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RENAULT 4 "PLEIN AIR"
Specifications
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The Renault 4 PLEIN AIR, derived from the R.T123,. differs
fromthe saloon due to body alterations.These alterations consist
principally of :- modification to the top part of the windscreen-
addition of side panels ensuring a rigid connection between
thefront pillars and the rear because of the absence of doors- the
cutting away of the two rear quarter light panels and thetailgate
^- the fitting of a soft top.
The addition of reinforcing pieces and connectirigLjgyssets,spot
welded or gas welded together, gives this assembly
sufficientrigidity to prevent possible distortion arising from hard
use.
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SUPERSTRUCTURE
D e s c r i p t i o n o f the v a r i o u s components c o n c e
r n e d in the bodyt r a n s f o r m a t i o n .
This drawing shows the main bodywork part:available from C.S.S.
(see PR.903 pages 882). Some strengthening pieces or connectgussets
will be made locally.
1. Windscreen frame2. Windscreen reinforcement3. Scuttle
reinforcement4. Side member5. Side panel6. Rear reinforcement
't$"' •'y'̂ 'l';*'̂ ]
7. Quarter!ight panel (spare p
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REPLACING BODYWORK COMPONENTS
Windscreen frame
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How to fix the reinforcement
70 90870323-A
This component is to be replaced when distortionwarrants it.In
order to limit the amount of dismantlingwork it is best to
partially replace it by cuttingin the areas (F) on the side
pillars.This work must be particularly strong andneatly done as the
absence of a roof panelslightly reduces the rigidity of the
frame.When fitting the new component (1) makesure of correct
spacing between the upper andlower portions (G) to ensure correct
fitting ofthe windscreen.
The gas welded joints will be covered withplastic filler +
hardener.Note at the same time that the two side rein-
'fprcements (2) are available from the C.S.S.the repair is less
serious.
70 9CC
Fitting the Yeinforpement (2) after cutting outthe
?ns1de/'of,'the windscreen frame upper part.Then
gas^weI'd?together.
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ASSEMBLING THE SIDE COMPONENTS
IT The fitting of these components has lead to
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- cutting out the top hinge (H) and the centrepillar level with
the floor (J).- the fixing of the front ;and rear reinforcements(6)
is made by hexagonal headed self tappingscrews.- the side member
(4) is held in position alongits lower edge by the unions of three
securingscrews inside on the body sill.- the 3 components
(reinforcements and sidemember) are spot welded together (L).-
modification to wiring harness location.
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X 70325
- the body side section is fitted to the bodyby double spot
weldingat (8) on the scuttle panel
i at (9) on the quarter light panel and the rear .I . W'n9
^§> at (10) on the top edge of the side member|| at (11) on the
filler piece brackets.f[ Only the lower part (12) is fitted by
rivets (R):"|ran the body side.
Method for repairing
DegpMIng on the damage, the complete orParJSltp!Qcement of the
body side can be
i|Jnd|fifa:ken.
Completely replacing
- Remove the mouldings, secured by rivets.- Unstitch the spot
welds and remove therivets (R) round the body side.This unstitching
can be done by means of achisel or by drilling with a flat ended
drill(see Use of small tools;MR.61 chapter Bodywork)
- Level off or grind the spot welds on thecomponents remaining
in position and protectthem with a coating of zinc based paint.-
Offer up the new component holding it inplace by body clamps or
vice grips.Spot weld and rivet to the side of the chassis
I
- Joints (13) and (14) will be brazed.- The welding seams will
be smoothed out byusing plastic filler + hardener.
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Partially replacing
Replacing part of the front or rear can becarried out as follows
:(For example the rear part).- Unstitch the damaged section up to
about250 mm (9-7/8") beyond the point where thecut out will be made
(15).- Offer up the new component (taken from acomplete new side
panel (from the C.S.S.).- Mark it off, cut it out and temporarily
placein position.
Cross section A-A
1,8
70 910
5 mm (3/16")1.5mm 0/16")
- Turn up the edge slightly, (see cross sectionA) the purpose of
this being to stretch the metal.- Fit the two components end to end
gas weldingpoints about every 25 mm (1").- Level off the welding,
then complete it in
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stages, that is to say :- Weld along about 50 mm (2"), level
off.- Weld along another 50 mm (2") level off etc.Carry on in this
manner, until the two parts arejoined.The aim of this method is to
restrict distortiondue to heat and make the levelling off
easier.
IMPORTANT -
While carrying this out make sure frequentlythat the new
component remains correctlypositioned by temporarily securing
it.The surface finish will be obtained by plasticfiller +
hardener.Tinning is not recommended (distortion risk dueto
heat).
Replacing front or rear reinforcements
sa
With the side panel removed, lift out thereinforcements by
removing the securing screwson the front and rear pillars and
unstufech thespot welds (L) on the side member > -$;{",When
replacing make sure that the sidjj memberand the front and rear
pillars which act as abase are not distorted. , 'j*Prepare the
front pillar by drilling iyvfp holesfor the fixing the
reinforcement.
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Replacing a side member 1
This component which is spot welded to bothreinforcements can be
taken off by removingthe front and rear pillar securing bolts
togetherwith the three securing bolts on the body sill.On the left
side be careful not to damage thewiring harness (M).When refitting
do not forget the anti-drummingfelts (S)'on the stiffener sides and
carry outsealing between the side member and the chassissection
using two wide strips of mastic 297sealing compound.
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220mm50 mm14 mm25 mm
Diameter 6 mm
(8-11/16")(1-15/16")( 9/16")
( 1" )( 1/4" )
Replacing a rear quarter panel Method of operation
-There are two possible methods for repairing arear quarter
panel.~V-
4,InTboth.cases, the parts must be completely orpartly, cut out
from the components available,fronrTc.S.S. (see PR.808).
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Onlyireplacement of the upper part of the rearquarter panel is
shown here.For a'bigger repair rejpinng wheel house
i replacement refei? to-MR. 103 section M-010'< "Accident
Damage".i\
_1.
Partially replacing (+ tailgate pillar).
Where only the rear part is damaged partialreplacement is
adyised, carrying out as follows!
'•" I '..I'..; ... pffe*-^. /t| »
: • ; • • . . - . - -VV' ;
- Reform to approximately the pre-accident
shape. '!•£• /;'''••'•- Remove the rear.^wmg-.securing bolts
(16) anddetach the rear,wing carefully (arrow), thefront.part
remaining 'covered by the side panel
(P).- Unstitch the spot welds at the joint betweenthe^heel house
and the rear pillar connecting.fane! '(17).
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- Separate the brazing points on the wheelhouse (18) and at the
bottom of the tailgatepillar (19).- Cut out the damaged section
following theline chosen (U).
- At the bottom of the pane) level off thewelding seam (21)
remaining in place.- Level off and clean the part to be welded.
- Mark off and cut out, in the new parts, thereplacement
sections required (quarter paneland tailgate frame).- Offer up
these parts using the tailgate door asa jig.-Weld together the
joint between :the wheel house and the tailgate frame (17)by spot
welding
- by spots of brazing at (18) and (19).The bottom face of the
panel (20) covers thewheel house (24). ,̂« c*Before fitting this
panel, drill several holes;(25) in order to fit the two components
(23),take care to cover the rear quarter panel witha sheet of
asbestos (26).
- Gas weld the panels (U) together, if necessarylevel.off and
cover with plastic filler.
- Ensure sealing by a wide strip of mastic 297sealing compound
placed after fitting therear wing at (27) and (28). The outside
joint(29) will be covered by a strip of mastic 307sealing
compound.- Refit the moulding .
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22 - Reqrrwj,ng7, ::23 - Wheel-Chouse
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Replacing a complete quarter panel
25. mm26 mm40 mm45 mm
0")0-1/16")(1-9/16")(1-3/4")
This operation is similar to the preceding onetjwith the
addition of partial removal of the
side panel.
Method of operation
- Unstitch the spot welds on the side panel andon the brackets
(30).- Remove the rivets (32) along the bottom.- Lift the side
panel gently without distortingit (arrow).- Cut out the blanking
piece (34) on the rearpillar and then remove the hood frame hinge.-
Unstitch the spotwelds on the rear pillar (31).
For a larger repair replace the pillar (seeoperating method in
MR. 103, section M-010"Accident Damage").When refitting, offer up
the new components,and hold in place by tack brazing. if- Check
that their position is correct by majcingsure that the measurement
between the rightand left hand hinges is 1,204 mm (51-5/16")and
using the tailgate as a jig 905 mm (35-5/811,)1.- Spot weld the
rear pillar and the tailgateframe together for good. '- Fit the
tailgate reinforcement (35) in place. YJ
--Wel'd the half moon closure plate (33).- Fit the blanking
plate (34) and the hoodframe hinge(plate (34) is to be made
locallyto the drying overleaf). , •>. ''
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70 873
81 mm15 mm16 mm46 mm26mm28. mm
(3-3/16")(9/16")(5/8")(1-13/16")0-1/16")-0-1/8"),0-1/4") -
R £-. 0/2")0/4")
Before brazing at (Z) ensure .hood hingecentralisation by
passing a rod through fromone side to the other.1204mm
(47-3/8").
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Tailgate
75 mm133 mm105. mm14 mm
905 mm
(2-15/161
(5-1/4")(4-1/8")(9/16")(35-5/8";
35 bis
Available as a special spare part componentthis door is hinged
using two hinges screwedon to the door frame.
The hinge pins (37), secured by female Allenscrews^ screw into
the reinforcements (35)and (35 bis).When replacing a tailgate frame
arrange tofit the hinge reinforcements and counter-balance before
welding the closure panels (33).The counter-balance fitting is,
further downby comparison with that on the saloon(holes (V)).
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