2004 DACIA SOLENZA open bonnet

GENERAL
Lower structure composing elements........... 40-1
Upper structure composing elements........... 40-2
Ca rriage bo dy remo vable elem ents.............. 40-3
Op enings clea rance ...................................... 40-4
Repairing general conditions ...................... 40-9
We ldin g ty pe s an d pa rame ters ..................... 40-10
Collision diagnosis....................................... 40-12
Ca rriage bo dy checking. ............................... 40-16
LOWE R STRUCTURE
Fr on t lo ngitu dina l gird er.............................. 41-1
Fr on t an ti-sh ock cr o ss memb er.................... 41-3
Re ar longitudinal girder............................... 41-4
FRONT UPPER STRUCTURE
Fr on t wi ng .................................................... 42-1
Front wing lining................. ......................... 42-2
Ra diator upper cro ss me mber...................... 42-3
H ead lamp su pport ........................................ 42-4
Wind scre en lowe r cro ss memb er................. 42-5
Dr iving post cro ss memb er.......................... 42-6
SIDE UPPER STRUCTURE
Front pillar ................................................... 43-1
Mi ddle pillar ............................................... 43-2
REAR UPPER STRUCTURE
Rear lower panel ..... .................................... 44-1
Re ar lamp support ....................................... 44-2
In ner wh eel pa ssage..................................... 44-3
Side panel .................................................... 44-4
TOP OF BODY
Ro of ............................................................ 45-1
Wind screen fram e ....................................... 45-2
BODY PROTECTION
Engine shield ............................................... 46-1 LATERAL OPENINGS
Rear door / Front door........ . ......................... 47-1
NON – LATERAL OPPENINGS
Fr on t bo nnet ................................................. 48-1
Ha tchba ck.................................................... 48-2
MECHANISMS OF LATERAL OPENINGS
Front door-opening mechanism withelectric
control .......................................................... 51-1
Front door-opening mechanism withmanual
control .......................................................... 51-2
Rear door-opening mechanism with electric
co ntro l .......................................................... 51-3
Rear door-opening mechanism with manual
co ntro l ........................................................ 51-4
Front door electric window regulator .......... 51-5
Front door manual window regulator .......... 51-6
Re ar door window regulator ........................ 51-7
Lock ............................................................ 51-8
MECHANISMS OF NON LATERAL
OPENINGS
Front bonnet lock..... ..................................... 52-1
Ha tchb ack lock ............................................ 52-2
Pneumatic balancing device .. ..................... 52-3
GLASSES
Wind scre en glass ......................................... 54-1
Ha tchb ack glass ........................................... 54-3
Front door glasses..... .................................... 54-4
Rear door glasses ......................................... 54-5
OUTSIDE PROTECTIONS
Front bumper.......... ....................................... 55-1
Rear bumper.......... ........................................ 55-2
Hatchback handle ornament. ........................ 55-3
Body4
40
41
42
43
44
45
46
47
48
Mechanisms and accesoires5
51
52
55
54
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43 - 01
43Front pillar
SI DE UPPER STRUCTURE
DISMOUNTIN G
Dismount the elements that are in contact
w ith the front pillar (front door, front bonnet,
front wing). Detach the welding points of the front pillar
(1), which are in connection with :
-side frame lining in the area (3) ;
- windscreen frame in the area (3)
- front pillar lining in the area ( 4).
Straighten the areas resulted by dismount-
ing. Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element on the
side frame lining. Clench in 2-3 points by m eans of sliding
tongs. Joint the front pillar border with side bor-
der of the windscreen frame. Wel d t he fro nt pi l l a r, fo l l owi ng t he
assembling outlines ( 2), (3) and (4) .
Pe rform an additional welding SE CO
2, in
the front pillar connection area with:
- side frame lining (6 weld x 15 mm);
- windscreen frame (4 weld x 15 mm);
- front pillar lining (6 weld x 15 mm).
Mount temporarily the front door, observin g
the openings clearance.
Weld the hinges on the front pillar (continuos
weld on all hinges sides).
Grind the performed welds.
Pr o t ect the perf ormed weld with a
corrosion-preventing product.
Mount the connection elements by
performing the dismounting operations in the
reverse order.
2 3
4
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52
52 - 1
MECHAN ISMS OF NON LATERAL OPENINGS
Front bonnet lock
3
4
2
1
TIGHTENING MOMENTS(daNm)
Attachment screws of the bonnet lock hock
and lock 0.7
-attachment screws (4) of the bonnet
lock on the ra diator upper cross beam. Release the opening control cable (5) from
the lock.
Remove the obturator ( 6) and release the
cable from the opening handle (8).
DISMOUNTING
Dismount :
- attachment screws (2) of the bonnet
lock (1) to the front bonnet lining; Di
smount the attachment screws (7) of the
handle (8) on the side frame lining.
REMOU NT I NG
Perform the di smounting operations in the
reverse order.
Required tightening moment for attachments
screws of the lock hook and lock is of 0,7 daNm.
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80
BATTERY - FRONT HEADLIGHTS
80 - 11
Disconnect the (-) plug of the battery;
Dismount
the headlamp adjusting control from the turning lamp-headlamp assembly:
- pull backward the gasket of the headlamp adjustment corrector ( 1);
- detach from clips the protector (2) of the headlamp adjustment mechanism;
- loosen the locking nut ( 3);
- detach from clips the he adlamp adjustment control cable ( 4) from the headlamp
adjustment corrector and then from the fork (5);
Dismount the headlamp adjusting control from the other turning lamp-headlamp assembly .
Detach from clips the headlamp adjustment control cables and cut the attachment collars.
Dismount the headlamps adjustment control button.
Dismount the attachment nut of the headlamp adjustment control on the dashboard.
Dismount the bonnet opening control cable from the opening handle (see chapter 52).
Detach from clips, by means of a straight screwdriver, the cables passing bushing from the
cowl panel.
Remove the headlamps adjusting control cables from the cowl-passin g hole. Mark the mounting
position of the headlamps adjustment control cables.
REMOU NT I NG
Insert the headlamps adjusting control cables through the cowl-passing hole, observing the
existent position prior to dismounting.
Insert the bonnet opening control cable through the cables passing bushing.
DISMOUNTIN G1
2
V
56 34
Replacement of the headlamps mechanic adjustment control
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BATTERY - FRONT HEADLIGHTS
80
80 - 12
Replacement of the headlamps mechanic adjustment control
Attach on the cowl panel, by means of clips, the cables passing bushing, ensuring the cockpit
co mpartment sealing against possible water drain along the cables passing bushing.
Mount the bonnet opening control cable in the opening handle (see chapter 52). Position the
headlamp s adjustment control on the dashboard.
Mount the attachment nut of the headlamps adjustment control on the dashboard.
Mo unt the headlamps adjustment control button and turn it in the position “3”.
Mount the headlamp adjustment control to a turning lamp-headlamp assembly :
-a ttach in clips by means of a straight screwdriver, the headlamp adjustment control cable
in fork (5) a n d t h en in the headlamp adjustment corrector;
- tighten initially the cable by hand till the fork ( 5) is in contact with support ( 6) so that fork
is remaining at max. 0.5 mm again st the support;
-block the headlamp adjustment cable by means of the nut ( 3);
-a ttach in clips the protector ( 2) o f t h e headlamp adjustment mechanism;
- position correctly the gasket of the headlamp adjustment corrector – the vertical adjustment
screw ( V) mu st come out through the gasket.
Mount the headlamp adjustment control of the other turning lamp-headlamp assembly.
Attach in the attachment points, by means of clips, the headlamps adjusting control cables,
replace and mount the attachment collars, observing the mounting position prior to the dismounting.
Keep a distance of approximate 40 mm
± 10 mm between the right cable and the cylinder
no .1 spark plug cable, in order to avoid the loses due to electric-magnetic induction.
Reconnect the battery ( -) term inal.
Switch on the headlamps and check the operation of the headlamps mechanic adjusting control.
The adju stment of the luminous spot dip of the headlamps in the downward sense of the vehicle
loading condition is to be performed by bringing the headlamps adjusting button in the “ 0” position
an d then in the desired condition.
REMA RK : The r equired tighteni ng moment of the attachment nut of th e headlamps
adju stment control on the dashboard: 2 Nm.
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