DACIA SOLENZA 2004 Repair Manual

44
REAR UPPER STRUCTURE
44 - 3
1
6
Inner whe el passage
DISMOUNTING
Dismount the elements, which are in c on-
tact with the inner wheel passage ( 1).
Detach the SE CO
2 welding points between
the rear wheel passage and : -backrest lock support in the area (2);
- connection bracket knee in the area (3);
Detach the welding points of the inner wheel
passage in contact with :
-si de frame l i ning, si de panel and
threshold obturator in the area (4 ) ;
-r ear floor in the area (5 );
-r ear longitudinal girder in the area (6).
Straigh ten 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 inner
wheel passage.
Weld the inner wheel passage (1) following
the assembling outlines 4, 5 and 6.
Perform SE CO
2 weld between inner wheel
passage and : -backrest lock support i n the are a (2)
(2 weld x 10 mm); -connection bracket knee in the area (3)
(2 weld x 10 mm).
Protect t he welding with a corr osion-
preventing product.
Apply a layer of sealant material, in the
contact area (5) of the inner wheel passage with
the rear floor.
Paint the affected area.
Mounting the conn ection elements by
performing the dismounting operations in the
reverse order.
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REAR UPPER STRUCTURE
44
44 - 4
Side panel
DISMOUNTING
Dismount the elements, which are in c on-
tact with the side panel ( 1).
Detach the welding points of the side panel,
which are in connection with : -side frame lining in the area (2);
-r oof in the area ( 3);
-r ear lower panel in the area ( 4)
- rear extreme cross member in the area (5).
Straigh ten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Apply a layer of 5322 size material on the
joint areas of the side panel with the side frame
lining and the rear lower panel.
Position and center the new element.
Check the correct positioning of the side panel.
W eld the side panel (1) following the welding
outlines 2, 3 , 4, and 5.
Retouch possible deformations.
Grind the performed welding.
Pr otect t he welding with a corr osion-
preventive product. Apply a layer of sealant material in the joint
areas of t he side panel with t he rear extreme
cross member and the rear lower panel. Paint the affected area in the carria ge body color.
M ount the connection elements by
performing the dismounting operations in the
reverse order.
1
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45
TOP OF BODY
45 - 1
R oof
DISMOUNTING
Dismount the elements, which are in con-
tact with the roof (front/rear doors,
w indscreen, hatchback, roof and re ar quar-
ter panel lining).). Detach the welding points of roof (1),
which are in connection with : -roof belt in the area (2 ) ( left/right);
- side frame lining in the area ( 3). (left/
right) -windscreen frame in the area ( 4);
- middle pillar in the area ( 5);
- side panel (left/right) in the area ( 6).
Straighten the areas resulted by dismount-
ing. Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the roof.
W eld the roof following the welding outlines
(2), (3) (4), (5), and (6).
Grind the performed welding.
Pr otect the perform ed welding with an
anticorrosive product. Paint the affected area.
Mount the elements in connection with the
roof by performing the dismounting operatio ns
in the reverse order.
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TOP OF BODY
45
45- 2
Windscreen frame
DISMOUNTING
Dismount the elements in connection with the
windscreen frame (front bonnet, windscreen, left/
right front wing, left/right front door).
Detach the welding points of the windscreen
frame (1), which are in contact with :
- side frame lining and roof belt in the area
(2) left/right; -windscreen lower cross member in the
area (3 );
- front pillar and front pillar lining in the
area (4) left/right
-r oof in the area (5 ).
D etaching is to be performed by means of a
special shar p drill Ø 6 for plate elements.
Straig hten the areas resulted from dismounting
Grind the area resulted from dismounting.
REMOU NT I NG
Position and center the new element on t he
side frame lining (left/right). Clench in 2-3 points by means of sliding tongs.
Joint the front pillar border with windscreen
frame side border (left/right). Perform a spot welding of the windscreen
frame on the outlines (2), (3), (4) and (5).
Perform an additional SE CO
2 welding in the
connection area of the front pillar upper border
with the windscreen frame side border (left/right)
(4 weld x 15 mm).
Check and restore the windscreen frame.
Grind the performed welding.
Protect the performed welding with an anti-
corrosion product. Paint the affected area.
Mount the elements in connection with t he
windscreen frame by performing the dismount-
ing operations in the reverse order.
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46
BODY PROTECTION
46 -1
Engine shield
DISMOUNTIN G
Dismount four M 6x1 – 20 Embase scre ws attached in four (3) M6x1 safety nuts on the
power train support. Release the engine shield (1).
REMOU NT I NG
Perform the dismounting operations in the reverse order.
1
2
3
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47 - 01
47Rear door
F ront door
LATERAL OPENINGS
DISMOUNTIN G
Dismount the elements, which are in connection with the front/rear door.
Dismount the door panel.
Di smount the door wiring protected by sleeve ( 1) and remove i t through the e xistent door
caisson hole. Dismount the attachment screw (2) of the limiting mechanism of the front/rear door.
Dismount the upper hinge axle ( 3) and lower hinge axle (4).
REMOU NT I NG
Perform the dismounting operations in the reverse order.
Grease the hinges with white grease (Te roson).
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48
NON – LATERAL OPPENINGS
48 - 1
Front bonnet
DISMOUNTIN G
Dismount :
- attachment screws (1) and (2) of the
upper half-hinges on the front bonnet lining; -front bonnet.
R EMOU NT I NG
Pr e-attach the screw (1) from the
windscreen frame on the front bonnet lining
(left/right). Place the front bonnet i n the upper half-
hinge (t hrough the channel made in it) a nd
adjust the clearances. Mount the ot her t wo attachment screws
of the upper half-hinges on the front bonnet
lining and tighten all the four screws to the
required moment of 22,44 Nm. Grease the hinges with white grease
(Teroson).
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NON – LATERAL OPPENINGS
48
48 -2
Hatchback
DISMOUNTIN G
Dismount the hatchback wiring (1) and
remove it t hrough the e xistent hole in the
hatchback lining. Dismou nt :
- safety locks (2) of the balancing shock
absorbers on the hatchback - attachment screws (3) of the balancing
s hock-absorbers on the hatchback;
- attachment screws (4) of the hinges on
the hatchback;
- hatchback.
REMOU NT I NG
Perform the dismounting operations in the
reverse order. Grease the hi nge s wi th whi t e gre a se
(Teroson).
3
4
1
2
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51
51 - 1
MECHA NISMS OF LATERAL OPENINGS
Front door-opening mechanism with electric control
1 2
13
TIGHTENING MOMENTS (daNm)
Attachment screw of assembled box 1.1
Mechanism bolt 5
A ttachment sc re w of o ut si d e ope ni n g
mechanism 0.5
DISMOUNTIN G
Disconn e c t t he ba t t ery ( for ve h i c l e s
equipped with central locking mechanism). Dismo unt :
-w indow lifting crank, by detaching i t
from the crank axle (for vehicles without electric
windows regulator).
- attachment screw ( 2) of the inside
opening mechanism ( 1);
- closing handle ( 13);
- front door panel (s ee chapter 72);
- front door deflective panel. Di
smount the lock fork ( 13) from the
electric control latch. Disconnect the actuator connector (7).
Remove the opening control rod of the front
door (3).
Dismount the attachment screws (5 ) of the
assembled box (4) from the front door caisson.
R emove the electric control latch ( 6) through the
technological opening from the front door caisson. Dismo unt :
- attachment screws ( 10) of the outside
ope ning mechanism (9 ) on the door external panel;
- mechanism bolt (12);
-scr ews (8) attaching the actuator ( 7)
to the electric control latch ( 6).
REMOU NT I NG
Perform the dismounting operations in the
reverse order, taking into account the follow-
ing recommendation: - actuator attachment on the l atch is to
be performed so that its acting stroke is of
minim 18 mm;
-for the front door latch mounting, the
connecting fork (11) of the outside opening
mechanism will be fixed on the existing ball joint
on the lock; -all springs, rivets and elements that are
in movement are to be lubricated with UM 185
Li2 grease;
-for the latch attachment screws to the
electric c ontrol, product Fixamed M28 is to
be used;
-front door deflectiv e panel is to be fixed
on the caisson by means of a sealing material
Ro mtix 1502 P;
- adjustment of the front door closing is
to be performed by means of the m echanism
bolt ( 12), that is to be tighten to the require d
moment of 5 daNm.
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51
51 - 2
MECHA NISMS OF LATERAL OPENINGS
12
13
F ront door-opening mechanism with manual control
TIGHTENING MOMENTS (daNm)
Attachment screw of assembled box 1.1
Mechanism bolt 5
Attachment screw of outside
opening mechanism 0.5
DISMOUNTING
-window lifting crank, by detaching it
from the crank axle. -attachment screw ( 2) of the inside
opening mechanism ( 1);
- closing handle ( 13); -
front door panel (see chapter 72);
- front door deflective panel.
Detach:
-lock fork (12) from the latch.
- opening control rod of the door ( 4);
Detach from clips the blocking rod.
Dismount the attachment screws (6 ) of the
assembled box (5) from the front door caisson.
Remove t he manua l co ntro l latch ( 7)
through the technological opening from the front
door caisson.
Dismo unt :
- attachment screws ( 9) of the out side
opening mechanism ( 8) on the door external
panel; - mechanism bolt (11);
REMOU NT I NG
Perform the dismounting operations in the
reverse order, taking into account the follow-
ing recommendation: - for blocking control mounting, the
blocking rod (3) will be placed in the position
where the latch is blocked. -for the latch mounting, the connecting
fork (11) of the outside opening mechanism
will be fixed on the existing ball joint on the
lock;
-all springs, rivets and elements that are
in movement are to be lubricated with UM 185
Li2 grease; -for t he l atch att achment screws ,
product Fixamed M28 is to be used;
- front door deflective panel is to be fixed
on the caisson by means of a sealing material
Ro mtix 1502 P;
- adjustment of the front door closing is
to be performed by means of the m echanism
bolt ( 11 ) , that is to be tighten to the re quired
moment of 5 daNm.
38
122 7
5116
9 10
1 43
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