DACIA SUPERNOVA 2004 Repair Manual

LOWER STRUCTURE
FRONT LONGITUDINAL GIRDER ASSEMBLY41- 1
41
REPLACEMENT
This operation shall be performed only on the repair bench. For the specific supports mount-
ing on the bench, please see the 40 sub-chapter.
DISMOUNTING
In order to reduce the distortion risk of
the front longitudinal girder, for the welding
points detaching it is recommended the use
of steel cutter. Dismount the damaged elements, which
are in contact with the front longitudinal girder.
Pr oceed to a straightening on the body
checking/straightening Celette type, until
bringing it, as closed as possible to the initial
shape.
Detach the welding points of the front longitudinal girder which are in connection with : - the front cross bar in t he a rea (1);
- the front wing lining in the area (2);
- the central floor in the area (3);
- the c entral cross bar in the a rea (4);
- the upper longitudinal girder closing plate in the area (5).
Detach the welding points of the cross bar with the floor closing plate and the central floor in
the are a (6). Remove the damaged element.
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element.
Perform an electric welding (by spots and under gas protection) as follows: - in the area (1) connecting the front longitudinal girder with the front cross bar;
- in the area (2) connecting the front longitudinal girder with the front wing lining;
- in the area (3) connecting the front longitudinal girder with the central floor;
- in the area (4) connecting the front longitudinal girder with the front cross bar;
- in the area (5) connecting the front longitudinal girder with the upper girder closing plate;
- in the area (6) connecting the front longitudinal girder with the cowl panel.
Protect the new element with a corrosion preventing and noise absorbent product.
1
5 3
6
4
2
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LOWER STRUCTURE41
REAR LONGITUDINAL GIRDER
REPLACEMENT
This operation shall be performed only on the repair bench. For the specific supports mounting
on the bench, please see t he 40 chapter.
41 - 2
DISMOUNTING
Dismount
the damaged elements, which are
in contact with the rear longitudinal girder. Proceed to a straightening on the body
checking/straig htening Celette type, until bringing
the ve hicle a s closed as possible to t he i nitial
shape.
Detach the welding points of the rear longitudinal girder (1) which are in contact with:- the central floor in the area (1);
- the rear floor in the area (2);
- the rear end floor in t he area (3);
- the re ar side cross bar in t he are a (4);
- the t ank front cross bar in t he area (5);
- the tank re ar cross bar i n the area (6);
- the inner wheel passage in the area (7);
Straighten the areas resulted after dismounting.
Grind the areas resulted after dismounting.
REMOUNTING
Position and center the new element
W eld the rear longitudinal girder following the assembling outlines 1,2,3,4,5,6 and 7 (spots
and under gas protection welding) Protect the new element with a corrosion preventing and noise absorbent product.
1 5
47
2
3
6
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42
UPPER FRONT STRUCTURE
FRONT WING 42 - 1
DISMOUNTING
Dismount partially
the front bumper.
Dismoun t the side-sign aling lamp from the
front wing.
Dismount the attachment screws (1) of
wheel passage protection. Dismount the attachment screws (2 ), (3),
(4) and (5) of the wing on the vehicle body.
Dismount the front wing.
FRONT WING PREPARATION
A pply by means of a brush a layer of thermo- weldable product cls. 33 b, cs 4603 – 202 on
the contact areas of front wing with: - the contact area with the front wing lining;
- the contact area with the side frame l ining on the wing upper edge;
- the contact area with the wing fixing supports on the front pillar;
- the contact area of the wing rear lower part with the side frame lining;
- the contact area with the front part wing fixing support.
A pply also a sealant materi al l ayer type 223 in the contact area of t he front wing with: the
front wing lining, the side frame lining and the front pillar.
REMOUNTING
Perform the dismounting operations in the reverse order.
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42
UPPER FRONT STRUCTURE
CARRIAGE BODY FRONT PART
42 - 2
REPLACEMENT
This operation shall be performed only on the repair bench. For the specific supports mount-
ing on the bench, please see the 40 chapter
DISMOUNTING
Dismount the damaged elements, which are
in contact with the front part body. Perform a straightening on the body checking/
repairing bench, until bringing the carriage body
almost at the initial shape.
Detach the welding points from to front part
of carriage body (1) as follows : - in (2) joining area of the front longitudinal
girders with the central floor; - in (3) joining area of the front cross bar
with the central floor;
- in (4) joining area of the central cross bar with the floor closing plate;
- in (5) joining area of the front wing linings with the cowl panel;
- in (6) joining area of the cross bar with floor closing plate;
- in (7) joining area of the front wing linings with the front pillar linings.
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element on the repairing bench.
Check the correct positioning of the front part carriage body.
W eld the front part carriage body, following the assembling outlines 2,3,4,5,6 and 7 (spots
welding under gas protection). Protect the welding with a corrosion-preventing product.
Apply noise absorbent product on the whole surface: front wings linings, front pillar linings,
cowl panel and the central floor.
By means of a spraying gun, apply on the whole surface corrosion protectin g products through
the front cross bar and front longitudinal girder holes. Perform the sealing of the front PART carriage body.
Mount the front wings, the front grill, and the front bonnet.
17 633
4
2
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42
UPPER FRONT STRUCTURE
FRONT WING LINING 42 - 3
REPLACEMENT
This operation shall be performed only on the repair bench. For the specific supports mount-
ing on the bench, please see the 40 sub-chapter.
DISMOUNTING
Dismount the damaged elements, which
are in contact with the front wing lining. Detach the welding points from to the front
wing lining (1) which are in contact with :
- the upper longitudinal girder in (2) area;
- the front c ross bar in the a rea (3 );
- the front grill in the area (4);
- the closing plate in the area; (5) ;
- the floor in t he area (6 );
- the cowl panel in the area (7 );
the climate control box in the area (8).
REMOUNTING
Position and center the new element.
Check the correct positioning of the front
wing lining.
Weld the front wing lining (1) following the
assembling outlines 2, 3, 4, 5, 6, 7 and 8.
Protect the new element with a corrosion
preventing and noise absorbent product.
1
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42
UPPER FRONT STRUCTURE
42 - 04
RADI
ATOR UPPER CROSS BAR
DISMOUNTING
Dismount the elements, which are in contact
w ith the radiator upper cross bar.
D etach the welding points of the radiator
upper cross bar (1) which are in connection with:
- the front wing lining in the area (3);
- the headlamp support in the area (4);
- the side wall in the area (5 );
Straighten the areas resulted by dismountin g.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element.
Check the correct positioning of the radiator
upper cross bar. Weld the radiator upper cross bar (1) following
the welding outlines (3), (4) and (5).
Protect the welds with a corrosion-preventing
product.
Mount the elements, which are in connection
w ith the radiator upper cross bar.
1
4
5
3
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42
UPPER FRONT STRUCTURE
42 - 05
HEADLAMP SUPPORT
DISMOUNTING
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 :
- the front wing lining in the area (6);
- the radiator upper cross bar in the area (7);
- the front cross bar in the area (8 ).
Straighten the areas resulted by dismountin g.
Grind the areas resulted by dismounting.
REMOUNTING
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.
7
8 6
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UPPER FRONT STRUCTURE
AERATION GRILL
DISMOUNTING
T ake out the clips (1) from the front grill
grippers taking care to prevent their distortion
or damaging.
REMOUNTING
Per f o r m in the reverse order the
dismounting operations.
1
42 - 06
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43 - 1
43
SIDE UPPER STRUCTURE
FRONT PILLAR LINING
1. Front pillar
2. Front pillar lining
DISMOUNTING
Dismount the elements that are in contact
with the front pillar lining. Detach the welding points of the front pillar
lining ( 2) which are in connection with :
- side frame lining in the area (8);
- windscree n lower cross bar in the area (5);
- front wing lining in the area (6);
- climate control box in t he area (7 ) .
Straigh ten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element .
Check the correct positioning of the front pillar lining.
W eld the front pillar lining (2) following the assembling outlines (5), (6), (7) and (8).
Protect the new element with a corrosion preventing and noise absorbent product.
FRONT PILLAR LINING
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UPPER SIDE STRUCTURE43
DISMOUNTING
Dismount the elements that are in contact with
the front pillar.
Detach the welding points of the front pillar
(1) which are in connection with :
- side frame lining in the area (3) ;
- roof in the area (4).
Straighten the areas resulted by dismountin g.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element.
Check the correct positioning of the front pil-
lar. Weld t he front pi llar (1) fol l owing t he
assembling outlines (3) and (4) .
Pr otect the new element with a corrosion
preventing and noise absorbent product.
FRONT PILLAR
43 - 2
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