wheel DACIA SUPERNOVA 2004 Manual Online

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
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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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 - 2
UPPER STRUCTURE COMPOSING ELEMENTS
1. Headlamp support
2. Upper radiator cross bar
3. Front grill
4. Front wing lining
5. Front pillar lining
6. Front pillar
7. Side frame lining
8. Middle pillar
9. Inner wheel passage
10. Side panel
11 . Rear panel
12. Ceiling
13. Windscreen frame
14. Windscreen lower cross bar
15. Climate control box
16. Climate control box centra l part
17. Cowl panel DE
SIGNATION OF PARTS (BLOW-UP)
123
456 78 9
10
11
12
13
14151617
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40
GENERAL
40 - 8
C
OLLISION DIAGNOSIS
Du ring the vehicle exploitation, the carriage body may suffer different distortions, that
lead many times to the wheels setting angles change, body elements breakage, vibra tions
or even mechanical parts wear. In these conditions, be fore performing the vehicle body re paration, some checking is
necessary:
Visual checking - consisting in the e xamination of the mechanical elements attachments
and of the distortions occurring in the vehicle damaged areas.
Checking with the bar (control gauge) – consisting in comparing the measurements
done in symmetric points. The ge ometry checking of t he rol ling t ransmissions – this checking is t he only one
enabling to find out if the body damage was not affecting the vehicle road behavior.
IMP ORTANT
This checking must be not ignored, except some border-line cases, the checking of
the rolling transmissions leading to t he identification of the distortions occurred further
to an accident.
C OLLISION DIAGNOSIS
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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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LOWER STRUCTURE41
REAR LONGITUDINAL GIRDER
REPLACEMENT
This operation shall be performed only on the repair bench. For the specific supports mounting
on the bench, please see t he 40 chapter.
41 - 2
DISMOUNTING
Dismount
the damaged elements, which are
in contact with the rear longitudinal girder. Proceed to a straightening on the body
checking/straig htening Celette type, until bringing
the ve hicle a s closed as possible to t he i nitial
shape.
Detach the welding points of the rear longitudinal girder (1) which are in contact with:- the central floor in the area (1);
- the rear floor in the area (2);
- the rear end floor in t he area (3);
- the re ar side cross bar in t he are a (4);
- the t ank front cross bar in t he area (5);
- the tank re ar cross bar i n the area (6);
- the inner wheel passage in the area (7);
Straighten the areas resulted after dismounting.
Grind the areas resulted after dismounting.
REMOUNTING
Position and center the new element
W eld the rear longitudinal girder following the assembling outlines 1,2,3,4,5,6 and 7 (spots
and under gas protection welding) Protect the new element with a corrosion preventing and noise absorbent product.
1 5
47
2
3
6
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42
UPPER FRONT STRUCTURE
FRONT WING 42 - 1
DISMOUNTING
Dismount partially
the front bumper.
Dismoun t the side-sign aling lamp from the
front wing.
Dismount the attachment screws (1) of
wheel passage protection. Dismount the attachment screws (2 ), (3),
(4) and (5) of the wing on the vehicle body.
Dismount the front wing.
FRONT WING PREPARATION
A pply by means of a brush a layer of thermo- weldable product cls. 33 b, cs 4603 – 202 on
the contact areas of front wing with: - the contact area with the front wing lining;
- the contact area with the side frame l ining on the wing upper edge;
- the contact area with the wing fixing supports on the front pillar;
- the contact area of the wing rear lower part with the side frame lining;
- the contact area with the front part wing fixing support.
A pply also a sealant materi al l ayer type 223 in the contact area of t he front wing with: the
front wing lining, the side frame lining and the front pillar.
REMOUNTING
Perform the dismounting operations in the reverse order.
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REAR UPPER STRUCTURE
44
44 - 2

IN NER REAR WHEEL PASSAGE
DISMOUNTING
Dismount the elements, which are in contact
with the inner rear wheel passage.
Detach the welding points of the two rear
safety belt supports. Detach the welding points of the rear wheel
passage (1 ) which are in connection with:
- side frame lining in the area (2);
- side panel i n the are a (3);
- rear longitudinal girder in the area (4).
Straighten the areas resulted by dismountin g.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element.
Check the correct positioning of the rear
wheel passage. Weld the rear wheel pa ssage (1) following
the assembling outlines 2,3 and 4.
W eld the rear safety belts supports on the rear
wheel passage.
Prot ect the weldi ng wi t h a c orro si on-
preventing product. Apply a layer of sealant ma terial
PL ASTISOL 4, in the contact are a (5) of the
rear wheel passage with the rear floor.
4
1
2
5 3
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