Renault Duster 2007 User 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
0General 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 suf-
fix 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, vehi-
cle 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 trim code

01C-2
VEHICLE BODYWORK SPECIFICATIONS
Vehicle panel gaps: Adjustment value 01C
WARNING
The clearance values are given for information pur-
poses.
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 compo-
nents 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 prod-
ucts 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

03B-1
COLLISION
Vehicle involved in an impact: Impact fault finding 03B
a
I - CHECKING THE SUBFRAME
Chronological order of checks
aFRONT impact
Compare the following distances between diagonal-
ly opposite points:
-1: B1 - G2 = B2 - G1
-2: G1 - C2 = G2 - C1
aREAR impact
Compare the following distances between diagonal-
ly opposite points
-1: G2 - B1 = G1 - B2
-2: B1 - J2 = B2 - J1
145391

03B-2
COLLISION
Vehicle involved in an impact: Impact fault finding 03B
II - DETAILED VIEW OF INSPECTION POINTS
Point B1 - B2
Point G1 - G2
Point C1 - C2
Point J1 - J2
a
145397
145393
145392
145395

04B-1
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
Consumables for mechanical repair:
DEFINITION PACKAGING PART NUMBER
MECHANICAL SEALANTS
SILICOR
sealing paste
85 g tube 77 11 236 470
MASTIXO
Joint face seal
100 g tube 77 11 236 172
BEARING SEALING KIT
For crankshaft bearing cap side
sealing
Kit 77 11 237 896
SILICONE ADHESIVE SEAL
Engine and gearbox sealing paste
100 g cartridge 77 11 227 484
TRANSPARENT SEALING MAS-
TIC 45 g tube 77 11 223 369
SILICOJOINT 90 g tube 77 11 236 469
LOCTITE ADHESIVE 597
Sealing paste for PXX gearboxes
Cartridge 77 11 219 705
RESIN ADHESIVE or SEALING
RESIN
Sealing resin for engine and gear-
box covers
25 ml tube 77 11 237 640
EXHAUST MASTIC
For exhaust pipe union seals
1.5 kg tin 77 01 421 161
LEAK DETECTOR 400 ml aerosol 77 11 236 176
ADHESIVES
FRENETANCHE
Sealing the threading at low and
medium pressure
50 ml bottle 77 11 236 471
HIGH-STRENGTH THREADLOCK
For locking bolts
50 ml bottle 77 11 230 112
SEALING RESIN
For locking the bearings
50 ml bottle 77 11 236 472
LUBRICANT CLEANERS
NÉTELEC
Avoid bad contacts in electrical cir-
cuits
150 ml aerosol 77 11 225 871

04B-2
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
INJECTOR CLEANER 355 ml container 77 11 224 188 or 77 11 225 539
CLOTH FOR INJECTION SYSTEM 77 11 211 707
SUPER RELEASING AGENT 500 ml aerosol 77 11 236 166
SUPER RELEASING AGENT 250 ml aerosol 77 11 420 439
SUPER CLEANER FOR JOINT
FACES
For cleaning joint faces
300 ml aerosol 77 11 238 181
SURFACE CLEANER 5 L container 77 01 404 178
SILICONE LUBRICANT 500 ml aerosol 77 11 236 168
SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 167
BRAKE CLEANER 600 ml aerosol 77 11 422 413
150 ml aerosol 77 11 422 414
BIO BRAKE CLEANER 750 ml spray bottle 77 11 427 217
AIR CONDITIONING CLEANER 250 ml aerosol 77 11 230 498
CARBURETTOR CLEANER Aerosol 77 11 236 177
IXTAR ENGINE CLEANER 400 ml can 77 11 229 365
GREASE
BR2+ GREASE
For:
- the lower arm bearings,
- the anti-roll bar grooves,
- the driveshaft splines.
1 kg pack 77 01 421 145
SILICONE GREASE
For:
- the tubular rear axle bushes,
- the anti-roll bar bushes.
100 g tube 77 11 419 216
COPPER ANTI-SEIZE GREASE
Grease for turbochargers (high
temperature)
85 g tube 77 11 236 173
COPPER-ALUMINIUM LUBRI-
CANT
Grease for turbochargers (high
temperature)
500 ml aerosol 77 11 236 169
GREASE
For driveshaft seals
180 g sachets 77 11 420 011

04B-3
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
WHITE GREASE
For wheel sensors
400 ml aerosol 77 11 236 174
MULTIPURPOSE GREASE 500 ml aerosol 77 11 236 170
250 ml aerosol 77 11 236 171
FLUORSTAR 2L
Silicone-free electric sealing grease
100 g tube 82 00 168 855
LACQUER
JELT ARGENT
Varnish for repairing heated rear
screens
5 g bottle 77 11 230 111
BRAKE
DOT 4, ISO CLASS 6, RENAULT
STANDARD:03-50-006,
For vehicles with and without elec-
tronic stability program (ESP)
0.5 L container 77 11 218 589
5 L container 77 11 238 318
25 L container 77 11 238 319
DOT 4, ISO CLASS 4, RENAULT
STANDARD:03-50-005
Authorised for vehicles without ESP
0.5 L container 77 11 172 381
5 L container 77 01 395 503
25 L container 77 11 171 926
DOT 4
Authorised for vehicles without
ESP, without clutch with hydraulic
tappet
0.5 L container 86 71 000 000
5 L container 86 71 014 277
25 L container 86 71 014 278
COOLING SYSTEM
ANTIFREEZE (TYPE D) 1 L container 77 11 170 548
COOLANT (TYPE D)
1 L container 77 11 171 589
2 L container 77 11 170 545
5 L container 77 11 170 546
OIL
ENGINE OIL (see Engine oil: Specifications) (Technical Note 6013A, 04A, Lubri-
cants)
GEARBOX OIL
(see Manual gearbox oil: Specifications) (Technical Note 6012A, 04A,
Lubricants)
(see Automatic gearbox oil: Specifications) (Technical Note 6012A,
04A, Lubricants)
(see Sequential gearbox oil: Specifications) (Technical Note 6012A,
04A, Lubricants)

04B-4
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
AXLE OIL (see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubri-
cants)
ELF RENAULT MATIC D2
Oil for power-assisted steering:
Pump connected, pump assembly
(except Laguna III)
2 L container 77 01 402 037
TOTAL POWER-ASSISTED
STEERING FLUID
Oil for power-assisted steering:
Pump assembly (Laguna III)
1 L container no part number
PLANETELF PAG 488
250 ml container
77 11 172 668
SANDEN SP 10
Oil for air conditioning compressor
77 01 419 313
UNIVIS J26
Oil for retractable roof hydraulic
system
250 ml container 77 11 172 160
TYRES
TYRE PASTE 1 kg pack 77 11 223 052
5 kg pack 77 11 223 053
TYRE REPAIR AGENT 400 ml tube 77 11 221 296
300 ml tube 77 11 222 802
BLANKING PLUG
Engine type Injection type Part no.
F5R 77 01 206 382
F8Q 77 01 206 340
F9Q 77 01 208 229
G9T AND G9U 77 01 208 229
K9K DELPHI 77 01 206 804
K9K SIEMENS 77 01 476 857
M9R 77 01 209 062
P9X 77 01 474 730
ZD3 77 01 208 229
MISCELLANEOUS
GREY ABRASIVE PAD 77 01 405 943

04B-5
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
Consumables for bodywork repair:
HOLLOW SECTION WAX
SPR CC 1 L container 77 11 172 672
SPR CC SPRAY 500 ml aerosol 77 11 211 654
STRUCTURAL ADHESIVE
STRUCTURAL ADHESIVE Kit =2 80 ml cartridges 77 11 219 885
HIGH PERFORMANCE STRUC-
TURAL ADHESIVE 1195 ml cartridge 77 11 419 113
GLAZING PRODUCTS AND ADHESIVES
MONOPAC EVOLUTION ADHE-
SIVE KIT 310 ml cartridge 77 11 421 430
MONOPAC EVOLUTION ADDI-
TIONAL CARTRIDGE + NOZZLE 310 ml cartridge 77 11 421 431
S-P KIT ADHESIVE KIT 310 ml cartridge 77 11 421 432
ADDITIONAL S-P KIT CAR-
TRIDGE + NOZZLE 310 ml cartridge 77 11 421 433
BIPAC EVOLUTION ADHESIVE
KIT 2225 ml cartridges 77 11 421 434
LINT-FREE CLOTH Box of 340 cloths 77 11 237 262
WINDOW SEALING MASTIC 310 ml cartridge 77 11 170 222
SPECIAL ADHESIVE FOR WIN-
DOWS 77 11 425 759
ADHESION PROMOTER
For bonding double-sided adhesive
tape
Cloth 77 11 423 222
MISCELLANEOUS
DOUBLE-SIDED ADHESIVE 18 mm wide 77 11 226 308
DOUBLE-SIDED ADHESIVE 8 mm wide 77 11 427 869
FRENETANCHE 50 ml bottle 77 11 236 471
ADHESIVE PATCH 82 00 043 181
ADHESIVE PAD 77 05 042 163
SEALS
BLACK MJ PRO (Electroweldable) 310 ml cartridge 77 11 172 676
WHITE MJ PRO II (Electroweld-
able) 310 ml cartridge 77 11 426 951

04B-6
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
PREFORMED SEALING MASTIC
BEAD 2.6 m roll 77 01 423 330
BRUSH MASTIC 1 kg pack 77 11 228 113
FILLER MASTIC 60 beads Ø 6 mm by 0.3 m 77 11 170 230
GREASE
WHITE GREASE 400 ml aerosol 77 11 236 174
OPENING ELEMENT MECHA-
NISM GREASE 20 g sachets 77 11 419 865
SILICONE LUBRICANT 500 ml aerosol 77 11 236 168
SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 167
SOUNDPROOFING
SPR GREY EVOLUTION 1 l cartridge 77 11 419 114
SPR GREY EVOLUTION SPRAY 400 ml aerosol 77 11 419 116
SPR BLACK EVOLUTION II 1 l cartridge 77 11 419 115
SOUNDPROOFING PAD (3.5 Kg/
m²)Pack of 10 77 01 423 546
SOUNDPROOFING PAD (6.5 Kg/
m²)Pack of 5 77 01 423 269
POLISHING
POLISHING LIQUID 1 L container 77 11 420 288
FINISHING LIQUID 1 L container 77 11 420 289
MASTIC
Universal mastic
GALAXI 2.5 kg pack 77 11 172 238
OPTIMAX 1.23 l cartridge 77 11 172 239
EXCELLENCE +
For finishing plastic repair
960 g cartridge 77 11 423 539
1 kg pack 77 11 423 540
Plugging mastic
XFIBRE FIBREGLASS MASTIC 975 kg pack 77 11 172 235
STANDARD BASIX POLYESTER
MASTIC 1.975 kg pack 77 11 172 234
ALUX ALUMINIUM MASTIC 975 kg pack 77 11 172 236
Sprayable mastic

04B-7
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
PIXTO SPRAYABLE POLYESTER
MASTIC 1.5 kg tin 77 11 172 237
Finishing mastic
IXTRA POLYESTER MASTIC 1.625 kg pack 77 11 172 233
Anti-grit mastic
MAG PRO 1 310 ml cartridge 77 11 172 679
MAG PRO 3(Dual component) 1.5 kg tin 77 11 218 364
SURFACE CLEANER
HEPTANE 500 ml container 77 11 170 064
SOLVENT SURFACE CLEANER 5 L container 77 01 404 178
WATER-BASED SURFACE
CLEANER 5 L container 77 11 421 337
ANTISTATIC THINNER (for plastic
materials) 400 ml aerosol 77 01 408 493
COMPOSITE MATERIAL REPAIR BY BONDING
PLASTIC REPAIR KIT 77 11 170 064
NOZZLE FOR PLASTIC REPAIR
KIT 77 11 423 523
PLASTIC REPAIR CLEANER 1 L container 77 11 423 517
PLASTIC REPAIR PRIMER 150 ml bottle 77 11 423 518
PLASTIC REPAIR ADHESIVE 2 x 25 ml bicomponent cartridge 77 11 423 519
PLASTIC REPAIR CLOTH 90 m roller 77 11 423 520
PLASTIC REPAIR NOZZLES 12 nozzles 77 11 423 522
COMPOSITE MATERIAL REPAIR BY WELDING
PLASTIC WELD REPAIR SET 77 11 425 742
PROTECTIVE STRIPS Bag of 10 protective strips 77 11 425 744
STAINLESS STEEL MESH Bag of 2 meshes 77 11 425 743
COOLER 400 ml aerosol 77 11 425 745
BRUSH Box of 10 brushes 77 11 237 793
WINDOW MASKING TAPE
10 MM WINDSCREEN TAPE 77 11 171 708
20 MM WINDSCREEN TAPE 77 11 171 709
PROTECTIVE WELDING

04B-8
CONSUMABLES - PRODUCTS
Vehicle: Parts and consumables for the repair 04B
ANTI-SPLASH SPRAY 400 ml aerosol 77 11 218 270
SPECIFIED UNDERCOAT
PRE-TREATMENT PRIMER WITH-
OUT ZINC CHROMATE (I-Alpha) +
THINNER 1 L container 77 11 420 027 (Primer)
77 11 420 028 (Thinner)
I-PREMIA REACTIVE PRIMER (do
not use on aluminium) 3.5 l container 77 11 239 243 (Primer)
77 11 228 654 (Thinner)
I-PREMIA REACTIVE PRIMER (do
not use on aluminium) 400 ml aerosol 77 11 419 416
ADHÉRA SPRAY (adhesion pro-
moter for thermoplastics) 400 ml aerosol 77 11 423 734
PRIMARA BLACK (adhesion pro-
moter/primer for thermoplastics) 1 L container 77 11 423 735
77 11 171 514 (Activator)
PRIMARA (adhesion promoter/
primer for thermoplastics) 1 L container 77 11 171 513
77 11 171 514 (Activator)
UNDERCOAT
LEVIA 3.5 l container 77 11 228 651
FORTIA 3.5 l container 77 11 228 650