ESP DACIA SUPERNOVA 2004 User Guide

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
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DRIVE SHAFTS
29BELLOWS TO WHEEL
REMOUNTING
The mounting of the new bellows is to be
pe rform e d by m e a ns of t he PF 573 – 03
device.
Catch the inclined transmission in a vice
w ith soft jaws in ord er to avoid the sha ft
damaging. Engage t he PF 537 – 03 device over t he
tulip of the transmission shaft.
Obturate the small e xtremity of the bellows
and, abundantly grease with automatic
transmission oil or ELF CARDREXA RNT
2 grease: - the all outer surface of t he PF 537 – 01
device - the inner part of t he bellows, especially
its smaller diameter part (this operation is
performed for slipping help).
29 - 8
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30
GENERAL
30 - 8
1
I. FAILURE : RIGID PEDAL (ctd)
On e o f th e
rigid brake
pipes is it
smashed ?
Dismount the bra ke caliper or
the brake cylinder?
Replace the corresponding
rigid pipe.
Are the brake
caliper’s pistons
or the cylinders ones correctly gliding ?
STOP
Replace the defective parts
(with Genuine Spare Parts)
Replace the brake pads,
consequently the bra ke shoes (see bellow situations).Are the brake pads,
consequently the shoes
gasket in good
condition?
The brake linings are to be replaced when
they are: -greasy
-shiny
-not in accordance with the
manufacturer ’s prescriptions (genuine Spare
Pa rts have not been used).
Ye s Ye s
No
No
No
BRAKING SYSTEM DIAGNOSTIC
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30
GENERAL
30 - 13
BRAKE FLUID
PERIODICITY OF THE BREAK FLUID CHANGE
The manufacturing conception of the brakes equipping the Dacia vehicles, especially
the di sks brake type (F 54 inner empty pistons, low qua ntity of fluid in t he c ylinders,
sliding calipers avoiding existence of a fl uid reserve in the less cooled area of t he wheel)
enable t he m aximum re jection of fluid vapori zation ri sk, even in c ase of intensive using of
brakes (mountain are a). The current bra ke fluids are subject in all cases to a slight degradation during the fi rst
months of use by a slight humidity absorpt ion seri es (see the Vehicle Warra nty and
Maintenance Booklet, for brake fluid change)
LEVEL COMPLETION
The wear of brakes pads and shoes generate a gradually diminution of brake fluid level
in its reservoi r. It is useless t o compensate t his diminution, because the level will be re -
stored in the moment of next changing the brake pads and shoes. Obviously, in the mean-
time, the level of brake fl uid in re servoir must not go down bellow the minimal mark.
HOMOLOGATED BRAKE FLUIDS
The mixture i n t he bra king circuit of two non compatible brake fluids may leads to loss
important risks mainly due to gasket damage
In order t o avoid such risks, it is obligatory t o use bra ke fluids checked and approved by
our laboratories and which are accordi ng to Norm SAEJ 1703, DOT 4.
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30
GENERAL
30 - 21
DIAGNOSIS
THE DEVIATION TO THE LEFT OR TO RIGHT AT STABLE SPEED
Pe rform the preliminary checking:
Wheels (front, rear) : Joints clearance:
- pressure - bushings
- dimensions
- types Checking points heights
- balancing - simetri e
A.m.
conditions
are respected
Correct the defi cient
The deviation persists
Checking fi nished
Check the front axle
steering geometry
The deviationpersists
NO
YES
NO
YES
YES
Check the rear axle
parallelism and the alignmentA
Checking fi nished
NO
C HECKING OF THE FRONT AXLE ADJUSTMENT
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31
FRONT BEARING ELEMENTS
31 - 6
BRAKE GASKETS
NOTE
In order to maintain the brake efficiency,
the replacement of the brake pads shall be
made only in complete kit.
Never fit brake pads of diffe rent makes
and different qualities .
DISMOUNTING
Lift t he vehicle by means of a two columns
elevator;
Dismount the front wheel;
Disconnect the wear sensor wire;
Dismou nt : - the safety of the wedges (1);
- the wedges, by sliding them.
Detach the caliper assembly from the fork
together with the flexible hose;
Remove : - the elastic blades - the brake pads
Remount :- the brake pads their places in the fork;
- the elastic blades;
- the caliper;
- the wedges and their locks.
Reconnect the wear sensor wire.
Pr ess several times the brake pedal.
Mount the wheels.
Get down the vehicle from the elevator the
ground. NOTE
It
is forbidden to push the brake pedal
after the calipers were dismounted from
the fork. If the brake pads are not fully used but
on their friction surface, especially i n the
middle pad c hannel, there are material
traces, i t i s recommended t he cleaning of
these surfaces in order to avoid the noise
when braking.
REMOUNTING
Push the c aliper pi ston by means of the
FR 500 s pecial t ool.
SPECIAL TOOLS
FR 500 Pushing piston device
FR 500
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WHEELS AND TYRES
35CARACTERISTICS
1 - 165 - Tire width in mm ( 1 )
2 - 70 - h / l height / width ratio;
4 - R - Radial structure
5 - 13 - Inner diameter in inches (Æ) ;
this is corresponding with the rim diameter
6 - 79 - Charging index
3 - T - Speed index max. 190 km/ h
Symbols speed
M ax speed
R 170
S 180
T 190
U 200
H 210
V 240
ZR more than 240
Stru cture types :
D iagonal No marking
Radial R
D iagonally belted B
TIRES
Identification marking examples: 165 / 70 R 13 79 T
165 / 70 R 13 79 T
1 2 4 5 6 3
35 - 2
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MECHAN ICAL ELEMENTS CONTROL
37
B. DE-BRAKING
After effort ending, the two pistons resume their initial position under the effect of the retainer
springs, while the fluid is coming back and the pressure is decreasing in both circuits.
PRIMARY CIRCUIT – PRESSURE LOOSING
Lack of pressure in the primary circuit leads to the following situation :
The primary piston is a dvancing up to the pin, so is controlling mechanically the secondary
piston. The secondary piston reaches a fluid pressure that shall operate on the piston – linings
assembly moving it t o the right, opening also t he second e xit of t he rear circ uit ( the by-pass
circuit) increasing the pressure for this circuit. In this moment, by means of the transducer, the warning light on the instrument panel is on.
SECONDARY CIRCUIT – PRESSURE LOOSING
Both pump pistons go on. The caliper cylinders of the front brake shall normally operate.
The secondary piston re aches its respective pi n, but the pre ssure will decrease (due to the
failure). BRAKE PUMP
37 - 2
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MECHAN ICAL ELEMENTS CONTROL
37BRAKE FLEXIBLE HOSES
The SUPER NOVA vehicles are equipped with flexible hoses with copper gaskets in order
to ensure the sealing.
PRECAUTIONS IMPOSED TO BE RESPECTED WHENDIS MOUNTING – REMOUNTING A RECEIVER
OR A BRAKE FLEXIBLE HOSE
D ue 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.
37 - 14
TIGHTENING MOMENTS (daNm)
X (caliper flexible) 2,0
Y (the attachment connection screw of the rigid pipe on the flexible) 1,5
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EXTERNAL PROTECTIONS
55
55 - 2
DISMOUNTING
Disconnect
the rear fog spotlights, from the rear wiring.
Dismo unt :
- the nuts ( 1) and the attachment screws (3) of the rear bumper (4) on the carriage body,
by means of lateral supports (2), respectively by the bumper ends on the rear wheels passage.
-the attachment nuts (7) of the counterblade (6) on the carriage body.
D etach the rear bumper (5).
REMOUNTING
Perform the dismounting operations in the reverse order. RE
AR BUMPER
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