roof 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

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
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
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

UPPER SIDE STRUCTURE
Windscreen aperture pillar
43B
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of the front pillar
for a front side 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.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with aerial cable guide.
PRB4312
JOINTS WITH:
Roof front cross member
Roof
Body side
Roof stretcher
PARTS CONCERNED (thickness in mm) :
1Windscreen pillar lining 1
2Roof front cross member 0.8
3Roof 0.7
4Body side 1
5Roof stretcher 0.7
6Centre pillar upper reinforcement 1.2
7Body side lining 0.7
43-6

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
Rear wing panel
44A
INTRODUCTION
Below there are special details for vehicles fitted
with a roof flap.
VERSION WITH
ROOF FLAP
13475R
CAC11541-1R6
A
1 13
CAC11541-1R6
B
1 5
44-8

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
44B
VERSION WITH
ROOF FLAP
INTRODUCTION
Below are special details for vehicles fitted with a
roof flap.
13475R
CAC11541-1R6
A
1 2
CAC11541-1R6
B
1 5
44-16