Page 2369 of 2492

Contents
Page
40
41
GENERAL
Dimensions 40-1
Lifting equipment 40-2
Towing 40-3
Key to symbols 40-4
Description of parts (exploded view) 40-5
Opening clearances 40-8
Collision fault finding 40-13
Sub-frame dimensions 40-16
Body jig bench 40-18
Special tooling 40-29
LOWER STRUCTURE
Rear floor 41-1
Rear side member 41-5
Rear end cross member 41-7
Front towing ring mounting
reinforcement 41-10
Rear towing ring bracket 41-12
Bearing rear mounting support 41-13
Bearing front mounting support 41-15
Acceleration sensor mounting 41-16
Central floor rear reinforcement 41-18
UPPER FRONT STRUCTURE
Wing 42-1
UPPER SIDE STRUCTURE
Front section of the body side 43-1
Complete sill panel 43-4Page
44 UPPER REAR STRUCTURE
Rear wing panel 44-1
Light support 44-3
End panel 44-9
Lower hinge mounting
reinforcement 44-20
Upper hinge mounting
support 44-23
Lower hinge mounting
support 44-26
Luggage compartment lid stop mounting
support 44-28
NON-SIDE OPENING ELEMENTS
Tailgate 48-1
Luggage compartment lid 48-3Sheet Metal Work
P
S
T
V
W
X
Y
Z
AA
42
A
43
F
HA
F
J
K
L
M
N
48
C
D
Mechanisms and Accessories
50
A
52
A
B GENERAL
Tooling 50-1
NON-SIDE OPENING ELEMENT
MECHANISMS
Luggage compartment lid and rear
screen locks 52-1
Luggage compartment lid exterior handle 52-3
Page 2370 of 2492
Contents
Page
54 WINDOWS
Rear screen 54-1
EXTERIOR PROTECTION
Front bumper protector 55-1
Front and rear valance protectors 55-3
Front wing extender 55-5
Rear wing extender 55-8
Front bumper (central section) 55-10
Rear bumper 55-13
Front and rear door panels 55-14
Luggage compartment lid embellishers 55-16
EXTERIOR ACCESSORIES
Rear corner wing extender 56-1
Rear windscreen wiper arm 56-2
Rack embellishers 56-4 A
55
A
B
C
D
E
F
G
H
56
A
B
C
Trim and upholstery
73
ANON-SIDE OPENING ELEMENTS TRIM
Luggage compartment lid trim 73-1
Page 2371 of 2492
GENERAL INFORMATION
Dimensions
40
140GENERAL INFORMATION
Dimensions
Dimensions in metres
Turning circle between walls: 11.20 m.
* Unladen. For vehicles with roof racks, add 7.5 cm.
40-1
Page 2372 of 2492
GENERAL INFORMATION
Means of lifting
40
40-2
Means of lifting
IMPORTANT: before fitting the lifting pads under
the body flange, you must fold the valance
protector flaps (A) by unclipping them to the
outside.
Rear protector
Front protectorPOSITION OF THE LIFTING PADS
Front
Rear
18111R
18112R
18109S
18110S
Page 2373 of 2492
GENERAL INFORMATION
Towing
40
40-3
Towing
OBSERVE THE TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the
vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either directly or indirectly.
FRONT REAR
18128S16892S
Page 2374 of 2492

GENERAL INFORMATION
Key to Symbols
40
40-4
Key to Symbols
Chiselling Crimping of exterior door panels.
Grind back beads or spot welds Straight
grinding wheel with a 75 mm diameter
Bakelite disc, 1.8 to 3.2 mm thickness.Safety symbol.
This means that the welding operation in
question concerns one or more of the
vehicle's vital safety components.
Grind back spot welds.
Straight grinding wheel 20 000 rpm fitted
with a spherical burr Ø 10 or 16 mm.Body solder - lead fill.
Hot air torch.
Nozzle output temperature min. 600˚
Handle + 33% tin solder + tallow
Note: to a large extent, body solder filling
compensates for the heat distortion caused
by welding. Drill spot welds.
Hardened steel bit. Speed of rotation 800 to
1 000 rpm.
Drill < Ø 8 mm
Steel drill bit
Speed of rotation 800 to 1000 rpm.Application of weldable mastic.
This mastic is a conductor, interposed
between two spot welding sheets, it ensures
the seal between the sheets and avoids
corrosion of the spot weld Drill > Ø 8 mm
Tapered burr
Speed of rotation 800 to 1000 rpm.
Cleaning surfaces to be welded.
Fibre disc Ø 100 mmApplication of aluminium paint.
This is to be applied to the joint faces of each
of the parts to be plug welded. This paint is
conductive and can withstand high
temperatures; it gives anti-corrosion
protection around welds Cutting with a saw.
Pneumatic power hacksaw.
Cut out part by grinding off flange or grinding
back remaining traces of spot weld. Weld
finish refining Angle grinder fitted with a
rubber pad and a fibre disc Ø 120 to 180 mm
grain P36Apply a fillet of extruded mastic
from a manual or pneumatic spray gun.
one or two pot mastic for crimped and butt
joints.
Unsoldering.
MAG stitch weld
Note: to ensure high quality welding, we
recommend that you use gas composed of
Argon + 15% CO
2 which is considered an
active gas (MAG)Apply mastic by spraying
spray gun.
anti-chipping and anti-corrosion in two
parts
Resistance spot weldingApply a bead of extruded adhesive mastic
from a manual or pneumatic spray gun.
adhesive mastic in one or two parts
Plug welding.
Under MAG gas protection.Thermal cleaning of extruded or spray
mastic
Page 2375 of 2492
GENERAL INFORMATION
Description of parts (exploded view)
40Description of parts (exploded view)
LOWER STRUCTURE
1Front towing ring mounting reinforcement (41-V)
2Acceleration sensor mounting (41-Z)
3Front bearing mounting support (41-Y)
4Rear bearing mounting support (41-X)
5Central floor rear reinforcement (41-AA)
6Rear side member (41-S)
7Rear towing ring bracket (41-W)
8Rear floor (41-P)
9Rear end cross member (41-T)
PRF4021
40-5
Page 2376 of 2492
GENERAL INFORMATION
Description of parts (exploded view)
40
40-6
UPPER STRUCTURE
10Light support (44-F)
11End panel (44-J)
12Luggage compartment lid stop mounting support (44-N)
13Upper hinge mounting support (44-L)
14Lower hinge mounting support (44-M)
15Rear wing panel (44-A)
16Lower hinge mounting reinforcement (44-K)
17Complete sill panel (43-H)
18Body side front section (43-F)
PRF4022