light 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
Engine and equipment
40
SPECIFIC BODYWORK FEATURES
Driver’s airbag
Passenger’s and driver’s airbag
Height adjustable front head restraint
Height adjustable and tiltable front head restraint
Rear parcel shelf
Luggage compartment net
Electric one touch windows
Heated electric rear view mirrors
Heated screen + timed windscreen wiper
Heated front seats
Front seat driver emergency exit
Rear bench seat 1/1
Rear bench seat 1/3 - 2/3
Cabin rack without stop
Headlining
Boot carpet
Parcel shelf luggage cover
Two front fog lights in bumper
(excluding F8 AC PAS)Pay load 600 kg
Pay load 625 to 710 kg depending on
engine/equipment
Pay load 800 kg
Glazed, sliding side door and rear opening doors
or glazed tailgate
Sliding side door (reflective glass)
Sliding side door (panel)
Rear door, panel
Rear door, glazed
Opening doors, panels
Opening doors, glazed
Tailgate
Opaque roof flap (excluding tailgate)
Glazed roof flap (excluding tailgate)
Fixed side window (meaning glazed side door)
Sliding side window
Fixed rear quarter panel (meaning the glazed
sliding side door )
Heat insulating windscreen (with air conditioning)
2 point rear centre seat belt
3 point rear centre seat belt
40-3

GENERAL
Description of parts (exploded view)
40
PRB4003
UPPER STRUCTURE
25 Body side, rear section, panel
26 Body side , rear section, glazed
27 Rear wing panel lining
28 Roof
29 Roof front cross member
30 Roof centre cross member
31 Roof rear cross member (with roof flap)
32 Roof rear cross member (without roof flap)
33 Roof flap mounting reinforcement
34 Roof stretcher lining (with roof flap)
35 Roof stretcher lining (without roof flap)
36 Side panel lining
37 Side panel rain channel (lights mounting)
38 Rear wing panel extension
39 Rear wing panel stiffener
40 Stiffener spacer on rear wing panel
41 Rear inner wheel arch
42 Side panel, panel43 Side panel, glazed
44 Left hand side sill panel
45 Sill panel reinforcement
46 Centre pillar/door pillar reinforcement
47 Windscreen pillar lining
48 Front pillar
49 Cowl side panel reinforcement, rear section
50 Upper reinforcement of cowl side panel
51 Cowl side panel (pillar lining)
52 Headlight carrier panel
53 Wheel arch, front section
54 Wheel arch, complete
55 Plenum chamber
56 Bulkhead
57 Windscreen aperture lower cross member
58 Steering column mounting
59 Centre pillar / right hand side sill panel
60 Rear wing panel ( glazed )
40-13

GENERAL
Collision fault finding
40
12664-1R
Before carrying out repairs to the bodywork of a car, even if the damage seems slight, it is necessary to carry
out a series of tests :
•
VISUAL INSPECTION
This inspection involves the examination of the sub-frame of the vehicle where mechanical components
are mounted and in the crumple zones or vulnerable areas in order to detect folds where materials have
been deformed.
•
INSPECTION USING TRAMMEL GAUGE
The visual inspection may be completed using a trammel gauge which will allow measurement of certain
deformations by symmetrical comparisons (for more detail on each point to check, refer to the repair
bench paragraph below).
•
INSPECTION OF AXLE ASSEMBLY GEOMETRY
It is the only check which determines whether the impact suffered by the vehicle has or has not affected
its road holding.
Important : In borderline cases, it is essential not to neglect checking the axle assembly components which
may also have been subject to deformation.
On principle, no welded component in the body shell may be replaced without ensuring that the sub-
frame was not affected by the impact.
40-22

GENERAL
Repair Bench
40
12843R1
2 - Front mechanical units in place
The bracket covers the sub-frame mounting bolt
and washer.
It is used:
- following a frontal collision for a slight im-
pact,
- for fault finding for the gauge inspection of
the front section .
C - FRONT SUB-FRAME FRONT MOUNTINGIII - REFERENCE POINTS FOR POSITIONING REPLACED PARTS
12668R
1 - Front mechanical units removed
The bracket rests under the sub-frame front
mounting and is centred in the hole with the
mounting bolt.
It is used when replacing :
- a front end cross member,
- a side member, part section,
- a half unit.
40-31

GENERAL
Repair Bench
40
12667R
The bracket touches below the side member and
is centred in the pilot hole (slot).
It may be used for a slight rear impact without re-
moving the rear axle, but requires the removal of
the exhaust mounting.
P - FRONT AND REAR ENGINE MOUNTINGIII - REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont)
12841S
The bracket is positioned from above the engine
mounting, and is centred in the mounting holes of
the engine mounting.
It is used with the mechanical units removed for
replacing a front half unit.
J - REAR SIDE MEMBER REAR END
40-33

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

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
Headlight carrier panel
42B
13002R
CAC11541-1R6
A
1 4
CAG11548R6
B
1 4 5
CAA11538-1R2
C
1 5
42-3