MR-326-KANGOO-GV-4

Sheet Metal Work

GENERAL INFORMATION

LOWER STRUCTURE

UPPER REAR STRUCTURE

TOP OF BODY

77 11 292 482

"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed."

JANUARY 2000

All copyrights reserved by Renault.

EDITION ANGLAISE

Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.

© RENAULT 2000

Sheet Metal Work

Contents

Page

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

GENERAL INFORMATION

Engine and equipment

BODY AND EXTENDED PASSENGER COMPARTMENT

Vehicle type

Engine

Clutch type

Gearbox type

manual and automatic

Type

Capacity

(cm

)

FC0HHF

E7J

1390

180 CP 3300

JB3

FC0EHF

F8Q

1870

200 COPV 3250

JB1

BODY

EXTENDED

PASSENGER

COMPARTMENT

Petrol

Diesel

Petrol

Diesel

Pay load (kg)

550

600

580

Weight (kg) when empty and ready for operation
(basic vehicle)

1175 1220 1195 1240

Weight (kg) when empty and ready for operation
on front

610 660 610 655

Weight (kg) when empty and ready for operation
on rear

565 560 585 585

Weight (kg) when empty and ready for operation
(all options)

1227 1270 1246 1291

40-2

GENERAL INFORMATION

Towing

40-3

Towing

OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.

NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.

SPECIAL FEATURES OF THE KANGOO GRAND VOLUME

This vehicle does not have a rear towing eye.

FRONT

The towing eye may only be used for towing on the
road.

REAR

Under no circumstances should the rear towing ring of
the basic body be used for towing.

GENERAL INFORMATION

Key to Symbols

Chiselling

Crimping of exterior door panels.

Grind back beads or spot welds.
Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm.

Safety symbol.
This means that the welding operation in
question concerns one or more of the
vehicle's vital safety components.

Grind back spot welds.
Straight grinding wheel 20 000 rpm fitted
with a spherical burr Ø 10 or 16 mm.

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.

Drill spot welds.
Hardened steel bit.
Speed of rotation 800 to 1 000 rpm.

Unpicking

Application of weldable mastic.
This mastic is a conductor, interposed
between two spot welding sheets, it
ensures the seal between the sheets and
avoids corrosion of the spot weld

Cleaning surfaces to be welded.
Fibre disc Ø 100 mm

Cutting with a saw.
Pneumatic power hacksaw.

Application of aluminium paint.
This is to be applied to the joint faces of
each of the parts to be plug welded. This
paint is conductive and can withstand high
temperatures; it gives anti-corrosion
protection around welds

– Cut out part by grinding off flange or

grinding back remaining traces of spot
weld.

– Finish surface after welding.
– Angle grinder fitted with a rubber pad

and a 120 to 180 mm diameter fibre disc
grain size P36.

Unsoldering.

Apply a fillet of extruded mastic

●

from a manual or pneumatic spray gun

●

one or two pot mastic for crimped and
butt joints.

MAG stitch weld
Note: to obtain a good quality weld we
recommend the use of a gas consisting of
argon + 15% CO2 which is considered an
active gas (MAG)

Apply mastic by spraying

●

spray gun.

●

anti-chipping and anti-corrosion in two
parts

Apply a bead of extruded adhesive mastic

●

from a manual or pneumatic spray gun

●

adhesive mastic in one or two parts

Resistance spot welding

Plug welding.
Under MAG gas protection.

Thermal cleaning of extruded or spray
mastic

40-4

GENERAL INFORMATION

Fitting extension elements

40-5

Roof

Rear ring

Side panel

Wing panel

Basic body

GENERAL INFORMATION

Description of parts

UPPER STRUCTURE

Roof added

Roof rear cross member

Rear wing panel (panel and glazed version)

Side panel rain channel support

Side panel added (panel and glazed version)

Side panel extender

Side inner panel extender

Upper rear corner stiffener

Roof inner panel extender

PRF4011

40-6

GENERAL INFORMATION

Sub-frame dimensions

DESCRIPTION

DIAMETER

SLOPE %

Rear end cross member (end panel)

3 446

- 497.5

151

40-8

GENERAL INFORMATION

Repair Bench

SPECIAL TOOLING PART NUMBER

BLACKHAWK

Special heads for MS System

Order at:

BLACKHAWK S.A.
Centre Eurofret
Rue de Rheinfeld
67100 STRASBOURG

Supplier’s part number: REN 88222

CELETTE

Specific plates for MZ System

Order at:

CELETTE S.A.
B.P. 9
38026 VIENNA

Supplier’s part number: 760 308

40-11

GENERAL INFORMATION

Tools and specific products

40-12

Tools and specific products

FITTING ADDED ELEMENTS

PRODUCTS

It is VITAL to fit the elements added to the KANGOO
Grand Volume with:
– the glue cartridge

part number 56 89 330 053 used by RENAULT
Industrial Vehicles,

– its grip primer part number 56 89 330 052,
– the vents with blades (sold singly)

part number 77 11 172 866,

– degreaser, heptane

part number 77 11 170 064,

SPECIAL NOTES

In the areas where the original paintwork has been
altered (to the sheet), it will be necessary to apply
anticorrosion impression type "ALPHA"
(part number 77 01 423 933).

The grip primer (part number 56 89 330 052) is applied
on the cataphoresis after sanding with a grey buffer on
the areas treated for "ALPHA" impression without
sanding after drying.

NOTE: for all additional instructions, refer to the
technical sheets for each product.

MATERIAL

PHOTO 14342 (SHOWN IN REPAIR MANUAL 338 SECTION 5)

LOWER STRUCTURE

Semi-rear end cross member

141

LOWER 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

3 Side cross member stiffener

4 Extreme rear cross member

1.2

5 Side cross member

6 Side panel extender

7 Rear floor extender

0.8

8 Lower central extender

9 Basic body rearend panel

Cut 1

order a right or left demi-cross member,

Cut 2

order 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

LOWER STRUCTURE

Rear 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

3 Extreme rear cross member

1.2

4 Lights support lower bracket

5 Lights mounting side panel rain channel

1.5

6 Side inner panel extender

0.8

7 Central lower extender

8 Side cross member

9 Seal contour

41-8

UPPER REAR STRUCTURE

Basic body rear wing panel

144

UPPER REAR STRUCTURE

Basic body rear wing panel

INTRODUCTION

The basic body sheet wing panel of the Kangoo Grand
Volume may be replaced partially by following the
method given below.

COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT

PARTS CONCERNED (thickness in mm):

1 Basic body wing panel

0.8

44-1

UPPER REAR STRUCTURE

Rear 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

UPPER REAR STRUCTURE

Rear wing panel fitted

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

6 Upper rear corner stiffener

16619S

16619-1S

UPPER REAR STRUCTURE

Rear wing panel fitted

44-8

REFITTING

We recommend that you follow the order given below:
– position the panel on the body,
– bond the panel,
– fit and adjust it,
– strap the part (refer to section 44Bb),
– solder.

NOTE: the panel should be stuck and fitted to the body
as quickly as possible.
The adhesive moulding diameters change depending
on the glue course (see below).

16619-1R1

16584-1R1

Adhesive moulding ∅ 5 mm
between sheets (1) and (2)

16586-1R1

Adhesive moulding ∅ 5 mm
between sheets (1) and (6)

UPPER REAR STRUCTURE

Rear wing panel fitted

44-9

16595R1

A adhesive moulding ∅ 7 mm
between sheets (1) and (3)
B adhesive moulding ∅ 5 mm
between sheets (1) and (3)

16589R1

Adhesive moulding ∅ 7 mm
between sheets (1) and (3)

16596R1

Adhesive moulding ∅ 7 mm
between sheets (1) and (3)

UPPER REAR STRUCTURE

Rear wing panel fitted

44-10

SPECIAL FEATURE

Wide masking tape should be applied to the basic
body wing panel at the adhesive moulding position
(section 6), which will prevent the mounting body wing
panel being damaged when the part is removed once
more.

Masking tape width 5 cm

Adhesive moulding ∅ 7 mm

16691R

Between sheets (1) and (A)

16593R1

Adhesive moulding ∅ 5 mm
between sheets (1) and (3)

16592R1

Adhesive moulding ∅ 7 mm
between sheets (1) and (3)

UPPER REAR STRUCTURE

Basic body side panel

INTRODUCTION

The basic body side panel of the Kangoo Grand
Volume may be partially replaced by following the
method given below.

This is made possible by masking the connection
when the Grand Volume added panel is in place.

IMPORTANT: this method cannot be used on a series
Kangoo.

COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT

Part assembled with sliding door rail units and striker
plate mounting.

PARTS CONCERNED (thickness in mm):

1 Basic body side panel

0.8

44-12

UPPER REAR STRUCTURE

Basic body side panel

44-13

SPECIAL FEATURE

Only operations related to the partial cut are dealt with
in this method. Other operations are described in
Repair Manual 326.

764B1-16606

CAA11536-2R7

CAS13033R7

UPPER REAR STRUCTURE

Added 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

UPPER REAR STRUCTURE

Added side panel

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

6 Upper rear corner stiffener

UPPER REAR STRUCTURE

Added side panel

44-19

REFITTING

We recommend that you follow the order given below:
– bond the panel,
– adjust and strap the part (refer to section 44Bb),
– solder.

ATTENTION: The adhesive moulding diameters
change depending on the glue course (see below).

16620-1R

16584-1R3

Adhesive moulding ∅ 5 mm
between sheets (1) and (2)

Adhesive moulding ∅ 5 mm
between sheets (1) and (3)

Adhesive moulding ∅ 7 mm
between sheets (1) and (3)

Adhesive moulding ∅ 5 mm
between sheets (1) and (6)

UPPER REAR STRUCTURE

Added side panel

44-20

SPECIAL FEATURE

Wide masking tape should be applied to the basic
body wing panel at the adhesive moulding position
(section 6), which will prevent the mounting body side
panel being damaged when the part is removed once
more.

Masking tape width 5 cm

Adhesive moulding ∅ 7 mm

16595R3

Adhesive moulding ∅ 5 mm
between sheets (1) and (3)

Adhesive moulding ∅ 7 mm
between sheets (1) and (3)

16691R

Between sheets (1) and (A)

UPPER REAR STRUCTURE

Added side panel

44-22

Example of plating for the stuck parts

Fit the weather-strip for the front door in the
opposite direction on the door. Close the door,
then position the straps (see below).

ATTENTION: protect the seals from glue spillages
using masking tape.

16588R3

16587R3

16631S

UPPER REAR STRUCTURE

Side panel extender

INTRODUCTION

This part may be replaced in two ways:
1

total replacement complementary to the side panel,

partial 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):

Side panel extender

Side cross member

Lower lights bracket

Extreme rear cross member

1,2

Basic body side panel extender

44-24

UPPER REAR STRUCTURE

Side 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

PRF4413

16629R

CAS13033R7

44-28

UPPER REAR STRUCTURE

Upper 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

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

UPPER REAR STRUCTURE

Lights 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

TOP OF BODY

Grand volume added roof

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

6 Upper rear corner stiffener

45-1

TOP OF BODY

Grand volume added roof

45-2

REMOVAL - REFITTING

Moulding ∅ 5 mm

765A2-16625

16584R

Between sheets (1)
and (2)

16582R

Between sheets (1)
and (3)

TOP OF BODY

Grand volume added roof

45-3

Moulding ∅ 5 mm

765A1-16626

16586R

Between sheets (1)
and (2)

Between the sheet
(1) and the part (5)

16583R

Between sheets (1)
and (4)

TOP OF BODY

Grand volume added roof

45-4

Apply a coating of glue to the spacer extractor on (1),
tighten it manually until the two sheets are plated, then
finish by tightening with a key - tightening torque
2.37 da N.m.

Apply a coating of glue on (2) before refitting the
added roof.

Example of plating method for refitting the added roof.

16829R

16633S

TOP OF BODY

Roof 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

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 lining

0.7

REMOVAL

F = bolt of Ø 8 mm

765E1-16643

CAA11538R8

45-5

Document Outline