tow DACIA SUPERNOVA 2004 Owner's Guide

36
STEERING ASSEMBLY
36 - 6
BELLOWS
DISMOUNTING
Lift the front part of the vehicle.
Dismount the wheel.
Loosen the attachment nut (5) of the auxiliary connecting rod ball joint to the steering knuckle
s upport and depress the ball joint (4).
Remove the attachment collar (6) of the bellows on the steering casing box.
Remove the bellows
(7) from the steering casing box.
Straighten the edges of the safety washer.
Unscrew the steering connecting rod from the rack, using the special wrench and remove it
out together with the safety washer (2) and the locking washer (1).
1. Locking washer
2. Safety washer
3.Assembl ed e nd of t he a uxi lia ry
connecting rod 4.Assembled auxiliary connecting rod
fu nnel
5. Attachmen t nut
6. Attachment collar of the bellows
7.B ellows
REMOUNTING
Fold the bellows towards the connecting rod funnel.
Before assembling the rack with the steering auxiliary connecting rods (the threaded parts
being free from any tra ces of grease) a pply a layer of FIXAMED R 58- C.S. 1/82 on the
threaded parts of the auxiliary connecting rods. Place the safety washer and t he l ocker washer (in t his order) on the threaded shaft of the
steering auxiliary connecting rod, passing the curved pin of the safety washer through the slot of
the locking washer. Screw the steering auxiliary connecting rod in the rack.
Tighten the joint body at the moment of 5 daNm by means of the 6902-4105 special wrench.
Bend the safety washer in the opposite part to t he pin in at l east one of the cuts made on the
ball joint body. Mount the bellows in its channel from the steering casing.
Mount the auxiliary connecting rod funnel in the steering knuckle support.
Check the tightening of the nut (5) at a moment of 4daNm,on the vehicle.
1
2
3
4
5
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MECHAN ICAL ELEMENTS CONTROL
37
BRAKE PUMP
BRAKE PUMP WITH PRESSURE DROP INDICATOR ( ICP ) INCLUDED
COMPONENTS
1. Assembled primary piston with gaskets
2. Assembled secondary piston with gaskets
3. Primary piston pin.
4. Secondary piston pin.
5. Primary piston return spring
6. Secondary piston return spring.
7. Purging screw
8. ICP transducer
A –A ICP assembly section
OPERATIONA. B RAKING
THE FRONT BRAKE CIRCUIT
The primary piston is controlled by the pushing rod. A part of the brake fluid under pressur e
will operate together with the spring on the secondary piston, and the other part of the brake flui d
shall penetrate through the ducts to the upper floor towards both exits leading to the front brak e
calipers.
THE REAR BRAKE CIRCUIT
The secondary piston is continuing its movement, conducting the brake fluid under pressure ,
through the ducts, to the upper floor, towards the exit to the pressure-reducing valve. During al l
this time, the linings-pistons assembly will be balanced due to the two side springs .
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MECHAN ICAL ELEMENTS CONTROL
37
BRAKE PUMP REPAIRING
The operation is performed after dismounting the central pump off the vehicle.
DISMOUNTING
Dismount the brake fluid reservoir, recover-
ing the two sealing gaskets of the brake fluid res-
ervoir. Dismount the transducer and the purging
screw. Clamp a 3,5 mm drill in the vice.
Introduce the drill in the elastic pin
Rotate and draw the pump until the pin is ex-
tracted;
Extract the secondary piston elastic pin, in the
same way. Remove from the pump:
-the Pp primary piston assembled ;
- the primary piston return spring;
- the Ps secondary piston assembled;
- the secondary piston return spring
Wa sh the part s with alcohol and bl ow them
with compressed air. Check:
-the pump bore
- the pistons gaskets
- the springs
The parts of the “ primary piston” Pp and those of the “ secondary piston” Ps, cannot be repaired.
In case one of these parts is damaged, replace the whole kit ” primary piston” and “secondary
piston”, primary piston return spring, secondary piston return spring.
REMOUNTING
Before remounting, the parts and the pump bore will be lubricated with brake fluid.
Mount the “ secondary piston” and “primary piston “ assembly .
Compress the pistons and introduce the elastic pins; the pins slot shall be oriented towards the
pump attachmen t flange.
Mount the purging screw;
P urge the brake circuit and remount the ICP transducer. BRAKE PUMP
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MECHAN ICAL ELEMENTS CONTROL
37
BRAKE PRESSURE CONTROLLER
Brake pressure controller, load sensitive, avoiding the rear wheels blocking.
OPERATION PRINCIPLE
The brake pressure controller enables the rear circuit pressure “ modulation “ according to
two parameters:
-the pressure value in the front circuit
- the load on the rear axle
The pressure controller is operating on the principle of pressure compensation in two enclosures,
separated by means of a ball and spring valve. The back pressure at the valve level is created by means of the forc e developed by the
continuos action compensating spring and of the control spring acting in proportion as the rear
axle load is increasing. The pushing rod is transmitting the force of the lever spring to the pressure controller piston,
which is controlling the valve ball being in the open normal position (position P 1).
BRAKING MOMENT
In the same time with pressure increase when entering in the pressure controller, this will act
upon the ball, forcing it to overcome the c ontinuos acting spring force and by uncovering the
valve hole, to facilitate the releasing of this pressure. In the braking moment, due to position
changing of the vehicle body compared to the rear axle, by means of the acting levers, the limiting
piston is moving toward the interior, reducing the fluid exist diameter, leading to the obtaining in
this way of the pressure reduction in the rear circuit.
DE BRAKING MOMENT
In the moment of fluid inlet pressure restoring ( by leg lifting from the brake pedal ), the piston
will come back in the initial position, gradually and quickly allowing the same diameter existent at
the beginning of the braking for which the valve is open ( position P1 ). 1.
Pressure controller body
2. Valve
3. Plug
4. Spring
5. Ball
6. Piston
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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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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
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40
GENERAL
40 - 12
12
Fo r checking, straightening or repairing the DACIA vehicles bodies, the use of the
CELLETTE bench is recommended. The checking/straightening bench type CELETTE ( service code CAR 500 ) is composed of:
-C AR 501 (1 mobile bench with four wheels, four parts for vehicle anchori ng, one
traction arm of 10 t, type
“CAIMAN“).
-C AR 502 - set modular c ross bars
-C AR 503 - set of 22 towers MZ
-C AR 504 - set accessories for traction
-C AR 505 - set of specific supports for DACIA Bl, Bk
-C AR 506 - set of specific supports for DACIA 1304, 1307
-C AR 507 - set of specifi c supports for DACIA NOVA.
NOTE
The purchase of the checking / straightening bench - CELETTE type- is to be done
through Automobile Dacia S.A.
1. CAR 501
The mobile bench (1) is provided with four a nchoring parts (2) - (fig 1), which can be
used when a carriage body straightening operation is performed.
(pict.1)
CAR
RIAGE BODY CHECKING/ STRAIGHTENING
BENCH CELETTE TYPE
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GENERAL
40 - 13
CAR
RIAGE BODY CHECKING / STRAIGHTENING BENCH
CELETTE TYPE
To straighten the vehicle body, CE LETTE bench is provided with a traction arm of 10
tons, Caiman type, 250-mm stroke of the hydraulic cylinder, with rapid anchora ge on any
side of the mobile bench ( pi ct. 2 ).
2. CR OSS BARS MODULAR SET ( CAR 502)
CELETTE bench has in its composition, five modular cross bars (pict.3), as follows: - two front cross bars A and B (T shaped) which are always in the same position
(towards front of bench) - pi ct. 4 . - two straight cross bars C1 and C2 and one D cross bar (U-shaped) which may be
placed in differe nt positions subject to the vehicle type. The marke d figures (14……36) are engraved on the mobile bench, every mounting
being supplied with a drawing indicating the exact position of the m odular crossbars subject
to the vehicle type.
( pict. 3 ) ( pict.4 )
( pict.
2)
one.... two... and tree!
A
B
C2D
A
B
C1
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GENERAL
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CA RRIAGE BODY CHECKING / STRAIGHTENING
BENCH CELETTE TYPE
3.TRACTION ACCESSORIES SET ( CAR 504)
CELETTE bench is equipped with a traction accessories set CAR 504, which a llows
the operator to achieve different a nchoring when a body strengthening is performed (pi ct. 5).
4. SET OF MZ TOWERS AND SPECIFIC SUPPORTS ( CAR 503 +CAR 507)
This kit re presents a MZ system and consists of two elements: - kit of 22 MZ towers, universal CAR 503 – ( see pict.6 )
- kit of specific supports CAR 507
( pict. 6 ) ( pict.
5)
Each MZ tower has an a rrow, which settles
its ori entation on th e cross bar a nd a MZ
reference (pict.7) Example – MZ 080, where:
MZ- measurem ent on OZ axle of the
vehicle.
080 – MZ tower height (in mm)
In the same way as for COMPACT
assembly, the arrow (1) marked on the specific
support must be oriented towards the bench
front part, as follows: - attachment on the right part of the
mobile bench
- attachment on the left part of the
mobile bench
NOTE
The MZ towers may be used also for the checking/ straightening of the c arriage
bodies of other vehicles types, being then necessary the purchasing of the specific supports
for each type of v ehicle.
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40
GENERAL
40 - 15
( pict.
7 ) Each specific support is identified by
a number ( 2 ) marke d at the l ower part
and has one or two attachments holes in
the MZ tower ( in t his case you should
take into consideration the specific
diagram from the assembly drawing
supplied together with the kit.
Symbols:
1 – wit h or without dism ounted
mechanical elements. 4 – with dismoun ted mechanical
elements.
NOTE :
Identification and mounting of the
towers on different modular cross bars
and of the specific supports in the MZ
towers (1…20), when repairing a Dacia
SupeRNova body, is t o be performed as
per mounting drawing ( pict.8 and pict.9)
which is supplied together with t his kit.
CAR RIAGE BODY CHECKING / STRENGTHENING
BENCH CELETTE TYPE
( pict. 8 )( pict.9 )
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