wheel 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
Key to Symbols
40
- Cutting out part by grinding off flange
or grinding back remaining traces of
spot weld.
- Finish surface after welding.
- Angle grinder equipped with a rubber
pad and a 120 to 180 mm diameter
fibre disc grain size P36. Chiselling
Grind back beads or spot welds.
Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm.
Grind back spot welds.
20 000 rpm straight grinder with 10 or 16
mm diameter spherical burr.
Drill spot welds.
Hardened steel bit. Speed of rotation 800
to 1 000 rpm.
Unpicking
Cleaning surfaces to be welded.
100 mm diameter fibre disc.
Cutting with a saw.
Pneumatic power hacksaw.
Unsoldering.
Plug welding.
Under MAG gas protection.
Crimping of exterior door panels.
Safety symbol.
This means that the welding operation
in question concerns one or more of the
vehicle’s vital safety components.
Body solder - lead fill.
Hot air torch.
Nozzle output temperature 600° min.
Slipper+ 33 % tin solder + tallow.
Note : to a large extent, body solder
filling compensates for the heat
distortion caused by welding.
Application of weldable mastic.
This mastic conducts electricity, applied
between two panels to be spot welded,
it ensures the seal between the panels
and avoids corrosion of the spot welds.
Application of aluminium paint.
This is to be applied to the joint faces of
each of the parts to be plug welded.
The paint conducts electricity and is is
resistant to high temperatures. It
provides anti-corrosion protection
around the plug welds.
Apply a fillet of extruded mastic
• from a manual or pneumatic spray
gun.
• one or two pot mastic for crimped
and butt joints.
Spray on sealer
• spray gun.
• two pot anti-gravel and anti-
corrosion mastic.
MAG stitch weld
Note : to obtain a good quality weld we
recommend the use of a gas consisting
of argon + 15 % CO2. This is
considered to be an active gas (MAG).
Spot weld
40-11

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
Repair Bench
40
12841S
The bracket rests under the shock absorber cup
and is centred in the shock absorber mounting
hole.
It is used when replacing :
- wheel arches,
- a front half unit.
It is also used when straightening. E -
REAR SHOCK ABSORBER UPPER MOUNTINGIII - REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont)
12665R
The bracket is fitted at the shock absorber clevis
location and positions this mounting for repla-
cing :
- a rear side member,
- the rear floor unit.
It is also used when straightening.F -
FRONT SHOCK ABSORBER UPPER
MOUNTING
40-32

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 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 side member closure panel
41C
PRB4123
INTRODUCTION
The replacement of this part may be done in two
ways :
A Complete front side member closure panel.
B Partial front side member closure panel (see
diagram below).
This operation is carried out by straightening or
replacing the front side member. It is complemen-
tary to the front end lower cross member and to
the wheel arch.
As a result, joints with these parts will not be
considered here, they will be dealt with in the res-
pective section.
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part on its own.
JOINTS WITH:
Front side member, front section
Front sub-frame front mounting
PARTS CONCERNED (thickness in mm) :
1Front side member, front section 1.5
2Front sub-frame front mounting 1.2
3Side member closure panel 1.2
4Front sub-frame front mounting 1
reinforcement
41-10

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
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
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