RENAULT KANGOO 2000 KC / 1.G Sheet Metal Work Workshop Manual

Sheet Metal Work
GENERAL INFORMATION
LOWER STRUCTURE
UPPER REAR STRUCTURE
TOP OF BODY
77 11 292 482
"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 introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed."
JANUARY 2000
All copyrights reserved by Renault.
EDITION ANGLAISE
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.
© RENAULT 2000

EXPLODED VIEW

Sheet Metal Work
Contents
Page
40
41
44
45
GENERAL INFORMATION
Dimensions 40-1
Engine and equipment 40-2
Towing 40-3
Key to symbols 40-4
Fitting the extension elements 40-5
Description of parts 40-6
Sub-frame dimensions 40-8
Repair bench 40-9
Tools and specific products 40-12
LOWER STRUCTURE
Semi-extreme rear cross member 41-1
Rear floor extender 41-8
UPPER REAR STRUCTURE
Basic body rear wing panel 44-1
Added rear wing panel 44-3
Basic body side panel 44-12
Added side panel 44-14
Side panel extender 44-24
Side inner panel extender 44-28
Upper rear corner stiffener 44-30
Lights mounting side panel rain channel 44-33
TOP OF BODY
Grand volume added roof 45-1
Roof inner panel extender 45-5 P
X
A
Aa
B
Bb
G
I
J
K
Aa
E

GENERAL INFORMATION
Dimensions
40
140GENERAL INFORMATION
Dimensions
(1) Empty
(2) Laden
Dimensions in metres.
40-1

GENERAL INFORMATION
Engine and equipment
40Engine and equipment
BODY AND EXTENDED PASSENGER COMPARTMENT
Vehicle typeEngine
Clutch typeGearbox type
manual and automatic

TypeCapacity
(cm
3)
FC0HHF E7J 1390 180 CP 3300 JB3
FC0EHF F8Q 1870 200 COPV 3250 JB1
BODYEXTENDED
PASSENGER
COMPARTMENT
Petrol Diesel Petrol Diesel
Pay load (kg) 550 600 580 580
Weight (kg) when empty and ready for operation
(basic vehicle)1175 1220 1195 1240
Weight (kg) when empty and ready for operation
on front610 660 610 655
Weight (kg) when empty and ready for operation
on rear565 560 585 585
Weight (kg) when empty and ready for operation
(all options)1227 1270 1246 1291
40-2

GENERAL INFORMATION
Towing
40
40-3
Towing
OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
SPECIAL FEATURES OF THE KANGOO GRAND VOLUME
This vehicle does not have a rear towing eye.
FRONT
The towing eye may only be used for towing on the
road.REAR
Under no circumstances should the rear towing ring of
the basic body be used for towing.

GENERAL INFORMATION
Key to Symbols
40Key to Symbols
Chiselling Crimping of exterior door panels.
Grind back beads or spot welds.
Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm.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 600° min.
Slipper+ 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.
Unpicking
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 Cleaning surfaces to be welded.
Fibre disc Ø 100 mm
Cutting with a saw.
Pneumatic power hacksaw.
Application 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 –Cut out part by grinding off flange or
grinding back remaining traces of spot
weld.
–Finish surface after welding.
–Angle grinder fitted with a rubber pad
and a 120 to 180 mm diameter fibre disc
grain size P36.
Unsoldering.Apply a fillet of extruded mastic
●from a manual or pneumatic spray gun
●one or two pot mastic for crimped and
butt joints.
MAG stitch weld
Note: to obtain a good quality weld we
recommend the use of a gas consisting of
argon + 15% CO2 which is considered an
active gas (MAG)Apply mastic by spraying
●spray gun.
●anti-chipping and anti-corrosion in two
parts
Apply a bead of extruded adhesive mastic
●from a manual or pneumatic spray gun
●adhesive mastic in one or two parts Resistance spot welding
Plug welding.
Under MAG gas protection.Thermal cleaning of extruded or spray
mastic
40-4

GENERAL INFORMATION
Fitting extension elements
40Fitting extension elements
40-5
1Roof
2Rear ring
3Side panel
4Wing panel
5Basic body

GENERAL INFORMATION
Description of parts
40Description of parts
UPPER STRUCTURE
1Roof added
2Roof rear cross member
3Rear wing panel (panel and glazed version)
4Side panel rain channel support
5Side panel added (panel and glazed version)
6Side panel extender
7Side inner panel extender
8Upper rear corner stiffener
9Roof inner panel extender
PRF4011
40-6

GENERAL INFORMATION
Description of parts
40
40-7
SUB-FRAME
10 Rear floor extender
11 Demi-rear end cross member
12 Rear end panel
PRF4012