DACIA SOLENZA 2004 Repair Manual

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GENERAL
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Openin gs clearance
2523
2422
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GENERAL
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26
32
36
31
35
26a
33
Op enings clearanc e
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GENERAL
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Repairing general conditions
The replacement (reparation) operations of the weldable elements described in this chapter
are specified subject to: cutting out of the parts to be replaced, access to the welded elements,
tools and checking devices accessibility , etc.
In case the vehicle body has suffered important deformations it is recommended the straight-
ening of the damaged body elements, by means of some hydraulic presses.
For this range of vehicles, the elements resistance structure which are affecting the vehicle
s ecurity, are not to be partially replaced (not to be cut), but entirely.
After welding detaching, the body elements must remain straight, without breakage or cracks,
the possible holes being covered out with filling material or by tinning. The body elements sur-
faces are to be pickled ( to eliminate possible oxidation marks), dried and initially applied a paint
layer. The electric welding detaching of the body elements, may be performed as follows:
- with a well sharpen c hisel, t his method may lead t o parts de formation or e ven pa rts
breaking. - by using some extractors equipped with steel cutter type Brendeo or Pickvant (max. 6
mm) having the cutting head shaped as shown in pict.1.
1. Centering point
2. Sharpen slope
3. Drill acting edges
4. Gap for catching the welding material
P = aprox. 0.4 mm
Whatever m ethod is used, the remaining element must be in good order and to a llow per-
forming of a good quality welding point.
The plates cutting it is recommended to be performed (subject of importance and thickness)
using manual scissors or pneumatic portable tools for plates cutting. During cutting or welding of the body elements it is necessary to protect the electric wiring
from the interior of the body structure. The cutting, welding, or strengthening operation done on body welded elements, are to be
performed on body checking/ straightening benches recommended by the producer.
IMP ORTANT !
When removing or straightening the body resistance elements, it i s forbidden the
total or partial heating, in order to avoid the mechanical resistance and metal elastic-
ity de creasing.
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Plate thickness( mm) Welding current(KA) Welding time(per) Tightening force(daNm)
0,5 6,55130
0,8 8,08200
1,0 9,510 250
1,25 10,510295
1,5 10,0 14310
2,0 12,0 16350
Plate thickness (mm) 0,6 1,0 1,5 2,0
Electrode di ameter (mm) 0,6 0,8 0,8 1,0 0,8 1,0 0,8 1,0
We l d ing wire speed (m/min) 2,5 1,9 3,2 2,4 4,4 3,8 5,7 4,4
Welding wire speed (A) 35 35 55 80 80 120 100 130
We l d ing speed (m/min) 0,25 0,25 0,35 0,33 0,33 0,50 0,45 0,45
We l d ing voltage (V) 17 17 18 18 19 19 20 20
Protection gas flow (1/min) 12 - 17
Elec trode free length (mm) 6 - 12
joint plates
welding butt welding fillet
welding
0- 1, 5m m 0- 1, 5m m
We
ldin g types and parameters
At the reparation of the welded body elements, three welding categories may be used: protection
gas welding (CO2), electric spot-welding and filling materials (built-up) welding (oxyacetylene).
At the built-u p welding, it is recommended that flame must be slightly inclined so that arch can be seen
and the flame extremity to be maintained at aprox. 5 mm from the part to be welded.
1. Spot welding resistive parameters for steel plates with carbon content C < 0,15 %.
R EMARK :
1 peri od = 1/50 part of a second.
2. We lding parame ters for the welding in protection gas for carbon steel plates or low-allo ye d steel.
Horizontal welding position (pict.1)
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Plate thickness 0,612 2,0
Electrode diameter (mm) 0,6 0,8 0,8 1,0 0,8 1,0
Welding wire speed (m/min) 2,5 1,9 3,3 3,2 5,7 4,4
W elding current (A) 35 35 70 100 100 130
We l ding speed (m/min) 0,25 0,25 0,38 0,48 0,50 0,50
W elding voltage (V) 17 17 18 18 20 20
Protection gas flow (1/min) 12 - 17
Electrode free length (mm) 6 - 12
REMARK :
In case of using the Ar + CO2 mixture, the welding voltage will decrease with 2
V.
Vertical welding position (obligatory from top to bottom)- pict. 2
We ldin g types and parameters
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GENERAL
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Collision diagnosis
During the vehicle exploitation, the carriage body may suffer different distortions, that lead
many times to the wheels setting angles modification, body elements breakage, vibrations or even
mechanical parts wear.
In these conditions, before performing the vehicle body reparation, some checking is necessary:
Visual checking - consisting in the examinatio n of the mechanical elements attachments and
of the distortions occurring in the vehicle damaged areas.
Checking with the bar (control gauge) – consisting in comparing the measurements done
in symmet ric points.
The geometry checking of the rolling transmissions – this checking is the only one enabling to
find out if the body damage was not affecting the vehicle road behavior.
IMPORTANT :
This checking must be not ignored, except some border-line cases, the checking of
the rolling transmissions leading t o the identification of t he distortions occurred further
to an accident.
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Collision diagnosis
CENTRAL PART CHECKING
The central part checking is performed in the purpose to establish if one of the distortions is
not affecting this part of the floor, from where the checking starts.
Compare the followings lengths : EI = FJ ; EJ = FI .
FRONT LONGITUDINAL GIRDERS CHECKING Compare the followings lengths: CG = DH; CH = DG .
If the l engths ( CH - DG) and the diagonals ( CG – DH) are not identical, c heck a gain the
point (3). If points ( 1) and (2) are good, the front axle a ngles may be checked.
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Collision diagnosis
REAR LONGITUDINAL GIRDERS CHECKING
Compare the following lengths: EK = FL ; EL = FK .
REAR ARM CHECKING
Compare the following lengths: FM = EN.
If a differe nce i s noticed when measuring the lengths ( FM – EN), the re ar arms a re to be
replaced.
The checking operation of the rear arms is followed by a checking performed with the gauge
fixed on the arm and on the central longitudinal girder.
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GENERAL
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Collision diagnosis
POWER-TRAIN SUPPORT ASSEMBLY CHECKING
FLOOR FRAME CHECKING
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fig.1
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40Carriage body checking GENE
RAL
The checking / straightening bench type CELETTE (service code CAR 500) is composed of
: - CAR 501 (1 m obile bench with four wheels, four parts for ve hicle a nchoring, one
traction arm of 10 t, t ype CAIMAN). - CAR 502 – set modular cross bars;
- CAR 503 – set of 22 towers MZ;
- CAR 504 - set accessories for t raction ;
- CAR 505 - set of specific supports for DACIA Berline, Bre ak.
- CAR 506 - set of specifi c supports for DACIA 1304, 1307
- CAR 507 - set of specifi c supports for DACIA Nova/SupeRNova /SOLENZA.
1. CAR 501
The mobile bench (1) is provided with four anchoring parts (2) - (fig 1 ), which can be used when
a carriage body straightening operation is performed.
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