DACIA SOLENZA 2004 Repair Manual

THE M ECHANICAL ELEMENTS CONTROLS
37
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Brake flexible hoses
IMPOSED PRECAUTIONS TO BE RESPECTED WHEN
DISMOUNTIN G – REMOUNTING A RECEIVER
OR A BRAKE FLEXIBLE HOSE
Due to security reasons, in order to avoid brake flexible hose twisting and the risk to get i n
contact with the suspension elements, it is necessary to observe the following operations sequence,
as well as the flexible attachment on the wing lining by means of a stopper, positioned at 135 ± 2
mm, value to be measured from the connection screw of the rigid pipe with the flexible hose.
DISMOUNTIN G
Dismount the connection ( 1) of the rigid pipe (6) from the flexible hose ( 2) till the moment
when the spring (3) is relaxed, having releasing the splinted area (4) of the sustaining support (5).
TIGHTENING MOMENTS (daNm)
X (flexible on caliper) 2.0
Y (attachment screw of the rigid pipe on the flexible 1.5
135 ± 2
1
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THE M ECHANICAL ELEMENTS CONTROLS
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Brake flexible hoses
Unscrew t he flexible from the caliper and after that from the connection with the rigid pipe.
REMOU NT I NG
Assemble the caliper with the caliper fork.
Mount the caliper wedges and then tighten to the required moment the flexible on the caliper.
The flexible hoses must be tighten to the required moment with the rigid pipes, when the front
axle is in the position :
-symmetric wheels (mounted suspension );
- front axle in straight line.
REMARK :
Position the hexagonal area (4) of t he flexible in t he sustaining support (5) so that
it is not mounted twisted. Mo unt the spring (3) and the connection of the rigid pipe on the flexible hose,
observing the required tightening m oment. Purge the brake circuit.
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THE M ECHANICAL ELEMENTS CONTROLS
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Brake pr essure c ontroller
REMARK :
Brake pressure controller is not to be repaired.
DISMOUNTING
Drain of fluid, the braking circuit.
Lift the vehicle by means of a two-column elevator.
Dismount the connection screws ( 1) of the rigid piping on the pressure controller.
Dismount the attachment nuts (2) of the pressure controller support on the carriage body.
Remove the support together with the pressure controller from the carriage body.
Dismount the pressure controller off the support.
R EMOU NT I NG
Remount:
-pressure controller attachment screws on the support;
- attachment nuts of the pressure controller assembly on the carriage body;
- connection screws of the rigid piping on the pressure controller, observing the required
tightening moments.
Purge the braking circuit.
Adjust the pressure controller.
TIGHTENING MOMENTS (daNm)
Attachment nut of the pressure controller assembly on the carriage body 1
Con nection screws of the rigid pipe on the pressure controller 1.5
2
1
3
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THE M ECHANICAL ELEMENTS CONTROLS
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ADJUSTMENT OF TH E BRAKE PRESSURE CONTROLLER FOR
THE PARALLEL BRAKING SYSTEM
Imposed conditions : -the vehicle on wheels
- empty trunk
- one person on board
ADJUSTMENT METHOD
Mount the flexible connection of the FR 501 device at the purging screw of one rear wheel
cylinder. Purge the manometer.
Push the brake pedal to enable reading several times the limiting pressure obtained on the
rear wheels cylinders.
Unscrew the adjustment nut ( A) to distance it from the pushing rod end (B ).
A ct upon the rod end ( B):
- by unscrewing it towards the pushing rod ( C ) in order to increase the pressure in the
rear circuit;
-by screwing it towards the pushing rod (C ) in order to decrease the pressure in the rear
circuit.
Tighten to the required moment ( 0.15 damn) the adjustment nut (A) locked with the pushing
rod end ( B) so that between the lever end a nd the lever ( D) a c learance of L = 0.5 mm to be
ensured.
Brake pr essure c ontroller
SPECIAL TOOLS
FR 501 Purging device
TIGHTENING MOMENTS (d aNm)
Adjustment nut 0.15
L 0,5
DACB
Check several times the limiting pressure obtained on the rear wheels cylinders, which must
be between 28-30 bars.
Dismount the manometer and purge the braking circuit.
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THE M ECHANICAL ELEMENTS CONTROLS
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DISMOUNTING
The dismounting of the gears changing lever shall be performed after dismounting the
centra l c onsole (see chapter 58 – “ Inside accessories”).
Dismount under the vehicle the control lever ( 1).
Dismount inside the vehicle the four attachment nuts (2) of the control case.
Dismount the assembly composed of control case (3) and gears control lever.
G ears control
REMOU NT I NG
Perform the dismounting operations in the reverse order.
Tighten to the required moment :
- the c ontrol case attachment nuts ( 2)-----------------------------------1.2 daNm
- the control ba r connection screw ( 4) with the GB connecting rod ----- 2.7 daNm
- the connection screw ( 5) of the control bar with the control l ever
-----1.2 daNm
Grease t he pa rts of t he j oint composed of control ba r and GB connecting rod with
MOLYKOTE 33M grease.
Introduce in the protection bellows aprox. 10 ml of grease.
AT T E N T I O N !
The tightening of t he connection screw (5) be tween the control bar and the control
lever shall be performed aft er adjustment of t he gearbox control.
4
15
3
2
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THE M ECHANICAL ELEMENTS CONTROLS
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GEARS CONTROL ADJUSTMENT
This is to be performed after mounting the engine-gearbox assembly and the assembly lever-
control case every time when : -dismounting of the engine-gearbox assembly, the control bar or the assembly lever-control
case;
- establishing of failures such as: gear change impossibility or unexpected gear uncoupling,
gears blocking.
For the gear control adjustment the CV 550 device i s to be used.
M ount the CV 550 device on the assembly lever- control case.
A ttach the control bar to the c ontrol lever end.
Place the gear lever in the device seat and fix it in this position by means of the device handle.
Tighten the attachment screw 1 of the bar to the lever at the required moment of 1.2 daNm.
Dismount the CV 550 device from the control box.
Check the gears coupling.
G ears control
SPECIAL TOOLS
CV 550 Linkage adjusting device
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THE M ECHANICAL ELEMENTS CONTROLS
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CLUTCH PEDAL
DISMOUNTIN
G
Release the clutch cable from the pedal cam ( 6) ( after releasing it from clutch control fork).
Clutch and brake pedals
Dismount the safety l ock ( 1) together with the washers ( 2) and (3).
Push the pedals shaft (10) in the arrow direction.
Release the c lutch pedal ( 5) together with the bushing (4).
BRAKE PEDAL
Dismo unt :
- actuating spring ( 7) (which is attached with one end on the clutch pedal, and the other
one on the pedals support ( 18)) ;
- bushings (8), ( 9) and (11);
- pin (16 ) together with the washer ( 15);
- shaft (14) connecting the brake pedal with the servobrake connection fork.
- pedals shaft (10);
- brake pedal ( 12) together with bushing ( 13) and (11).
REMOU NT I NG
Remounting of the brake and clutch pedals is done by performing the dismounting operations
in the reverse order. Adjust the clutch control ( see chapter 37 – “ Clutch control adjustment”).
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THE M ECHANICAL ELEMENTS CONTROLS
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DISMOUNTING
In the engine compartment :
- release the clutch cable ( 1) from the
clutch control fork.
- detach from carri age body clips the
clutch cable.
Clutch cable
TIGHTENING MOMENTS (Nm)
Clutch cable counter nut 8
In the cockpit:
-r elease the c lutch cable ( 1) from the clutch
pedal cam and depress it from the pedals
support.
R EMOU NT I NG
Perform the dismounting operations in the
reverse order. Adjust the clutch control
C LUTCH CONTROL ADJUSTMENT
In order t o adjust the clutch pe dal stroke,
proceed as follows:
- place a gauge to ensure the 15 mm
clearance between the pedal and the pedals
s upport (4);
- tighten t he nut ( 3) on the clutch cable
end, until obtaining a stroke of 29 ± 1 mm at
the clutch disengaging fork by acting upon the
clutch pedal;
- tighten the co unter nut ( 2) to the
required moment of 8 Nm.15
4 1
1
23
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THE M ECHANICAL ELEMENTS CONTROLS
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DISMOUNTING
Dismount the nut and the lock nut from the clutch cable end.
Mount the buffer (1 ).
REPLACEMENT OF CLUTCH CABLE BUFFER
1
R EMOU NT I NG
Remounting is done by performing the dismounting operations in the reverse order.
A djust the clutch control ( see chapter 37 – “ Clutch control adjustment”).
Clutch cable
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THE M ECHANICAL ELEMENTS CONTROLS
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DISMOUNTING
Disconnect :
- battery;
-stop contact connectors.
Dismo unt :
- clutch cable ( 3) from t he pe dal c am
(after it has been released from the clutch control
fork); -servobrake ( see page 37 – 5);
- pedals support attachment nuts ( 1) o n the
cowl panel;
Pedals support
-attachment screw ( 2) of the pe dals
support to the welded support of the driving
post cross-beam;
-clutch pedal ( 4);
-b rake pedal ( 5);
-s top contact ( 6).
Release the pedals support.
R EMOU NT I NG
Perform the dismounting operatio ns in the
reverse order. Adjust the clutch control (see chapter 37
– Clutch control adjustment ).
Check the operation of the stop contact.
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