ABS DACIA SUPERNOVA 2004 Service Manual

36
STEERING ASSEMBLY
36 - 5
NOISE ABSORBER BEARING
DISMOUNTING
Loosen the screws of the wheel;
Lift the front part of the vehicle
Dismount the wheel on the opposite side of the steering column;
Dismou nt :
-casing protection bellows;
-the steering auxiliary connected rod.
Rotate the steering wheel until the rack is withdrawn.
Remove, by means of a screwdriver the noise absorber bearing.
REMOUNTING
Carefully clean t he rack and the noise absorber bearing seat and grease with special grease
containing MoS2.
In the same way as at the dismounting, place back the noise absorber bearing paying attention
to fix the three pins (A) in their seats.
Rotate the steering wheel in the opposite direction until the rack stands out the bearing.
Remount on the rack: - the steering auxiliary connecting rod (mount a new safety washer);
- protection bellows.
Check and adjust the parallelism, if necessary.
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40
GENERAL
40 - 16
CAR
RIAGE BODY CHECKING / STRENGTHENING
BENCH CELETTE TYPE
R EFERENCE POINTS ON VEHICLE
GMP frame fixing on the lower cross member
The specific supports (1) and (2) are used
in front straightening, front mechanic
elemen ts dism ounted, enabling the
pos i t i oni ng of t he l owe r c r oss m e m be r,
conseq uently th e front fixing of the GMP
frame (pi ct. 10).
NOTE
These holes are for main refe rence for
the vehicle front part. ( pict. 10 )
( pict. 11)
Ce
ntering under front longitudinal girder
The specific supports (3) and (4) are used
for positioning, centeri ng, and alignment of
the front longitudinal girders. They are to be
used for a ll reparation cases because t hey a re
a main refe rence of vehicle setting on the
bench (pict. 11).
( pict. 12 )
S
pecific supports (5) and (6) are used in
fron t stre ngt he ni ng, m e chani c al eleme nts
dismounted, e nabling the positioning of the
shock absorbers e nds, consequently the front
linings positioning (pict.12). U
pper fixing on front shock absorber( shock absorber column)
21
65
43
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40
GENERAL
40 - 17
CAR
RIAGE BODY CHECKING / STRAIGHTENING BENCH
CELETTE TYPE
Their centering in the shock absorbers ends
is perfo rm e d by m e a n s of t he c e nt e ri ng
wa shers (1)- (pict.13).
The cente ri ng wa she rs a re use d whe n
str aightening a body and also when re placing
the front wing lining or the body front part.
(pict.13)
The specific supports (7) and (8) are used
in the front straightening, enabling the
positioning of the front longitudinal girder and
c onse que nt l y the re ar fi xi ng of t he GMP
frame. In case of the rear straightening, these are
enabling the front alignment of t he ve hicle
on the bench. (pict.14).
( pict. 14 )
GMP frame rear fi xing on front longitudinal girder
The specific supports (9) and (10) have t he
purpose of positioning, centering and
ali gnment of the front longitudinal
gi rde rs.T he se a re to be use d i n all cases
because they are a setting refere nce of the
vehicle on the bench. (pi ct. 15). ( fig. 15)
Ce
ntering under the central fl oor
78
910
( pict. 15 )
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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
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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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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Mechanisms and accesoires5
Climatisation6
Garnishing and tack room7
Electr ic equipment8
57 LOWER INTERNAL ACCESSORIESDashboard..................................................... 57-1
Dashboard upper part ................................... 57-3
Central console............................................. 56-4
Documents compartment.............................. 57-5
Ste ering whee l axle hal f-cases...................... 57-6
Inside rear view mirror.................................. 57-7
S un visors...................................................... 57-8
Turning handles............................................ 57-9
Handbrake case............................................. 57-10
59 SAFETY ELEMENTS Front safety belts........................................... 59-1
Re ar safety belts............................................ 59-2
61 HEATING Climat e control asse mbly.............................. 61-1
Housing manifold.......................................... 61-2
Heating radiator............................................. 61-3
C limat e control blower.................................. 61-4
Diagnosis....................................................... 61-5
62 AIR CONDITIONING Generalities.................................................. 62-1
AC unit operating diagram........................... 62-4
Evaporator.................................................... 62-5
Comp ressor................................................... 62-7
Condenser..................................................... 62-8
Pr essure controller........................................ 62-9
Dryer filter tank............................................ 62-10
Unit piping.................................................... 62-11
C limat e control unit...................................... 62-12
Diagnosis....................................................... 62-13
65 SEALING OPENING ELEMENTS Carriage body se aling................................... 65-1
66 SEALING WINDOWS AND SCREENS Glasses sealing............................................. 66-1
Insi de wipers ............................................... 66-2
Outside wipers.............................................. 66-3
71 INTERNAL BODY TRIM Carriage body coverings.............................. 71-1
Fr ont door threshold covering...................... 71-2
Upper front pillar covering........................... 71-3
Re ar door threshold covering....................... 71-4
Mi ddle pillar covering.................................. 71-5
Re ar passa ge covering.................................. 71-6
Re ar wheel passage covering........................ 71-7
Mi ddle pillar lower covering........................ 71-8
Re ar side panel covering............................... 71-9
R oof gasket .................................................... 71-10 Carpets
......................................................... 71-11
Cowl panel noise absorbent ......................... 71-12
72 SIDE OPENING ELEMENTS TRIM Front door panel........................................... 72-1
Re ar door panel............................................ 72-2
74 BACK SEAT TABLES AND PARCEL SHELVES Upper back panel replacement...................... 74-1
75 FRONT SEATS FRAMES AND RUNNERS Front seats.................................................... 75-1
Fr ont seat slides guides................................ 75-2
Fr ont seat armature...................................... 75-3
76 REAR SEATS FRAMES AND RUNNERS Rear bench................................................... 76-1
B ench seats .................................................. 76-2
77 FRONT SEAT TRIM Seats upholstery dismounting...................... 77-1
Back rest upholstery dismounting................ 77-2
78 REAR SEAT TRIM Seats upholstery dismounting...................... 78-1
Back rest upholstery dismounting................ 78-2
80 BATTERY - FRONT HEADLIGHTS Battery... ...................................................... 80-1
Head lamp asse mb ly..................................... 80-4
F og lamps.................................................... 80-5
Bulbs r eplacement....................................... 80-6
Headlamps adjustment................................. 80-7
81 REAR AND INTERIOR LIGHTING Bulbs r eplacement........................................ 81-1
Bulbs ............................................................ 81-2
Diagnostic.................................................... 81-3
Cockpit fuse box.......................................... 81-6
82A HORN - ENGINE IMMOBILISER Gene ralities.................................................. 82A-1
Key head repla ceme nt.................................. 82A-6
E.C.U. decoder repla ceme nt........................ 82A-7
Antistarting bushing replaceme nt................ 82A-8
RF remote control for blocking/unlocking
t he doors...................................................... 82A-9
Electric control unit injection repla cement... 82A-10
Pr ocedures.................................................... 82A-11
Diagnostic..................................................... 82A-17
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