battery DACIA SUPERNOVA 2004 Owner's Guide

31
FRONT BEARING ELEMENTS
31 - 10
SPECIAL TOOLS
Hub disk extractor PF600
Ball joint extractor PF476
DISMOUNTING
Disconnect the battery.
Lift the vehicle by means of an elevator with
two column. Dismou nt :
- the wheel
- the brake disk assembly together with
the flexible connection;.
- the transmission gear nut.
- the brake disk a ssembly by means by
means of the PF 600 extractor.
Continue by dismounting t he steering
knuckle, observing the operations sequence: - dismount the steering ball joint nut;
- depre ss the steeri ng ball joint by
means of the PF 476 extractor;
- dismount the t wo screws that attach
the steering knuckle on the shock absorber; - dismount the attachment screws that
attach the steering ball joint – steering knuckle;
- detach the steering knuckle.
TIGHTENING MOMENTS (daNm)
Wheel attachment screw 7,5
Steering ball joint nut 3,5
Transmission nut 21
Attachment fork screw on steering knuckle 6,5
The screw nut of the steering knuckle
attachment with the shock absorber leg 7,5
The attachment screw nut of the ball
joint with the steering knuckle 5,5
STEERING KNUCKLE
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36
STEERING ASSEMBLY
36 - 8
DISMOUNTING
Disconnect the battery.
Mark the steering wheel position (straight line driving position).
Dismount the connection screw (1) between the deformable lower shaft and the steering
wheel shaft. Loosen the screws of the front left wheel.
Lift the vehicle by means of a two-column elevator.
Dismount the left front wheel.
Dismount the connection screw (2) between the deformable lower shaft and the gear shaft
of the steering box. Dismount the sealing gasket (3) from the cowl panel.
Extract the lower shaft.
ATTENTION !
It is forbidden the damaging of the lower shaft and of the connection parts from the
steering system (steering box gear, steering wheel shaft) when dismounting/remounting
the lower shaft.
REMOUNTING
Clean the steering box gear shaft and grease it with grease UM 185 Li2 or UM 180 Li2.
Perform the dismounting operations in the reverse order. Tighten the connection screws between
the lower shaft and the steering box gear shaft, consequently between the lower shaft and the
steering wheel shaft to the required moment of 1.4 daNm.
D
EFORMABLE LOWER SHAFT
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MECHAN ICAL ELEMENTS CONTROL
37
BRAKE PUMP
Close the connection pipe between the brake fluid reservoir and clutch transmitter cylinder
by means of the MOT 453 device. Disconnect the battery.
Drain the brake fluid reservoir.
Disconnect the connection pipe between the brake fluid reservoir and clutch transmitter
cylinder.
Dismount the brake fluid reservoir off the brake pump (avoiding fluid leakage).
Dismou nt :
- the rigid pipe screws from the brake pump and mark their position;
- the two attachment nuts of the brake pump on the servobrake .
DISMOUNTING
37 - 3
TIGHTENING MOMENTS (daNm)
Rigid pipe connection 1,5
Nut attachment P.C. with servobrake 1,3
I.C.P. (pressure drop indicator) 2
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MECHAN ICAL ELEMENTS CONTROL
37
HAND BRAKE CONTROL LEVER
DISMOUNTING
Disconnect the battery.
Lift the vehicle by means of a two columns elevator;
Release the hand brake control lever.
D etach the fork end rod by unscrew the lock nut ( 2).
Dismo unt :
- the hand brake ornament;
- the lever support with toothed part ( 3);
- the e nd shaft rod ( 4);
- the lever shaft ( 5);
- the claw shaft (6) ;
- the c law control rod ( 7).
Detach the lever.
RE MOUNTING
Gr ease the shafts with UM 185 Li 2 grease.
Perform the dismounting operations in the reverse order.
Check and adjust the adjustment if necessary.
37 - 11
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MECHAN ICAL ELEMENTS CONTROL
37
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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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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LOWER INTERNAL ACCESSORIES
57
57 - 2
DASHBOARD
DASHBOARD VISOR
Dismount by frontal withdrawal and detachment.
LOWER DASHBOARD CASING
DISMOUNTING
Disconnect the front wiring connectors from the fuse box fixed by means of four screws on
the door (4) of the lower casing (5) and disconnect the c hoke cable.
Dismount the screw and the cage nut, which fix the lower casing on the front hood opening
control support.
Loosen the three screws that fix the lower casing on the lower side of the dashboard.
REMOUNTING
Perform in the reverse order the dismounting operations.
DISMOUNTING
For the dismounting of the dashboard assembly, perform the following operations:
Disconnect the battery.
Dismo
unt :
1. - the steering wheel and the steering wheel half-cases;
2. - dashboard visor;
3. - central console and the climate control assembly;
4. - dashboard lower casing;
5. - documents compartment;
6. - uppe r dashboard.
1
2
3
4
5
7
6
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HEATING
61
61 - 1
DISMOUNTING
Disconnect the battery.
Dismount
the documents compartment.
Di smount the attachment c lip of the mixing flow flap control cable, (8) (from the c limate
control unit). Remove the right aeration grill (from the right side of the central console).
Dismount the attachment clip of the distribution flow flap control cable, (7)(from the climate
control unit). Dismount the attachment metal screws (5 ) of the climate control assembly (6 ) on the central
console of the dashboard. Remove the climate control assembly from its seat.
Disconnect the connection box of the climate control switch.
Disconnect the connection box of the instrument panel lighting.
Dismo unt the attachment clip of the recycling flow flap control cable (9) and remove it from its seat.
Remove: the mixing flow flap control cable (8 ) from the heating control button (2 ) and the
distribution flow flap control cable (7) from the distribution control button (3), by releasing the
clips attachment screws.
Remove the climate control switch (4) out of its seat by detaching from clips.
Dismount the four lighting bulbs.
REMOUNTING
Pe rform in the reverse order the dismounting operations, taking into account the following
recommendations: - the flow flaps c ontrol cables are first fixed to the board with the jacket, in axial contact
with the limiting support and then pass the panel button and the similar flow flap on the
corresponding position, then clamp the cable to the unit support; - check if the levers from the climate unit and from the distribution box, have the adequate
strokes t o ensure the close-opening of the flow flaps; - if yes, mount the assembly (6 ) on the central console, the documents compartment and
the aeration grill ;
- if not, set the sleeve l ength of each control cable to the mounting bracket of the climate
unit and the distribution box.
- the maximum moment for the full flow flaps opening is 1,9 Nm.
CLI
MATE CONTROL ASSEMBLY
9
8
7
6
1
2
3
4
5
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HEATING
61
61 - 2
DISMOUNTING
Disconnect the battery.
Drain the cooling system.
Dismount the attachment
collar of the hoses
on the heating radiator. Clog the hoses of the he ating radiator by
means of the device MOT 453.
Dismount the documents compartment.
Dismount the central console.
Dismount the control climate control.
Disconnect the airflow pipes from the climate
control unit. Dismount the nuts and the attachment screws
of the climate control unit from the carriage body.
Release the climate control unit.
REMOUNTING
Perform in the reverse order the dismounting operations.
HOUSING MANIFOLD
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AIR CONDITIONING
62
62 - 5
Basically, the air conditioning unit is formed of a closed circuit, composed by the following main
elem ents:
- ev aporator
- compre ssor
- c ondenser
- thermo static expansion valve
- conn ection pipes.
The evaporator is the component that ex t racts the heat from the passengers compartment and
is generally placed in the passengers compartment. In order to cool the passengers compartment
the hot air must be absorbed, the heat extracted and the “cooled” air redistributed. The hot air is
pa ssing through the evaporator to who is giving part of the temperature reducing so, its own
temperature. The cooled air is so conveyed in the passengers compartment, progressively reducing
the temperature.
In the same time, the refrigerant fluid which goes into the evaporator, is absorbing the heat, from
ai r pa ssing through the evaporator and at the same temperature, is transforming it from liquid into
va pors. At the evaporator exit, the refrigerant fluid is in vapor condition.
The evaporator is placed in the climate control unit and is protected by cases.
EVAPORATOR
EVAPORATOR CASES ASSEMBLY REPLACEMENT
DISMOUNTING
Disconnect the battery.
Drain the refrigerant circuit.
Dismount the sealing gaskets on the climate box outliner.
Dismount the thermostatic expansion valve.
Dismount the climate case locking plate.
Di sconnect the pipes evaporator – compressor and evaporator – tank filter.
Dismount the evaporator cases attachment nuts, on the right side.
Release the evaporator cases.
Replace the assembly .
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