air condition DACIA SUPERNOVA 2004 Workshop Manual

19 - 9
19
COOLING - EXHA U ST - FUEL TANK
RESISTANCE COOLING FAN REPLACEMENT
for vehicles with air conditioning
De scription of t he opera tion :
Di sconnect the battery (-) term inal.
Di sconnect the resistance connector.
Di smount the two attachment screws of the re sistance.
Position the new resistance assembly.
Mount the two attachment screws of the resistance (tightening moment 4.5 Nm).
Connect the resistance connector.
Connect t he battery (-) terminal. In case the vehicle is equipped with programmable
radio-cassettes player, electronic clock, etc, those are to be re-programmed before return-
ing the vehicle to the client. Check the engine motor fa n operation.
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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 - 11
19
COOLIN G - EX HA U ST - FU EL TANK
COOLING FAN DIAGNOSTIC
for vehicles without air conditioning
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33
REAR BEARING ELEMENTS
BRAKE CYLINDER
A djust:
- the shoes, by applying a repeated pressure to the brake pedal;
- the rear axle bearing clearance.
Mount the wheel.
Lower the vehicle from the elevator.
Pu rge the braking system (see chapter 38).
Adjust the hand bra ke.
REPAIRING
DISMOUNTING
Di smount the bra ke cylinder off the vehicle;
Di smount:
- the purging screw;
- the protection bellows;
- the Ö22 pistons assembled with the pressure ga skets.
Check the condition of the cylinder boring, any trace of wear, oxidation or scratches
implies the re placement of the assembled bra ke cylinder.
If the cylinder components are in a good condition, lubri cate them with brake fluid and
mount them in the reverse order of dismounting. Check the easy moving of the assembled pistons in the cylinder boring.
Mount the brake cylinder on the plate;
Mount the wheel brake drum .
Check the adjustment of t he hand bra ke.
Purge the braking system.
33 - 9
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52 NON SIDE OPPENING ELEMENTSMEC HANISMS
The composition of the front hood locking
system ............................................................ 52-1
Fr ont hood locking system............................. 52-2
Hatc hback lo cking sy stem .............................. 52-3
Hatchback balancing device........................... 52-5
54 WINDOWS Windscreen and hatc hback glass.................... 54-1
Hatchback gla ss repla cement......................... 54-3
55 EXTERNAL PROTECTIONS Front bumper.................................................. 55-1
Rear bumper................................................... 55-2
56 EXTERNAL ACCESSOIRES Outside accesor ies.......................................... 56-1
Aileron........................................................... 56-2
40 GENERAL
Designation of parts (blow-up)..................... 40-1
Openings cle arance....................................... 40-4
Repairing general conditions........................ 40-5
Welding types and parameters...................... 40-6
Col lision diagnosis........................................ 40-8
Ca rriage body checking/ Straightening bench
CELETE type................................................ 40-12
41 LOWER STRUCTURE Front longitudinal girder assembly............... 41-1
Re ar longitudinal girder................................ 41-2
42 UPPER FRONT STRUCTURE Front wing..................................................... 42-1
Ca rriage body front part................................ 42-2
Fr ont wing lining........................................... 42-3
R adiator upper cross bar............................... 42-4
Headlamp support......................................... 42-5
Aeration grill................................................. 42-6
43 UPPER SIDE STRUCTURE Front pillar lining.......................................... 43-1
Fr ont pillar..................................................... 43-2
Mi ddle pillar.................................................. 43-3
44 REAR UPPER STRUCTURE Side panel...................................................... 44-1
Inner rear wheel passa ge............................... 44-2
Re ar panel..................................................... 44-3
45 TOP OF BODY Roof.............................................................. 45-1
47 LATERAL OPENINGS Front/Rear door............................................ 47-1
48 NON SIDE OPPENING ELEMENTS Front bonnet.................................................. 48-1
Hatchback..................................................... 48-2
51 SIDE OPPENING ELEMENT S MECHANISMS Lock and front door lock cylinder................. 51-1
Lock and rear door lock cylinder.................. 51-3
Window and front door window regulator
(with cable)................................................... 51-5
Window and rear door window regulator
(with cable)................................................... 51-6Body4
Mechanisms and accesoires5
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40
GENERAL
40 - 5
The replacement (repara tion) operations of t he weldable elements descri bed i n t his
chapter a re specified subject to: cutting out of t he parts t o be replaced; the a ccess to the
welded elements, tools and checking devices accessibility, etc.
In case the vehicle body has suffered import ant deform ations it is recommended the
str aightening of t he damaged body elements, by means of some hydraulic pre sses, the
operation being performed slowly and at cold. For this range of vehicles, the e lements re sistance structure which a re a ffecting the
vehicle securi ty, are not to be partially re placed ( not to be cut), but entirely.
After welding detaching, the body elements must remain stra ight, without breakage or
cracks, the possible holes being covere d out with filling material or by tinning. The body
elements surfaces are t o be pickled ( to eliminate possible oxidation marks) , dried and
initially applied a paint layer. The electric welding detaching of the body elements, is performed as follows:
- with a well sharpen chisel, this method may lead to part s deformation or even
parts breaking.
- by using some extractors equipped with steel cutter type Bre ndeo or Pickvant
max. 6 mm, having the cutting head as per shape shown in pict.1.
1. Centeri ng point
2. Sharpen slope
3. Drill acting edges
4. Gap for catching the welding materialP = aprox. 0.4 mm
Whatever method is used, the remaining element m ust be in good order a nd to allow
performing of a good quality welding point.
The pl ates cutting it is recommended t o be pe rformed ( subject of importance and thick-
ness ) using manual scissors or pneumatic portable tools for plates cutting.
Du ring cutting or welding of the body elements it is necessary to protect the electric
wir ing from the interi or of the body structure.
The cutting, welding, or strengthening operation done on body welded elements, are to
be performed on body checking/ straightening bench type CELETTE .
IMP ORTANT
When removing or straightening the body resistance e lements i t i s forbidden t he
total or partial heating, in order to avoid the mechanical resistance and metal elasticity
decreasing. REPAIRIN
G GENERAL CONDITIONS
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EXTERNAL PROTECTIONS
55
55 - 3

WORKING PROCEDURE
Smooth the margins of the exfoliated area (dry abrasive paper 220 grams; 400) and slightly
depolish the whole bumper. Ungrease with extraction petrol.
Using a gun, spray on exfoliated areas, Primer (liability ground)
Apply by spraying on the exfoliated areas, fuller till equalization , then spray on a thin layer on
the whole bumper.
In case after 20 minutes of fuller layer e xposing in the air, the applied Fuller film does not
presents painting defects, spray using a gun two layers, wet +wet enamel in the vehicle color.
If the film presents painting defe cts, remove t hem by grinding and depolish the rest of the
s urface. The opera tion will be performed a fter 6 hours of air drying, a nd after 20-30 minutes
when there is the possibility of drying at 60gr. C.
NOTE
For this operation, the di smounting of the bumper is not necessary with the condition
that the areas, which might be exposed to the used materials, should be protected. RE
AR BUMPER
FRONT/REAR BUMPER PAINTING/REPAINTING PROCEDURE
The necessary materials for the r epainting operation are the following:
-Abrasive paper gr 220; 4001sheet/4 bumpers;
-Extraction petrol S27 0,05 kg./bumper;
-Gauze 0,05 mp./bumper;
-Primer P572-212 10-15 gr./bumper;
-Fuller P565-777 80 gr./ bumper ;
-Catalytic agent P850-1492 40 gr./bumper;
-Thinner 15 gr./bumper; -Same color enamel
-For opaque -opaque enamel S 5505 180gr./bumper
- catalytic agent S 3538 45gr./ bumper
-thinner S 4300 35 gr./bumper
-For metallic paint -metal enamel S 5901 175 gr./bumper
-thinner S 5900 35 gr./bumper
-cata lytic agent S 493242 65 gr./bumper
-lacquer thinner 362077 35 gr./bumper
-L acrit lacquer 22 8050 30 gr./bumper
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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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HEATING
61
61 - 5
CLI
MATE CONTROL BLOWER DOES NOT WORKING
Check fuse F 01.
F01 good. Check F09.
F09 good. Check blower supply.
F01 blown. Replace the fuse.
The blower is not supplied.
Check R2 relay. The blower is supplied.
Check the air conditioning switch.
Relay R2 is damaged.
Replace the relay.The relay is not da
maged.
Broken or disconnected
relay switch wiring. Good switch.
Ma
ss wire
disconnected or brok en.Damaged switch.
Replace the switch.
DIAGNOSIS
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AIR CONDITIONING
62
62 - 1
GENERALITIES
GENERALITIES
The purpose of the a ir conditioning unit i s to produce a decrease of t he temperature in the
passengers compartment a nd to obtain a l ower value t emperature compared to the external
environment one, reducing in the same time the air moisture.
MAINTENANCE
For a vehicle equipped with air conditioning, it is recommended a frequent checking of the
refrigerating agent level. During the year it is recommended:
- the checking of the refrigerant fluid filling;
- the cleaning and the air-blowing of the condenser and the cooling radiator fins;
- the checking of the condensation removal pipe on order not to be clogged.
For important leakage repair, for any components replacement (compressor, condenser, etc)
and if moisture was noticed in t he air conditioning circuit, the dryer filter tank is to be replaced
and the unit draining is to be performed. The same is valid also in case the conditioning circuit
remains open without protection covers more than 10 minutes.
IMP ORTANT
Duri ng winter, it is recommended the frequent start of the system, in order to pro-
long the lifetime of the compressor and of the whole system.
The vehicle equipped with an air conditioning system shall be not exposed for more
than 20 minutes i n painting c abin where there are temperatures higher than 80 °C.
It is obligatory the use of the refrigerating agent and compressor oil type prescribed
by the manufacturer. It is absolutely forbidden to perform welding on the elements of the air condition
circ uits. The filling of the air conditioning system can be pe rformed only by m eans of charging
units and observing the instructions of the manufacturer. For mechanical or body
operations it is recommended pi ping protection in order to avoid their disconnection
by accident. Avoid the drip of the oil compressor on the painted vehicle body.
For component replacement implying the circuit draining, it is absolutely necessary
the use of new parts and of a special oil for compressor.
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