Page 1913 of 2492
Contents
GENERAL
Dimensions
Engine and equipment
Identification
Using symbols
Key to symbols
Description of parts (exploded)
Opening clearances40-1
40-2
40-2
40-3
40-5
40-6
40-7
LOWER STRUCTURE
41-1
41-2
41-5
41-7
41-8
41-11
41-14Page Page40
41
Sheet metal work
UPPER SIDE STRUCTURE43
AAbsorber support mounting
BRear floor base
CRear floor base support
DRear floor base front stiffener
ERear end pillar lower reinforcement
FRear end cross member assembly
GRear floor unit
43-1 ATop of bodyNON-SIDE OPENING ELEMENTS
48
TOP OF BODY
SIDE OPENING ELEMENTS45
47
45-1
45-6
45-8
45-10 ARoof
BRoof acoustic cross member
CRoof bow
DRoof rear cross member
47-1
48-1 ATailgate ARear door panel UPPER REAR STRUCTURE
44
44-1
44-10
44-12
44-15
44-20
44-21
44-27
44-31 ARear wing panel
BRear lights mounting
CUpper side drip moulding
DRear pillar reinforcement
ERear inner wheel arch
FRear quarter panel lining assembly
GOuter wheel arch
HRear end panel
Page 1914 of 2492
GENERAL
Dimensions
40
15309R
Dimensions in metres
* Unladen.
40-1
Page 1915 of 2492
GENERAL
Engine and equipment
40
(1) If necessary, unleaded fuel with an octane rating of 91 may be used.
Vehicle
typeVersionEngine
Type Ratio InjectionCapacity
(cm
3)Idle speed
(rpm)Fuel type
KA0M
KA0V1.4 l E7J 9.5/1 Multipoint 1390Non-
adjustableUnleaded
95 or 98 (1)
KA0W
KA0D1.4 l
16 VK4J 10/1 Multipoint 1390Non-
adjustableUnleaded
95 or 98 (1)
KA04
KA0B1.6 l
16 VK4M 10/1 Multipoint 1598Non-
adjustableUnleaded
95 or 98 (1)
KA0J
VA0J1.9 l D F8Q 21.5/1 Indirect 1870 825±50 Diesel
KA05
VA05
KA0N
VA0N
KA01
VA011.9 l
DtiF9Q
Turbo18.3/1 Direct 1870850±50
Non-
adjustableDiesel
Vehicle Rim TyresTyre inflation pressure -
cold (bar) (1)
Front Rear
KA0M/KA0V
KA0W/KA0D5.5 J 14 175/70 R 14 2.2 2.0
KA04/KA0B6.0 J 15 185/60 R 15 2.2 2.0
KA0J/VA0J6.0 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 motorway use.
Tightening torque for wheel nuts : 9 daN.m
Rim run-out: 1.2 mm
Identification
40-2
Page 1916 of 2492

GENERAL
Using symbols
40
11644R1
The above diagram shows parts on the vehicle for
which a section of the panel butt welding joint is
shown by the diagrams which follow.
This dashed line shows the centre line
of the sections
The point shows the exact position of
the weld join
This letter designates the drawing
corresponding to the section (It is gi-
ven in one of the upper corners of
each drawing )
F - G -
H - I - J
CAA11538R8
G
1
e = 1+1 7The following indications are found in the section
diagrams :
The part in black is the one which will
be removed in the operation
are the part numbers corresponding to
the list on the introduction page 1
and 7
e = 1 + 1are the thicknesses (in mm) of the
panels affected by the spot weld
This arrow on the diagram designates
the access point for the unpicking of
spot welds (see specific cases)
It also indicates the logical sequence of operations
in the symbols which follow each diagram.
place of operation and logical sequence
spot welding
weldable mastic
unpicking with grinder
Example :
40-3
Page 1917 of 2492
GENERAL
Using symbols
40
The references which follow indicate different
operations :
unpicking
welding
SPECIFIC CASES
CAA11537-1R6
J
1 2
In this example, there is no direct access for remo-
ving part 1. The spot welds should be unpicked
through part 2, which should be kept.
CAQ11697-1R5
I
1 2
➜
➝
This arrow indicates that it is necessary
to cut the part it crosses before acces-
sing the joint
.
Under diagram I
➜
➝
unpicking
with grinderapply weld fil-
let1st opera-
tion
site of operation and order of operations
10354R
D
In this particular case, the arrow indicates that
the joint is made by arc welding (MIG).
10349R
E
In this example, the joint is
made by bonding.
chisel the edge2nd opera-
tion
➜ ➝
➜
➝
40-4
Page 1918 of 2492

GENERAL
Key to symbols
40
- Cutting out part by grinding off flange
or grinding 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 welds.
Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm.
Grind back spot welds.
20 000 rpm straight grinder with 10 or 16
mm diameter spherical burr.
Drill spot welds.
Hardened steel bit. Speed of rotation 800
to 1 000 rpm.
Unpicking
Cleaning surfaces to be welded.
100 mm diameter fibre disc.
Cutting with a saw.
Pneumatic power hacksaw.
Unsoldering.
Plug welding.
Under MAG gas protection.
Crimping of exterior door panels.
Safety symbol.
This means that the welding operation
in question concerns one or more of the
vehicle’s vital safety components.
Body solder - lead fill.
Hot air torch.
Nozzle output temperature 600° min.
Slipper+ 33 % tin solder + tallow.
Note : to a large extent, body solder
filling compensates for the heat
distortion caused by welding.
Application of weldable mastic.
This mastic conducts electricity, applied
between two panels to be spot welded,
it ensures the seal between the panels
and avoids corrosion of the spot welds.
Application of aluminium paint.
This is to be applied to the joint faces of
each of the parts to be plug welded.
The paint conducts electricity and is is
resistant to high temperatures. 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
• spray gun.
• two pot anti-gravel and anti-
corrosion mastic.
MAG stitch weld
Note : to obtain a good quality weld we
recommend the use of a gas consisting
of argon + 15 % CO2. This is
considered to be an active gas (MAG).
Spot weld
40-5
Page 1919 of 2492
GENERAL
Description of parts (exploded view)
40
PRE4005
290 Roof
* 291 Roof rear cross member
292 Absorber support
293 Rear end panel
294 Lights mounting
295 Tailgate
* 296 Wing panel
* 297 Top of body
* 298 Rear door
* 299 Rear door panel
300 Rear end pillar lower reinforcement
* 301 Rear end cross member
302 Emergency spare wheel mounting sup-
port
303 Rear floor base
* Parts for which repaired areas must be electro zinc plated304 Base support
305 Base stiffener
* 306 Sill panel
* 307 Front pillar
* 308 Body side, front section
309 Rear floor unit
310 Rear pillar reinforcement
* 311 Rear quarter panel lining assembly
312 Inner wheel arch
313 Stretcher extension
314 Roof cross member support
* 315 Wing panel drip moulding
316 Speaker support
317 Roof stiffener
40-6
Page 1920 of 2492
GENERAL
Opening clearances
40
15072R2
40-7