suspension 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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SPECIFICATIONS
01
VEHICLE IDENTIFICATION
a.. Manufactu rer identification code;
b. Code of the vehicle;
c. Gearbox ty pe code;
d. Engine type code and driving location ( according to VIN code structure);
e. Vehicl e code;
f. Trailer ma ximum authorized weight without braking system;
g. Homologation number for the importer country;
h. VIS sign-one character for year model code + 7 characters for the chassis manufacturing number;
i. Maximum technical admissible weight of the loaded car;
j. Maximum admissible weight with trailer with braking system;
k. Maximum technical admissible weight on front axle;
l. Maximum technical admissible weight on rear axle.
LABEL T YPE OVAL PLATE
The se lf- adhesive label type oval plate is stuck on the right lateral side surface of the
dashboard. This enables the identification of the vehicle type and of its equipment, being exclusively
used fo r after-sale activity.
01 - 3
1,1
2,1 2,2
4,1 4,2
The reading of the codes marked on the oval plate type label
Caption:
Line 1
1.1 Cod type auto APV (after-sale):
B41A(E U 9 6 ) B41B(EU00) B41D(1 5 .04)
Line 2
2.1 Le vel of equipping: E0, E1, E2, E3
2.2 Options eq uipping code:
Line 4
4. 1 Technical definition code, driving place.
S2 : Left hand drive
4.2 Options equipment code: A: Normal suspension K: Without pre-filter
C : Temperate climate M: Steering mechanical system
E: Warm climate R: Without variable shock absorber
F : Normal heating T: Without plate corrector
G : Air conditioning V: Without wheels anti blocking (ABS)
B = represents body type
A ,B,D = represents engine type E7J, 1397 cmc, front wheel
drive type, mechanical gearbox.
Attention
Do not unstuck or damage the label from the lateral side surface of the dashboard. This
label represents the only way of vehicle identification needed to the after sale services, for a
period of 8 (eigh t) years from the purchasing date.
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LIFTING
02MOBILE JACK - PROTECTION ROUTESSafety sign
(particularly cautions to be observed in case of an intervention)
SPECIAL TOOLS
DENOMINATION CODE
Protection route Cha 280-02
Adjusting socket on mobile jack Cha 408-01 or Cha 408-02
The use of a mobile jack implies the necessity of using protection routes.
It absolutely forbidden the vehicle lifting using the front suspension arms or the rear axle as
supporting points. The following type of m obile jack is using the sockets, the support Cha 408 – 01 or Cha
408 – 02 in orde r to place the route Cha 280 – 02. In order to lift the front or rear part of the vehicle, take as support the lifting points used also
for the vehicle jack.
LATERAL MOBILE JACK
Use the CHA 280 hold.
P lace it on under the threshold at the front door level.
The floor closing plate shall be positioned in the channel of the hold.
02 - 1
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VALUES AND SETTINGS
07C HECKING VALUES OF THE REAR AXLE ANGLES
07 - 10
ADJUSTMENTSNot adjustable
Not adjustable
REAR AXLE
POSITION
Rele ase
Rele ase
H4 - H5 = 20
VALUES
0
0 ... 00 30’
1 +/- 0,5 mm
ANGLES
CAMBER ( nega tive)
P ARALLELISM
( toe in )
TIGHTENING POSITION
OF TH E ELASTIC
BUSHINGS
For the values checking of the front axle angles, consequently the rear axle angles, the vehicle
must:
- to be placed with the wheels on the rotating plates ( of the bench ) being in horizontal plane;
- to ensure its braking;
- to check its suspension for vehicle setting at its free height;
- to compress its front axle at half loading ( by means of the compressing device DIR 500);
- to check its suspension for vehicle setting at its free position;
- steering brought at middle point and the steering box blocked in this position;
These op erations are followed by the optical device attachment on the vehicle, observing the
instructions of the steering angles checking bench manufacturer.
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ENGINE E7J-A-2/6011
UPPER AND FRONT ENGINE UNITS
Tightening couples (daNm)
Screws of wheels7.5
Screw of the crankshaft pulley 2+68
o+/-6o
S crew-nut of stretching runner 5
Screws right-side stand 6.2
Screw-nut hydroelastic buffer 3.7
DISMONTING
The car is placed on a lifting stand.
The fore part of the engine is proppe d
on the frame using the MOT.545 device.
The following are taken apart: -front right-side wheel;
-the right-side pendular suspension;
11 - 1 -the alterna tor belt;

-the carrying belt of the compressor
(AC) ;
-the pulley of the crankshaft and its hub;
-the carryi ng pulley of the compressor;
-the distri bution crankcases.
DIS TRIBUTION BELT
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ENGINE E7J-A-2/6011
UPPER AND FRONT ENGINE UNITS
SPECIAL TOOL- AND-CHECK SETS
MOT.1202-01 -”CLIC” collar-pincers
MOT.1505 -Device for measuring belt tension
MOT.484 -Device for jacket maintaining -Wrench for angular tightening
-Pincers for elastic collar
TIG H TENING CO UPL E S (daNm )
S crew-nut of stretching runner/pulley 5
Screw of crankshaft pulley 2+68
o+/-6o
Screws of pendular suspension stand 6.2
Screw-nut of hydro-elastic buffer 3.7
Wheel Screws 7.5
Co mbustion-head Screws 2+97
o+/-2o
To take apart :
-the connector of the induction coil;
-the fue l hoses (t he going- and re -
turn circ uit); -the connectors of the injectors;
-the plugs of the sparks;
-the induction coil.
11 - 3
CYLINDER HEA D FITTING
D
IS M O UNT ING
The car is placed on a two-column lift -
ing stand; The battery i s disconnected;
The cooling circuit is emptied at the
jack situated at the lower pa rt of the radia-
tor; The distribution belt is taken apart (see
Chapter Distri bution Belt);
The following are taken apart: -air-filter;
-the c onnector of the c lapper-posi-
tion potentiometer (1); -the acceleration cable;
-the connector of the atmosphe ric
pressure sensor (2);
-the co nnector of the step-by-step
engine (3); -the connector of t he air temperature
sensor (4) on the intake collector;
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30
GENERAL
30 - 11
BRAKING SYSTEM DIAGNOSTIC
II.
CONSTANT EFFECT AT BEHAVIOUR
EFFECTS
Brakes not accomplishing the
required braking distance
Vibrating brakes
When braking, the vehicle ( front
p art) is left/right deviating
Braking
Heating brakes POSSIBLE CAUSES
- No n- un if o rm wo rn brake lin ings
(backing off);
- Brake linings slightly greased;
- Springs with modified characteristics.
- Brake disks with high wobbling;
- Inconstancy brake disks width;
- Particles abnormal deposit on brake disks
(oxidation between linings and disk).
- Front axl e suspension, steering (to be
checked);
- Stuck piston;
- Tires – wear, inflati on pressure;
- Rigid duct narrowed (flattening).
- Stuck piston;
Automatic adjustment : hand brake cable very
tighten.
REMARK :
Automatic recovering is performed by
means of the brake pedal, if there is no ab-
no rm al t ensi on in the hand brake cable
when released (hand brake released).
- Return spring.
- Insufficient hydraulic stroke of the brake
pump, not allowing the return at rest of
the brak e pump pistons ( brake pump
remaining under pressure);
- Stuck pistons or hardly returning;
- Rigid duct narrowed (flattening);
- Def ective adjustment of the hand brake
control.
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30
GENERAL
30 - 16
THE INFLUENCE OF THE FRONT AXLE ANGLES ON THE ROAD
BEHAVIOR (VEHICLE COMPORTMENT) AND ON TYRES WEAR
CAMBER ANGLE 0
0 +/- 30’
It is formed by the wheel plane with the vertical that crosses the wheel axis.
A difference higher that 1° between the two angles leads to :
- the deviation from the trajectory that must be adjusted by means of the steering wheel.
- abnormal wear of the tires and bearings.
The angle is not adjustable.
THE BALL JOINT ANGLE 12
045’ +/- 30’
It is formed in transversal plane between the axe connecting the attachment point of the
shock absorber with the ball joint center and the vert ical passing through the wheel axis.
The ba ll joint angle i s genera ting a ne gative offset, allowing the maintaining of the vehicle
route when the braking is unequal distributed. The angle is not adjustable.
THE CASTER ANGLE 2
030’
It is formed in longitudinal plane, between the axis connecting the attachment point of the shock
absorber with the suspension ball joint center and the vertical axis passing through the wheel axis. A difference higher than 1° between the two angles leads to : - the deviation from the trajectory that must be adjusted by means of the steering wheel.
- a normal wear of the tires.
The angle is not adjustable.
STEERING BOX POSITIONING
The steering box must be at a certain height from the attachment points of the steering auxiliary
connecting rod ball joints. The position of the steering box (choking) is influencing the variation
of the parallelism. The steering box is mounted in the position for which the variation is minimal.
The modification of t he para llelism between left side and right side leads to: - the deviation of the vehicle, in one sense, upon accelera ting;
- the deviation of the vehicle in the opposite side upon braking.
- the deviation of the tra jectory on the hilly ground;
- the premature wear of the tires.
The horizontally of the steering box is ensured by the producer.
PARALLELISM
( TOE-IN OR ANGULAR SPREAD ANGLE )
It is measured in horizontal plane as a differen ce between the front and rear part of the same axle wheels.
The wheels are divergent. The value of the opening is between 0 – 2 mm (1 +/- 1 m m).
ATTENTION:
A too much opening causes the wear of the tires on the inner pa rt of the camelback.
A too much closing causes the wear of the tires on the exterior part of the camelback.
The para llelism is adjustable by rotating the tie bar of the steering connecting rod.
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30
GENERAL
30 - 18
PRELIMINARY CHECKING
Due to the geometr ic conception of the front axle, the modificati on of one of one-
si de angles (castor, camber, ball joint) has no major impact on the value of other side
angles (the parallelism being the one directly influenced). The m odification of t hese a ngles doe s not oc cur duri ng vehicle exploitation, but onl y as
a consequence of a vehicle accident.
It is import ant to observe the following sequence : - placing the vehicle on rotating plates;
- braked vehicle
- suspension checking for pl acing the vehicle at its free height;
- establishing the steering centra l point and steeri ng box blocking.
- attachment of the optical devices on the vehicle, observing the manufacturer
instructions.
REPARTITION CHECKING AND ADJUSTMENT
Check the “ X” dimension symmetry of
the connecting rods.
Reading of t he “ A” value on the scale.
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31
FRONT BEARING ELEMENTS
31 - 1
CHARACTERISTICS
The front axle is composed of two joint half axles with independents wheels, designed for the
suspension type Mc.Pherson.
The joints of front half axle arm are done by means of an elastic bear ing (chassis side) and
by means of a suspension ball joint (wheel side)
The transmission of the motion to the wheels is done by means of two planetary axles, not
equal, with homocinetic tripod joints.
The wheel hub is assembled in the steering knuckle by means of a preset and sealed
bearing. The brake disks are aerated.
Tigh tening moments (daNm)
Wheel attachment screw 7,5
Suspension arm shaft nuts 7,5
Attachment nut of the ball joint screw 5,5
The nut of the attachment screw of the steering
knuckle with the shock absorber 7,5
Transmissio n nut 21,0
Steering ball joint nut 4,0
The attachment anti roll bar nut 2,5
The connecting strap screw 2,7
The attachment screw of the suspension ball joint on the arm 7,5
The attachment screws of the disk on the hub 2,5
Aux.connecting rod- assembled connecting rod end stop nut 5,0
Assembled connecting rod end- rack joind body 5,0
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