brake DACIA SUPERNOVA 2004 Workshop Manual

MECHAN ICAL ELEMENTS CONTROL
37BRAKE FLEXIBLE HOSES
The SUPER NOVA vehicles are equipped with flexible hoses with copper gaskets in order
to ensure the sealing.
PRECAUTIONS IMPOSED TO BE RESPECTED WHENDIS MOUNTING – REMOUNTING A RECEIVER
OR A BRAKE FLEXIBLE HOSE
D ue to security reasons, in order to avoid brake flexible hose twisting and the risk to get i n
contact with the suspension elements, it is necessary to observe the following operations sequence.
37 - 14
TIGHTENING MOMENTS (daNm)
X (caliper flexible) 2,0
Y (the attachment connection screw of the rigid pipe on the flexible) 1,5
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MECHAN ICAL ELEMENTS CONTROL
37
BRAKE FLEXIBLE HOSES
DISMOUNTING
U nscrew the connection ( 1) (wrench) of the rigid pipe on the flexible hose till the moment
when the spring (3) is relaxed, having releasing the splinted area (4) of the sustaining bed.
Unscrew the flexible from the caliper and eventually dismount the caliper.
REMOUNTING
Assemble t he caliper with the caliper fork, mount the wedges and then screw the flexible i n
the caliper, then tighten at the m oment of 2 daNm.
The flexible must be mounted when the half axle is in the position: - symmetric wheels (mounted suspension)
- train in line (straight wheels)
Position the female end of the flexible on the sustaining bed ( 5) without twisting forcing and
check if the splinted area ( 4 ) is freely coupling in the bed splints, then place back the spring (3)
and screwing the rigid pipe on the flexible avoiding twisting.
Tighten the connection screw at a moment of 1,5 daNm.
Purge the brake circuit.
37 - 15
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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
37 - 16
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MECHAN ICAL ELEMENTS CONTROL
37
BRAKE PRESSURE CONTROLLER
NOTE
The brake pressure controller is not to be repaired.
DISMOUNTING
Drain the circuit, recover the fluid;
Detach the four connections (1) of the rigid pipes.
Dismount the two M6 attachment screws of the pressure controller support on the floor (2).
Remove the support together with the pressure controller from the fixing clips.
Dismount the pressure controller off the support.
REMOUNTING
Mount the pressure controller attachment screws on the support.
Attach the support-pressure controller assembly on the floor.
Mount : -control lever
- the four connection screws of the brake pipes
Purge the braking circuit and adjust the pressure controller.
37 - 17
TIGHTENING MOMENTS (daNm)
Pressure controller attachment screws on support 0,58 daNm
Pipe tightening connection screws to the pressure controller 1,5 daNm
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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
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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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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MECHAN ICAL ELEMENTS CONTROL
37
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.
37 - 25
PEDALS SUPPORT
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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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