DACIA SUPERNOVA 2004 Repair Manual

REPAIR MANUAL
DACIA
RM 524-2 BODYENGINE: E7J
G ERBOX: JH3
TA P V: B 41A, B41B, B41D
Ref: 6001999443 APRIL 2004 English version
The reparation methods prescribed by the manufacturer in the present document are established subject to
t echnical specifications in force at the document issuing date.
These a re subject to modifications brought by the manufacturer at the fabrication of different assemblies,
s ubassemblies or accessor ies of its vehicles.
All rights rese rved to SC Automobile Dacia SA.
Re production or transla ting even partia lly of this prese nt doc ume nt is forbidde n without the writte n
authorisation of AUTOMOBILE DACIA S.A.
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52 NON SIDE OPPENING ELEMENTSMEC HANISMS
The composition of the front hood locking
system ............................................................ 52-1
Fr ont hood locking system............................. 52-2
Hatc hback lo cking sy stem .............................. 52-3
Hatchback balancing device........................... 52-5
54 WINDOWS Windscreen and hatc hback glass.................... 54-1
Hatchback gla ss repla cement......................... 54-3
55 EXTERNAL PROTECTIONS Front bumper.................................................. 55-1
Rear bumper................................................... 55-2
56 EXTERNAL ACCESSOIRES Outside accesor ies.......................................... 56-1
Aileron........................................................... 56-2
40 GENERAL
Designation of parts (blow-up)..................... 40-1
Openings cle arance....................................... 40-4
Repairing general conditions........................ 40-5
Welding types and parameters...................... 40-6
Col lision diagnosis........................................ 40-8
Ca rriage body checking/ Straightening bench
CELETE type................................................ 40-12
41 LOWER STRUCTURE Front longitudinal girder assembly............... 41-1
Re ar longitudinal girder................................ 41-2
42 UPPER FRONT STRUCTURE Front wing..................................................... 42-1
Ca rriage body front part................................ 42-2
Fr ont wing lining........................................... 42-3
R adiator upper cross bar............................... 42-4
Headlamp support......................................... 42-5
Aeration grill................................................. 42-6
43 UPPER SIDE STRUCTURE Front pillar lining.......................................... 43-1
Fr ont pillar..................................................... 43-2
Mi ddle pillar.................................................. 43-3
44 REAR UPPER STRUCTURE Side panel...................................................... 44-1
Inner rear wheel passa ge............................... 44-2
Re ar panel..................................................... 44-3
45 TOP OF BODY Roof.............................................................. 45-1
47 LATERAL OPENINGS Front/Rear door............................................ 47-1
48 NON SIDE OPPENING ELEMENTS Front bonnet.................................................. 48-1
Hatchback..................................................... 48-2
51 SIDE OPPENING ELEMENT S MECHANISMS Lock and front door lock cylinder................. 51-1
Lock and rear door lock cylinder.................. 51-3
Window and front door window regulator
(with cable)................................................... 51-5
Window and rear door window regulator
(with cable)................................................... 51-6Body4
Mechanisms and accesoires5
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40
GENERAL
40 - 1
1.
Front cross member
2. Front longitudinal girde r assembly
3. Upper front longitudinal girder
4. Longitudinal girder closing plate
5. Floor cross member
6. Floor side plate
7. Tank front cross member
8. Rear side cross member
9. Rear longitudinal girder a ssembly
10. Tank re ar cross member
11 . Rear extreme cross member
12. Rear floor
13. Middle floor
14. Tunnel lining
15. Middle cross member LOWER STRUCTURE COMPOSING ELEMENTS
DE
SIGNATION OF PARTS (BLOW-UP)
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40
GENERAL
40 - 2
UPPER STRUCTURE COMPOSING ELEMENTS
1. Headlamp support
2. Upper radiator cross bar
3. Front grill
4. Front wing lining
5. Front pillar lining
6. Front pillar
7. Side frame lining
8. Middle pillar
9. Inner wheel passage
10. Side panel
11 . Rear panel
12. Ceiling
13. Windscreen frame
14. Windscreen lower cross bar
15. Climate control box
16. Climate control box centra l part
17. Cowl panel DE
SIGNATION OF PARTS (BLOW-UP)
123
456 78 9
10
11
12
13
14151617
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40
GENERAL
40 - 3
CAR
RIAGE BODY REMOVABLE ELEMENTS
1. Front wing
2. Front door
3. Rear door
4. Hatchback
5. Aer ating gri ll
6. Front bonnet DE
SIGNATION OF PARTS (BLOW-UP)
12 34
65
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40
GENERAL
40 - 4
OPENINGS CLEARANCE
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40
GENERAL
40 - 5
The replacement (repara tion) operations of t he weldable elements descri bed i n t his
chapter a re specified subject to: cutting out of t he parts t o be replaced; the a ccess to the
welded elements, tools and checking devices accessibility, etc.
In case the vehicle body has suffered import ant deform ations it is recommended the
str aightening of t he damaged body elements, by means of some hydraulic pre sses, the
operation being performed slowly and at cold. For this range of vehicles, the e lements re sistance structure which a re a ffecting the
vehicle securi ty, are not to be partially re placed ( not to be cut), but entirely.
After welding detaching, the body elements must remain stra ight, without breakage or
cracks, the possible holes being covere d out with filling material or by tinning. The body
elements surfaces are t o be pickled ( to eliminate possible oxidation marks) , dried and
initially applied a paint layer. The electric welding detaching of the body elements, is performed as follows:
- with a well sharpen chisel, this method may lead to part s deformation or even
parts breaking.
- by using some extractors equipped with steel cutter type Bre ndeo or Pickvant
max. 6 mm, having the cutting head as per shape shown in pict.1.
1. Centeri ng point
2. Sharpen slope
3. Drill acting edges
4. Gap for catching the welding materialP = aprox. 0.4 mm
Whatever method is used, the remaining element m ust be in good order a nd to allow
performing of a good quality welding point.
The pl ates cutting it is recommended t o be pe rformed ( subject of importance and thick-
ness ) using manual scissors or pneumatic portable tools for plates cutting.
Du ring cutting or welding of the body elements it is necessary to protect the electric
wir ing from the interi or of the body structure.
The cutting, welding, or strengthening operation done on body welded elements, are to
be performed on body checking/ straightening bench type CELETTE .
IMP ORTANT
When removing or straightening the body resistance e lements i t i s forbidden t he
total or partial heating, in order to avoid the mechanical resistance and metal elasticity
decreasing. REPAIRIN
G GENERAL CONDITIONS
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40
GENERAL
40 - 6
WELDING TYPES AND P
ARAMETERS
At the reparation of the welded body elements, thre e welding categories may be used:
prot e c t ion ga s weldi ng (CO2), e l e ctri c spot weldi ng and fi l l ing m a teri als wel ding
(autogenous). At the autogenous 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 m m from the
part to be welded.
1. Spot welding resistive para meters for steel plates with carbon c ontent C < 0,15 %.
Plate thic kness (mm) Welding current (KA) Welding time (per) Tightening force ( daN m. )
0,5 6,5 5 130
0,8 8,0 8 200
1,0 9,5 10 250
1,25 10,5 10 295
1,5 10,0 14 310
2,0 12,0 16 350
NOTE
1 period = 1/50 part of a second
2. Welding parameters for the welding in protector gas for carbon steel plates or low-
alloyed steel.
Horizontal welding position ( pict.1)
Plate thickness (mm) 0,61,0 1,5 2,0
Electrode diamet er (mm) 0,6 0, 80,8 1,00 ,8 1,0 0,8 1,0
Welding wire speed (m/min) 2,5 1,9 3,2 2,4 4,4 3,8 5,7 4,4
Welding current (A) 35 35 55 80 80 120 100 130
Welding speed (m/min) 0,25 0,25 0,35 0,33 0,33 0,50 0,45 0,45
Welding voltage (V) 17 17 18 18 19 19 20 20
Protection gas flow (1/min) 12 - 17
Electrode fr ee length (mm) 6 - 12
plates welding
in tiers end to end
welding corner
welding
0-1,5mm 0-1,5mm
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40
GENERAL
40 - 7
WELDING TYPES AND P
ARAMETERS
NOTE
In case of using the Ar + CO2 mixture, the welding voltage will decrease with 2 V.
Ve rtical welding position ( obligatory from top to bottom) pict. 2
Plate thickness 0,6 12 2,0
Electrode diameter (m m) 0,6 0,8 0,8 1,0 0,8 1,0
We l ding wire speed (m /min) 2,5 1,9 3,3 3,2 5,7 4,4
We l ding 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
We l ding voltage (V) 17 17 18 18 20 20
Pr otection gas flow (1/min) 12 - 17
Electrode fre e length (mm) 6 - 12
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40
GENERAL
40 - 8
C
OLLISION DIAGNOSIS
Du ring the vehicle exploitation, the carriage body may suffer different distortions, that
lead many times to the wheels setting angles change, body elements breakage, vibra tions
or even mechanical parts wear. In these conditions, be fore performing the vehicle body re paration, some checking is
necessary:
Visual checking - consisting in the e xamination 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 symmetric points. The ge ometry checking of t he rol ling t ransmissions – this checking is t he only one
enabling to find out if the body damage was not affecting the vehicle road behavior.
IMP ORTANT
This checking must be not ignored, except some border-line cases, the checking of
the rolling transmissions leading to t he identification of the distortions occurred further
to an accident.
C OLLISION DIAGNOSIS
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