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

Sheet Metal Work
Contents
Page
40
41
44
45
GENERAL INFORMATION
Dimensions 40-1
Engine and equipment 40-2
Towing 40-3
Key to symbols 40-4
Fitting the extension elements 40-5
Description of parts 40-6
Sub-frame dimensions 40-8
Repair bench 40-9
Tools and specific products 40-12
LOWER STRUCTURE
Semi-extreme rear cross member 41-1
Rear floor extender 41-8
UPPER REAR STRUCTURE
Basic body rear wing panel 44-1
Added rear wing panel 44-3
Basic body side panel 44-12
Added side panel 44-14
Side panel extender 44-24
Side inner panel extender 44-28
Upper rear corner stiffener 44-30
Lights mounting side panel rain channel 44-33
TOP OF BODY
Grand volume added roof 45-1
Roof inner panel extender 45-5 P
X
A
Aa
B
Bb
G
I
J
K
Aa
E

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
44
44-4
ORIGINAL MOUNTING
MOUNTING FOR REPAIR
Moulding ∅ 7 mm
Moulding ∅ 5 mm
PARTS CONCERNED (thickness in mm):
1 Added rear wing panel 0.8
2 Basic body roof 0.8
3 Basic body rear wing panel 0.8
4 Lights mounting side panel rain channel 1.5
5 Side panel extender 1
6 Upper rear corner stiffener 1
16619S
16619-1S
Aa

UPPER REAR STRUCTURE
Added side panel
44
44-15
ORIGINAL MOUNTING
MOUNTING FOR REPAIR
Moulding ∅ 7 mm
Moulding ∅ 5 mm PARTS CONCERNED (thickness in mm):
1 Added side panel 0.8
2 Basic body roof 0.8
3 Basic body side panel 0.8
4 Lights mounting side panel rain channel 1,5
5 Side panel extender 1
6 Upper rear corner stiffener 1
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

UPPER REAR STRUCTURE
Lights mounting side panel rain channel
44
44-34
REMOVAL - REFITTING
1Remove the two bolts
2Bore the rivet
16627R
CAS13033R5
K