DACIA SOLENZA 2004 Repair Manual

42
42 - 1
FRONT U PPER STRUCTURE
DISMOUNTING
Dismount the two attachment screws of the bonnet lower half-hinge on the front pillar lining.
Dismount partially the front bumper.
Dismount the attachment screws (1) of the wheel passage fairing.
Dismount the side-signaling lamp from the front wing.
Dismount the attachment screws (2), (3), (4) and (5) of the wing on the front wing lining, front
pillar lining, front bumper attachment side support, front pillars support and side frame lining
(front lower area). Dismount the front wing.
REMOU NT I NG
Perform the dismounting operations in the reverse order, ensuring the sealing by applying a
sealant material layer in the connection area of the wing with the front wing lining, front pillar and
side frame lining.
F ront wing
vnx.su

42
42 - 2
FRONT U PPER STRUCTURE
Front wing lining
2
45
6 7 8
3
RE PLAC EMEN T
This operation shall be performed only on the c hecking/repair bench. For the specific sup-
ports mounting on the bench, please see the 40 sub-chapter.
DISMOUNTING
Dismount t he damaged elements, which are
in contact with the front wing lining. Detach the welding points of the front wing
lining (1), which are in contact with :
- upper longitudinal girder in (2) area;
- front cross member in the area ( 3);
- headlamp support in the area ( 4);
- closing plate in the area ( 5) ;
- front floor in the area (6);
- cowl panel in the area ( 7);
- climate control box in the area ( 8)
Str aig h ten the area resulted from
dismounting. Grind the area resulted from dismounting.
REMOU NT I NG
Position and center the new element by
means of the repairing bench. Weld the front wing lining (1) following the
assembling outlines 2, 3, 4, 5, 6, 7 and 8.
Pr otect th e perfo rmed welding with a
corrosion-preventing product.
Protect the front wing lining with a noise
absorbent product and paint the a ffected area
in the carriage body color. Mount the connection elements by pe rform-
ing the dismounting operations in the reverse
order.
1
vnx.su

42
42 - 3
FRONT U PPER STRUCTURE
Radiator upper cross member
2
1
3
54
DISMOUNTIN
G
Dismount the elements, which are in c on-
tact with the radiator upper cross member. Detach the welding poi nts of t he ra diator
upper cross member ( 1), wh i ch a re in
connection with:
- front wing lining in the area ( 3);
- headlamp support in the a rea (4);
- side wall in the a rea ( 5);
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the radia-
tor upper cross member. Weld t he radiator upper cross member (1)
following the welding outlines (3), (4) and (5).
Pro t ect the welds with a corrosion-
preventing product.
Mount the elements, which are in connection
w ith the radiator upper cross member, by
performing the dismounting operations in the
reverse order.
vnx.su

42
42 - 4
FRONT U PPER STRUCTURE
Headlamp support
7
86DISMOUNTIN G
Dismount the elements, which are in contact
with the headlamp support. Detach the welding points of the headlamp
support (2), which are in connection with : -front wing lining in the area ( 6)
- radiator upper cross member in the area (7);
- front cross member in the area ( 8).
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the headlamp support.
W eld the headlamp support (2) following the welding outlines (6), (7) and (8).
Protect the welding with a corrosion-preventing product.
Mount the elements, which are in connection with the headlamp support, by performing the
dismounting o perations in the reverse order.
vnx.su

42
42 - 5
FRONT U PPER STRUCTURE
Windscreen lower cross member
DISMOUNTIN G
Dismount the elements, which are in con-
tact with the windscreen lower cross member
(front bonnet, windscreen, dashboard, driving
post cross member).
Detach the welding points of the windscreen
lower cross member (1), which are in contact
with :
-windscreen frame in the area (2 );
- side frame lining (left/ right) in the area (3);
- climate c ontrol box in the area (4);
D etach the welding poi nts between the
column support a ssembly and t he c limate
control box in the area (5).
Restore and straighten the outlines resulted
from dismounting. Grin d the outlines resulted from dismounting.
REMOU NT I NG
Position and attach the new element.
Pe rform a spot welding and under
protection gas (SE CO
2), in the connection
areas of the windscreen lower cross member
with : -windscreen frame in the area (2 );
- right/left side frame lining in the area (3);
- climate control box in the area (4).
W eld the column support assembly on the
climate control box in the area (5).
Check and straighten the windscreen frame.
Grind the performed welding.
A ppl y a seal ant materi al laye r in t he
connection area of the windscreen lower cross
member with the right/left side frame lining and
the climate control box.
Mo u n t the connection elements by
performing the dismounting operations in the
reverse order.
1
vnx.su

42
42 - 6
FRONT U PPER STRUCTURE
Driving post cross member
DISMOUNTIN G
The dismounting operatio n of the driving post
cross member is usually an additional operation
in case of replacin g such carriage body elements
as:
-windscreen lower cross member;
- cow panel;
- climate control box.
This operation is requiring the previous
dismounting of the dashboard.
Dismount the 8 Embase attachment screws
(2) M8 –20 of the driving post c ross member
(1) on the carriage body.
Dismount the driving post cross member.
REMOU NT I NG
Mount by perfor ming the dism ounting
operations in the reverse order.
2
vnx.su

43 - 01
43Front pillar
SI DE UPPER STRUCTURE
DISMOUNTIN G
Dismount the elements that are in contact
w ith the front pillar (front door, front bonnet,
front wing). Detach the welding points of the front pillar
(1), which are in connection with :
-side frame lining in the area (3) ;
- windscreen frame in the area (3)
- front pillar lining in the area ( 4).
Straighten the areas resulted by dismount-
ing. Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element on the
side frame lining. Clench in 2-3 points by m eans of sliding
tongs. Joint the front pillar border with side bor-
der of the windscreen frame. Wel d t he fro nt pi l l a r, fo l l owi ng t he
assembling outlines ( 2), (3) and (4) .
Pe rform an additional welding SE CO
2, in
the front pillar connection area with:
- side frame lining (6 weld x 15 mm);
- windscreen frame (4 weld x 15 mm);
- front pillar lining (6 weld x 15 mm).
Mount temporarily the front door, observin g
the openings clearance.
Weld the hinges on the front pillar (continuos
weld on all hinges sides).
Grind the performed welds.
Pr o t ect the perf ormed weld with a
corrosion-preventing product.
Mount the connection elements by
performing the dismounting operations in the
reverse order.
2 3
4
vnx.su

SIDE UPPER STRUCTURE
43
43 - 02
Middle pillar
DISMOUNTIN G
Dismount the elements, which are in contact
with the middle pillar.
Detach the welding points of the middle pillar
(1) which are in connection with :
- side frame lining in the areas (3) and (4);
- middle pillar reinforcement in the area (4);
-r oof belt in the a rea (2);
- threshold closing plate in the area (5).
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Fit temporary the middle pillar (1) on the side
frame lining and clench it in 203 points. Check the correct pillar positioning using the
door as geometric gauge.
Weld the middle pillar following the welding
outlines (2), (3) (4) and (5).
Pe rform a ha rdening gas prot ection welding
(SE CO
2) in t he are as (2) and (3) (2 + 2 weld
x 10 mm ).
Attach the rear door observing the openings
clearance.
We ld the door hinges on the middle pillar
(e l ectri c we ld unde r prot e c tion ga s, wit h
continuos weld on all hinges sides).
Grind the performed welding.
Protect the performed welding with a corro-
sion-protection product. Paint the a ffected are a in the carriage body
color.
Mount the connection elements by performing
the dismounting operatio ns in the reverse order.
vnx.su

44
REAR UPPER STRUCTURE
44 - 1
Rear lower panel
DISMOUNTING
Dismount the elements that are in contact
with the rear lower panel.
Detach the welding points of the rear lower
panel (1) which are in connection with :
- lamp support (left/rig ht) in the area (2);
- side panel (left/right) in the area (3);
-r ear extreme cross m ember and rear
lamp support in the area (4).
Straigh ten the areas resulted from
dismounting
Grind the areas resulted from dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the rear
lower panel. Perform a spot weld with a dditional SE
CO
2 (weld of 10 mm with 30 mm pitch)
between the rear lower panel and : -left/right rear lamp support in the area (2);
- left/ right rear lower panel in the area (3);
-r ear extreme cross m ember and rear
lamp support in the area (4 ).
Grind the performed welding.
Pr otect the welding with a corrosion
preventive product. Apply a sealant material l ayer on the
joining area between the rear lower panel and
the rear extreme c ross member. Paint the affected area.
Moun t t he c onne c t i on e l eme nt s by
performing the dismounting operations in the
reverse order.
1
3
vnx.su

REAR UPPER STRUCTURE
44
44 - 2
Rear lamp support
DISMOUNTING
Dismount the elements in connection with the
rear lamp support (re ar bum per, rear lamp,
equipping elements). Detach from welding points of the rear lamp
support in connection with:
-s ide panel in the area (2);
-r ear lower panel in the area (3 );
-r ear lower panel and rear extreme cross
member in the area (4).
Straig hten the areas resulted from dismounting
Grind the areas resulted from dismountin g.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the rear lamp
support. We ld the re ar l amp support fol lowing the
welding outlines (2 ), (3) and (4).
Grind the performed welding.
Prot ect t he perform ed weldi ng with an
anticorrosive product. Apply a sealant material l ayer in the joining
area of the rear lamp support with the rear lower
panel and the rear extreme cross member. Paint the affected a rea i n the carriage body
color. Mount the connection elements by performing
the dismounting operations in the reverse order.
vnx.su