DACIA SOLENZA 2004 Repair Manual

pict.3 fig.
4
one... two... and three!
40 - 17
A
B
C2D
A
B
C1
GENERAL
pict. 2
40Carriage body checking
To straighten the vehicle body, CELETTE bench is provided with a traction arm of 10
tons, Caiman type, 250-mm stroke of the hydraulic cylinder, with rapid anchorage on any side
of the mobile bench (pict. 2).
2. CROSS BARS MODULAR SET ( CAR 502)
CELETTE bench has in its composition, five modular cross bars (pict.3), as follows:
- two front cross bars A and B (T shaped) which are always in the same position
(towards front of bench) – fig 4 .
- two straight cross bars C1 and C2 and one D cross bar (U-shaped) which may be
placed in different positions subject to the vehicle type.
The m arked figures (14…36) are engraved on t he m obile bench, every mounting being
s upplied with a drawing i ndicating the e xact position of the m odular crossbars subject to the
vehicle type.
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GENERAL
40 - 18
L
pict. 5
pict. 6
3. TRACTION ACCESSORIES SET ( CAR 504)
CELETTE bench is equipped with a traction accessories set CAR 504, which allows the op-
erator to achieve different anchoring when a body strengthening is performed (pict. 5).
4. SET OF MZ TOWERS AND SPECIFIC SUPPORTS ( CAR 503 +CAR 507)
This kit represents a MZ system and consists of two elements: - kit of 22 MZ t owers, universal CAR 503 – (see pict. 6);
- kit of specific supports CAR 507. Each MZ tower has an arrow, which settles
its orientation on the cross bar and a MZ
reference (fig 7) Example – MZ 080, where:
MZ - measurement on OZ axle of the vehicle,
080 – MZ tower height (in mm).
In the same way as f o r COMPAC T
assembly , the arrow (1) marked on the specific
support must be oriented towards the bench
front part, as follows: -attachment on the right part of the
mobile bench; - attachment on the left part of
the mobile bench.
REMARK :
The MZ tow ers may be used also for the checking/ straightening of the carriage
bodies of other vehicles types, being then necessary the purchasing of the specific
supports for each type of vehicle.
Carriage body checking
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GENERAL
40 - 19
fig.7
pict.
8 pict.
9
Carriage body checking
Each specific support is identifi ed by a
number (2) marked at the lower part a nd has
one or two attachments holes ( 3) in the MZ
tower (in this case you should take into
consideration the specific diagram from the
assembly drawing supplied together with the
kit. Symbols:
1 – with or without dismounted mechanical
elements. 4 – with dismounted mechanical elements.
REMARK :
I dent i ficat ion and m ount ing of t he
towers on different modular cross bars
and of the specifi c supports in the MZ
towers (1…20), when repairing a carriage
body, is to be performed as per mounting
drawing (pict.8 and pict.9) which is
supplied together with this kit.
R EFERENCE POINTS ON VEHICLE
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GENERAL
40 - 20
21
65
43
pict. 10
pict. 11
pict. 12
Power train frame attachment on the lower cross member
The specifi c supports (1 ) and (2) are used in front straightening, front m echanic elements
being dismounted, enabling the positioning of
the lower cross member, consequently the front
attachment of the power train frame (pict. 10).
REMARK :
Thes e holes are destined as main
re ference for the vehicle front part.
Centering under front longitudinal girder
The specifi c supports (3) and (4) are used
for positionin g, centering, and alignment of the front longitudinal girders. They are to be used for
all reparation cases because they are a main reference of vehicle setting on the bench. (pict. 11).
Upper attachment on front shock ab-
sorber (shock absorber column)
S pecific supports (5) and (6) are used in
front strengthening, mechanical elements
dismounted, enabling the positioning of the
shock absorbers ends, consequently the front
linings positioning (pict. 12).
Their centering in the shock absorbers ends
is performed by means of the centering washers
(1)- (fig 13).
The center i ng washers are used when
str aightening a carriage body a nd also when
Carriage body checking
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GENERAL
40 - 21 fig.
13
( fig. 15)
78
910
pict 15
fig.
14
replacing the front wing lining.
Power train frame rear attachment on
front longitudinal girder.
The specific supports ( 7) and (8) are used
in the front straightening, enabling the position-
ing of the front longitudinal girder and conse-
quently the rear attachment of the power train frame.
In case of the rear straightening, these a re
enabling the front alignment of the vehicle on
the bench (fig 14).
Centering under the central floor
The specific supports ( 9) and (10) have
the purpose of positioning, centering and align-
ment of the front longitudinal girders. These
are to be used in all c ases, because they are a
setting reference of the vehicle on the bench. (pict. 15).
Carriage body checking
1
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GENERAL
40 - 22
( fig.
17)
( fig. 18 )
1314
1112
1516
1718
1920
pict. 17
pict. 18
pict.
16 pe banc în cazul unei restructurãri.
Acestea vor fi utilizate în toate cazurile fiind o referin
ã principalã de aºezare a vehiculului pe
banc ( fig. 16 ).
Centrare sub lonjeron spate
Capetele specifi ce ( 17) ºi (18) permit
pozi
ionarea, centrarea ºi alinierea lonjeroanelor spate ( fig. 17 ).
Rear axle arm attachment
Carriage body checking
The specific supports (11), (12 ), (13), ( 14),
(15 ) and ( 16) are enabling the positioning, cen-
tering and rear alignment of the vehicle on the
bench in case of a straightening. These are to be used i n all cases, be ing a
main reference for vehicle setting on the bench
(pict.16 ).

Centering under rear longitudinal girder
The specifi c supports (17) and (18) a r e
enabling the positioning, centering, and align-
ment of the rear longitudinal girders. (pict. 17)
Rear plate attachment
The specific supports (19) and ( 20) used
in the rear straightening, for rear plate positioning is used in the same time for the vehicle align-
ment in the front straightening. (pict. 18).
Upper structure composing elements
C arriage body removable elements
Openings clearance
Re pairing general conditions
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41 - 1
LOWER STRUCTURE
Front longitudinal girder
1
REPLAC EMEN T
This operation shall be performed only on
the checking/repair bench. For the specific sup-
ports mounting on the bench, please see the
40 sub-chapter.
DISMOUNTIN G
Dismount the damaged elements, which are
in contact with the front longitudinal girder.
Proceed t o a straightening on the body
checking/ stra ightening, until bringing it, as
closed as possible to the initial shape.
Fo r spot welding punching, a special steel
cutter with a diameter of 6 mm is to be used.
Detach the welding points of the front lon-
g itudinal girder ( 1) which are in connection with:
- front cross member in the area (2);
- front wing lining in the area (3);
- central floor in the are a ( 4) ;
- central cross member in the are a (5);
- upper longitudinal girder closing plate
in the are a ( 6).
Detach the welding points of the cross mem-
ber with the thre shold closing plate and the
central floor in the area ( 7);
Straigh ten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Position the new element on the reparation
bench. Perform an e lectric welding by spots and
under gas prot ection on t he a ssembling out -
lines (2), (3), (4), (5), (6) and (7). Grind the performed welding.
Protect the performed welding with an an-
ticorrosive product.
Protect the new e lement with a noi se a b-
s orbent product.
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41 - 2
LOWER STRUCTURE
Mount the connection elements by performing
the dismounting operatio ns in the reverse or der.
Front longitudinal girder
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41 - 3
LOWER STRUCTURE
DISMOUNTING
Dismount the elements in contact with the
front anti-shock cross member. Detach the welding point of the front anti-
s hock cross member (1) in contact with t he
front cross member in the area ( 2)- u pper bor-
der and area ( 3) – lower border.
Straighte n the areas resulted from dismount-
ing.
Grind the areas resulted after dismountin g.
REMOU NT I NG
Position and center the new element on the
front cross member. Check the correct positioning of the front
anti-shock cross member.
Perform a spot welding with SE Co
2 addition
(layers of 10 mm with 30 mm pitch) between the
front anti-sh ock cross member and the front cross
member on the outlines ( 2) a nd (3).
Grind the performed welding.
Protect the performed welding with an an-
ticorrosive product.
Paint the affected area and mount the con-
nection elements by perfor ming the dismount-
ing operations in the reverse order.
1
F ront anti-shock cross member
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41 - 4
LOWER STRUCTURE
1
Rear longitudinal girder
REPLAC EMEN T
This operation shall be performed only on the repair/checking bench.. For the specific sup-
ports mounting on the bench, please see the 40 chapter.
DISMOUNTIN G
Dismount the damaged elements, which are
in contact with the rear longitudinal girder. Proceed to a straightening on the body
checking/ straightening until bringing the ve-
hicle as closed as possible to the initial shape.
D etach the welding points of the rear
longitudinal girder (1), which are i n contact
with:
- central floor in the area ( 2);
- rear floor in the are a ( 3);
- rear extreme cross member in the area ( 4);
- tank front cross member in the area ( 5);
- tank rear cross member in the area ( 6);
- inner wheel passage in the area ( 7);
- rear towing hock in t he area ( 9).
Detach the welding points between the rear
s ide cross member, re ar floor a nd threshold
closing plate in the area ( 8).
Strai ghten the areas resulted after dismounting.
Grind the areas resulted after dismounting.

R EMOUNTIN G
Position and center the new element by
means of the repairing bench. Weld the rear longitudinal girder following
the assembling outlines 2,3,4,5,6,7, 8 and
9(spots and under gas protection welding) Grind the performed welding.
Protect the performed welding with an
anticorrosive product.
Protect the replaced element with a noise
absorbent product. Mount the co nn ect i on e l eme n ts b y
performing the dismounting operations in the
reverse order.
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