dimensions DACIA SUPERNOVA 2004 Repair Manual

01 SPECIFICATIONSEngine – Clutch - Gearbox............................. 01-1
Vehicle identification.. ................................. 01-2
02 LIFTING Mobile jack - Protection route;....................... 02-1
Elevator positioned under the carriage body... 02-3
03 TOWING All types.......................................................... 03-1
04 LUBRICANTS CONSUMABLES Condition....................................................... 04-1
05 DRAINING – FILLING Engine............................................................ 05-1
Gearbox.......................................................... 05-2
07 VALUES AND SETTINGS Dimensions..................................................... 07-1
Capaci ty - Qualities........................................ 07-2
Driving belts tightening and accesorie s.......... 07-3
Distribution belt tension................................. 07-4
Cy linder head tightening................................ 07-5
Wheeles and tyres........................................... 07-6
Br akes............................................................. 07-7
Dimensions under carriage body.................... 07-8
C hecking values of the fr ont axle angles........ 07-9
C hecking values of the rear axle angle s......... 07-10
10 ENGINE AND LOWER ENGINE UNITS Ingredients...................................................... 10-1
Motor-propelling group.................................. 10-2
Separation - Dismantling................................ 10-7
Characteristics................................................ 10-10
Rec overy engine.............................................10-17
Lowervcrankase..............................................10-37
Oil pump........................................................ 10-38
Tightening moments....................................... 10-39
11 UPPER AND FRONT ENGINE UNITS Distribution belt............................................. 11-1
Cylinder head fi tting....................................... 11-3
12 FUEL MIXTURE Characteristics................................................ 12-1
Cl apper body .................................................. 12-4
Intake cole ctor................................................ 12-5
Exhaust collector............................................ 12-6
13 PUMP SUPPLY
Br eaking fuel supply ..................................... 13-1
Injection pump............................................... 13-2
Petrol filter.................................................... 13-3
P upm flow...................................................... 13-4
Supply pressure.............................................. 13-5
14 ANTI-POLLUTION Petrol vapours-aspiration ............................. 14-1
16 STARTING AND CHARGING Alternator....................................................... 16-1
Starter............................................................. 16–7
17 IGNITION AND INJECTION Ignition system.............................................. 17-1
Sparking plugs.............................................. 17-2
Peculi arities.................................. ................ 17-3
Placi ng of elements........................................ 17-4
Idling regime adjustment............................... 17-9
Adjustment of the fuel mixture enriching...... 17-11
Enriching adaptive correction....................... 17-12
Diagnosing-Introduction... ............................ 17-15 Diagnosing-Interpreting the defects.............. 17-17
Diagnosing-Conformity test........................... 17-49
Diagnosing-Interpreting the states................. 17-55
Diagnosing-breakdown localization
algorithm....................................................... 17–66
19 COOLING - EXHAUST - FUEL TANK Characteristics............................................... 19-1
Filli ng and draining ...................................... 19-2
C ontrol.......................................................... 19-3
The schema.................................................... 19-4
Ra diator dismounting and remounting.......... 19-5
C ooling fan replacement
for vehicles with air conditioning................. 19-6
C ooling fan diagnostic
for vehicles with air conditioning................. 19-7
Re sist ance cooling fan replacement
for vehicles with air conditioning................. 19-9
C ooling fan replacement
for vehicles without air conditioning............ 19-10
C ooling fan diagnostic
for vehicles with air conditioning.................. 19-11
Water pump .................................................. 19-12
Dismounting - remounting exhaust................ 19-14
Emptyng of tank............................................ 19-16
Tank fuel description..................................... 19-17
Tank fuel....................................................... 19-20
Electric petr ol pump...................................... 19-21
20 CLUTCH Identification................................................. 20-1
Diagnostic.. ................................................... 20-3
Clut ch disc mechanism.................................. 20-9
Moteur et peripherics
General poinds vehicle0
1
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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
07DIMENSIONS UNDER CARRIAGE BODY
DIMENSIONS UNDER CARRIAGE BODY CONDITIONING
ADJUSTMENT OPERATIONS OF THE STEERING ANGLES
H 1, H4 - distance between the wheel center to the ground.
H2 - distance from the girder lower part at the ground to the front wheels axis level.
H5 - distance from the attachment screw axis of the rear axle a rm, to the ground
07 - 8
H5
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30
GENERAL
30 - 6
COMPOSITION AND DIMENSIONS OF THE MAIN BRAKING
SYSTEM ELEMENTS
Front brake
Brake caliper bore diameter F 54 mm
Aer ated bra ke disk diameter F 235 mm
The axial run out of the disk measured at Æ215 0,1 mm
Brake disk m aximum thickness 20 mm
Brake disk minimum thickness 19 mm
Braking pad thickness (support included) 14 mm
Minimal brake pad thickness (support included) 7 mm
R ear brake
Wheel braking cylinder bore diameter F 22 mm
Ne w drum diameter F 228 mm
Dr um diameter aft er grinding F 229 mm
Shoe braking lining width 40 mm
Braking lining thickness 5 mm
Minimal accepted braking lining height above rivets 0,5 mm
Master brake pump cylinder
Bore diameter 20,6 mm
Pump maximum stroke 32 mm
Brake fluid reservoir Without level alert sensor
Pressure limite r For parallel circuit
Ser vobrake master vac 7” 177,8 mm
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30
GENERAL
30 - 17
PRELIMINARY CHECKING
Before c hecking and adjustment of the front a xle ge ometry, pe rform t he followings
operations: * The checking of tires concerning: - dimensions
- air pressure
- the state of wear;
NOTE :
The t ires must be of same t ype, with the same state of wear, ai r pressured at the
prescribed pressure.
*The check of joints: - the wear of e lastic bushings
- the steering ball joints clearance
- the wheels bearings clearance.
NOTE :
The axial clearance of the bearings must be in admissible limits. ESTABLISHING OF THE STEERING CENTRAL POINT
In order to perform a front a xle checking and adjustment, it is ne cessary t o e stablish the
centra l point in order t o avoid measurement errors.
To do that, bring the steering wheel so that device DIR 500 for steering box ra ck
blocking is enteri ng in the orifice placed at its right upper part .
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30
GENERAL
30 - 21
DIAGNOSIS
THE DEVIATION TO THE LEFT OR TO RIGHT AT STABLE SPEED
Pe rform the preliminary checking:
Wheels (front, rear) : Joints clearance:
- pressure - bushings
- dimensions
- types Checking points heights
- balancing - simetri e
A.m.
conditions
are respected
Correct the defi cient
The deviation persists
Checking fi nished
Check the front axle
steering geometry
The deviationpersists
NO
YES
NO
YES
YES
Check the rear axle
parallelism and the alignmentA
Checking fi nished
NO
C HECKING OF THE FRONT AXLE ADJUSTMENT
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35
WHEELS AND TYRES
CARACTERISTICSRIMS
The wheels identification marking is represented in two ways:
- engraved marking for steel rims
- cast marking for aluminum rims
The marking enables acknowledgment of the main wheels dimensions criteria. This marking
may be:
complete,
Example: 5
1/2 B 13 4 CH 46 ; 5 1/2 J 13 4 H2 46
or simplified,
Example: 5
1/2 B 13 ; 5 1/2 J 13 H2
The wheel bolts (studs) are situated on a diameter of 100 mm.
Maximum axial runout : 1 mm measured on the rim edge ( in G ).
Maximum radial runout : 1 mm measured on the supporting side of the tires beads.
AB C D EF
Whe els Width The rim Æ Nominal Number of Tire Offset
type (in inches) edge profile rim (in inches) wholes under staffing profile (in mm) the tire bead
5
1/2B13 5 1/2B1 34C H46
4 CH48
5
1/2J13 5 1/2J1 34H 246
4H 2
35 - 1
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WINDOWS
54
54 - 1
WINDSCREEN AND HATCHBACK GLASS REPLACEMENT
The replacement of t hese glasses is performed in case they a re broken, when they are not
according to the required overall dimensions or when they have manufacturing defects (image
distortions, cracks, etc).
PREPARING FOR MOUNTINGPosition the gasket (2) around the glass (1)
and place the assembly on a protection plate.
Place in the gasket channel all around the
gasket frame; a cotton cord ( 4 ) of 3 – 4
mm diameter, l eaving at its fre e ends (3)
about 20 cm of cord, and between the ends,
the distance shall not be more than 10 cm.
MOUNTING OF THE WINDSCREEN
M ount on the carriage body, the windscreen – cord - glass gasket assembly, so that the cord
ends are placed towards the inside of carriage body.
From the inside of the vehicle, successively draw each end of the cord, the drawing direction
being parallel with the glass surface, towards the surface inner part, perpendicular on the frame,
beginning with the lower part, in this way the gasket edge is lifted and then lowered on the frame.
At the outside, the gasket is seated by slightly and successively pressing it on glass, so that the
tightening is uniform on the whole windscreen contour and frame. DISMOUNTING OF A BROKEN
GLASS
If the glass or part of i t did not fa ll, t he
dismounting and the cleaning of the window
gaskets by the pieces of the broken glass
will be easier to be made by sticking a sheet
of paper on each surface.
WINDSCREEN AND HATCHBACK GLASS
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