Megane break sheetmetal

7/31/2019 Megane break sheetmetal

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EXPLODED VIEW

DI4017R


3/82

Contents

GENERAL

Dimensions

Engine and equipment

Identification

Using symbols

Key to symbols

Description of parts (exploded)Opening clearances

40-1

40-2

40-2

40-3

40-5

40-640-7

LOWER STRUCTURE

41-1

41-2

41-5

41-741-8

41-11

41-14

PagePage

40

41

Sheet metal work

UPPER SIDE STRUCTURE43

A Absorber support mountingB Rear floor baseC Rear floor base supp ort

D Rear floor base fron t stiffenerE Rear end pillar lower reinforcementF Rear end cross mem ber assemblyG Rear floor unit

43-1A Top of body NON-SIDE OPENING ELEMENTS48

TOP OF BODY

SIDE OPENING ELEMENTS

45

47

45-1

45-6

45-845-10

A RoofB Roof acoustic cross mem ber

C Roof bowD Roof rear cross mem ber

47-1

48-1A Tailgate

A Rear door p anel

UPPER REAR STRUCTURE44

44-1

44-10

44-12

44-15

44-20

44-2144-27

44-31

A Rear wing pan elB Rear lights mou ntingC Upper side drip m ouldingD Rear pillar reinforcementE Rear inner wh eel arch

F Rear qu arter p anel lining assemblyG Outer w heel archH Rear end panel


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GENERAL

Dimensions 40

15309R

Dimensions in metres

* Unladen.

40-1


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GENERAL

Engine and equipment 40

(1) If necessary, un leaded fuel with an octane rating of 91 may be u sed.

Vehicle

typeVersion

Engine

Type Ratio InjectionCapacity

(cm3)

Idle speed

(rpm)Fuel type

KA0M

KA0V1.4 l E7J 9.5/ 1 Multipoint 1390

Non-

adjustable

Unleaded

95 or 98 (1)

KA0W

KA0D

1.4 l

16 VK4J 10/ 1 Multipoint 1390

Non-

adjustable

Unleaded

95 or 98 (1)

KA04

KA0B

1.6 l

16 VK4M 10/ 1 Multipoint 1598

Non-

adjustable

Unleaded

95 or 98 (1)

KA0J

VA0J1.9 l D F8Q 21.5/ 1 Indirect 1870 82550 Diesel

KA05

VA05

KA0N

VA0N

KA01

VA01

1.9 l

Dti

F9Q

Turbo18.3/ 1 Direct 1870

85050

Non-

adjustable

Diesel

Vehicle Rim Tyres

Tyre inflation pressure -

cold (bar) (1)

Front Rear

KA0M/ KA0V

KA0W/ KA0D5.5 J 14 175/ 70 R 14 2.2 2.0

KA04/ KA0B 6.0 J 15 185/ 60 R 15 2.2 2.0

KA0J/ VA0J 6.0 J 15 175/ 70 R 14 2.2 2.0

KA0N/ VA0N

KA05/ VA05

KA01/ VA01

6.0 J 15 185/ 60 R 15 2.2 2.0

(1) Fully laden and m otorway use.

Tightening torque for wheel nuts : 9 daN.m

Rim ru n-out: 1.2 mm

Identification

40-2


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GENERAL

Using symbols 40

11644R1

The above diagram show s parts on the vehicle for

wh ich a section of the panel butt w elding joint is

shown by the diagram s which follow.

This dashed line show s the centre line

of the sections

The point show s the exact position of

the w eld join

This letter d esignates the d rawing

corresponding to the section (It is gi-

ven in one of the up per corners of

each drawing )

F - G -H - I - J

CAA11538R8

G

1

e = 1+1

7

The following ind ications are found in th e section

diagrams :

The part in black is the one wh ich w illbe removed in th e operation

are the part nu mbers correspond ing to

the list on the introduction page1 and 7

e = 1 + 1are the th icknesses (in mm) of the

pan els affected by the spot weld

This arrow on the d iagram designatesthe access point for the u np icking of

spot weld s (see specific cases)

It also indicates the logical sequen ce of operations

in the symbols wh ich follow each diagram.

place of operation and logical sequen ce

spot welding

weldable m astic

unpicking with grinder

Example :

40-3


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GENERAL

Using symbols 40

The references which follow indicate d ifferentoperations :

unpicking

welding

SPECIFIC CASES

CAA11537-1R6

J

12

In this examp le, there is no d irect access for rem o-

ving part 1. The spot w elds should be u npicked

through part 2, which should be kept.

CAQ11697-1R5

I12

This arrow ind icates that it is necessary

to cut th e part it crosses before acces-

sing the joint.

Under diagram I

unpicking

with grinder

app ly weld fil-

let

1st opera-

tion

site of operation and order of operations

10354R

D

In this particular case, the arrow ind icates that

the joint is made by arc welding (MIG).

10349R

E

In this examp le, the joint is

made by bonding.

chisel the ed ge 2nd opera-

tion

40-4


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GENERAL

Key to symbols 40

- Cutting out part by grinding off flange

or grind ing back remaining traces of

spot weld.

- Finish surface after welding.

- Angle grinder equipped with a rubber

pad and a 120 to 180 mm diameter

fibre disc grain size P36.

Chiselling

Grind back beads or spot w elds.Straight grinding w heel with 75 mm

diameter bakelite impregnated disc,

thickness 1.8 to 3.2 mm .

Grind back spot welds.

20 000 rp m straight gr inder with 10 or 16

mm d iameter spherical burr.

Drill spot welds.

Hard ened steel bit. Speed of rotation 800

to 1 000 rpm .

Unpicking

Cleaning sur faces to be welded.

100 mm d iameter fibre d isc.

Cutting with a saw.

Pneum atic pow er hacksaw.

Unsoldering.

Plug welding.

Und er MAG gas protection.

Crimping of exterior d oor p anels.

Safety sym bol.

This means that the welding operation

in question concerns one or more of the

vehicles vital safety compon ents.

Body solder - lead fill.

Hot air torch.

Nozzle outpu t temperature 600 min.

Slipper+ 33 % tin solder + ta llow.Note : to a large extent, body solder

filling comp ensates for the heat

distortion caused by welding.

App lication of weldable mastic.

This mastic conducts electricity, app lied

between two p anels to be spot welded,

it ensures the seal between the pan els

and avoids corrosion of the spot w elds.

App lication of aluminium paint.

This is to be ap plied to the joint faces of

each of the par ts to be plug welded .

The paint cond ucts electricity and is is

resistant to high temperatu res. It

provides anti-corrosion protection

around the plug welds.

Apply a fillet of extruded mastic from a manual or pneumatic spray

gun.

one or two pot mastic for crimped

and butt joints.

Spray on sealer

sp ray gu n.

two pot anti-gravel and anti-

corrosion mastic.

MAG stitch weld

Note : to obtain a good qu ality weld w e

recomm end the u se of a gas consisting

of argon + 15 % CO2. This is

considered to be an active gas (MAG).

Spot w eld

40-5


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GENERAL

Description of parts (exploded view) 40

PRE4005

290 Roof

* 291 Roof rear cross mem ber

292 Absorber su p por t

293 Rear en d p an el

294 Ligh ts m ou ntin g

295 Tailgate

* 296 Wing panel

* 297 Top of body

* 298 Rear door

* 299 Rear door panel

300 Rear end pillar lower reinforcement

* 301 Rear en d cross m em ber

302 Emergency spare wheel mounting sup-

port

303 Rear floor base

* Parts for wh ich rep aired areas mu st be electro zinc plated

304 Base su pp ort

305 Base stiffener

* 306 Sill panel

* 307 Front pillar

* 308 Body side, fron t section

309 Rear floor u nit

310 Rear pillar reinforcement

* 311 Rear quarter panel lin ing assembly

312 In ner wh eel ar ch

313 Stretcher extension

314 Roof cross member support

* 315 Wing p an el d rip mou ld in g

316 Sp eaker su p por t

317 Roof st iffener

40-6


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GENERAL

Opening clearances 40

15072R2

40-7


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GENERAL


15344R

1

15348R

15342R 15345R

2

3

4

40-8


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GENERAL


15346R

5

15343R

15347R

6

7

40-9


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LOWER STRUCTURE

Absorber support mounting

INTRODUCTION

Basic operation for a rear imp act.

This part is moun ted by three M8 nuts on the rearend p anel.

COMPOSITION OF PART FROM PARTS

DEPARTMENT

Single par t.

251a01-15362

41 A

PRE4105

41-1


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LOWER STRUCTURE

Rear floor base

This part m ay be replaced in tw o ways:

A comp letely, as a complementary operation to

the rear end cross member.

B by p art section, as a comp lementary operation

to the rear end pillar lower reinforcement.

The method described only contains d escriptions

of joints specific to the part concerned . Joints w ith

complementary parts are not includ ed.

These are dea lt with in th eir respective section (re-

fer to the contents page).

COMPOSITION OF PART FROM PARTSDEPARTMENT

Single par t.

PRE4106

41 B

or

PARTS CONCERNED (thickness in mm) :

1 Rear floor base 0.82 Rear end cross member 0.8

3 Rear end pillar lower reinforcement 14 Rear floor 0.75 Body side lining 0.76 Rear inner wheel arch 0.87 Rear floor base side side-member 18 Rear floor base intermediate st iffener 0.89 Rear floor base front stiffener 0.8

41-2


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LOWER STRUCTURE

Rear floor base

251b01-15363

41 B

A

CAS13033R1

1 1

C

CAA11538R3b

3

1

B

CAR11700R6

2 1

D

CAA11536-4R1

14

E

CAF11547-2R4

1

3

5

41-3


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LOWER STRUCTURE

Rear floor base 41 B

F

CAA11538R3a

1

5

G

CAA11538R4

1

6

H

CAA11538-1R6

1

8

I

CAW13605-4R2

1 1

8

J

CAA11536-3R5

1 1

K

CAS13028R4

1 19

41-4


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LOWER STRUCTURE

Rear floor base support

PRE4107

41 C

INTRODUCTION

The replacement of this par t is a complementary

operation to the rear floor base.







DEPARTMENT

Part assembled w ith:- rear floor base side side-member,

- rear floor base intermediate stiffener,

- rear floor base front st iffener.


1 Rear floor base side side-member 12 Rear floor base intermediate st iffener 0.8

3 Rear floor base front stiffener 0.84 Rear floor 0.75 Rear side member 1.2

41-5


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LOWER STRUCTURE

Rear floor base support

251c01-15364

41 C

A

CAT13327R3

1

4

5

B

TOI14637-4R5

1

24

C

CAA11538R5

13

41-6


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LOWER STRUCTURE

Rear floor base front stiffener

PRE4108

41 D

INTRODUCTION


operation to the rear floor base supp ort.







DEPARTMENT

Single par t.


1 Rear floor base front stiffener 0.82 Rear floor 0.7

251d01-15364-1

A

CAA11538R1

12

41-7


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LOWER STRUCTURE

Rear end pillar lower reinforcement

PRE4109

41 E

INTRODUCTION


operation to the rear end cross member.




These are dealt with in th eir respective section (re-



DEPARTMENT

Part assembled with welded n uts.


1 Rear end pillar low er reinforcement 1

2 Rear end cross member 0.83 Body side lining 0.74 Rear end pillar lining 15 Rear floor 0.76 Rear side member 1.27 Lights mounting 0.78 Rear end pillar lining 1

41-8


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LOWER STRUCTURE

Rear end pillar lower reinforcement

251e01-15365

41 E

A

CAA11537R4

1

2

B

CAN11689R4

1

7

C

CAD11545R4

1

7

8

D

CAA11536-2R7

1

8

E

CAA11536R7

1

3

41-9


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LOWER STRUCTURE

Rear end cross member assembly

PRE4110

41 F

INTRODUCTION


operation to the rear end p anel.







DEPARTMENT

Part assembled w ith:- st riker plate reinforcement,

- cen tral rein forcement.


1 Rear end cross member 0.82 Rear end pillar low er reinforcement 13 Rear floor base 0.84 Rear floor 0.75 Tailgate striker p late central

reinforcement 1.2

6 Rear floor central reinforcement 0.8

41-11


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LOWER STRUCTURE


251f01-15367

41 F

A

CAN11689R5

1 4

B

CAA11538-1R8

1

4

C

CAS13024-4R5

1 5

6

D

CAA11537-1R1a

12

E

CAA11536-1R2

61

41-12


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LOWER STRUCTURE


251f02-15363-1

41 F

F

CAR11700-1R4

1 3

G

CAA11537-1R5

1 2

41-13


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LOWER STRUCTURE

Rear floor unit

PRE4111

41 G

INTRODUCTION

The replacement of this par t is iden tical to the me-

thod described in the basic manual (M.R. 313 -

Section 41). Only the joints at the r ear en d pillarlower reinforcements are different, which are des-

cribed in this document (section 41-E).






COMPOSITION OF PART FROM PARTSDEPARTMENT

Part assembled w ith:

- side member assemblies,

- floor assem bly,

- cross member under the floor,

- floor base assembly ,

- rear end cross member assembly,

- rear end pillar reinforcement .

41-14


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UPPER SIDE STRUCTURE

Top of body

INTRODUCTION


operation to the replacement of the roof for a

front side impact.





fer to the contents p age) and MR 313 for the front

section.


DEPARTMENT

Part assembled with welded pin.

43 A

PRE4310


1 Body side 0.772 Rear quarter panel lining 0.73 Rear pillar upper reinforcement 14 Rear pillar lower reinforcement 15 Stretcher lining 1.26 Centre pillar reinforcement 1.57 Rear corner reinforcement 1.28 Rear end pillar lining 1

9 Rear upper side drip moulding 1

or

43-1


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Top of body

253a01-15317

43 A

A

CAS13033R3

1

1

B

CAE11546-6R5

C

CAE11546-2R7

D

CAB11539R8

1

2

3

1

5

3

1

5

43-2


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Top of body 43 A

E

CAQ11697R1

F

CAT13326-1R1

G

TOW15255-3R1

12

12 7

1

7

2

8

43-3


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Top of body

253a02-15319

43 A

I

CAB11540-1R3

1

9

J

CAB11540-1R7

1

9

43-4


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UPPER REAR STRUCTURE

Rear wing panel

INTRODUCTION

This part m ay be replaced in tw o ways:

by part section as a basic operation for a rearside impact (see diagram),

completely, as a complementary operation to

the roof.







DEPARTMENT


- st riker plate reinforcement,

- p in to be welded 3 x2.9,

- sou nd proofing,

- bumper mounting reinforcement assembly.

PRE4415

44 A

or


1 Wing panel 0.82 Rear quarter panel lining 0.7

3 Sill panel closure panel 1.54 Rear pillar reinforcement 15 Rear outer wheel arch 0.76 Rear upper side d rip mould ing 17 Lights mould ing 0.78 Rear end pillar lining 19 Rear end panel 1

10 Rear end pillar lower reinforcement 1

44-1


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Rear wing panel

254a03-15385

44 A

A

CAS13033R4

B

CAE11546-6R5

C

CAQ11697R6a

D

CAE11546-8R1

1

1

1

2

4

2 1

1

42

E

CAE11546-2R1

1 5 2

44-2


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Rear wing panel 44 A

F

CAB11539R6

G

CAQ11697R3

H

CAS13033R3

or

1 4

1

2

1

1

44-3


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Rear wing panel

254a01-15368

44 A

I

CAN11691R7

J

CAS13033R4

or

1

1

5

1

44-4


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Rear wing panel

254a02-15382

44 A

K

TOA14581R6

1 5

L

CAB11539R8

1

5

M

CAI11550R2

15

10

N

CAI11550R2

15

9

O

CAI11550R7

1

95

44-5


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Rear wing panel

254a05-15381

44 A

P

CAB11540-1R7

1

6

Q

CAB11540-1R1

1 7

44-6


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Rear wing panel

COMPLETE REPLACEMENT

(with rem oval of the roof)

254a07-15384

44 A

R

CAE11546-2R7

1

4

11

S

CAS13033R1

1 1

or

44-7


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Rear wing panel

254a06-15387

44 A

T

CAB11540-1R3

1

6

254a04-15386

U

CAB11539R6

51

44-8


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Rear wing panel 44 A

V

CAE11546-2R3

1

5

3

W

CAS13033R1

1 1

or

44-9


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Rear lights mounting

PRE4416

44 B

INTRODUCTION


operation to the wing panel.







DEPARTMENT

Single par t.


1 Lights mounting 0.72 Rear upper side drip moulding 1

3 Rear end pillar lining 14 Rear end panel 1

254b01-15380

A

CAA11536-2R7

1

2

44-10


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Rear lights mounting 44 B

B

TOK14644-1R2

1

2

3

C

CAB11539R5

3 1

D

CAE11546-8R2

5

1

2

E

CAB11539R5

5 1

F

G

CAA11536-2R3

1

2

CAE11546-8R2

4

1

5

44-11


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Upper side drip moulding 44 C

INTRODUCTION


operation to the rear wing panel.







DEPARTMENT


- balancer ba ll join t,- parcel shelf mounting.


1 Rear upper side drip moulding 12 Lights mounting 0.73 Rear end pillar lining 14 Rear end pillar low er reinforcement 1

PRE4423

44-12


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Upper side drip moulding

254c01-15378

44 C

A

CAA11536R1

14

B

CAJ11551-1R5

143

C

CAV13466R1

13

44-13


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Upper side drip moulding

254c02-15379

44 C

D

CAT13319-1R7

1

2

E

CAE11546-8R2

3

1

2

44-14


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Rear pillar reinforcement

PRE4417

44 D

INTRODUCTION


operation to the rear wing p anel for a rear side

impact.







DEPARTMENT


- upper pillar reinforcement,

- mounting nuts,

- lower pillar reinforcement,

- acou stic p lu g.

NOTE : for this operation the up per p art of the

reinforcement m ust be unp icked on the new part.


1 Rear pillar lower reinforcement 12 Rear pillar upper reinforcement 1

3 Rear quarter panel lining 0.74 Rear outer wheel arch 0.75 Rear inner wheel arch 0.86 Sill panel closure panel 1.57 Seat belt mounting reinforcement 1.58 Stretcher lining 1.2

44-15


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254d01-15377

44 D

A

CAA11536R5

1 2

B

CAN11689R5

1 2

C

CAO11694R7

1

3

D

CAW13602R7

1

3

4

44-16


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254d02-15376

44 D

E

F

CAA11538R6

1 4

G

CAT13327R5

1

4

5

CAN11689R3

1

4

44-17


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254d03-15374

44 D

H

CAF11547-2R1

1

6 4

I

CAS13024-1R4

1

4

7

J

CAA11536R6

14

REAR PILLAR UPPER REINFORCEMENT

A

CAN11689R5

2 8

44-18


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Rear pillar reinforcement 44 D

B

CAJ11551R3

1

2

8

C

CAD11545-2R2

D

CAN11689R5

2 8

8 2 3

44-19


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Rear inner wheel arch

1 Right hand side

2 Left hand side

INTRODUCTION


operation to the replacement of a wing p anel

with rear qu arter pan el lining or a rear floor unit.

For details of the operation refer to the basic ma-

nual (M.R. 313).


DEPARTMENT

Welded stud.

PRE4418

44 E

44-20


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Rear quarter panel lining assembly

PRE4419

44 F

INTRODUCTION


operation to a complete wing p anel.







DEPARTMENT

Part assembled w ith:- ou ter wheel arch,

- seat mounting reinforcement,

- connecting bracket,

- rear end pillar lin ing assembly,

- upper corner reinforcement assembly.


1 Body side lining 0.72 Rear quarter panel lining 0.7

3 Centre pillar lining 1.24 Front sill closure panel 1.55 Rear sill closure panel 0.86 Rear inner wheel arch 0.87 Seat belt mounting reinforcement 1.58 Stretcher lining 1.29 Rear floor base 0.8

10 Rear floor 0.711 Rear end pillar lining 112 Rear end pillar lower reinforcement 1

or

NOTE : to avoid replacing the part located behind

the sill panel, cut the front lower section of the li-ning, see section (C) in the d iagram below.

44-21


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254f01-15375

44 F

or

A

CAW13602R7

1

6

5

B

C

CAA11537-1R1a

11

D

TOA14581R4

1

5

CAA11536-1R2

1 5

44-22


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254f04-15371

44 F

E

TOD14617R4

1

4

5

F

CAA11536R2

1 3

G

Ga

CAQ11697-2R1a

71 4

TOA14581R3

1

5

44-23


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254f03-15372-1

44 F

254f02-15373

H

CAA11537R2

18

I

TOB14593R5

1

11

J

CAW13603-2R8

1

11

12

44-24


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Rear quarter panel lining assembly 44 F

K

CAT13319-1R2

1

12

L

CAA11538-1R4

1

9

M

CAA11538-1R4

1

10

N

CAA11538-1R2

1

6

O

CAQ11697R6a

16

P

CAT13319-1R2

2

11

44-25


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Rear quarter panel lining assembly 44 F

Q

TOK14646-3R5

1

11

2

44-26


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Outer wheel arch

PRE4421

44 G

INTRODUCTION

This part can be rep laced in tw o ways:

by part section A , comp lementary to the rear

end pillar, by part section B , complementary to th e wing

panel.







DEPARTMENT


- ou ter wheel arch,

- seat mounting reinforcement,

- connecting bracket,

- rear end pillar lin ing assembly,

- upper corner reinforcement assembly.

PRE4420

SECTION A : complementary to rear end pillar

reinforcement.

SECTION B : complementary to rear wing pan el.


1 Body side lining 0.72 Rear quarter panel lining 0.73 Rear end pillar lining 14 Rear floor base 0.85 Rear floor 0.76 Rear inner wheel arch 0.8

7 Seat belt mounting reinforcement 1.5

or

44-27


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Outer wheel arch

COMPLEMENTARY TO REAR END PILLAR

REINFORCEMENT

254g01-15372

44 G

or

A

CAP11696-1R4

2

1

1

B

CAA11536-3R7

1

C

CAT13321-1R7

1

2

3

D

CAA11538-1R1

1

2

2

44-28


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Outer wheel arch 44 G

E

CAA11538-1R8

1

4

F

CAA11538-1R7

1

5

G

CAA11536-2R5

11

44-29


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Outer wheel arch

COMPLEMENTARY TO REAR WING PANEL

254g02-15370

44 G

or

A

TOB14593-1R7

1

1

B

TOB14593-1R2

1

1

C

CAA11536-1R1a

17

44-30


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Rear end panel

PRE4422

44 H

INTRODUCTION

The replacement of this par t is a basic operation

for a rear impact.







DEPARTMENT

Part assembled w ith rear end pan el lower reinfor-cement.


1 Rear end panel 1

2 Body side lining 0.73 Lights mounting 0.74 Rear end p illar low er reinforcement 15 Rear end cross member 0.86 Rear end panel inner reinforcement 17 Tailgate str iker p late r ein forcem en t 1.28 Rear wing panel 1

254h01-15369

or

A

TOK14644-1R1

1

3

4

44-31


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Rear end panel 44 H

B

CAA11536-2R8

1

3

C

CAB11539R7

D

CAE11546-2R8

1

4

1

4

5

E

CAB11539R7

1

5

F

CAE11546-2R8

1

4

6

44-32


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Rear end panel

254h02-15383

44 H

G

J

CAE11546-8R4

5

17

H

CAT13326-1R6

14 5

I

CAQ11697R6

15

CAI11550R1

12

8

44-33


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TOP OF BODY

Roof

INTRODUCTION


for a side impact or a roll-over.


DEPARTMENT

PRE4501R

45 A


1 Roof 0.72 Front roof cross member 0.73 Windscreen pillar lining 1.54 Body side 0.775 Centre pillar reinforcement 1.56 Rear corner reinforcement 1.27 Rear roof cross member 0.78 Rear upper side drip moulding 19 Rear quarter panel lining 0.7

10 Stretcher lining 1.211 Centre pillar lining 1.2

12 Rear end pillar lining 0.9

45-1


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TOP OF BODY

Roof

255a01-15311

45 A

A

CAQ11697R8

B

CAT13326-1R8

C

CAT13326-3R3

D

TOA14580-1R6

1

2

1

2

3

3

1

4

1 4

45-2


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TOP OF BODY

Roof

255a02-15312

45 A

E

CAP11696-2R2

F

TOP15254R2

G

CAP11696-2R2

H

CAA11536R5

1 43

1 4 3 11

5 3

1 8

1

45-3


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TOP OF BODY

Roof 45 A

I

J

CAN11689R1a

K

CAP11696-2R1

L

TOP15254R1

M

N

CAW13602R2

1 6 12

17

14 6

19 6 4

CAP11696-2R1

14 9

CAP11696-2R1

14 5

45-4


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TOP OF BODY

Roof 45 A

O

P

CAJ11551-1R5

CAP11696-2R1

14 10

176

255a03-15312

15342R1

A = 70 mm

B = 500 mm

C = 500 mm

D = 300 mm

NOTE : apply a bead of adhesive mastic (C) in

zones (B) and (D) of the basic diagram, to rein-

force the roof where the roof bars are moun ted.

E

Bead C

45-5


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TOP OF BODY

Roof acoustic cross member

INTRODUCTION



roll-over.

For reasons of standard isation, the Parts

Department on ly supp lies parts for the version w i-

thou t sunroof.Where a sunroof is fitted or iginally,

the roof and the centre roof cross member m ust

be cut according to the diagram below.

These cuts m ust also be mad e to fit a sunroof as an

accessory.

IMPORTANT : the roof cross member h as a struc-

tural reinforcement function. For the version withsunroof, the sunroof frame fulfils this function.

When fitting a su nroof as an accessory it is re-

commended that only sunroofs approved by the

Renau lt accessories departm ent are used.







DEPARTMENT

Single par t.

PRE4502

45 B


1 Acoustic cross member 0.72 Centre pillar reinforcement 1.5

For sunroof

45-6


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TOP OF BODY

Roof acoustic cross member

LEFT HAND SIDE

255b01-15313

45 B

RIGHT HAND SIDE

255b02-15316

A

CAA11536-3R6

B

CAA11536-5R6

12

12

45-7


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TOP OF BODY

Roof bow

PRE4503

45 C

INTRODUCTION



roll-over.







DEPARTMENT

Single par t.

Bows (A) and (B) are mounted by rivets.

Bow (C) is spot w elded .


1 Roof bow 0.72 Rear pillar upper reinforcement 13 Roof bow support 1.2

45-8


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TOP OF BODY

Roof bow

BOWS A and B

255c01-15315

45 C

A = rivet diameter 4.8 mm

(joint with bow supp ort)

255c02-15314

B

CAA11536-3R6

12

45-9


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TOP OF BODY

Roof rear cross member

PRE4504

45 D

INTRODUCTION



roll-over.



complementary p arts are not included. These are

dealt with in their resp ective section (refer to the

contents page).


DEPARTMENT

Single par t.


1 Roof rear cross member 0.72 Rear quarter panel lining 0.7

3 Rear corner reinforcement 1.2

45-10


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TOP OF BODY

Roof rear cross member

255d01-15318

45 D

A

CAT13318R2

1 3

B

CAA11538-1R2

C

TOD14617R4

1

3

1

2

3

45-11


75/82


Rear door panel

INTRODUCTION


for a side impact.

This par t may be par tially replaced (see cut and

method below).

NOTE : the original panels have MIG welded an -

chorage points. In rep air, these points are not

mad e (sections A on the d iagram below).


DEPARTMENT

Part assembled w ith:- sou nd proofing,

- stiffener.

PRE4701

47 A


1 Door panel 0.72 Door box section 0.7

3 Door frame 0.8

or

47-1


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Rear door panel 47 A

257a04-15322

A

TOB14587R5

1 2

257a06-15324

A

TOB14587R1

1 2

47-2


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257a01-15320

or

B

TOB14587R1

1 2

C

D

CAB11539R4

1

3

TOB14587R1

1 2

47-3


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E

CAS13033R3

1

1

47-4


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Rear door panel

257a03-15321

47 A

or

F

CAQ11697R6a

G

CAS13033R3

13

1

1

H

TOB14587R2

1 2

47-5


80/82

NON-SIDE OPENING ELEMENTS

Tailgate

REMOVAL

Remove the trim and disconnect the various wi-

ring h arnesses (see sections 52 and 71).

Remove:

- th e th ird stop ligh t,- the rear screen washer jet p ipe,

- th e w irin g h arn ess,

99386R1

48 A

PRE4803

- the headlining plugs using a screwdriver (torx

20).

99621R2

Unclip the ta ilgate balancers at (A).

Remove the mounting nu ts and remove thehinges (B) (two p ersons requ ired for this opera-

tion).

NOTE : if the tailgate or th e roof is being repla-

ced, retain the height adjustment shims located

un der th e hinges (B).

To do this, use a cut ting tool to destroy the finis-

hing seal around the shims and retain them.

The hinges are welded on the tailgate, so these

shims of thickness 1 mm are used to ad just the

clearance between the roof and the tailgate.

48-1


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Tailgate

PROCEDURE FOR ADJUSTING THE STRIKER PLATEREFITTING

48 A

IMPORTANT

When refitting the hinges, remember to ensure

sealing between the sealing washers (under the

mounting nuts) and the roof panel.

To do this, use plugging mastic Part Number 77 11

170 230 (refer to Technical Note 396A).

To adjust the tailgate and its lock after refi tting,

observe the opening clearances 4, 6 and 7 descri-

bed in section 40.

This adjustment must be made with the tailgate

fully fitted.

NOTE : before beginning the adjustments below,

slacken the lock striker plate mou nting bolt (C), so

there is no resistance to closing.

11295R199621R

48-2


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Tailgate

The adjustment op eration is carried out with two

persons. To do th is, hook the lock on the striker

plate and press the tailgate against the lower

stops (D) and (E).

At the same time, from insid e the vehicle, tighten

the striker plate mou nting bolt.

At the end of the adjustment op eration, app ly a

bead of pain t joint mastic around th e three visible

faces of the ad justing sh ims for the hinges.

Carry out an op eration to paint these beads.

PRE4803R

48 A

Documents

Megane break sheetmetal