lock DACIA SUPERNOVA 2004 Owner's Manual

19 - 10
19
COOLING - EX HA U ST - FU EL TANK
COOLING FAN REPLACEMENT
for vehicles without air conditioning
6 5
4 3 7
1
2
DISMOUNTING
Di
sconnect the (-) plug of the battery.
Di sconnect the cooling fan connector (7).
Dismount the three-attachement screws (6) of the cooling fan on the radiator, recovering the
attachement buffers (2), cross-pieces (3) and the washers (4) and (5).
Remove the cooling fan assembly (1).
REMOUNTING
Check the condition of the fan propeller, cooling fan electric motor, bushings and washers.
Tighten the attachement screw (6) of the assembly.
Connect the cooling fan connector (7).
Connect the battery pl ug (-). In case the vehicle is equipped with progammable radio-
cassettes, electronic clock, etc, these are t o be reset before re turning t he vehicle to the
client.
Check the cooling fan opera tion: start the ve hicle e ngine and disconnect t he water tem-
perature sensor. The cooling fan must start. Reconnect the water tempera ture sensor, then
by means of the CLIP tester, erase the memori zed failure related to the water t empera ture
sensor.
FAILURES
ERASING
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19 - 17
19
COOLING - EXHA U ST - FUEL TANK
The fuel tank has a watertight stopper; the inlet for the fi lling with unleaded fuel has a
filling orifice incompatible with a classical filling gun (as lead has a negative effect on the
anti-pol lution system, the oxygen probe and the catalyst).
THE ANTI - TILT VA L V E
In case the car is tilted / overthrown, the valve gets blocked, thus avoiding petrol from spilling
towards the carbon canister or the filling inlet.
T
HE SECURITY VALV E
In case the petrol vapour recycling circuit is stopped up, the security valve avoids over-pres-
sure or under-pressure in the tank. It is mounted with the red-marked end towards the joining tube “T”, and with the white-marked
en d towards the tube linking it to the filling inlet.
TANK FU EL DESCRIPTION
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CV JH3 - 05021
MANUAL GEARBOX
21 - 12
Dismount
the fixed pinion of the 5 th gear
by means of the C.V. 1000 extra ctor a nd
the body e xtractor C.V. 22 -01.
The hub of the 5 th step synchronizer is
extracted by means of the C.V. 1170 extractor.
Dismount the synchronizer ring of the 5
step, the inner bushing of the pinion, the pinion
an d its supporting washer.
The gearbox is set in the dead point, then
engage the 3-d step.
Di smount the external screws fixing the
crankcase of the m echanisms and blocking
pin of the reverse driving pinion axle. Dismount the reverse driving contact ( B).
GEARBOX DISMOUNTING
C.V. 1170
C.V. 1000
C.V. 22 -01
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CV JH3 - 05021
MANUAL GEARBOX
21 - 13
In order to recover t he balls and t he locking
s prings of the shafts, two magnets placed in the
C orifices are used.
Pull the control shaft towards exterior.
The crankcases are separated.
Rotate to the left the shaft – reverse driving
pinion assembly and dismount the control reverse
driving shaft velocity 5-th step. T
ake out the fork pin 3-4 by means of the
C.V. 949 device and dismount the a xle and
3-4 fork assembly. Simultaneously, dismount the primary shaft
and secondary shaft assembly with the axle
and 1-2 fork.
Place vertically the secondary shaft, with
the pinion of the 1 step downwards, so that
the other pinions will not fall. Recover the locking pi ns ( A) and ( B) of
the command axles.
GEARBOX DISMOUNTING
Easy lift the primary shaft and di smount the
shaft and reverse driving pinion assembly .
C.V. 1170
C.V. 94 9
A
B
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CV JH3 - 05021
MANUAL GEARBOX
21 - 24
The internal control
axles must not show any deformations or wear on the milling for locking
ball, and their sliding on bearings must be done make freely, without excessive clearance.
The contact surfaces of the forks with collar of the rocking must not show either deformations or
wear. Ensuring of the control forks axle is performed by means of the balls and springs located in
the holes made in the mechanisms crankcase.
The locking of the control axles is done by means of some cylindrical rolls mounted inside the
clutch–differential crankcase.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 26
The assembling surfaces must be flat (small
imperfections can be eliminated by means of a thin
file). Place the a xle and 1-2 fork assembled on the 1-
2 sliding collar of the secondary shaft.
The two shafts (primary and secondary) are taken
together with the fork and 1-2 axle and positioned
at the same time into the clutch – differential crank-
case.
The c rown and the secondary shaft are rotated
until the end of the secondary shaft fits into the bear-
ing.
Mounting the blocking roll of the shaft ˚ (A).
With the 1 – 2 axle in free position, the following
are mounted:
- synchronizing a ssembly 3 – 4 together axle
and 3 – 4 fork;
- mount the for pin 3 – 4 by means of the CV
949 device. Mount the blocking roll of the 5 th step axle ( B).
A
B
GEARBOX DISMOUNTING
CRANCKASE ASSEMBLING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 27
Check the positioning of t he
5 th gear oi ling
collector and of the aerating connection.
Additionally , ensure (check) if the aerating tube is
not damaged or clogged. Apply a layer of LOCTITE 518 on the ga sket
su rface between the clutch crankcase and the
mechanism crankcase. Engage the 3 -d gear step.
M ount the spring and the 5 th gear step locking
ball into the crankcase of the mechanism.
Press the locking ball and mount the mechanisms
crankcase. Ensure the correct positionin g of the two
centering bushings and of the magnet Mount the springs and the locking balls 1-2 and
3-4 in t he m echanisms crankcase, t hen the false
axes A with a 13 mm diameter a re introduced.
Than mount the followings:
- the c ontrol a xle for t he 5 gear a nd reverse
driving (A);
- the axle a nd the reverse driving pinion (B)
assembly , by easy lifting the primary shaft.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 28
REMARK :
The tightening at t he required moment of al l t he screws must be done i n no
more than 30 minutes after the mounting of the mechanisms crankcase, because of the
polymerization of LOCTITE 518.
Mount the a ttachment screws and tighten them at a 2,5 daNm moment, after rotating the
primary shaft in order to ensure o correct bearings setting.
Retrieve the false axes.
Mount the locking pin of the reverse driving pinion (A).
GEARBOX DISMOUNTING
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DRIVE SHAFTS
29 BELLOWS –BEARING ASSEMBLY
TO THE GEARBOX
THE JOINT TO THE GEARBOX - GI
SPECIAL TOOLS
Bearing mounting chuck on the shaft PF 1331
1. Tripod assembled
2. Bellows
3. bearing
4. bellows attachment lid
5. deflector
6. blocking ri ng
7. transmission shaft
DISMOUNTING
It is forbidden to use t h inner for
components parts cleaning.
Dismo u nt the blocki n g r i ng fr om t he
groove made on the transmission shaft, using
a special pincers for these types of rings.
29 - 04
Left
transmission
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DRIVE SHAFTS
29BELLOWS-BEARING ASSEMBLYTO THE GEARBOX
M aintaining the transmission on the press, on both sides, shall be ensured on the G
groove made on shaft, by means of a device type FACOM U 53 G, ( the flat side towards
bellows) in order t o avoid the defl ector damages on the wheel side. The pressing effort of the beari ng on the tra nsmission shaft ahas the value of = 100 –
700 daN. Press again the assembled tripod on the tra nsmission shaft observing the marks made
when depressing. The pre ss effort of t he tripod assembly on t he groove d area of t he shaft end, shall be
between 60 – 600 daN. Remount the blocking ring (Zeger lock) in the groove made on the tra nsmission shaft.
29 - 6Left
transmi ssion
G
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