Page 5 of 209
Contents
Rear end panel: General
descr iption 44A-24
Rear end panel: Description 44A-25
45A TOP OF BODY
Roof: General description 45A-1
Roof: Description 45A-2
Roof front section:
Description 45A-6
Roof rear section:
Description 45A-7
Roof front cross member:
General description 45A-8
Roof centre cross member:
General description 45A-9
Roof rear cross member:
General description 45A-10
47A SIDE OPENING ELEMENTS
Front side door: Removal -
Refitting 47A-1
Front side door: Stripping -
rebuilding 47A-3
Front side door: Adjustment 47A-5
Fuel filler flap co ver:
Removal - Refitting 47A-8
48A NON-SIDE OPENING ELEMENTS
Bonnet: Removal - Refitting 48A-1
Bonnet: Stripping -
Rebuilding 48A-3
Bonnet: Adjustment 48A-4
Tailgate: Removal - Refitting 48A-6 44A REAR UPPER STRUCTURETailgate: Stripping -
Rebuilding 48A-8
Tailgate: Adjustment 48A-10 48A NON-SIDE OPENING ELEMENTS
Page 29 of 209

40A-24
GENERAL INFORMATION
Vehicle structure, removable section: Description
40A
(6) Bonnet (see 48A, Non-side opening ele-
ments, Bonnet: Removal - Refit-
ting, page 48A-1) Steel
(7) Dashboard cross member (see 42A, Front upper structure,
Dashboard c ross member:
Removal - Refitting, page 42A-26) Steel
(8) Front side door (see 47A, Side opening ele-
ments, Front side door: Removal
- Refitting, page 47A-1) Steel
(9) Offset rear floor, front section (see 41D, Rear lower structure,
Raised rear floor, front section:
Removal - Refitting, page 41D-4) Steel
(10) Filler neck (see Filler neck: Removal - Refit-
ting) (MR 411, 19C, Tank)Noryl
(11) Rear impact lower cross member (see 41D, Rear lower structure,
Rear impact lower cross mem-
ber: Removal - Refitting, page
41D-18) Steel
(12) Tailgate (see 48A, Non-side opening ele-
ments, Tailgate: Removal - Refit-
ting, page 48A-6) Steel
(13) Strut mounting reinforcement (see: MR 400, 40A, General infor-
mation)Steel No. Description Classification Type
Page 113 of 209

42A-4
FRONT UPPER STRUCTURE
Front wing: Adjustment
42A
ADJUSTMENT
aFor information on panel gap values (see Vehicle
panel gaps: Adjustment value) (MR 412, 01C, Ve-
hicle bodywork specifications).
aSymbols A, B, C and D show the adjustment op-
tions.
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.I - ADJUSTMENT WITH BONNET
a
II - ADJUSTMENT WITH BUMPER AND FRONT
DOOR
aRemove:
-the front wheel arch liner (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection).
aAdjust the panel gaps with the front door.
121252
109496
Note:
Adjust the front wing with the bonnet during
reinstallation of the front wing upper mounting
support (see 42A, Front upper structure, Front
wing upper mounting support: Removal -
Refitting, page 42A-7) .
121232
Note:
Tighten the plastic nuts moderately so as not to
damage them.
Page 118 of 209

42A-9
FRONT UPPER STRUCTURE
Front end panel: Removal - Refitting
42A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the front bumper ( (see Front bumper: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip the wiring harness.
aRemove the bonnet opening cable.
aRemove the bolt (1) from the coolant bottle.
aUnclip the coolant bottle.
aRemove:
-the bolt (2) from the cooling radiator deflector,
-the bolts (3) from the cooling radiator support,
-the bolts (4) .
aUndo:
-the nut (5) ,
-the bolts (6) .
aRemove the front end panel.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the front end panel,
121037
Note:
The bolts (4) and (6) can be accessed between
the front end lower cross member and the coo-
ling radiator.
Note:
The front end panel is made up of the front upper
cross member and the headlight carrier panels.
Page 119 of 209
42A-10
FRONT UPPER STRUCTURE
Front end panel: Removal - Refitting
42A
-the bolts (4) ,
-the bolts (3) on the cooling radiator support,
-the bolt (2) on the cooling radiator deflector.
aTighten:
-The bolts (6) ,
-the nut (5) .
aClip on the coolant bottle.
aRefit the bolt (1) on the coolant bottle.
aPosition the bonnet opening release cable.
aClip on the wiring harness.
II - FINAL OPERATION.
aRefit:
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the front bumper ( (see Front bumper: Removal -
Refitting) ).
Page 120 of 209

42A-11
FRONT UPPER STRUCTURE
Headlight carrier panel: Removal - Refitting
42A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection),
-the halogen headlight (see Halogen headlight:
Removal - Refitting) (MR 411, 80B, Headlights),
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (MR 412, 52A, Non-side opening ele-
ment mechanisms),
-the front upper cross member (see 42A, Front up-
per structure, Front upper cross member: Re-
moval - Refitting, page 42A-13) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aLoosen nut (2) .
aRemove:
-the bolts (1) ,
-the headlight carrier panel.
REFITTING
I - REFITTING PREPARATIONS OPERATION
a
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the headlight carrier panel,
-the bolts (1) .
aTighten the nut (2) .
III - FINAL OPERATION.
aRefit:
-the front upper cross member (see 42A, Front up-
per structure, Front upper cross member: Re-
moval - Refitting, page 42A-13) ,
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (MR 412, 52A, Non-side opening ele-
ment mechanisms),
-the halogen headlight (see Halogen headlight:
Removal - Refitting) (MR 411, 80B, Headlights),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection).
121251
WARNING
For any adjustment or removal - refitting proce-
dure where it is necessar y to separate a bolted
connection, reapply the mating and sealing anti-
corrosion protection to the bolts using filler mas-
tic in a pre-formed bead.
Page 122 of 209

42A-13
FRONT UPPER STRUCTURE
Front upper cross member: Removal - Refitting
42A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the front bumper ( (see Front bumper: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip the wiring harness.
aRemove the bonnet opening cable.
aRemove the bolt (1) from the coolant bottle.
aUnclip the coolant bottle.
aRemove:
-the bolt (2) from the cooling radiator deflector,
-the front upper cross member bolts (3) .
aUndo the bolts (4) .
aRemove the front upper cross member.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the front upper cross member,
-the bolts (3) ,
-the bolt (2) on the cooling radiator deflector.
aTighten the bolts (4) .
aClip on the coolant bottle.
aRefit the bolt (1) on the coolant bottle.
aPosition the bonnet opening release cable.
aClip on the wiring harness.
II - FINAL OPERATION.
aRefit:
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the front bumper ( (see Front bumper: Removal -
Refitting) ).
121036
Note:
The bolts (4) can be accessed between the front
end lower cross member and the cooling radia-
tor.
Page 127 of 209
42A-18
FRONT UPPER STRUCTURE
Upper reinforcement of scuttle side panel: General description42A
DESIGN OF THE STRUCTURAL COMPONENT
This type of part secures the bonnet hinge mounting
and the front wing upper mounting support.Note:
The information contained in the following descri-
bes 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 associa-
ted with the vehicle. These special notes are speci-
fied if necessary in other par ts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connec-
tion, see MR 400.
121053