DACIA SUPERNOVA 2004 Repair Manual

43UPPER SIDE STRUCTURE
MIDDLE PILLAR
DISMOUNTING
Dismount the damaged 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 area (4);
- front lower panel in the area (3 );
- roof belt i n the area (2 ) .
Straighten the areas resulted by dismount-
ing. Grind the areas resulted by dismounting .
REMOUNTING Fit temporary the middle pillar (1) .
Check the correct pillar positioning using the door as geometric gauge.
W eld the middle pillar following the welding outlines (2), (3) and (4).
Perform a straightening gas protection welding in the areas (2).
Protect the welding with a c orrosion-protection product.
Mount in the reverse order the elements, which are in connection with the middle pillar.
43 - 3
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44
REAR UPPER STRUCTURE
SIDE PANEL
44 - 1
DISMOUNTING
Dismount
the elements, which are in con-
tact with the side panel.
Detach the welding points of the side panel
(1 ) which are in connection with :
- side frame lining in the area (2);
- roof in the area (3 );
- rear panel in t he are a (4);
- rear end c ross bar in t he a rea (5 ).
Straighten the areas resulted by dismount-
ing.
Grind the areas resulted by dismounting.
REMOUNTING
Apply a layer of 5322 size material on the
joint areas of the side panel with the side frame
lining and the rear panel.
Position and center the new element.
Check the correct positioning of the side
panel. We ld the side panel (1) following the
welding outlines 2, 3, 4, and 5.
Pr otect the welding with a c orrosion-
preventive product.
Mount in the re verse order the elements
in connection with the side panel.
4
5
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REAR UPPER STRUCTURE
44
44 - 2

IN NER REAR WHEEL PASSAGE
DISMOUNTING
Dismount the elements, which are in contact
with the inner rear wheel passage.
Detach the welding points of the two rear
safety belt supports. Detach the welding points of the rear wheel
passage (1 ) which are in connection with:
- side frame lining in the area (2);
- side panel i n the are a (3);
- rear longitudinal girder 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 rear
wheel passage. Weld the rear wheel pa ssage (1) following
the assembling outlines 2,3 and 4.
W eld the rear safety belts supports on the rear
wheel passage.
Prot ect the weldi ng wi t h a c orro si on-
preventing product. Apply a layer of sealant ma terial
PL ASTISOL 4, in the contact are a (5) of the
rear wheel passage with the rear floor.
4
1
2
5 3
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44
REAR UPPER STRUCTURE
REAR PANEL44 - 3
DISMOUNTING
Dismount
the elements that are in contact
with the rear panel.
Detach the welding points of the rear panel
(1) which are in connection with:
- side panel edge in t he area (2);
- side panel ( rear lamps area) in the
area (3 ) ;
- side panel i n the are a (4);
- rear end c ross bar in t he a rea (5 ) .
Straigh ten the areas resulted from
dismounting. Grind the areas resulted from dismounting.
REMOUNTING
Position and center the new element.
Check the correct positioning of the rear
panel. We ld the re ar panel (1) following t he
welding outlines (2), (3) and (4)…;
Pr otect the welding with a corr osion
preventive product. Mount in the re verse order the elements
that are in connection with the rear panel.
2
5
4 3
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45
TOP OF BODY
ROOF
1. Roof
2 Roof belt
3. Windscreen frame
DISMOUNTING
Di smount the elements, which are in
contact with the roof (fron t/rear doors,
windscreen, rear glass, roof sealing of the
ceiling and windows gaskets).
Detach the welding points of roof (1) which are in connection with :
-r oof belt in the a rea (4);
- side frame lining in the area (5);
-w indscreen lower cross bar in the area (6 );
- front pillar in the area (7).
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element.
Check the correct positioning of the roof.
W eld the roof (1) following the welding outlines (4), (5), (6) and (7).
Mount in the reverse order the elements, which are in connection with the roof.
4
5
6
1
3
2
45 - 01
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FRONT / REAR DOOR 47 - 147
DISMOUNTING
Dismount the elements, which are in
connection with the front/rear door.
Dismount the attachment screw (1 ) of the
limiting mechanism of the front/rear door.
Di smount the upper hinge (2) and lower
hinge axles (3) .
REMOUNTING
Per f o r m in the reverse order the
dismounting operations.
LATERAL OPENINGS
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48
NON SIDE OPENING ELEMENTS
48 - 1
FRONT BONNET
DISMOUNTING
Dismou nt :
- the aeration grill;
- the windscreen washer jets and hoses;
- the front bonnet locker (1);
- the safety hook (2);
- the attachment screws (3) of the
hi nges;
- front bonet.
REMOUNTING
Perform in the reverse order the dismounting operations.
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NON SIDE OPENING ELEMENTS
48
48 - 2
HATCHBACK
DISMOUNTING
Dism oun t the elements that are in
connection with the hatchback.
Dismount the hatchback attachment ball-
s haped joints (1) and the attachment screws
of the hinges.
Dismount the hatchback.
REMOUNTING
Perform in the reverse order the dismounting operations.
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SIDE OPENINGS ELEMENTS M ECHAN ISMS
51
51 - 1
DISMOUNTING
For the dismounting
of the front door assembled plate with electric control, dismount:
- the window lifting crank, inner opening mechanism, by detaching from it, the control rod
(8) of the front door opening, the rod which is fixed with the other end on the plate;
- the locking button (2) and the guiding case (3);
- the attachment screw (9 ) of the locking handle;
- the door pa nel.
Disconnect the actuator connector.
(7)
Di smount the attachment screws (5) of the box (6) from the caisson of the door.
Remove the electric control assembled plate assembly through the technological opening from
the caisson of the door.
Dismount the attachment screws of the outside opening mechanism on the external panel of
the door.
REMOUNTING
Perform in reverse order the dismounting operations, taking into account the following recom-
mendation:
- for the lock c ontrol mounting, t he lock rod (4) will be pl aced i n the position where t he
lock is blocked; - for the front door plate mounting, the connecting fork (1) of the outside opening mechanism
will be fixed on the existing ball joint on the lock;
mount the button (2) by self-threading on the rod (4).
MECHANISM WITH ELECTRIC CONTROL FOR
FRONT DOOR OUTSIDE OPENING
LOCK
AND FRONT DOOR LOCK CYLINDER
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SIDE OPENINGS ELEMENTS M ECHAN ISMS
51
51 - 2
DISMOUNTING
For the front door lock dismounting and the outside opening mechanism, beforehand dismount:
- the window lifting crank;
- the arm rest;
- the inside opening mechanism (1);
- the door panel inner ornament;
- the door panel upper ornament, the locking button (5) and the guiding case (4);
- the door pa nel.
After these operations dismount:
- the lock a ttachment fork (6) and the l ock (11) from the door;
- the front door lock attachment screws (9) on the door caisson;
- the door opening control rod (2) from the lock.
Remove the lock assembly through the technological opening from the door caisson.
Dismount the attachment screws (8) of the outside opening mechanism (7 ) on the front door
outside panel.
REMOUNTING
Perform in the reverse order the dismounting operations, taking into account the following
mounting instructio ns :
- for the lock control mounting, the lock rod (3) will be placed in the position where the
lock is blocked; - introduce the locking rod thought the caisson hole, in the panel guide, then fix it on the
lock by the attachment element;
- mount the button (5) by self-threading on the rod (3);
for the front door lock mounting, the connecting fork (6) of the outside opening mechanism will
be fixed on the existing ball joint on the lock.
11
FRONT DOOR LOCK AND OUTSIDE OPENING MECHANISMLOCK AND FRONT DOOR LOCK CYLINDER
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