brake DACIA SUPERNOVA 2004 Repair Manual

21 MANUAL GEARBOXSecti ons.......................................................... 21-1
Identification ................................................. 21-2
Tightening moments...................................... 21-3
Ratios ............................................................ 21-4
Capacity, lubricants....................................... 21-5
Particul arities................................................. 21-6
Ingredie nts..................................................... 21-7
Parts of systema tic replacement.................... 21-8
S pecial tools.................................................. 21-9
Gearbox dismounting ................................... 21-10
29 DRIVE SHAFTS Front transversa l transmission........................ 29-1
Bell ows - Be aring assembly to
t he gearbox.................................................... 29-4
Bell ows to wheel........................................... 29-7
Be llows to gearbox....................................... 29-12
Bell ows to wheel........................................... 29-15
30 GENERAL General principle sc hedule
of the brake circuit........................................ 30-1
Tightening moments...................................... 30-2
Com position and dimensions
of the ma in braking system elements............ 30-6
Br aking system diagnostic............................ 30-7
Br ake connections and se werage.................. 30-12
Br ake fluid.................................................... 30-13
Br aking circuit purging................................. 30-14
The inf luence of the front axle angle s on
t he road behaivior (vehicle comportment)
and on tyres wear........................................... 30-16
Prelimi nary checking..................................... 30-17
C hecking of the front axles adjustment......... 30-19
31 FRONT BEARING ELEMENTS Characteristics... .......................................... 31-1
Sus pension arm... .......................................... 31-2
Elastic bushings of suspension arm............... 31-4
Sus pension ball joint..................................... 31-5
Br ake gaskets................................................ 31-6
Br ake caliper................................................. 31-7
Br ake disk..................................................... 31-9
St eering knuckle............................................ 31-10
St eering knuckle bearing. .............................. 31-12
Fr ont suspension............................................ 31-13
Shock absor ber, Sprint. ................................. 31-14
Sp ring assembly shock absorber................... 31-15
Anti-roll bar................................................... 31-17
33 REAR BEARING ELEMENTS Characteristics............................................... 33-1
Rear axle....................................................... 33-2 Re
ar suspension............................................ 33-4
Shock absorber............................................. 33-5
Spring ........................................................... 33-6
Br ake drum................................................... 33-7
Br ake cylinder.............................................. 33-8
Br ake shoes.................................................. 33-10
Be aring (25 x 52 x 37)................................ 33-12
35 WHEELS AND TYRES Characteristics.............................................. 35-1
Wheels balancing......................................... 35–4
36 STEERING ASSEMBLY Axial ball joint............................................. 36-1
Steering box................................................. 36-3
Pus her........................................................... 36-4
Noise absorber bearing................................. 36-5
Bell ows......................................................... 36-6
Deformable lower shaft................................ 36-7
Ste ering weel position adjustment................ 36-9
37 MECHANICAL ELEMENTS CONTROLS Brake pump.................................................. 37-1
Servobrake................................................... 37-6
Air filter – se rvobrake reta iner valve........... 37-9
Handbrake adjustment.................................. 37-10
Handbrake control lever............................... 37-11
Handbrake secondary cable.......................... 37-12
Br ake flexible hoses..................................... 37-14
Br ake pressure controller.............................. 37-16
clutch hydraulic control................................ 37-19
The gear control........................................... 37-23
Pe dals support.............................................. 37-25
Acceleration pedal....................................... 37-26
Acceleration contr ol cable........................... 37-27
Transmission2
Chasis3
SION
LL
NT
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VALUES AND SETTINGS
07DIMENSIONS , WEIGHTS
07 - 1
DIMENSIONS (mm)
Total length (B) 4030
Total width (G) 1640
Total height (H) * em pty 1395
* with lifted hatchback (H1) 1940
Wheel base (A) 2475
Front wheel track width (E) 1410
Rear wheel track width (F) 1345
Ground clearance (K) * loaded 134
Hatchback free height (Q) 925
Turning radius * Between footways 4950
* Between walls 5000WEIGHTS (kg)
Unloaded vehicle weight: * on the front axle 545
* on th e rear axle 405
* total 950
Maxi mum authorized load
* on the front axle 715
* on th e rear axle 670
* total 1385
Authorized payload 425
Load w ith trailer with own brake 815
Load w ith trailer without own brake 450
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VALUES AND SETTINGS
07BRAKES
Vehicle
DACIA
SupeRN ova Normal
20 Minim
19 Normal
228 Maxim
229 Front
0,1 Rear
-
The width of brake disk and drums diameter (mm)
Front Rear The maxim axial run out
of disk
Vehicle
DACIA
SupeRN ova Normal
14 Minim
7 Normal
5 Minim
0,5 mm
above the r ivets SA
EJ 1703 DOT 4
The thickness of gaskets (mm)
Front Rear Brake fluid
07 - 7
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ENGINE E7J-A-2/6010
10 - 3
ENGINE AND LOWER ENGINE UNITS
MOTOR-PROPELLING GROUP
Di sconnect the wiring c onnector from t he
reverse driving contact. The right-side planetary transmission is un-
coupled as follows:
-the brake-stirrup set is dismantled;
-disconnect the wire for the brake pads
wear indicator; -the t wo screws for fixing the shock-
absorber of the steering-swivel stand are taken
off;
The steering-swivel stand is tipped up and
the planetary t ransmission is taken out from
the planetary pinion of the gearbox;
The l eft-side planetary transm ission is un-
coupled as follows:
-the steering-swivel screw-nut is dis-
mantled; -t he scre ws for fi xi ng t he pl a neta ry
transmission on the gearbox a re taken off; -the brake-stirrup set is dismantled;
-the e lectric wire of the wear-and-abra -
sion light-i ndicator is taken off; -the t wo screws for fixing the shock-
absorber of the steering-swivel stand are taken
off; -the steeri ng-swivel stand is t ipped up
and the planetary tra nsmission is taken out; The fuse-box in the engine compartment
is dismantled.The following are disconnected: -connector 1 from the UCE injection
(pull flap 2, then disconnect);
-the front cabling of the engine;
-the connector of t he shock-sensor;
-the ventilator connector;
-the mass wire on the gearbox.
The battery protection screen is dis-
mantled.
The following are taken off:-the linking pipes coming from the ra -
diator, by using the pincers for elastic pipe-
collars MOT.1202-01B ;
-the linking pipes coming from the de-
gassing vessel, by using the pincers for elas-
tic pipe-collars MOT.1202-01B ;
-the pipes for a ir-conditioning coming
from the therm ostat stand and the water-pi pe;
12
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ENGINE E7J-A-2/6010
10 - 5
ENGINE AND LOWER ENGINE UNITS
MOTOR-PROPELLING GROUP
The screw- nut of t he hyd ro- e l a st ic
buffer is taken off (right);
The Motor-Propelling set is taken out and
then placed on a stand.
Re- Mounting
The steps are taken in the re verse order (see dismantling / taking apart).
To do:
-the filling-up a nd the drainage of the cooling circuit (see Chapter “ Filling-up and
Dr aining”).
CAUTION! USE ONLY TYPE D A NTIFREEZE.
- filling-up the engine and the gearbox with oil;
- filling-up and draining the clutch hydraulic command circuit (see Chapter “Draining
of the clutch hydraulic command circuit”); The liquid to use is brake fluid type SAE J 1703, DOT 3, DOT 4.
The screws and the screw-nuts of the couple are fastened back.
When mounting, line up markings from hoses and related parts.
The Motor-Propelling set is upheld by
the two handles, by means of a m oving
lifting device (a mobile crane);
The four screws fixing the Motor-Propel-
ling set ba ttery stand are taken off, as well
as the screw-nut of t he elastic buffer;
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 57
DIAG
NOSING-INTERPRETING THE STATES
The idle mode rotation
ra tio > maximal limit. The id
le mode rotation ratio is too great.
- Chec k the oil level of the engine
- Chec k the good functioning of the atmospheric pressure sensor.
- Check the tubes connected to the admission collector.
-C heck the fittings of the admission collector
- Check the watertightness fittings of the clapper body
- Check the watertightness of the power-brakes.
- Chec k the presence of the nozzles of the oil-vapour re-aspiration circuit
- Chec k petrol pressure.
- Check the adjustment of the rocker-arms and the settling of the distribution.
If all the above are correct, then the step-by-step engine will have to be replaced.
Perform again the conformity test
AF T E R REPAIR
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 68
DIAG
NOSING-BREAKDOWN LOCALIZATION ALGORITHM
A
Check if there are cases of lack of watertightness (noise)
on the powe r-brakes.
Connect the “CLIP TEHNIC” device to do this test in
accordance with the usual manner of work.
Disconnect the tube between the draining valve and the
intake collector and strangle it up. If the disturbances
d isappear, the cause was the draining valve.
AFTER REPAIR Erase the def
ects memorized. If there are no other problems,
eras e the parameters memorized by the calculator.
Check the powe r -br a kes
Ch eck t h e engine compression
♦
♦
Check the canister
draining valve♦
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 70
DIAG
NOSING-BREAKDOWN LOCALIZATION ALGORITHM
Check if the clapper body is not clogged.
Check if there are cases of lack of watertightness (noise)
on the powe r-brakes.
Connect the tester “CLIP” and do the test corresponding
to the check-up of the rotation signal.
Check if the spurs, the brake cylinders and the wheel ball-
rings are no t seized-up.Check the body o f
the clapper♦
Ch eck t he power-br akes
Check the engine
flywheel
Check the running
train
Check the cooling
of the engine
♦
♦
♦
Check if there is enough engine cooling.♦
Check the canister
draining valve Disconnect the tube between the draining valve and the in-
take collector and strangle it up. If the disturbances disap-
pear, the caus
e was the draining valve.
Check the engine
comp ression Connect the “CLIP TEHNIC” device to do this test in accor-
dance w ith the usual manner of work.
AFTER REPAIR Erase the defec
ts memorized. If there are no other problems,
eras e the parameters memorized by the calculator.
♦
♦
A
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20
CLUTCH
It is a dry mono-disc clutch with hydraulic
command. The clutch mec hanism has a diaphragm
spring.
The clut ch d isc has an elastic hub.
Th e su pply of the hydraulic circuit is done
with liquid from the brake-liquid tank. The principle of this command is the same
as that of a brake command.
The cl utch pedal operates on the emitting
cy linder, which transmits the liquid under pres-
sure to a concentric hydraulic receiver, the mo-
bile part of which acts directly on the diaphragm
spring.
The hydrau lic receiver is fixed on the clutch crankcase through the agency of two screws.
20 - 1
IDENTIFICATION
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DRIVE SHAFTS
29
FRONT TRANSVERSAL TRANSMISSION
DISMOUNTING - THE SIDE TO WHEEL
Loosen the left wheel screws.
Lift the vehicle on an elevator with two columns.
Di smount the wheels.
Di smount the scre ws that attach the brake disk assembly on the steering knuckle.
Un screw the transmission nut by means of the RO 604 – 01 device.
Di smount :
- the nut of t he steering ball joint;
- steering ball joint from the steering knuckle, by means of the PF 476 extractor; the
attachment screws of the steering knuckle on the shock absorber end. S
PECIAL TOOLS
- RO 604-01 Hub immobilizing device
- PF 476 Ball joint extractor
TIGHTENING MOMENTS (daN/m)
- Transmission nut 21\
- Screw for fixing the bellows lid on the gearbox 2,5
- Wheels attachment screw 7,5
- Screws, nuts for fixing the steerin g knuc kle on the shock absorber 7,5
- Screw for fixing the caliper on the steeri ng knuckle 6,5
- Nut for steering ball joint 4
Pu sh the transmission in the steering knuckle and incline the latter.
Di smount the transmission, the wheel side.
29 - 1
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