DACIA SUPERNOVA 2004 Repair Manual

MECHAN ICAL ELEMENTS CONTROL
37
ADJUSTMENT OF TH E BRAKE PRESSURE CONTROLLER FORTHE PARALLEL BRAKING SYSTEM
Conditions : -the vehicle on wheels
- empty trunk
- one person on board
ADJUSTMENT
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 unscrewin g it towards the pushing rod (C) in order to increase the pressure in the rear circuit
- by screwin g it towards the pushing rod ( C ) in order to decrease the pressure in the rear circuit.
Tighten at t he required moment ( 0,35 daNm ) the adjustment nut ( A ) next to the pushing
rod end ( B ) so that between the lever end and t he lever ( D ) a clearance of L = 0,5 mm to be
ensured.
Check several times the limiting pressure obtained on the rear wheels cylinders : 30
+0
bar.
Dismount the manometer and purge the braking circuit.
For the purging of the hydraulic circuit and the pressure control, the FR 501 device is
to be used.
37 - 18-2
BRAKE PRESSURE CONTROLLER
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MECHAN ICAL ELEMENTS CONTROL
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The working principle of this control is similar to the one of a brake control, having the same
wo rking fluid : SA E J 1703 DOT 4.
TRANSMITTER CYLINDER REPLACEMENT
DISMOUNTING
Disconnect the battery.
Drain the clutch control hydraulic circuit ; for this purpose, open the purging connection and
connect to this a transparent hose for draining. Dismou nt :
- dashboard lower pa rt ;
- the feeding pipe 1 with brake fluid from the reservoir;
- the hydraulic pipe of the transmitter cylinder 2.
Detach the cylinder rod from the control pedal bolt (dismounting effort : min 5 daNm ).
Di smount the transmitter cylinder 3 as follows: by means of 24 mm wrench, rotate the
transmitter cylinder from the right to the left aprox. 45 ° and extract the cylinder ( dismounting
moment : min 0.2 daNm ).
37 - 19
CLUTCH HYDRAULIC CONTROL
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MECHAN ICAL ELEMENTS CONTROL
37CLUTCH HYDRAULIC CONTROL
37 - 20
REMOUNTING
Perform the dismounting
operations in the reverse order ;
-tr ansmitter cylinder mounting moment on the support – max 0.5 daNm
- cylinder rod mounting moment on the pedal bolt – max. 5.0 daN
Refill the brake fluid reservoir and purge the clutch control circuit by means of the purging
connection. Adjust the level in the brake fluid reservoir.
At t ent i on
When remounting the feeding pipe at the brake fluid reservoir and at the
transmitter cylinder, observe the positioning markings.
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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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37
Retrieve the feeding pipe (towards the arrow) to enable the fluid passing through the connection 1.
Bleed a little bit of fluid.
Close the purging connection (move the feeding pipe in reverse way).
2. FINAL PURGING OF THE CIRCUIT
a) Slowly push the clutch pedal to maximum position and keep it pushed.
W ait aprox. 10 seconds then open the purging connection.
b) Close the purging connection, release the clutch pedal, and slowly lift it by hand to
the upper position ( if the pedal does not come back itself in this position ).
Repeat the operations a and b till bubbles are not coming our through the purging.
connection, then repeat five more times these operations in order to be sure about a good circuit
pur ging.
These repeated purging allow “ the c leaning “ of the circuit from the air bubbles eventually
remained in the circuit after the circuit filling and purging.
An air bubble as little may be, remained in the circuit, may lead to operating deficiencies such
as: defective clutch pedal return or gears change noise being able to lead to a wrong diagnosis or
an inopportune replacement of a part of the clutch circuit.
CLUTCH HYDRAULIC CONTROL
37 - 22
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MECHAN ICAL ELEMENTS CONTROL
37
DISMOUNTING
The dismounting of the gears changing lever shall be performed after dismounting the central
case . Dismount under the vehicle the control lever.
Dismount under the vehicle the four attachment screws of the central case.
Dismount the assembly composed of control case and gears control lever. THE GEARS CONTROL
REMOUNTING
Perform the dismounting operations in the reverse order.
Tighten at the required moment :
- the control case attachment screws 1.2 daNm
- the control bar connection screw with the GB connecting rod 2.7 daNm
- the connection screw of the control bar with t he control lever 1.2 daNm
Grease the parts of the joint composed of control bar and GB connecting rod with MOLYKOTE
33M grease.
Introduce in the protection bellows aprox. 10 ml of grease.
NOTE
The tightening of the connection screw of the control bar with the control
lever shall be performed aft er adjustment of t he gearbox control.
37 - 23
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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
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SPECIAL TOOLS
CV 550 Linkage adjusting device
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DISMOUNTING
Dismount the acceleration, clutch, and brake pedals.
Dismount the attachment nuts (4) and washers ( 5) of the pedals support on the cowl panel.
Remove the spacer ( 2) and the ga sket (3).
REMOUNTING
Perform the dismountin g operations in the reverse order, by screws tightening at a moment of
1,5 – 2,5 daNm.
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PEDALS SUPPORT
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37
DISMOUNTING
Release the acceleration pedal (3) from its attachment with the acceleration cable by
compressing the two wings of the attachment clip (1).
Dismount the bearing attachment screw ( 2) and release the pedal (3).
REMOUNTING
Perform the dismounting operations in the reverse order. The tightening moment of the bearing
attachment screw is of C = 0,45 daNm. Check the 3,5 mm pedal stroke between the pedal pressure controller ( 5) and the pedal ( 3)
by means of the threaded pin adjusting ( 4) subject to valve maximum opening and cable tightening.
NOTE
The buffer ( 6 ) is at tached to the support before cable mounting.
37 - 26
ACCELERATION PEDAL
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DISMOUNTING
Act upon the cable attachment clip of the acceleration control lever and for the cable release
(2) from its attachment on the acceleration pedal, act upon the clip ( 1).
REMOUNTING
Perform the dismounting operations in the reverse order.
ACCELERATION CONTROL CABLE
37 - 27
1
2
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