ESP RENAULT KANGOO 2000 KC / 1.G Sheet Metal Work Workshop Manual

LOWER STRUCTURE
Semi-rear end cross member
41
141LOWER STRUCTURE
Semi-rear end cross member
INTRODUCTION
This part is changed in addition to changing the rear
end panel. It may be performed in two ways:
The separation operation should be carried out last,
when all the other links have been unhooked.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Connections associated with the additional parts are
not taken into consideration. These connections will be
dealt with in their respective section (refer to contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with:
– extreme rear cross member.
– lower central extender,
– striker support absorber,
– lower side extender,
– side cross member,
– side cross member stiffener,
– counter blade absorber.PARTS CONCERNED (thickness in mm):
1 Side panel rain channel light support 1.5
2 Lights lower bracket 1
3 Side cross member stiffener 1
4 Extreme rear cross member 1.2
5 Side cross member 1
6 Side panel extender 1
7 Rear floor extender 0.8
8 Lower central extender 1
9 Basic body rearend panel 1 Cut 1order a right or left demi-cross member,
Cut 2order the two demi-cross members
then fit them in (A) or (B). For this
operation, the use of the body jig bench
is vital.
41-1
P

LOWER STRUCTURE
Rear floor extender
41Rear floor extender
INTRODUCTION
For a rear impact, replacing this part is an additional
operation to replacing:
–the rearend panel,
–the demi-extreme rear cross member.
IMPORTANT: the separation operation should be
carried out last, when all the other links of the part
have been released, in order to move the part to
separate it.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Connections associated with the additional parts are
not taken into consideration. These connections will be
dealt with in their respective sections (refer to
contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with:
–seal contour,
–striker stiffener,
–towing ring plate.PARTS CONCERNED (thickness in mm):
1 Rear floor extender 0.8
2 Rear section rear floor 1
3 Extreme rear cross member 1.2
4 Lights support lower bracket 1
5 Lights mounting side panel rain channel 1.5
6 Side inner panel extender 0.8
7 Central lower extender 1
8 Side cross member 1
9 Seal contour 1
41-8
X

UPPER REAR STRUCTURE
Rear wing panel fitted
44Rear wing panel fitted
INTRODUCTION
The replacement of this part is a basic operation for a
rear side impact.
It also requires the replacement of the Grand Volume
added roof, which is fitted on top at their common
contact (refer to section 45Aa).
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on additional parts will be dealt with in their
respective sections (refer to the contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part 1.
IMPORTANT: in order to aid refitting, the panel
mounting on the body during repair is different from the
original mounting (refer to the method described
below).
PRF4417
44-3
Aa

UPPER REAR STRUCTURE
Added side panel
44Added side panel
INTRODUCTION
The replacement of this part is a basic operation for a
rear side impact.
It also requires the replacement of the Grand Volume
added roof, which is fitted on top at their point of
contact (refer to section 45AA).
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts will be dealt with in their
respective sections (refer to contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
IMPORTANT: in order to aid refitting, the panel
mounting on the body during repair is different from the
original mounting (refer to the method described
below).
44-14
Bb

UPPER REAR STRUCTURE
Side panel extender
44Side panel extender
INTRODUCTION
This part may be replaced in two ways:
1total replacement complementary to the side panel,
2partial changing complementary to the skirt and
lights mounting side panel rain channel.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts to which this is additional, will be
dealt with in their respective sections (refer to
contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part on its own.PARTS CONCERNED (thickness in mm):
1 Side panel extender 1
2 Side cross member 1
3 Lower lights bracket 1
4 Extreme rear cross member 1,2
5 Basic body side panel extender 1
44-24
G

UPPER REAR STRUCTURE
Side inner panel extender
44Side inner panel extender
INTRODUCTION
Replacing this part is an additional operation to the
rain channel lights support after a rear impact.
This operation may be carried out partially.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts will be dealt with in their
respective sections (refer to contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Assembled part with hinge stiffener.
PARTS CONCERNED (thickness in mm):
1 Side inner panel extender 0.8
2 Lights support side panel rain channel 1.5
3 Rear floor extender 0.8
4 Basic body side panel lining 0.7 or
PRF4413
16629R
CAS13033R7
44-28
I

UPPER REAR STRUCTURE
Upper rear corner stiffener
44Upper rear corner stiffener
INTRODUCTION
This part is changed in addition to changing roof with
cross member and inner panel.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts will be dealt with in their
respective sections (refer to contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part on its own.
PARTS CONCERNED (thickness in mm):
1 Upper rear corner stiffener 1
2 Side inner panel extender 0.8
3 Roof rear cross member 0.8
4 Lights support side panel rain channel 1.5
5 Roof inner panel extender 0.8
6 Basic body roof rear cross member 0.8
7 Basic body roof 0.8
8 Inner panel stiffener 0.8
764J1-16628
CAA11536-2R4
44-30
J

UPPER REAR STRUCTURE
Lights mounting side panel rain channel
44Lights mounting side panel rain channel
INTRODUCTION
This part is changed in addition to changing the
rearend panel. It is carried out partially.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts to which this is additional, will be
dealt with in their respective sections (refer to
contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part assembled with:
–side panel extension,
–lights mounting with studs and welded nuts,
–bumper counter blade,
–tailgate counter balance reinforcement,
–welded nuts,
–upper hinge reinforcement.
IMPORTANT: the Parts Department part should be cut
out before fitting at the level of the assembled side
panel extender (refer to diagram below). PARTS CONCERNED (thickness in mm):
1 Lights support side panel rain channel 1.5
2 Bolt diameter 8 mm key of 13
3 Steel rivet
16715S
44-33
K

TOP OF BODY
Grand volume added roof
45
145 TOP OF BODY
Grand volume added roof
INTRODUCTION
The replacement of this part is a basic operation for a
side impact.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on additional parts will be dealt with in their
respective sections (refer to the contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part provided with luggage grid spacer extractors and
blanking covers.
PARTS CONCERNED (thickness in mm):
1 Added roof 0.7
2 Added side panel 0.8
3 Basic body roof 0.8
4 Roof rear cross member 0.8
5 Luggage grid spacer extractor 15
6 Upper rear corner stiffener 1
45-1
Aa

TOP OF BODY
Roof inner panel extender
45Roof inner panel extender
INTRODUCTION
This part is changed in addition to changing roof with
cross member.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts to which this is additional, will be
dealt with in their respective sections (refer to
contents).
COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
Part on its own.
PARTS CONCERNED (thickness in mm):
1 Roof inner panel extender 1
2 Roof rear cross member 0.8
3 Lights support side panel rain channel 1.5
4 Side inner panel extender 0.8
5 Side panel lining0.7 REMOVAL
F = bolt of Ø 8 mm
765E1-16643
CAA11538R8
45-5
E