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

GENERAL
Using symbols
40
11644R1
The above diagram shows parts on the vehicle for
which a section of the panel butt welding joint is
shown by the diagrams which follow.
This dashed line shows the centre line
of the sections
The point shows the exact position of
the weld join
This letter designates the drawing
corresponding to the section (It is gi-
ven in one of the upper corners of
each drawing )
F - G -
H - I - J
CAA11538R8
G
1
e = 1+1 7The following indications are found in the section
diagrams :
The part in black is the one which will
be removed in the operation
are the part numbers corresponding to
the list on the introduction page 1
and 7
e = 1 + 1are the thicknesses (in mm) of the
panels for electrical spot welding
This arrow on the diagram designates
the access point for the unpicking of
spot welds (see specific cases)
It also indicates the logical sequence of operations
in the symbols which follow each diagram.
place of operation and logical sequence
spot welding
weldable mastic
unpicking with grinder
Example :
40-9

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
Front side cross member
41E
PRB4125
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of a front pillar or a
sill panel with a lining for a 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 sections.
The repair bench must be used.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with jack support.
JOINTS WITH:
Bulkhead
Floor
Windscreen wiper motor mounting
Rear side member, front section
Rear side member, rear section
Sill panel closure panel
Sill panel reinforcement
Sill panel
Front sub-frame rear mounting
PARTS CONCERNED (thickness in mm) :
1Front side cross member 1
2Bulkhead 1
3Floor 1
4Windscreen wiper motor mounting 1.5
5Front side member, rear section 1.8
6Front side member
reinforcement, rear section 2.5
7Sill panel closure panel 1.2
8Sill panel reinforcement 0.7
9Sill panel 1
10Front sub-frame rear mounting 2.5
41-17

LOWER STRUCTURE
Front side member, rear section
41F
PRB4126
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of the front half
unit.
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 :
- sub-frame front mounting,
- front side cross member,
- side member reinforcement.
JOINTS WITH:
Bulkhead
Floor
Sill panel closure panel
PARTS CONCERNED (thickness in mm):
1Bulkhead 1
2Floor 1
3Front side member, rear section 1.8
4Sill panel closure panel 1.2
5Sill panel reinforcement 0.7
6Sill panel 1
7Side member closure panel
reinforcement 2.5
8Front side cross member 1
41-21

LOWER STRUCTURE
Front mounting of sub-frame
41G
PRB4127
INTRODUCTION
The replacement of this part is a basic operation
for a sub-frame 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 sections.
The repair bench must be used.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with sub-frame front mounting
reinforcement.
JOINTS WITH:
Front side member, front section
Front side member closure panel
Bonnet hinge mounting
PARTS CONCERNED (thickness in mm):
1Front side member, front section 1.5
2Front mounting of front sub-frame 1.2
3Side member closure panel 1.2
4Front mounting reinforcement of
front sub-frame 1
5Bonnet hinge mounting 1.5
41-26

LOWER STRUCTURE
Sill panel closure panel
41H
PRB4128
INTRODUCTION
The replacement of this part is an operation for a
side impact and is complementary to:
1 - For a frontal side impact :
the front pillar
Replace part section along cut A (see follo-
wing diagram)
2 - For a rear side impact :
the side panel lining
the centre pillar reinforcement
the sill panel
Replace part section along cut A (see follo-
wing diagram)
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 sill panel reinforcement must be ordered as
an extra .
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
1 - Sill panel closure panel
2 - Sill panel reinforcement
JOINTS WITH:
Front pillar lining
Side floor
Seat cross member
Rear side member
Rear floor, rear section
PARTS CONCERNED (thickness in mm):
1Sill panel closure panel 1.2
2Cowl side panel pillar lining 1
3Side floor 0.8
4Front seat cross member 1
5Sill panel closure panel , rear section 1.5
6Front side cross member 1
7Sill panel 0.8
or
41-29

LOWER STRUCTURE
Cross member under front seat
41I
PRB4129
INTRODUCTION
The replacement of this part is an operation follo-
wing a side impact, complementary to the repla-
cement of the sill panel closure panel .
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 front seat spacer.
JOINTS WITH:
Side floor
Front side member, rear section
Sill panel closure panel
PARTS CONCERNED (thickness in mm):
1Cross member under front seat 1
2Floor 1
3Front side member, rear section 1.8
4Sill panel closure panel 1.2
5Tunnel 1.2
41-33

LOWER STRUCTURE
Side floor
41J
PRB4130
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of:
1 - For a frontal impact :
- the front side member, rear section ,
- the bulkhead
2 - For a side impact :
- the front pillar with lining
- the sill panel closure panel
In the operation below, there are only descrip-
tions 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 :
- side member closure panel reinforcement,
- cross member under front seat.
JOINTS WITH:
Tunnel
Rear floor
PARTS CONCERNED (thickness in mm):
1Tunnel 1.2
2Side floor 0.8
3Rear floor 1
41-36

LOWER STRUCTURE
Tunnel
41K
PRB4131
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of :
1 - For a frontal impact :
- the bulkhead
2 - For a side impact :
- the side floor
3 - For a rear impact :
- the rear floor unit
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:
- impact sensor unit mounting,
- front reinforcement of tunnel,
- seat anchoring reinforcement ,
- cable sleeve stop mounting,
- centre reinforcement of tunnel.
JOINTS WITH:
Rear floor
Side floor
Bulkhead
PARTS CONCERNED (thickness in mm):
1Rear floor 1
2Side floor 0.8
3Tunnel 1.2
4Bulkhead 0.7
41-39

LOWER STRUCTURE
Rear floor, front section
41L
PRB4132
INTRODUCTION
For a side impact, the replacement of this part is a
complementary operation to the replacement of :
- the sill panel closure panel,
- the rear floor unit,
- the rear floor front cross member.
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 :
- floor reinforcement,
- nuts .
JOINTS WITH:
Rear floor, rear section
Tunnel
Side floor
Sill panel closure panel
PARTS CONCERNED (thickness in mm):
1Rear floor, front section 0.8
2Rear floor, rear section 1
3Tunnel 1.2
4Side floor 0.8
5Sill panel closure panel 1.2
6Sill panel closure panel extension,
rear section 1.5
41-41