Tài liệu sửa chữa xe ô tô Renault 19 (Repair Manual) - P8

77 11 190 877
NOVEMBER 1996
Edition Anglaise
Sheet metal work
"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 by the manufacturer in the
production of the various component units and accessories from which his vehicles
are constructed".
All copyrights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
Renault.
C Renault S.A. 1988
GENERAL
LOWER STRUCTURE
UPPER FRONT STRUCTURE
UPPER SIDE STRUCTURE
UPPER REAR STRUCTURE
UPPER BODY SECTION
BODY PROTECTION
SIDE OPENINGS
BONNET AND TAILGATE
EXPLODED VIEW
PRS4011
Contents
GENERAL
Engine - Clutch - Gearbox
Vehicle dimensions
Lifting
Description of parts (exploded

views)
Description of symbols
Opening clearances
Collision damage assessment
Dimensions of the lower structure
Main bodywork dimensions
Body jig bench
Special tools
40-1
40-2
40-7
40-11
40-18
40-20
40-27
40-32
40-34
40-35
40-42
LOWER STRUCTURE
41-1
41-3
41-4
41-5
41-6
41-7
41-9
41-10
41-12
41-13

41-16
41-17
41-18
41-22
41-23
41-25
41-26
41-28
41-29
41-30
41-31
41-34
41-36
UPPER FRONT STRUCTURE
PagesPages
40
41
42
Panels
UPPER SIDE STRUCTURE
43
A Complete front end cross member
B Part front end cross member
C Complete front end panel
D Part front end panel
E Side member closing panel
F Front side member front section
G Part front side member front section
H Front side member rear section
I Front side cross member

J Front half unit
K Part centre floor panel
L Rear floor panel (part centre
section)
M Rear floor panel
N Utility vehicle floor panel
O Lateral side member lower section
P Lower side spacer
Q Sill closing panel stiffener
R Front pillar lower section stiffener
S Floor and cross member side
stiffener
T Floor panel upper cross member
U Assembled rear end panel
V Part rear end panel cross member
W Body
42-1
42-4
42-6
42-7
42-8
42-9
42-10
42-14
42-16
42-18
A Wing
B Complete radiator grille upper cross
member
C Part radiator grille upper cross

member
D Bonnet lock support
E Headlight carrier panel
F Part front wing panel (front section)
G Wheel arch (shock absorber turret)
H Part heater bulkhead partition
I Part windscreen aperture lower
cross member
J Front pillar upper stiffener
43-1
43-3
43-5
43-6
43-8
43-9
43-10
43-15
43-19
43-21
43-22
43-23
43-27
43-29
43-30
A Front pillar lower section
B Front door pillar by cutting at
windscreen upright
C Door hinges (on front pillar)
D Front door pillar
E Front pillar

F Front door pillar seal fastening
(KSM)
G Centre pillar
H Centre pillar lining
I Sill panel
J Body side
K Part sill panel
L Sill panel
M Sill panel front stiffener
N Sill panel rear stiffener
O Roof arch
SIDE OPENINGS
Contents
BODY PROTECTION
46
48
UPPER BODY SECTION
45
47
45-1
45-7
45-9
45-10
45-11
45-12
A Roof panel
B Windscreen surround
C Linings and stiffeners
D Windscreen pillar lining
E Windscreen aperture upper cross

member
F Rear roof cross member
UPPER REAR STRUCTURE
44
44-1
44-8
44-13
44-25
44-26
44-32
44-36
44-37
44-38
44-39
44-40
44-44
44-46
44-47
44-48
44-49
44-51
44-53
44-54
44-55
44-56
44-58
44-64
44-70
44-71
44-73

44-75
44-77
44-79
A Complete wing panel
Complete rear wing panel
B Part wing panel
Part rear wing panel
C Quarter panel lining
D Assembled wing panel lining
E Wing panel lower front lining
F Wing panel upper front lining
G Wing panel rear lining
H Tailgate upper rain channel
I Outer wheel arch
J Complete quarter panel arch
K Part quarter panel arch
L Backrest mounting stiffener
M Outer wheel arch stiffener
N Upper cross member between
wheel arches
O Hood compartment base partition
P Hood compartment rear cross
member
Q Backrest mounting stiffener
R Jack support (right hand side)
S Centre shelf
T Half unit
U Rear end panel
V Rear end panel lining and
assembled end panel

W Part end panel cross member
X Rear end panel extension piece
Y Side rain channel
Z Boot lid rain channel
2A Lighting support panel
46-1
46-2
A Sub-frame front protector
B Wheel arch mud shield
47-1
47-2
47-4
47-6
A Door hinges
B Front door panel
C Rear door panel
D Front door - rear door
BONNET AND TAILGATE
48-1
48-3
48-5
48-11
48-13
48-14
A Bonnet
B Tailgate
C Boot lid
D Hood cover panel
E Broken boot lid counter balance ball
joint

F Roof cross member (noise
reduction)
GENERAL
Engine - Clutch - Gearbox
40
Vehicle type
Engine
Type
Cubic
capacity
(cm
3
)
Clutch type Manual and automatic gearbox type
B530 - C530 - L530
S530
C1G 1237 180 CP 3300
JB0 - JB1 - JB4 - JB5
B531 - C531 - L531 C1J 1397 180 CP 3300
JB0 - JB1 - JB4 - JB5
B53H - B53P - C53P
L53H - L53P
C2J 1397 180 CP 3300
JB0 - JB1 - JB4 - JB5
B532 - C532 - L532 C3J 1390 180 CP 3300
JB0 - JB1
B53G - B537 - C537
L53G - L537 - S537
E6J 1390 180 CP 3300
JB0 - JB1 - MB1

B53A - C53A - L53A E7J 1390 180 CP 3300
JB1 - MB1
B535 - C535 - L535 E7J 1390 180 CP 3300
JB1 - MB1
B53W - C53W - L53W E7F 1171 180 CP 3300
JB0 - JB1 - JB3
B53E - B53M - B533
B536 - C53E - C53M
C533 - L533 - L536
F2N 1721 200 CP 4000
JB0 - JB1 - JB3 - AD4
B53B - B53C - B53F
C53B - C53C - C53F
D53C - L53B - L53C -
L53F
F3N 1721 200 CP 4000
AD4 - JB3 - MB3
B53V - B53Y - B538
C53V - C53Y - C538
D53V - D53Y - L53V
L53Y - L538 - 353A
353C - 353D - 353F
453A - 453C - 453D
453F - 453H - 553A
553C - 553D - 553F
553H - 853A - 853C
853F
F3P 1794 200 CP 4000
AD4 - JB3 - JC5
B53D - B539 - C53D

C539 - D53D - L53D
L539
F7P 1764 200 CP 4400
JB3 - JC5
B53I - B53J - B53K
B53T - B53Z - B534
C53I - C53J - C53K
C53T - C53Z - C534
L53I - L53J - L53K
L53T - L53Z - L534
S53I - S53J - S53K -
S534
F8Q 1870
200 CPV 4600
200 CPV 3500
JB1 - JB3 - JC5
40-1
GENERAL
Vehicle dimensions
40
91936R1
B53
Phase I
Mark Dimensions in metres
A 2.545
B 4.155
C 1.418
D 1.416 unladen
E 1.406 to 1.417
F 1.676 or 1.694

40-2
GENERAL
Vehicle dimensions
40
95890R
B53
Phase II
Mark Dimensions in metres
A 0.813
B 2.540 - 2.544 (1)
C 0.805 - 0.809 (1)
D 4.158 - 4.166 (1)
E 0.120 (2)
F 1.426
G 1.684 - 1.696 (1)
H 1.400 - 1.420 (1) - (3)
I 1.406 - 1.417 (1)
(1) Depending on version with option
(2) Laden
(3) Unladen
40-3
GENERAL
Vehicle dimensions
40
92866R
* Depending on version
L53 Saloon
Except Sport
Mark Dimensions in metres
A 2.545 or 2.540 *

B 4.262
C 1.412 unladen
D 1.418
E 1.406 to 1.417 *
F 1.684 or 1.694 *
40-4
GENERAL
Vehicle dimensions
40
92764R
B - C - L539
Sport
Mark
Dimensions in metres
B and C L
A
B 4.150 4.259
C 1.389 1.400
D
E
F
2.540
1.429
1.406
1.684
40-5
GENERAL
Vehicle dimensions
40
94726R

D53
Cabriolet
Mark Dimensions in metres
A 2.545
B 4.155
C 1.375 ± 5
D 1.418
E 1.406 to 1.417
F 1.676 or 1.694
40-6
GENERAL
Lifting
40
87709R
USING AXLE STANDS
To place the vehicle on axle stands, the stands
must be positioned under jacking points (1)
provided for lifting the vehicle using the jack
supplied with the vehicle.
To position the axle stands at the rear, lift the
vehicle from the side.
LIFTING USING A JACK FROM THE SIDE
Use cross piece Cha. 280-02.
Take the load under the front door sill.
Position the body sill flange correctly in the cross
piece groove.
91936G3
85679-1G7
40-7
GENERAL

Lifting
40
92556R
Safety symbol (special precautions to be taken while working)
ESSENTIAL SPECIAL TOOLS
Cha. 280 -02 Adjustable cross piece on trolley
jack
Cha. 408 -01
or Adjustable dowel on trolley jack
Cha. 408 -02
The vehicle must not be lifted by taking the load
under the front suspension arms.
Depending on the type of trolley jack , use dowels
Cha. 408-01 or Cha. 408-02 to fit cross piece Cha.
280-02.
To lift the front or the rear, take the load under
the lifting points provided for the on-board jack.
USING A TROLLEY JACK FROM THE FRONT
Apply the handbrake or chock the rear wheels.
Use cross piece Cha. 280-02.
Take the load under the front sub-frame.
Ensure that the cross piece does not come into
contact with the gearbox or the exhaust
downpipe.
Appropriate axle stands must be used if a
trolley jack is used.
For B537 and C537 type vehicles, make a clearance
notch in cross piece Cha. 280-02 to prevent it from
coming into contact with the exhaust.
USING A TROLLEY JACK FROM THE REAR

The rear of the vehicle
MUST NOT
be lifted by
taking the load under the rear axle. Lift each
wheel separately taking the load at the lifting
points provided for the on-board jack.
40-8
GENERAL
Lifting
AXLE STANDS
To place the vehicle on axle stands, the stands
must be positioned:
- either under the jacking points provided for
lifting the vehicle using the on-board jack,
- or under the pads located behind the stiffeners.
To position the axle stands at the rear, lift the
vehicle sideways.
40
98336G
85679-1G7
WHEEL FREE LIFT
SAFETY ADVICE
Several possibilities must be considered:
1 - REMOVAL OF COMPONENTS
In general, never use a two post lift when a four
post lift is suitable.
If this is not possible, fit the lifting pads under the
sill flange at the lifting points provided for the on-
board jack.
98703S

FRONT
98704S
REAR
The pads must be placed to the right of the
jacking points. They must be engaged in the ope-
nings in the sill panel flanges.
40-9
GENERAL
Lifting
40
LASHING FOR TOWING
FOR TOWING REFER TO THE CURRENT
LEGISLATION FOR EACH COUNTRY.
NEVER USE THE DRIVESHAFTS AS TIE-DOWN
POINTS.
The towing points are only to be used for towing
on the road. They must never be used for pulling
the vehicle out of a ditch, for any other similar
operations or for lifting the vehicle directly or in-
directly.
2 - SPECIAL CASE FOR REMOVAL - REFITTING OF
THE ENGINE AND TRANSMISSION ASSEMBLY
In this case, the vehicle body must be connected to
the arms of the two post lift using special pads.
FOG :
Part number FOG 449 8111 - 449 8411
or
CHEMICO :
Part number 39 2550 0001
or

SCHENCH
Part number 776 684
FRONT
98705S
REAR
98702S
40-10
GENERAL
Description of parts (exploded views)
40
PRS4012
B53 / C53
9 Rear floor panel front section
10 Rear floor panel
11 Floor panel stiffener cross member
12 Fuel tank mounting cross member
13 Cross member under rear floor panel
14 Rear side member
15* Front side cross member
16* Front side member rear section
17 Front side member closure panel
18 Front side member front section
18A Part front side member
19 Lower front cross member
19A Part lower cross member
20 Assembled front panel
20A Part assembled front panel
LOWER STRUCTURE ALL TYPES
1 Sill closing panel
2 Centre floor panel

2A Part centre floor panel
2B Part centre floor panel
3 Centre floor panel cross member
4 Front seat mounting cross member
5 Front 1/2 unit (wheel arch)
6 Rear 1/2 unit (wheel arch)
7 Assembled rear floor panel with side
member
8 Rear floor panel rear section
8A Part rear floor panel
8B Part rear floor panel
* Steel part with high degree of flexibility
40-11
GENERAL
Description of parts (exploded views)
40
PRS4013
B53 / C53
UPPER STRUCTURE
50 Front roof panel cross member
51 Windscreen pillar lining
52 B53 roof drip moulding lining
53 Rear roof cross member
54 Roof panel
55 Centre pillar lining
56 B53 quarter panel lining
57 Quarter panel arch
58 Rear outer wheel arch
59 Quarter panel lining (C53)
60 Sill panel partition (C53)

61 Door pillar lining (C53)
62 Body top lining (C53)
63 Centre pillar lower lining
64 Front wing bracket
65 Front wing
66 Front wheel arch
67 Front wheel arch extender
68 Diesel engine mounting cup
69 Headlight carrier panel
70 Bonnet lock support
71 Front upper cross member
71A Part front upper cross member
72 Inner wheel flange panel - front pillar
lining
72A Part inner wheel flange panel - front
pillar lining
72B Part inner wheel flange panel - front
pillar lining
73 Heater bulkhead partition
73A Part heater bulkhead partition
74 Bulkhead
75 Windscreen aperture lower cross member
75A Part lower cross member
76 Bonnet
40-12
GENERAL
Description of parts (exploded views)
40
PRS4014
B53 / C53

UPPER STRUCTURE
80 Tailgate
81 Front door
82 Rear door
83 Rear door panel
84 Front door panel
85 Lighting support
86 Rear end panel
87 Assembled rear end panel with cross
member
88 Rear end panel lining
89 Sill panel (C53)
90 Wing panel (C53)
90A Part wing panel in line with cross-section A
90B Part wing panel in line with cross-section B
91 Body top (roof drip moulding) (C53)
92 Sill panel (B53)
93 Body top (B53)
94 Front pillar
95 Body side
96 Centre pillar
97 Rear wing panel (B53)
97A Part rear wing panel (cross-section A)
97B Part rear wing panel (cross-section B)
98 Wing panel upper rain channel
99 Wing panel lower rain channel
40-13
GENERAL
Description of parts (exploded views)
40

PRS4015
1 Rear floor panel with side member
2 Part rear floor panel (rear section)
3 Rear floor pnel
4 Rear side member
5 Part rear end panel cross member
B53 / C53 / L53
LOWER STRUCTURE
40-14
GENERAL
Description of parts (exploded views)
40
PRS4016
L53
SALOON
UPPER STRUCTURE
1 Roof panel
2 Rear roof cross member
3 Boot lid
4 Counter balance ball joint
5 Boot lid strut
6 Quarter panel lining
7 Quarter panel arch
8 Outer wheel arch
9 Wing panel side rain channel
10 Wing panel
11 Rear end panel cross member
12 Rear end panel cross member blanking piece
13 Lighting support panel
14 Assembled rear end panel

15 Rear end panel side extender
16 Jack support (right hand side only)
17 Backrest mounting stiffener
18 Rear centre shelf
19 Half unit
40-15
GENERAL
Description of parts (exploded views)
40
PRS4017
D53
CABRIOLET
1 Windscreen surround
2 Rear floor panel upper cross member
3 Floor panel and cross member side stiffener
4 Lower side spacer
5 Lateral side member lower section
6 Sill panel stiffener
7 Sill panel rear stiffener
8 Sill panel outer panel
9 Bare sill panel outer panel
10 Door panel
11 Door
12 Front pillar upper stiffener
13 Front pillar
14 Front wing
15 Sill panel front stiffener
16 Front pillar lower lining
17 Windscreen pillar lining
18 Windscreen aperture upper cross member

40-16
GENERAL
Description of parts (exploded views)
40
PRS4018
D53
CABRIOLET
38 Lighting support component stiffener
39 Rear wing panel
40 Outer wheel arch stiffener
41 Outer wheel arch
42 Wing panel lower front lining
43 Wing panel upper front lining
44 Centre pillar
45 Centre pillar lining
46 Assembled wing panel lining
47 Boot lighting support
28 Upper cross member between wheel
arches
29 Hood compartment base partition
30 Hood compartment rear cross member
31 Boot lid rain channel
32 Hood compartment cover
33 Boot lid
34 Hood compartment cover hinge
35 Boot lid hinge
36 Wing panel rear lining
37 Lighting support component
40-17
Cut the part by grinding the flange or

grind down the remaining bits of spot
weld
Angle grinder fitted with a rubber
backing pad and a

120 to 180 mm P36
grade fibre disc
GENERAL
Description of symbols
40
Cut using a cold chisel
Grind the weld fillet or spot welds
Straight grinding wheel fitted with a
75mm diameter 1.8 to 3.2 mm thick
Bakelite disc.
Rotary grind the spot welds
20,000 rpm straight grinding wheel with
a 10 or 16mm diameter spherical cutter.
Rotary grind the spot welds
Spot weld drill. Speed of rotation 800 to
1,000 rpm.
Unpick the metal strip
Clean the surfaces to be welded
100 mm fibre disc
Cut using a hacksaw
Pneumatic power hacksaw
Release brazed joint
Dimensions and types of electrodes to
be used for the operation:
MIG stitch welding

Note: for good quality welding, it is
recommended that a gas composed of
Argon + 15% CO
2
, which is considered
to be an active gas, is used (MIG)
Plug welding
MIG welding
Inject wax into the hollow sections
Gun under pressure fitted with a
flexible end piece.
Safety symbol
This means that the welding operation
in question concerns one or more
aspects of vehicle safety
Lead fill
Hot air gun
Nozzle output temperature 600° min.
Palette+ 33% lead stick+ tallow
Note: to a large extent, the soft solder
finish compensates for the risks of
deformation due to welding
Application of electrically weldable
mastic
This conductive mastic, inserted
between two panels to be spot welded,
seals the panels and prevents corrosion
of the spot welds
Application of aluminium based paint
This must be applied to the mating

surfaces 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.
Apply a bead of extruded mastic
•
gun with a manual or pneumatic
cartridge
•
crimping or mating mastic with one
or two parts
Apply mastic by spraying
•
gun under pressure
•
anti-chipping and anti-corrosion
mastic with two parts
L = 100
L = 100
L = 100 +flat
L = 250
L = 350 +ball joint
L = 330
40-18
GENERAL
Description of symbols
40
LOCATION OF
OPERATIONS

TYPES OF TOOL AND
ORDER OF OPERATIONS
LOCATION OF
OPERATIONS
TYPES OF TOOL AND
ORDER OF OPERATIONS
CUTTING-UNPICKING
saw saw
or
chisel
rotary
grind
unpick clean
unpick cleangrind
rotary grind
unpick cleansand
grind
sandrelease
brazed joint
WELDING
grind lead
fill
stitch
weld
X
L (en
mm)
1-2
3-4
5

6
8
100
100
250
350
330
electric spot welder
WELDING
(cont)
plug weld
stitch weld
FINISHING
stud
extractor
PROTECTION OF CRIMPED WELD JOINTS
bead of mastic in cartridge
bead and spraying of mastic
ANTI-CHIPPING PROTECTION
spraying of mastic
PROTECTION OF HOLLOW SECTIONS
injection using angled nozzle
PAINTING STYLED AREAS
aerosol can
40-19
GENERAL
Opening clearances
40
92309-1R1
B53

Phases I and II
91936-4R
40-20
GENERAL
Opening clearances
40
92309-1R2
B53
Phases I and II
40-21