ABS RENAULT KANGOO 1997 KC / 1.G Sheet Metal Work Workshop Manual

Contents
GENERAL
Dimensions
Engine and equipment
Identification
Means of lifting
Towing
Using symbols
Key to symbols
Description of Parts (exploded)
Opening clearances
Collision fault finding
Sub- frame dimensions
Repair bench
Special tooling
Part Number of special tooling40-1
40-2
40-4
40-6
40-8
40-9
40-11
40-12
40-15
40-22
40-25
40-27
40-38
40-38
LOWER STRUCTURE
41- 1
41- 5
41-10
41-13
41-17
41-21
41-26
41-29
41-33
41-36
41-39
41-41
41-44
41-51
41-53
41-55
41-58
41-60
41-62
41-63
41-67
41-68
41-71UPPER FRONT STRUCTUREPage Page40
41
42
Sheet metal work
UPPER SIDE STRUCTURE43
AFront end lower cross member
BFront side member, front section
CFront side member closure panel
DFront half unit
EFront side cross member
FFront side member, rear section
GFront mounting of sub frame
HSill panel closure panel
ICross member under front seat
JSide floor
KTunnel
LRear floor, front section
MRear floor, rear section (part
section)
NFront cross member of rear floor,
front section
ORear floor stiffener
PRear end cross member
QRear absorber reinforcement
RRear side member extension
SRear side member, part section
TComplete rear side member
URear floor centre cross member
VSeat anchoring reinforcement
WRear floor unit42-1
42-2
42-5
42-8
42-12
42-17
42-24
42-28
42-32
42-34 AFront wing
BHeadlight carrier panel
CCowl side panel (pillar lining)
part section
DUpper reinforcement of cowl side
panel
EWheel arch, front section
FWheel arch
GPlenum chamber
HWindscreen aperture lower cross
member
ISteering column mounting
JBulkhead
43-1
43-6
43-9
43-14
43-19
43-23
43-25 AFront pillar
BWindscreen pillar
C Front pillar lining/Cowl side panel
DCentre pillar / sill panel
ECentre pillar lower reinforcement /
door pillar
FSill panel reinforcement
GLeft hand side sill panel
UPPER REAR STRUCTURE
44
44-1
44-9
44-17
44-26
44-30
44-33
44-38
44-41 ARear wing panel
BSide panel
CSide panel lining
DRoof stretcher lining
ERear inner wheel arch
FLights mounting side panel rain
channel
GRear wing panel extension
HRear end panel

GENERAL
Means of lifting
40
SAFETY SYMBOL
There are several examples :
1 - WHEN REMOVING PARTS
Generally speaking, never use a 2 post lift if a
four post lift would be more suitable.
If this is not possible, position the lifting pads
below the body flange at the jacking points for
the jack supplied with the vehicle.
98703S
FRONT
98704S
REAR
These absolutely MUST be placed to the right of
the jacking points. They must be clipped into the
sill panel flange openings.
2 -
SPECIAL CASE OF THE REMOVAL - REFITTING
OF THE ENGINE AND TRANSMISSION
ASSEMBLY
In this specific case, the body of the vehicle must
be attached to the arms of the two post lift with
special pads.
FOG Company
Part number FOG 449 8111 - 449 8411
or
CHEMICO Company
Part number 39 2550 0001
or
SCHENCH Company
Part number 776 684
40-7

GENERAL
Description of parts (exploded view)
40
PRB4002
1 Rear floor, front section
2 Rear floor unit
3 Rear floor, rear section
4 Rear end cross member
5 Rear end panel
6 Rear absorber reinforcement
7 Complete rear side member
8 Rear side member extension
9 Rear side member, part section
10 Rear floor stiffener
11 Rear floor centre cross member
12 Seat anchoring reinforcement13 Rear floor front cross member
14 Front side member, rear section
15 Front side cross member
16 Front side member, front section
17 Front mounting of front sub-frame
18 Front side member closure panel
19 Front end lower cross member
20 Front half unit
21 Tunnel
22 Side floor
23 Sill panel closure panel (side door)
24 Cross member under front seat
SUB-FRAME
40-12

GENERAL
Sub-frame dimensions
40
DESCRIPTION X Y ZDIAMETER SLOPE %
A Front sub-frame rear mounting 205 402.5 71 18.5 0
B Rear axle assembly front mounting 1 999.3 657 71.3 20×20 X : 8°20
C Front left sub-frame front mounting - 418 447 13010×10
(squared)0
Front right sub-frame front mounting - 418 465 13010×10
(squared)0
E Rear shock absorber upper mounting 2 333.13 545.75 184 12.5 0
F Front shock absorber upper mounting 18.5 545.50 657 48X : 3°02
Y : 1°
G1 Rear section of front left side member 600 - 375 020×20
(squared)0
Rear section of front right side member 600 351.6 020×20
(squared)0
J Rear point of rear side member 2 918 497.5 151 12.2×16.2 X : 3°
K Front end cross member 575 315 280 14.25X : 4°30
Z : 5°
L Rear end cross member (end panel) 3 121 - 497.5 151 M8 0
P Front engine mounting - 247 483.5 514 M10 0
Rear engine mounting - 113 483.5 514 M10 0
40-25

GENERAL
Repair Bench
40
12841S
The bracket rests under the shock absorber cup
and is centred in the shock absorber mounting
hole.
It is used when replacing :
- wheel arches,
- a front half unit.
It is also used when straightening. E -
REAR SHOCK ABSORBER UPPER MOUNTINGIII - REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont)
12665R
The bracket is fitted at the shock absorber clevis
location and positions this mounting for repla-
cing :
- a rear side member,
- the rear floor unit.
It is also used when straightening.F -
FRONT SHOCK ABSORBER UPPER
MOUNTING
40-32

GENERAL
Repair Bench
40
12668R1
The bracket helps with the fitting of the cross
member and rests vertically against the front end
cross member, then it is centred by a centring bolt
at (K).
1 - Front mechanical units removed
It is used for replacing the front end cross mem-
ber, with or without mechanical units.
NOTE : The operation for replacing the front end
cross member can be carried out without the re-
moval of the engine and transmission assembly,
but requires the removal of the radiator.
2 - Front mechanical units in place
The bracket helps with fault finding on the front
cross member.
III - REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont)
L - REAR END CROSS MEMBER (REAR END)
12667R1
The bracket helps with the fitting of the cross
member and rests vertically against the rear end
cross member, then centres itself in the mounting
hole of the absorber mounting.
It is used for replacing the whole rear end, with or
without mechanical units.
K - FRONT END CROSS MEMBER
40-34

LOWER STRUCTURE
Front side member, front section
41B
PRB4122
INTRODUCTION
The replacement of this part can be done in two
ways :
A Front side member, complete front section .
B Front side member, partial front section (cut
to be made in front of the front mounting of
the sub-frame), see the following diagram.
In the two cases these are complementary opera-
tions to the replacement of the front end lower
cross member and the headlight carrier panel. As
a result, the joints with these parts will not be
considered here, they will be dealt with in the res-
pective sections.
The repair bench must be used.
The replacement of this part also requires the re-
placement of the side member closure panel
which will have to be ordered separately.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
1 -Side member
Part assembled with:
- engine mounting height adjuster (only on the
right hand side),
- sub-frame front mounting.
2 - Front side member closure panel
Part on its own.
JOINTS WITH:
Side member closure panel
Front side member, rear section
Front wheel arch
Shock absorber cup height adjuster
Engine mounting *
PARTS CONCERNED (thickness in mm) :
1Front side member, front section 1.5
2Front side member, rear section 2.5
3Front wheel arch 0.8
4Shock absorber cup height adjuster 0.8
5Side member closure panel 1.2
6Engine mounting height adjuster* 1.8
7Engine mounting reinforcement * 1.5
* Only the right hand side.or
41-5

LOWER STRUCTURE
Front half unit
41D
PRB4124
INTRODUCTION
The operation for the replacement of this part is
complementary to :
- the front end lower cross member,
- the headlight panel
- the cowl side panel.
This operation requires the replacement of the
cowl side panel (pillar lining) and of the cowl side
panel upper reinforcements, which have to be or-
dered separately.
In the operation described below there are only
descriptions of the specific joints to the part
concerned, information concerning the parts to
be ordered separately is not considered here. This
will be dealt with in the respective sections.
The repair bench must be used.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with:
1 Front side member , rear section
- engine mounting height adjuster (right
hand side)
- engine mounting reinforcement (right
hand side),
- engine mounting plate (right hand side),
- sub-frame front mounting,
- front side member closure panel ,
- wheel arch,
- shock absorber cup,
- shock absorber cup height adjuster,
- ABS mounting (right hand side),
- injection unit mounting and impact sensor
(left hand side).
2 Cowl side panel (pillar lining)
3 Cowl side panel upper reinforcementJOINTS WITH:
Plenum chamber
Injection unit mounting and impact sensor (left
hand side)
Front side member, rear section
Shock absorber cup height adjuster
PARTS CONCERNED (thickness in mm) :
1Plenum chamber 1
2Injection unit mounting and impact
sensor (left hand side) 2
3Front side member, front section 1.5
4Front side member, rear section 1.8
5Shock absorber cup height adjuster 1
6Shock absorber cup 2
7Cowl side panel (pillar lining) 1.5or
41-13

LOWER STRUCTURE
Rear floor, rear section (part section)
41M
PRB4133
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of:
1 - For a side impact :
- the sill panel reinforcement ,
- the rear inner wheel arch,
- the rear wing panel lining.
Replace part section along cut A (see diagram
and method below).
2 - For a rear impact
- the rear end panel,
- the rear side member, part section or
complete.
Replace part section along cut B (see diagram
and method below).
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 sections.
The repair bench must be used.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with towing ring reinforcement.
JOINTS WITH:
Side floor
Upper shock absorber gusset
Sill panel closure panel
Rear axle assembly mounting unit
Shock absorber mounting upper reinforcement
Sill panel closure panel, rear section
Rear floor front cross member, front section
Rear side member
Wheel arch
Spring bumper mounting
Rear floor stiffener
Centre cross member
PARTS CONCERNED (thickness in mm):
1Rear floor, rear section 1
2Side floor 0.8
3Upper shock absorber gusset 1.5
4Sill panel closure panel 1.2
5Rear axle assembly mounting unit 1.2
6Shock absorber mounting
upper reinforcement 1.2
7Sill panel closure panel, rear section 1.5
8Rear floor front cross member 0.8
9Rear side member 1.5
10Wheel arch 1
11Spring bumper mounting 1.5
12Spring bumper mounting
reinforcement 1.5
13Rear floor stiffener 1
14Centre cross member 1.5
15Rear floor, front section 0.8
or
41-44

LOWER STRUCTURE
Rear end cross member
41P
PRB4136
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of the rear end pa-
nel for a rear impact.
The side member extensions must be replaced
(11) and (12) , and must be ordered 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 sections.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
10 - Part assembled with rear shock absorber
reinforcement
11 and 12 - Side member extension
JOINTS WITH:
Rear shock absorber reinforcement
Towing ring (left hand side)
Rear side member extension
Side panel rain channel
Side panel lining
Rear floor
Side member
PARTS CONCERNED (thickness in mm):
1Rear end cross member 1.2
2Rear shock absorber reinforcement 1
3Towing ring (left hand side) 1.5
4Rear side member extension 1.5
5Side panel rain channel 1.5
6Side panel lining 0.7
7Rear floor 0.8
8Side member 1.5
41-55