battery replacement DACIA SUPERNOVA 2004 Repair Manual

19 - 6
19
COOLING - EX HA U ST - FU EL TANK
COOLING FAN REPLACEMENT
for vehicles with air conditioning
1 6 5
3 2 4
7
8
DISMOUNTING
Di
sconnect the (-) plug of the battery.
Di sconnect the cooling fan connector (5).
Di sconnect the cooling fa n resistance connector (1). Mark t he mounting position iden-
tification of the two connectors.
Detach the wiring from clip (6).
Cut the clip attaching the wiring on the cooling fan assembly in point (7).
Dismount the four-attachement screws (3) of the cooling fan on the radiator, recovering the
washers (2) and (4). Remove the cooling fan assembly.
REMOUNTING
Check the condition of the fan propeller, cooling fan electri c motor, washers.
Tighten the attachement screw (3) of the assembly.
Replace the clip from point (7).
Mount the wiring of t he cooling fan assembly taking i nto the considera tion the mount-
ing position m arked before dismounting. This is to be fi xed by means of a clip in point (7)
and will pass trough the clip (6). Connect the cooling fan re sistance connector (1).
Connect the cooling fan c onnector (5). Observe t he m ounting position i dentification of
the two connectors. Connect the battery plug (-). In case the vehicle is equipped with progammable radio-
cassettes, electronic clock, e tc, these a re to be reset before returning the vehicle to t he client. Check t he c ooling fan opera tion: start the vehicle engine and disconnect the water
temperature sensor. The cooling fa n must start. Reconnect the water t emperature sensor,
then by means of the CLIP tester, erase the memorized failure related to the water t em-
perature sensor.
FAILURES
ERASING
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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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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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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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AIR CONDITIONING
62
62 - 7
The compressor is absorbing the vapors coming from the evaporator at low pressure and
temperature, is compressing them and convey the gas at high temperature and pressure. The refrigerant fluid in high pressure and temperature vapor condition is entering in the second
he at exchanger, which by condensation is transmitting the heat to the external environmental.
At the exit from the condenser, the refrigerant fl uid is in liquid condition, at a high pressure and temperature.
Type of compressor: SD 7Y15
Compressor oil : PAG SP 10 or SP20, volume –135 cmc.
Refrigerant: HFC 134 a, quantity of refrigerant : 0.590 kg
C OMPRESSOR REPLACEMENT
DISMOUNTING
Disconnect the battery.
Drain the refrigerant circuit.
Disconnect the compressor’s connection.
Disconnect the pipes from the compressor.
Dismount the belt tensioning screw and release the belt.
Dismount the compressor attachment screws.
Dismount the compressor.
Replace the compressor.
REMOUNTING
Perform in the reverse order the dismounting operations.
T ension the belt and tighten at the required moment the tightening attachment screw.
Fill the refrigerant circuit and check the good operation of the climate control system.
COMPRESSOR
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AIR CONDITIONING
62
62 - 8
THE CONDENSER
The condenser is placed on the cooling radiator, in the front part of the vehicle and is ensuring
the exhaust of the refrigerant heat accumulated at compression.
In order to grant the optimum condenser operation, frequently check if its outside surfaces are
always clean and the air penetration is not stopped. Also, check the condenser pipes in order not
to show deformations. CONDENSER
CO
NDENSOR REPLACEMENT
DISMOUNTING
Disconnect the battery.
Drain the cooling circuit.
Dismount the pipes connected to the condenser.
Dismount the radiator-condenser assembly.
Separate t he cooling radiator from the condenser.
ATTENT ION:
A void the possible deformation of t he ducts and fi nned plates.
Replace the condenser.
REMOUNTING
Perform the dismounting operations in the reverse order.
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AIR CONDITIONING
62
62 - 10
DRY
ER FILTER TANK
The dryer filter tank has a triple function in the air conditioning unit:
- filtering the refrigerant fluid from the unit;
- absorbing the moisture from the unit;
- it is a buffer storage tank of refrigerant fluid.
DRY ER FILTER TANK
REMOUNTING
Perform the dismounting operations in the reverse order.
Fill the refrigerant circuit, check the leakage and the good operation of the unit.
AT TENT ION
Do not mount dryer fi lter tanks that do not have protection covers. DRY
ER FILTER TANK REPLACEMENT
DISMOUNTING
Disconnect the battery.
Drain the refrigerant circuit.
Dismount the piping and protect the threads.
Disconnect the connector of the air conditioning pressure controller.
Dismount the receiver tank filter from the collar support.
Replace the tank filter.
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AIR CONDITIONING
62
62 - 12
CL
IMA TE CONTROL UNIT REPLACEMENT
DISMOUNTING
Disconnect the battery.
Release t he lateral and central console.
Disconnect the wires from the dashboard wiring.
Disconnect the distribution flow flap control cables and the mixing flow flap from the control
lever and the recycling flow flap cable from the climate control panel.
Disconnect the air flow pipes.
Dismount the screws from the front side of the climate box.
Dismount the nuts from the welded screws in the backside of the climate box.
Release the climate control unit.
Replace the climate control unit.
REMOUNTING
Perform in the reverse order the dismounting operations.
CL
IMA TE CONTROL UNIT
AIR INLET ASSEMBLY REPLACEMENT
DISMOUNTING
Dismount the sealing gaskets on the climate box outliner.
Dismount the climate box locking plate.
Dismount the nuts from the right side of the climate box.
Release the air inlet assembly .
Replace the assembly .
REMOUNTING
Perform in the reverse order the dismounting operations.
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