engine DACIA SUPERNOVA 2004 Repair Manual

30
GENERAL
30 - 7
Rigid pedal: when braking,
an increased e ffort for a small
deceleration is perform ed
Ye s Replace: shaft , pedal or
servobrake fork.
Ye s
Ye s
Ye s No
No
No
No
Replace the servobrake(broken membrane)
Replace the servobrake (broken membrane)
Check:
- the integrity of the depre ssion
pipe, consequently of the retain-
ing valve;
- the sealing of the depression pipe
at the servobrake, consequently at
the vacuum pump (inlet manifold).
Is the engine
regime
changing when
braking ?
The e ngine
pedal is rig id
fro m t i me to
time ?
1
Is the connection
sh af t between
the serv ob ra k e
fork and the pedal,
grabed?
At the servobrake
entrance i s the
depre ssion the
imposed one ? I. FAILURE : RIGID PEDAL
BRAKING SYSTEM DIAGNOSTIC
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30
GENERAL
30 - 10
BRAKING SYSTEM DIAGNOSTIC
I. CONSTANT EFFECT TO THE PEDAL
EFFECTS
To u g h pedal:
High effort for small deceleration.
Elastic pedal
In order to di agnose, an i ncident where
the use was normal is t o be analyzed and
two tests are to be perform ed:
1. While driving the vehicle :
Interpretation tes t: pedal stroke/
deceleration rate.
2. While vehicle i s stopped, engine c ut.
Additional test of bra ke pedal press:
Pe rform five c onsecutive pressings on the
brake pedal in order to vacuum the
se rvobrake, before taking into
consideration the test re sult.
Long pedal
The test i s to be performed with stopped
vehicle and cut engine. REMARK:
It is neces sary to perform five
consecutive pressings on the brak e
peda l, in o rd er t o v a cuum t he
s ervobrake before takin g into
consideration the test result.
Floor pedal
The test i s to be performed with stopped
vehicle and cut engine.
REMARK :
Perfor m five consecutive pressings on
the brake pedal, i n order to vacuum the
s ervobrake before takin g into
consideration the test result. POSSIBLE CAUSES
- Assi stance defect
- Brake linings:
- greasy
- stacking to the disk ( non-conform )
- heating, prolonged bra king with c onstant
pedal pre ss
- Stuck piston
- Rigid duct narrowed (flattening)
- Air presence in the c ircui t: de fective
purging
- Internal leak in the braking circuit.
- Leak of fluid from reservoir (external fluid
leak from braking circuit).
Automatic adjustment : ha nd brake c able too
tighten. - Important and asymmetric wear of the
b rake linings
- St roke too ample between the servobrake
pushing rod and the brake pump
- Brake fluid having high temperature.
- Hydraulic leak (check the sealing of
the braking system components)
- Sealing gaskets defects of the two
b rake pump circuits.
- Brake fluid having high temperature
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30
GENERAL
30 - 14
BRAKING CIRCUIT PURGING
AIR ELIMINATION FROM THE H YDRAULIC
CIRCUIT (PURGING)
The air existence in the hydraulic circuit may be noticed by an elastic displacement of
the bra ke pedal, sometimes even, close to the floor. T his fact is more e vident with the
engine stopped.
GE NERA L RECOMMENDATIONS
Always use for completion or total changing, the brake fluid Norm SAE J 1703 , DOT 4.
In case of changing the brake fluid, it is necessary to wash the system with one liter of
industrial alcohol (diluted). Du ring the purging, the brake fluid from the reservoir must not go down bellow the
minimal level marke d on the re servoir.
To perform the operation, one person will stay on the driver place, to push the brake
pedal and the other one will perform the purging (bleeding) at the wheels using a 500 ml
vessel, a tra nsparent plastic tube and brake fl uid for completion.
NOTE
The brake fluid resulted after performing t he purging operation, IS NOT TO BE
RE-USED but only after 48 hours, in order to avoid air-bubbling ge neration on the
hydraulic circuit which shall have as effect an elastic brake pedal.
WORKING PROCEDURE
Place on the purging screw, a transparent tube with its end in a vessel with bra ke fluid
and proceed as follows: - press the brake pedal slowly, di smount t he purging screw, maintaining the full
str oke of the pedal, then tighten the screw and slowly re lease the brake pedal. Repeat the
same procedure until complete cease of air bubbles. Proceed in the same way also for the
other purgi ng places.(take i nto c onsideration t he existence all t he t ime of t he bra ke fl uid i n
the reservoi r)
Observation:
Before beginning the purging procedure, dismount the I.C.P. indicator from the pump,
which shall be remounted at the end of t he operation.
It is important to observe the fol lowing sequence of the purging places:
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MECHAN ICAL ELEMENTS CONTROL
37
The tightness of the servobrake is checked on the vehi cle, with the hydraulic
circuit under operation.
Connect the vacuum meter between the servobrake and the inlet collector by means of a “ T
” type connector. The connecting hose of the vacuum meter shall be as long as possible.
Start the engine and let it idle run for 1min.
Block the air suction hose by means of the MOT 453 device.
Stop the engine.
If air suction lowers with more than 33 mbar (25Hg) in a 15 seconds period, it means there
is a loss at t he retainer valve (replace the valve) or at t he servobrake m embrane (replace t he
servobrake) Dismount the MOT 453 device
Dismount the vacuum hose
Reinstate the connection be tween t he servobrake and the inlet c ollector by m eans of the
vacuum hose. TIGHTNESS CHECKING
SERVOBRAKE
SPECIAL TOOLS
Shutter MOT 453
37 - 8
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MECHAN ICAL ELEMENTS CONTROL
37
HYDRAULIC RECEIVER REPLACEMENT
This operation shall be performed after dismounting of the engine-gearbox assembly and after
disconnecting of the engine from the gearbox.
DISM OUNTING
Dismount the two attachment screws and dismount the hydraulic receiver.
REMOUNTING
Perform the dismounting operations in the reverse order.
Tighten the screws at the required moment of 2.1 daNm.
PHYDRAULIC CIRCUIT PURGING
1. CIRCUIT REFILLING
Check if the clutch pedal is in the “up” position, maintain it by hand if necessary.
Fill the reservoir with brake fluid.
Remove the protection cap of the purging connection 1.
Connect a transparent hose a t the purging connection to recover the brake fluid.
Retrieve the clip 2 (do not definitely remove it in order to limit the movement of the feeding
pipe).
37 - 21
CLUTCH HYDRAULIC CONTROL
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MECHAN ICAL ELEMENTS CONTROL
37
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 a ssembly, t he c ontrol ba r or the assembly lever-
control case;
- establishin g of failures such as: gear change impossibility or unexpected gear uncoupling,
gear 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 c ase;
A ttach the control bar to the control 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. THE GEARS CONTROL
37 - 24
SPECIAL TOOLS
CV 550 Linkage adjusting device
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REPAIR MANUAL
DACIA
RM 524-2 BODYENGINE: E7J
G ERBOX: JH3
TA P V: B 41A, B41B, B41D
Ref: 6001999443 APRIL 2004 English version
The reparation methods prescribed by the manufacturer in the present document are established subject to
t echnical specifications in force at the document issuing date.
These a re subject to modifications brought by the manufacturer at the fabrication of different assemblies,
s ubassemblies or accessor ies of its vehicles.
All rights rese rved to SC Automobile Dacia SA.
Re production or transla ting even partia lly of this prese nt doc ume nt is forbidde n without the writte n
authorisation of AUTOMOBILE DACIA S.A.
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REPAIR MANUAL
DACIA
RM 524-3 SEALING, ELECTRICITY
ENGINE: E7J
G EARBOX: JH3
TA P V: B 41A, B41B, B41D
Ref: 6001999442 APRIL 2004 English version
The reparation methods prescribed by the manufacturer in the present document are established subject to
t echnical specifications in force at the document issuing date.
These a re subject to modifications brought by the manufacturer at the fabrication of different assemblies,
s ubassemblies or accessor ies of its vehicles.
All rights rese rved to SC Automobile Dacia SA.
Re production or transla ting even partia lly of this prese nt doc ume nt is forbidde n without the writte n
authorisation of AUTOMOBILE DACIA S.A.
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Mechanisms and accesoires5
Climatisation6
Garnishing and tack room7
Electr ic equipment8
57 LOWER INTERNAL ACCESSORIESDashboard..................................................... 57-1
Dashboard upper part ................................... 57-3
Central console............................................. 56-4
Documents compartment.............................. 57-5
Ste ering whee l axle hal f-cases...................... 57-6
Inside rear view mirror.................................. 57-7
S un visors...................................................... 57-8
Turning handles............................................ 57-9
Handbrake case............................................. 57-10
59 SAFETY ELEMENTS Front safety belts........................................... 59-1
Re ar safety belts............................................ 59-2
61 HEATING Climat e control asse mbly.............................. 61-1
Housing manifold.......................................... 61-2
Heating radiator............................................. 61-3
C limat e control blower.................................. 61-4
Diagnosis....................................................... 61-5
62 AIR CONDITIONING Generalities.................................................. 62-1
AC unit operating diagram........................... 62-4
Evaporator.................................................... 62-5
Comp ressor................................................... 62-7
Condenser..................................................... 62-8
Pr essure controller........................................ 62-9
Dryer filter tank............................................ 62-10
Unit piping.................................................... 62-11
C limat e control unit...................................... 62-12
Diagnosis....................................................... 62-13
65 SEALING OPENING ELEMENTS Carriage body se aling................................... 65-1
66 SEALING WINDOWS AND SCREENS Glasses sealing............................................. 66-1
Insi de wipers ............................................... 66-2
Outside wipers.............................................. 66-3
71 INTERNAL BODY TRIM Carriage body coverings.............................. 71-1
Fr ont door threshold covering...................... 71-2
Upper front pillar covering........................... 71-3
Re ar door threshold covering....................... 71-4
Mi ddle pillar covering.................................. 71-5
Re ar passa ge covering.................................. 71-6
Re ar wheel passage covering........................ 71-7
Mi ddle pillar lower covering........................ 71-8
Re ar side panel covering............................... 71-9
R oof gasket .................................................... 71-10 Carpets
......................................................... 71-11
Cowl panel noise absorbent ......................... 71-12
72 SIDE OPENING ELEMENTS TRIM Front door panel........................................... 72-1
Re ar door panel............................................ 72-2
74 BACK SEAT TABLES AND PARCEL SHELVES Upper back panel replacement...................... 74-1
75 FRONT SEATS FRAMES AND RUNNERS Front seats.................................................... 75-1
Fr ont seat slides guides................................ 75-2
Fr ont seat armature...................................... 75-3
76 REAR SEATS FRAMES AND RUNNERS Rear bench................................................... 76-1
B ench seats .................................................. 76-2
77 FRONT SEAT TRIM Seats upholstery dismounting...................... 77-1
Back rest upholstery dismounting................ 77-2
78 REAR SEAT TRIM Seats upholstery dismounting...................... 78-1
Back rest upholstery dismounting................ 78-2
80 BATTERY - FRONT HEADLIGHTS Battery... ...................................................... 80-1
Head lamp asse mb ly..................................... 80-4
F og lamps.................................................... 80-5
Bulbs r eplacement....................................... 80-6
Headlamps adjustment................................. 80-7
81 REAR AND INTERIOR LIGHTING Bulbs r eplacement........................................ 81-1
Bulbs ............................................................ 81-2
Diagnostic.................................................... 81-3
Cockpit fuse box.......................................... 81-6
82A HORN - ENGINE IMMOBILISER Gene ralities.................................................. 82A-1
Key head repla ceme nt.................................. 82A-6
E.C.U. decoder repla ceme nt........................ 82A-7
Antistarting bushing replaceme nt................ 82A-8
RF remote control for blocking/unlocking
t he doors...................................................... 82A-9
Electric control unit injection repla cement... 82A-10
Pr ocedures.................................................... 82A-11
Diagnostic..................................................... 82A-17
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82B HORN - ENGINE IMMOBILISERGene ralities.................................................. 82B-41
Sy stem functionning..................................... 82B-42
The pin code................................................. 82B-43
The system’s memory.................................... 82B-44
Functional checking of the system................ 82B-45
Table 1.......................................................... 82B-47
Table 2...........................................................82B-49
Dismounting - remounting of the
antiintrusion UCE......................................... 82B-51
Si rene dismounting - remounting.................. 82B-52
Dismounting - remounting of the
hood conta ct ................................................. 82B-53
Vo l u m e sensor
dismounting - rem ounting............................. 82B-54
83 INSTRUMENT PANEL Instrument panel (until 01.06.2001).............. 83-1
Connectors (until 01.06.2001)....................... 83-2
Instrument panel (after 01.06.2001).............. 83-3
C onnectors (until 01.06.2001)....................... 83-4
Instrument panel replacement ........................ 83-5
Dismounting/remounting speedometer
cable (flexible shaft)...................................... 82-7
Diagnostic...................................................... 83-9
F uel leve l transmitter..................................... 83-10
84 CONTROLS - SIGNALLING Anti theft mechanism.................................... 84-1
Under wheel control module......................... 84-3
Fog lamps switch.......................................... 84-5
Rear windows defrosting switch
(impulsional type)........................................ 84-6
Hazard switch............................................... 84-7
Doors closing switch..................................... 84-8
AC starting buton.......................................... 84-9
85 WINDSCREEN WIPERS Windscreen wiper mechanism....................... 85-1
Diagnostic...................................................... 85-5
.
86 RADIO General.......................................................... 86-1
Connectors..................................................... 86-4
87 ELECTRICAL ASSISANCE EQUIPEMENT Windscreen washing....................................... 87-1
89A ELECTRICAL DIAGRAMS Generalites.................................................... 89A-1
Functional diagrams list................................ 89A-10
Electric components index............................ 89A-12
Couplings list. Mass index............................ 89A-14
Location of ele ctric coupling on the vehicle
Mass attachments on the vehicle................... 89A-15 Location of ele ctric coupling on
the vehic le................................................... 89A-16
Cockpit fuse box......................................... 89A-18
Fu
se box from engine compartment............ 89A-22
Wires functions index in connector s and
couplings...................................................... 89A-24
C onnectors and connections wires function.. 89A-27
Wires functions explanation......................... 89A-102
89B ELECTRICAL DIAGRAMS Functional diagrams list................................ 89B-1
Electric components index............................ 89B-3
Couplings list. Mass index............................ 89B-4
Location of ele ctric coupling on the vehicle
Mass attachments on the vehicle................... 89B-5
Location of ele ctric coupling on
the vehic le......................................................89B-6
Cockpit fuse box............................................89B-8
Fu se box from engine compartment..............89B-12
Wires functions index in connector s and
couplings....................................................... 89B-14
C onnectors and connections wires function...89B-17
Wires functions explanation.......................... 89B-90
89C ELECTRICAL DIAGRAMS Functional diagrams list................................ 89C-1
Electric components index............................ 89C-3
Couplings list. Mass index............................ 89C-4
Location of ele ctric coupling on the vehicle
Mass attachments on the vehicle................... 89C-5
Location of ele ctric coupling on
the vehic le......................................................89C-6
Cockpit fuse box............................................89C-8
Fu se box from engine compartment..............89C-12
Wires functions index in connector s and
couplings...................................................... 89C-14
C onnectors and connections wires function...89C-17
Wires functions explanation.......................... 89C-90
89D ELECTRICAL DIAGRAMS Generalites................................................... 89D-1
Functional diagrams list............................... 89D-6
Electric components index........................... 89D-8
Couplings list. Mass index........................... 89D-9
Location of ele ctric coupling on the vehicle
Mass attachments on the vehicle .................. 89D-10
Location of ele ctric coupling on
the vehic le.................................................... 89D-11
Cockpit fuse box........................................... 89D-13
Fu se box from engine compartment............. 89D-17
Wires functions index in connector s and
couplings...................................................... 89D-19
C onnectors and connections wires function.. 89D-22
Wires functions explanation.......................... 89D-91
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