2004 DACIA SUPERNOVA Repair Manual

40
GENERAL
40 - 13
CAR
RIAGE BODY CHECKING / STRAIGHTENING BENCH
CELETTE TYPE
To straighten the vehicle body, CE LETTE bench is provided with a traction arm of 10
tons, Caiman type, 250-mm stroke of the hydraulic cylinder, with rapid anchora ge on any
side of the mobile bench ( pi ct. 2 ).
2. CR OSS BARS MODULAR SET ( CAR 502)
CELETTE bench has in its composition, five modular cross bars (pict.3), as follows: - two front cross bars A and B (T shaped) which are always in the same position
(towards front of bench) - pi ct. 4 . - two straight cross bars C1 and C2 and one D cross bar (U-shaped) which may be
placed in differe nt positions subject to the vehicle type. The marke d figures (14……36) are engraved on the mobile bench, every mounting
being supplied with a drawing indicating the exact position of the m odular crossbars subject
to the vehicle type.
( pict. 3 ) ( pict.4 )
( pict.
2)
one.... two... and tree!
A
B
C2D
A
B
C1
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40
GENERAL
40 - 14
CA RRIAGE BODY CHECKING / STRAIGHTENING
BENCH CELETTE TYPE
3.TRACTION ACCESSORIES SET ( CAR 504)
CELETTE bench is equipped with a traction accessories set CAR 504, which a llows
the operator to achieve different a nchoring when a body strengthening is performed (pi ct. 5).
4. SET OF MZ TOWERS AND SPECIFIC SUPPORTS ( CAR 503 +CAR 507)
This kit re presents a MZ system and consists of two elements: - kit of 22 MZ towers, universal CAR 503 – ( see pict.6 )
- kit of specific supports CAR 507
( pict. 6 ) ( pict.
5)
Each MZ tower has an a rrow, which settles
its ori entation on th e cross bar a nd a MZ
reference (pict.7) Example – MZ 080, where:
MZ- measurem ent on OZ axle of the
vehicle.
080 – MZ tower height (in mm)
In the same way as for COMPACT
assembly, the arrow (1) marked on the specific
support must be oriented towards the bench
front part, as follows: - attachment on the right part of the
mobile bench
- attachment on the left part of the
mobile bench
NOTE
The MZ towers may be used also for the checking/ straightening of the c arriage
bodies of other vehicles types, being then necessary the purchasing of the specific supports
for each type of v ehicle.
L
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40
GENERAL
40 - 15
( pict.
7 ) Each specific support is identified by
a number ( 2 ) marke d at the l ower part
and has one or two attachments holes in
the MZ tower ( in t his case you should
take into consideration the specific
diagram from the assembly drawing
supplied together with the kit.
Symbols:
1 – wit h or without dism ounted
mechanical elements. 4 – with dismoun ted mechanical
elements.
NOTE :
Identification and mounting of the
towers on different modular cross bars
and of the specific supports in the MZ
towers (1…20), when repairing a Dacia
SupeRNova body, is t o be performed as
per mounting drawing ( pict.8 and pict.9)
which is supplied together with t his kit.
CAR RIAGE BODY CHECKING / STRENGTHENING
BENCH CELETTE TYPE
( pict. 8 )( pict.9 )
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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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40
GENERAL
40 - 18
CAR
RIAGE BODY CHECKING / STRAIGHTENING
BENCH CELETTE TYPE
Rear axle arm fixing The specific supports (11), (12 ), (13), (14),
(15) and (16) are enabling the positioning,
centering a nd rear a lignment of the ve hicle
on the bench in case of a straightening. These are to be used in all cases, being a
main re fe re nce for ve hi cle se tti ng on t he
bench.
( pict. 16 )
( fig. 17)
Ce
ntering under rear longitudinal girder
The specific supports (17) and (18) are
enabli ng t he po si t i oni ng , c e nt e ri ng , a nd
al ignment of the rear longit udi nal girde rs
(pict.17).
( fig. 18 ) The specific supports (19) and (20) used in
the rear straiteghning, for rear plate positioning
is used in the same time for the vehi c l e
alignment in the front straiteghning when the
vehicle front part is replaced (pict. 18).
R
ear plate fi xing
1314
11121516
1718
1920
( pict. 17 )
( pict. 18 )
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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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