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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.

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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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- 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

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- 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

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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\

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Partially replacing (+ tailgate pillar).

Where only the rear part is damaged partialreplacement is adyised, carrying out as follows!

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: • ; • • . . - . - -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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