towing 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
Towing
40
FRONT OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
The towing points may only be used for towing the vehicle on the road. They should never be used for remo-
ving the vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either direct-
ly or indirectly.
REAR
13366S13189S
40-8

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
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

LOWER STRUCTURE
Rear shock absorber reinforcement
41Q
PRB4137
INTRODUCTION
For a rear impact, the replacement of this part is a
complementary operation to the replacement of
the rear end 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.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part only.
JOINTS WITH:
Rear shock absorber reinforcement
Rear end cross member
PARTS CONCERNED (thickness in mm):
1Rear shock absorber reinforcement 1
2Rear end cross member 1.2
3Towing ring (left hand side) 1.5
4Rear side member extension 1.5
41-58

LOWER STRUCTURE
Rear side member extension
41R
PRB4138
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of the rear end
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.
Use of the repair bench is advised, to ensure that
the rear cross member is correctly geometrically
positioned.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with towing ring (left hand side).
JOINTS WITH:
Rear side member
PARTS CONCERNED (thickness in mm):
1Rear side member extension 1.5
2Rear side member 1.5
3Towing ring (left hand side) 1.5
41-60

LOWER STRUCTURE
Rear side member, part section
41S
PRB4139
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of the rear end
cross member for a rear impact
This part may be replaced partially (see cut and
diagram 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 :
- side member rear reinforcement
- towing ring (left hand side),
- rear side member extension .
PARTS CONCERNED (thickness in mm):
1Rear side member 1.5
13221R3
or
CAS13033R1
A
1 1 or
41-62

LOWER STRUCTURE
Complete rear side member
41T
PRB4140
INTRODUCTION
The replacement of this part is a complementary
operation to the replacement of the side panel
with lining and the inner wheel arch for a rear
side impact.
It requires the partial replacement of the rear
floor, rear section and the front cross member of
the rear floor .
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:
- side member rear reinforcement,
- towing ring (left hand side),
- rear side member extension ,
- upper shock absorber gusset,
- rear axle assembly mounting unit,
- upper gusset of rear axle assembly mounting,
- side member reinforcement,
- sill panel closure panel, rear section.
JOINTS WITH:
Sill panel closure panel
Centre cross member
Rear floor stiffener
PARTS CONCERNED (thickness in mm):
1Rear side member 1.5
2Rear floor 1
3Centre cross member 1.5
4Sill panel closure panel 1.2
5Sill panel closure panel,
rear section 1.5
6Rear floor stiffener 1
7Rear shock absorber lower gusset 1.5
41-63