diagram RENAULT KANGOO 1997 KC / 1.G Sheet Metal Work User Guide

UPPER FRONT STRUCTURE
Plenum chamber
42G
PRB4214
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of :
- the wheel arch for a frontal impact,
- cowl side panel for a side impact.
This operation may be carried out partially (see
diagram and method below).
The Parts Department only provides chambers of
the (1) "air conditioning" type, as a result, the
closure panel must also be ordered (2).
In the following operation there are only descrip-
tions of the joints specific to the part concerned.
Information concerning other parts is dealt with
in the respective section.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
1 Plenum chamber
Part assembled with :
- bonnet lock mounting,
- windscreen wiper motor mounting.
2 Partition closure panel.
JOINTS WITH :
Wheel arch
Injection unit and impact sensor mounting (left
hand side)
Bulkhead
Pillar lining (cowl side panel)
Windscreen aperture lower cross member
PARTS CONCERNED (thickness in mm) :
1Plenum chamber 1
2Shock absorber cup height adjuster 1
3Shock absorber cup 2
4Injection unit and impact sensor
mounting (left hand side) 2
5Bulkhead 1
6Cowl side panel (pillar lining) 1.5
7Windscreen wiper mounting 1.5
8Windscreen aperture lower cross
member 1.2
or
42-24

UPPER FRONT STRUCTURE
Windscreen aperture lower cross member
42H
PRB4215
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of :
- the wheel arch with the cowl side panel for a
frontal impact,
- the front pillar with lining for a side impact.
This operation may be carried out partially (see
diagram and method below).
In the following operation there are only descrip-
tions of the joints specific to the part concerned.
The Parts Department supplies the windscreen
aperture lower cross member (1) without the stee-
ring column mounting (2), which must be ordered
separately.
Information concerning other parts is dealt with
in the respective section.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
1 Windscreen aperture cross member
Part assembled with :
- steering column mounting height adjus-
ter,
- lower reinforcement of windscreen aper-
ture cross member.
2 Steering mounting
Part only.
JOINTS WITH :
Bulkhead
Windscreen aperture lower cross member
Windscreen aperture lower cross member
reinforcement
Steering column mounting height adjuster
Steering column mounting
Cowl side panel (pillar lining)
Windscreen wiper mounting
PARTS CONCERNED (thickness in mm) :
1Bulkhead 1
2Windscreen aperture lower cross
member 1.2
3Windscreen aperture lower cross
member reinforcement 1.2
4Steering column mounting height
adjuster 1.5
5Steering column mounting 2
6Cowl side panel (pillar lining) 1.5
7Windscreen wiper mounting 1.5or
42-28

UPPER FRONT STRUCTURE
Bulkhead
42J
PRB4217
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of :
1 - for a frontal impact :
- the wheel arch with the cowl side panel,
- the plenum chamber ,
2 - for a side impact:
- the front pillar with lining,
- the windscreen aperture lower cross mem-
ber,
- the plenum chamber .
This part may be partially replaced (see diagram
and method below).
In the following operation there are only descrip-
tions of the joints specific to the part concerned.
Information concerning other parts is dealt with
in the respective section.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with :
- windscreen wiper mounting,
- windscreen wiper mounting reinforcement.
JOINTS WITH :
Floor
Windscreen wiper mounting
Windscreen wiper motor mounting
Windscreen pillar
Windscreen pillar lining
Front side cross member
PARTS CONCERNED (thickness in mm) :
1Bulkhead 0.7
2Floor 0.8
3Windscreen wiper motor mounting 1.5
4Windscreen pillar 1
5Windscreen pillar lining 1
6Rear side member, front section 2.5
7Front side cross member 1
8Front pillar 0.8
or
42-34

UPPER SIDE STRUCTURE
Left hand side sill panel
43G
PRB4317
INTRODUCTION
The replacement of this part is a basic operation
for a rear side impact.
This part can be partially replaced (see diagram
and method below).
In the operation described below there are only
descriptions of the joints specific to the part
concerned.
Information concerning other parts will be dealt
with in the respective section.
This part may be replaced in two ways :
1 - Cut A-A (described below)
2 - Cut B-B (refer to operation N for the front pil-
lar)
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part only.
or
LIST OF JOINTS :
Body side lining
Sill panel closure panel, rear section
Sill panel closure panel, front section
PARTS CONCERNED (thickness in mm) :
1Left hand side sill panel 0.8
2Body side lining 0.7
3Sill panel closure panel, rear section 1.2
4Sill panel closure panel, front section 1.2
43-25

UPPER REAR STRUCTURE
Rear wing panel
44A
PRB4413
INTRODUCTION
The replacement of this part is a basic operation
for a rear side impact.
In the operation described below there are only
descriptions of the joints specific to the part
concerned.
Information concerning the other parts will be
dealt with in the respective section.
For the panel version, this part may be replaced in
two ways (see cuts marked on the diagram be-
low) :
1 - complete replacement with cut A.A
2 - partial replacement with cut B.B
At the end of the section there are special details
for the glazed version and for the version with
roof flap.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with sliding door rail units and
striker plate mounting.
JOINTS WITH :
Lights mounting side panel rain channel
Body side lining
Centre pillar reinforcement
PARTS CONCERNED (thickness in mm):
1Rear wing panel (right hand side) 0.8
2Rear wing panel lining
(right hand side) 0.7
3Lights mounting side panel rain
channel 1.2
4Rear wing panel extension 1
5Side panel rain channel
upper reinforcement 1.2
6Centre rail mounting 1
7Stretcher lining 0.7
8Roof 0.7
9Centre pillar upper reinforcement 1.2
10Centre pillar reinforcement 1.2
11Sill panel rear closure panel 1.5
12Seat belt mounting reinforcement 1.2
13Roof flap rain channel 0.7
44-1

UPPER REAR STRUCTURE
Side panel
44B
PRB4414
INTRODUCTION
The replacement of this part is a basic operation
for a rear side impact.
In the operation described below there are only
descriptions of the joints specific to the part
concerned.
Information concerning the other parts will be
dealt with in the respective section.
For the panel version, this part may be replaced in
two ways (see cuts on the diagram below) :
1 - complete with cut A.A on the upper section
2 - partial with cut B.B for the glazed version
At the end of the section there are also special de-
tails for the glazed version and the version with a
roof flap.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with sliding door rail units and
striker plate mounting.
JOINTS WITH :
Lights mounting side panel rain channel
Body side lining
Door pillar reinforcement
Wing panel stiffener spacer
PARTS CONCERNED (thickness in mm):
1Rear wing panel 0.8
2Rear wing panel lining 0.7
3Lights mounting side panel rain
channel 1.2
4Rear wing panel extension 1
5Side panel rain channel
upper reinforcement 1.2
6Centre rail mounting 1
7Stretcher lining 0.7
8Roof 0.7
9Door pillar upper reinforcement 1.2
10Door pillar reinforcement 1.2
11Sill panel closure panel 1.5
12Roof flap rain channel 0.7
13Sill panel pillar reinforcement 1.2
14Wing panel stiffener spacer 0.7
15Wing panel stiffener 0.7
44-9

UPPER REAR STRUCTURE
Side panel lining
44C
PRB4415
INTRODUCTION
The replacement of this part is a complementary
operation to the wing panel or a side panel for a
rear side impact.
It also requires replacement of the centre pillar
reinforcement, the door pillar will need to be or-
dered separately.
In the operation described below there are only
descriptions of the joints specific to the part
concerned.
Information concerning the other parts will be
dealt with in the respective section.
This part is replaced in three ways (see cuts on the
diagram below) :
1 - complete
2 - partial by cut A-A
3 - partial by cut B.B for glazed version
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with welded nuts.
JOINTS WITH :
Door pillar upper reinforcement or centre pillar
reinforcement
Roof stretcher lining
Lights mounting side panel rain channel
Sill panel closure panel
Sill panel closure panel, rear section
Rear wheel arch
Rear end cross member
PARTS CONCERNED (thickness in mm):
1Rear wing panel lining 0.7
2Stretcher lining 0.7
3Lights mounting side panel rain
channel 1.2
4Rear wing panel extension 1
5Side panel rain channel
upper reinforcement 1.2
6Sill panel closure panel 1.5
7Sill panel closure panel, rear section 1.5
8Door pillar upper reinforcement 1.2
9Door pillar lower reinforcement 1.2
10Inertia reel mounting reinforcement 1.5
11Inner wheel arch 1
12Seat mounting reinforcement 1.5
13Rear end cross member 1.2
44-17

UPPER REAR STRUCTURE
Lights mounting side panel rain channel
44F
PRB4418
INTRODUCTION
The replacement of this part may be carried out in
two ways :
1 - Complete replacement, complementary to the
side panel with lining.
2 - Partial replacement, complementary to the
rear end panel and rear end cross member
(see cut in the diagram below).
In the operation described below there are only
descriptions of the joints specific to the part
concerned.
Information concerning other parts will be dealt
with in the respective section.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with :
- side panel extension,
- lights mounting with studs and welded nuts,
- bumper counter blade,
- tailgate counter balance reinforcement,
- welded nuts,
- upper hinge reinforcement.
JOINTS WITH:
Panel upper rain channel
Side panel lining
Rear floor
Rear end cross member
Roof stretcher lining
Roof
PARTS CONCERNED (thickness in mm):
1Lights mounting side panel rain
channel 1.5
2Panel upper rain channel 1.2
3Panel lining 0.7
4Rear floor 0.8
5Rear end cross member 1.02
6Roof stretcher 0.7
7Roof 0.7
8Wheel arch 1
9Side panel 1
10Rear wing panel extension 1
or
44-33

UPPER REAR STRUCTURE
Rear wing panel extension
44G
PRB4419
INTRODUCTION
The replacement of this part is carried out partial-
ly following a rear side impact and is complemen-
tary to the rear wing panel (see diagram and me-
thod below).
The bumper side mounting must also be replaced
and is sold separately.
In the operation described below there are only
descriptions of the joints specific to the part
concerned.
Information concerning other parts will be dealt
with in the respective section.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part only.
JOINTS WITH:
Wing panel lining
Lights mounting side panel rain channel
Bumper mounting
PARTS CONCERNED (thickness in mm):
1Rear wing panel extension 1
2Wing panel lining 0.7
3Acoustic insert 0.7
4Bumper mounting 1.2
44-38

UPPER REAR STRUCTURE
Rear end panel
44H
PRB4420
INTRODUCTION
The replacement of this part is a basic operation
for a rear impact.
In the operation described below there are only
descriptions of the joints specific to the part
concerned.
Information concerning other parts will be dealt
with in the respective section.
This part may be replaced partially (see cut and
diagram below).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part only.
JOINTS WITH:
Rear end panel
Rear end cross member
Side panel rain channel
Floor
Rear pillar lower gusset
PARTS CONCERNED (thickness in mm):
1Rear end panel 1
2Rear end cross member 1.2
3Side panel rain channel 1.5
4Floor 0.8
5Rear wing panel extension 1
or
44-41