2010 Renault Duster Service and Repair Manual

© Renault s.a.s 2007 "The repair procedures given by the manufacturer in this document are based on the technical specifications current when it was prepared. The procedures may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are constructed". All rights reserved by Renault. 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. NOVEMBER 2009 EDITION ANGLAISE X79 0 General vehicle information 01A VEHICLE MECHANICAL SPECIFICATIONS 01C VEHICLE BODYWORK SPECIFICATIONS 02A LIFTING EQUIPMENT 03B COLLISION 04B CONSUMABLES - PRODUCTS

DUSTER - Chapitre 0 Contents Pages DUSTER - Chapitre 0ContentsPages 01A VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 01A-1 01C VEHICLE BODYWORK SPECIFICATIONS Vehicle: Identification 01C-1 Vehicle panel gaps: Adjustment value 01C-2 02A LIFTING EQUIPMENT Vehicle: Towing and lifting 02A-1 03B COLLISION Vehicle involved in an impact: Impact fault finding 03B-1 04B CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair 04B-1

01A- 1 VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 01A Dimensions in metres: 144900 4X2 TRANSMISSION (A) 0.822 (B) 2.673 (C) 0.820 (D) 4.315 (E) 1.560 (F) (unladen) 1.690 (G) 1.567 (H) 1.822

01A- 2 VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 01A Dimensions in metres: 4X4 TRANSMISSION (A) 0.822 (B) 2.671 (C) 0.822 (D) 4.315 (E) 1.560 (F) (unladen) 1.682 (G) 1.570 (H) 1.822 Engine Gearbox Emissions standard Engine type Engine suffix Cubic capac- ity(cc) Gearbox type Gearbox suffix Transmission type K4M 606 1598 TL8 002 4x4 EURO 4 EURO 5 690 JR5 187 4x2 EURO 4 K9K 796 1461 JR5 189 4x2 EURO 4 884 TL8 000 4x4 EURO 1 EURO 3 EURO 4 898 EURO 5

01C-1 VEHICLE BODYWORK SPECIFICATIONS Vehicle: Identification 01C I - LOCATION OF VEHICLE IDENTIFICATION PLATE (A) II - LOCATION OF THE VEHICLE IDENTIFICATION NUMBER (B) III - DETAILED VIEW OF THE VEHICLE IDENTIFICATION PLATE Plate (A) 145261 145260 Note: If the complete body is being replaced, it must be marked in compliance with the current regulations. 19031 (1) Vehicle type and type number; this information also appears on marking (B) (2) MGVW (Maximum Gross Vehi- cle Weight) (3) GTW (Gross train weight, vehicle under load with trailer) (4) Maximum permissible front axle load (5) Maximum permissible rear axle load (6) Vehicle technical specifications (7) Paintwork reference number (8) Equipment level (9) Vehicle type (10) Upholstery code (11) Additional equipment details (12) Production number (13) Interior tr im code

01C-2 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value 01C WARNING The clearance values are given for information purposes. When adjusting clearances, certain rules have to be followed: - maintain symmetry with respect to the opposite side, - ensure the flush fitting is correct, - check correct operation of the opening, and water/ air-tightness. 145389 No. Location Clearances (mm) (1) bonnet / headlight 5 ± 2 (2) bonnet / front wing 4 ± 1.5 (3) headlight / front wing 2 ± 1.5 (4) front bumper / front wing 0.5 (5) front side door / front wing 4.5 ± 1 (6) front side door / windscreen pillar 18 ± 1

01C-3 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value 01C (7) windscreen / roof 4.5 ± 1 (8) side doors / roof 18 ± 1 (9) front side door / rear side door 4.5 ± 1 (10) rear side door / rear wing panel 4.5 ± 1 (11) side doors / sill panel 6 ± 2 145390 No. Location Clearances (mm) No. Location Clearances (mm) (12) rear wing panel / fuel filler flap cover 3 ± 1.5 (13) rear wing panel / rear bumper 0.5 (14) roof / tailgate 5 ± 1 (15) tailgate rear screen / rear wing panel 4.5 ± 2 (16) tailgate / rear wing panel 4.5 ± 1.5 (17) tailgate / rear bumper 7 ± 2 (18) rear quarter panel window / rear wing panel 3 ± 1

02A- 1 LIFTING EQUIPMENT Vehicle: Towing and lifting 02A I - TOWING 1 - Position of front attachment point 2 - Position of rear attachment point II - LIFTING BY TROLLEY JACK Equipment required safety strap(s) WARNING See the current towing regulations in each country. Never use the driveshafts, axle assembly components or suspension components as attachment points. Tighten and lock the towing ring before use. Always pull in the direction of the rod's length in order to avoid breaking it. Vehicles fitted with automatic transmission: - It is preferable to transport the vehicle on a flatbed or to tow it by lifting the front wheels; as an excep- tion, the vehicle can be towed with the wheels on the ground, but at a speed of less than 12 mph (20 km/h) over a maximum distance of 18 miles (30 km) (with the gear lever in neutral). 145262 145263 IMPORTANT Appropriate axle stands must be used if a trolley jack is used. WARNING The subframe of this vehicle is protected by products providing a 6-year anti-corrosion warranty. Never use equipment not fitted with rubber pads, to avoid direct metal to metal contact which could damage the original protection. The vehicle must not be raised by support points under the front suspension arms or under the rear axle.

02A- 2 LIFTING EQUIPMENT Vehicle: Towing and lifting 02A To raise a front or rear wheel, use (1) as the support point. To mount the vehicle on axle stands, the entire vehicle must be lifted on one side and axle stands must be placed under the jacking points for the tool kit jack (1) . III - LIFTING ON A LIFT 1 - Safety advice reminder If it is necessary to remove heavy components from the vehicle, it is preferable to use a four-post lift. After removing certain components (e.g. engine and transmission assembly, rear axle, fuel tank, etc.), there is a danger that the vehicle will tip on a two post lift. When the vehicle is raised on an underbody two post lift, fit safety strap(s), part no. 77 11 172 554 available from the Parts Department. 108416 108418 14894

02A- 3 LIFTING EQUIPMENT Vehicle: Towing and lifting 02A 2 - Fitting the straps For safety purposes, the straps must always be in per- fect condition; replace them if they are damaged. When fitting the straps, check that the seats and fragile parts of the vehicle are correctly protected. a - Tilting towards the front Pass the strap under the rear right-hand arm of the lift. Pass the strap through the inside of the vehicle. Pass the strap under the rear left-hand arm of the lift. Pass the belt through the inside of the vehicle again. Tighten the strap. b - Tilting towards the rear Pass the strap under the front right-hand arm of the lift. Pass the strap through the inside of the vehicle. Pass the strap under the front left-hand arm of the lift. Pass the belt through the inside of the vehicle again. Tighten the strap. 3 - Permitted jacking points To raise the vehicle, position the pads of the lift arms as indicated below taking care not to damage the end of the front wing or the underside of the sill panel. At the front Position the lift arms under the end of the sill panel body flanges. At the rear Position the lift arms under the end of the sill panel body flanges. 108420 IMPORTANT Only the jacking points described in this section allow the vehicle to be raised in complete safety. Do not raise the vehicle using points other than those described in this section. 108419 108417

2010 Renault Duster Service and Repair Manual

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