headlamp DACIA SUPERNOVA 2004 Repair Manual

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 - 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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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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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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80
BATTERY - FRONT HEADLIGHTS
80 - 4
HEADLAMP ASSEMBLY
DISMOUNTING
Disconnect the battery.
Dismount the headlamp adjustment correction control from the headlamp adjustment device,
by detaching from clips.
Disconnect the connector (1).
Disconnect the supply wires for the parking bulb and turning light bulb.
Dismount the attachment nuts (5) of the headlamp-turning lamp assembly .
Push ahead the headlamp assembly.
REMOUNTING
Place the headlamp assembly in its place and tighten the attachment nuts (5).
Mount the headlamp correction cable.
Reconnect the connector (1) and the supply wires to the parking and turning bulbs.
Reconnect the battery.
NOTE :
After headlamps dismounting, their adjustment must be performed.
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80
BATTERY - FRONT HEADLIGHTS
BULBS REPLACEMENT80 - 6
HEADLAMP BULB REPLACEMENT
DISMOUNTING
Disconnect the connector (1).
Disconnect the supply wires of the parking bulb and remove the parking bulb.
Remove the rubber protector (2).
Release t he attachment clamps (3) and remove the low-main beam bulb.
REMOUNTING
Perform the dismounting operations in the reverse order.
NOTE:
In case the headlamp is equipped with a halogen bulb, do not touch its glass balloon
directly by hand.
FRONT TURNING BULB REPLACEMENT
DISMOUNTING
Disconnect the bulb supply wires
Rotate the holder (4) and remove it.
Remove the burnt bulb from the holder.
REMOUNTING
Pe rform the dismounting operations in the reverse orde r, with the checking of the correct
holder (4) positioning to avoid dust and humidity penetration in the headlamp assembly .
The turning lamps are using orange color bulb; when replacing the bulb, use the same bulb type.
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80
BATTERY - FRONT HEADLIGHTS
80 - 7
HEADLAMPS ADJUSTMENT
MEETING LIGHTS ADJUSTMENT (LOW BEAM) This is performed by acting upon the V screw
(vertically p lane adjustment) or H (horizontally
p lane adjustment). By screwin g, t he lighting beam
is ”lowering” and by unscrewing is “ascending”.
Check if the lighted area i s centered on the
vertical axis and if the optical separation at 15°
coincide with the headlamp lighting. An error
of 1 cm is admissible.
A lighting beam displaced towards left has
the aspect shown in ( pict.a) and a lighting beam
displaced towards right has the aspect shown
in (pict.b).
RO AD LIGHTS ADJUSTMENT (LONG BEAM)
Check the position to coincide with the
adjustment performed for low beam a nd with
the lighting beam distributed between the two
vertical lines on the panel. When checking the long beam, the lighting
center of the ellipse, must be located on the
cross marking the screen center.
If a m ajor de viation c ompared with t he low be am i s noticed, i t is re commended t he bul b
replacement, this one being in most of the cases, responsible for such defect.
pict.a
pict.b
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80
BATTERY - FRONT HEADLIGHTS
80 - 8
HEADLAMPS ADJUSTMENT
FOG LAMPS ADJUSTMENT
The fog lamps adjustment is to be performed in the following conditions:
- the vehicle to be placed on a horizontal surface;
- the vehicle has not passengers inside the cockpit or weights in the trunk;
- the tires a re pressurized a t the manufacturer prescribed pressure.
Further on, proceed as follows:
Bring the vehicle at the working place.
Position the adjustment device (headlamp adjustment device – E) in front of an optical center
of a fog lamp.
Switch on the fog lamps.
Rotate the adjustment screw of the fog lamp (D), so that an adjustment of 2 % is obtained and
the separation between the lighted area and the dark one from the adjustment device is located
under the marked line (G).
This adjustment is performed in the same way as for the meeting lights adjustment.
Bring the adjustment device in front of the optical center of the second fog lamp.
Perform the fog lamp adjustment.
Switch off the fog lamps.
G
E
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83
INSTRUMENT PANEL
DISMOUNTING
Disconnecting battery.
Dismounting flexible shaft( speedometer cable) from the gearbox.
Dismounting control cable from the recyclin g flap.
Dismounting steering wheel and the steering wheel casing.
Dismountin g dashboard lower fairing.
Dismountin g documents compartment.
Disconnect documents compartment lamp.
Dismountin g central console.
Dismounting flaps control cables from the climate control unit.
Discon necting: cigarette lighter, climate control lighting, ashtray lighting, climate control switch .
Dismounting headlamps adjustment control from the dashboard.
Dismounting dashboard from the windscreen lower cross bar.
Disconnecting flexible shaft (speedometer cable) from the instrument panel.
Disconnecting air conducting ducts to aerators.
Disconnecting front wiring from the instrument panel and from the dashboard wiring.
Dismounting instrument panel attachmen t clamps from the dashboard.
Dismountin g clamps from the instrument panel.
Mounting clamps on the new instrument panel.
Mounting instrument panel with clamps on dashboard.
Connecting flexible shaft to the instrument panel.
Connecting front wiring to the instrument panel and to the dashboard wiring.
Positioning and fixing air conducting ducts.
IN
STRUMENT PANEL REPLACEMENT
83-5
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