2004 DACIA SOLENZA Repair Manual

44
REAR UPPER STRUCTURE
44 - 1
Rear lower panel
DISMOUNTING
Dismount the elements that are in contact
with the rear lower panel.
Detach the welding points of the rear lower
panel (1) which are in connection with :
- lamp support (left/rig ht) in the area (2);
- side panel (left/right) in the area (3);
-r ear extreme cross m ember and rear
lamp support in the area (4).
Straigh ten the areas resulted from
dismounting
Grind the areas resulted from dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the rear
lower panel. Perform a spot weld with a dditional SE
CO
2 (weld of 10 mm with 30 mm pitch)
between the rear lower panel and : -left/right rear lamp support in the area (2);
- left/ right rear lower panel in the area (3);
-r ear extreme cross m ember and rear
lamp support in the area (4 ).
Grind the performed welding.
Pr otect the welding with a corrosion
preventive product. Apply a sealant material l ayer on the
joining area between the rear lower panel and
the rear extreme c ross member. Paint the affected area.
Moun t t he c onne c t i on e l eme nt s by
performing the dismounting operations in the
reverse order.
1
3
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REAR UPPER STRUCTURE
44
44 - 2
Rear lamp support
DISMOUNTING
Dismount the elements in connection with the
rear lamp support (re ar bum per, rear lamp,
equipping elements). Detach from welding points of the rear lamp
support in connection with:
-s ide panel in the area (2);
-r ear lower panel in the area (3 );
-r ear lower panel and rear extreme cross
member in the area (4).
Straig hten the areas resulted from dismounting
Grind the areas resulted from dismountin g.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the rear lamp
support. We ld the re ar l amp support fol lowing the
welding outlines (2 ), (3) and (4).
Grind the performed welding.
Prot ect t he perform ed weldi ng with an
anticorrosive product. Apply a sealant material l ayer in the joining
area of the rear lamp support with the rear lower
panel and the rear extreme cross member. Paint the affected a rea i n the carriage body
color. Mount the connection elements by performing
the dismounting operations in the reverse order.
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44
REAR UPPER STRUCTURE
44 - 3
1
6
Inner whe el passage
DISMOUNTING
Dismount the elements, which are in c on-
tact with the inner wheel passage ( 1).
Detach the SE CO
2 welding points between
the rear wheel passage and : -backrest lock support in the area (2);
- connection bracket knee in the area (3);
Detach the welding points of the inner wheel
passage in contact with :
-si de frame l i ning, si de panel and
threshold obturator in the area (4 ) ;
-r ear floor in the area (5 );
-r ear longitudinal girder in the area (6).
Straigh ten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the inner
wheel passage.
Weld the inner wheel passage (1) following
the assembling outlines 4, 5 and 6.
Perform SE CO
2 weld between inner wheel
passage and : -backrest lock support i n the are a (2)
(2 weld x 10 mm); -connection bracket knee in the area (3)
(2 weld x 10 mm).
Protect t he welding with a corr osion-
preventing product.
Apply a layer of sealant material, in the
contact area (5) of the inner wheel passage with
the rear floor.
Paint the affected area.
Mounting the conn ection elements by
performing the dismounting operations in the
reverse order.
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REAR UPPER STRUCTURE
44
44 - 4
Side panel
DISMOUNTING
Dismount the elements, which are in c on-
tact with the side panel ( 1).
Detach the welding points of the side panel,
which are in connection with : -side frame lining in the area (2);
-r oof in the area ( 3);
-r ear lower panel in the area ( 4)
- rear extreme cross member in the area (5).
Straigh ten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Apply a layer of 5322 size material on the
joint areas of the side panel with the side frame
lining and the rear lower panel.
Position and center the new element.
Check the correct positioning of the side panel.
W eld the side panel (1) following the welding
outlines 2, 3 , 4, and 5.
Retouch possible deformations.
Grind the performed welding.
Pr otect t he welding with a corr osion-
preventive product. Apply a layer of sealant material in the joint
areas of t he side panel with t he rear extreme
cross member and the rear lower panel. Paint the affected area in the carria ge body color.
M ount the connection elements by
performing the dismounting operations in the
reverse order.
1
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45
TOP OF BODY
45 - 1
R oof
DISMOUNTING
Dismount the elements, which are in con-
tact with the roof (front/rear doors,
w indscreen, hatchback, roof and re ar quar-
ter panel lining).). Detach the welding points of roof (1),
which are in connection with : -roof belt in the area (2 ) ( left/right);
- side frame lining in the area ( 3). (left/
right) -windscreen frame in the area ( 4);
- middle pillar in the area ( 5);
- side panel (left/right) in the area ( 6).
Straighten the areas resulted by dismount-
ing. Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the roof.
W eld the roof following the welding outlines
(2), (3) (4), (5), and (6).
Grind the performed welding.
Pr otect the perform ed welding with an
anticorrosive product. Paint the affected area.
Mount the elements in connection with the
roof by performing the dismounting operatio ns
in the reverse order.
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TOP OF BODY
45
45- 2
Windscreen frame
DISMOUNTING
Dismount the elements in connection with the
windscreen frame (front bonnet, windscreen, left/
right front wing, left/right front door).
Detach the welding points of the windscreen
frame (1), which are in contact with :
- side frame lining and roof belt in the area
(2) left/right; -windscreen lower cross member in the
area (3 );
- front pillar and front pillar lining in the
area (4) left/right
-r oof in the area (5 ).
D etaching is to be performed by means of a
special shar p drill Ø 6 for plate elements.
Straig hten the areas resulted from dismounting
Grind the area resulted from dismounting.
REMOU NT I NG
Position and center the new element on t he
side frame lining (left/right). Clench in 2-3 points by means of sliding tongs.
Joint the front pillar border with windscreen
frame side border (left/right). Perform a spot welding of the windscreen
frame on the outlines (2), (3), (4) and (5).
Perform an additional SE CO
2 welding in the
connection area of the front pillar upper border
with the windscreen frame side border (left/right)
(4 weld x 15 mm).
Check and restore the windscreen frame.
Grind the performed welding.
Protect the performed welding with an anti-
corrosion product. Paint the affected area.
Mount the elements in connection with t he
windscreen frame by performing the dismount-
ing operations in the reverse order.
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46
BODY PROTECTION
46 -1
Engine shield
DISMOUNTIN G
Dismount four M 6x1 – 20 Embase scre ws attached in four (3) M6x1 safety nuts on the
power train support. Release the engine shield (1).
REMOU NT I NG
Perform the dismounting operations in the reverse order.
1
2
3
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47 - 01
47Rear door
F ront door
LATERAL OPENINGS
DISMOUNTIN G
Dismount the elements, which are in connection with the front/rear door.
Dismount the door panel.
Di smount the door wiring protected by sleeve ( 1) and remove i t through the e xistent door
caisson hole. Dismount the attachment screw (2) of the limiting mechanism of the front/rear door.
Dismount the upper hinge axle ( 3) and lower hinge axle (4).
REMOU NT I NG
Perform the dismounting operations in the reverse order.
Grease the hinges with white grease (Te roson).
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