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

Contents
NON-SIDE OPENING ELEMENTS48
TOP OF BODY
SIDE OPENING ELEMENTS45
47
45-1
45-7
45-8
45-9 ARoof
BRoof front cross member
CRoof centre cross member
DRoof rear cross member
47-1
47-2
47-6
47-8
47-11
47-14
48-1
48-2
48-3
48-4
48-5 ABonnet
BBonnet hinge
CRear opening doors
D Tailgate
ERoof flap AFront door
BFront door panel
CFront door stiffener
DSide door
ESide door panel
FSide door stiffener

GENERAL
Description of parts (exploded view)
40
PRB4004
61 Hinged roof flap
62 Tailgate
63 Rear opening door, right hand side
64 Rear opening door, left hand side
65 Front door panel
66 Front door
67 Front wing
68 Bonnet
69 Side door
70 Side door panel
REMOVABLE COMPONENTS
40-14

LOWER STRUCTURE
Front end lower cross member
41A
PRB4121
INTRODUCTION
The replacement of this part is a basic operation
for a frontal impact .
The repair bench does not have to be used, on
condition that the side members have not been
affected by the impact.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with :
- closure panel,
- towing ring,
- reinforcement on the front end lower cross
member (left hand side).
JOINTS WITH:
Cowl side panel
Front right wheel arch
Side member
Side member closure panel
PARTS CONCERNED (thickness in mm) :
1Front end lower cross member 1.5
2Bonnet hinge mounting 1.5
3Cross member partition reinforcement 1.5
4Cowl side panel 1
5Front right wheel arch 0.8
6Front side member, front section 1.5
7Side member closure panel 1.2
8Towing ring 2.5
41-1

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

UPPER FRONT STRUCTURE
Headlight carrier panel
42B
PRB4209
INTRODUCTION
The replacement of this part is a basic operation
for a frontal impact.
The fitting jig should be used.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with bonnet hinge mounting.
JOINTS WITH:
Front side member, front section
Front sub-frame mounting
Cowl side panel (pillar lining)
Cowl side panel upper reinforcement
PARTS CONCERNED (thickness in mm):
1Headlight carrier panel 1
2Front side member, front section 1.5
3Front sub-frame mounting 1.5
4Cowl side panel (pillar lining) 1
5Cowl side panel upper reinforcement 1
6Front end lower cross member 1.5
7Bonnet hinge mounting 1.5
42-2

UPPER FRONT STRUCTURE
Cowl side panel (pillar lining), part section
42C
PRB4210
INTRODUCTION
The replacement of this part is a complementary
operation for a frontal impact to a headlight car-
rier panel.
It will be partially replaced according to the cut on
the diagram and the method below.
The replacement of this part also requires the re-
placement of the cowl side panel upper reinforce-
ments.
In the operation described below there are only
descriptions of joints specific to the part concer-
ned.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
1 - Cowl side panel , part assembled with :
- front wing mounting,
- impact retainer reinforcement (bonnet),
- dashboard mounting support,
- shock absorber cup height adjuster reinforce-
ment .
2 - Cowl side panel upper reinforcement, front
section.
3 - Cowl side panel upper reinforcement, rear
section.
JOINTS WITH :
Engine support plate
Shock absorber cup
Plenum chamber
PARTS CONCERNED (thickness in mm):
1Cowl side panel (pillar lining) 1.5
2Engine support plate 2
3Shock absorber cup 2
4Plenum chamber 1
5 Shock absorber cup height adjuster 1or
42-5

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

NON-SIDE OPENING ELEMENTS
Bonnet
REFITTING
Refit in the opposite way to removal and refer to
section 40 (opening clearances) to correctly make
adjustments.
ADJUSTMENT
The height adjustment is carried out using strut
mounting bolts (B) on the headlight carrier panel.
The front and rear adjustments are carried out
using mounting nuts (A) on the bonnet .
REMOVAL
48A
PRB4808
13238R
Remove the bonnet nuts (A) (operation must be
carried out by two people).
48-1

NON-SIDE OPENING ELEMENTS
Bonnet hinges
48B
PRB4809
REFITTING
Refer to the preceding section, to make adjus-
tments to the bonnet.
REMOVAL
13238R
Remove:
- the bonnet nuts at (A) (operation must be car-
ried out by two people),
- the bonnet,
- the strut mounting bolts (B) on the headlight
carrier panel.
48-2