wheel 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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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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TOWING
03
Front (right) Rear (left)
03 - 1
NE VE R U SE AS T OW IN G POIN
TS, THE TRANSMISSION AXLES
(PLANETARY SHAFTS)
The towing points, front, or rear, are to be used only for vehicles towing on wheels.
These poi nts cannot be a nyhow used for drawing out the damaged vehicle from a trench
(hole), or for direct or indirect vehicle lifting on a transport platform. ALL TYPES
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LUBRICANTS CONSU MABLES
04
ProductPlace where it is used
OILING (GREASING)
MOLYKOTE ”BR2”
(LOCTITE 8103) Front transmission pinion grooves
Grease Right transmission joint G.I
ELF CARDREXA RNT2 Transmission joint G.E.
Grease
MO LY K OTE 33M Gearbox control protection bellows
Grease
Li C a Pb t ip II c u MoS
2Steering rack, pinion, oil seal ring( steering box)
SEALING
LOCTITE 518 Water pump Support thermostat
Crankshaft half crankcase
Gearbox half crankcase assembling
Thread of the reverse driving contact.
Crankshaft no.1 bearing cap
LOCTITE 5900
(RHODORSEAL 5661) Engine lower crankcase
SOLDERING
LOCTITE 270 Nut of primary shaft
(FRENBLOC) Screw of secondary shaft Speed V fix pinion grooves
Speed V hub grooves
LOCTITE 549
(AUTOFORM) Fly wheel seating surface on the crankshaft CLEANING
LOCTITE METALLREINIGER
(DECAPJOINT) Cylinder head gasket surface cleaning
04 - 1
CONDITI
ONS
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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
07WHEELS AND TYRES
VEHICLE
DACIA
SUPERNOVA RIMS
5,5B x13
5,5 Jx13H2 TIRES
165 / 70 R 13
PRESSURE (daN/cm
2)
FRON TR EAR
1,9 2,0
Tightening moments of the wheels nuts 7.5 daNm.
Axial run out : max 1 mm
Radial run out : max 1 mm
07 - 6
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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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VALUES AND SETTINGS
07C HECKING VALUES OF THE FRONT AXLE ANGLES
07 - 9
ADJUSTMENTS
Not adjustable
Not adjustable
Not adjustable
Adjustable by
rotating the tie
rod of th e steer-
ing rod; one rota-
tion
1 tur = 15’
(1,5 mm)
POS ITI
ON OF
THE FRONT AXLE
H5 - H2 = 20 mm at half load
H1 - H2 = 80 mm - at ha lf load
H1 - H2 = 80 mm - at ha lf load
H1 - H2 = 80 mm - at ha lf load
H1 - H2 = 80 mm - at ha lf load
VALUES
2
0 +/- 30’
Maximu m difference
between left wheel
camber an gle and
the right one
= 10
00 +/- 30’
Maximu m difference
between left wheel
caster angl e a n d the
right on e = 1
0
12045’ +/- 30’
Maximu m difference
between left wheel
ball joint transversal angle a nd the right
one = 1
0
Toe in 0 - 2 mm lat half load or 1 +/- 1
mm
ANGLES
CAMBER ANGLES
CASTER ANGLES
TRANSVERSAL BALL JOI NT
ANGLE
PARALLELISM
TIGHTENING POSITION OF
THE ELASTIC BUSHINGS
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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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