steering wheel DACIA SUPERNOVA 2004 Repair Manual

21 MANUAL GEARBOXSecti ons.......................................................... 21-1
Identification ................................................. 21-2
Tightening moments...................................... 21-3
Ratios ............................................................ 21-4
Capacity, lubricants....................................... 21-5
Particul arities................................................. 21-6
Ingredie nts..................................................... 21-7
Parts of systema tic replacement.................... 21-8
S pecial tools.................................................. 21-9
Gearbox dismounting ................................... 21-10
29 DRIVE SHAFTS Front transversa l transmission........................ 29-1
Bell ows - Be aring assembly to
t he gearbox.................................................... 29-4
Bell ows to wheel........................................... 29-7
Be llows to gearbox....................................... 29-12
Bell ows to wheel........................................... 29-15
30 GENERAL General principle sc hedule
of the brake circuit........................................ 30-1
Tightening moments...................................... 30-2
Com position and dimensions
of the ma in braking system elements............ 30-6
Br aking system diagnostic............................ 30-7
Br ake connections and se werage.................. 30-12
Br ake fluid.................................................... 30-13
Br aking circuit purging................................. 30-14
The inf luence of the front axle angle s on
t he road behaivior (vehicle comportment)
and on tyres wear........................................... 30-16
Prelimi nary checking..................................... 30-17
C hecking of the front axles adjustment......... 30-19
31 FRONT BEARING ELEMENTS Characteristics... .......................................... 31-1
Sus pension arm... .......................................... 31-2
Elastic bushings of suspension arm............... 31-4
Sus pension ball joint..................................... 31-5
Br ake gaskets................................................ 31-6
Br ake caliper................................................. 31-7
Br ake disk..................................................... 31-9
St eering knuckle............................................ 31-10
St eering knuckle bearing. .............................. 31-12
Fr ont suspension............................................ 31-13
Shock absor ber, Sprint. ................................. 31-14
Sp ring assembly shock absorber................... 31-15
Anti-roll bar................................................... 31-17
33 REAR BEARING ELEMENTS Characteristics............................................... 33-1
Rear axle....................................................... 33-2 Re
ar suspension............................................ 33-4
Shock absorber............................................. 33-5
Spring ........................................................... 33-6
Br ake drum................................................... 33-7
Br ake cylinder.............................................. 33-8
Br ake shoes.................................................. 33-10
Be aring (25 x 52 x 37)................................ 33-12
35 WHEELS AND TYRES Characteristics.............................................. 35-1
Wheels balancing......................................... 35–4
36 STEERING ASSEMBLY Axial ball joint............................................. 36-1
Steering box................................................. 36-3
Pus her........................................................... 36-4
Noise absorber bearing................................. 36-5
Bell ows......................................................... 36-6
Deformable lower shaft................................ 36-7
Ste ering weel position adjustment................ 36-9
37 MECHANICAL ELEMENTS CONTROLS Brake pump.................................................. 37-1
Servobrake................................................... 37-6
Air filter – se rvobrake reta iner valve........... 37-9
Handbrake adjustment.................................. 37-10
Handbrake control lever............................... 37-11
Handbrake secondary cable.......................... 37-12
Br ake flexible hoses..................................... 37-14
Br ake pressure controller.............................. 37-16
clutch hydraulic control................................ 37-19
The gear control........................................... 37-23
Pe dals support.............................................. 37-25
Acceleration pedal....................................... 37-26
Acceleration contr ol cable........................... 37-27
Transmission2
Chasis3
SION
LL
NT
vnx.su

SPECIFICATIONS
01
VEHICLE IDENTIFICATION
a.. Manufactu rer identification code;
b. Code of the vehicle;
c. Gearbox ty pe code;
d. Engine type code and driving location ( according to VIN code structure);
e. Vehicl e code;
f. Trailer ma ximum authorized weight without braking system;
g. Homologation number for the importer country;
h. VIS sign-one character for year model code + 7 characters for the chassis manufacturing number;
i. Maximum technical admissible weight of the loaded car;
j. Maximum admissible weight with trailer with braking system;
k. Maximum technical admissible weight on front axle;
l. Maximum technical admissible weight on rear axle.
LABEL T YPE OVAL PLATE
The se lf- adhesive label type oval plate is stuck on the right lateral side surface of the
dashboard. This enables the identification of the vehicle type and of its equipment, being exclusively
used fo r after-sale activity.
01 - 3
1,1
2,1 2,2
4,1 4,2
The reading of the codes marked on the oval plate type label
Caption:
Line 1
1.1 Cod type auto APV (after-sale):
B41A(E U 9 6 ) B41B(EU00) B41D(1 5 .04)
Line 2
2.1 Le vel of equipping: E0, E1, E2, E3
2.2 Options eq uipping code:
Line 4
4. 1 Technical definition code, driving place.
S2 : Left hand drive
4.2 Options equipment code: A: Normal suspension K: Without pre-filter
C : Temperate climate M: Steering mechanical system
E: Warm climate R: Without variable shock absorber
F : Normal heating T: Without plate corrector
G : Air conditioning V: Without wheels anti blocking (ABS)
B = represents body type
A ,B,D = represents engine type E7J, 1397 cmc, front wheel
drive type, mechanical gearbox.
Attention
Do not unstuck or damage the label from the lateral side surface of the dashboard. This
label represents the only way of vehicle identification needed to the after sale services, for a
period of 8 (eigh t) years from the purchasing date.
vnx.su

LUBRICANTS CONSU MABLES
04
ProductPlace where it is used
OILING (GREASING)
MOLYKOTE ”BR2”
(LOCTITE 8103) Front transmission pinion grooves
Grease Right transmission joint G.I
ELF CARDREXA RNT2 Transmission joint G.E.
Grease
MO LY K OTE 33M Gearbox control protection bellows
Grease
Li C a Pb t ip II c u MoS
2Steering rack, pinion, oil seal ring( steering box)
SEALING
LOCTITE 518 Water pump Support thermostat
Crankshaft half crankcase
Gearbox half crankcase assembling
Thread of the reverse driving contact.
Crankshaft no.1 bearing cap
LOCTITE 5900
(RHODORSEAL 5661) Engine lower crankcase
SOLDERING
LOCTITE 270 Nut of primary shaft
(FRENBLOC) Screw of secondary shaft Speed V fix pinion grooves
Speed V hub grooves
LOCTITE 549
(AUTOFORM) Fly wheel seating surface on the crankshaft CLEANING
LOCTITE METALLREINIGER
(DECAPJOINT) Cylinder head gasket surface cleaning
04 - 1
CONDITI
ONS
vnx.su

VALUES AND SETTINGS
07DIMENSIONS UNDER CARRIAGE BODY
DIMENSIONS UNDER CARRIAGE BODY CONDITIONING
ADJUSTMENT OPERATIONS OF THE STEERING ANGLES
H 1, H4 - distance between the wheel center to the ground.
H2 - distance from the girder lower part at the ground to the front wheels axis level.
H5 - distance from the attachment screw axis of the rear axle a rm, to the ground
07 - 8
H5
vnx.su

VALUES AND SETTINGS
07C HECKING VALUES OF THE REAR AXLE ANGLES
07 - 10
ADJUSTMENTSNot adjustable
Not adjustable
REAR AXLE
POSITION
Rele ase
Rele ase
H4 - H5 = 20
VALUES
0
0 ... 00 30’
1 +/- 0,5 mm
ANGLES
CAMBER ( nega tive)
P ARALLELISM
( toe in )
TIGHTENING POSITION
OF TH E ELASTIC
BUSHINGS
For the values checking of the front axle angles, consequently the rear axle angles, the vehicle
must:
- to be placed with the wheels on the rotating plates ( of the bench ) being in horizontal plane;
- to ensure its braking;
- to check its suspension for vehicle setting at its free height;
- to compress its front axle at half loading ( by means of the compressing device DIR 500);
- to check its suspension for vehicle setting at its free position;
- steering brought at middle point and the steering box blocked in this position;
These op erations are followed by the optical device attachment on the vehicle, observing the
instructions of the steering angles checking bench manufacturer.
vnx.su

ENGINE E7J-A-2/6010
10 - 2
ENGINE AND LOWER ENGINE UNITS
MOTOR-PROPELLING GROUP
Di smounting and re -mounting the motor-propelling group i s done at the upper pa rt of the
engine compart ment by means of a moving lift ing device. C
OUPLES FO R S
CRE W-FIXING (daNm)
Screws for fixing right-side stand on engine 6,2
Hydro- elastic buffer attachment nut 3,7
Screw-nut for left-side elastic buffer 6,2
Wheel sc rews 7,5
Screws for fixing motor-propelling group-battery stand 2,1
Screw-nut for fixing small connecting rod on steering traverse 6,2
Screw for fixing anti-swing connecting rod on gearbox case 10,5
Control bars attachment screw on gearbox connecting rods 2,7
Car is placed on a lift-stand with two columns;
The fol lowing are taken down: battery, air-
filter case, engine bonnet, front wheels; Oxygen probe connector is taken off;
Dismantle: therm ic protection screen, cata-
lytic convert er on the exhaust collector;
DIS M O UNT ING
The fol lowing are eva cuated:
-the cooling circuit at the bottom par t
of the radiator ;
-the oil in the gearbox ;
-the oil in the engine, if necessary.
The fol lowi ng are ta ken dow n: -engine shield;
-the screws that fasten the catalyti c
converter on the stand;
-the pipe-collar between the catalyti c
converter and the trigger ;
-the catalytic converter;
-the anti-swing auxiliary connectin g
rod.
vnx.su

ENGINE E7J-A-2/6010
10 - 37
ENGINE AND LOWER ENGINE UNITS
TIG H TENING CO UPL E S (daNm)
Screws for fixing at front of motor-propelling frame 6.2
Screws for fixing at back of motor-propelling fram 10.2
Lower crankcase screws 1
Screws for fixing steering wheel lower axis 1.4
Screws of wheel 7.5
Screw of the ball-and-socket joint 5.5
Screw-nut of the steering ball-and-socket joint 3.5
Screw for fixing anti-swing auxiliary connecting rod (on frame) 6.2
Screw for fixing anti-swing auxiliary connecting rod (on gearbox) 10.5
D
IS M O UNT ING
The c ar i s placed on a l ifting stand with
two columns; The battery i s disconnected;
The engine is emptied of oil;
The engine-shield is taken apart ;
To take apart :
-front wheels;
-screw-nut for fixing the lower steer-
ing wheel axis on the pinion of t he steer-
ing case; -the steering ball-and-socket joints
and the arm ball-and-socket joints; -side clearance devices;
-thermic protection screen;
-catalytic convert er;
-front bumper ba r;
-anti-swing auxiliary connecting rod.
The screws for fixing the motor-propelling
s et fra me are taken a part, and the frame is
lowered; The lower c rankcase is taken apart.
R
E-MOUNT ING
The lower c rankcase is cleaned.
A ca. 3 mm-thick girdl e of RHODERSEAL
5661 is applied, as in the adjoining drawing. Do not forget to replace the two cres-
cent-sha ped fitti ngs at the e nds of the
crankcase.
Mind that the relative displacement be-
tween the lower crankcase and the cylin-
d er crankcase, along the gearbox-assem-
b ly surface, should not exceed 0.3 mm.
LOWER CRANKCASE MOUNTED ON THE CAR
LOWER CRANKCASE
vnx.su

DRIVE SHAFTS
29
FRONT TRANSVERSAL TRANSMISSION
DISMOUNTING - THE SIDE TO WHEEL
Loosen the left wheel screws.
Lift the vehicle on an elevator with two columns.
Di smount the wheels.
Di smount the scre ws that attach the brake disk assembly on the steering knuckle.
Un screw the transmission nut by means of the RO 604 – 01 device.
Di smount :
- the nut of t he steering ball joint;
- steering ball joint from the steering knuckle, by means of the PF 476 extractor; the
attachment screws of the steering knuckle on the shock absorber end. S
PECIAL TOOLS
- RO 604-01 Hub immobilizing device
- PF 476 Ball joint extractor
TIGHTENING MOMENTS (daN/m)
- Transmission nut 21\
- Screw for fixing the bellows lid on the gearbox 2,5
- Wheels attachment screw 7,5
- Screws, nuts for fixing the steerin g knuc kle on the shock absorber 7,5
- Screw for fixing the caliper on the steeri ng knuckle 6,5
- Nut for steering ball joint 4
Pu sh the transmission in the steering knuckle and incline the latter.
Di smount the transmission, the wheel side.
29 - 1
vnx.su

DRIVE SHAFTS
29
FRONT TRANSVERSAL TRANSMISSION
REMOUNTING – THE SIDE TO THE GEARBOX
The left side
Engage the t ransmission GI joint in the ge arbox (the transmission position as horizontally
as possible).
Mount the thre e attachment screws of the bellows lid on the gearbox.
The right side
Grease the t ulip fra me grooves (the grooves area) and t he tra nsmission shaft of t he
gearbox with transmission oil.
Engage the transmission GI joint (the tulip) on the transmission shaft of the gearbox
(the tra nsmission position must be as horizontally as possible).
REMOUNTING – THE SIDE TO THE WHEEL
For both sides
Engage the transmission in the steering knuckle, this one being necessary to freely enter,
so that threaded area of the steering knuckle is allowing to remounting the transmission nut.
Pe rform then the dismounting opera tions in the reverse orde r.
Ob serve the tightening moments.
Remount the brake disk assembly.
Refill the gearbox with oil.
Pr ess several times the brake pedal to enable caliper piston coming in contact with the
brake pads.
29 - 3
vnx.su

DRIVE SHAFTS
29
BELLOWS TO WHEEL
JOINT TOWARDS WHEEL
1. Steeri ng knuckle casing ass.
2. Retainer star
3. Tripod to the wheel
4. Tulip shaft
5. Maintaining collars
6. Rubber protection bellow S
PECIAL TOOLS
GE 86 joint bellows replacement device PF 537-03
DISMOUNTING
Dismount the two maintaining collars
off t he be l lows by means of t wo rods,
locally manufactured (see the dra wing) Cut and remove the damaged bellows.
Remove as much grease as possible.
Mark one of the groove routes of the shaft
subject to its working corresponding clog by
marking w ith a centre punch on casing outer
conse quently on the shaft.
Detach th e connection be twe en the
transmission shaft and the steering knuckle
casing, lift ing one by one the arms of the
reta ining star from the three stamps performed
on the pe tals of the shaft tulip.
WHEN DISMOUNTING, DO NOT DEFO RM
THE ARMS OF THE RETAINING ST AR
Retrieve the head and the spring from the
tripod to wheel.
29 - 7
Left
transmi ssion
vnx.su