
a Refit a new sliding side door trim with new clips (4) .

K61
a Refit the bolts (1) .
126889
a Clip the trim piece in place (1) .
a Remove:
- the clips (4) using an unclipping tool,
- the sliding side door trim.
REFITTING
K61
a Always replace the clips on the sliding side door
trim.
F61
a Always replace:
- the sliding side door trim,
- the clips (4) .
72A-4
http://vnx.su

Tailgate lining: Removal - Refitting
REMOVAL
CONCERNED
126459

a Unclip the tailgate trim at (2) .
REFITTING
a Always replace the tailgate trim clips.
CONCERNED
a Clip the tailgate trim in place.
73A-1
http://vnx.su
73A

73A

Car. 1363
REMOVAL
CONCERNED
140632
a Unclip the tailgate trim using the tool (Car. 1363).
REFITTING
140633
a Remove:
- the blanking covers (1) ,
- the bolts (2) .
140634
a Always replace the tailgate trim clips.
73A-2
http://vnx.su

CONCERNED
a Clip the tailgate trim in place.
a Refit:
- the bolts (2) ,
- the blanking covers (1) .
73A-3
http://vnx.su
73A

Right-hand rear loading door trim: Removal - Refitting
F61
REMOVAL
CONCERNED
126464
a Unclip the clips (1) using unclipping pliers.

a Remove the stop handle for the rear right-hand load
door.
a Remove the rear right-hand loading door trim.
REFITTING
a Always replace:
- the right-hand rear loading door trim,
- the clips (1) .
CONCERNED
a Refit a new rear right-hand loading door trim.
73A-4
http://vnx.su
73A

Left-hand rear loading door trim: Removal - Refitting
73A
F61
REMOVAL

CONCERNED
126466
126465
a Unclip the clips (2) using unclipping pliers.

a Move aside the interior stop handle for the rear loading door.
a Remove:
- the trim (1) ,
a Remove the rear left-hand loading door trim.
- bolt (1) .
a Unclip the rear left-hand loading door interior opening handle.
REFITTING
a Always replace:
- the left-hand rear loading door trim,
- the clips (2) .
CONCERNED
a Refit a new rear left-hand loading door trim.
a Clip on the rear left-hand loading door interior handle.
73A-5
http://vnx.su

Front seat frame: Precautions for repair
75A
Special notes for seats fitted with an AIRBAG
127374
IMPORTANT
102189
Finger tighten all the mountings and tighten to torque

and in order, as indicated above, to eliminate noise
from the seat and to ensure correct electrical contacts
(if vehicle is fitted with automatic connector).

IMPORTANT
All operations on airbag and pretensioner systems
must be carried out by qualified trained personnel.
The air bags have a pyrotechnic gas generator, with
an ignition module and bag which must not be
separated.
The pretensioners have a pyrotechnic gas generator and an ignition module which must under no circumstances be separated.
108298
IMPORTANT
Note:
Components may only be removed (lugs, wires,
brackets, etc.) to modify the replacement seat
frame according to the type of vehicle.
NO WELDING OPERATIONS ARE PERMITTED.
75A-1
http://vnx.su

Front seat frame: Removal - Refitting
75A
RETRACTABLE PASSENGER SEAT or FOLDING PASSENGER SEAT

- the front seatback trim (see 77A, Front seat trim,
Front seatback trim: Removal - Refitting, page
77A-8) ,
Essential equipment
diagnostic tool
- the front seat belt buckle stalk (see Front seat belt
buckle: Removal - Refitting) (88C, Airbags and
pretensioners).
IMPORTANT
Consult the safety and cleanliness advice and operational recommendations before carrying out any
FRONT SIDE AIRBAG, and RETRACTABLE PASSENGER SEAT

a Remove the front side airbag (chest) (see Front
(chest) side airbag: Removal - Refitting) (88C,
Airbags and pretensioners).
IMPORTANT
REFITTING
CONCERNED

FRONT SIDE AIRBAG, and RETRACTABLE PASSENGER SEAT

a Refit the front side airbag (chest) (see Front (chest)
side airbag: Removal - Refitting) (88C, Airbags
and pretensioners).
IMPORTANT
a Refit:
REMOVAL
a Remove the complete front seat (see 75A, Front
seat frames and mechanisms, Complete front
pretensioners).
77A-8) ,
- the front seat cushion trim (see 77A, Front seat
trim, Front seat base trim: Removal - Refitting,
page 77A-1) ,
- the lower seat covers (see 77A, Front seat trim,
Front seat lower cover: Removal - Refitting,
page 77A-16) .
II - REMOVAL PREPARATION OPERATION

a Remove:
page 77A-16) ,
page 77A-1) ,
75A-2
http://vnx.su

RETRACTABLE PASSENGER SEAT or FOLDING PASSENGER SEAT
a Refit the complete front seat (see 75A, Front seat
75A-3
http://vnx.su
75A

75A
MANUAL AIR CON 1, and MANUAL PASSENGER SEAT 1

77A-8) ,
Essential equipment
diagnostic tool
pretensioners),
IMPORTANT
Consult the safety and cleanliness advice and operational recommendations before carrying out any
- the front seat runners (see 75A, Front seat frames

and mechanisms, Front seat runner: Removal Refitting, page 75A-9) .
REFITTING
CONCERNED
IMPORTANT
a Refit:
and mechanisms, Front seat runner: Removal Refitting, page 75A-9) ,

pretensioners).
77A-8) ,
IMPORTANT

page 77A-1) ,
page 77A-16) .
REMOVAL
II - REMOVAL PREPARATION OPERATION

a Remove:
page 77A-16) ,
page 77A-1) ,
75A-4
http://vnx.su

Front seat base frame: Removal - Refitting
75A
DRIVER HEIGHT ADJUSTER

page 77A-1) ,
Essential equipment
diagnostic tool

Tightening torquesm
seat base frame bolts
pretensioners).
60 Nm
IMPORTANT

CONCERNED
IMPORTANT
IMPORTANT
127375
a Remove:
REMOVAL
- the seat frame bolts (1) ,

- the front seat base frame.

(seeFault finding - Replacement of components)
a Remove:
REFITTING
a Always replace the seat base frame bolts (1) .
- the compete front seat (see 75A, Front seat frames and mechanisms, Complete front seat: Removal - Refitting, page 75A-13) ,

CONCERNED

page 77A-16) ,
a Torque tighten the seat base frame bolts (60 Nm)

(1) .
a Refit the front seat base frame.
75A-5
http://vnx.su

Front seat base frame: Removal - Refitting
a Refit:
pretensioners),
page 77A-1) ,
page 77A-16) ,
- the entire front seat (see 75A, Front seat frames
and mechanisms, Complete front seat: Removal - Refitting, page 75A-13) .
75A-6
http://vnx.su
75A

Front seatback frame: Removal - Refitting
75A

77A-8) .
Essential equipment
diagnostic tool
FRONT SIDE AIRBAG

a Remove the front side airbag (chest) (see Front
(chest) side airbag: Removal - Refitting) (88C,
Airbags and pretensioners).
Tightening torquesm
front seatback frame
bolts60
Nm
IMPORTANT

CONCERNED
IMPORTANT
IMPORTANT
127571
a Remove:
REMOVAL
- the seatback frame bolts (1) ,

- the front seatback frame (2) .

REFITTING
a Remove:
a Always replace the seatback frame bolts (1) .

CONCERNED

page 77A-16) ,
a Torque tighten the front seatback frame bolts60

(Nm) (1) .
a Refit the front seatback frame (2) .
75A-7
http://vnx.su

Front seatback frame: Removal - Refitting
FRONT SIDE AIRBAG
a Refit the front side airbag (chest) (see Front (chest)
side airbag: Removal - Refitting) (88C, Airbags
and pretensioners).
a Refit:
77A-8) ,
page 77A-16) ,
75A-8
http://vnx.su
75A

Front seat runner: Removal - Refitting
75A
DRIVER HEIGHT ADJUSTER or MANUAL AIR CON 1, and MANUAL PASSENGER SEAT 1
CONCERNED
Essential equipment
diagnostic tool
Tightening torquesm
front seat runner nuts
20 Nm
IMPORTANT
IMPORTANT
126876
a Remove:
- the nuts (1) from the front seat runners,

- the front seat runners.
REFITTING
IMPORTANT

a Always replace the front seat runner nuts (1) .
CONCERNED
REMOVAL
a Refit the front seat runners.
a Torque tighten the front seat runner nuts (20 Nm)

(1) .

a Remove:
pretensioners).
75A-9
http://vnx.su

Front seat runner: Removal - Refitting
DRIVER HEIGHT ADJUSTER or MANUAL AIR CON 1, and MANUAL PASSENGER SEAT 1
a Refit:
pretensioners),
tool (see Fault finding - Replacement of components)(88C, Airbags and pretensioners).
75A-10
http://vnx.su
75A

Rear seat access mechanisms: Removal - Refitting
75A
K61, and SHORT CHASSIS, and 2 ADDITIONAL REAR SEATS

CONCERNED
Essential equipment
diagnostic tool
1 - Rear seat access control.
REMOVAL
a Remove:
- the front seat (see 75A, Front seat frames and
mechanisms, Complete front seat: Removal Refitting, page 75A-13) ,
- the front seat "cover - foam" assembly partially
(see 77A, Front seat trim, Front seat base trim:
142564

WARNING
To avoid any risk of damaging the seat trims and
mechanisms, remove any metal residues of the
seat trim clips and/or from drilling the rivet.
a Remove the strap (2) for the rear seat access mechanism.
75A-11
http://vnx.su

Rear seat access mechanisms: Removal - Refitting
75A

2 - Rear seat access control.
2 - Front seat runners unlocking cable
a Refit:
- the strap for the rear seat access mechanism,
- a new rivet.
a Refit:
- the front seat base "cover - foam" assembly (see
77A, Front seat trim, Front seat base trim: Removal - Refitting, page 77A-1) ,
mechanisms, Complete front seat: Removal Refitting, page 75A-13) .
142565
a Remove the cable stop from the front seat runners

unlocking cable of the front seat base frame by turning it a quarter of a turn.

Note:
Mark the routing of the front seat unlocking cable
(3) .
a Unclip the unlocking cable of the front seat runners
on the front seat base frame.
a Release the unlocking cable from the front seat runners.
REFITTING
a parts always to be replaced: Rivet of rear seat
access control (70,08,04,36).
CONCERNED
1 - Front seat runners unlocking cable

a Engage the unlocking cable for the front seat runners.
a Position the unlocking cable of the front seat runners
on the front seat base frame.
a Refit the stop for the front seat runners unlocking cable on the front seat base frame by turning it a quarter of a turn.
75A-12
http://vnx.su

Complete front seat: Removal - Refitting
75A

Car. 1848
DRIVER HEIGHT ADJUSTER or MANUAL AIR

CON 1, and MANUAL PASSENGER SEAT 1 or
RETRACTABLE PASSENGER SEAT
Rear seat stop unlocking

forks
Essential equipment
diagnostic tool
Tightening torquesm
new front seat bolts
35 N.m
lower bolt of the front

seat belt
21 N.m
lower bolt of the front

seat belt
21 N.m
IMPORTANT
126870
a Move the front seat forwards.

a Remove:
- the trim (1) ,
IMPORTANT
- the lower bolt of the front seatbelt.

IMPORTANT
REMOVAL
75A-13
http://vnx.su

75A

CONCERNED
FOLDING PASSENGER SEAT

126871
a Tilt the front seat base.

a Remove:
- the lower bolt of the front seatbelt.
126872
a Remove the bolts (3) from the front seat.
75A-14
http://vnx.su

K61, and SHORT CHASSIS, and 2 ADDITIONAL

REAR SEATS
75A
126873
142486
a Fit the tool (Car. 1848) onto the runners of the front
seat at the rear (5) .
75A-15
http://vnx.su


REAR SEATS, and DRIVER HEIGHT ADJUSTER
or MANUAL AIR CON 1, and MANUAL PASSENGER SEAT 1 or RETRACTABLE PASSENGER
SEAT
75A
126871

126874
a Move the front seat back.

75A-16
http://vnx.su

75A

SEAT
141684
a Torque tighten in order (9) , (10) , (11) , (12) the new

front seat bolts (35 N.m) (3) , (4) , (6) and (7) .
126875
a Tilt the front seat backwards.

a Remove the protective flap for the connector.
a Refit the lower mounting of the front seat belt.
a Torque tighten the lower bolt of the front seat belt

(21 N.m) (1) .
a Remove the front seat.
a Refit the trim piece (1) .
REFITTING
a parts always to be replaced: Front seat mounting on body (70,06,02,01).

CONCERNED
a Refit the front seat.

a Refit the lower mounting of the front seat belt.
a Torque tighten the lower bolt of the front seat belt
(21 N.m) (2) .
a Refit the blanking cover (2) .
a Put the seat back into position.
a Refit the protective flap for the connector.
75A-17
http://vnx.su

75A-18
http://vnx.su
75A

Rear seat frame: Removal - Refitting
76A
REMOVAL
REFITTING

CONCERNED
a Refit:
- the rear seat runner (see 76A, Rear seat frames
and mechanisms, Rear seat runner: Removal Refitting, page 76A-2) ;

CONCERNED
a Remove:
- the rear seat base cover - foam assembly (see

78A, Rear seat trim, Rear seat base trim: Removal - Refitting, page 78A-1) ,
- the rear seat headrest (see 79A, Seat components, Rear headrest: Removal - Refitting, page
79A-6) ,
- the rear seat headrest guides (see 79A, Seat components, Rear seat headrest guide: Removal Refitting, page 79A-7) ,
- the rear seatback cover - foam assembly (see

78A, Rear seat trim, Rear seatback trim: Removal - Refitting, page 78A-4) ,
- the rear seatback cover - foam assembly (see

78A, Rear seat trim, Rear seatback trim: Removal - Refitting, page 78A-4) ,
- the rear seat headrest guides (see 79A, Seat components, Rear seat headrest guide: Removal Refitting, page 79A-7) ,
- the rear seat base cover - foam assembly (see
78A, Rear seat trim, Rear seat base trim: Removal - Refitting, page 78A-1) ,
- the rear seat runner (see 76A, Rear seat frames
and mechanisms, Rear seat runner: Removal Refitting, page 76A-2) .
79A-6) .
a Refit the rear seat.
142556
a
IMPORTANT
In order not to weaken a seat frame or bench
seat frame, all welding operations on the seat
frames or bench seat frames are forbidden.
76A-1
http://vnx.su

Rear seat runner: Removal - Refitting
76A
Tightening torquesm
new nuts of the rear
seat runner frame on
the rear seat frame
25 N.m
REMOVAL
a Remove:
- the rear seat,
- the cover - foam assembly of the rear seat base
(see 78A, Rear seat trim, Rear seat base trim:
142553
a Remove the runner casing from the rear seat at (2)

and (3) .

CONCERNED
142551
a Remove the side casings of the rear seat runners at

(4) and (5) .
142550
a Remove:
REFITTING
- the nuts (1) of the rear seat runner,

- the runner - runner casing assembly for the
rear seat.

a parts always to be replaced: Rear seat runner
mounting on 2nd row rear seat frame (70,14,02,
11).
CONCERNED
a Refit:
- the side casings of the rear seat runners,
76A-2
http://vnx.su

Rear seat runner: Removal - Refitting
- the rear seat runner casing,
- the runner - runner casing assembly for the
rear seat.
142550
a Torque tighten in order the new nuts of the rear

seat runner frame on the rear seat frame (25
N.m).
a Refit the cover - foam assembly of the rear seat
base (see 78A, Rear seat trim, Rear seat base
trim: Removal - Refitting, page 78A-1) .
76A-3
http://vnx.su
76A

Complete rear bench seat: Removal - Refitting
76A
K61
CONCERNED
Tightening torquesm
complete rear bench
seat bolts
44 Nm
universal joint bolt
62 Nm
REMOVAL
127473
a Unlock the quicklock rear bench seat hooks using a

screwdriver and a mallet through the openings (3) .
a Unlock the seat base in order to release the front
legs.
a Tilt the rear bench seat.
127472
a Remove:
- the bolts (1) ,
- the protective housing (2) .
76A-4
http://vnx.su

76A
K61
127474
127477
a Remove the universal joint bolt (6) .

a Tilt the universal joint (7) .
127475
a Strap the rear bench seat into place (5) .

127476
a Remove:
- the complete rear bench seat bolts (8) ,
- the complete rear bench seat (9) .
Note:
It is to advisable to take out the entire rear bench
seat in the vertical position through the side door.
76A-5
http://vnx.su

K61
REFITTING
a Always replace the bolts (8) .
CONCERNED
a Refit the entire rear bench seat (9) .
a Torque tighten the complete rear bench seat bolts
(44 Nm) (8) .
a Tilt the universal joint (7) .
a Torque tighten the universal joint bolt (62 Nm) (6) .
a Remove the strap (5) .
a Tilt the entire rear bench seat.
a Refit the front legs.
a Lock the quicklock hooks into position on the rear
bench seat by tilting the entire rear bench seat.
a Refit the protective cover (2) .
76A-6
http://vnx.su
76A

Rear bench seatback frame 1/3 and 2/3: Removal - Refitting
76A
K61
REMOVAL
a Refit:
- the 1/3 and 2/3 rear bench seat base frame (see 1/
3 and 2/3 rear bench seat:Removal - Refitting) ,
a Remove:
seat: Removal - Refitting, page 76A-4) ,
- the 1/3 and 2/3 rear bench seat seatback trim (see
78A, Rear seat trim, 1/3 and 2/3 rear bench seat
seatback trim: Removal - Refitting, page 78A-8)
,
,
- the 1/3 and 2/3 rear bench seat base frame (see 1/
3 and 2/3 rear bench seat:Removal - Refitting) .
CONCERNED
a Remove:
- the rear bench seat mechanism (see 76A, Rear
seat frames and mechanisms, Rear bench seat
mechanism: Removal - Refitting, page 76A-10) ,
- the rear seat belt stalks (see Rear seat belt buckle: Removal - Refitting) (88C, Airbag and pretensioners),
- the rear central seatbelt (see Rear centre seat
belt: Removal - Refitting) (88C, Airbag and pretensioners),
- the 1/3 and 2/3 rear bench seat base frame.
REFITTING
CONCERNED
a Refit:
- the 1/3 and 2/3 rear bench seat seatback frame,
- the rear central seatbelt (see Rear centre seat
belt: Removal - Refitting) (88C, Airbag and pretensioners),
- the rear bench seat mechanism (see 76A, Rear
seat frames and mechanisms, Rear bench seat
mechanism: Removal - Refitting, page 76A-10) .
76A-7
http://vnx.su

Rear bench seat base frame: Removal - Refitting
76A
K61
2 - Section 1/3
Tightening torquesm
2/3 seatback/base bolts
19 Nm
1/3 seatback/base bolts
19 Nm
REMOVAL
a Remove:
- the 1/3 and 2/3 rear bench seat base trim (see
trim: Removal - Refitting, page 78A-6) .
127478
a Remove:

CONCERNED
- partially the cover at (4) ,

- the 1/3 seatback/base bolts (5) ,
1 - Section 2/3
- the 1/3 rear bench seat base frame (6) .
REFITTING
a Always replace the seatback/base bolts (5) and (2) .
CONCERNED
1 - Section 2/3
a Refit:
- the 2/3 rear bench seat base frame (3) ,
- the cover at (1) .
a Torque tighten the 2/3 seatback/base bolts (19
Nm) (2) .
127479
a Remove:
- partially the cover at (1) ,
- the 2/3 rear bench seat base frame (3) .
76A-8
http://vnx.su

Rear bench seat base frame: Removal - Refitting
K61
2 - Section 1/3
a Refit:
- the 1/3 frame of rear bench seat (6) ,
- the cover at (4) .
a Torque tighten the 1/3 seatback/base bolts (19
Nm) (5) .
a Refit:
trim: Removal - Refitting, page 78A-6) ,
76A-9
http://vnx.su
76A

Rear bench seat mechanism: Removal - Refitting
76A
K61
Tightening torquesm
seat base lock bolts
23 N.m
seatback lock bolts
23 N.m
REMOVAL
a Remove:
.
127471
a Remove:

CONCERNED
- the seat base lock bolts (5) ,
a Note the lock cable routing for the backrest and the
seat base.
- the 1/3 and 2/3 seat base locks (6) .

a Remove the rear bench seat mechanism.
III - REMOVING THE REAR BENCH SEAT

MECHANISM CABLES
127470
a Remove:
- the bolts for the backrest locks (1) ,
- the rivet (2) ,
- the 1/3 and 2/3 backrest locks (3) ,
- the logicbox unit (4) .
132072
a Unclip the tie rod (7) on the seatback lock control.
76A-10
http://vnx.su

76A
K61
132073
a Unclip the cable on the seatback lock control at (8)

and (9) .
132075
a Open the logicbox at (12) .
132076
132074
a Unclip the cable on the seat base lock control at (10)

and (11) .
a Unclip the seat base lock unlocking cable at (13) and

(14) .
76A-11
http://vnx.su

76A
K61
Incorrectly fitted
132077
a Unclip the seatback lock unlocking cable sleeve at

(15) .
132078
Correctly fitted
a Remove the seatback lock unlocking cable mechanism assembly (16) .
REFITTING
a Always replace the bolts (1) , (5) and the rivet (2) .
II - REFITTING THE REAR BENCH SEAT
MECHANISM CABLES
a Refit the seatback lock unlocking cable mechanism assembly (16) .
a Clip:
- the seatback lock unlocking cable sleeve at (15) ,
- the seat base lock unlocking cable.
132079
a
Note:
When refitting the seatback lock mechanism, the
locking shaft must not be protruding from the
logicbox (1 7) but must be fitted flush with the
logicbox (18) .
76A-12
http://vnx.su

76A
K61
IV - FINAL OPERATION.
a Refit:
,
132080
a
Note:
In the event that the locking shaft is not flush with
the logicbox (17) , it is necessary to remove the
unlocking cable - mechanism assembly and
turn the bolt (19) then refit the unlocking cable mechanism assembly.
a Close the logicbox.
a Clip:
- the cable on the seat base lock control,
- the cable on the seatback lock control,
- the tie rod on the seatback lock control.
III - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the rear bench seat mechanism,
- the 1/3 and 2/3 seat base locks (6) .
a Torque tighten the seat base lock bolts (23 N.m)
(5) .
a Refit:
- the logicbox unit (4) ,
- a new rivet (2) ,
- the 1/3 and 2/3 backrest locks (3) .
a Torque tighten the seatback lock bolts (23 N.m) (1)
.
76A-13
http://vnx.su
FRONT SEAT TRIM

Front seat base trim: Removal - Refitting
REMOVAL

Car. 1363
77A
Essential equipment

SEAT
diagnostic tool
SEAT
a
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and operation recommendations before carrying out any
repair:

a Remove the front seat (see 75A, Front seat frames
and mechanisms, Complete front seat: Removal
- Refitting, page 75A-13) .
- (see A i r b ag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners),
- (see Vehicle: Precautions for repair) (01D,
Mechanical introduction).
IMPORTANT
diagnostic tool.
142568
IMPORTANT
a Unclip the blanking cover (1) from the front seatback

angle adjustment control using the tool (Car. 1363).
77A-1
http://vnx.su
FRONT SEAT TRIM

77A

REAR SEATS, and MANUAL AIR CON 1, and
MANUAL PASSENGER SEAT 1
142567
a Remove the front seatback angle adjustment control.

142560
a Remove the elastic retaining strap (2) on the seatback cover.
142566
a Remove the exterior casing from the front seat base.
77A-2
http://vnx.su
FRONT SEAT TRIM

77A
- the front seat lower casings (see 77A, Front seat

trim, Front seat lower cover: Removal - Refitting, page 77A-16) .
127365
a Remove the elastic retaining strap (3) on the seatback cover.
127367
a Tilt the front seat base.

127368
a Remove:
- the elastic retaining strap (4) on the seatback cover,
77A-3
http://vnx.su
FRONT SEAT TRIM

77A

CONCERNED
142559
a Remove the two elastic retaining straps (6) from the

seat base cover.
142569
a Unclip the side retaining clips using the tool (Car.

1363) or unclipping pliers.
127366
142570
a Remove the front, rear and side retaining sections

(5) using the tool (Car. 1363).
a Remove the retaining sections (7) from the seat

base cover using the tool (Car. 1363).
77A-4
http://vnx.su
FRONT SEAT TRIM

77A
127369
a Remove:
127367
a Remove the retaining sections (11) from the seat

- the clips (8) ,

- the retaining sections (9) from the seat base cover
using the tool (Car. 1363).
a Remove the foam - cover assembly from the

front seat base.
142571
a Remove the front seat base cover (12) .

127370
a Remove the elastic retaining straps (10) from the

seat base cover.
77A-5
WARNING
To avoid any risk of damaging the foam, separate
the cover from the foam by holding the velcro
strips.
http://vnx.su
FRONT SEAT TRIM

77A
REFITTING
a Refit:
- the elastic retaining straps on the seat base cover,
- the front, rear and side retaining sections (5) .
a Clip on the side retaining clips.

a Refit the retaining sections (7) for the seat base cover.
138022
a Align the velcro strips with the marks.
a Refit:
Note:
- the elastic retaining straps (10) on the seat base

cover,
The pre-markings on the foam are a guide for

positioning the ends of the velcro strips.
- the retaining sections (9) on the seat base cover,

- the clips (8) .
WARNING
To avoid any risk of detaching or creating folds in
the cover, check that the velcro strips are secured correctly on the foam. If the velcro strips tear,
replace the foam.

a Refit the retaining strips (11) on the seat base cover.

CONCERNED
a Refit:
- the front seat base cover (12) on the foam,
- the foam - cover assembly on the front seat base.

a Refit the elastic retaining strap (2) on the seatback
cover.
77A-6
http://vnx.su
FRONT SEAT TRIM


a Refit the elastic retaining strap (3) on the seatback
cover.

a Refit:
- the front seat lower casings (see 77A, Front seat
trim, Front seat lower cover: Removal - Refitting, page 77A-16) ,
- the elastic retaining strap (4) on the seatback cover.

a Put the seat in its initial position.

SEAT
a Refit:
- the exterior casing for the front seat base,
- the front seatback angle adjustment control,
- the blanking cover for the front seatback angle adjustment control,
77A-7
http://vnx.su
77A
FRONT SEAT TRIM

Front seatback trim: Removal - Refitting


Car. 1558
77A
Pliers for zip fastener.
Essential equipment
a Remove the front seat lower covers (see 77A, Front

seat trim, Front seat lower cover: Removal - Refitting, page 77A-16) .
diagnostic tool
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and operation recommendations before carrying out any
repair:

CONCERNED
- (see Airbag and Pretensioners: Precautions

for repair) (88C, Airbag and pretensioner),
MANUAL AIR CON 1, and MANUAL PASSENGER

SEAT 1
- (see Vehicle: Precautions for repair) (01D,

Mechanical introduction).
IMPORTANT
IMPORTANT
127371
a Remove the elastic retaining strap (1) for the seatback cover.
REMOVAL
a Remove:
- the front seat headrest (see 79A, Seat components, Front headrest: Removal - Refitting,
page 79A-1) ,
77A-8
http://vnx.su
FRONT SEAT TRIM


REAR SEATS
77A

SEAT 1
142560
a Remove the elastic retaining straps (2) for the seatback cover.
127423
a Remove:
- the headrest guides (3) ,
- the side retaining section (4) of the seatback cover.
142705
a Remove the rear retaining section (5) of the seatback cover.
77A-9
http://vnx.su
FRONT SEAT TRIM

77A
127425
a Partially lift the front seatback cover (6) .

127414
a Remove the upper stops of the backrest (9) .
127426
a Partially remove the front seatback cover at (7) and

at (8) .
127415
a Remove the backrest assembly at (10) .

WARNING
strips.
77A-10
http://vnx.su
FRONT SEAT TRIM

127416
77A
127417
a Unclip the head rest guides (11) .
a Cut the clip (14) using pliers.
a Remove the seatback cover retaining sections (12) .
a Undo the zip fastener (15) .
127409
77A-11
http://vnx.su
FRONT SEAT TRIM

77A
1 - With seatback casing - folding table

assembly on front seatback
DRIVER HEIGHT ADJUSTER, and RETRACTABLE PASSENGER SEAT
127420

127418
a Remove:
- the rivets (16) of the folding table,
- the seatback casing - folding table assembly on
the front seatback.
127419
77A-12
http://vnx.su
FRONT SEAT TRIM

77A
2 - Without seatback casing - folding table

127411
127409

REAR SEATS
142558
127410
77A-13
http://vnx.su
FRONT SEAT TRIM

77A
a Remove:
- the headrest guides (see 79A, Seat components,
Front seat headrest guide: Removal - Refitting,
page 79A-4) ,
- the "foam - cover" assembly of the front seatback.
138022
142561
a Remove the front seatback trim (24) .
WARNING
strips.
Note:
REFITTING

CONCERNED
a Refit the foam of the front seatback (24) on the front

seat frame.
a parts always to be replaced: Seat trim clip (70,10,

02,19).
a parts always to be replaced: Seatback parcel
shelf rivet (70,18,02,17).
WARNING
replace the foam.
a Refit the front seatback cover.

1 - With seatback casing - folding table

a Clip on the headrest guides (19) for the front seat.
a Refit:
- the retaining sections of the seatback cover (18)
and (17) on the front seat,
- the seatback casing - folding table assembly on
the front seatback,
- new rivets on the folding tables (16) .
77A-14
http://vnx.su
FRONT SEAT TRIM

77A
- the headrest guides (3) of the front seat (see Front

bench seat headrest guide: Removal - Refitting)
,
2 - Without seatback casing - folding table

- the elastic retaining strap (1) on the front seatback

cover.

a Refit the retaining sections of the seatback cover
(22) and (21) on the front seat.


a Refit the elastic retaining straps (20) on the front
seatback cover.
a Refit the front seat lower covers (see 77A, Front

seat trim, Front seat lower cover: Removal - Refitting, page 77A-16) .
a Refit:

a Close the zip fastener (15) using the tool (Car.

1558).
page 79A-1) .
a Refit:
- a new clip (14) ,
- the elastic retaining straps (13) on the front seatback cover.


a Refit the retaining sections (12) on the front seatback cover.
a Clip on the headrest guides (11) for the front seat.
a Refit:
- the front seatback casing,
- the upper stops (9) of the front seatback.

a Refit:
- the front seatback cover (6) ,
- the rear retaining section of the seatback cover (5)
and side cover (4) on the front seat,
77A-15
http://vnx.su
FRONT SEAT TRIM

Front seat lower cover: Removal - Refitting
77A
REMOVAL
Essential equipment
diagnostic tool

a
IMPORTANT
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see Airbag and Pretensioners: Precautions for repair) (88C, Airbags and pretensioners).
IMPORTANT
diagnostic tool.


CONCERNED

MANUAL AIR CON 1, and RETRACTABLE PASSENGER SEAT
IMPORTANT
127377
a Remove the trim (1) .
77A-16
http://vnx.su
FRONT SEAT TRIM

77A
127378
a Unclip the front seatback hinge control (2) (exterior

part).
127380
a Remove:
- the bolts (5) ,
- the front seat lower cover (6) (internal part).
127380
a Remove:
127381
a Remove the trims (7) .
- the bolts (3) ,

- the front seat lower cover (4) (exterior part).
77A-17
http://vnx.su
FRONT SEAT TRIM

77A

127382
a Remove:
- the bolts (8) ,
- the front seat base height adjuster control (9) (exterior part).
a Unclip the seatback hinge control (1 0) (exterior
part).
127385
a Unclip the front seat lower cover (13) (internal part).
127383
a Remove:
- the bolt (11) ,
- the front seat lower cover (12) (exterior part).
77A-18
http://vnx.su
FRONT SEAT TRIM

77A
- the bolts (3) .


a Refit:
- the front seat lower cover (12) (exterior part),
- bolt (11) .
a Clip the seatback hinge control into position (10) (exterior part).
a Refit:
- the front seat base height adjustment control (9)
(exterior part),
- the bolt (8) ,
- the trims (7) .
127384
a Unclip the handle (14) at (15) and at (16) (exterior

part).

a Clip on the front seat lower cover (13) (internal part).
REFITTING

CONCERNED
a Clip on the handle (14) (exterior part).
MANUAL AIR CON 1, and RETRACTABLE PASSENGER SEAT

a Clip the front seatback hinge control into position (2)
(exterior part).

a Refit:
- the front seat lower cover (6) (internal part),

- the bolts (5) ,

- the front seat lower cover (4) (exterior part),
77A-19
http://vnx.su
REAR SEAT TRIM

Rear seat base trim: Removal - Refitting
78A

Car. 1363
REMOVAL
142546
a Drill out the rivets (2) of the rear seat runner casing.
WARNING
To avoid any risk of damaging the seat trims and
mechanisms, remove any metal residues from
the seat trim clips and/or from drilling the rivet.
142543
a Remove the casing from the rear seat runners at (3)

.
a Partially detach the cover (4) of the rear seat base.
a Remove:
- the rear seatback angle adjustment control using
unclipping pliers,
- the rear seat belt stalks (see Rear seat belt buckle: Removal - Refitting) (88C, Airbag and pretensioners).
CONCERNED
142548
a Remove:
142552
- the rear retaining section (5) of the rear seat base

cover,
a Unclip the retaining sections (1) of the rear seat

- the elastic retaining strap (6) of the rear seat base

cover.
78A-1
http://vnx.su
REAR SEAT TRIM

78A
REFITTING
a
WARNING
replace the foam.
a parts always to be replaced: Rivet of rear seat
runner casing (70,14,04,34).
142547
a Remove:
- the cover - foam assembly partially,
- the cover at the hinges of the rear seat frame (7) ,
- the cover - foam assembly.
138022

Note:
142549
a Remove the cover of the rear seat base.

WARNING
strips.

CONCERNED
a Refit:
- the cover over the foam of the rear seat base,
- the cover - foam assembly of the rear seat base,
- the cover at the hinges of the rear seat frame.
a Refit:
- the elastic strap (6) for the rear seat base cover,
78A-2
http://vnx.su
REAR SEAT TRIM

- the rear retaining section (5) of the rear seat base
cover.
a Reposition the rear seat base cover (4) .
a Check that there are no folds in the cover.
a Refit new rivets on the casing of the rear seat runners.
a Clip on the retaining sections (1) of the rear seat
base cover.
a Refit:
- the rear seatback angle adjustment control,
- the rear seat.
78A-3
http://vnx.su
78A
REAR SEAT TRIM

Rear seatback trim: Removal - Refitting
78A

Car. 1558
REMOVAL
a Fold down and lock the rear seatback.
a Remove:
- the rear seat,
79A-6) .
CONCERNED
a Open the zip fastener of the rear seatback cover.
142545
a Remove:
- the rear seatback cover partially,
- the guides of the rear seat headrest (see 79A, Seat
components, Rear seat headrest guide: Removal - Refitting, page 79A-7) ,
- the cover - foam assembly of the rear seatback
trim.
WARNING
strips.
a Remove the rear seatback cover.
REFITTING
142544
a Unclip the retaining sections (1) of the rear seatback

cover.

a
WARNING
replace the foam.
a Unlock and lift the rear seatback.
78A-4
http://vnx.su
REAR SEAT TRIM

Rear seatback trim: Removal - Refitting
78A
138022
142557
a Close the zip fastener of the rear seatback cover

using the tool (Car. 1558) and with the help of a second operator.

Note:
The markings on the foam are a guide for positioning the ends of the velcro strips.
WARNING
To avoid any risk of damaging the zip fasteners,
close the zips using the tool (Car.1558) while
keeping the zips taut with the two edges as close
as possible to each other.

CONCERNED
a Refit:
- the rear seatback foam on the frame,
- the rear seatback cover,
a Refit:
- the guides of the rear seat headrest (see 79A, Seat

components, Rear seat headrest guide: Removal - Refitting, page 79A-7) ,
79A-6) ,
- the retaining sections (1) of the rear seat cover.
- the rear seat.
a Check that there are no folds in the cover.
78A-5
http://vnx.su
REAR SEAT TRIM

1/3 and 2/3 rear bench seat trim: Removal - Refitting
78A
1 - 1/3 rear bench seat cushion trim:
REMOVAL
a Remove the complete rear bench seat (see 76A,
Rear seat frames and mechanisms, Complete
rear bench seat: Removal - Refitting, page 76A-4)
.
CONCERNED
127483
a Remove the 1/3 rear bench seat cushion trim (2) .

127373
a Remove:
- the retaining sections (1) ,
- the foam - trim assembly for the 1/3 and 2/3
rear bench seat cushion.
127482
a Remove the 2/3 rear bench seat cushion trim (3) .
a
Note:
Hold the velcro strips while separating the
foam-trim .
78A-6
http://vnx.su
REAR SEAT TRIM

1/3 and 2/3 rear bench seat trim: Removal - Refitting
REFITTING
CONCERNED
a
Note:
Before refitting the 1/3 and 2/3 rear bench seat
cushion trim, check that the velcro strips are properly attached to the foam.
a Refit the 1/3 rear bench seat cushion trim (2) .
a Refit the 2/3 rear bench seat cushion trim (3) .
a Refit:
- the foam - trim assembly for the 1/3 and 2/3
rear bench seat cushions,
- the retaining strips (1) .
a Refit the entire rear bench seat (see 76A, Rear seat
78A-7
http://vnx.su
78A
REAR SEAT TRIM

1/3 and 2/3 rear bench seat seatback trim: Removal - Refitting
78A
K61
Car. 1558
REMOVAL
a Remove:
- the rear left-hand side seat belt buckle (see Rear
side seat belt: Removal - Refitting) (88C, Airbags and pretensioners).
CONCERNED
127465
a Unlock the headrests at (3) .

a Remove the headrests (4) .
a Unclip the blanking cover for the centre rear seat
belt guide (5) .
1 - 1/3 rear bench seat seatback trim:
127460
a Remove the trims (1) at (2) .
127463
a Remove the clips (6) and (7) .

a Open the zip fasteners (8) .
78A-8
http://vnx.su
REAR SEAT TRIM

78A
K61
127464
a Remove the retaining sections (9) .
127469

a Remove the 1/3 rear bench seat seatback trim foam assembly (12) .
127478
a Partially remove the 1/3 rear bench seat seatback

cover at (10) .
127466
a Remove:
- the bolts (13) ,
- the rear centre seat belt guide (14) .
78A-9
http://vnx.su
REAR SEAT TRIM

78A
K61
127461
a Partially remove the 2/3 rear bench seat seatback

cover at (19) .
a Remove the clips (15) and (16) .

a Open the zip fasteners (17) .
127462
a Remove the retaining sections (18) .
127479
127468

a Remove the 2/3 rear bench seat seatback trim foam assembly (21) .
78A-10
http://vnx.su
REAR SEAT TRIM

78A
K61
a Refit the 1/3 rear bench seat seatback trim foam assembly.
a Clip on the headrest guides (11) .
a Refit:
- the 1/3 rear bench seat seatback cover,
a Close the zip fasteners (8) using the tool (Car.
1558).
a Refit the new clips (7) and (6) .
a Refit the 2/3 rear bench seat seatback trim foam assembly (21) .
127481
a Remove the 1/3 and 2/3 rear bench seat seatback

trim (22) ,
a Clip on the headrest guides (20) .

a Refit:
- the 2/3 rear bench seat seatback cover,
Note:
Hold the velcro strips while separating the

foam-trim .
a Close the zip fasteners (17) using the tool (Car.

1558).
a Refit:
REFITTING
- the new clips (16) and (15) ,
- the rear centre seat belt guide (14) .
a Always replace:
- the clips (6) , (7) , (15) and (16) ,
a Clip on the blanking cover of the centre rear seat belt

guide (5) .
- the trims (1) .

CONCERNED
a Refit:
- the headrests (4) ,
- the new trims (1) .
Note:
Before refitting the 1/3 and 2/3 rear bench seat
seatback trim, check that the velcro strips are
properly attached to the foam.
a Refit the 1/3 and 2/3 rear bench seat seatback trim
(22) .
a Refit:
- the rear left-hand side seat belt buckle (see Rear
side seat belt: Removal - Refitting) (88C, Airbags and pretensioners),
78A-11
http://vnx.su
SEAT COMPONENTS
Front headrest: Removal - Refitting
79A
REMOVAL
SEAT 1 or RETRACTABLE PASSENGER SEAT

CONCERNED
127421
a Unlock the front seat headrest by pushing at (2) and

using a small flat-blade screwdriver to press at (3) .
127413
a Unlock the front seat headrest by pushing at (1) .
79A-1
http://vnx.su
SEAT COMPONENTS
79A

REAR SEATS
127422
a Unlock the front seat headrest by pushing at (4) .
142487
a Press the unlocking button (5) of the front seat headrest guide.
Note:
The front seat headrest has an integrated control.
a Remove the front seat headrest.
REFITTING
a
IMPORTANT
To avoid any risk of incorrectly positioning the
rods of the front seat headrest, align the rods
before inserting them in the headrest guides.
79A-2
http://vnx.su
SEAT COMPONENTS
Headrest rods misaligned
142683
Headrest rods aligned
142684
a Bring the rods out of the front seat headrest as far as

possible by pulling upwards.
a Clean the rods of the front seat headrest.
a Insert the rods of the front seat headrest in the headrest guides.
a Push the front seat headrest until it locks into place
with the locking notches then adjust the headrest to
the low position.
IMPORTANT
To prevent the headrest coming away from the
guide during a collision, check that headrest
guide locking system is functioning correctly.
79A-3
http://vnx.su
79A
SEAT COMPONENTS
Front seat headrest guide: Removal - Refitting
79A

CONCERNED
Essential equipment
diagnostic tool
REMOVAL
a Remove:
page 79A-1) ,
142562
- the front seatback cover partially (see 77A, Front

seat trim, Front seatback trim: Removal - Refitting, page 77A-8) .
142563
a Remove the front seat headrest guides.
79A-4
http://vnx.su
SEAT COMPONENTS
Front seat headrest guide: Removal - Refitting
REFITTING
CONCERNED
a Refit the headrest guides fully into the front seatback
frame.
Note:
To prevent the headrest guides from being mixed
up, each headrest guide has a specific indexing
device.
a Check that the headrest guides are secure in the
front seatback frame.
a Refit:
- the front seatback cover (see 77A, Front seat
trim, Front seatback trim: Removal - Refitting,
page 77A-8) ,
page 79A-1) ,
tool (see Fault finding - Replacement of components)(88C, Airbag and pretensioners).
IMPORTANT
guide during a collision, check that the headrest
79A-5
http://vnx.su
79A
SEAT COMPONENTS
Rear headrest: Removal - Refitting
REMOVAL
CONCERNED
142488
a Press the rear seat headrest guides at (1) .

a Remove the rear seat headrest.
REFITTING
a Refit the rear seat headrest.
IMPORTANT
79A-6
http://vnx.su
79A
SEAT COMPONENTS
Rear seat headrest guide: Removal - Refitting
79A
REMOVAL
REFITTING

CONCERNED
a Remove:
a Refit the rear seat headrest guides.
- the rear seat,

79A-6) ,
a Refit:
- the rear seatback cover partially (see 78A, Rear
seat trim, Rear seatback trim: Removal - Refitting, page 78A-4) ,
- the rear seatback cover partially (see 78A, Rear

seat trim, Rear seatback trim: Removal - Refitting, page 78A-4) .
79A-6) .

CONCERNED
IMPORTANT
142554
142555
a Unclip the rear seat headrest guides (1) and (2) .

a Remove the rear seat headrest guides (2) .
79A-7
http://vnx.su

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0

General vehicle information

VEHICLE MECHANICAL SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

All copyrights reserved by Renault.

Renault s.a.s 2008

KANGOO II - Section 0 ContentsPage

VEHICLE MECHANICAL SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

Vehicle damaged at rear:

Vehicle damaged at front:

VEHICLE MECHANICAL SPECIFICATIONS

VEHICLE MECHANICAL SPECIFICATIONS

VEHICLE MECHANICAL SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

III - DETAILED VIEW OF THE VEHICLE

I - LOCATION OF VEHICLE IDENTIFICATION

II - LOCATION OF THE VEHICLE IDENTIFICATION

Vehicle type mine and type number; this information also

MGVW (Maximum Gross Vehicle Weight)

GTW (Gross train weight, vehicle under load with trailer)

Maximum permissible front axle

Maximum permissible rear axle

Vehicle technical specifications

Paintwork reference number

Additional equipment details

Interior trim code

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

When adjusting clearances, certain rules have to be

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

(X16) = 4.5 mm 1.5

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

(X24) = 3.3 mm 1 (without blocker) / 3.7 mm 1

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

K61, and SHORT CHASSIS

(X40) = 1.5 mm 1.5

VEHICLE BODYWORK SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

- protect the accessories and timing belts, the electrical

2 - Special tooling - ease of use

- replace roll pins, self-locking or bonded nuts or bolts

- do not pull on the wiring,

New repair procedures are constantly being developed

Operations on certain equipment and certain parts (for

The procedures contained in this document merit your

The safety symbol used in this manual indicates that

Following the recommended procedures will help you

Maintenance and repair operations must be carried out

The property class is indicated on the bolt (1) or (2) .

The bolting system connects parts of an assembly to

* Special notes on the electrical earths

The assembly is submitted to forces that are:

Creating tension (or preload) F0

III - TIGHTENING PROCEDURES

The assembly is held together by the tension created in

This practise spreads the tension significantly due to

- insufficient tension: risk of loosening,