REPAIR MANUAL DACIA COMMERCIAL RM 502-1 MECHANICS ENGINE: C3L GERBOX: NG1; NG7 TAPV: U75B; U75F The reparation methods prescribed by the manufacturer in the present document are established subject to technical specifications in force at the document issuing date. These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA.
0 General poinds vehicle 01 SPECIFICATIONS Engine – Clutch - Gearbox ........................... 01-1 Vehicle identification ................................. 01-2 02 LIFTING Mobile jack and protection route .................. 02-1 Elevator positioned under the carriage body... 02-2 03 TOWING All types ........................................................ 03-1 04 LUBRICANTS CONSUMABLES Conditions ..................................................... 04-1 05 DRAINING AND FILLING Engine .............
21 MANUAL GEARBOX Identification................................................. 21-1 Sections ........................................................ 21-2 Diagnostics ................................................. 21-6 Characteristics .............................................. 21-9 Tightening moments ..................................... 21-10 Ingredients.. .................................................. 21-11 Dismounting - Remounting .......................... 21-12 Repair ....................
SPECIFICATIONS ENGINE - CLUTCH - GEARBOX VEHICLE TYPE 1304 Pick-Up 1304 Drop-Side 1304 King-Cab 1305 Pick-Up 1305 Drop-Side 1305 King-Cab 1307 01 ENGINE CLUTCH GEARBOX TYPE CYLINDER CAPACITY (cmc) D 26119 D 46169 106 -02 106 -10 1557 1557 200 GR 200 DBR 50 C 51 C D 27119 D 47169 106 -02 106 -10 1557 1557 200 GR 200 DBR 50 C 51 C D 2S119 D 4S169 106 -02 106 -10 1557 1557 200 GR 200 DBR 50 C 51 C D 16119 106 -02 106 -10 1557 1557 200 GR 200 DBR 365 D 17119 102 -14 106 -02 106
01 SPECIFICATIONS VEHICLE IDENTIFICATION UNITL THE DATE OF 26.06.2003 Manufacturer plate Identification number VIN MANUFACTURERPLATE a. Manufacturer identificationcode; b. Code of the vehicle; c. Gear box type code; d. Engine type code and driving device location ( according to VIN code structure); e.Vehicle code; f. Maximum authorized weight without braking system; g. Locationplace of the homologationnumber for the importer country; h.
SPECIFICATIONS 01 VEHICLE IDENTIFICATION UNITL THE DATE OF 26.06.
01 SPECIFICATIONS VEHICLE IDENTIFICATION UNITL THE DATE OF 26.06.2003 OVAL TYPE PLATE LABEL The self-adhesive label is applied on the right part side surface of the dashboard. This enable the identification of the vehicle type and its equipment, being used exclusively for the after sale activity. OVAL PLATE INSTRUCTIONS THE INTERPRETATION OF THE CODES MARKED ON THE OVAL TYPE PLATE LABEL : 1,1 2,1 4,1 2,2 4,2 Line 1 1.
SPECIFICATIONS VEHICLE IDENTIFICATION 01 UNITL THE DATE OF 26.06.2003 OVAL TYPE PLATE LABEL Line 4 4.1 Tehnical definition code, driving post: S2: Left hand drive 4.
01 SPECIFICATIONS Vehicle identification STARTING WITH THE DATE OF 26.06.2003 MANUFACTURER’S PLATE DISPOSAL TYPE SELF-ADHESIVE Fig.2.1 01 - 6 vnx.
SPECIFICATIONS Vehicle identification 01 STARTING WITH THE DATE OF 26.06.2003 The MANUFACTURER PLATE, self-adhesivetype, has the bellowpresentedconfiguration, with two distinctive areas, presenting :manufacturer’s identification data and APV type identification data. A B C D E F G H I J APV IDENTIFICATION DATA MANUFACTURER’S IDENTIFICATION DATA A. Manufacturer’sname B. Community reception number or homologation number. C. Identification number. D. Total authorized weight of the loaded vehicle. E.
LIFTING MOBILE JACK AND PROTECTION ROUTE 02 It absolutely forbidden the vehicle lifting using the front or rear suspension arms as supporting points. The mobile jack shall not be used to lift the car in order to perform certain operations under the carriage body. LIFTING THE FRONT PART OF THE CAR For lifting, the rolling jack and the CHA 280 hold are used, in order to protect the body and mechanical item of the car, which are placed on longitudinal girders on wheels axle.
02 LIFTING ELEVATOR POSITIONED UNDER THE CARRIAGE BODY For lifting, place the elevator buffers on the same points where the car jack of the vehicle is usually placed. The edge of the threshold shall be placed correctly in the buffer channel. 02 - 2 vnx.
TOWING 03 ALL TYPES FOR TOWING OBSERVE THE LAW IN FORCE OF EACH COUNTRY NEVER PERFORM TOWING USING FRONT TRANSMISSION The towing of the cars on wheels must be obligatory done by means of the unique towing points These points cannot be anyhow used for drawing out the car from a trench ( hole ), for a similar intervention or for direct or indirect lifting of the car. FRONT REAR 03 - 1 vnx.
LUBRICANTS CONSUMABLES CONDITIONS PRODUCT Grease UM 170 Li Ca Pb 2M ELF CARDREXA RNT2 UM 185 Li 2M Grease UM 185 Li 2M Grease U 95 Ca 2 Grease Li Ca Pb type II with MoS2 (or 20 UM Li III) Grease 22 Grease U100 Ca 4-5 04 PLACE WHERE IT IS USED GREASING Clutch shaftgroves Pinions groves of front transmission Gear box control lever Pressure bearing Cardan flange sealing ring Front transmission Front wheel steering stub groves Cardanic transmission Front transmission Front wheel bearing Suspension ball j
LUBRICANTS CONSUMABLES 04 CONDITIONS PRODUCT RHODORSEAL 5661 LOCTITE 518 LOCTITE 577 Mastic 503 PLACE WHERE IT IS USED SEALING Inferior crankcase Distribution cover Propeller shaft pins Half crankcase Clutch crankcase Fuel pump ( with membrane ) Cover palier 1 Rear axle Thread of the reverse lamp contact. Gear box plug M 16 Rear axle Differential rear axle SOLDERING FIXAMED M28 Screwsof flywheelfixing Screws of crank shaft pulley CLEANING DECAPJOINT The surface of cylinder head gasket S.E.
DRAINING AND FILLING ENGINE Necessary special tools - wrench for draining plug : CV 514 Draining: plug (2) Filling:plug (1) 05 - 1 vnx.
05 DRAINING AND FILLING GEARBOX Draining: plug (2) Filling:plug (1) 05 - 2 vnx.
DRAINING AND FILLING REAR AXLE DIFFERENTIAL Draining:plug(2) Filling:plug (1) 05 - 3 vnx.
VALUES AND SETTINGS DIMENSIONS 07 DACIA 1304 PICK - UP DACIA 1305 PICK - UP DIMENSIONS ( mm ) Total length Total width Total height Empty Loaded Axle base Front wheel track width Rear wheel track width Ground clearance Empty Loaded Turn radius Between footways Between walls WEIGHT ( kg ) 4674 1636 1550 1450 2675 1334 1320 Unloaded vehicle weight On the front axle On the rear axle Total Maximum authorized load On the front axle On the rear axle Total Authorized payload 600 480 1080 760 1550 2250 1000
07 VALUES AND SETTINGS DIMENSIONS DACIA 1304 PLATFORM DACIA 1305 PLATFORM WEIGHT ( kg ) DIMENSIONS( mm ) Total length Total width Total height Empty Loaded Axle base Front wheel track width Rear wheel track width Ground clearance Empty Loaded Turn radius Between footways Between walls 4599 1615 1550 1450 2675 1334 1320 165 Unloaded vehicle weight On the front axle On the rear axle Total Maximum authorized load On the front axle On the rear axle Total Authorized payload Load with own brake trailer Load
VALUES AND SETTINGS DIMENSIONS 07 DACIA 1307 WEIGHT ( kg ) DIMENSIONS ( mm ) Total length Total width Total height Empty Loaded Axle base Front wheel track width Rear wheel track width Ground clearance Empty Loaded Turn radius Between footways Between walls 4794 2636 1525 2795 1310 1334 165 Unloaded vehicle weight On the front axle On the rear axle Total Maximum authorized load On the front axle On the rear axle Total Authorized payload Weight on towing hook 5600 5800 07 - 3 vnx.
VALUES AND SETTINGS 07 CAPACITY - QUALITIES DENOMINATIO CHARACTERISTICS CAPACITY (liters) SAE 15 W 40 / API SJ/CF Engine oil 3 SAE 80 W 90 / API GL4/GL5 2,3 Differential oil SAE 80 W 90 / API GL 5 2 Breaking fluid SAE J 1703; DOT 4 0,3 Gearbox oil Cooling fluid * Refrigerant A.C. Tip C Tip D - GLACEOL RX ** (from 26.11.2001 ) HFC 134 a PAG SP 10 Oil compresor 6 0,700 kg, 265 cmc * Mixture: 50 % concentrate antifreeze + 50 % distilled water.
VALUES AND SETTINGS DRIVING BELTS TIGHTENINGANDTIGHTENINGCHECKING 07 The checking of the belt tightening may be done by means of the MOT 557 device which has two scales; one shows the arrow’s value ,and the other implicitly translates the value of the tension ( force ).
07 VALUES AND SETTINGS DRIVING BELTS TIGHTENINGANDTIGHTENINGCHECKING * press on the device until the big “O” ring passes over the rule; ∗ read the value of force N on the scale with small “O” ring; ∗ compare the read value with the imposed value : - if the N force value is within the imposed range, the belt tightening is good; - if the read value is bigger or smaller than the imposed value, perform the adjustment of the distance between pulleys axles ( re tighten the belt ), until obtaining a value within
VALUES AND SETTINGS CYLIDER HEAD TIGHTENING AND RETIGHTENING 07 ATTENTION! In order to obtain a correct tightening of the cylinder head screws, clean the attachment holes of the cylinder head of oil or coolant liquid, by means a syringe. Grease the thread of screws with engine oil. CYLINDER HEAD TIGHTENING Tighten at the required moment (6,5 daNm) observing the tightening sequence from the drawing.
07 TYPE VALUES AND SETTINGS WHEELS ANDTYRES ROLLING WHEELS TYRES CIRCUMFERENCE VEHICLE 1304 1307 (mm) PRESSURE (daN/cm2 ) FRONT REAR 5 J 14 with deport 175 R 14 48 mm PR 8 1920 +/- 25 1,9 4,2 1307 - 4WD 5 J 14 with deport 175 R 14 1305 PR 8 48 mm 1304 - 4WD 1920 +/- 25 2,0 4,5 * Tightening moment of the wheels nuts (screws) 9 daNm. ∗ Axial run out: max 1,2 mm. ∗ Radial run out: max 1,2 mm. ∗ Pressure in tires to be checked at cold.
VALUES AND SETTINGS 07 BRAKES FRONT BRAKES Brake caliper bore diameter (for brake disk non aerated) Φ 48 mm Brake caliper bore diameter (for aerated brake disk) Φ 54 mm Disk thickness non aerated 10 mm Disk thickness aerated 20 mm Minimal disk thickness non aerated 9 mm Minimal disk thickness aerated 19 mm Brake pad thickness ( the support included) 14 mm 7 mm Minimal brake pad thickness (the support included) Disk axial run out, measured at Φ215 mm 0,1 mm REAR BRAKE Wheel braking cylinde
07 VALUES AND SETTINGS HEIGHTS UNDER CARRIAGE BODY VALUES UNDER CARRIAGE BODY CONDITIONING THE ADJUSTMENT OPERATIONS OF THE STEERING ANGLES. H1 – the distance measured from the wheels center to the ground H2 – the distancemeasured from the longitudinalgirder lower part to the ground H5 – the distance measured from the joint axis of the front leaf spring to the ground, measured in the area of the lower arm attachment.
VALUES AND SETTINGS 07 CONTROL VALUE OFFRONT AXLE ANGLES COMMERCIAL U 75 DRIVE (1304, 1307) ANGLES POSITION OF THE VEHICLE VALUES 1304 CASTER CAMBER BALL JOINT 1 0 11' 1 028' ± 30' 1 045' 2 002' 2 019' 2 036' 2 052' Maximum Left / Right difference = 10 10 22' 1 021' 1 020' 1 018' ± 30' 1 017' 1 015' 1 014' Maximum Left / Right difference = 10 8 0 01' 8 002' 8 003' 8 004' ±30' 8 005' 8 007' 8 008' Maximum Left / Right difference = 10 H5 H5 H5 H5 H5 H5 H5 - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = -
VALUES AND SETTINGS 07 CONTROL VALUE OFFRONT AXLE ANGLES OTHER STEERING SYSTEM VALUES TO BE RESPECTED ANGLES VALUES POSITION OF THE VEHICLE 1304 Steering box positioning 6 – 7,75 on the scale T.F.246 Steering rack central C=65mm point 07 - 12 vnx.
VALUES AND SETTINGS 07 CONTROL VALUE OFFRONT AXLE ANGLES COMMERCIAL U 75 / 4X4 DRIVE (1304, 1307) ANGLES CASTER CAMBER PIVOT BALL JOINT POSITION OF THE VEHICLE VALUES 1307 1304 H5 - H2 = H5 - H2 = H5 - H2 = H5 - H2 = H5 - H2 = H5 - H2 = H5 - H2 = 265 255 Adjustable by modifi245 cation of the tie-rod 235 length from previous mounting 22 215 205 1 0 11' 1 029' ± 30' 1 046' 0 2 02' 2 019' 2 036' 2 053' Maximum Left / Right difference = 10 H5 H5 H5 H5 H5 H5 H5 1 0 21' 1 020' 1 019' 1 018' ± 30' 1
07 VALUES AND SETTINGS CONTROL VALUE OFFRONT AXLE ANGLES OTHER STEERING SYSTEM VALUES TO BE RESPECTED ANGLES VALUES POSITION OF THE VEHICLE 1304 Steering box positioning 6 – 7,75 on the scale T.F.246 Steering rack central C=65mm point 07 - 14 vnx.
VALUES AND SETTINGS 07 CONTROL VALUE OFREAR AXLEANGLES COMMERCIAL U 75 DRIVE (1304, 1307) ANGLES VALUES VEHICLE POSITION 00 ± 34'30'' Empty (For two wheels) Toe out Empty ADJUSTMENTS CAMBER Not adjustable PARALLELISM Not adjustable 0 0 ± 34'30'' Empty ELASTIC JOINTS BLOCKI NG Empty - 07 - 15 vnx.
07 VALUES AND SETTINGS CONTROL VALUE OFREAR AXLEANGLES COMMERCIAL U 75 / 4 X 4 DRIVE (1304, 1307) ANGLES VALUES VEHICLE POSITION ADJUSTMENTS 0 0± 19'59'' Empty Not adjustable Empty Not adjustable CAMBER PARALLELISM (For two wheels) Toe out 0 ± 19'59'' 0 ELASTIC JOINTS BLOCKING Empty * In order to check and adjustthe front axle anglesvalues,respectivelythe rear axle ones, the following must be done: - perform the tires checking concerning: - dimensions - inflatingpressure - degree of wear -
ENGINE AND LOWER ENGINE UNITS INGREDIENTS UTILISATION TYPE RHODORSEAL 5661 LOCTITE 518 10 Propeller shaft pins. Oil sump and distribution cap. Petrol pump sealaing ( membrane type ) and cap of bearing no. 1. OMNI - FIT RAPID ( FIXAMED M 28 ) Flywheelattachementscrews,bearings cap screws. Engine lubrication,parts lubrication when mounting. Washing of steel,aluminium and cast iron parts. OIL SUPER 15 W 40 API SJ S.E. DERO 100 10 - 1 vnx.
10 VEHICLE TYPE ENGINE AND LOWER ENGINE UNITS IDENTIFICATION ENGINE G EAR BOX DISPLACEMENT ( cm 3 ) 1304 Pick-up 1304 Drop-side 106 - 10 1304 King-cab 1305 Pick-up 1305 Drop-side 106 - 02 1305 King-cab 1307 102 - 14 365 50 C 51 C 365 50 C 51 C 365 50 C 1557 BORE ( mm ) STROKE COMPRESS ( mm ) ION RATIO 77 83,6 8,5:1 1557 77 83,6 8,5:1 1397 76 77 8,5:1 10 - 2 vnx.
ENGINE AND LOWER ENGINE UNITS IDENTIFICATION 10 The engine identificationis done by meansof a plate attached to the cylinder block, above the oil filter. 1. Type of engine. 2. Engine manufacture series. 10 - 3 vnx.
10 ENGINE AND LOWER ENGINE UNITS MEASUREMENT OF OIL CONSUMPTION PREPARATION FOR TEST Place thecar on the elevator,dismountthe engine shield,checkthe presenceof oil leaks. If there are any leaks,eliminateit and then check again. Drain the oilfrom the engine. Fill the engine with 2,750 l new oil 15 W 40, start the engine and let it run in force ( 1000 - 1200 rpm. ) during aprox. 10 minutes, then stop the engine.
ENGINE AND LOWER ENGINE UNITS MEASUREMENT OF OIL CONSUMPTION 10 CONSUMPTION CALCULATION The oil consumption is given by the difference between the first weighing and the second weighing. Oil consumption G1 - G2. ADMISSIBLE CONSUMPTION The admissibleconsumptionis determinatedby: - the wear general condition of the engine; - the oil quality; - driving style,rpm; - engine tuning: carburattion. The engines with a oil consumption greater of 100 grams at 100 km need to be adjusted.
10 ENGINE AND LOWER ENGINE UNITS OIL PRESSURECHECKING The oil pressure checking is done in the followingconditions:oilto be up to the required level and of a adequate quality;oil temperature to be 80 ºC. To check the oil pressure use the followingprocedure : - check the oil level and fill in until the required level is reached(if this is necessary); if the oil is unsuitable(used) it shal be replaced. - start the engine and let it run until the oil temperature reach 80 ºC.
ENGINE AND LOWER ENGINE UNITS OIL FILTER REPLACEMENT 10 DISMOUNTNG Disconnect the battery. Loosen the filter by means of the MOT 445. Hand dismount thefilter. REMOUNTING Lubricatethe gasketof the new filter with oil. Tighten the filterby hand untill the asketcomesin the contactwith the block. Tighten 1/2 rotation more by means of the MOT 445 wrench. Loosenthefilter,bring the gasketinto contactwith the block and tighten 1/2 -3/4 morerotations.
10 ENGINE AND LOWER ENGINE UNITS ENGINE DISMOUNTING - REMOUNTING The engine may be independentlydismountedby taking it out through the upper part of theengine compartment. DISMOUNTING ( in the engine compartment ) Disconnect the battery. Dismountthe engine hood. Dismount the plug of the cylinder head cap,the plug of the oil casingand drainthe oil from the engine. Drain the coolingcircuit: - dismountthe radiatorplug; - dismountthe cylinders block plug. Dismountthe watterand fuel ducts.
ENGINE AND LOWER ENGINE UNITS ENGINE DISMOUNTING - REMOUNTING DISMOUNTING (under the car ) Dismountthe engineshield. Dismountthebeambetweenthe longitudinal girders. Dismount the nuts that attach(fix) the bushings to the stabilizerrod. Dismount the nuts that attach the gearbox to the engine. Dismountthe protectionplate of the clutch. Dismountthe pulleyof the crakshaft. Dismountthe attachment ring of the discharge tube. Unscrew the nuts that attach the engine supports to the buffers.
10 ENGINE AND LOWER ENGINE UNITS ENGINE DISMOUNTING - REMOUNTING PARTICULARS ON REMOUNTING Check the existanceof the two bushingsby meansof which the clutch casingis centered on the block. Slightlygrease ( thin coat) the clutch shaft grooves with Li Ca Pb type II grease. Adjust the stroke of the acceleration pedal. Perform: - thefillingwith oilof the engine; - the filling and aeration of the cooling circuit. Adjustthe engine running (ignition,carburation).
ENGINE AND LOWER ENGINE UNITS ENGINE AND GEARBOX DISMOUNTING - REMOUNTING 10 The engine-gearbox assembly may be dismounted from the car only by taking it out at the uper part of the engine compartment. DISMOUNTING ( inside the engine compartment ) Perform the operations described for the sole engine dismounting,except the following operations: - dismountingof the starter protection; - dismounting of starter; - dismountingof the screwsfixing the gearboxto the engine.
10 ENGINE AND LOWER ENGINE UNITS ENGINE AND GEARBOX DISMOUNTING - REMOUNTING Placethe cross bars supportingthe front axle. Dismountthe front wheels. Dismount the upper suspenssion ball joints and the ball jointsof the steering connecting rod. Disconnectthe transmissions. . Placea jack under the gearbox to maintainit in the right position. Dismount the back cross bar of the gearbox. Dismount the fixing nuts of the engine supports. 10 - 12 vnx.
ENGINE AND LOWER ENGINE UNITS ENGINE AND GEARBOX DISMOUNTING - REMOUNTING 10 Remove the jack from under the gearbox. Mountthe liftingdevice. Move the engine-gearbox assembly forward,bend it and lift it. Place the engine on support. Dismount the gearbox( if necessary). REMOUNTING Perform in the reverse order the operationsdescibedat the dismounting. PARTICULARS UPON REMOUNTING Slightlygreasewith grease LiCa Pb type II the grooves of the front axlespinions.
10 ENGINE AND LOWER ENGINE UNITS TIGHTENING BY SCREWING UP MOMENTS 10 - 14 vnx.
ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS ENGINE TYPE 102 - 14 Cylinder (cmc) Bore (mm) Stroke (mm) Compressionratio Maximumpower 1397 76 77 8,5:1 42,6 KW DIN at 5000 rpm 10,2 daNm at 3500 rpm 750 - 800rpm cold / warm 0,15 / 0,18 0,20 / 0,25 0,4 1557 77 83,6 8,5:1 50 KW DIN at 5000 rpm 11,9 daNm at 2500 rpm 750 - 850rpm cold / warm 0,15 / 0,18 0,20 / 0,25 0,4 57+/- 3 0 63+/- 3% 0+/- 10 1-3-4 -2 line 5500 rpm Petrol CO/R min 90 57+/- 3 0 63+/- 3% 0+/- 10 1-3-4 -2 line 5500 rpm Petrol CO/R min 95/8
10 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS CYLINDER HEAD Aluminium alloy castcylinder head TYPE DU MOTEUR Couple for tightening the attachment screws of the cylinder head (daNm) - cold engine - warm engine * Cylinder head height (mm) - normal - for repairs (minimum) Reprise maximum autorisee du plan de joint Maximum accepted grinding of the support surface of the gasket Iginition chamber volume (cmc) Cylinder head identification (stamp on the cylinder head) 102 - 14 106 - 10 106 - 02 5,5 - 6,5
ENGINE AND LOWER ENGINE UNITS 10 CHARACTERISTICS VALVES TYPE OF ENGINE 102 - 14 Diameter of shaft (mm) Angle of the support side - inlet - outlet Diameter of the head (mm) - inlet - outlet Max. clearance between the valve shaft and the valve guide (mm) - inlet - outlet 106 - 02 106 - 10 7 7 90 0 90 0 90 0 90 0 33,5 30,3 34,6 30,3 0,03 0,08 0,03 0,08 VALVES SEATS The specialcast iron valves, warm pressed, not to be replaced.
10 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS VALVES GUIDES The cast iron guides ,warm pressed ,may be replaced. TYPE DU MOTEUR 106 - 02 106 - 10 102 - 14 Inner diameter (mm) Outside diameter (mm): - normal - 1 st repair (1 channel) - 2-nd repair (2 channels)* Guides inclination (inlet,outlet) as per the surface of the gasket 7 7 11 11.10 11,25 11 11.10 11,25 17 0 17 0 Guide position as per seat (mm) - inlet - outlet 26,5 26,2 27,4 26,1 * Done only upon speialrequest.
ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS 10 PUSHERS TYPE OF THE ENGINE ALL TYPES Outside diameter (mm) - normal - reparation * Alesage du trou d’embase (mm) - normal - reparation 19 19,2 19 + 0,21 0 19 + 0,210 * Done only upon specialrequest.
10 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS * The adimisibleclearance between the piston and the cylinder jacketis J = 0,045 - 0,065 mm and is done by corresponding matching as per table : CYLINDER P ISTON MARK JACKET MARK Green Blue Red Yellow A B C D CRANKSHAFT ALL TYPES TYPE OF THE ENGINE Number of bearings Type of bushings Tightening by screwing up moment of the bushing caps (daNm) Axial clearance ( mm ) Thickness of washers thrust for axial clearance adjustment (mm) (half bushings ) Slid
ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS 10 CONNECTING RODS TYPE OF ENGINE ALL TYPES Tightening by screwing up moment of the bushing caps (daNm) Type of bushings 4,5 Axial clearance of the connecting rod head (mm) Diametre alesage du pied de bielle (mm) Diametre alesage de la tete de bielle (mm) Torsion ou courbement (mm) Distance entre les axes de bielle (mm) Coussinets de bielle: - côte normale - côte de reparation aluminium - stanium 0,31- 0,57 20 - 0,029 - 0,041 47, 614 + 0,011 0 max.
10 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS * Matchingof the piston with the piston shaft is done as per followingtable: PISTON MARKING PISTON SHAFT MARKING X Y Z Red Yellow Blue OIL PUMP TYPE OF THE ENGINE ALL TYPES Oil pressure a 80 0 C ( bars ) - for iddle running ( 750 - 800 rpm ) minimum 0,7 - for 4000 rpm minimum3,5 - 4 FUEL PUMP Diaphragm pump ( for engines with carburettor ) Staticpressure (pump does not work) (bars) - minimum- 0,170 - maximum- 0,265 Electric pump ( for engine with i
ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismount from erngine: - the alternatorand the fixinfclip; - the distributorand the ignintion cable; - the fuel pump; - the oil filter; - the oil dip stick; - the oil pressuire transmitter; - the engine left side support and the elasticbuffer. Mounts the bolts of MOT 460 on the engineblock. Place the engine on theMOT 460 support. Dismount: - the rubber hoses; - the inlet-outlet colector; - the colector gasket; - the pressure plate and the clutch disk.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismountthe cylinederhead and take out the cylinder head gasket. In order to do that,unscrew the the fixing bolts of the cylinderhead,exceptthe centralscrew,on the side of the breaker-distributor. Because of the thightening, always when dismounting,the cylinder head gasketis stuck to the casing or the cylinder head the latter shall not be lifted in order to avoid the shifting of the jackets and breaking of the sealing gaskets at their bottom.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismountthe distribution chaintightener. Straighten the lock washer and unscrew the camshaft pinion fixing screw. Take out the camshaft pinion and the distribution chain. Dismountthe screwsof the camshaft clip. Take out the camshaft. Take out the crankshaft pinion by meansof the MOT 49. 10 - 25 vnx.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismount theengine flywheel. Check the marking of the connecting rods: number 1 towardsthe flywheel ond on thereverse side of the camshaft. Dismount the connecting rods caps and the half bushings and place them in order. The bearing caps are marked from 1 to 5 number 1 towards the flywheel. Dismountthe bearing caps and the half bushings and place them in order. Dismountthe crankshaft.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING RETIGHTENING OF THE CYLINDER HEAD SCREWS The re tightening of the cylinder head screws is performed: - for new cars.upon revisionat 800-1000 km; - upon an engine checking whichrequires dismounting of the cylinder head; - after every 10 000 km. To re tighten, loosen the screw (1) by 1/4 turns,thentightenas per required moment: - 6,5 daNmat warm (50 min.afterengine stop); - 5,5 daNm at cold.
ENGINE AND LOWER ENGINE UNITS 10 DISMOUNTING - MOUNTING Repeat the operation for the cylinders 3 - 4 - 2 according to the table: OUTLET VALVE TO BE ADJUSTED INLET OUTLET VALVE COMPLETELY OPENED 1 3 4 2 3 4 2 1 4 2 1 3 Tilters clearance : at cold - inlet 0,15 mm; - outlet 0,20 mm; at warm - inlet 0,18 mm; - outlet 0,25 mm. The checking of the distancebetween the tilter and the valve is done by meansof a distance calliper(spy) at the correspondingdimensionof the constructive cleranace.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING 10 Dismountthe alternator. Dismount the acceleration and shock cables. Disconnectthe thermocontacts. Dismount the water hoses(cylinder headcarburator; carburator-water pump; water pump- radiator). Dismount the collector from the cylinder head. Dismountthe tilters cap. Dismount the tilters shafts. Place them in order so that they maybe mounted again in theeir former place.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING CHECK OF THE GASKET PLANE DEFORMATION The checking of the deformation of the gasketplane is done by meansof a ruler and of a set of gauges. The maximumaccepteddeformationis: x = 0,05 mm. If the maximum deformation exceedsthis value,thegasketplane is corrected by grinding. Before grindingwaterpump and tilters platform are to be dismounted.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING 10 PARTICULARITIES UPON RE MOUNTING The contact surfaces of the gasket must be clean. The greaseor antifreeze fluid must be removed from the holes of the cylinder head fixing screws by means of a. This is necessary in order to obtain a correct thightening of the screws and to avoid the appearance of casing cracks. Dismount the MOT 484 device for jackets attachments. Place the gasket with the marking “HAUT” or “TOP” upwards.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismountthe tilters platform. Compressthe valves springs by meansof the MOT 382 compressing device. Take out the lock half cotters,release the spring,take out the upper tray,the spring and the lower tray. Place the parts in order so that theymay be mounted back in the sameplace where they have been dismounted from. Remove the valvessupport plate,take out the valvesand set them in order. Wash,clean and air blow the new cylinder head.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING 10 Compress the springs by means of the MOT 382 compression device and mount the lock half cotters. Mount the cylinder head closingplate and the waterpump with new gaskets. Mount the alternator support. Mount the cylinder head with new gasketobserving the mounting instructions. Mount the tiltershafts in the place where they have been removedfrom. Adjustthe tilters. Mount the tilters cap. Adjust theacceleration pedal stroke.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Compress the spring by means of the MOT 382 device and mount the lock half cotters. Mount the tiltershaft. Adjustthe tilter. Mount the tilters cap. The nuts tighteningmoment: 0,5 – 0,7 daNm. Mount the acceleration cable and adjust the acceleration pedal stroke. Dismount the MOT 61 valve support device and mount the spark plug. Check and adjustthe engine ( ignition,carburation). REPLACEMT OF THE VALVE SHAFT SEALING RING Disconnect the battery.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Compress the spring by means of the MOT 382 and mount the lock half cotters. Mount the tilters shaft. Mount the tilters cap. The nuts tihteningmoment is : 0,5 - 0,7 daNm. Mount the acceleration cable and adjust the acceleration pedal stroke. Dismountthe valve maintainindeviceMOT 61 and mount the spark plug. Check and adjustthe engine (ignition,carburation). TILTERS PLATFORM ( on car ) DISMOUNTING Disconnect the acceleration cable.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING REMOUNTING Lubricatethe supports,thetilters and the shaft with cleanoil. Mount the parts on the shaft in the reverse order of the operation performed for dismounting.Pay attentionthat attachment holes in the supports identify with the sockets on the shaft. Mount the assembled shaft on the cylinder head and tighten it at the moment of 1,5 - 1,7 daNm . Adjust the tilters. Mount the tilters cover.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Check the diameterof the depressedguiding: - nominal value 11 mm; - value 1-st repair 11,1 mm; - value 2-nd repair 11,25 mm; NOTE: The guiding at the repair value are supplied only by request REMOUNTING Turn the cylinder head on the support plate and bore the seat of the guide at the correspondening value of the new guie.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Bore the guiding at the value φ 7. Grind the valve seat. Perform the lappingof the valve with the valve seat. Wash carefully the cylinder head and the component partsand blow themwith airunder pressure.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING 10 VALVE SEATS GRINDING Dismountthe cylinder head from the engine. Dismountfrom the cylinder head: - the water pump; - the valves; - the valves shafts sealing rings; - the tilters platform; - the cap attachment bolts; - the spark plugs. Place the cylinder head on the MOT 121 support plate.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Perform the fillingand aeration of the cooling system. Perform the checkingand adjustmentof engine operation (ignition,carburation). Re tighten the cylinder head after driving800 km. ENGINE KIT REPLACEMENT ( on car ) DISMOUNTING Disconnect the battery. Drain the cooling circuit and the oil from the engine. Dismount: - the tilters cap; - the cylinder head; - the oil sump; - the oil pump. Identify the connecting rods: connectingrod no.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING NOTE: The parts contained in the repair kit are in pairs ( jackets-piston-piston shaft ) according to colours. The colour (1) marked on the piston head must correspond to the colour marked on the jacket. The colour (2) marked represents the piston weight and must be the same for all the pistons. The colour (3) marked on the piston head must correspond to the one marked on the head of the piston shaft.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING For all types of engines,thejacketsshall be positionedas follows: - the maximumdifferencebetweenthe heightsof two adjoing jacketsshallbe maximum0,02 mm,withinthe limitof the prescribed tolerance; - the jackets shall be placedin growing order ( by steps ). After obtaining the correct height,theposition of the jackets in the block is marked so that it may be paired with the corresponding connecting rods.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING 10 NOTE: If wear of the connecting rods is noticed or if the parallelism of the shafts is not correct, the connecting rods shall be corrected or replaced. For the new connecting rods, a check shall be made so that they belong to the same weight class (they shall not have the same colour marked on them). PREPARATION OF THE PISTON SHAFT Check if the piston shafts rotate freely in the corresponding pistons.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING When assembling the piston with the connecting rod,the following instructions are to be observed: - place the piston withthe bladeditem on the bushing (B) of the pistonshaft mounting device;in this situationthe arrow on the piston head shall be upwards oriented; - place the connecting rodon the piston with the marking or with theslotsfor bushings oriented towards the right side of the worker; in this situationwhen mounting the assemblyin the block th
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING 10 Lubricatethe jacketswith fresh oil. Mount in the jacketsthe piston-connecting rod assemblywith the bushing: - MOT 502 for 102 engines; - MOT 655 for 106 engines. When mounting, the connecting rod sides will be parallel with the flattenings made on the jackets. Mount the sealing gaskets on the jackets. Mount the bushings on the connectingrods.
ENGINE AND LOWER ENGINE UNITS 10 DISMOUNTING - MOUNTING OIL PLATFORM PLUGS REPLACEMENT DISMOUNTING Dismount the plugs from the block by boring with a φ 10 drill. Wash the block,clean the platform and the channels in the block and blow it with compressed air. REMOUNTING Oil the new plugs with OMNI - FIT RAPID. Place the plugs (1) in their seats in the block and clamp them by meansof the MOT 111A rivet set. REPLACEMENT OF THE CRANKSHAFT BEARING ANNULAR OIL SEAL DISMOUNTING Disconnect the battery.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING 10 Mount theannularoilsealin its place,slightly tapping the chuck head until it comes into contact with the crankshaft. The mounting chuck for the annular oil seal shall be kept with care in order to avoid deterioration of the collar on which the annular oil sealis placed. Protect the chuck by placing a worn annular oil sealon it. Mount the flywheel.thescrewswillbe lubricatedwith FIXAMED M 28. Tighten the screws at a 5 daNm moment.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING REMOUNTING Pressthe new bushingby means of the clutch disk centering chuck. Center the disk by means of the centering chuck. Mount the clutchmechanism. Mount the gear box. Check all the fluid fillings and perform all necessary adjustments. CRANKSHAFT REPLACEMENT DISMOUNTING Dismountthe engine from the car. Mount the engine on the MOT 369 support. Drain the oil off the engine.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Place the engine on the MOT 460 suPlace the engine on the MOT 460 support.pport. Dismount: - the pressure plate and the clutch disk; - the breaker-distributtor pinion by means of a M 12 x 1,5 screw. Rotate the engine by 180 º and dismountthe following parts: - the crankshaft pulley; - the oil casing; - the oil pump; - the distribution cap.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Take out the crankshaft pinion by means of the MOT 49 device. Dismount theengineflywhhe. Check the marking of the connecting rods: - no.1 towards the flywheel andopposite to the camshaft. Unscrew the connectingrod caps nuts. Dismountthe connecting rods cas and the half bushingsand place them in order. Dismountthe crankshaft. Dismountthe connecting bearing and the half bushingsand place them in order. Dismount the crankshaft. 10 - 50 vnx.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING 10 Remove the halfbushings from the connectingrod and from the block and put them in order. Dismount the washer thrusts for the axial clearance adjustment. Remove the annular oil seal from the bearing. REMOUNTING Wash and air blow the new crankshaft; check the existenceof the lubricatinholes in the shaft. Clean the contact surface of the gasket to the block and oil sump. Mount the half bushingson the connectingrods.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Mount the half bushings on the bearing heads ( the half bushings for caps do not have lubricating holes). Lubricatethe halfbushings with fresh oil and mount the bearing caps at their place according to the marking. It is obligatory to degrease the contact surfaces of the no.1 bearingcap and then to apply a layer of LOCTITE518 in order to ensure the sealing. Tighten the attachmentscrews of the caps at 5,5 – 6,5 daNm moment using.
ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING 10 NOTE: In case the old crankshaft is to be mounted, displace the annular oil seal position by inserting a 2 mm thick washer between the chuck and the crankshaft end so that the annular oil seal does not work in its initial position. Mountthe flywheelusing new screws.Before mounting lubricatewith FIXAMED M 28 the screws. Tighten the screws at a 5 daNm moment using.
10 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Mount : the il pump and the distribution,the oil sump and the distributioncap with new gaskets or sealant,the disk and mechanismclutch.
ENGINE AND LOWER ENGINE UNITS REPLACEMENTOF THE DISTRIBUTIONANNULAROIL SEAL DISMOUNTING Disconnect the battery. Place the no.1cylinder at the dead point in orde to avoid the falling of the key from the crankshaft when disountingthe crankshaft pulley. Dismount : - engine shield; - alternator belt; - crankshaft pulley. Dismountthe old annularoil sealby means of the MOT 457 A device. REMOUNTING Mount the new annular oil sealon the mounting chuck of the MOT 457 A device.
10 ENGINE AND LOWER ENGINE UNITS DISTRIBUTION CAP DISTRIBUTION CAP REPLACEMENT DISMOUNTING Disconnect the battery. Drain the oil off the engine. Dismountthe alternatorbelt, the waterpump pulleyand the engine shield. Dismount the oil sump:(adjust the enginewith no.1 and4 pistonsin the lower deadpoint),rotate the front partof the oil sump towards the left and lower it. Dismountthecrankshaft pulley. Dismountthe distribution cap. Dismountthe annular oil sealfrom the cap.
ENGINE AND LOWER ENGINE UNITS DISTRIBUTION CAP 10 REMOUNTING Mount thedistribution annular oil seal. Placethecap withnew gasketor on the blockafter sealant material has been appliedpreviously. Center the cap by means of the MOT 457 A device. Attach the cap on the block; the tightenin of the screws is done from the upper part towards the lower part. Re mount the crankshaft pulley,the waterpump pulley, the alternator belt. Place: - the rubber gaskets of the bearings; - the side gaskets of the oil sump.
10 ENGINE AND LOWER ENGINE UNITS DISTRIBUTION CAP Clean with 002solvent the contact surfacesof the engine casing and of the distribution cap . Place a continous sealantmaterial layer of a 3 mm thickness on the lower part of the contact surface of the distribution cap,taking care not to obturate the its fixing holes. Mount the distribution cap and tighten the attachemntscrews at the required moment.
ENGINE AND LOWER ENGINE UNITS TIGHTENER AND DISTRIBUTION CHAIN 10 REPLACEMENT OF TIGHTENER AND DISTRIBUTION CHAIN DISMOUNTING Disconnect the battery. Drain the oilfrom the engine. Dismount:the engine shield,thecrossbar betweenthe longitudinal girders,theelastic bushingnuts of the stabilizerrod,the alternator belt,thefan and the waterpump pulley,the oil sump and the distribution cap. Unscrew the tightener fixing screw. Dismountthe tightener. ATTENTION ! Do not let spring the crosshead shoe and the spring .
10 ENGINE AND LOWER ENGINE UNITS TIGHTENER AND DISTRIBUTION CHAIN Placethe new chain on the camshaft pinion and on the crankshaft pinion. Mount the camshaft pinion maintainingthe alignement of the markings on the pinions. Tighten the fixingscrew at a 2 daNm moment and strain the safety washer. Mount the tightener performing the dismountingoperations in the reverseorder: 1.Tightenercrossheadshoe. 2. Spring 3. Shaft 4. Tightening washer 5.
ENGINE AND LOWER ENGINE UNITS CAMSHAFT 10 CAMSHAFT REPLACEENT DISMOUNTING Disconnect the battery. Drain: oil from engine and the coolingcircuit. Dismount : - air filter,front grill,radiator,crossbarbetwennthe longitudinal girders,the fixing nuts of the elasticbushers from the stabilizerrod. Dismount the breaker- distributtor,thetilters cap,the cylinder head,the tilters shafts and the pushers;arrange them in order so that they may bere mounted in the places they have been removedfrom.
10 ENGINE AND LOWER ENGINE UNITS CAMSHAFT REMOUNTING Mount on the new camshaft : the disk key,a new attachement clip,a new cross piece;tapp the cross piece with a rod until it comesinto contactwith the camshaft shoulder). Mount the camshaft pinion and tighten the screw at the moment of 3 daNm using. Check the attachement clip clearance ( J ) ; the clearance must be between 0,06 and 0,11 mm. If clearance is not the required one, replacethe clip. Dismountthe camshaftpinion.
ENGINE AND LOWER ENGINE UNITS CAMSHAFT 10 Mount the control pinion of the breakerdistributor. The controlpinion is positioned as follows: - place the no.1 cylinder at the upper dead point, on ignition; - mount the pinion with a cylinder head attachement screw so that the slots are perpendicular on the engine longitudinal axle andthe larger part (D) is oriented towards the flywheel. Re mount the pushers lubricatedwith fresh oil,the cylinder head ,the tilters shafts.
10 ENGINE AND LOWER ENGINE UNITS LOWER CRANKCASE OIL SUMP DISMOUNTING – REMOUNTING DISMOUNTING Disconnect the battery. Drain the oil off the engine. Dismount: engine shield and oil sump attachementscrews. Place the crankshaft with pistons 1 and 4 to the lower dead point. Rotatethe front parts of the sump to the left and lower it. Clean the contact surfaces of the gaskets (engine block,oil sump) or those where sealant material has been applied.
ENGINE AND LOWER ENGINE UNITS LOWER CRANKCASE 10 The quantity of sealantmaterial necessary for one engine is max. 60 grams, of which max.15 grams for the distribution cap and max.45 grams for oil sump. Proceed as follows: Remove trheoil sump. Remove the old sealantmaterial using a knife by scrapping , from the contact surface a of oil sump and enine casing. Clean with 002solventthe contactsurfacesof the engine casingand the oil sump.
10 ENGINE AND LOWER ENGINE UNITS OIL PUMP OIL PUMP DISMOUNTING – REMOUNTING DISMOUNTING Disconnect the battery. Drain the oil off the engine. Dismount:engine shield,crossbarbetweenthe longitudinal girders,elasticbushingnuts on the anti rolling shaft and the oil pump. Unscrew the attachement screws and take out the oil pump. Clean the contactsurfacesof the gaskets or those with sealant material ( engine bloc and oil sump). REMOUNTING Mount the new oil pump with a new gasket. Τighten the attachmentscrews.
ENGINE AND LOWER ENGINE UNITS OIL PUMP 10 REPAIR OF OIL PUMP DISMOUNTING Dismountthe pump cap. Dismount:the free pinion and its respectiveshaft. ATTENTION ! The valve spring and the ball may spring up. Wash the parts and check the maximumclearance wear between the pinions and the pump body to be 0,2 mm. If clearance is bigger,replace the pinions. REMOUNTING Mount in the body of the pump the followings: - the free pinion; - the drive pinion; - the spring tray; - the spring; - the valve ball.
FUEL MIXTURE 12 CHARACTERISTICS ENGINE CHECKING TO BE DONE ON IDLE RUNNING * POLLUTION EMISSIONS TYPE RATE ( rtm ) INDEX FUEL ( minimum octane number CO) Co ( % ) Co2 ( % ) HC (1) ( ppm ) LAMBDA (λ) Unleaded fuel 106 10 775 - 850 max. 0,5 min.14 max. 60 0,97 - 1,03 ( COR min 95 ) ( 1 ) The CO value at 2500 rpm must be maximum 0,3 %.
12 FUEL MIXTURE INJECTOR VALVE BODY DISMONTING Disconnect the ( - ) battery terminal. Dismount the air duct fixing clips. Dismount the air duct attachment screws. Dismount acceleration cable from the injector valve body. Disconnect the feeding and return hoses and the connecting hose to the can purging electrovalve. Disconnect the connectors of injector valve, as follows: - push the lock (3) towards the arrow (a); - disconnect the connector.
FUEL MIXTURE INLET EXHAUST MANIFOLD 12 TIGHTENING TORQUES ( daNm ) Inlet exhaust manifold nuts ....................................................................1,8 Attachment nuts of the tube on the inlet exhaust manifold ....................1,8 DISMOUNTING Disconnect the battery. Dismount the injector valve body ( see chapt.” Replacement of the injector valve body” ). Dismount the starter protection shield. Dismount the 3 attachment nuts of the inlet-exhaust manifold.
PUMP SUPPLY FUEL FILTER ( INJECTION ENGINE ) 13 The fuel filter is placed in the fuel feeding circuit after the fuel pump and can be found under the body of the vehicle close to the tank. The filter element is made of paper, with 0,01mm porosity and has the very important function to retain the eventual impurities and stop them to reach the pressure regulator and injector.
ANTIPOLLUTION GASOLINE VAPOURS REASPIRATION 14 The cycling circuit of the fuel vapours has as purpose the reduction of the environment pollution with gasoline vapours, and is composed of: 1. Fuel tank, tight 2. Active carbon can 3. Carbon can purging valve 4. Fresh air intake 1 3 4 2 The gasoline vapours are absorbed from the tank (1) in the can (2) with active carbon grains and arriving then at the purging valve (3).
14 ANTIPOLLUTION CARBON CAN DISMOUNTING Remove the can from its fixing support by pulling up. Dismount the fixing ring clips of the hoses to the can and disconnect the hoses. REMOUNTING Perform in reverse order the dismounting operations. ATTENTION: Take into consideration when mounting, about the hoses connection direction (the gasoline vapour cycling is from the duct to the carbon can purge valve). Use good ring clips,which must be well tightened. 14 - 2 vnx.
ANTIPOLLUTION 14 CARBON CAN VALVE DISMOUNTING Disconnect the ( - ) terminal of the battery. Disconnect the connector of coupling the fuel injection control wiring to the purging valve, pushing the lock (1),after that disconnecting the connector. Dismount the fixing clips of the hoses to the purging valve and disconnect the hoses. 1 REMOUNTING Perform in reverse order the dismountingoperations.
STARTING AND CHARGING 16 ALTERNATOR The Dacia pick-up vehicles can be equipped with following types of alternators: Type of alternator 1114.200 Operating voltage 12V 50 A Ampere rating in stable operating conditions Maximum excitation current 3,9 A Maximum power 700 W Type of relay used 1410;1342 electronic 1180 12V 80 A 5A 1100 W electronic incorporated For vehicles of Dacia range, there are used alternators type 1114.200 and type 1180 (used for vehicles provided with AC).
16 STARTING AND CHARGING ALTERNATOR ALTERNATOR CHECKING ( for alternator type 1180 ) The general electric diagrams and the curves of the load characteristic of the alternator type 1180 are the followings: A. CHECKING OF THE CURRENT INTENSITY A - Unstable operating conditions B - Stable operating conditions GENERATOR ROTATION SPEED (rot/min) GENERATOR ROTATION SPEED (rot/min) Tip 1114. 200 Tip 1180 16 - 2 vnx.
STARTING AND CHARGING 16 ALTERNATOR LOAD CHARACTERISTIC RPM REGIM [ rot/min ] N0 N1 N2 N3 N4 Nmax. I = f ( n ); U = ct = 13,5 V CORRESPONDING INTENSITY [ A ] 1200 1250 1500+/- 1% 3000+/- 1% 6000+/- 1% 12500+/- 1% I0 I1 I2 I3 I4 I max. >0 > 10 > 20 > 43 > 48 > 50 B. CHECKING OF THE ADJUSTED VOLTAGE For checking the adjusted voltage, perform an assembly similar to next diagram.
16 STARTING AND CHARGING ALTERNATOR MAINTENANCE OF THE ALTERNATORAND OF THE ELECTRINIC REGULATOR It is recommended the periodical checking of the connections to avoid the loosening of the imperfect connections which may produce electric arc during operation.
STARTING AND CHARGING ALTERNATOR 16 DISMOUNTING Disconnect: - battery; - wires connected to the alternator. Dismount: - tightening screw (A ); - belt; - attachment screw (B). REMOUNTING Mount: attachment screw (B) ,the belt, the tightening screw (A). Tighten the belt. Connect: wires to the alternator and the battery. NOTE: The belt will be tighten so to obtain the maximum arrow of 7,5 mm at half distance between the water pump pulley and the alternator pulley.
16 STARTING AND CHARGING ALTERNATOR ALTERNATOR TYPE 1180 16 - 6 vnx.
STARTING AND CHARGING ALTERNATOR 16 DISMOUNTING Disconnect: battery, wires connected to the alternator and the connections box from the voltage electronic regulator. Dismount: tightening screw (2) by acting on the locking nut, the tightened (3) by unscrewing, the belt; pushing down the alternator,take out the alternator belt from the pulley and the alternator attachment screw (1). REMOUNTING Mount: attachment screw (1), the V-belt, the tightening screw (2) and the tightener (3).
16 STARTING AND CHARGING ALTERNATOR CHECKING OF THE ALTERNATOR MOUNTED ON THE VEHICLE. The operation of the alternator can be checked on the vehicle, by connecting a voltmeter to the battery plugs. At rpm of 2000 rot/min without consumers, the voltage read on the instrument must be about 14,6 +/ - 0,1 V . At same rpm ( 2000 rot/min ) with consumers ( headlights, air conditioner,windscreen wipers ) the voltage read on the instrument must be between 13,5 and 14,5 V.
STARTING AND CHARGING ALTERNATOR 16 CHEKING THE VOLTMETER OF THE INSTRUMENT BOARD Checking is performed by means of a voltmeter connected according to the above diagram,where you can identify: B = battery , V = voltmeter, A = alternator , R = voltage regulator , Key = ignition contact, Tb = instrument board. For a voltage of 12,8 V read on instrument, the needle of the voltmeter on the instrument board must be placed in the left side of the central area.
STARTING AND CHARGING 16 ALTERNATOR ALTERNATOR REPAIR ( type 1114.200 ) DISMOUNTING Dismountthe alternator from the vehicle. Unscrew the two attachment screws of the brushes support and dismount them. Clamp on vice thepulley provided with an old belt to avoid its faulting. Unscrew the fixing nut of the pulley. Dismount : - the pulley; - the pulley wedge; - the fan. Dismount the brushes supports. Unscrew the alternator ass embly screws.
STARTING AND CHARGING ALTERNATOR Dismountthe front bearing from the rotor by tapping the shaft end with a piece of wood. Unscrew the attachment screws of the sustaining shield of the front bearing. The dismounting operation of the front bearing is performed only in case of front bearing replacement. Check the aspect ofthe coiling ( damaged insulation, scratched rings, broken wires). 16 - 11 vnx.
16 STARTING AND CHARGING ALTERNATOR REMUONTING Remount : - the end bearing and the stator; - the front bearing; - the attachment screws; - the pulley wedge; - the fan and the pulley; - the snap ring and the pulley fixing nut; - the brushes support; - the voltage regulator ( for alternator type 1180 ). Check the alternator on the bench. Mount the alternator on the vehicle. Connect the battery. NOTE: Tightening moment: - for the pulley nut 3 – 3,5 daNm ( for type 1114.
STARTING AND CHARGING ALTERNATOR 16 ALTERNATOR BEARINGS REPLACEMENT Dismount the alternator from the vehicle. A. FRONT BEARING REPLACEMENT Dismount : pulley, washers and Grower washer, fan, pulley wedge and the drive shield. Place the drive shield in a horizontal position and unscrew the three attachment screws of the bearing cap and take out the bearing. Mountthe new bearing in the drive shieldand fix thebearing cap by meansof the threescrews.
16 STARTING AND CHARGING ALTERNATOR Place the protector RO 15.01 on the rotor shaft end. Mount the new bearing by means of a press and using a tube, which shall rest only on the inner ring of the bearing. Assembly the alternator and then mount it on the vehicle. Mount the belt and adjust its tightening. Connect the battery. ALTERNATOR BRUSHES REPLACEMENT DISMOUNTING Disconnect the battery. Unscrew the attachment screws of the brushes support. Dismount the used brushes off the support.
STARTING AND CHARGING ALTERNATOR 16 ALTERNATOR DIODE SUPPORTREPLACEMENT DISMOUNTING Dismount the plastic protection cap and the condenser. Disconnect the terminals: mark the position of the wires so that may be reconected in the same place. Unscrew the attachment nuts;dismount the diode support. REMOUNTING Mount the diode support ; tighten the attachment nuts. Connect the terminals ; observe the marking made upon disconnecting. Mount the protectioncap and the condenser. Check on the bench the alternator.
16 STARTING AND CHARGING ALTERNATOR REMOUNTING Check the new diode. Press the new diode in the diode support observing the marking : red for “ + “ , black for “ - “. Mount the diode support on the alternator. CHECKING OF THE RECTIFYING BRIDGE After dismounting the diode support perform a visual checking of the diodes to avoid defects ( short circuits, broken ) as well as the connections state. A.
STARTING AND CHARGING ALTERNATOR 16 CHECKING OF THE ALTERNATOR STATOR After visual checking of the coils which must not show heating or oxidation traces,check the resistance and the insulation of the coils. A.CHECKING OF THE COILS INSULATION After placing the ohmmeter terminals on chassis ground , on “ I point and on one of the three terminals marked with “ f “ , “ g “ , “ h “ , the ohmmeter needle must not deviate ( resistance = ). B.
16 STARTING AND CHARGING ALTERNATOR CHECKING OF THE ALTERNATOR ROTOR After the visual checking of the coiling (without heating or oxidation traces), check the collecting rings for defects (sometimes it is recommended their polishing with very fine granulation sandpaper). A. CHECKING OF THE COILING INSULATION Placethe ohmmeterterminalson chassis ground, on 1 and on one of the M or N collector rings. The ohmmeter needle must not deviate ( resistance = ).
STARTING AND CHARGING ALTERNATOR 16 VOLTAGE REGULATOR ( alternator type 1114.200 ) DISMOUNTING Disconnect: the battery, the ( + ) supply cable and the excitation wire of the voltage regulator by unscrewing the fixing nut. Unscrew the right side nut, loosen the left side one and dismount the relay. REMOUNTING Place in its place the regulator and tighten the fixing screws. Connect : - the supply cable; - the excitation wire by tightening the nut; - the battery. 16 - 19 vnx.
STARTING AND CHARGING 16 STARTER TYPE OF STARTER MAXIMUM POWER NOMINAL VOLTAGE MINIMUM STARTING ROTATION Number of te eth PINION CHARACTERISTICS Module Pressure angle Voltage ( Us ) Intensity ( Is ) CHARACTERISTICS Coupling ( Cs ) IN LOAD Minimum rpm ( n min s ) Voltage ( Ub ) BLOCKED COUPLING Coupling ( Cb ) Absorption current ( Ia ) (bendix to be blocked) 2146 995 W ( 1,35 CP ) 12V 150 tr./ min. 9 2,116 / 1,1814 12 0 9,5 +/- 0,5 V 200 A 0,5 daNm 1400 rot. / min.
STARTING AND CHARGING STARTER 16 Characteristics of load at the temperature of 20 0 +/- 5 0 C. Average curves: Test must not be done more than 4 – 5 seconds To lay out these characteristics measure the absorbed current, supply voltage,RPM and coupling. B. ELECTRIC DIAGRAM OF THE 2600 TYPE STARTER The starter type 2600 is an engine of continuos current with excitation by constant magnets having a coupling mechanism with rolls and gearing commended by side electromagnet. 1. Battery 2. Contact switch 3.
16 STARTING AND CHARGING STARTER Test must not be done more than 4 – 5 seconds To lay out these characteristics measure the absorbed current, supply voltage,RPM and coupling. STARTER 16 - 22 vnx.
STARTING AND CHARGING STARTER 16 DISMOUNTING Disconnect: battery, starter supply cable,supply wire of the coupling relay. Dismount: air filter, starter protection screen, and the three screws, which attach the starter to the clutch housing. Detach the starter let its end down until comes into contact with the exhaust pipe, rotate the starter by 90° and take it out. REMOUNTING Place the starter with its end up; lower it until it comes in contact with the engine support.
16 STARTING AND CHARGING STARTER STARTER REPAIR The operation is performed after the starter is dismounted from the vehicle. DISMOUNTING Dismount: sheet cap and the screw from the rotor top (A) electric plug (B), back bearing with brushes support, stator,attachment nuts of the coupling relay, take out the rotor and the solenoid. Check the state of the collector; if the wear on diameter is higher than 0,5 mm, grind and then clean the channels.If rotor is replaced, adjust the fork stroke.
STARTING AND CHARGING STARTER 16 BENDIX REPLACEMENT Dismount the starter. Take out the rotor. Move the stopping bushing by means of a rod. Take out the lock then the bendix. Mount the new bendix , the stopping bushing and the safety ring. Grease with a thin coat ofUM 185 Li2 grease the grooves, the area between the grooves and the support ring the fork shaft and the rolling area of the coupling mechanism with the fork. Remount the rotor and adjust the fork stroke.
16 STARTING AND CHARGING STARTER SOLENOID REPLACEMENT The operation is performed after dismounting the starter from the vehicle. DISMOUNTING Dismount the stator and the rotor. Dismount the solenoid. Unscrew the (A) screw and recover the fork, which can be used again if it is in good state. REMOUNTING Mount the fork on solenoid shaft. Tighten the screw (A). Assembly the starter and adjust the fork stroke. 16 - 26 vnx.
STARTING AND CHARGING STARTER 16 FORK STROKE ADJUSTMENT Dismount the protector from the solenoidend. Check the clearance (F) between the screw and the adjustment nut, which must be as small as possible. In this situation the coupling mechanism ( bendix ) must be leaning on the rotor. Check if clearance (H) is between 1 + / - 0,5 mm. For adjustment act on the adjustment nut ( 1 ) until clearances F and H are correct. By loosening the nut the clearance ( H ) is reduced.
16 STARTING AND CHARGING STARTER STARTER DOES NOT WORK Check the battery voltage and the terminals state. Dead battery; charge the battery;check the charging circuit. Charged battery : clean and tighten Terminals. Check if solenoid is supplied when switch on contact with the key. Solenoid is supplied; dismount the starter and check it; Solenoid is not supplied. Check the ignition contact. Ignition contact working; the supplied wire of the solenoid is interrupted or disconnected.
IGNITION AND INJECTION SPARKPLUGS 17 The followingspark plugs are to be used for Daciavehicles: The followingspark plugs are to be used for Daciavehicles: The inducing voltage of the spark plug is 4 – 8 KV. The maximum voltagedifference between the spark plugs, measured on the engine is 2 KV. The distancebetweenthe electrodes is set by meansof thicknessgauges at the presetvalues, according to the spark plug type.
17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. IGNITION AND INJECTION SPARKPLUGS Terminal nut Terminal thread Anti-power hazard protectionstep Insulator Conductingmaterial Internal gasket Ventilationroom Connectionrod Insuringarea Sealing ring Insulating bulb Central electrode Mass electrode 1 2 3 4 181 9 5 6 7 10 11 12 13 17 - 2 vnx.
IGNITION AND INJECTION 17 OPERATION PRINCIPLE MONO - MOTRONIC INJECTION SYSTEM ( MA 1.7 ) OPERATION PRINCIPLE The BOSCH MONO-MOTRONIC injection system is a (á, n) type, where: á = angle indicating the position of the valve and reading the engine load.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM DESCRIPTION OF THE SYSTEM AND ITS COMPONENTS The components of the injection system are: (drawing no.1). 1 - Fuel electric pump 3 - Fuel filter 4 - Fuel pressure regulator 5 - Injector Central unit 6 - Air temperature sensor ( injector valve body ) 8 - Valve position potentiometer 9 - Idle motion regulator 10 - Carbon canister purging valve 11 - Active carbon canister 12 - Electronic control unit ( computer for injection and ignition ).
IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM 17 INJECTION CENTRAL UNIT The injection central unit consists of: 1 - The upper part (hydraulic part) 2 - The lower part (body-valve) 3 - Pressure regulator 4 - Injector 5 - Air sensor T 6 - Fuel input ( supply connection ). 7 - Fuel output ( back-feed connection ) 8 - Idle motion regulator A = Connector for air sensor T aer and injector. B = Connector for valve potentiometer. C = Connector for idle motion breaker and valve positioning engine. Fig.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM INJECTOR The injector (drawing 4) is placed above the valve in order to ensure an optimal supply and homogenous mixture of the fuel. The injector basic function is to ensure a very fine and homogenous spraying of the fuel, shaped as a conic jet. This fuel is sprayed through the half-moon gap between the valve and the wall, without hitting the latter, as it happens in case of a straight spraying (carburetor).
IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM 17 A sign shaped as follows will be displayed on the oscilloscope screen. It is to be used for the calculation of the injection time = ti. The injection time value increases when the battery voltage is lower than 12 V. Reference values for the injector: - resistance measured between the wires 2 and 3, R2-3 = 6.3 - 7.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM The valve potentiometer consists of a first potentiometer, working on the range (0° - 22°) and a second one, working on the range (19° - 90°). A common area is noticed, between (19° - 22°) established for a more precise reading of the load necessary in the partial load area, the most used for the engine exploitation.
IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM 17 REGULATOR OF IDLE RUNNING This regulator (drawing 1, position 9) is used to position the valve in order to obtain the idle rotation. It is mounted into a case together with a switch. The idle running is realized at the moment of switch contact closing (position 4), being necessary to the normal idle functioning or to the engine brake. The computer sends an electric signal to the regulator through the pins 32 and 34.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM IMPORTANT: The connector disconnection and connection is to be done only with contact OFF for the following checking and adjustment. The basic adjustment of the valve (drawing 5) is the correlation between the potentiometer position and the positioning engine of the valve.
IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM 17 EXAMPLE: When U v = 5 V, U 1 should be within 3.75 – 4.25 V for a correct adjustment. This adjustment is used in case of changing regulator or of an irregular functioning during the idle motion.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM From now on, we can calculate the injection time (ti), the injection moment and the ignition advance moment for each engine cycle. The rotation sensor is fixed on the clutch case of the gearbox therefore it should be at 1 ± 0,5 mm from the teeth peak of the flywheel.
IGNITION AND INJECTION 17 DESCRIPTION OF THE SYSTEM ENGINE TEMPERATURE SENSOR The engine sensor T is an NTC type (negative temperature coefficient); its internal resistance will decrease with the increasing of the temperature. It is checked with an ohmmeter connected to the sensor terminals or even better with a voltmeter, during the engine running The voltage of the cold engine should be U = 5 V; this voltage decreases according to the heating of the engine.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM INDUCTION COIL The induction coil is a double-coil with stationary distribution of the voltage without moving elements. The voltage in the secondary circuit of the coil can reach 30 KV, the distance between the spark plugs electrodes should be 0,8 mm and the spark plugs wires should have a special construction according the new concept of anti-electric interference.
IGNITION AND INJECTION 17 DESCRIPTION OF THE SYSTEM EXAMPLE: - piston 4 at compression = ignition spark; about 20 KV (drawing 10). - piston 1 evacuation = auxiliary spark; about 300 V (drawing 11). The two voltages can be viewed through an oscilloscope and an adapter. Fig. 10 Fig.11 The reference values, measured at the ignition coil connector are as follows: - for secondary windings: R1-4 = R1-3 = 10 – 16 KÙ at 20°C - for primary windings: R1-2 = R3-4 = 0.4 – 0.
IGNITION AND INJECTION 17 DESCRIPTION OF THE SYSTEM ELECTRONIC CONTROL UNIT The electronic control unit is situated in the engine compartment and fixed on the right bumper column. It is connected to the injection control cables through a 35 pins connector.
IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM 17 WARNING! In case of electric welding on the vehicle, the battery the alternator and the electronic control unit should be disconnected. In case of fine painting above 85°C, the electronic control unit should be taken off the vehicle. When remounting the fixing screws of the control unit should be well secured, in order to ensure a perfect electric contact to the vehicle chassis.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM The pin 23 should be tightly fixed to the mass. The pin 16 is very important; it ensures a permanent supply (+) to the computer in order to keep in its memory all thedamages which might occur during the running and to introduce the necessary connection at starting up for the ignition and injection system.
IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM Pin no. computer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Injection and ignition system component MA 1.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM OXYGEN SENSOR ( Lambda ) The oxygen sensor (Lambda) is fixed on the primary down tube, in front of the catalytic converter. Its purpose is to determine the oxygen content of the exhausted gases; this oxygen content value depends upon the dosing of the air-fuel mixture.
IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM 17 For starting the oxygen sensor as soon as possible after the engine start up it should be heated by its electric resistance, type PTC = positive temperature coefficient. The evacuation track of the burned gases should be 100% sealed in the area in front of the ë rod and of the catalytic converter in order to not get measurements errors of the oxygen content in the burned gases.
17 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM CATALYTICCONVERTER The catalytic converter (drawing 1, position 17) is placed on the burned gases evacuation track between the primary down tube and the detector it is three ways type and it is used for simultaneous transformation of the three gases existing in the evacuationgas, according to the following chemicalreactions: m CO2 + n/2 H2 O C m Hn + ( m+n/4 ) O2 2CO2 2 CO + O2 2 NO + 2 CO N2 + 2CO2 The catalytic converter is honeycomb shaped, in ceramic
IGNITION AND INJECTION DIAGNOSTIC 17 WORKING MODE IN CASE OF INTERVENTION ON THE MONO-MOTRONIC INJECTION SYSTEM Prior to the engine start up one should check the correct connection of the battery; the battery should be wellloaded and its terminals should be cleanedand welltightenedup. The maximumsupplyingvoltage of the systemshould not excel 15 V. The battery should be disconnectedonly after stopping the engine, the contactkey being on the position“St” (contactclosed).
17 IGNITION AND INJECTION DIAGNOSTIC IMPORTANT: Two protecting relays and two fuses,placed on a fixedsupport on the front of theleft mudguard coating (front) electricallyprotect the injectionsystem.
IGNITION AND INJECTION DIAGNOSTIC 17 PRELIMINARYCHECKING OPERATIONS PRIOR THE DIAGNOSIS The starting up electric circuit components should be under best conditions: - Starter battery and cables; - Fuel in accordancewith the indications(withoutlead), sufficientquantity (minimum 5 l); - Fuel filter according to the indicationsand correctlyinstalled; - Correct recirculationcircuit (fuel vapors) with no clogging; - Supplying circuit: good sealingbetweenthe components, air filter in order; - Acceleration cable
17 IGNITION AND INJECTION DIAGNOSTIC A. DIAGNOSIS BY SAGEM CLIP TESTER The injection and ignition systemdiagnosis can be done by using the SAGEM CLIP tester, after connectingit to the diagnosisplug of the vehicleand after its + 12 V supply from the battery terminalsand from the lighterplug. The detaileddescription of the testeras well as the diagnosissoft DACIA installing and their operation mode are written on the CD no.1 joint to the tester purchase.
IGNITION AND INJECTION DIAGNOSTIC 17 After accessing the diagnosismenu by pressingthe key >, a submenu is displayed, with the following options: - press key 1 for reading the memorized damages; - press key 2 for displaying the real values of the checked measures; - presskey 3 for checkingthe functioning of the acting items; - presskey H for displayingthe helping menu; - presskey N for returning to the diagnosismenu.
17 IGNITION AND INJECTION DIAGNOSTIC The next unit is activatedwith each pressing of the key “ 1 ”. When pressingkey “ 3 ” the working instructionsfor canceling the malfunctioning causeof the unit will be displayedand by pressingthe key “ > ” the unit is reselected. When pressingkey “ N ”during the activationof a unit,one returns to the checkingsub-range of the activationunits.
IGNITION AND INJECTION DIAGNOSTIC 17 The diagnosis of the injectionsystem by KTS 300 Testerpermits the detection of the systemdamages components;the damage code is provided in the followingtable: DAMAGE COD DAMAGED COMPONENT 011 A 0203 0204 0204 0206 0206 0206 0206 0206 020A 020A 020A 020B 020B 020D 010D 0219 0219 0231 0231 0303 463A FFFF DAMAGE DENOMINATION Idle motion regulator Rotation sensor Idle motionswitch Idle motionswitch Valve potentiometer Valve potentiometer Valve potentiometer Valve potent
17 IGNITION AND INJECTION ELECTRONIC CONTROL UNIT DISMOUNTING Disconnectingof the battery terminal (-). Disconnecting of the connector coupling the control unit to the control cables of the fuel injection, as follows: - the lock (1) is pulled arrow-sense; - the connector is turned around point (2), arrow-sense(a), until its disconnection; - the fixing screwsof the electronic control unit on theright bumper column aredismounted. REMOUNTING Reverse the above mentionedoperations.
IGNITION AND INJECTION 17 ROTATION SENSOR DISMOUNTING The connector is disconnected from the rotation sensorby pressing the fuse (1), arrow-senseand then it is dismounted. The fixing screw of the sensor on the clutch caseis dismounted. 1 REMOUNTING Reverse the above mentionedoperations. Functioning tests(testingof the rotation sensorfunctioning). WARNING: In order to avoid its damaging, the sensor should be placed in the clutch case by pushing, not by hammering.
17 IGNITION AND INJECTION ENGINE TEMPERATURE SENSOR DISMOUNTING The injectioncontrol cables from the sensor are disconnectedby pushing the fuse (1), arrow-senseand by dismountingit. The sensoris dismounted. 1 REMOUNTING Reverse the above mentioned operations.The coolingand the checking of the cooling liquid level in the gas vessel are to be done. Functioning tests(testingof the engine temperature sensorfunctioning). WARNING! Avoid bumping the sensor. The tightening of the sensor to the couple = max.
IGNITION AND INJECTION OXYGEN SENSOR 17 DISMOUNTING The sensor coupling connector to the fuel injectioncontrol cablesis disconnectedas follows: - the blocking valve (1) is pulled arrow-sense (a); - the connectoris dismounted. The sensor is dismounted from the primary down tube. 1 a REMOUNTING Reverse the above mentioned operations; when fixing the rod, its thread should be lubricated with 12 g anti-gripping grease. Functioning tests(testingof the oxygen sensorfunctioning).
17 IGNITION AND INJECTION INDUCTION COIL DISMOUNTING Disconnectthe battery terminal (-) Disconnect the connector of fuel injection control cables from the coil as follows: - push the lock (1) arrow-sense; - disconnectthe connector from the coil. Disconnect the spark plugs cables from the coil. Disconnectthe coil fixing screwson the cylinder headclosingplate. REMOUNTING 1 Reverse the above mentionedoperations. Functioning tests(ignitiontesting).
IGNITION AND INJECTION SPARK PLUGS SET 17 DISMOUNTING Disconnect the spark plugs and the coil cables. RISMOUNTING Connect the cables to the spark plugs and to the corresponding plots of the induction coil. Functioning tests(testingof ignition system). WARNING! When mounting the cables, they should be connected to the cylinder corresponding to the number marked near the coil plot. Tightening couple for the spark plugs 20 – 40 Nm. 17 - 35 vnx.
COOLING - EXHAUST - FUEL TANK 19 CHARACTERISTICS Cooling system with under pressure liquid in the circuit, mechanical fan driven by belt and radiator core type, with vertical basins.
19 COOLING - EXHAUST - FUEL TANK FILLING AND AERATION OF THE COOLING SYSTEM Check : - the tightness of the rings; - the tightness of the draining plugs from the engine block and from the radiator. Dismount the radiator plug and mount in its place the MOT 401 filling device. Completely open the air conditioning radiator tap. Open the water pump and the air conditioning radiator hose purges. Fill the expansion vessel 30 mm over the maximum level mark.
COOLING - EXHAUST - FUEL TANK CONTROL 19 The cooling circuit is filled with a fluid which ensures the protection against frost,up to - 40º C. The fluid is made up of a mixture of distilled or de mineralised water and antifreeze fluid as follows: - for a protection up to - 21º = 35 % concentrate antifreeze fluid + 65 % distilled water. - for a protection up to - 40º = 50 % concentrate antifreeze fluid + 50 % distilled water.
COOLING - EXHAUST - FUEL TANK 19 CONTROL CHECKING OF THE COOLING FLUID CONCENTRATION Protection up to - 210 C Warm countries Protection up to - 400 C Cold countries The value of protection The fluid quantity temperature red on (liters) which is replaced thermal densimeter with concentrated antifreeze The value of protec- The fluid quantity tion temperature red (liters) which is on thermal densimeter replaced with concentrated antifreeze - 50 C 1,6 - 100 C 1,1 - 150 C 0,7 0 - 20 C 0,2 - 50 C
COOLING - EXHAUST - FUEL TANK CONTROL 19 CHECKING OF THE COOLING CIRCUIT TIGHTNESS AND TAR RING OF THE EXPANSION VESSELVALVE 1.CHECKING OF THE CIRCUIT TIGHTNESS Mount the MS 554 device instead of the radiator plug. Open the heating tap. Warm the engine till the thermostat opens. Clamp the radiator - expansion vessel hose by means of the MOT 453 device.
19 COOLING - EXHAUST - FUEL TANK CONTROL 2. CHECKING OF EXPANSION VESSELVALVE TARRING After checking the tightness of the cooling circuit, release the radiator-expansion vessel hose. Create pressure in the circuit,value of the pressure shall be 0,1 bar higher that the value marked on the valve. In this situation,the pressure must decrease.If the pressure does not decrease,the valve is blocked and shall be replaced.The valve shall be also be replaced in case it permits the fluid passing.
COOLING - EXHAUST - FUEL TANK COOLING RADIATOR DISMOUNTING Disconnect the battery. Clamp the radiator hoses by means of the MOT 453 device. Drain the radiator and recover the cooling fluid. Dismount the radiator hoses. Unscrew the fixing screw and take out the radiator. REMOUNTING Check the presence of the lower buffers. Mount the radiator Mount the upper buffer and tighten the fixing screw. Mount the hoses and tighten the collars. Dismount the MOT 453 device.
19 COOLING - EXHAUST - FUEL TANK COOLING G.M.V. ( for A.C. ) DISMOUNTING Disconnect the battery. Drain the coolingsystem. Drain the A.C system. Disconnect the hosesfrom the radiator. Disconnect the hosesfrom the condenser. Disconnect the G.M.V connector.. Dismount the radiator attachmentscrewson the vehiclebody.. Detach the radiator – condenser – cooling GMV assembly. Dismount the G.M.Vattachmentscrews onthe condenser. Take out the G.M.V REMOUNTING Perform the same operations in the reverse order.
COOLING - EXHAUST - FUEL TANK COOLING G.M.V. THERMOCOUPLE CHECKING ( for Pick-Up with C.A. ) 19 NOTE: The GMV thermocouple may not be repaired ;I t is located on the radiator. The G.M.V. thermocouple is locatedon the lateral right side of the radiator,attachedon this. The tighteningmoment is5 daNm. It has a double purpose: - it controlsthe engine cooling G.M.V.
19 COOLING - EXHAUST - FUEL TANK WATER PUMP DISMOUNTING Disconnect the battery. Drain the cooling circuit and recover the cooling fluid. Dismount : - the hoses connected to the pump; - the fan belt; - the fan and the water pump pulley. Unscrew the fixing screws of the pump and dismount the pump by tapping it with a plastic hammer. The water pump is not to be repaired. REMOUNTING Clean the contactsurface of the gasket and mount a new gasket on the pump. Mount the water pump pulley and the fan.
COOLING - EXHAUST - FUEL TANK WATER PUMP COVER 19 DISMOUNTING Disconnect the battery. Drain the cooling circuit. Dismount : the pump belt,the fan and the water pump pulley. Unscrew the fixing screws of the cover and take out the cover by slightly tapping it with a plastic hammer. REMOUNTING Clean the contact surface of the gasket and mount the cover with a new gasket. Mount the water pump pulley and the fan. Connect the battery. Perform the filling and aeration of the cooling circuit. 19 - 11 vnx.
COOLING - EXHAUST - FUEL TANK 19 THERMOSTAT DISMOUNTING Loosen the tightening ring and dismount the pump hose Loosen the tightening ring of the thermostat and dismount the thermostat. CHECKING OF THE THERMOSTAT OPERATION Pour in a vessel a convenient quantity of cooling fluid. Check the fluid temperature by means of a thermometer.
COOLING - EXHAUST - FUEL TANK EXHAUSTASSEMBLY 19 The exhaustassembly ensure the evacuationof the burnt gasesissued during the engine running and reduction of both noise level and dangerous emissions. The assembly is composed of : - downtake pipe (1); - pipe and expansion chamber (8); - intermediatepipe (4); - silencer(7). For vehiclesequipped with injectionsystemthe downtakepipe is equippedwith catalyst(11) which has the purposeof pollutionemissionsreduction.
COOLING - EXHAUST - FUEL TANK 19 EXHAUSTASSEMBLY 11 9 10 8 1 2 3 4 5 6 7 REMOUNTING Perform in reverse order the dismountingoperations. 19 - 14 vnx.
COOLING - EXHAUST - FUEL TANK 19 FUEL TANK ASSEMBLY DISMOUNTING In order to dismountthe fuel tank the followingoperationsare to be performed: Disconnect the battery. Drain the fuel tank (1). Disconnect the rear wiring from the tank cap. Dismountthe fuel pump (2). Dismount the hose fixing ring (3) on the air exhaustduct (4) for Dacia1304 Pick-up, respectivelythe sealing gasket(8) for Dacia1304 Dropside. Dismountthe fixing collar(5) of the fuel duct on the lower fillinghole.
19 COOLING - EXHAUST - FUEL TANK ELECTRICFUEL PUMP PARTICULARITIES The electricfuelpump (picture2) is fixed on the tank,beingimmersedin fueland is commended by the computer,bymeansof the fuel pump relay (R1). When contactis on,with the key in the positionM (engine),but without startingthe engine,the pump willbe fed with electricity only for 3-4 sec.Thepump willpermanentlyflow only when the computer is receiving signalfrom the rpm sensorand must ensure a minimum flow of 1 - 1,1 l/min.
COOLING - EXHAUST - FUEL TANK ELECTRICFUEL PUMP 19 ( dismounting the tank from the vehicle not required ) DISMOUNTING Unscrew the fixing screwsof the fuel tank visitingcap. Disconnect the rear wiring from the tank cap. Dismount the fixingrings of the hosesand disconnectthe hosesfrom the tank cap. Dismountby turningcounter clockwisedirection,theblockingring of the tankcap.
19 COOLING - EXHAUST - FUEL TANK FUEL LEVEL SENSOR ( dismounting the tank from the vehicle not required ) DISMOUNTING Unscrew the fixing screwsof the fuel tank visitingcap. Disconnect the rear wiring from the tank cap. Dismountthe hosesfixing rings and dismountthe hosesfrom the tank cap. Dismount,byturning counter clockwisedirection,the fixing ring of the tankcap.
CLUTCH CHARACTERISTICS Dry single disk clutch. Membrane mechanism. Clutch disk with elastic hub. Disk thickness: 7,4 mm Clutch stroke at the lever end: 2,5 - 3,5 mm 20 - 1 vnx.
CLUTCH 20 IDENTIFICATION The clutch type is marked on the front side of the mechanism. Φ 180 DBR CLUTCH Φ 200 DBR CLUTCH Φ 200 GR CLUTCH 20 - 2 vnx.
CLUTCH CLUTCH DISK – MECHANISM CLUTCH DISMOUNTING - REMOUNTING DISMOUNTING Dismountthe gearbox. from the vehicle. ATTENTION! For the injection engines, before gearbox dismounting from the vehicle, dismount the RPM transducer in order to avoid its damaging. Unscrew the clutch mechanism attachment screws and dismount the clutch. Check the state of the component parts and replace the used or defective ones. REMOUNTING Degreasethe flywheelfrictionsurface.
20 CLUTCH CLUTCH DISK – MECHANISM PRESSURE BEARING REPLACEMENT DISMOUNTING Dismount the gearbox. from the vehicle. Release the spring from the pressure bearing ears. Dismount the pressure bearing. REMOUNTING Grease the bearing guide and the clutch forksends with greaseUM 170 Li Ca Pb 2M. Place the new bearing. Place the spring by introducing the ends in the bearing holes. Slightly grease the contact surface between the diaphragm and the bearing with grease UM 170 Li Ca Pb 2M. Remount the gearbox.
CLUTCH CLUTCH FORK REPLACEMENT 20 DISMOUNTING Dismountthe gearboxfrom the vehicle. Dismount the pressure bearing. Extract the attachment shaft of the clutch fork by means of the AMB 384 A extractor. Dismount the fork spring and recover the fork and the spring. REMOUNTING Grease the fork shaft with UM 170 Li Ca Pb 2M. Introduce the shaft with the sealing bushing. Mount on shaft the new fork and the return spring. Mount the fork attachment pins by means of the AMB 384 A device, observing the value D = 1mm.
MANUAL GEARBOX 21 IDENTIFICATION IDENTIFICATION Identification of the gearbox is done by means of a rectangular plate, attached to the clutch housing of the gearbox with a 3,5 mm POP rivet. On the rectangular plate, the type ,variant and fabrication serial numbers of the gearbox are marked. Type G.B Var. 365 50C 51C - 0000000 21 - 1 vnx.
21 MANUAL GEARBOX SECTIONS GEARBOX 50C 21 - 2 vnx.
MANUAL GEARBOX SECTIONS GEARBOX 51C 21 - 3 vnx.
21 MANUAL GEARBOX SECTIONS GEARBOX 365 21 - 4 vnx.
MANUAL GEARBOX SECTIONS DIFFERENTIAL 51C DIFFERENTIAL 365 21 - 5 vnx.
MANUAL GEARBOX 21 DIAGNOSTICS GLOSSARY Checking Operations to be performed. A. NOISY GEAR SHIFTING (AFTER CLUTCH CHECKING) Dismount the gearbox. Check the sinchro assembly of the velocity step : - friction cones of the synchro pinion and gear; - synchro hub,springs and wedges; - coupling gears of the pinion and the sliding gear. B. IMPOSSIBILITY OF GEAR COUPLING ( AFTER CLUTCH CHECKING ) Check gear linkage. BAD GOOD Adjust gear linkage. Check the wear of linkage gear.
MANUAL GEARBOX 21 DIAGNOSTICS C. SLIPS OUT OF VELOCITY STEPS OF GEAR BOX Check the situation of brackets of assembly. GOOD BAD Tighten brackets attachment screws or replace brackets. Checking of the wea and adjustment of the linkage gear GOOD BAD Dismount the gearbox: Check coupling teeth of the shifter sleeves and pinions. Check shifter fork contact surfaces with shifter sleeves. Check roller attachment system. Replace defective parts. Replace defective parts of the gear linkage.
MANUAL GEARBOX 21 DIAGNOSTICS E. UNUSUAL NOISES DURING DRIVING Stop the vehicle. Bring the gear shifting handle to dead point. Let the engine running. YES The noise stops. NO Check the state of clutch stroke. GOOD BAD Check transmission state. Check the clutch control system. Replace defective parts. GOOD Check the level of the gearbox oil. Fill to proper level if needed. BAD Repair the transmission. The noise stops. NO Declutching, press the clutch pedal to end of stroke.
MANUAL GEARBOX 21 CHARACTERISTICS The 365, 50C, 51 C gearboxes are monoblock type , mechanical in steps (5 forward steps and one reverse step). The forward driving velocity steps are provided with Borg – Warner synchronizers. The reverse driving step is not synchronized. GEARBOX TYPE VAR. 30 32 50C 33 78 51C 31 37 38 73 76 CONICAL SPEEDOMETER GEARS RATIO RATIO OF TEETHES RATIO 6X13 I. 42X11 II. 38X17 III. 34X23 IV. 29X28 V. 29X38 M.Î.40X13 3,81 2,23 1,47 1,03 0,76 3,07 6X12 I. 42X11 II.
21 MANUAL GEARBOX TIGHTENING MOMENTS ADJUSTEMENT VALUES Distance between the conical gears: 59 mm. Differential gear bearings pre-tightening : - reused bearings : free, without clearance; - new bearings : 1-3 daN. Gear teeth clearance: 0,12- 0,25 mm; Clearance in differential gear: max. 0,1mm TIGHTENING MOMENTS (daNm) - Half crankcases assembling screws : * M7............................................................................................. 1,9 - 2,4 * M8........................................
MANUAL GEARBOX INGREDIENTS 21 MATERIALS Parts that are to be obligatory replaced, if they were dismounted: paper gaskets, annular oil rings, toothed crown attachment screws, speedometer endless screw, elastic pins, primary shaft nut, secondary shaft nut, reverse selector shaft nut, shifter shaft nut.
21 MANUAL GEARBOX DISMOUNTING - REMOUNTING GEARBOX DISMOUNTING – REMOUNTING FROM THE VEHICLE NOTE: For the vehicles equipped with injection system ,first dismount RPM transducer attached on the clutch casing, to avoid its damaging during gearbox dismounting. Disconnect the battery. Disconnect: -starter power cable; -supply wire of cutting relay. Unscrew the three attachment screws of the starter shield. Take out the starter, by drawing it along the shaft.
MANUAL GEARBOX DISMOUNTING - REMOUNTING Disconnect the vacuum hoses and the electrical connector of the vacuumcapsule (G.B. 51 C). Dismount the 4 attachment screws of the secondary shaft flange and rock the transmission (G.B. 51 C; 50 C). Disconnect the speed gear control by unscrewing the control auxiliary rod screws. Unscrew the attachment nut of the exhaust pipe. Disconnect the backward driving contact wire. Disconnect the speedometer cable. Lift the back part of the gearbox by means of a jack.
21 MANUAL GEARBOX DISMOUNTING - REMOUNTING REMOUNTING Check the state of the centering bushing from the crankshaft end. Grease the grooves of the clutch shaft with grease U M 170 Li Ca Pb 2 M. Assembly the gearbox to the engine. ATTENTION! Do not catch the clutch mechanism. Mount the clutch shield plate. Mount the back crossbar. Connect the electric wire of the back drive connector. Connect the propeller shaft and tighten at the required moment ( 5 daNm ) the 4 attachment screws M10 (G.B. 50 and G.B. 51).
MANUAL GEARBOX DISMOUNTING - REMOUNTING 21 Place the new elastic pins. The pins notches shall be oriented towards the wheel. The ends of the pins shall be sealed with RHODORSEAL 5661. Mount (on both sides): a. the upper suspension joint b. the steering joint Mount the front wheels, take the vehicle down from the elevator and tighten the wheels nuts at the required moment (9 daNm). Dismount the TF 509 support cross bar. Mount the clutch cable with its support.
21 MANUAL GEARBOX REPAIR Dismount the gearbox off the vehicle Dismount the reverse driving lamp contact. Dismount the clutch casing. DISMOUNTING OF THE COUPLING MECHANISM 4X4 (G.B. 51 C) Dismount the attachment pin of the connection bolt (1) between the vacuum capsule shaft and the control lever and take out the bolt. Dismount the vacuum capsule support from the gearbox casing. Take out the safety washer (2) of the control lever fixing. Dismount the control lever (3) of the front transmission.
MANUAL GEARBOX 21 REPAIR Clean the annular oil seal place from the differential cover. Take out the cover (7) from the hub differential. Dismount the safety ring (8) from the propeller shaft gear. Take out slotted shim (9). Extract the hub-gear assembly (10) together with fork and shaft (11). Take out the claw (12) and the pins housing (13). 11 12 13 10 9 DISMOUNT THE VELOCITY STEP V Dismount the flange attachment nut flange on secondary shaft and take out the flange (G.B. 50C , 51 C).
21 MANUAL GEARBOX REPAIR Dismount the velocity step V fork pin by means of 31 B mandrel. Observe the hub and the tooth gear sliding mechanism of velocity step V. Dismount: - the synchronizing mechanism and the fork of velocity step V; - the velocity step V pinions. Dismount the distance plate. For G.B. 365 and 51 C Dismount the nuts lock washers for the differential gear adjustment. Dismount the adjus tment nuts of the differential gear by means of the CV 377 wrench.
MANUAL GEARBOX REPAIR FORKS AND SHAFTS DISMOUNTING Bring the fork III - IV to the dead point. Dismount the speed V fork shaft and recover : - the interlocking ball between forks shafts III -IV and V. - the ball and the attachment spring of the speed V fork shaft; Dismount the elastic pin of fork III IV by means of the CV 31 B mandrel. Take out the interlocking disk of the forks shafts. Engage speed I. Move toward back the reverse driving shaft.
21 MANUAL GEARBOX REPAIR REVERSE DRIVING PINION DISMOUNTING Dismount: - the lock ring; - the shaft; - the pinion; - the friction ring; - the guiding wedge. Recover the spring and the attachmentball. HALF CRANKCASES DISASSEMBLING Dismount the outer ring of the bearing by means of a trod. Dismount the annular oil seals from the differential gear adjustment nuts. (G.V. 365 ºi 51C). 21 - 20 vnx.
MANUAL GEARBOX REPAIR PRIMARY SHAFT DISASSEMBLING Dismount the elastic pin by means of the CV 39 mandrel and separate the clutch shaft from the primary shaft. Take out the outer rings of the bearings and the rollers cage. Dismount the bearing inner ring by means of the CV 22 extractor. Dismount the biconical bearing on a press by means of the TS 65 extractor. 21 - 21 vnx.
21 MANUAL GEARBOX REPAIR SECONDARY SHAFT DISASSEMBLING Dismount : - the biconical bearing; - the ring for the adjustment of the distance between the cones gear; - the velocity step IV pinion and its synchronizing ring; - the synchronizer tooth gear sliding mechanism III - IV. Dismountthe speeds III-IV synchronizer hub on a press, by means of the TS 65 extractor.
MANUAL GEARBOX REPAIR Dismount: - the lock ring of the speed II pinion; - the speed II free pinion and its synchronizer ring; - the lock ring of the synchronizer hub speeds I -II; - the synchronizer tooth gear sliding mechanism of speeds I – II (observe the position of the gear sliding corresponding to that of the synchronizer hub). Dismount on a press, the hub of the velocity steps I-II synchronizer, by means of the TS 65 extractor.
21 MANUAL GEARBOX REPAIR DIFFERENTIAL GEAR DISASSEMBLING ( G.B. 365 ºi 51C ) Unscrew two opposite attachmentscrews of toothed crown. Dismountthebearings by meansof theCV 28 A extractor, provided withthe CV 48 grippers. Dismount the toothed crown; the screws may not be re-used. Dismount the elastic attachment pin of the pinions shaft, by means of the CV 31 B mandrel. Dismount : - the differentialpinions shaft; - the different pinions; - the friction washers; - the propeller shaft pinion. 21 - 24 vnx.
MANUAL GEARBOX REPAIR BACK CAP DISASSEMBLING Dismount : - the speedometer pinion guide and its sealinggasket; - the speedometerpinion. Dismount the nut at the end of the rocking lever; take out the shaft. Dismount the plug of the V velocity step pusher, recover the spring, the pusher and the gasket. Dismount the elastic pin from the end of the control shaft, by meansof theCV 344 mandrel. Dismountthe lock ring of the rocking lever shaft; dismount the shaft and the rocking lever.
21 MANUAL GEARBOX REPAIR SECONDARY SHAFT ASSEMBLING For G.B. 365 ºi 51C. The differentialdrive pinion and the toothed crown are lapped together. Replacingof one part obligatory requires replacingthe pair part. A pairing number is marked both on the pinion end and on the toothed crown. No other markings shallbe taken into consideration besidesthe pairing number. NOTE: All spare parts will be lubricated with 80W 90 oil before bein mounted.
MANUAL GEARBOX REPAIR The mounting of the hub I – II can be performed in two variants : 1.By difference of temperature (for gearbox made until 26.04.1999 , series 172321). Place the velocitysteps I– II synchroniser hub on electrical stove , at a 120° C, dgr temperature , and keep it there for about 15 minutes, to heat it. 2. Without differenceof temperature ( for gearbox made after 26.04.1999, series 172321). The pressing force for the hubs I – II and III – IV will be max. 2000 daN.
21 MANUAL GEARBOX REPAIR Mount the velocity step III pinion and its synchronisingring. Mount : - the velocitystep III pinion lockwasher; - the lock wedge of the washers; the wedge is mounted in a channel which has a lubricating hole. Mount on the velocitysteps III– IV synchroniser hub : - the three wedges ; - the two springs ; - the tooth gear slidingmechanism ,with its groove oppositeto the groove hub.
MANUAL GEARBOX REPAIR Mount : - the velocitystep IVpinion and its synchroniserring; - the adjustment washer for the conical mechanism dist ance, recovered upon dismounting; - the biconicalbearing; - the spacer; - the velocitystep V pinion; - the elastic washer. Mount the speedometerendlessscrew (G.B. 365). Mount the speedometer endless and flange of the secondary shaft (G.B. 51 C). Tightenthe velocitystep I, in a soft dies vice. Engage gearbox in speedI.
21 MANUAL GEARBOX REPAIR PRIMARY SHAFT ASSEMBLING Mount the biconicalbearing. Press the needle-roller bearing inner ring. Mount the outsidebearing ring together with its rollers casing. Mount the lock washer. Mount the clutch shaft ; place anew compensation washer between the end of the shaft, in order to prevent the noise. Mount the elastic pin by means of the C.V. 31B mandrel. 21 - 30 vnx.
MANUAL GEARBOX REPAIR 21 DIFFERENTIAL GEAR ASSEMBLING ( G.B. 365 and 51C ) Placethe followingparts in the casing: - the textolite washer ,with the lubricating grooves directed towards the propeller shaft pinion ; use 1.96 - 2 mm thick washers. The 2.03 - 2.07 mm thick washers shallbe used only if the clearance betweenthe propeller shaft pinionand the differentialpinion is very big.
21 MANUAL GEARBOX REPAIR Mount the differentialbearings on a press. ADJUSTMENT OF THE CONICAL DISTANCE (G.B.365 AND 51 C) The differentialdrive pinion is in the correct position, when its front is at distance A=59 mm from the toothed crown axis. This position is obtained by mounting a washer (1) of the adequate thickness between the biconical bearing (2) and thedifferential drive pinion shoulder(3).
MANUAL GEARBOX REPAIR 21 The checking of the conical distance is performed by means of the CV239 - 01 control device, which materializes the toothed crown axis and by meansof a spacer CV 239 - 02, with the height H = 48,5 mm. The height (H) of the 48,5 mm spacer plus radius (C) of the device axis of 10 mm represents: 48,5 mm + 10 mm = 58,5 mm. The distancevalue (X) measured between the spacerand the pinion face shall be: X = 59 mm - 58,5 mm = 0,5 mm (when the actual value is A = 59mm).
21 MANUAL GEARBOX REPAIR DIFFERENTIAL GEAR BEARINGS ADJUSTMENT ( G.B. 365 and 51 C ) 1 2 2 1 The differentialgear bearings adjustmentis performed by meansof the nuts (1) and (2). Mount the annular oil sealrings on the adjustmentnuts. Grease the adjustment nuts threads with sealing paste LOCTITE518 NOTE: Before mounting, the annular oil rings will be immersed in oil 80W/90.
MANUAL GEARBOX REPAIR 21 Tightentheadjustmentnuts by means of theCV 377 wrench, until they come into contact,withthe outer rings of the bearings. 1. REUSED BEARINGS The reused bearings shallbe mounted freely, withoutclearance. Tightenthe adjustmentnuts until the bearingsrotate freely, withoutany clearance. 2. NEW BEARINGS The new bearings shallbe mounted by pretightening. Tighten the adjustmentnuts until the bearings show a certain resistance to rotating.
21 MANUAL GEARBOX REPAIR Noticethe nuts positioncorresponding to the half crankcases. Dismount the left side half crankcaseand the differentialgear. REMOUNTING OF FORKS AND SHAFTS NOTE: Upon remounting, the elastic pins shall be positioned with the slot towards the back side of the gearbox. Mount the reverse drivingshaft in the rightside half crankcase. Position the reverse drive selectorin the notch of the reverse driving shaft.
MANUAL GEARBOX REPAIR Placethe interlocking disk of the forks shafts. Place the attachment spring and ball of the velocitysteps III IV fork shaft. Introduce the shaft. Mount the velocitysteps III - IVfork with the hub towards front side of the box. Introduce the elasticpin. Placethe attachmentball and spring of the fork shaft velocitystep V. Place the blocking ball of forks shafts, velocitysteps V and III - IV. Introduce velocitystep V fork shaft. 21 - 37 vnx.
21 MANUAL GEARBOX REPAIR Engage the velocity steps III - IV fork in the position required for the coupling of velocity step IV and keep it in this positionuntil completemounting of the gearbox. REMOUNTING OF THE REVERSE DRIVING PINION Place the attachment spring and ball of the shaft in the left side half crankcase. NOTE: The spring is black painted to be different from lockingspringof forks shafts.
MANUAL GEARBOX REPAIR 21 HALF CRANKCASE ASSEMBLING Placein the right side half crankcase - primary shaft; - secondary shaft together with the lock pin of the biconicalbearing taking care that the assembled forks to be positioned in their seats; - the differential gear (G.B. 365 and G.B. 51C). Grease the assembling areas of the crankcases with sealing paste LOCTITE 518. Place theleft side half crankcaseover the right side half crankcase; positioncorrectly the reverse selector.
21 MANUAL GEARBOX REPAIR Placethe followingparts on the secondary shaft: - the velocitystep V pinion; - the elastic washer; - the speedometerendless. Check the clearance “J” between the synchronizing ring and the surface of the hub : J = min 0,2 mm The checkingshallbe performed as follows: - the pinion in contact with the hub; - the synchronizing ring in contact with the pinion con. Couple the reverse driving and the velocity step V.
MANUAL GEARBOX REPAIR Mount a comparing device on the crankcase and place thefeeler perpendicularly on the crown tooth flank, as much to the edge of the rim as possible. Check the clearance of the gear which should be: 0,12-0,25 mm. Adjustthe nuts until correct clearance is obtained. Mount the nuts locks. . BACK CAP ASSEMBLING Mount the control shaft annular oil seal. Assemble the rocking lever with its shaft. Mount together: - the assembled rocking lever shaft; - the control shaft.
21 MANUAL GEARBOX REPAIR Mount the speedometerpinion and its guide provided with a sealing gasket. Mount: - the velocity step V pusher; - the spring; - the gasket; - the plug greased with LOCTITE 577 and tighten atthe required couple (1,1-1,5daNm) BACK CAP RE MOUNTING Bring the forks to the dead point. Place the back cap gasket lubricate with oil. Placethe backcap; positionthe velocity steps selector in the forks shafts notches. Tighten at the required moment (1- 1,4daNm) the back cap attachment screws.
MANUAL GEARBOX 21 REPAIR CLUTCH CASING RE MOUNTING Pressin the clutch casingthe guidingbushingof the pressure bearing (only if it has previously been dismounted). Mount the annular oil seal of the clutch shaft by means of the device CV 488. NOTE: Before mounting, the annular oil seal shall be immersed in 80W/90. Apply a layer of sealing paste LOCTITE 518 on the assembling area of the clutch casing with mechanismscrankcase. Mount the clutch casingby meansthe device CV 488 for oil sealring protection.
21 MANUAL GEARBOX REPAIR Replacethe annular oil sealfrom the differentialcap, as follows: - grease the new annular oil seal with gear oil 80W90; - mount the new annular oil sealby slightly tapping by means of the plastichammeruntil it came into contact with the support shoulder from the differential cap resultingin this casethe dimension of 6 + 0,5 mm. Mountthe differentialcap assemblywith a new lubricatedgasket.
MANUAL GEARBOX BACKCAP 21 (on vehicle ) DISMOUNTING REMOUNTING Lift the car on the elevator. Drain the oil from the gearbox. Disconnect: - the speedometer cable; - the velocitysteps control. Support the back part of the gearbox. Unscrew the attachment nut of the exhaust pipe from back cap cross bar gearbox. Dismount the back crossbar of gearbox. For G.B. 50C and 51C: - dismount the cardan transmission from the secondary shaft flange and tilt it over. - dismountthe secondary shaft flange.
21 MANUAL GEARBOX CONTROL SHAFT ANNULAR OIL SEAL REPLACEMENT (on vehicle ) REMOUNTING DISMOUNTING Lift the car on the elevator. Drain the oil from the gearbox. Dismount the back crossbar of the gearbox. For G.B. 50C and G.B.51 C: - disengage the cardan transmission; - dismount the flange of secondary shaft. Dismount the back cap. Unscrew the nut from the end of the rocking levershaft. Dismount the elasticpin from the control shaft end.
MANUAL GEARBOX SPEEDOMETER ENDLESS SCREW PINION REPLACEMENT DISMOUNTING 21 (on vehicle ) REMOUNTING Lift the car on the elevator Drain the oil from the gearbox. Disconnect: - the speedometer cable; - the velocitysteps control. Disconnect the cardan transmission and dismount the secondary shaft flange (G.B.50C;51). Dismount the back crossbar. Dismount the back cap. Dismount the speedometer endless pinion from the back cap. Replace the speedometer endless (G.B.50C,51C).
21 MANUAL GEARBOX VELOCITY STEP V SYNCHRONIZER REPLACEMENT (on vehicle ) REMOUNTING DISMOUNTING Lift the car on the elevator Drain the oil from the gearbox. Disconnect: - the speedometer cable; - the velocitysteps control. Disconnect the cardan transmission and dismountthe flange (G.B. 50C,G.B.51C). Dismount the back crossbar of the gearbox. Dismount the back cap. Engage the velocitystep V and the reversedriving. Dismounttheprimaryshaft nut.
MANUAL GEARBOX CLUTCH SHAFT ANNULAR OIL SEAL REPLACEMENT 21 (on vehicle ) DISMOUNTING Clutch annular oil seal replacement requires gearbox dismounting from the vehicle. Dismountthe gearboxfrom the vehicle. Dismountthe pressure bearing. Dismountthe clutchcasing. Dismountthe annularoil sealclutchshaft. REMOUNTING NOTE: Before mounting ,the annular oil seal shall be immersed in 80W/90 oil.
21 MANUAL GEARBOX PROPELLERSHAFT ANNULAR OIL REPLACEMENT (on vehicle ) DISMOUNTING Mount the TF 509 support crossbars betweenthe attachmentshaft of the shock absorber and the lower suspension arm shaft. Lift the car on the elevator. Dismountthe front wheels. Drain the oil from the gearbox. Take out the attachment pins of the transmission by meansof the CV 31 mandrel. Disconnect: - the steering joint; - the upper suspensionjoint, by meansof the TF 476 extractor.
MANUAL GEARBOX PROPELLER SHAFT ANNULAR OIL REPLACEMENT 21 (on vehicle ) Dismount the lock washer. Dismount the adjustmentnut by meansof the CV377 wrench; mark the number of rotationsof the nut to enable the mountingin the sameposition,avoiding this way the further adjustmentof the differentialgear bearings. Dismounttheannular oilsealand the tightening ring. Clean the nut. REMOUNTING NOTE: Before mounting, the annular oil seals shall be immersed in 80W/90. Mount thenew annular oil sealand tightening ring.
DRIVE SHAFTS FRONT CROSS TRANSMISSIONS 29 I. FRONT CROSS TRANSMISSION CHARACTERISTICS Transmission of the motion from the gearbox to the front two driving wheels is performed by means of two assembled homo-kinetics transmissions provided at their ends with two joints of the following type: - GE 86 - towards the wheel; - GI 69 - towards the gearbox.
29 DRIVE SHAFTS FRONT CROSS TRANSMISSION SPECIAL TOOLS Pivot pins extractor Mandrel Hub immobiliser Device for mounting transmission in the hub PF 476 C.V. 31 B PF 235 A PF 236 TIGHTENING MOMENTS ( daNm ) Suspension upper joint nut Steering joint nut Transmission nut Wheels nut 5 4 23 9 29 - 2 vnx.
DRIVE SHAFTS FRONT CROSS TRANSMISSION 29 DISMOUNTING Mount the TF 509 support cross bar between the shock absorber attachment shaft and the suspension lower arm shaft. Lift the vehicle on the elevator. Dismountthe wheel. Loosen: - the attachment nut of the suspension upper ball joint; − the steering joint fixing nut. Depress by means of the PF 476 extractor: - the upper suspension ball joint; - the steering ball joint. Remove the attachment elastic pin by means of the CV 31 B mandrel.
29 DRIVE SHAFTS FRONT CROSS TRANSMISSION REMOUNTING Grease the propeller shaft pinion grooves with Li Ca Pb type II. Couple the transmission with the propeller shaft pinion. Introduce the new elastic pins. The pins notches shall be oriented towards the wheel. The pins ends shall be sealed with RODORSIL. Introduce the transmission in the hub. Mount the transmission in the hub by means of the PF 236 device. Mount: - the suspension upper ball joint; - the steering ball joint.
DRIVE SHAFTS BELLOWS TOWARDS TO THE GEARBOX 29 GI 69 JOINT BELLOWS REPLACEMENT Joint bellows replacement - the part towards the gearbox – is to be performed with dismounted transmission. 1. Tulip 2. Assembled tripod 3. Assembled type 4. Casing 5. Collar 6. Bellows 7. Ruber ring 8. Transmission shaft DISMOUNTING Dismountthe transmissionoff the vehicle. Dismount the collar (5) maintaining the bellows (6) on the tulip. Dismount the rubber ring (7). Cut the bellows on the entire length.
29 DRIVE SHAFTS BELLOWS TOWARDS TO THE GEARBOX REMOUNTING Grease, the transmission shaft, the bellows and the rubber ring with MoS 2 grease. Place on the shaft, the rubber ring and the new bellows. Mount the tulip on the shaft. Mount the safety ring. Mount the tulip on the shaft. Introduce approximate 14,0 cl special grease ELF CARDEXA or UM 185 Li 2 M in the bellows and the tulip. Introduce a bar between the bellows and the transmission shaft in order to dose the quantity of air inside the bellows.
DRIVE SHAFTS BELLOWS TOWARDS THEWEEL 29 GE 86 JOINT BELLOWS REPLACEMENT Bellows replacement – the wheel side- is to be performed having the transmission dismounted. 1. Steering knuckle casing 2. Retention star 3. Tripod assembly 4. Tulip shaft 5. Collars 6. Bellows 7. Spring 7 DISMOUNTING Remove the two collars (5) taking care not to damage the channelsmade on the steering knuckle surface. Cut and remove the damaged bellows. Take out maximum of grease.
29 DRIVE SHAFTS LONGITUDINAL TRANSMISSION ( CARDANIC ) II.LONGITUDINAL TRANSMISSION ( CARDANIC ) CHARACTERISTICS Longitudinal transmission is specific and is equipping the D1304, D 1307 vehicles (rear wheel drive or f.w.d. 4 W D) and has the purpose to transmit the motion from GB to rear axle (drive axle).
DRIVE SHAFTS LONGITUDINAL TRANSMISSION ( CARDANIC ) 29 IMPORTANT ! The cardanic joints forks which are mounted at the both ends of the longitudinal transmission are to be placed in the same plane.
GENERAL GENERAL PRINCIPLE SCHEDULE OF A BRAKE CIRCUIT IN PARALLEL WITH BY-PASS CIRCUIT 30 The DACIA commercial vehicles, are equipped with hydraulic braking system, double circuit by-pass brake pump , brake amplifier, pressure limiter in order to avoid the rear wheels blocking. The front brakes are disk type and the rear brakes are drums type. The brake disks are aerated, for the wheels with 5 attachment screws and non aerated for wheels with 3 attachment screws.
GENERAL 30 TIGHTENING MOMENTS ( daNm ) FRONT DRIVING AXLE 1,5 6 9,5 4 4 5 9 23 8 11 6,5 5 30 - 2 vnx.
GENERAL TIGHTENING MOMENTS ( daNm ) 30 FRONT NON DRIVING AXLE 1,5 9,5 5 4 4 5 9 8 23 11 6, 5 30 - 3 vnx.
30 GENERAL TIGHTENING MOMENTS ( daNm ) REAR DRIVING AXLE 2,5 24 1,54 6,3 30 - 4 vnx.
GENERAL TIGHTENING MOMENTS ( daNm ) REAR UNDRIVING AXLE 2,5 9 6,5 24 1,54 30 - 5 vnx.
30 GENERAL TIGHTENING MOMENTS ( în daNm ) TIGHTENING MOMENT ELEMENT 1 - 1,2 Caliper purging screw 2 Flexible hoses in calipers Rigid tubing linkage in wheel cylinder 1,5 Pad holder attachment screw 6,5 Attachment screw disk to the hub 2 Front wheel steering knuckle nut 23 Wheel attachment screw 9 Wheel fixing nuts 9 Main brake cylinder fixing nut with servobrake 1,3 I.C.P.
GENERAL 30 THE DIMENSIONS OF MAIN BRAKING ELEMENTS ( in mm ) FRONT BRAKE Brake caliper bore diameter (for 3 screws wheel) φ 48 Brake caliper bore diameter (for 5 screws wheel) φ 54 Brake disk diameter 228 Disk thickness non aerated 10 Disk thickness aerated 20 Minimal disk thickness non aerate 9 Minimal disk thickness aerated 19 Braking pad thickness ( the support included) 14 Minimal brake pad thickness (the support included) 7 Disk axial run out measured at Φ 215 0,1 REAR BRAKE Wheel
30 GENERAL BRAKE CONNECTIONS AND SEWERAGE The sewerage connection between the brake pump, brake calipers, pressure limiter is performed by means of the sleeves threaded with METRIC PITCH Therefore it is important to use only original spare parts, recommended in the spare parts catalogue specific for this type of vehicle. Spare parts identification A The cupping shape of the copper or steel ducts (A). B The shape of the threaded lengths on parts (B). C Connections of ducts (C). 30 - 8 vnx.
GENERAL BRAKE FLUID 30 PERIODIC CHANGE OF THE BREAK FLUID The manufacturing conception of the brakes equipping the Dacia vehicles especially the disk brake type (inner empty pistons, low quantity offluid with cylinder, sliding calipers avoiding existence of a fluid reserve in the less cooled area of the wheel) enable the maximum rejection of fluid vaporization even in case of intensive using of brakes (mountain area).
30 GENERAL BRAKING CIRCUIT PURGING AIR ELIMINATION FROM THE HYDRAULIC CIRCUIT ( PURGING ) The air existence in the hydraulic circuit may be noticed by an elastic displacement of the brake pedal, sometimes even, close to the floor. This fact is more evident with the engine stopped. GENERAL RECOMMENDATIONS Always use for completionor total changingthe brake fluid Norm SAE J 1703, DOT 4. In case of changing the brake fluid it is necessary to wash the system with one liter of industrial alcohol.
GENERAL 30 DIAGNOSTIC Rigid pedal: when braking, an increasedeffort for a smalldeceleration is performed Is the connection shaft betweenthe servobrake fork andthe pedal, grabed? I. FAILURE : RIGID PEDAL Yes Replace:shaft, pedal or servobrakefork.
GENERAL 30 DIAGNOSTIC I. FAILURE : RIGID PEDAL (ctd) 1 One of therigid brake pipes is it smashed ? Yes Replacethe corresponding rigid pipe. No Replacethe defective parts (with GenuineSpare Parts) No Dismount the brake caliperor the brake cylinder? Are the brake caliper’spistons or the cylinders ones correctly gliding ? Yes Are the brakepads, consequently the shoes gasketingood condition? STOP Replace the brake pads, consequently the brake shoes (see bellowsituations).
GENERAL 30 DIAGNOSTIC II. FAILURE : LONG PEDAL When braking, the brakepedal is slowlymoving. Perform a testwith the stopped engine,afterpreviously performing fivesuccessivepushing on the brakepedal (in order to vacuum the servobrake). Isthebrakefluid levellower comparedto the requiredone? Yes No Replace the brake pump, because the pressure gasket (sealing) betweenthe primary circuit and the secondary circuit is defective. STOP 30 - 13 vnx.
30 GENERAL DIAGNOSTIC I. CONSTANT EFFECT TO THE PEDAL EFFECTS Tough pedal: High effort for smalldeceleration. POSSIBLE CAUSES - Assistance defect - Brake linings: - greasy - stacking to the disk ( non-conform ) - heating, prolonged braking with constant pedal press - Stuck piston - Rigid duct narrowed (flattening) Elastic pedal - Air presence in the circuit: defective purging In order to diagnose, an incident where - Internal leak in the braking circuit.
GENERAL 30 DIAGNOSTIC II. CONSTANT EFFECT AT BEHAVIOUR EFFECTS POSSIBLE CAUSES Brakes not accomplishing the required braking distance - Non-uniform worn brake linings (backing off); - Brake linings slightly greased; - Springs with modified characteristics. Vibrating brakes - Brake disks with high wobbling; - Inconstancy brake disks width; - Particles abnormal deposit on brake disks (oxidation between linings and disk).
30 GENERAL THE INFLUENCE OF ANGLES FRONT AXLE ANGLES CAMBER ANGLE 10 30’ +/- 30’ It is formed by the wheelplane with the verticalthat crosses the wheelaxis. A difference higher that 1°betweenthe two camber angles(left side and right side) leadsto: - the deviationfrom the trajectory that must adjustedby meansof the steering wheel; - abnormal wear of the tires and bearings. This angle results from building may not be adjusted.
GENERAL THE INFLUENCE OF ANGLES 30 PARALLELISM It is measured in horizontalplane as a difference betweenthe front and rearpartof the wheels of sameaxle. The wheels of the front axle are : - divergent for DACIA commercial vehicles with front drive (opening 1 – 4 mm); - convergent for DACIA commercial vehicles with rear drive or four wheelsdrive (closing1 – 3 mm). ATTENTION! A too much opening causes the wear of the tires towards the interior.
30 GENERAL STEERING PRELIMINARY CHECKINGS AND ADJUSTMENT POSSIBILITIES ADJUSTMENT POSIBILITIES Only the followingparameters may be adjusted: - the caster angle, by means of the rod; - the parallelismand the distribution, from the connectingrod pipe; - the steering gear box position,by meansof the eccentrics (positioning willbe adjusted only if the steering gear box has been dismountedDIR 487).
GENERAL FRONT AXLE CHECKING -ADJUSTMENT 30 THE SEQUENCE OF THE OPERATIONS Due to the geometric conception of the front axle , modification of one side angle (castor angle, camber angle,ball joints) has no major impact on the value of other side angles (the parallelism being directly influenced). The modification of these angles does not happen during vehicleexploitation,butonly as a consequenceof a vehicleaccident.
30 GENERAL FRONT AXLE CHECKING -ADJUSTMENT REPARTITION CHECKING ANDADJUSTMENT Check the connecting rods symmetry “X”. Read the value “A” on the scale. 31 - 20 vnx.
GENERAL FRONT AXLE CHECKING -ADJUSTMENT 30 Case1. The symmetry dimension “X” is correct: - the value “A” is equal distributed. Case2. The symmetry dimension“X” is incorrect: - read the value “A” on each side, mark it, calculate an average value,establishing the value for each side. EXAMPLE Right side value: A = 16; Left side value: A = 10; 16 + 10 = 26; 26 : 2 = 13. Operating the steering rods tie bar,restore the same value for both side A = 13. In this position,lock the rotating platesto zero point.
GENERAL 30 DIAGNOSTIC THE AXIAL DEVIATION OF THE WHEELS TO THE LEFT OR RIGHT AT STABLE SPEED Preliminarychecking: WHEELS (front,rear):- pressure; - dimensions; - types; - adjustingwheels. HINGES: - bush.
FRONT BEARING ELEMENTS UPPER ARM 31 SUSPENSION UPPER ARM SPECIAL TOOLS DENOMINATION Front axle support cross bars Ball joints extractor Dynamometric wrench CODE PF 509 PF 476 MOT 50 DISMOUNTING The operation that where performed on a half axle are identical to those performed on the other one. Suspend the vehicle on the elevator.
31 FRONT BEARING ELEMENTS UPPER ARM REMOUNTING Position the arm and clamp the lower joint of the shock absorber. Couple the upper suspension ball joint with the steering knuckle and slightly tighten the nut. Mount , without tightening ; - the upper arm shaft; - the lower joint shaft of the shock absorber; - the steering ball joint; - the caster rod. PF 509 Mount the crossbar PF 509 or compress the front axle in position H1 – H2 = 80 mm.
FRONT BEARING ELEMENTS UPPER ARM 31 CHECKING SPECIAL TOOLS DENOMINATION Front axle support cross bars Ball joints extractor Upper arm checking device Dynamometric wrench CODE PF 509 PF 476 PF 502 MOT 50 Dismount the upper arm of the suspension. Place the device on the arm and mount the shaft. The arm should easily enter in the device central guiding and should be placed on one of the support pins (1,2,3,4). Measure the distance between the support pins and arm, which should be between 0 and 1 mm.
31 FRONT BEARING ELEMENTS ELASTIC BUSHING, UPPER ARM BALL JOINT ELASTIC BUSHING REPLACEMENT SPECIAL TOOLS: DENOMINATION CODE Front axle support cross bar Ball joint extractor Dynamometric wrench PF 509 PF 476 MOT 50 Dismount the upper arm of the suspension. Dismount on a press the worn bushing, using a rod with the outer diameter of D = 26mm. Press the new bushing. On pressing,observe the value A = 6mm. Mount the upper arm on the vehicle.
FRONT BEARING ELEMENTS ELASTIC BUSHING,UPPER ARM BALL JOINT Lift the vehicle using a two columns elevator. Dismount the wheel, mounting the PF 509 crossbar, between the lower arm shaft and the shock absorber joint shaft. Release the ball joint from the steering knuckle by means of the PF 476 extractor. Dismount the attachment screw of the upper ball joint. Dismount the ball joint. Assemble the attachment screw of the rod with the ball joint and place it on the arm.
FRONT BEARING ELEMENTS 31 LOWER ARM SUSPENSION LOWER ARM SPECIAL TOOLS: DENOMINATION CODE Front axle support cross bar Ball joint extractor Dynamometric wrench PF 509 PF 476 MOT 50 DISMOUNTING Lift the vehicle on the elevator and dismount the wheel. Release the lower suspension ball joint by means the PF 476 extractor Dismount the elastic bushings of the rod stabilizer. Slowly lower the stabilizer rod to enable the taking out of the shaft. Unscrew the nut and take out the shaft.
FRONT BEARING ELEMENTS LOWER ARM 31 REMOUNTING Mount the lower ball joint in the steering knuckle and slightly tighten the nut. Lift the half-front axle by means of a jack. Position the arm, grease it with special MoS2 grease and mount it. Mount the elastic bushings of the stabilizer rod. Compress the front axle in the lock position of the elastic bushings, introducing the PF 509 support cross bar between lower arm shaft and shock absorber shaft.
31 FRONT BEARING ELEMENTS LOWER ARM CHECKING SPECIAL TOOLS: DENOMINATION CODE Front axle support cross bar Ball joint extractor Lower arm checking device Dynamometric wrench PF 509 PF 476 PF 502 MOT 50 Dismount the suspension lower arm. Mount the lower arm checking device PF 502 on the lower arm and introduce the shaft. By means of the pin (D) placed on the arm, measure the distance between the pins (A,B,C) and arm, which should be between 0 and 1 mm . Mount the suspension lower arm on the vehicle.
FRONT BEARING ELEMENTS ELASTIC BUSHING, LOWER ARM BALL JOINT 31 ELASTIC BUSHING REPLACEMENT SPECIAL TOOLS: DENOMINATION Front axle support cross bar Ball joint extractor Dynamometric wrench CODE PF 509 PF 476 MOT 50 This operation implies bushings replacement one by one ,in order to maintain their position as to the arm shaft. Dismount the suspension lower arm. Depress one elastic bushing, using a 31 mm outside diameter (D) rod. Mount the new bushing on a press ,observing the value A = 151 mm.
31 FRONT BEARING ELEMENTS ELASTIC BUSHING, LOWER ARM BALL JOINT BALL JOINT REPLACEMENT SPECIAL TOOLS: DENOMINATION CODE Front axle support cross bar Ball joint extractor Dynamometric wrench Release the ball joint by means of the PF 476 extractor. Dismount the suspension lower arm. Bore and remove the ball joint attachment rivets. Mount the new ball joint and attach it with screws, which shall have the head oriented towards the bellows. Mount the lower arm on the vehicle.
FRONT BEARING ELEMENTS BRAKE GASKETS SPECIAL TOOLS: Pushing 31 piston device FR 500 FRONT BRAKE PADS REPLACEMENT NOTE: In order to maintain the brake efficiency, the replacement of the brake pads shall be made only in complete kit; never fit brake pads of different makes and different qualities.The replacement is made when the pad thickness is less than 7 mm (support included). DISMOUNTING Lift the vehicle by means of a two columns elevator. Dismount the wheels.
31 FRONT BEARING ELEMENTS BRAKE GASKETS REMOUNTING Mount the protection bellow. Check : - the wear of brake disk; - the wear of flexible hoses. Push the piston by means of the FR 500 device. Mount: - the protection bellows; - the elastic blades; - the new brake pads; pads must easily slide in the caliper fork. Mount the calipers. Mount the wheels and get down the vehicle on the ground. Press the brake pedal for several times in order to bring the pistons in contact with the brake pads. 31 - 12 vnx.
FRONT BEARING ELEMENTS BRAKE CALIPER TIGHTENING MOMENTS ( daNm ) Wheel nuts Rigid sewerage-connection screws 9 1,5 DISMOUNTING Drain the brake fluid tank. Lift the vehicle by means of a two columns elevator Dismount the wheel. Dismount: -safety wedges; -the wedges (B) by lateral sliding. Disconnect the brake wear sensor. Unscrew the rigid sewerage-connection from the brake flexible hose. Remove the safety washer of the flexible connectionfrom the stopper and dismount the caliper.
31 FRONT BEARING ELEMENTS BRAKE CALIPER Clean and grease the sliding surfaces of the caliper, wedges and pads holder. Mount the caliper on the pad holder. Mount the lower wedge, which must smoothly slide. Introduce a screwdriver between upper caliper part and pad holder and press the screwdriver. Mount the upper wedge. Mount the wedges safety washers. Place the flexible connection on its stopper. Connect the rigid connection with the flexible connection. Mount the safety maintenance washer.
FRONT BEARING ELEMENTS BRAKE CALIPER 31 TEMPORARY REMOUNTING FOR TESTING Lubricate the caliper groove and the sealing gasket with brake fluid. Mount the sealing gasket in its seat. Lubricate the piston with brake fluid and introduce it in the brake caliper. The piston should be displaced easily by hand; in any case, it shall be not forced or tapped by a hammer. Mount the purging screw. BRAKE CALIPER SEALING CHECKING Connect to the brake caliper, a pressure gauge attached to a compressed air source.
31 FRONT BEARING ELEMENTS BRAKE CALIPER If the brake caliper lets the air flow by the piston, dismount the caliper brake once more. If the piston has been reused, it shall be replaced, and if has been replaced, it shall be recovered and the brake caliper shall be replaced with a new assembly. Perform again the sealing test. After having performed the sealing test, dismount the brake caliper and blow it with compressed air. If the brake caliper is in a good state, it shall be mounted.
FRONT BEARING ELEMENTS BRAKE DISK 31 FRONT BRAKE DISK SPECIAL TOOLS: DENOMINATION CODE Caliper piston pusher Dynamometric wrench TIGHTENING FR 500 MOT 30 MOMENTS - Brake caliper fork attachment screw on steering knuckle................ 6,5 daNm - Disk attachment screw on the hub..................................................... 2 daNm - Steering knuckle front wheel nut....................................................... 23 daNm - Wheel nut......................................................
31 FRONT BEARING ELEMENTS BRAKE DISK DISMOUNTING Lift the vehicleon the elevator Dismount : - the wheel; - the front wheelsteering knuckle nut; - the caliperwithoutdisconnecting the flexible connection; - the brake pads; - the calipersupport. Lock the hub by means the of the PF 235 A device and unscrew the steering knuckle nut. Unscrew the three attachmentscrews of the hub disk, locatedat 120° one of another; mount in their place the RO 482 – 01 extractor.
FRONT BEARING ELEMENTS BRAKE DISK 31 REMOUNTING Check the state of the flexible hose and of the brake pads; replacethem if necessary. Attach the disk to the hub. Grease the bearing with LiCaPb type II grease. Mount the cross bar on the hub and place the “hub – disk” assembly on the steering knuckle. Mount the “ hub – disk” assembly on the steering knuckle by meansof the PF 236 device. Mount the steering knuckle nut and tighten at 23 daNm moment by meansof the MOT 50 wrench.
FRONT BEARING ELEMENTS 31 BRAKECALIPER SUPPORT TIGHTENING MOMENTS ( în daNm ) The attachment caliper support screw on steering knuckle .......6,5 The attachment protector screw on thecaliper support.................1,3 The attachment protector screw on the steering knuckle............ .......2 DISMOUNTING Lift the vehicleon a two columns elevator; Dismount: - the wheel; - the caliperwithoutdisconnecting the flexibleconnection; - the brake pads.
FRONT BEARING ELEMENTS STEERING KNUCKLE DISMOUNTING SPECIAL TOOLS: DENOMINATION CODE Transmissiongear and hub extractor PF 235 A Transmissiongear mountingdevice PF 236 Ball jointsextractor PF 476 Front axle support cross bar PF 509 Dynamometricwrench MOT 50 TIGHTENING MOMENTS - Upper ball joint nut.......................................5 daN.m - Lower ball joint nut.......................................5 daN.m - Steering ball jointnut....................................4 daN.m - Transmission nut.....
31 FRONT BEARING ELEMENTS STEERING KNUCKLE Mount the PF 235 A extractor on the hub; Depress the “hub – disc”assembly; Dismount the three ball jointsby means PF 476 and take out the steering knuckle. REMOUNTING Positionand pressthe steering knuckle on the “ hub – disk “assembly,afterpreviously having introduced a greasesupply. Mount the “hub – disk - steering knuckle ”assembly, by coupling the ball joints and tighten their nuts to the required moment.
FRONT BEARING ELEMENTS STEERING KNUKLE 31 STEERING KNUKLE - CHECKING SPECIAL TOOLS: DENOMINATION Steering knuckle checking device CODE PF 496 The steering knuckle is dismountedoff the motor car. Dismountthe innerbearing of the steering knuckle. In its seat, place the pin (C) of the PF 496 checking device, and place mandrels (A) and (B) in the suspensionball joint seats.
31 FRONT BEARING ELEMENTS STEERING KNUCKLE BEARING STEERING KNUCKLE - BEARINGS REPLACEMENT SPECIAL TOOLS: DENOMINATION Front axle support crossbar Transmissiongear and hub extractor Transmissiongear mountingdevice Ball joint extractor Shaft protectionbushing Bearings extractor Dynamometricwrench CODE PF509 PF 235 A PF 236 PF 476 RO 15 - 01 CV 28 A MOT 50 Dismountthe steering knuckle off the vehicleand dismountthe sealingplate.
FRONT BEARING ELEMENTS STEERING KNUKLE BEARING 31 INNER BEARING REMOUNTING Mount the new bearing by meansof a press,using a bushing having the outer diameterof 71 mm and the inner diameterof 66 mm. The bushing shallbe supported and shallbe pressedon the bearing outer ring. NOTE: Do not deteriorate the bearing sealing gasket ! OUTER BEARING REMOUNTING Mount bearing by pressing it on the hub, using a 36 mm inside diameter rod. This shall be supported and shallpress the inner ring of the bearing.
31 FRONT BEARING ELEMENTS CHARACTERISTICS OF FRONT SUSPENSION MAIN ELEMENTS FRONT SUSPENSION ( section) FRONT SUSPENSION With helical springs, hydraulic shock absorber with double effect, with incorporated lock buffers and stabilizerrod. The helical springs have a flat support area at the upper part, and a flat support area at the lower part. 31 - 26 vnx.
FRONT BEARING ELEMENTS SUSPENSION - TIGHTENING MOMENTS 31 NOTE: Make sure the suspension springs of each axle have the same characteristics. TYPE COIL DIAMETER FREE LENGHT / OF MOTOR CARE ( mm ) UNDER LOAD daN/mm FRONT SPRINGS 14,5 Pick - up 1304, 1305,1307 410 / 250 STABILIZER ROD VEHICLE TYPE DIAMETER ( mm ) 19 Pick - up 1304, 1305,1307 FRONT SUSPENSION TIGHTENING MOMENTS - Upper arm shaft nut...............................................................9,5 daN.m - Lower arm shaft nut.........
FRONT BEARING ELEMENTS 31 FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER REPLACEMENT BY MEANS OF THE SUS 478 - 01 DEVICE The front shock absorber may be dismountedas follows: - single, using the SUS 478 – 01 device; - together with the spring, using the SUS 478 device. DISMOUNTING Mount the PF 509 support crossbarbetween the shock absorber lower attachment shaft and the suspensionlower arm shaft. Lift the engine by means of a 2 columns elevator.
FRONT BEARING ELEMENTS FRONT SHOCK ABSORBER REMOUNTING Grease the threaded parts of the shock absorber with special MoS2 grease. Press the rod , tilt andplace the shock absorber. Fully screw the shock absorber into the lower joint. Pull the shock absorber rod by means of the SUS 513 device. Positionthe rubber buffers and the crossbar. Tighten the upper nut at the required moment. Tighten the lock nut. Tightenat the required couple: - the lower lock nut; - the stabilizerrod shaft nut.
FRONT BEARING ELEMENTS 31 FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER REPLACEMENT BY MEANS OF THE SUS 478 DEVICE DISMOUNTING Mount the PF 509 support crossbar. Lift the vehicle by means of a 2 columns elevator. Dismountthe wheel.
FRONT BEARING ELEMENTS FRONT SHOCK ABSORBER REMOUNTING Grease the threaded parts of the shock absorber with special MoS2 grease. Place the “ device – spring – shock absorber “ assembly. Fully screw the shock absorber into the lower joint. Pull the shock absorber rod by means of the SUS 513 device. Positionthe rubber buffers and the crossbar. Tighten the upper nut at the required moment. Tighten the lock nut. Tightenat the required couple: - the lower lock nut; - the stabilizer rod shaft nut.
31 FRONT BEARING ELEMENTS FRONT SUSPENSION SPRING DISMOUNTING Dismount the shock absorber and the spring by means of the SUS 478 device. Clamp the SUS 480 device into the vice. Place the “ SUS 478 device – spring “ assembly on the SUS 480 device. Place the upper plate and press the spring until the SUS 478 device is released. Dismount the SUS 478 device. Depress the spring and remove it. REMOUNTING Place the new spring on the SUS 480 device. Press the spring , observing its mountingposition.
FRONT BEARING ELEMENTS FRONT STABILIZER ROD 31 DISMOUNTING Unscrew : - the attachmentnuts (1)and (2) of the casingon thelongitudinal girder; - the nuts (3) of the stabilizerrod auxiliary connectingrod. Dismount the stabilizerrod together with the auxiliary connecting rod. Check the state of the elastic bushings; if it shows marks of wear,replace the auxiliary connectingrod. REMOUNTING Mount the auxiliaryconnecting rods on the stabilizerrod.
REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE 33 PLATE DRIVE REAR AXLE DACIA 1304,1307 CHARACTERISTICS It is a rigid type axle made of plate, with differential gear and propeller shafts. It is attached to the chassis by means of semi elliptic springs and hydraulic shock absorbers. The main transmission is simple type, with hypoid gear between the pinion and the rim.The differential is symmetrical, simple, with four conical differential pinions.
33 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE ANGLES VALUE Parallelism Camber angle Pressing position of the leave spring 00 00 G = 162 mm TIGHTENING MOMENTS - Shock absorber lower nut..........................................3 daN.m - Axle attachment nut...............................................11 daN.m - Wheel nut.................................................................9 daN.m DRIVE REAR AXLE DISMOUNTING Lift the rear axle by means of a two columns elevator. Dismount the wheels.
REAR BEARING ELEMENTS PLATE DRIVE REARAXLE 33 Dismount : - the four screws of the cardanic flange at the side towards the differential gear; - the shaft nut that attaches the shock absorber; - the clamping clips of the half-elliptic spring. Detach the brake cable from the hand brake levers. Disconnect the flexible connecting hose of the braking hydraulic circuit from the three ways connection.
REAR BEARING ELEMENTS 33 BRAKE DRUM The two rear brake drums must have the same diameter, the rectifying of one drum implying the same operation for the other one. SPECIAL TOOLS Depress bearing closing assemble device PS 65. TIGHTENING MOMENTS - Wheels nuts ...................................................................................................9 daN.m - Slotted nut ....................................................................................................24 daN.
REAR BEARING ELEMENTS BRAKE DRUM 33 DISMOUNTING Dismount the M 8 x 1,25 - ( 1 ) screw. Dismount the elastic ring 32 and washer 8,1 x 12,7 - ( 3 ). Dismount the four 4 screws M 10 x 1,5 - ( 4 ). Dismount the “ hub drum – brake plate “ assembly and place it on a bench. Straighten the shoulder of the slotted nut ( 5 ). Unscrew the slotted nut and take out the bearing washer ( 6 ). Separate the brake plate from the drum-hub assembly.
33 REAR BEARING ELEMENTS BRAKE CYLINDER TIGHTENING MOMENTS - Wheels nuts ..................................................................................................9 daN.m - Slotted nut .....................................................................................................24 daN.m - Attachment screws of the assembly “ drum – axle brake plate “…...............6,3 daN.m - Connecting screw propeller shaft – drum hub assembly ..........................1,54 daN.
REAR BEARING ELEMENTS BRAKE CYLINDER 33 REPAIRING Dismount the cylinder off the vehicle. Dismount: the protection bellows assembled with pistons, the pressure gaskets, and the purging screw. Check the state of cylinder boring, pressure gaskets of the bellows and of the pistons. Any trace of wear, oxidation or scratches implies the replacement of brake cylinder assembly. If the cylinder components are in a good state, lubricate the parts with brake fluid and mount them in the reverse order of dismounting.
33 REAR BEARING ELEMENTS BRAKE SHOES TIGHTENING MOMENTS - Wheels nuts ...................................................................................................9 daN.m - Attachment screws of the assembly “ drum – axle brake plate “...............6,3 daN.m - Slotted nut ...................................................................................................24 daN.m - Connecting screw propeller shaft – hub drum .......................................1,54 daN.
REAR BEARING ELEMENTS BRAKE SHOES 33 REMOUNTING The shoes assembled with the lower return spring is attached on the plate ( the shoes P foots in contact with supporting plate C). Remount the auxiliary connecting rod assembled with the hand brake lever. By means of a brake shoes nipper, set the upper connection of shoes by means of the upper return spring. Mount the brake shoes maintaining clips. Apply a sealant layer ( ROMTIX 1502 ) in the areas of the maintain clips with the brake plate.
REAR BEARING ELEMENTS 33 BEARING ( 39X68X37 ) SPECIAL TOOLS Depressing device for bearing casing assembly PS 702 TIGHTENING MOMENTS - Wheels nuts ...........................................................................................9 daN.m - Slotted nut ............................................................................................24 daN.m - Attachment screws of the assembly “drum axle brake plate” .............6,3 daN.m - Connecting screw propeller shaft – hub drum ................
REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 33 The rear axle assembly is dismounted from the vehicle, placed on an universal support, having its propeller shaft removed. DISMOUNTING Dismount: - the flage nut (1); - the washer (2); - the cardanic flange (3); - the sealing ring (4) ( annular oil ring ) 42 x 72 x 12; - the deflector (5); - the bearing (6) ( the inner ring with balls) 30 x 72 x 28,75; - the adjustment bushing set (7). 33 - 11 vnx.
33 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL Remove the differential assembly by unscrew the eight screws of the casing. Dismount : - the screws that attach the differential nuts lock washers (1); - the differential adjustment nuts (2); - the stub bolts nuts that attach the bearings half casings (3); Remove the centering bushing and unscrew the stub bolts. Together with the conical balls bearings, remove the differential assembly, detaching it from the front part of the drive pinion.
REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 33 Dismount the elastic pin that attaches the differential pinions shaft by means of the mandrel CV 31 B. Dismount: - the differential pinions lock washer; - the differential pinions shaft, the ball joint; - the differential pinions; - the friction washers (elastic bushings); - the propeller shaft pinions. REMOUNTING The differential gear shall be re mounted by performing the dismounting operations in the reverse order.
33 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL The two conical ball bearing shall be mounted by pressing in the differential casing. Press the two outer rings of the differential drive pinion bearing in the differential casing. Put the differential drive pinion in the casing; the former has the adjustment washer mounted on it and the 30 x 80 x 32,75 conical balls bearing pressed on.
REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 33 - place continuos sealant material layer on the whole contact surface of the rear axle taking care not to close the attachment wholes of differential casing; - mount the differential assembly and tighten the screws at the required couple of 2 - 2,5 daNm. NOTE: The interchangeable of the gasket with the layer is not affected.
33 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL MOUNTING CONDITIONS 1. Adjustment of the conical distance 54 0 mm between the rim axis and the front - 0,1 surface of the pinion head. 2. The propeller shafts and the differential pinions shall be selected so that a maximum 0,1 mm clearance is obtained in the whole differential assembly, one propeller shaft being locked, the moment required for the rotation of the propeller shaft should be maximum 1 daN.m. 3.
REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 33 Check the distance 90 +/- 0,015 mm by reading the value shown by the device. OBSERVATION: Regarding the mounting conditions: - in case there are accidental deviations from the absolute value 54, on the front side of differential drive pinion it will be marked the effective deviation in hundredth; - the conical distance of 54 0 mm shall be algebraic corrected with a.m. value.
33 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 2. ADJUSTMENTOF THE PINION – RIM GEARING CLEARANCE Checkingof the clearance of the conicalassemblygear is performedinitiallyby estimation, by hand. If the clearance felt is too big, act upon the nut on the side of the casing; by unscrewing it a number of rotations, until a smaller clearance in the conical assembly gear is obtained, or, perform the opposite operation clearance is too small.
REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 33 3. DIFFERENTIAL GEAR BEARINGS ADJUSTMENT It is performed by means of the adjustment nuts until the bearing opposes a certain resistance. The bearing clearance is correct if upon rotation of the differential, without differential drive pinion, the resistant moment shall have values between 0,10 – 0,15 daNm. The adjustment shall be performed as follows. Rotate the differential rim several times so that the bearings get in their seats.
33 REAR BEARING ELEMENTS NON DRIVE PLATE REAR AXLE NON DRIVEPLATE REAR AXLE DACIA 1305, 1307 F CHARACTERISTICS It is rigid, drawn type. From the manufacturingpoint of view, it looks like the plate driveaxle. The central and annular part is sealed by means of a cap. Provided for : DACIA 1305 ,1307 F. Valuesof the steering angels: - parallelism ....................................................................0 0 - pivot cross indicator angle ............................................
REAR BEARING ELEMENTS NON DRIVE PLATE REAR AXLE 33 WHEEL HUB DISMOUNTING NOTE: It is assumed that the axle is dismounted and fixed on the support. Dismountthe wheel. Unscrew the M8 sunk screw. Unscrew the four M 10 screws attaching the bi-conicalbearing casing to the axle end. Remove the hub – bearing casingassembly. Dismount: - the slotted nut and the spacerwhich attachthe bearing casing on the inner part; - the insidesafetyring. Depress the hub from the bearing casing by means of the PS 65 device.
33 REAR BEARING ELEMENTS NON DRIVE PIPE REAR AXLE NON DRIVEPIPE REAR AXLE DACIA 1305, 1307 F CHARACTERISTICS It is a drawn, rigid type axle. Attachmentto the chassis is performed by meansof the half axial bladessprings and of the hydraulic shock absorbers. Provided for Dacia 1305, 1307 F. Valuesof steering angles: - parallelism..............................0 0 - pivot cross angle....................0 0 - tightening position of the leafsprings .................................
REAR BEARING ELEMENTS NON DRIVE PIPE REAR AXLE REMOUNTING Perform the dismountingoperationsin the reverse order. 33 - 23 vnx.
33 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE REARDRIVE AXLE OFCASTIRON DACIA 1304, 1307 ( supplier ARO CÂMPULUNG ) CHARACTERISTICS It is a rigid type castiron axle, with differentialand propeller shafts. It is attached to the chassis by means of the half-elliptical springs and the hydraulic shock absorbers. The main transmission is simple type , with hypoid gearing between the pinion and the rim. The differentialis symmetrical,simple,withtwo differentialconical pinions.
REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE 33 WHEEL HUB DISMOUNTING NOTE: It is assumed that the axle is dismounted and fixed on the support. Dismountthe wheel. Detachthe drum from the wheelhub by unscrewing the three M8 sunk screws. Unscrew the six attachment screws of the propeller shaft flange on the wheelhub and remove the propeller shaft. Straighten the retainerblade which is found on the nut groove. Unscrew the slotted nut and remove : - the nut retainer; - the bearing support washer.
33 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE TIGHTENING MOMENTS - Screws assembling the propeller shaft flange................2,5 daN.m - The sunk screw ..................................................0,8 +/- 0,3 daN.m - The rear wheel stud bolt nut.............................................7 daN.m THE DIFFERENTIAL OF THE REAR DRIVE AXLE CAST IRON The rearaxle assemblyis dismounted from the vehicle, placed on an universal support; having its propeller shaftsdismounted.
REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL From the back part of the axledismount the cap of the axle , by unscrewingthe fourteenM 8 screws. Remove the G 3 – 36 and G 5 – 36 elastic pins of the slotted bushing , by means of the 31 B set of mandrels, marking the position of the bushingand shiftingit towards the exterior. Dismountthe adjustmentnuts retainers,marking the position of the nuts in correspondence with the casing. Unscrew the bearings nuts.
33 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL Dismounttheattachmentelasticpin of the differentialpinions shaft by meansof theφ 5 CV 31 B mandrel. Dismount: - the differential pinions shaft ; - thedifferential pinions; - thedifferential pinions bushings; - the propeller shaft pinions. Recover the support washer of the propeller shaft pinion oppositeto the rim. DIFFERENTIAL REMOUNTING Perform the dismounting operationsin the reverseorder, to remount the differential.
REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL 33 By means of a → 5 mandrel,attach and push the G 5 – 40 elastic pin. Mount the second propeller shaft pinionin the rim. Mount the rim on the casing by means of the ten M 11 x 22 screws ( use new ,self locking screws). Tighten them at the moment of 9 – 11 daNm.
33 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL NOTE: Check the marks on the axes in correspondence with the casing. Mark the adjustment nuts in correspondence with the casing. When remountingthe maintransmission,observe the followingtechnicalconditions: 1. The pinion and rim are lapped together. They are inseparable. Replacingone part obligatory impliesreplacingof the other one. There is a common symbol marked both on the rim and on the pinion.. 2.
REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL 33 Workingprocedure: Temporarily mount the inner ring with ballsof the back bearingon the pinion, and introduce it in the casing, without mountingthe adjustmentwasher. Tighten the flange nut at a moment of 3 – 4 daNm. Set the comparator dial to zero. 1. ADJUSTMENT OF THE CONICAL DISTANCE Now set the 18 mm spacerC in front of the differentialdrive pinionand the chuckM, in the half casingsof the bearings.
33 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL 2. ADJUSTMENT OF THE DRIVE PINION BEARINGS The drive pinion is mountedin the casingtogetherwiththe two bearings,without the adjustment washer. Mount the cardanic flange and tighten the nut at a moment of about 0,20 daNm, so that the pinion rotates easily at a load between 2 and 3 daNm. Mount the support S of the comparator dial CC on the cardanic flange.
REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL 33 3. ADJUSTMENT OF THE DIFFERENTIAL DRIVE PINION AND DIFFERENTIAL RIM CLEARANCE In a first phase, the clearance of the conical group gearing is measured by hand. The checking and the exact correction are performed using the comparator dial. Workingprocedure: Place the differential drive pinion, the rim – casingassembly, the bearings set, the adjustmentnuts in the differential casing, observing the marking make upon dismounting.
REAR BEARING ELEMENTS 33 SHOCK ABSORBER REAR SUSPENSION WITH LEAF SPRINGS AND HYDRAULIC SHOCK ABSORBERS TIGHTENING MOMENTS - Shock absorber upper attachment nut ………………………………….....8,5 daNm - Shock absorber lower attachment nut ………………………………….....8,5 daNm - Leaf spring front attachment nut………………………………………..….11 daNm - Leaf spring rear attachment nut……………………………………....…..7,5 daNm - The nut that attach the clip of the leaf spring on the rear axle……….
REAR BEARING ELEMENTS SPRING 33 REMOUNTING Performedin the reverse orderthe shock absorber dismountingoperations, taking into account the shafts greasingand tightening at requiredmoments,as follows: - upper attachment nut ………………………..8,5 daNm - lower attachmentnut ………………………..8,5 daNm REAR SPRING Dacia 1304, 1305, 1307, light trucks are provided with leaf springs.
33 REAR BEARING ELEMENTS REAR ANTIROLL ROD TIGHTENING MOMENTS - Anti roll rod shaft attachment screw.............................................. 1,5 daN.m - Antiroll rod-auxiliary connectingrod connectionaxlesnut ........... 8 daN.m DISMOUNTING Loose the rear wheels nuts. Lift the vehicleon a two columns elevator. Dismountthe rear wheelsnuts. Dismountthe rear wheels. Unscrew the connections of the rear anti roll rod (1) with connectingrods (2).
WHEELS AND TYRES 35 CHARACTERISTICS RIMS 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 J 14 3 CH 48, or - simplified.
WHEELS AND TYRES 35 CHARACTERISTICS TIRES Identification marking examples: 175/70 R 14 83 S 175 1 / 70 R 14 83 S 2 4 5 6 3 1 - 175 - Tire width in mm ( 1 ) 2 - 70 - Ratio 4 - R - Radial structure 5 6 3 h height l width - 14 - Inner diameter in inches ( φ ): This is corresponding with the rim diameter - 83 - Charging index - S - Speed index max. 180 km/h max. 35 - 2 vnx.
WHEELS AND TYRES 35 CHARACTERISTICS Some speed markings: Structure types: Diagonal Radial Diagonally belted Max.
35 WHEELS AND TYRES WHEELS BALANCING BALANCING WEIGHTS Use exclusivelythe weights delivered as spare parts : - fixed by meansof clampson steelrims (clampsincluded in weights). 35 - 4 vnx.
36 STEERING ASSEMBLY CHARACTERISTICS, TIGHTENING COUPLERS CHARACTERISTICS The steering mechanism is rack-and-gear drive. The multiplication ratio in the steering box is: 20:1. The steering wheel number of rotations, corresponding to passing from one end to the other of the rack: 3,5. The central point of the steering gear is: c = 65 mm The diameter of the turning circle between: - pavement.........................11,2 m - walls.... ...........................
36 STEERING ASSEMBLY CHARACTERISTICS, TIGHTENING COUPLERS CROSS SECTION TIGHTENING MOMENTS - Screws for the attachment of the box on the cross rod......................2,5 daNm - Steering ball joint nut............................................................................4 daNm - Elastic coupling nut.......................................................................... 1 ,3 daNm - Steering auxiliary connecting rod shaft nut.......................................
STEERING ASSEMBLY SETTING THE STEERING GEAR CENTRAL POINT 36 In order to set the steering gear central point, bring the rack in the position in which the value C = 65mm. This position is obtained when a rivet of the elastic coupling is oriented upwards. Performing of a checking and adjustment operation of the front axle, impose the identification of the steering gear central point in order to avoid measurement errors occurrence.
36 STEERING ASSEMBLY SETTING THE STEERING GEAR CENTRAL POINT Dismount: - the attachment screws of the elastic coupling; - the steering box attachment screws on the cross rod. NOTE: If the steering gear box is not replaced, do not dismount the eccentrics safety rings, so that, after remounting, it will not be necessary to adjust the height of the steering gear box. REMOUNTING Perform the dismounting operations in the reverse order: Grease the ball joints with Li Ca Pb Hp2 grease.
STEERING ASSEMBLY NOISE ABSORBER BEARING REPLACEMENT OF THE NOISE ABSORBER BEARING DISMOUNTING 1. Noise absorber bearing 2. Elastic bushings 3. Inside support washer 4. Outside support washer 5. Safety ring Place the car on the elevator. Dismount the wheel on the noise absorber bearing side (right side). Dismount: - the steering auxiliary connecting rod; - the protection bellows. Rotate the steering wheel until the rack is withdrawn. Dismount: - the safety ring; - the outer washer.
36 STEERING ASSEMBLY NOISE ABSORBER BEARING REMOUNTING Carefully clean the rack and the noise absorber bearing seat and grease with a special grease containing MoS2. Mount the elastic rings on the noise absorber bearing. Rotate the steering wheel towards the left until the rack is on the extreme right position. Mount the following parts on the rack: - the new noise absorber bearing; - the support washer; - the old noise absorber support.
STEERING ASSEMBLY PUSHER ADJUSTMENT 36 The pusher clearance adjustment shall be performed taking into account the wear degree of the following parts: rack, pusher, casing. The adjustment method shall be observed every time it is necessary to alter the spacers clearance, in order to maintain a normal operation of the steering gear box. 1. Cap 2. Elastic washer 3. Sprig 4. Adjustment washer 5. Pusher The operation shall be performed after removing the steering gear box off the vehicle.
36 STEERING ASSEMBLY PUSHER ADJUSTMENT MEASUREMENT OF THE FREE HEIGHT “ H “ OF THE ELASTIC WASHER Place the washer on a straight plate and measure its height by means of a comparator, using a set of spacers with a known thickness. Note the average value. RACK WEAR CHECKING The rack wear degree is established by measuring the difference betweenthe maximum and minimumvalues onthe rack, in the central area. Attach the comparator support instead of the cap. Bring the feeler in contact with the pusher.
STEERING ASSEMBLY PUSHER ADJUSTMENT 36 Move the rack up to the point where the value is the highest. In this point, reset the comparator to zero. MEASUREMENT OF DISTANCE ( D ) ABOVE THE PUSHER In the position previously set, rotate the rack by means of a fixed wrench, without forcing, until the pusher comes into contact with the adjustment washers;the rotation must be done in both directions. Read the displacement value on the comparator and note the highest value. 36 - 9 vnx.
36 STEERING ASSEMBLY PUSHER ADJUSTMENT SETTING OF THE ADJUSTMENT WASHERS THICKNESS The thickness of the adjustment washers shall be measured for the lowest point of the rack, so that a pre compression of the washer is obtained: E = ( D + 0,06 mm ) - H E - washers thickness; D - the distance above the pusher; H - the free height of the elastic washer; 0,06 - pre compression of the washer.
STEERING ASSEMBLY PUSHER ADJUSTMENT 36 ADJUSTMENT EXAMPLE The distance between the pusher and the adjustment washers: D = 1,48 mm Free height of the elastic washer: H = 1,32 mm Thickness of the adjustment spacer: E = ( D + 0,06 ) - H = ( 1,48 + 0,06 ) - 1,32 E = 0,22 mm PARTICULAR CASE It may happen that value found for the adjustment washers thickness is negative.
36 STEERING ASSEMBLY ADJUSTABLE STEERING AUXILIARY CONNECTING ROD DISMOUNTING Unscrew The attachment nutof the funnel to the steering knuckle support and depress the auxiliary connecting rod ball joint. Take out the attachment collar of the bellows on the casing box. Detach bellows (2) from the steering box. Straighten the edges of the safety washer (4).
STEERING ASSEMBLY ADJUSTABLE AUXILIARY CONNECTING ROD 36 The tightening at the moment of 5 daNm shall be performed with the 6902-4105 special wrench. AUXILIARY CONNECTING ROD FUNNEL In case only the auxiliary connecting rod funnel is worn, this may be replaced. DISMOUNTING Dismount the attachment nut of the auxiliary connecting rod funnel ball joint on the steering knuckle support. Depress the funnel ball joint from the steering knuckle support Loosen the nut (5).
36 STEERING ASSEMBLY STEERING WHEEL SHAFT BUSHING STEERING WHELL SHAFT BUSHINGS REPLACEMENT DISMOUNTING Disconnect the battery. Dismount: - the lower half case; - the steering wheel; - lights control switch; - windscreen washer control switch; - the steering cardan; - upper bushing safety ring; - the ignition/starting contact. Push the steering wheel shaft by means of a bronze mandrel and a plastic hammer until the lower bushing gets out of the steering gear support. Take out the upper bushing.
STEERING ASSEMBLY STEERING WHEEL SHAFT BUSHING 36 REMOUNTING Place an old lower bushing, with the diameter diminished by 2mm, under the new lower bushing(1). Push the steering wheel shaft (3) upwards until the lower bushing gets in its seat. Push downwards the steering wheel shaft and recover the old bushing. Mount the new upper bushing (2) by means of a pipe. Check the correct positioning of the bushings in their respective seats. Mount the safety ring (4) of the upper bushing.
36 STEERING ASSEMBLY STEERING GEAR SHAFT DISMOUNTING Disconnect the battery. Dismount: - the lower half casing; - the steering wheel; - the lights control switch; - the turn lights relay. Disconnect the stop lamp switch and the ignition/starting contact. Dismount: - the steering cardan; - the servo brake attachment nuts; - the servo brake. Disconnect: - the brake pedal pushing rod and the clutch cable. Unscrew the two attachment nuts of the steering column and dismount the column.
MECHANICAL ELEMENTS CONTROLS 37 BRAKE PUMP DOUBLEBRAKEPUMPWITHPRESSUREDROPINDICATOR ( ICP) INCLUDED TIGHTENING MOMENTS ( daNm ) The hydraulic ducts guides 1,4 The attachment nuts brake pump with servobrake 1,3 COMPONENTS 1. Assembled primary piston with gaskets 2. Assembled secondary piston with gaskets 3. Primary piston pin. 4. Secondary piston pin. 5. Primary piston return spring 6. Secondary piston return spring. 7. Purging screw 8.
37 MECHANICAL ELEMENTS CONTROLS BRAKE PUMP PRIMARY CIRCUIT – PRESSURE LOOSING Lack of pressure in the primary circuit leads to the following situation: The primary piston advances up to the pin, so it controls mechanically the secondary piston.. The secondary piston reaches a fluid pressure that shall operate on the piston – linings assembly moving it to the right, opening also the second exit of the rear circuit (the by-pass circuit) increasing the pressure in this circuit.
MECHANICAL ELEMENTS CONTROLS BRAKE PUMP 37 BRAKE PUMP REPAIRING The operation is performed after dismounting the central pump off the vehicle. DISMOUNTING Dismount the brake fluid reservoir, recovering the two gaskets. Dismount the transducer and the purging screw. Clamp a 3,5 mm drill in the vice. Introduce the drill in the elastic pin of the primary piston. Rotate and draw the pump until the pin is extracted. Extract the secondary piston elastic pin, in the same way. 37 - 3 vnx.
37 MECHANICAL ELEMENTS CONTROLS BRAKE PUMP Remove from the pump bore : - the primary piston assembled with Pp gaskets; - the primary piston return spring; - the secondary piston assembled with Ps gaskets; - the secondary piston return spring. Wash the parts with alcohol and blow them with compressed air. Check: - the pump bore; - the pistons gaskets the springs. The parts of the “ primary piston” Pp and those of the “secondary piston” Ps, cannot be repaired.
MECHANICAL ELEMENTS CONTROLS SERVOBRAKE 37 MASTER - VAC SERVOBRAKE TIGHTENING COUPLE ( daNm ) Servobrake on the iron brake 2 The attachment nut of the central pump with servobrake 1,3 CHARACTERISTICS The Master-Vac servobrake is a brake booster with the objective of reducing the driver effort on the brake pedal and may be of 152 mm or 177,5 mm with a minimal booster rate of 1,9.
37 MECHANICAL ELEMENTS CONTROLS SERVOBRAKE DISMOUNTING Drain the liquid out of the reservoir. Detach the four brake ducts from the pump. Disconnect the electrical contact from ICP transducer. Dismount the central pump from the servobrake. Disconnect t he suction hose of the servobrake. Dismount : - the connecting fork shaft to brake pedal (1); - the attachment nuts of the servobrake on the iron plate. Dismount the servobrake.
MECHANICAL ELEMENTS CONTROLS SERVOBRAKE 37 TIGHTNESS CHECKING The tightness of the servobrake is checked on the vehicle, with the hydraulic circuit under operation. Connect the vacuum meter between the servobrake and the inlet collector by means of a “ T ” type connector. The connecting hose of the vacuum meter shall be as short as possible. Start the engine and let it idle run for 1min. Block the air suction hose by means of the MOT 453 device. Stop the engine. Read the indicator.
MECHANICAL ELEMENTS CONTROLS 37 AIR FILTER - SERVOBRAKE RETAINER VALVE AIR FILTER REPLACEMENT DISMOUNTING Dismount the servobrake off the vehicle. Loosen the lock nut and dismount : the coupling brake and the lock nut. Remove the old filter, F. REMOUNTING Mount the new filter. Mount: - the lock nut; - the coupling fork. Adjust the value L. Tighten the lock nut on the fork. Mount the servobrake on the vehicle. Purge the braking circuit if necessary.
MECHANICAL ELEMENTS CONTROLS HAND BRAKE 37 Lever on floor, mechanical controlled, operating on the rear wheels. TIGHTENING MOMENTS ( daNm ) The attachment screws of the hand brake lever assembly on the floor 1,2 The primary cable tightening nut on swing bar 2 ADJUSTMENT With rear wheels suspended and hand brake lever released ,tighten the castle nut M until the shoes gaskets come lightly into contact with the brake drum. Tighten the lock nut N at the required moment.
37 MECHANICAL ELEMENTS CONTROLS HANDBRAKE CONTROL LEVEL DISMOUNTING Disconnect the battery. Lift the vehicle by means of an elevator. Release the hand brake. Disconnect the primary cable from the rocking joint. Dismount the hand brake ornament case. Dismount the screws that attach the hand brake lever to the floor. Release the hand brake lever. Dismount: - the locking ring of the primary cable fork shaft; - the primary fork shaft; - the hand brake lever.
MECHANICAL ELEMENTS CONTROLS HANDBRAKE PRIMARYAND SECONDARY CABLE THE HAND BRAKE SECONDARY CABLE REPLACEMENT DISMOUNTING Dismount the hand brake lever. Disconnect the primary cable from the rocking joint. Dismount the stop sheath of the primary cable. REMOUNTING Place a sealant material layer between the floor and the primary cable case. Mount the primary cable. Mount the stop sheath. Mount the hand brake lever. Adjust the hand brake. 37 - 11 vnx.
37 MECHANICAL ELEMENTS CONTROLS HANDBRAKE PRIMARYAND SECONDARY CABLE HAND BRAKE SECONDARY CABLE REPLACEMENT DISMOUNTING Disconnect the battery. Release the primary cable from the rocking joint. Dismount the drums. Lift the motor-car by means of a jack. Unscrew the nuts M and N. Release the secondary cable from the control levers. Dismount the sheathes stops (from the plate and from the floor). Dismount the secondary cable. REMOUNTING Position the secondary cable.
MECHANICAL ELEMENTS CONTROLS BRAKE LIMITER 37 BRAKE LIMITER CHECKING-ADJUSTMENT Place the vehicle on the checking bench so that wheels are in contact with the ground (unloaded pick up and one person on board ). Mount in the place ofthe purging screw of the brake cylinder, the FR 214 – 02 checking manometer. Dismount the fork from the big spring. After 3,4 successively pressings, the brake pedal remains pressed. Read the value of the pressure which must be 20+0 bars.
37 MECHANICAL ELEMENTS CONTROLS BRAKE LIMITER O1 O2 O After obtaining the pressure of 20 +- 20 bars, with the brake pedal pressed, slide the passing fork (3) until the contact with the limiter control lever. In this moment block the passing fork by means of the screw (1) and the nut (2). Release the brake pedal and purge the braking circuit. Dismount the manometer and the adjustment is considered ready.
MECHANICAL ELEMENTS CONTROLS BRAKE PEDAL AND CLUTCH DISMOUNTING Remove the safety clip (1). Detach the spring (2) of the clutch cable shaft. Remove the pins and the shaft (3) of the main cylinder pushing rod. Remove the clutch pedal from the pedals shaft. By means of a bronze nail, push the pedals shaft towards the right, then remove the brake pedal. REMOUNTING Grease the shaft (A) with special grease containing MoS2. Mount in the following order: -the brake pedal(F); -the washer (C).
37 MECHANICAL ELEMENTS CONTROLS CLUTCH CABLE – CLUTCH STROKE ADJUSTMENT CLUTCH CABLE REPLACEMENT DISMOUNTING Dismount the clutch lever cable. Dismount the attachment clip (1) of the pedal. Push the shaft rightward and take out the pedal. Release the spring (2) and the shaft (3) of the fork. Dismount the fork. Release the cable rfom the housing stopper on the pedal support and dismount it. REMOUNTING Perform the dismounting operations in the reverse order. Grease : -the pedal shaft; -the fork shaft.
MECHANICAL ELEMENTS CONTROLS THE STEERING COLUMN SUPPORT ASSY AND FIRE WALL 37 DISMOUNTING Dismount the throttle, brake and clutch pedals. Dismount the attachment screws (2) of the steering column mounting (1) on the wall metal. REMOUNTING Perform the dismounting operations in the reverse order by screws tightening at the moment of 1,5 – 2,5 daNm. 2 1 37 - 17 vnx.
MECHANICAL ELEMENTS CONTROLS 37 THROTTLE PEDAL THROTTLE PEDAL REPLACING DISMOUNTING Release the throttle pedal by dismounting the clip (8),the washer (7) and support shaft (6). Dismount the attachment nuts of the pedal support (2) and release the throttle pedal (3).
MECHANICAL ELEMENTS CONTROLS GEARBOX CONTROL MECHANISM 37 DISMOUNTING Dismount the return spring (1). Dismount the control auxiliary connecting rod screw. Dismount the four attachment support nuts M8 (2) of the gearbox control case. Dismount the attachment screws M7 of the bellow control lever. Remove from the vehicle, the gears control assembly . Dismount the attachment strap (3) from the control rod (4). 2 6 5 7 3 1 4 Dismount the safety ring from the lever end.
37 MECHANICAL ELEMENTS CONTROLS GEARBOX CONTROL MECHANISM REMOUNTING Re mounting is done by performing in the reverse order, the dismounting operations. Before mounting grease the parts with grease UM 170LiCa Pb2M. Tighten at the required moment the attachment nuts and screws: - nuts M8 ..........................1,5 - 2 daNm - screws M7 .......................... 1 - 1,5 daNm GEARS CONTROL ADJUSTMENT Engage the end lever of the gearbox in the velocity step IV.
ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING PRESENTATION 38 It is used for the Dacia 1304, 1307 vehicles equipped with 51 C type gearbox, for front transmission coupling. This is allowed after vehicle stopping or during driving, at a speed of max.10 km/h, after declutching.
38 ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING PRESENTATION - one-way vacuum valve ( 2 ) – is placed on the connection hose between the inlet manifold and the electric valves. - “ 4x4 ” coupling control wiring – is performing the connection of the system components to the vehicle electrical equipment. The system is working based on the vacuum from the inlet manifold (1), which, during engine running, is acting on the membrane separating the two vacuum capsule compartments (12).
ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING ELECTROVACUUMATIC CONTROLADJUSTMENT 38 Suspendthe vehicleon an elevator. Dismount the fixing lock pin of the connection bolt (8) between the capsule axle and the control lever (6), then remove the bolt from its place. Rotate the front right wheel and set the positions coupled-uncoupled acting upon the front transmission control axle. The front transmission control axle stroke = 11,5 mm.
38 ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING ELECTROVACUUMATIC CONTROLADJUSTMENT -The vacuum piping connecting mode betweenthe electric valvesand the vacuum capsule is according to the drawing: the pipe from the vacuum capsule axle is connected to the electric valve having the pipeson both sides of its body, and the pipe from the opposite part of the capsule axle is to be connected to the electric valve having the pipes on the same side of its body.
ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING VACUUM CAPSULE 38 DISMOUNTING Suspend the vehicle on an elevator. Disconnect the vacuum capsule connector. Disconnect the vacuum hoses from the capsule. Dismount the lock pin and remove the bolt which is connecting the capsule axle with the GB control lever. Dismount the capsule attachment nuts on the support. REMOUNTING Perform the dismounting operations in reverse order.
38 ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING ELECTROVALVE DISMOUNTING Disconnect the connector from the electric valve. Disconnect the hoses from the electric valve. Dismount the electric valve attachment screw. REMOUNTING Perform the dismounting operations in the reverse order. NOTE: Observe the connection position ofthe hosesto the electric valve, bef ore disconnecting. 38 - 6 vnx.
REPAIR MANUAL DACIA COMMERCIAL RM 502-2 BODY ENGINE: C3L GERBOX: NG1; NG3 TAPV: U75B; U75F The reparation methods prescribed by the manufacturer in the present document are established subject to technical specifications in force at the document issuing date. These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA.
4 Body 40 GENERAL 48 Designation of parts (blow-up) ........................... 40-1 Openings clearances ...................................... 40-7 Repairing general conditions ............................. 40-8 Welding types and parameters ............................ 40-9 Collision diagnosis ....................................... 40-11 Body checking/straightening bench type CELETTE ................................................... 40-14 41 LOWER STRUCTURE Lower longitudinal girder ............
GENERAL DESIGNATION OFPARTS (BLOW-UP) LOWER STRUCTURE COMPOSING ELEMENTS DACIA 1304 1. Front cross member 2. Upper longitudinal girder assembly 3. Steering cross member 4. Lower longitudinal girder assembly 5. Longitudinal girder closing plate 6. Intermediary longitudinal girder 7. Rear unit assembly 8. Rear longitudinal girder 9. Rear cross member 40 - 1 vnx.
GENERAL 40 DESIGNATION OFPARTS (BLOW-UP) LOWER STRUCTURE COMPOSING ELEMENTS DACIA 1304 PICK-UP, DROP - SYDE 2 1 1. Pedals floor 2. Cabin closing panel 3. Central floor panel 40 - 2 vnx.
GENERAL 40 DESIGNATION OFPARTS (BLOW-UP) LOWER STRUCTURE COMPOSING ELEMENTS DACIA 1307 1. Front cross member 2. Upper longitudinal girder assembly 3. Steering cross member 4. Lower longitudinal girder assembly 5. Longitudinal girder closing plate 6. Intermediary longitudinal girder 7. Rear unit assembly 8. Rear longitudinal girder 9. Rear cross member 1 2 3 1. Front side plate. 2. Central floor 3. Rear floor 40 - 3 vnx.
GENERAL 40 DESIGNATION OFPARTS (BLOW-UP) UPPER STRUCTURE COMPOSING ELEMENTS DACIA 1304, 1307 11 10 12 13 9 8 14 7 15 3 2 1 16 4 5 1. Headlamp support 2. Front grill simple 3. Front wing lining 4. Front pillar lining 5. Front pillar 6. Buffer 7. Middle pillar 8. Front part belt 9. Side windscreen lining 6 10. Separating wall 11. Ceiling 12. Windscreen frame 13. Lower cross member 14. Climate control box 15. Iron plate 16. Upper radiator cross bar 40 - 4 vnx.
GENERAL 40 DESIGNATION OFPARTS (BLOW-UP) UPPER STRUCTURE COMPOSING ELEMENTS DACIA 1304 PICK - UP, 1307 7 4 5 2 3 1 5. Rear extensor 1. Side panel 6. Rear wheel passage 2. Side panel upper part 7. Rear plate 3. Front extensor 4. Rear lamp lining DACIA 1304 DROP - SIDE 3 1 2 1. Side panel 2. Side panel 3. Rear wheel passage 40 - 5 vnx.
GENERAL 40 DESIGNATION OFPARTS (BLOW-UP) BODY REMOVABLE ELEMENTS DACIA 1304 PICK - UP, 1307 4 6 5 3 2 1 1. Front wing 2. Front door 3. Rear door 4. Rear drop side 5. Aerating grill 6. Front bonnet DACIA 1304 DROP - SIDE 3 4 1 2 1. Front drop side 2. Left drop side 3. Rear drop side 4. Right drop side 40 - 6 vnx.
GENERAL OPENINGS CLEARANCES 40 - 7 vnx.
40 GENERAL REPAIRING GENERAL CONDITIONS The replacement ( reparation ) operations of the weldable elements described in this chapter are specified subject to: removing of the parts to be replaced, access to the welded elements, tools and checking devices accessibility, etc. In case the vehicle body has suffered important deformations it is recommended the straightening of the damaged body elements, by means of some hydraulic presses, the operation being performed slowly and at cold.
GENERAL 40 WELDING TYPES AND PARAMETERS At the reparation of the welded body elements, three welding categories may be used: protection gas welding (CO2), electric spot welding and filling materials welding (autogenous). At the autogenous welding, it is recommended that flame must be slightly inclined so that arch can be seen and the flame extremity to be maintained at aprox. 5 mm from the part to be welded. 1. Spot welding resistive parameters for steel plates with carbon content C < 0,15 %.
40 GENERAL WELDING TYPES AND PARAMETERS NOTE: In case of using Ar + CO2 mixture, the welding voltage will decrease with 2 V. Vertical welding position (obligatory from top to bottom) fig. 2 Plate thickness (mm) Electrode diameter (mm) Welding wire speed (m/min) Welding current (A) Welding speed (m/min) Welding voltage (V) Protection gas flow (l/min) Electron free lenght (mm ) 0,6 2,5 35 0,25 17 0,6 0,8 1,9 35 0,25 17 12 0,8 3,3 70 0,38 18 6 - 12 40 - 10 vnx.
GENERAL COLLISION DIAGNOSIS 40 During the vehicleexploitation,the body maysuffer different distortions, that lead manytimes to the wheels setting angles change, body elements breakage, vibrations or even mechanical parts wear. In these conditions, before performing the vehicle body reparation, some checking is necessary: Visual checking - consisting in the examination of the mechanics elements attachments and of the distortions that occur in the damaged areas.
GENERAL 40 COLLISION DIAGNOSIS CHECKING WITH THE BAR GAUGE CENTRAL PART CHECKING It is performed in the purpose to establish if one of the distortions is not affecting this part, from which the checking starts. F’ H The checking points are : Holes A – F – F’ –A’ and consequently H – H’ and B – B’. FRONT LONGITUDINAL GIRDERS CHECKING Checking points are: B – B’ for lower longitudinal girders and G – G’ for upper longitudinal girders.
GENERAL COLLISION DIAGNOSIS 40 REAR LONGITUDINAL GIRDERS CHECKING The checking points are C – C’ , H – H’, D – D’ and E – E’. Compare the A’ – H diagonals, continuos line with A – H’ diagonal broken line and the A’ – C diagonal continuos line with A – C’ diagonal broken line. These four holes being closest to the rear axle, must be first checked. Compare diagonals H’ – D and H’ – E continuos line with diagonals H – D’ and H – E’ straight line.
40 GENERAL BODY CHECKING/ STRAIGHTENING BENCH TYPE CELETTE For checking, straightening or repairing the DACIA vehicles bodies, the use of the CELLETTE bench is recommended. The checking / straightening bench type CELETTE ( service code CAR 500 ) is composed of: -CAR 501 ( 1 mobile bench with four wheels, four parts for vehicle anchoring, one traction arm of 10 t, type “ CAIMAN “).
GENERAL BODY CHECKING / STRAIGHTENING BENCH TYPE CELETTE 40 To straighten the vehicle body, CELETTE bench is provided with a traction arm of 10 tons, Caiman type, 250 mm stroke of the hydraulic cylinder, with rapid anchorage on any side of the mobile bench ( fig. 2 ) stands is. one.... two... and tree ! ( fig.2) 2. CROSS BAR MODULAR SET CAR 502 ) CELETTE bench has in its composition, five modular cross bars ( fig.
GENERAL 40 BODY CHECKING / STRAIGHTENING BENCH TYPE CELETTE 3. TRACTION ACCESSORIES SET( CAR 504 ) CELETTE bench is equipped with a traction accessories set CAR 504, which allow the operator to achieve different anchoring when a body strengthening is performed (fig. 5). ( fig. 5) 4. SET OF SPECIFIC SUPPORTS FOR DACIA 1304, 1307 ( CAR 506 ) The mounting of the specific supports for DACIA vehicles1304,1307 shall be performed according with the mounting diagram which is supplied with this KIT (fig.
GENERAL BODY CHECKING / STRENGTHENING BENCH TYPE CELETTE Dacia 1304 40 Dacia 1307 ( fig. 8 ) ( fig. 10 ) Dacia 1307 Dacia 1304 ( fig. 9 ) ( fig. 11 ) Each support is identified by a plate showing the CELETTE specific item number, the mounting direction and its orientation on the bench. (fig. 12,13) ( fig. 12 ) 40 - 17 vnx.
GENERAL 40 BODY CHECKING / STRAIGHTENING BENCH TYPE CELETTE attachment on the bench right side(orientation direction towards front) attachment on bench left side (orientation direction towards front) reference number (specific CELETTE) support identification in view of mounting on the bench. Caption: ( fig. 13 ) 1 - with dismounted mechanic elements 3 - with or without dismounted mechanic elements.
GENERAL BODY CHECKING / STRAIGHTENING BENCH TYPECELETTE 40 Front suspension upper arm supports fixing Supports (7) and (8) are used in front straightening. They enable the positioning and centering of the upper longitudinal girders- ( fig. 16 ). 7 8 ( fig. 16 ) Centering under front longitudinal girder Supports (27) and (28) are used for centering and alignment of the front longitudinal girders.
LOWER STRUCTURE LOWER LONGITUDINAL GIRDER 41 REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. DISMOUNTING Dismount the damaged elements that are in contact with lower longitudinal girder. Straighten the areas resulted from disassembling. Process the areas resulted from disassembling.
41 LOWER STRUCTURE ASSEMBLED FRONT LONGITUDINAL GIRDER REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. DISMOUNTING Dismount the damaged elements, which are in contact with the longitudinal girder.
LOWER STRUCTURE 41 ASSEMBLED FRONT LONGITUDINAL GIRDER REMOUNTING Position the new element.
41 LOWER STRUCTURE INTERMEDIARY LONGITUDINAL GIRDER REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. DISMOUNTING Dismountthe elements,which are in contact with the intermediary longitudinal girder.
LOWER STRUCTURE 41 REAR LONGITUDINAL GIRDER ( Dacia 1304 ) REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. DISMOUNTING Dismount the elements, which are in contact with the rear longitudinal girder.
41 LOWER STRUCTURE REAR LONGITUDINAL GIRDER ( Dacia 1307 ) REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter DISMOUNTING Dismount the elements whichare in contact with the rear longitudinal girder.
UPPER FRONT STRUCTURE FRONT WING 42 DISMOUNTING Dismount the elements which are in contact with the front wing ( front bumper, the turning lamp from the wing). Dismount from the front wing the following screws: - in (1) at the upper part; - in (2) at the connection of the wing with the front grill, at the lower part; - in (3) at the connection of the wing with the front pillar (it is not necessary dismounting of the front door); - in (4) at the lower part of the body.
42 UPPER FRONT STRUCTURE FRONT UNIT CARRIAGE BODY REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. DISMOUNTING Dismount the damaged elements, which are in contact with the front part body. Perform a checking redressing on the checking/repairing bench, until bringing the carriage body almost at the initial shape.
UPPER FRONT STRUCTURE FRONT WING LINING 42 REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. DISMOUNTING Dismount the damaged elements, which are in contact with the front wing lining.
42 UPPER FRONT STRUCTURE HEAD LAMP SUPPORT DISMOUNTING Dismount the elements, which are in contact with the headlamp support. Detach the welding points of the head lamp (1) support which are in connection with : - the radiator upper cross member in the area (3); - the reinforcement in the area (4); - the lower part of the front wing lining in the area (5); - the front wing lining in the lateral part in the (6) area. Straighten the areas resulted by dismounting. Grind the areas resulted by dismounting.
UPPER FRONT STRUCTURE 42 RADIATOR UPPER CROSS MEMBER DISMOUNTING Dismount the elements, which are in contact with the radiator upper cross-member. Detach the welding points of the radiator upper cross member (2) which are in connection with: - the head lamp support (7); - the reinforcement in the (8) area. Straighten the areas resulted by dismounting. Grind the areas resulted by dismounting. 7 8 REMOUNTING Position and center the new element.
42 UPPER FRONT STRUCTURE AERATION GRILL DISMOUNTING Dismount the two nozzles (1) of the windscreen washer. Dismount the attachment screws (2) of the aeration grill. Take out the clips (3) from the front grill grippers taking care to prevent their distortion or damaging. REMOUNTING The mounting shall be done by performing the dismounting operations in reverse order. 42 - 6 vnx.
UPPER SIDE STRUCTURE 43 FRONT PILLAR LINING DISMOUNTING Dismount the elements which are in contact with the front pillar lining. Detach the welding points of the front pillar lining (1) which are in connection with: - front pillar in the area (4) and (5); - floor closing plate in the area (8); - windscreen lower cross bar in the area (9); - front wing lining upper edge in the area (10); - climate control box end in the area (11); - iron plate in the area (12).
43 UPPER SIDE STRUCTURE FRONT PILLAR DISMOUNTING Dismount the elements which are in contact with the front pillar . Detach the welding points of the front pillar (2) which are in connection with : - lateral frame in the areas (3); - front pillar lining in area (4) and (5); - upper spacer and the lower windscreen lining in the areas (6), and (7). Straighten the areas resulted by dismounting. Grind the areas resulted by dismounting. REMOUNTING Position and center the new element .
UPPER SIDE STRUCTURE 43 FRONT LOWER PANEL DISMOUNTING Dismount the elements which are in contact with the front lower panel . Detach the welding points of the front lower panel (1) which are in connection with : - floor closing plate in the area (2); - front pillar in the (3) area; - in the length of the area (4) with floor closing plate; - side panel in the area (5); - central pillar in the area (6). Straighten the areas resulted by dismounting. Grind the areas resulted by dismounting.
43 UPPER SIDE STRUCTURE MIDDLE PILLAR DISMOUNTING Dismount the damaged elements which are in contact with the middle pillar. Detach the welding points of the middle pillar which are in connection with: Ceiling in the area (1). Front lower panel in the (2) area. Straighten the areas resulted by dismounting. Grind the areas resultedby dismounting. 1 REMOUNTING Fit temporarily the middle pillar (3), by introducing the pillar lining under the upper frame (7) and under the lower panel plate (6).
REAR UPPER STRUCTURE 44 SIDE PANEL DACIA 1304 PICK - UP, 1307 DISMOUNTING Dismount the elements which are in contact with the side panel. Detach the welding points of the side panel (1) which are in connection with: - middle pillar in the area (2); - floor side plate and front extensor lower edge in the (3) area; - the rear side plate andrear extensor lower edge in the area (4); - the platform floor in the area (5); - the cabin side plate in the area (6). Straighten the areas resulted by dismounting.
44 REAR UPPER STRUCTURE SIDE PANEL DACIA 1304 DROP - SIDE DISMOUNTING Dismount the elements whichare in contact with the side panel. Detach the welding points of the side panel (1) which are in connection with : - middle pillar in the area (2); - separating wall in the (4) area; - floor side plate in the area (5). Detach the 5 welding strippers between the side panel and outer frame in the (6) area. Straighten the areas resulted by dismounting. Grind the areas resulted by dismounting.
REAR UPPER STRUCTURE 44 REAR WHEEL PASSAGE DISMOUNTING 1 Dismount the elements which are in contact with the rear wheel passage. Detach the welding points of the rear wheel passage (1) which are in connection with : - platform floor in the area (2); - front extensor in the (3) area; - rear extensor in the area (4). Straighten the areas resulted by dismounting. Grind the areas resultedby dismounting. Rear extensor Front extensor Rear wheel passage REMOUNTING 4 Position and center the new element.
44 REAR UPPER STRUCTURE REAR PLATE DISMOUNTING Dismount the elements whichare in contact with the rear plate. Detach the welding points of the rear plate (1) which are in connection with: - platform floor rear edge in area (2); - corner plate edge in the area (3). Straighten the areas resulted from dismounting. Grind the areas resultedfrom dismounting. 1 REMOUNTNG Position and center the new element. Check the correct positioning of the rear plate.
TOP OF BODY 45 ROOF DISMOUNTING 1 Dismount the elements which are in contact with the roof ( doors, front wings, windscreen, cabin glass, roof sealing of the ceiling and windows gaskets). Detach the welding points of roof (1) which are in connection with : - windscreen lower cross-bar in (2) area; - front pillar in (3) area; - front safety belt (front side ) in the (4) area; - windscreen pillar lining in the (5) area; - front safety belt (rear side ) in the (6) area.
LATERAL OPENING 47 FRONT DOOR DISMOUNTING Front door dismounting may be performed in two different ways: a) by removing the clips (1) and pushing out the hinge pins. b) by removing the attachment screws (2) on the front pillar. 2 1 2 2 1 C REMOUNTING Perform the dismounting operations in the reverse order. ADJUSTMENT a) Horizontally, adjustment bush C are to be used. b) Vertically, the front pillar holes are to be used. 47 - 1 vnx.
47 SIDE OPENING ELEMENTS FRONT DOOR OUTSIDE PANEL DISMOUNTING Dismount the front door and the elements which are in contact with this. Cut the outside panel of the door following the outliner (1). Unscrew the screws (2) from the joint of outside panel-glass frame. Adjust, if necessary, the extensor (3). M M 2 3 1 5 4 REMOUNTING Apply a strip of zinc on the caisson. Apply a sealant material layer in the area (4). Position the new outside plate and weld in the (2) area.
NON SIDE OPENING ELEMENTS FRONT BONNET DISMOUNTING Dismount : - the attachment screws (1) of the hinges; - the front bonnet. 1 REMOUNTING Perform the dismounting operations in the reverse order. 48 - 1 vnx.
48 NON SIDE OPENING ELEMENTS DROPSIDE DACIA 1304 PLATFORM DISMOUNTING Dismount : - the attachment screws (1) of the hinges (2); - the rear drop side (the drop side). REMOUNTING Perform the dismounting operations in the reverse order. 2 48 - 2 vnx.
NON SIDE OPENING ELEMENTS DROP SIDE DACIA 1304 Pick - Up, 1307 DISMOUNTING Dismount : - the screws (1) from the end of the limiting mechanism (6). Then, the rear drop side dismounting may be performed in two different ways: a) extract the safety ring (2) and the hinge shaft (3). b) unscrew the screws (4) of the hinges (5). Dismount the rear drop side. 48 1 4 2 5 REMOUNTING Perform the dismounting operations in the reverse order. 6 3 48 - 3 vnx.
SIDE OPENING ELEMENTS MECHANISMS DOOR LOCK FRONT / REAR 51 DISMOUNTING Dismount the arm rest, the window regulator , the locking knob and the front/rear door panel. Detach the door panel from the door frame. Dismount the lock control of the front/rear door (1). Dismount the attachment screws (3) of the front/rear door lock. Release the control lever (2)of the outside opening flap. Release the distance control lever (4) by taking out the clips bracket (5).
51 SIDE OPENING ELEMENTS MECHANISMS FRONT/REAR DOOR OPENING MECHANISM DISMOUNTING Before dismounting the door lock control , remove thedoor panel and leave the window in the lift position. Dismount: - opening knob (1); - ornament (3) attachment screws (2); - the attachment screw (4) of opening mechanism (5); - control lever (6)off the hinge, releasing the opening mechanism. 1 2 3 4 5 6 REMOUNTING Perform the dismounting operations in reverse order. 51 - 2 vnx.
SIDE OPENING ELEMENTS MECHANISMS FRONT DOOR WINDOW REGULATOR 51 DISMOUNTING To dismount the door window regulator assembly, perform the following operations: Bring the window in the position P = 85 mm. Unscrew the attachmentnuts (10), press the shaft (11) for releasing the window regulator towards the inner side. Easy bend the “ window regulatorwindow “ assembly, take out the supports (12), the slides from the window base (13) and the glass slide (14).
51 SIDE OPENING ELEMENTS MECHANISMS FRONT DOOR WINDOW REGULATOR Put in its place the window regulator , introducing the shaft (11) in the frame than the attachment washer (17) and attachment nuts (10). Place the supports (12) at the glass bottom and perform a first sliding test. Grease the window regulator hinges and supports and perform the others operations in reverse order. PREPARING THE GLASS BASE When fitting the bottom edge and at the glass positioning in the slide-bars, observe the value of 92 mm.
SIDE OPENING ELEMENTS MECHANISMS REAR DOOR WINDOW REGULATOR 51 DISMOUNTING In order to dismounta door windowand the window regulator of the back door window, perform the following operations: Remove the screws (11) and (12). Using the technologicalopening (14) in the inner side of the door , remove the elastic washer and the safety washer (20), which make the connection with the window slide-bar, by slightly sliding it to the lower part.
NON SIDE OPENING ELEMENTS MECHANISMS FRONT HOOD LOCK 52 DISMOUNTING Release the cable of front hood (1) from the connection with lock (3) and take out by lock hook rod (4). Dismount the attachment front hood lock nuts (2). 2 3 1 4 REMOUNTING Perform in the reverse order the dismounting operations. 52 - 1 vnx.
52 NON SIDE OPENING ELEMENTS MECHANISMS REARDROP SIDE LOCKINGSYSTEM REAR DROP SIDE LOCKING SYSTEM DACIA 1304 Pk, 1307 DISMOUNTING To dismount the rear drop side lock (1) unscrew the screws (2) of the closing hook (3) and the screws (4) of the assembled lock (5). 4 1 3 2 REMOUNTING Perform in the reverse order the dismounting operations. 52 - 2 vnx.
NON SIDE OPENING ELEMENTS MECHANISMS REARDROP SIDE LOCKINGSYSTEM 52 REAR DROPSIDE LOCKING SYSTEM DACIA 1304 platform DISMOUNTING Dismount : - the screws (1) and (2) of the end of the stopper chain (3); - the lock attachment screws (4) of the side panel the lock attachment screws (5) of the rear drop side panel. 2 3 1 REMOUNTING Perform the dismounting operations in the reverse order. 4 5 52 - 3 vnx.
WINDOWS WINDOWS 54 WINDSCREEN AND CAB REAR WINDOW The replacement of these windows is performed in case they are broken, when they are not according to the required overall dimensions or have manufacturing defects (image distortions,cracks, etc). DISMOUNTING OF A BROKEN WINDOW If the window or part of it did not fall, the window gasket shall be dismounted and the pieces of broken window shall be removed from it easier by sticking a sheet of paper on each surface.
EXTERNAL PROTECTIONS FRONT BUMPER DISMOUNTING Dismount : - the attachment screw (1) and (3) of the front bumper (2) on the front wings; - the nuts (4) which attach the bumper supports (5) on the front grill; - release the front bumper. 2 REMOUNTING Perform the dismountingoperationsin the reverse order. 55 - 1 vnx.
EXTERNAL PROTECTIONS 55 REAR BUMPER REAR BUMPER ( for vehicles Dacia 1304 Pk., 1307 ) DISMOUNTING Dismount : - the protectors (1) and the side attachment screws (2) of the rear bumper (3); - the attachment screws (4) of the rear bumper on side panels ; - the attachment screws (5) of the rear bumper supports (6) on the rear girders; - release the rear bumper. 3 2 6 5 4 1 REMOUNTING Perform the dismounting operations in the reverse order. 55 - 2 vnx.
EXTERNAL PROTECTIONS REAR BUMPER 55 REAR BUMPER ( for Dacia 1304 platform drop side ) DISMOUNTING Dismount : - the attachment screws (3) of the rear bumper (2) on the end rear cross bar; - the attachment screws (4) of the rear bumper supports on the rear girders; - release the rear bumper. 2 3 1 REMOUNTING Perform the dismounting operations in the reverse order. 55 - 3 vnx.
EXTERNAL ACCESSORIES OUTSIDE REAR VIEW MIRROR DISMOUNTING Detach the protector of the outside rear view mirror (3). Dismount the attachment screws (2) of outside rear view mirror (1). Release the outside rear view mirror. 1 2 3 REMOUNTING Perform the dismounting operations in the reverse order. 56 - 1 vnx.
REPAIR MANUAL DACIA COMMERCIAL RM 502-3 SEALING, ELECTRICITY ENGINE: C3L GEARBOX: NG1; NG7 TAPV: U75B; U75F The reparation methods prescribed by the manufacturer in the present document are established subject to technical specifications in force at the document issuing date. These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA.
5 Mechanisms and accessories 72 SIDE OPENING ELEMENTS TRIM Front door panel ........................................... 72-1 Dacia 1307 rear door panel .......................... 72-2 57 LOWER INTERNAL ACCESSORIES Dashboard .......................................................... Documents compartment ..................................... The hand brake casin and gearbox lever ornament .............................................................. Inside rear view mirror ...............................
Temperature transmitter checking ................ 83-16 Fuel level transmitter .................................... 83-17 84 CONTROLS - SIGNALLING Starting-ignition switch ................................. 84-1 Under wheel control module ........................ 84-3 Switches dashboard ...................................... 84-5 85 WINDSCREEN WIPERS Windscreen wiper mechanism ...................... Windscreen wiper drive motor ..................... Windscreen washer assembly .......................
LOWER INTERNAL ACCESSORIES 57 DASHBOARD 11 7 10 15 16 1 2 3 12 14 13 4 5 6 8 9 DISMOUNTING Dismount the battery Dismount: - the windscreen, - the steering wheel and the lower/upper casing. Dismount the attachment nut (12) of the coupling bar for dashboard sustaining. Dismount the dashboard attachment screws (8) on the side support (9). Dismount the dashboard attachment screws (11) on the windshield lower frame cross member.
57 LOWER INTERNAL ACCESSORIES DASHBOARD - fog headlamps switch, - windscreen wiper timer, - radio-cassettes player. Disconnect the following wires: - lighter lighting, - climate control lighting, - ashtray lighting, - documents compartment lighting. Dismount the followings: diagnostic socket and the three hoses from the climate control unit, observing the corresponding positions. Extract the dashboard from cockpit.
LOWER INTERNAL ACCESSORIES 57 DASHBOARD DASHBOARD TYPE DACIA 1325 DISMOUNTING 11 10 9 1 2 3 4 5 6 7 In order the dismount the dashboard, perform the following operation : Dismount: - the steering wheel and the upper-lower steering wheel half cases; - the ash try (5); - wiper timer by dismounting the control knob (2), disconnecting the wiper timer wires and the attachment nuts on dashboard; - valve control cable on the control lever; - upper flaps control cable from the climate maintenance block to
57 LOWER INTERNAL ACCESSORIES DASHBOARD DASHBOARD TYPE DACIA 1325 DISMOUNTING 3 11 10 9 2 4 5 12 1 8 13 In order the dismount the dashboard, perform the following operation : Dismount : - the steering wheel and the upper-lower steering wheel half cases; - the ash try (5); - wiper timer by dismounting the control knob (2), disconnecting the wiper timer wires and the attachment nuts on dashboard; - valve control cable on the control lever; - upper flaps control cable from the climate maintenance bloc
LOWER INTERNAL ACCESSORIES DOCUMENTS COMPARTMENT 2 1 DISMOUNTING Disconnect the battery. Dismount the diagnostic socket. Dismount the documents compartment attachment screws (2) on the dashboard. Disconnect the documents compartment lighting wires. Extract the documents compartment from the dashboard. REMOUNTING Perform the dismounting operations in the reverse order. 57 - 5 vnx.
57 LOWER INTERNAL ACCESSORIES THE HANDBRAKE CASIN AND GEARBOX LEVER ORNAMENT DISMOUNTING Dismounting the screws (1) and release the gearbox lever ornament (2). Dismounting the screws (3) and release the handbrake casing (4). 4 3 1 2 REMOUNTING Perform the dismounting operations in reverse order. 57 - 6 vnx.
LOWER INTERNAL ACCESSORIES INSIDE REAR VIEW MIRROR 57 DISMOUNTING Dismount the protector support (1). Dismount the rubber buffer (2). Detach from clips the sun visors rod from the inside rear view mirror support. Release the inside rear view mirror (3) by dismounting the attachmentscrews (4). 1 2 4 1 3 REMOUNTING Perform the dismounting operations in reverse order. 57 - 7 vnx.
57 LOWER INTERNAL ACCESSORIES SUN VISORS DISMOUNTING Take out inside rear view support protector. Detach the sun visors (2) rod from the inside rear view mirror support. Release the sun visors (2) by dismount the attachment screws (1). 1 2 REMOUNTING Perform the dismounting operations in reverse order. 57 - 8 vnx.
LOWER INTERNAL ACCESSORIES TURN HANDLES DISMOUNTING Dismount the turn handles (1) attachment screws (2) from the stretcher. Dismount the turn handles. 2 REMOUNTING Perform the dismounting operations in reverse order. 57 - 9 vnx.
57 LOWER INTERNAL ACCESSORIES DOORS THRESHOLDS DISMOUNTING Dismount the screws (1) from the cable supports (3). Release the front doors (2) respectively rear doors thresholds. 1 REMOUNTING Perform the dismounting operations in the reverse order. 57 - 10 vnx.
SAFETY ELEMENTS 59 FRONT SAFETY BELTS DISMOUNTING 1 2 3 Dismount : - the protector and attachments front safety belts screws on the upper middle pillar (pos. 1); - the attachments front safety belts screws on the lower middle pillar (pos.2); - the attachment screw of lock front safety belts on the front plate protection (pos.3) of fixing front belt on middle pillar – lower part; - front safety belt. REMOUNTING Perform the dismounting operations in reverse order. 59 - 1 vnx.
59 SAFETY ELEMENTS REAR SAFETY BELTS DISMOUNTING 2 1 3 Dismount : - the protector and the attachment rear safety belt screw on the upper part of lateral panel (pos.1); - the attachment rear safety belt screw on the inner lateral frame (pos. 2); - the attachment screws of the rear belt lock on central floor (pos.3); - rear safety belt. REMOUNTING Perform the dismounting operations in reverse order. 59 - 2 vnx.
HEATING 61 CLIMATE CONTROL BLOCK DISMOUNTING Disconnect the battery. Dismount the ash try from the dash board. Dismount the attachment screws (4) of the block on the dash board and detach the block from its place. Disconnect: - the control cables (5) of the flaps; - the control cable (6) of the climate control valve.
HEATING 61 CLIMATE CONTROL BLOCK ( for the commercials with dashboard type 1325 ) DISMOUNTING Disconnect the battery. Dismount the switch knob (1), the climate control switch and the luminous plate (2). Disconnect the connections of the luminous plate and the vacuum hoses. Dismount the attachment screws (3) of the climate control. Take out the climate control block from its housing. Disconnect the climate control valve cable (4) and the climate control cable.
HEATING 61 CLIMATE CONTROL UNIT DISMOUNTING In case AC system can not be used, the classis climate control system may be used according to necessities. Dismount the dashboard. Disconnect the wires from the dashboard wiring. Dismount the control cables of the distribution flaps and mixing flaps from the control levers and the recycling flaps cable from the climate control panel. Dismount the ducts of the heating valve and the aeration connection.
61 HEATING CLIMATE CONTROL VALVE DISMOUNTING Clamp the heating hoses (1) , (2) by means of the clamp (3) – MOT 453 and dismount the hoses from the valve. Dismount the control cable (4) of the valve (5)and bring the valve in the OFF position. Dismount the climate control valve. NOTE: The valve cannot be repaired.
HEATING CLIMATE CONTROL G.M.V. 61 A.COMMERCIALS EQUIPPED WITH DASH BOARD TYPE SERIES Climate control GMV is located under the dashboard, in the right side and can bewith one or two rotation steps. DISMOUNTING Disconnect the battery. Disconnect the GMV connectors from the right connection plate (+DC). Dismount the attachment screws of the GMV on the iron plate. REMOUNTING Perform the dismounting operations in the reverse order. B.
HEATING 61 DIAGNOSTIC CLIMATECONTROL BLOWER NOT WORKING Yes Check the F02 fuse from the cockpit fuse box. Is it blown ? No Replacethe fuse. Check if the blower is supplied. No Yes Supply wire disconnectedor broken. Fix it. Is the blower mass connected? No Yes Is the blower switch mass connected? Yes No Replacethe blower Replacethe blower switch Mass wire disconnectedor broken. Fix it. 61 - 6 vnx.
AIR CONDITIONING GENERALITIES 62 The purpose of the air conditioning unit is to produce a decrease of the temperature in the passengers compartment and to maintain this temperature at an inferior value compared to the environment one, reducing in the sametime the air moisture. Basically, theAC unit is operatingin a closedcircuit and it is composed of the followingmain elements: - evaporator - compressor - condenser - thermostaticexpansion valve - connectionpipes. 62 - 1 vnx.
62 AIR CONDITIONING GENERALITIES DRAINING – FILLING REFRIGERANT CIRCUIT DRAINING Connect the chargingequipment piping to the filling-draining valves. Perform the vacuuming of the air condition system,recoveringthe oil and the refrigerantfluid. Close the hoses valves. Disconnectthe charging equipment piping and stopthe equipment. TIGHTENING MOMENTS FILLING Attachthe draining – fillinghosesof the equipment to the air conditioning valves. Put compressoroil type SP 10 in the charging equipment vessel.
AIR CONDITIONING A.C. CIRCUITOPERATING DIAGRAM Warning grup 62 - 3 vnx.
62 AIR CONDITIONING MAINTENANCE For important leakageremoval, for any components replacement(compressor, condenser,etc ) and if moisture wasnoticed in the air conditioning circuit, the dryer filtertank is to be replacedand the unit draining is to be done. The sameis valid also when the conditioning circuit stillopen withoutprotectioncoversmore than 10 minutes. For component replacementimplyingthe circuit draining, it is absolutelynecessary the use of new parts and of a specialoil for compressor.
AIR CONDITIONING DETECTION OF REFRIGERANT FLUID LEAKAGE 62 In order to detectthe refrigerant liquid leakage,the detector INFICON type HDL 300 (or similar) may be used, calibrated to detect leakageof aprox. 9gr./an. Start the engine and switchon the air conditioningunit.
62 AIR CONDITIONING CONDENSER Condenser has the purpose to achievethe second heat exchange, where the refrigerant fluid by condensation, is transmitting outside the abstracted heat. When coming out from the condenser,the refrigerant fluidis liquid, at high pressure. The condenser is made of aluminum, Harrison type, with parallelflows. It is mounted in front of the vehicle’sradiatorin thefront partof the vehicle and is ensuringthe abstraction of heat of the refrigerant fluid.
AIR CONDITIONING DRYER FILTER TANK 62 The dryer filter tank is mounted by means of a support, on the front wing lining and it has a triple purpose in the airconditioning system: - filteringthe refrigerant fluid from the system; - absorbing the moisture from the system; - it is a buffer storage tankof refrigerant fluid. FILTER TANK REPLACEMENT DISMOUNTING Disconnect the battery. Drain the refrigerant circuit. Dismountthe refrigerant fluid pipes (1) and (2).
62 AIR CONDITIONING COMPRESSOR 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 to the condenser. The compressoris type HarrisonV5, alternating, with pistons and variablecylinders capacity. Compressor oil used PAG SP 10 Quantityof compressor oil used 265 cmc The compressoris mounted on the left sideof the engineblock by meansof two supports.
AIR CONDITIONING COMPRESSOR 62 REMOUNTING Position the compressoron the attachment supports. Tightenthe compressoron the supports, by meansof 3 screws,which are to be initialscrewed in the followingorder : front upper left, rearlower right, front lower left. Positionand tighten the tie rod on the compressor upper support and on the cylinders housing.
62 AIR CONDITIONING COMPRESSOR COMPRESSOR SUPPORTS DISMOUNTING Dismountthe compressor (see “ Compressor replacement“). Dismountthe upper support. Dismountthe lower support. REMOUNTING Positionthe lower support (1) of the compressoron the cylinder housing and initialtighten its attachmentscrews. Positionthe upper support (2) of the compressoron the cylinder headand initialtightening its attachment screws.
AIR CONDITIONING EVAPORATOR 62 Evaporator has the purpose to transfer to the refrigerantliquid the air heat, which is passing through it. The cooled air, is so conveyed in the passengers compartment, progressivelyreducing the temperature. The refrigerant fluidwhich goes into the evaporator,absorbs the passengers compartment heat, cycled transmitted by the GMV-AC at constant temperature and is transformingit from liquid intovapors. At the inlet refrigerant is liquid at the outlet in G.M.V.
62 AIR CONDITIONING EVAPORATOR REMOUNTING Perform the dismountingoperationsin the reverse order. Fillthe refrigerant circuit and check the good operation of the climatecontrol system. NOTE : Ensure that evaporator finned plates are not deformed and they are not excessive dirty. ATTENTION ! For mounting or remounting the piping connections from refrigerant circuit, use two wrenches to balance the tightening moment in order to avoid the piping spinning. 62 - 12 vnx.
AIR CONDITIONING SYSTEM PIPING 62 The air conditioning systempipingensure the refrigerantfluid circulation betweenthe system components. When pipes are replaced, check the existence of the protective covers. Lubricate the connectionsand gasketswith compressoroil and fill up with compressoroil. The systemfillingand draining valves are placed on the compressorpipingand have different diameters, so that they can not be reversed.
62 AIR CONDITIONING THERMOSTATIC EXPANSIONVALVE Thermostatic expansion valve – allows the reduction of the refrigerant liquid which is coming from the condenser,passingthrough the tank filter and is continuously adjusting the refrigerant flow from the evaporator,to reach the compressor in gaseous shape.
AIR CONDITIONING PRESSURE CONTROLLER 62 PRESSURE CONTROLLER The pressure controller is mounted on the dryer filter tank. The pressure controlleris an electric/mechanicaldevice,which has the purposeto protectthe air conditioning unit and it has the following functions: - cuts off the compressoroperation, when the pressure in the high pressure circuit is lowering more than 2,5 bars. - cuts off the compressoroperation, when the pressure in the high pressure circuit is more than 27 bars.
AIR CONDITIONING 62 DIAGNOSTIC Defective cooling. Yes No Is GMV working? Yes Adequate air flow and relay? Yes Check the GMV fuse. Are they defective? Replace them. No No Check the air flow flaps GMV engine.Operation and the air ducts integrity. Change GMV Supply the GMV at (+12V). Does it works? No Yes Replace the air switch or repair the electric circuit. Compressor belt tensioning is good conditioning? No Yes Restore the belt tension.
AIR CONDITIONING 62 DIAGNOSTIC Correct A.C. system filling. Compressor does not work. Yes Check the clutch coil ? Broken, short-circuit ? Yes Re pla ce the compressor. No Is +12V at pole 2 of 584 relay ? Is +12V at pole 8 of 584 relay? Yes No Restore the electric circuit between E and clutch. Yes The wiring between injection computer and the pole 6 of 584 relay is broken ? Yes Check fuse F01 from engine compartment. Restore the wiring between F01 and relay 584.
SEALING OPENING ELEMENTS 65 FRAME SEALING GASKETS DISMOUNTING 1 - gasket under front grill 2 - front bonnet gasket 3,4 - wing chute gaskets 5,6 - rear/front doors frames gaskets Manually dismount by pulling one end toward applying area external. 6 1 2 5 4 3 REMOUNTING To be mounted by hammer tapping. Cut the extra ends. Tighten the clipping areas 65 - 1 vnx.
65 SEALING OPENING ELEMENTS DOOR SEALING GASKETS DISMOUNTING Dismountthe gasketsfrom the door profile,by pullingthem towards exterior, followingthe door outline. REMOUNTING Perform the dismountingoperationsin the reverse order. Mounting of the sealinggaskets on the door framesis performed by plastichammer tapping. 65 - 2 vnx.
SEALING WINDOWS AND SCREENS GLASSES SEALING GASKETS 66 2 3 1 1 - Side glass rubber gasket ( D 1304 King - cab ) 2 - Separating wall glass rubber gasket 3 - Windshield rubber gasket DISMOUNTING Remove the glass together with the rubber gasket, by pushing it from the interior of the vehicle. Clean the rubber gasket if it will be reused or replace it with a new one.
66 SEALING WINDOWS AND SCREENS INNERWIPERS DISMOUNTING Dismount the arm rest at the upper part. Dismount the window regulator handle and the inner opening mechanism. Dismount the panel by removing it from clips and take out the inner wiper. REMOUNTING Perform the dismountingoperationsin the reverse order. 66 - 2 vnx.
SEALING WINDOWS AND SCREENS OUTSIDE WIPERS 66 DISMOUNTING Lower the window to the minimum position The dismounting of the outside wiper is performed by removing it from the fixing clips. REMOUNTING Perform the dismounting operations in the reverse order. 66 - 3 vnx.
INTERNAL BODY TRIM 71 FLOOR CARPETS 1 2 3 1. molded carpet 2. under bench carpet ( Dacia Double Cab) 3. platform carpet ( bed mat) MOLDED CARPET DISMOUNTING Dismount: - the front seats - the front safety belts locks - the gearbox lever ornament - the front/rear doors thresholds. Dismount by hand the molded carpet. REMOUNTING Perform the dismounting operations in the reverse order.
INTERNAL BODY TRIM 71 WINDSCREEN COVERING 8 9 7 6 1. front pillar covering 2. windscreen covering 3. middle pillar lining 4. side lining lower covering 5. upper side panel lining 6. side panel covering 7. cabin wall lining 8. plate screw 9. flat washer 1 2 3 4 5 REPLACEMENT OF THE WINDSCREEN COVERING DISMOUNTING Dismount : - the windscreen - partially the front doors weather-strip. Unstuck the windscreen covering REMOUNTING Perform the dismounting operations in the reverse order.
INTERNAL BODY TRIM MIDDLE PILLAR LINING 71 REPLACEMENT OF THE MIDDLE PILLAR LINING DISMOUNTING Move ahead the front seat, in order to enable the access at the middle pillar. Dismount : - the front thresholds - partially the front/rear doors weather-strips - the front safety belts at their upper/lower part attachment on the middle pillar. Unstuck in the reverse order of the dismounting operations. REMOUNTING Perform the dismounting operations in the reverse order. 71 - 3 vnx.
INTERNAL BODY TRIM 71 UPPER SIDE PANEL LINING REPLACEMENT OF THE UPPER SIDE PANEL LINING DISMOUNTING Swing over the rear bench back Dismount : - the rear safety belts at the upper part. - partially the rear doors weather-strip. Unstuck the upper side panel lining. REMOUNTING Perform the dismounting operations in the reverse order. 71 - 4 vnx.
INTERNAL BODY TRIM CABIN WALL LINING REPLACEMENT OF THE CABIN WALL LINING DISMOUNTING Swing over the rear bench back Dismount : - the rear glass grill - the rear cabin glass - the screws and washers attaching the cabin wall lining. REMOUNTING Perform the dismounting operations in the reverse order. 71 - 5 vnx.
INTERNAL BODY TRIM 71 CEILING COVERING REPLACEMENT OF THE CEILING COVERING DISMOUNTING Dismount : - the front and rear doors weather-strips; - the front windshield and the cabin separating glass; - the side lamps, sun visors and turn handles ; - the ceiling covering from the front doors upper frames, rear doors upper frames ( Dacia Double Cab, windshield fixing frame and the cabin rear glass in the contact areas with the ceiling covering.
INTERNAL BODY TRIM 71 FLOOR NOISE ABSORBENT MATS DISMOUNTING Dismount by hand the floor mat (1 ) the under bench mat (2) and the molded mat (3). Remove (unstuck): front cross member noise absorbents (4),(8),the cowl panel noise absorbent (5), the front wheel noise absorbents (6) ,(7) and the gearbox casing noise absorbent (9). 1 2 3 4 5 6 7 REMOUNTING Perform the dismounting operations in the reverse order, the stacking of the elements no. 3,4,5,6,7,8,9 being done with adhesive. 71 - 7 vnx.
SIDE OPENING ELEMENTS TRIM 72 FRONT DOOR PANEL DISMOUNTING Dismount: - the arm rest connection (3); - the arm rest (2) from the screws (1); - the window regulator handle; - the distance control cover (8) by dismounting the attachment screw; - the inner wiper (5) from the clips (6); - the store box (9). Detach the front door panel from its clips. Pull toward exterior to enable the panel releasing from the attachment done by clips (7).
72 SIDE OPENING ELEMENTS TRIM DACIA 1307 REAR DOOR PANEL DISMOUNTING Dismount: - the arm rest (2) from the screws (1); - the windowregulator handle; - the distance control cover (5) by dismounting the attachment screw; - the inner wiper (4) from the clips (6); - the store box (9). Detach the rear door panel from its clips. Pull toward exterior to enable the panel releasingfrom the attachmentdone by clips(7). 7 6 4 3 2 1 REMOUNTING Perform the dismountingoperationsin the reverse order.
FRONT SEATS FRAMES AND RUNNERS FRONT SEATS 75 ADJUSTMENTS The front seats equipping the Dacia vehicles offer the following adjustment possibilities: - longitudinal displacement back and forth which may be performed by using the control lever (L). - the back rest rocking until the horizontal position is obtained by using the button (M).
75 FRONT SEATS FRAMES AND RUNNERS FRONT SEATS FRAMES REPLACEMENT DISMOUNTING Dismount the seat off the vehicle. Dismount the slide guides from the front seat. Remove the upholstery and the clothing from the armature. REMOUNTING Perform the dismounting operations in the reverse order. 75 - 2 vnx.
FRONT SEATS FRAMES AND RUNNERS 75 FRONT SEATS SLIDE GUIDES DISMOUNTING Dismount: - the front seat attachment screws (5) and cross- pieces (3) and (6)on the central floor; - the slide guides (1) and (2) attachment screw (4) on the seat armature; - release the slide guides (1) and (2). REMOUNTING Perform the dismounting operations in the reverse order. 75 - 3 vnx.
REAR SEAT FRAMES AND RUNNERS BACK REST ARMATURE 76 DISMOUNTING Dismount the closing plate (1) by removing it from the clips of the rear bench back rest. Dismount the upholstery and clothing from the rear bench back rest (2). REMOUNTING Perform the dismounting operations in the reverse order 2 1 3 4 76 - 1 vnx.
76 REAR SEAT FRAMES AND RUNNERS REAR BENCH SEATARMATURE 2 1 3 4 DISMOUNTING The rear bench seat (4) is dismounted by rocking it in the supports (3). Remove the upholstery from the seat clothing. REMOUNTING Perform the dismounting operations in the reverse order . 76 - 2 vnx.
FRONT SEAT TRIM 77 SEATSUPHOLSTERY DISMOUNTING Take out the rods (3) from the seat upholstery (7) attachment clips (4) on the clothing (14). Take out the rods (6) from the attachment clips (5) with the front seat armature. 1 5 67 8 9 10 11 12 13 4 2 14 3 REMOUNTING Perform the dismountingoperationsin the reverse order. 77 - 1 vnx.
FRONT SEAT TRIM 77 BACKREST UPHOLSTERY 1 5 6 7 8 9 10 11 12 13 4 2 14 3 DISMOUNTING Dismount the back rest control button (2) releasing the screw, the washer, the plate and the counter plate. Remove the sleeves for the headrest from the pipes (1) welded on the front seat armature. Take out the rods (9) from the clips (8).
REAR SEAT TRIM 78 SEATSUPHOLSTERY DISMOUNTING Take out the rods (1) from the attachment clips (2) of the seat upholstery (4) with the seat clothing. Dismount the rods (3) from the chains (5) , consequently the attachment clips from the bench seat armature rod. Remove the upholstery from the seat clothing. 1 2 5 4 3 REMOUNTING Perform the dismounting operations in the reverse order. 78 - 1 vnx.
78 REAR SEAT TRIM BENCH BACK RESTUPHOLSTERY DISMOUNTING Dismount the back rest plate from its plastic clips. Take out from clips the rods (2) at the lower part and the side ends rods (1) from the clips (4) Release the clipping rods (5) from the attachment with the back rest clothing, by means of the chains (3). Remove the back rest upholstery from the bench back rest clothing. 5 4 1 3 2 REMOUNTING Perform the dismounting operations in the reverse order. 78 - 2 vnx.
BATTERY - FRONT HEADLIGHTS BATTERY 80 ELECTRIC EQUIPMENT PROTECTION When performing a reparation at the vehicle, a set of actions must be taken to protect the electric equipments of damages or to avoid a short-circuit which may lead to vehicle burning.The battery is always disconnected by first disconnecting the negative terminal and then the positive one.The connecting is done in reverse order.
BATTERY - FRONT HEADLIGHTS 80 BATTERY BATTERY CHARACTERISTICS The DACIA vehicles are equipped with the following types of batteries:12V/45 Ah , 55 Ah, and 60 Ah. The battery is attached to its support by means of a clip, supported by two bars. The battery is connected to the vehicle electric system with the negative terminal to the mass. The battery terminals and cables clips shall be clean and well tightened, after which they shall be greased with neutral grease.
BATTERY - FRONT HEADLIGHTS BATTERY ELECTROLYTE 3 DENSITY [ g/cm ] 80 QUANTITY OF SULFURIC ACID 1,23 1,25 1,27 1,29 [ cm 3 ] 290 328 368 412 To prepare electrolyte of a certain density, for each liter of distilled water, add a quantity of sulfuric acid as per a.m. table. BATTERY CHARGING The batteries are charged in special rooms, well ventilated, where the working temperature shall be of 20 – 25° C.
BATTERY - FRONT HEADLIGHTS 80 BATTERY The charging currents of the batteries are showed in the following table: TYPE OF BATTERY 12 V - 45 Ah 12 V - 55 Ah 12 V - 66 Ah 12 V - 70 Ah NOMINAL VOLTAGE [V] 12 12 12 12 CHARGING CURRENT I I[A ] I II [ A ] 4,5 5,5 6,6 7,0 2,25 2,75 3,3 3,5 If after battery charging the density is higher, add distilled water, and if it is lower add electrolyte with 1,40 g / cm≈ density, observing that the electrolyte level to be 10 – 15 mm over the separators.
BATTERY - FRONT HEADLIGHTS HEADLIGHT BULBS REPLACEMENT 80 DISMOUNTING Disconnect the battery. Take out the headlight corrector attachment clip (B). Unscrew the headlight corrector control screw (C). Disconnect the headlight and signaling lamp connectors. Push the headlight forward. REMOUNTING Place by pressing the adjustment screws in the headlight seats (by pushing towards the engine compartment of the headlight). Mount the headlight corrector control screw (C).
80 BATTERY - FRONT HEADLIGHTS LAMPS HEADLIGHT BULB REPLACEMENT DISMOUNTING Disconnect the connector (1). Take out the protector (2). Release the springs sustaining the bulb. Replace the bulb. REMOUNTING Perform the dismounting operations in the reverse order. NOTE: After headlight or bulb replacement it is recommended the adjustment checking. FRONT SIGNALING BULB REPLACEMENT Disconnect the wires from the signaling lamp. Rotate the lamp-holder (3) and then remove it (draw it). Replace the bulb.
BATTERY - FRONT HEADLIGHTS LAMPS 80 BULBS BULBS Two phases bulb R2 - 12 V - 40/45 W, holder with flange P 45 t 41. Headlights Front parking, side signaling lamp, trunk lighting Bulb 12 V - 4W with holder B A9 s. Front turn signal lamps Fog projectors Rear lampe Rear fog lamp Bulb 12 V - 21W (colored) with holder BAU 15 s. Halogen bulb H3; 12 V - 55 W with holder P 16225. Stop, parking Bulb12 V - 21/5 W with holder B AY 15 d. Turn signal and back-up Bulb 12 V - 21W with holder BA 15 s.
80 BATTERY - FRONT HEADLIGHTS FOG PROJECTOR FOG PROJECTOR DISMOUNTING – REMOUNTING Disconnect the battery. Detach the projector supply wires from the front wiring. Dismount the attachment screws of the projector from front bumper. Mounting is done by performing in the reverse order the dismounting operations. 80 - 8 vnx.
BATTERY - FRONT HEADLIGHTS HEADLIGHTS ADJUSTMENT 80 The DACIA pick ups are equipped with two rectangular headlights. B C A A The headlights adjustment is performed observing the following conditions : - the vehicle shall be placed on a horizontal surface; - the vehicle shall be empty (without load or passengers on board); - the tires shall be inflated at the prescribed pressure; - the dynamic adjustment switch in position “ empty “ (without load – rotate it to the right).
80 BATTERY - FRONT HEADLIGHTS HEADLIGHTS ADJUSTMENT A lightening fascicle deviated to the left side is shown as in ( figure a ), and a lightening fascicle deviated to the right is shown as in ( figure b ). ( fig a ) ( fig a ) HIGH BEAM ADJUSTMENT ( LONG BEAM ) Check that the position to coincide with the adjustment made for the low beam, and the lightening fascicle shall be uniform distributed between the two vertically lines on the panel.
REAR AND INTERIOR LIGHTING REAR AND INTERIOR LIGHTING 81 MOUNTING – REMOUNTING LICENCE PLATE LAMP. Dismount the protector of the license plate lamp, then the attachment screws of the lamp on the body. Disconnect the lamp from the vehicle wiring. Mounting is done by performing the dismounting operations in the reverse order. REAR LAMP DISMOUNTING – REMOUNTING Dismount the screws that attach the protector ( DACIA 1304 Pick – up ).
81 REAR AND INTERIOR LIGHTING DIAGNOSTIC REAR RIGHT FOGG LAMP NOR WORKING Check if the bulb is not burnt. The bulb is burnt; replace it between. The bulb is not burnt; the supply wire lamps is broken or not connected. REAR RIGHT FOGG LAMP WORKING; THE WARNING IS NOT WORKING Check if the warning bulb is not burnt. The bulb is burnt; replace it. The bulb is not burnt. The bulb supply or the instrument panel mass are broken. 80 - 2 vnx.
HORN - ENGINE IMMOBILISER PRESENTATION 82 PRESENTATION This anti starting system( type 0802) is composedof the followingcomponents elements: - UCE anti starting (1) attachedby meansof threescrewson the side wallof the left side dashboard; - anti starting electronic keys (2) are attachedto the vehiclekeys; - anti startingreceiver(3) is fixed by clipson the dashboard, in theleft side of the central aerator.
82 HORN - ENGINE IMMOBILISER PRESENTATION CIRCUIT DIAGRAM On the circuit diagram of the systemtype 0802, the followings component elements may be identified: 1. UCE anti starting 2. Anti starting receiver(2 a = electronic key contact,2 b = anti starting LED indicator) 3. Inside fuse box 4. Left connection plate ( + I.C. ) 5. Anti theft device (starting- ignitioncontact) 6. Rear/front wiring connection 7. Electric fuel pump 8. Left side dashboard ground. 9.
HORN - ENGINE IMMOBILISER PRESENTATION 82 OPERATING CONDITIONS The anti starting has the purpose to block the supplyof the electric fuel pump and the ignition and injectionsystem. The anti starting systemis automaticallyarmed after 30 secondsfrom the ignition contactoff.( bringing the key on “S” positionor takingout the key from the anti theft device); the LED indicatorwilllight,showingin this way that anti starting systemhas been activated.
82 HORN - ENGINE IMMOBILISER ELECTRONIC KEYS PROGRAMMING PROCEDURE ELECTRONIC KEYS PROGRAMMING PROCEDURE This is to be applied when the replacement of the electronic keys is needed and the procedure is as follows: - bring the switch(1) of the UCE anti starting in position“ON”; - place the end of the first electronic key in contactwith the anti starting receiver; - after one second, place the end of the second electronic key in contactwith the anti starting receiver; - bring the switch(1) of the anti start
INSTRUMENT PANEL INSTRUMENTS PANEL - SERIES 5136 ( SÃCELE ) 83 - 1 vnx.
83 INSTRUMENT PANEL REPLACEMENT OF INSTRUMENTPANEL ( for vehicles made after 02.04.2003) The instrumentspanel dismounting does not imply dashboard dismounting. 1 2 3 4 DISMOUNTING Disconnect the battery. Disconnect the speedometercable from the instrumentspanel. Disconnect connectors from the instrumentspanel. (1, 2 and 3). Disconnectconnectors of the switchesfrom the instrumentspanel. Dimountingthe cable of tachometer,by realising,at the back of the panel instrument.
INSTRUMENT PANEL CONNECTORS - SERIES 5136 ( SÃCELE ) 83 Connectors disposal– front view of instrumentspanel: CONNECTOR A 1. Hazard warning light 2. Headlight mainbeam warninglight 3. Side lights warning light 4. Mass ( - ) 5. Revolutions counter (RPM) 6. Supply ( + DC ) after contact switch 7. Foglights warning light 8. Mass CONNECTOR B 1. Hand brake warning light 2. Choke warning light 3. Battery charging warning light or fog projector 4. Rearwindowheating warning light 5. Dashboardlighting 6.
INSTRUMENT PANEL 83 CONNECTORS - SERIES 5136 ( SÃCELE ) VEHICLE EQUIPMENT 4x2 BOSCH injection P OSITION IN CONNECTOR 2 2 4x4 BOSCH injection 4 Carburetor 4x4 4 Standard equipment 3 INITIAL BECOMING B Choke warning light Choke warning light Rear window heating light Defrost fieldglass indicator Fuel injection warning light Fuel injection warning light 4x4 coupling warning light 4x4 coupling warning Batterycharging light light 120 km/h speed warning light 83 - 4 vnx.
INSTRUMENT PANEL CONNECTORS TYPE TAKOSAN 83 Beginning with 01.01.2000 the DACIA type pick-ups have beenequipped with instruments panel SACELEtype, where the oil pressure indicatorand the water temperature warning light were suppressed i.e. the corresponding positions 2 and 7 from connector C. INSTRUMENTS PANELTYPE TAKOSAN Connectors – view of rear instrumentspanel. CONNECTOR B CONNECTOR A 1. 2. 3. 4. 5. 6. 7. 8.
83 INSTRUMENT PANEL 120 Km/h SPEED WARNING PRESENTATION This indicator,locatedon the instrumentspanel, has the warning purposefor the driverwhen the vehicle is running with over 120 km/h.The signal generatedfrom the RPM sensor(2), located on the speedometer cable will act on the indicator relay (4) through which the “120 km/h” warning light from the instrumentspanel is lighted. INCLUDED ELEMENTS On the circuit diagram the followingcomponents elementsmay be noticed: 1. Right connection plate (+DC) 2.
INSTRUMENT PANEL INSTRUMENTS PANEL ( Commercials equipped with C.A. ) 83 A: 1. Hazard warning light B: 1. Hand brake warning light 2. Headlights main beamwarning light 2. Fuel injection warning light 3. Side lights warning light 3. 120 km/h speed warning light 4. Mass 4. 4x4 warning light 5. Revolutions counter (RPM) 5. Rheostat lightening board 6. Supply ( + DC ) 6. Brakingsystemfailure warning light 7. Foglights warning light ( I.C.P. and wear of brake pads ) 8. Mass C: 1. Supply ( + DC ) 2. 3.
83 INSTRUMENT PANEL FASTEN SAFETYBELTS WARNING LIGHT PRESENTATION This functionis activatedafter switchon the ignition contact (engine starting) and is warning if the driverhas not fastenits safety belt, by meansof the safety beltswarning light, locatedon the central dashboard. OPERATING DIAGRAM The followingcomponents elementsmay be identified: 1. Safety beltswarning light board lamps 2. Safety belts contacts 3. Right connectionplate ( + DC ) 4.
INSTRUMENT PANEL VEHICLE WITH DASHBOARD TYPE 1325 REPLACEMENT 83 DISMOUNTING Disconnect the battery. Disconnect the speedometercable from the dash board. Disconnect the connectors and the speedometercable. Dismountthe half housingsof the steering wheel. Dismountthe headlight adjustmentcontrol. Dismount the screwsthat attachthe instrument frame. Releasethe two side attachmentclips that attachthe instrument panel on the dashboard. Take out the instrumentspanel.
83 INSTRUMENT PANEL DIAGNOSTIC OIL PRESSURE WARNING LIGHTSTILL ON AFTER ENGINE STARTING Check the oil pressure. The pressure is not correct; there is a failurein the oil circuit. The pressure is correct; replacethe oil pressure switch. OIL PRESURE WARNING LIGHT IS NOT ON WHEN CONTACT SWITCHON Placethe wire from the oil pressure switch to the mass. Warning light is on; replacethe oil pressure switch. Warning light is not on. Check if the bulb is not burnt. Burnt bulb; replacethe bulb.
INSTRUMENT PANEL DIAGNOSTIC 83 FUEL LEVELINDICATOR SHOWING ALWAYS FULL Disconnect the connectionwire to the probe. The indicatorcomes back to zero; replace the probe. The indicator does not come to zero; Is there any mass short-circuit of the connectionwire to the probe? Yes. Repair the wiring. No. Replacethe indicator. FUEL LEVELINDICATOR NOT SHOWING CORRECTLY Disconnect the connectionwire to the probe. The indicator comes back to zero. There is a shortcircuit;Repair the wiring.
83 INSTRUMENT PANEL DIAGNOSTIC FUEL LEVEL INDICATOR NOT OPERATING Place at mass the connectionwire to the probe. The indicatordoes not work. The indicatordoes not work; Replace theprobe. Check the indicatorsupply and mass. Iff correct. Place at mass the connectionwire to the probe. Not correct. Repair the mass wiring or probe supply. Indicator does not work. Repair the wiring between the probe and indicator. 83 - 12 vnx.
INSTRUMENT PANEL 83 FLEXIBLECABLE Dismounting of the speedometer cable does not imply the dismountingof the instrument panel from the dashboard. DISMOUNTING Push in the direction of A and B arrows, then pull in the C direction. Loosen the attachment screw E at the gearbox and pull the cable. Detachthe cable from the attachmentclips on the longitudinalgirder.
83 INSTRUMENT PANEL OIL PRESSURE SWITCH CHECKING NOTE: The oil pressure switch may not be repaired. It is placed on the left side of the engine block. To check the oil pressure switch,the following items are required: - a compressed air source; - a 0 – 1 bars manometer; - a control lamp. Make an assembly according to the diagram.Whenthe airis off, thecontrollamp should be lighted. If the lamp does not light, replacethe oil pressure switch.
INSTRUMENT PANEL THERMOCOUPLE CHECKING 83 NOTE: The thermocouple may not be repaired. It is located on closing plate of the cylinder head. In order to check the thermocouple, there are necessary : a vessel with cooling liquid( antifreeze + distilledwater ), a 0 – 200 ° C thermometer, a control lamp, a heat source. Make an assemblyaccording to the diagram. When the temperature of the fluid is low, the control lamp should be off. If the lamp is on, replacethe thermocouple. Warm up the fluid in the vessel.
83 INSTRUMENT PANEL TEMPERATURE TRANSMITTER CHECKING NOTE: The temperature transmitter may not be repaired. It is attached on the closing plate of the cylinder head. In order to perform the checking there are necessary: a vessel with cooling fluid (antifreeze + distilledwater ), a thermometer 0 – 200° C, a heat source, an ohm meter. Make an assemblyaccording to the diagram.
INSTRUMENT PANEL FUEL LEVEL TRANSMITTER 83 DISMOUNTING Disconnect the battery. Disconnectthe transmitterconnector from the rearwiring. Rotate the gauge attachmentflange anti-clockwiseby about 1/3 rotation. Take out the transmitterfrom the tank, by lift it carefully. REMOUNTING Perform in the reverseorder the dismountingoperations. NOTE: When remounting, pay attention that rubber sealing gasket of the transmitter to be in good state and flange to tightly fix it on the tank. 83 - 17 vnx.
CONTROLS - SIGNALLING STARTING - IGNITION SWITCH 84 ANTI THEFT MECHANISM REPLACEMENT ( STARTING - IGNITION SWITCH ) The anti theft mechanism is placed on the right part of the steering column and has the purpose to starter control when electric wiring is connected, being provided in the same time also with a steering locking device, with anti theft lock.
84 CONTROLS - SIGNALLING STARTING - IGNITION SWITCH DISMOUNTING Disconnect the battery Dismount the half steering wheel housings. Disconnects the connecting plugs of the contact switch. Bring the key in G position. Unscrew the attachment screw (1). Press the mobile pin (2) and draw the contact backwards. REMOUNTING Mount the contact in its seat. Tighten the attachment screw (1). Connect: - the contact switch; - the battery. Check the contact switch operation.
CONTROLS - SIGNALLING UNDER WHEEL CONTROL MODULE 84 LIGHTS CONTROL SWITCH The DACIA vehicles are provided with a lights control switch shown in the bellow drawing. NOTE: The lights control switch may not be repaired. . DISMOUNTING Disconnect the battery. Dismount the lower half housing of the steering wheel. Cut the plastic ring that attach the wiring on the steering wheel column. Disconnect: - the switch connector to the front wiring; - the wires attached by the nut.
84 CONTROLS - SIGNALLING UNDER WHEEL CONTROL MODULE TURN SIGNALING SWITCH DISMOUNTING Disconnect the battery. Dismount the lower housing of the steering wheel. Cut the plastic ring. Disconnect the connecting coupling to the front wiring. Unscrew the connecting screws of the signaling switch off the steering wheel column. Remove the switch. REMOUNTING Mount the switch. Tighten the switch attachment screws. Connect the connecting coupling to the front wiring.
CONTROLS - SIGNALLING 84 SWITCHES DASHBOARD for vehicles made after 02.04.2003 FOG LAMPS SWITCH 4X4 SWITCH Pos. 1 2 4 5 FOG LIGHTS SWITCH Pos. 1 2 4 5 Pos. 1 2 4 5 Destination Supply + accessories 4x4 couplingcommand + Position lights Mass Destination High - beams / Road lights Fog lampscommand + Position lights Mass TEMPORISATEURESSUIE-GLACES PARE-BRISE Pos. 1 2 3 4 Destination + Position lights Fog lampscommand relay + Position lights Mass 5 84 - 5 vnx.
84 CONTROLS - SIGNALLING SWITCHES DASHBOARD for vehicles made after 02.04.2003 CA SWITCH Pos. 1 2 3 4 HEATINGSWITCH Pos. 2 3 4 5 6 Destination Mass + Positionlights AC command Supply + accessories DAMAGE SWITCH Pos 1 2 3 4 5 6 7 8 9 Destination Command + signaling Leftsignalisation Right signalisation Damagewitness + Positionlights Mass Supply+ signalisation relay Supply + after contact Supply + permanent 84 - 6 vnx.
WINDSCREEN WIPERS WINDSCREENWIPER MECHANISM 85 The windscreen wiper mechanismwhich is equipping the DACIA pick-ups and its components may be seen in the followingdetaileddrawing. Subject to the type of dashboard which the DACIA pick-ups are equipped with (restyled dashboard or dash board type CN) the mechanism dismounting shall be perform differently.
85 WINDSCREEN WIPERS WINDSCREENWIPER MECHANISM VEHICLE WITH DASH BOARD TYPE 1325 DISMOUNTING Disconnect the battery. Dismount the attachmentnuts of the windscreen wiper arms and the blades. Unscrew the attachmentnuts of the shafts on the lower frame of the windscreen, recover the rubber washers and bushings. Dismountthe dashboard. Disconnectthe wiring connector from the windscreen wiper drivemotor. Unscrew the attachmentscrews of the mechanismon the plate.
WINDSCREEN WIPERS 85 WINDSCREENWIPER MECHANISM WINDSCREEN WIPER DRIVE SHAFT REPAIR This operation shall be performed for Dacia vehicles, as per the following drawing, after dismountingthemechanism from the vehicle. A 2 B 1 DISMOUNTING Disconnect the auxiliary connecting rods (A) and (B) off the shafts. Dismount the shafts (1) off the mechanismsupport (2). Depress the grooved bushing. Dismount the shaft; recover the bushing and the rubber gaskets. REMOUNTING Check the state of the rubber gaskets.
WINDSCREEN WIPERS 85 WINDSCREEN WIPER DRIVE MOTOR The operationshallbe performedafterdismountingthe mechanism off the vehicle. DISMOUNTING Unscrew the attachment nut of the control auxiliaryconnecting rod, ( B ) on the drive motor shaft. Unscrew the attachment screws of the drive motor on the mechanismsupport. REMOUNTING Perform the dismounting operations in reverse order. NOTE: When remounting, the auxiliary connecting rods A and B shall be aligned, the drive motor being “stopped at fix position”.
WINDSCREEN WIPERS WINDSCREEN WIPER DRIVE MOTOR 85 - loosen the adjustment screw of the rotor axial clearance. Dismount:the reductiongear cap, the pinion. 2. Rotor dismounting: - unscrew the attachmentscrews (A) of the reduction gear casing,on the drive engine. Dismount: the reduction gear casing, the bearing at the back of the motor and the rotor. REMOUNTING Clean the parts. Check the stateof the parts( pinions, bearings, collector), replacethe defectiveor worn parts.
85 WINDSCREEN WIPERS WINDSCREEN WASHERASSEMBLY The windscreen washerassemblyis placed in the engine compartment,beingattachedon the left front wing lining. According to the manufacture variant, this may have the electric pumps attachedon the front wing lining (fig. a) or on the washerreservoir (fig. b). ( fig.a ) ( fig.b ) DISMOUNTING Disconnect the battery; thenthe connectingwires from washerpumps. Disconnect the aspiration and exhausttubes from the couplings and adjustablenozzles.
WINDSCREEN WIPERS DIAGNOSTIC 85 THE WINDSCREEN WIPER IS WORKING THE WASHER PUMP IS NOT WORKING Place the plug (-) of the pump at the mass. The pump is not working. The pump is working; the mass wire broken or not connected. Performm a direct supply of the pump. The pump is not working; replacethe pump. The pump is working. Check if when lever is acted the contact end is voltage supplied. The contactend is not voltage supplied. Replacethe contact.
85 WINDSCREEN WIPERS DIAGNOSTIC THE WINDSCREEN WIPER IS NOT WORKING THE PUMP IS WORKING Connect the pump motor casingat the mass. The motor is not working. The motoris working; repair the mass. Check if the supply wires of the motor are voltage suppliedat the contactexit. + 12 V voltage existing at the contact end;motor is not working. Check if the motor is supplied. The wires are not supplied; replace the contact. The motor is supplied. Replacethe motor.
WINDSCREEN WIPERS DIAGNOSTIC 85 WINDSCREEN WIPER NOT WORKING ATHIGH SPEED; THE PUMP IS WORKING Check the gray wire supplying from the wiring plug connected to the drivemotor. The wire is not voltage supplied;replace. The plug or repair the wiring to the plug. The wire is voltage supplied. Check the motor supply. The motor is supplied; replacethe motor. The motor is not supplied;the supply wire is broken or not connected.
WINDSCREEN WIPERS 85 DIAGNOSTIC WINDSCREEN WIPER WORKING ON BOTH SPEEDS, BUT IT DOES NOT STOP AT FIX POINT; THE PUMP IS WORKING Yes No Check existence of + 12V at the white wire from the wiper? Repairthe electricwiring right connectionplate - wiper motor. Check presence of + 12V at the black wire on the return wiring? Yes No Check the correct operation of the timer and switch. Replace the wiper electric motor. Both are defective.Replace them.
ELECTRICAL DIAGRAMS GENERALITIES 89 GENERALPRESENTATION From the electric point of view, the electric diagrams of the vehicle have been structured as AppliedPrincipleSchemes(APS), which are presentedaccording to each function of the systems. These APS diagrams also contain detail concerning the internal function of some simple electric components (contacts,relays), thus contributing to a better understanding of the systemfunctioning and of the incidentgood diagnosis.
89 ELECTRICAL DIAGRAMS GENERALITIES FUNCTIONAL DIAGRAMS INTERPRETATIONS The functional diagrams information included in Chapter 7 are to be interpreted taking into considerationthe explanationreferring to the followingexample: 1 = vehicle class 2 = manufacturing year 3 = electric functional diagramdenomination 4 = criteria of equipmentdifferentiationfor identifying the functional diagram 5 = electric connector colour* 6 = connector graphicalrepresentation 7 = electric component index number 8 = fuses box
ELECTRICAL DIAGRAMS GENERALITIES ANTISTARTING 89 - 3 vnx.
89 ELECTRICAL DIAGRAMS GENERALITIES INTERPRETATION OF CONNECTORS WIRES FUNCTION INDEX The information concerning the function of the wires in connecters and couplings included in Chapter 1, are to be interpreted taking into account the explanations based upon the following example: 1 = symbol of the pages containingconnectors and couplings 2 = connector destination 3 = vehicleclass 4 = manufacturing year 5 = name of the wiring on which the respective connector is placed 6 = wire colour 7 = connector code
ELECTRICAL DIAGRAMS 89 GENERALITIES X 75 03 ENGINE WIRING DETONATION SENSOR 1 CY2AE 11 12 MA 1 3 CM 13 N 146 2 5 3 4 2 3S X 6 14 Position Section Destination 1 0,5 3CM DETONATION SENSOR MASS 2 0,5 3S DETONATION INFO INJECTION COMPUTER ATMOSPHERE PRESSURE SENSOR 7 ZW3DT 9 VE A B C 3CM N 3F 3D G 10 8 147 AS 13 - 07 89 - 5 vnx.
89 No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
ELECTRICAL DIAGRAMS 89 FUNCTIONAL DIAGRAMS LIST No. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. Electric diagrams denomination Rear fog lights Rear fog lights Fog lights High - beams Backward running lights Backward running lights Position lights Position lights Road lights STOP lights STOP lights Signalisation and break down lights Signalisation and break down lights NOTA : S= equipment series; O = opπional equipment 89 - 7 vnx.
89 CODE 101 103 104 105 107 113 120 121 122 124 125 137 145 149 155 156 160 163 166 167 171 172 173 176 177 180 184 185 199 205 209 210 212 216 217 221 222 225 226 227 228 230 231 234 ELECTRICAL DIAGRAMS ELECTRIC COMPONENTS INDEX CODE 236 238 244 247 250 251 255 256 262 267 268 271 272 298 319 321 326 329 333 335 362 371 411 448 474 478 484 503 584 597 Switch for lights, signalisation direction and horn 600 Electronic clock 654 Windscreen wiper motor 659 Front right brake plate 687 Front left brake plate
ELECTRICAL DIAGRAMS COUPLINGS LIST.
89 ELECTRICAL DIAGRAMS LOCATION OFELECTRIC COUPLING ON THE VEHICLE A. for U75 (Pick-up), M75 (King Cab) Κ L C H J D G F N M E A B. for E75 (Drop -Side) K L C H D J BP G F N M E A C. for H75 (Double Cab) K L C D G H J BP N M E F A 89 - 10 vnx.
ELECTRICAL DIAGRAMS 89 FIXATION OF ELECTRIC MASS ON THE VEHICLE A. for U75 (Pick-up), M75 (King Cab) MF MA MU MB MN MG B. for E75 (Drop -Side) MF MA MU MB MN MG C. for H75 (Double Cab) MF MA MU MB MN MG 89 - 11 vnx.
89 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 ELECTRICAL DIAGRAMS ELECTRIC COMPONENTS LOCATION ON THE VEHICLE 35 36 37 38 39 40 Air conditioning control (pusch button + switch ) 41 Indicating relay for over-limit speed 120km/h 42 43 Rotation sensor 44 Vacuum capsule contact 45 Supplyinig plate (+DC) 46 Windscreen wiper motor 47 Climate control GMV 48 Cockpit GMV2 (for A.
ELECTRICAL DIAGRAMS 89 ELECTRIC COMPONENTS LOCATION ON THE VEHICLE A. PENTRU U75 (Pick-up), M75 (King Cab) 31 32 33 41 40 34 42 59 58 57 29 56 15 24 10 55 35 14 1312 1 2 3 4 28 27 25 26 7 20 19 62 9 56 8 39 11 17 16 64 30 18 54 53 43 22 23 44 21 52 61 51 50 60 49 66 48 65 47 46 36 37 38 63 45 B.
89 ELECTRICAL DIAGRAMS ELECTRIC COMPONENTS LOCATION ON THE VEHICLE C. PENTRU H75 (Double Cab) 31 32 33 59 58 57 29 54 53 52 41 42 15 35 14 13 24 10 12 1 2 56 55 40 34 3 4 28 27 25 26 7 20 19 21 62 9 8 56 39 17 11 16 64 30 18 22 43 23 44 61 51 50 60 49 66 48 65 47 46 36 37 38 63 45 89 - 14 vnx.
ELECTRICAL DIAGRAMS COCKPIT FUSE BOX 89 The DACIA commercial vehicles are providedwith a fusesbox (10 safety fuses)situatedin the cockpit, under the board, left side. In caseof electric system damage, before other interventionswe mustfirst check the fuses and connections of the equipment, power off.
ELECTRICAL DIAGRAMS 89 ENGINE COMPARTMENT FUSE BOX The electric equipmentof DACIA commercial vehiclesis provided with safety fusesand relay, situatedin the engine compartment and fixed on the left mudguard coating. Electric circuitsprotectedby fusesand relays: FUSE FUSE TYPE NUMBER F01 F02 F03* 10 A 10 A 15 A RELAY R1 R2 R 3* PROTECTED CIRCUIT Fuel electric pump Oxygen rod Foglights PROTECTED CIRCUIT Oxygen rod,fuel electric pump. Injectioncomputer,injectionwitness.
ELECTRICAL DIAGRAMS ENGINE COMPARTMENT FUSE BOX 89 The vehiclesprovidedwith AC system,the fuse box situatedin the engine compartmentis fixed on the left mudguard coating, having the followingconfiguration. FUSE NUMBER F01 F02 F03 F04 F05* DIODE D1 D2 RELAY R1 R2 R3 R 4* R5 R6 FUSE TYPE PROTECTED CIRCUIT 10 A 10 A 10 A 30 A 15 A A.C. compressor Oxygen rod Fuel electric pump G.M.V. cooling Fog lights TYPE DESTINATION 6A 6A A.C. compressor A.C.
89 ELECTRICAL DIAGRAMS WIRE FUNCTIONS INDEX IN CONNECTORS AND COUPLINGS CONNECTOR DENOMINATION NO. 101 ELECTRICLIGHTER 103 HA ALTERNATOR 103HB ALTERNATOR EXCITATION 104 ANTI-THEFT SYSTEM 105 ACOUSTICALARM 107AA BATTERYTERMINAL (+) 107AB BATTERYTERMINAL (-) 113 WINDSCREEN WIPER TIM ER 120 INJECTIONU.C.E.
ELECTRICAL DIAGRAMS WIRE FUNCTIONS INDEX IN CONNECTORS AND COUPLINGS 225 226 227 228 230 231 234 236 238 244 247 250 251 255 256 262 267 268 271 272 298 326 329 333 335 371 411 474 484 478 584 597 654 720 778 797 1016 1091 1155 1187 1335 DIAGNOSISPLUG RIGHTSHEADLIGHT LEFTHEADLIGHT IDLEMOTIONREGULATOR FOGLIGHTSRELAY FOGLIGHTS CONTROLRELAY GMVRÃCIRECOOLINGCONTROLRELAY FUEL PUMP CONTROLRELAY MAINRELAY WATER INJECTIONTEMPERATURESENSOR BOARD PANEL VEHICLESPEED TRANSDUCER WATERTHERMO-CONTACT RIGHT FRONTSIGNALIS
89 ELECTRICAL DIAGRAMS WIRE FUNCTIONS INDEX IN CONNECTORS AND COUPLINGS R9 R 25 R 67 R 82 R 93 R 99 R 106 R 107 R 111 R 112 R 122 R 212 R 265 R 318 ADDITIONALFRONTWIRES COUPLING/ADDITIONAL BOARDANEL P FRONTWIRES COUPLING /BA TTERY ADITTIONAL FRONT WIRES C OUPLING/ADITTIONAL FRONT DIAVIA ADITTIONALBOARD PANELWIRE COUPLING/AC CONTROL ADITTIONALBOARD PANELWIRE COUPLING//GMV 2COCKPIT AIR HEATER SWITCH WIRE COUPLINGAIR / HEATER MOTOR FRONTWIRECOUPLING/WINDSCREEN WIPER FRONTWIRE COUPLING/ BOARDANEL P BOARD PAN
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING INJECTION U.C.E.
89 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING M INTI NO 18 17 16 ML 3BR B N G 15 R 14 3C X 13 12 11 10 9 8 7 3B 3LS 3LW 3GH 3GK 3AY X X X N X 35 34 33 32 31 30 29 28 27 3AM 3BV ML 3BU 3FH 38R 3BB 3AC NF 120 X X N X X X X X Vi-N 6 X 26 25 24 3AQ X 5 4 3 2 HK 3BL 1 3CV X X X 23 22 21 20 19 MB 49F 3BG ML 3CW X As-M X X N X ROTATION SENSOR Destination Position Sectioning 1 2 3 0,35 0,35 0,35 3BG 3BL M ENGINE ROTATION SIGNAL> ROTA
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING A.C. COMPRESSOR CLUTCH (for A.C. providedvehicles) Position Sectioning 1 0,75 Destination 38R CONTROL + A.C. COMPRESSOR CLUTCH NO 38R 171 X 89 - 23 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING VALVE POTENTIOMETER Destination Position Sectioning 1 2 3 4 5 0,5 0,75 NF 3LS POTENTIOMETER MASS SIGNAL +POTENTIOMETER 1 0,75 0,75 3LW 3AQ SIGNAL +POTENTIOMETER 2 SUPPLY+ VALVEPOTENTIOMETER DIAGNOSIS PLUG Position Sectioning 1 2 0,75 0,5 Destination HK ML LINE KDIAGNOSIS SIGNA L MASS 89 - 24 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING IDLE MOTION REGULATOR Position Sectioning 1 2 3 4 1,0 1,0 0,75 0,75 Destination 3BU 3BV 3AY ML CONTROL1 IDLEMOTION REGULATOR CONTROL2 IDLEMOTION REGULATOR IDLE MOTION SWITCH M ASS SIGNAL MASS FUELPUMP CONTROL RELAY Destination Position Sectioning 2 4 6 8 1,0 0,75 0,75 2,5 3NR AP29 3AC B + INJECTOR > FUELPUMP RELAY +AFTER PROTECTEDCONTACT CONTROL- FUELPUMP RELAY + BATTERY CS6P NO 2 3NR OR 6 B 4 AP29 R G 3
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING MAIN RELAY Position Sectioning 2 4 6 8 1,0 0,75 1,0 0,75 Destination 3BR AP29 B ML + AFTER CONTACT > MAIN RELAY + AFTER PROTECTED CONT ACT + BATTERY MASS CS6P NO 2 3BR OR 238 6 B 4 AP29 R G ML N 8 INJECTION WATER TEMPERATURE SENSOR Position Sectioning 1 2 0,75 0,5 Destination 3C NF SIGNAL +WATERTEMPERATURE SENSOR MASSWATER TEMPERATURE SENSOR 89 - 26 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING INJECTOR / AIR TEMPERATURE SENSOR Destination Position Sectioning 1 2 3 4 0,75 1,0 1,0 0,5 3B 3NR 3AM NF SIGNAL + AIRTEMPERATURE SENSOR + INJECTOR >FUELPUMP RELAY CONTROL- INJECTOR AIRTEMPERATURE SENSOR MASS CANISTER PURGING VALVE Position Sectioning 1 2 0,75 0,75 Destination 3BB B CANISTERPURGINGVALVE CONTROL + BATTERY 89 - 27 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING A.C.COMPRESSOR CLUTCH CONTROL RELAY (For A.C. provided vehicles) Position Sectioning 2 4 6 8 0,75 0,5 0,75 0,75 Destination 38R 3BR B 38R CONTROL +A.C. COMPRESSOR CLUTCH + AFTER CONT ACT >MAIN RELAY + BATTERY CONTROL + C. A.COMPRESSOR CLUTCH >COMPUTER CS6P NO 2 38R X 6 B 4 3BR R 584 G 38R X 8 89 - 28 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING ENGINE RELAYS AND SAFETYFUSES BOX PositionSectioning F01 F02 F04 1 2 1 2 1 2 1,0 1,0 1,5 1,5 2,0 2,0 Destination 3 NR 3 PP 3NR 3N B BP54 +INJECTOR >F02 FUSE INPUT OXYGEN ROD HEATING CONTROL + INJECTOR > F03FUSE INPUT + FUEL PUMP + BATTERY + BATTERY >FOG HEADLIGHTRELAY NO 1 B R F03 2 BP54 R 1 3NR 231 F02 2 3N R-A R-G 1 3NR 2 3PP R-A F01 R-AS 236 597 89 - 29 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 ENGINE WIRING IGNITION COIL Destination Positin Sectioning A B D 1,5 2 1,5 3CW AP29 3CV CONTROL-2-3CYLINDERSIGNITION COIL + AFTER PROTECTING CONT ACT CONTROL- 1-4 CYLINDERSIGNITIONCOIL OXYGEN ROD Position Sectioning 1 2 3 4 1,0 1,0 0,5 0,5 Destination 3PP ML 3GK 3GH OXYGEN ROD HEATING CONTROL MASS UPSTREAMOXYGEN RODSIGNAL UPSTREAMOXYGENROD MASS L 89 - 30 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING ALTERNATOR Position Sectioning 1 7,0 Destination B + BATTERY B 103 HA R ALTERNATOR EXCITATION Position Sectioning 1 0,75 Destination A CONTROL-CHARGE WITNESS AFTER + CONTACT BA A R 103 HB 89 - 31 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING ANTI -THEFT SYSTEM Destination Position Sectioning A1 A2 A2 B1 B2 2,0 3,0 1,5 3,0 3,0 S A A B D SUPPLY + ACCESSORIES SUPPLY + +AFTER CONTACT SUPPLY + +AFTER CONTACT + BATTERY CONTROL +STARTER BA 104 D B X R A S G M 2 1 B A ACOUSTIC ALARM Position Sectioning 1 0,75 Destination 67A CONTROL + ACOUSTIC ALARM BA 67A X 105 89 - 32 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING SIGNALISATION RELAY Position Sectioning 1 2 4 0,75 0,75 0,5 Destination 64 AP + PROTECTED SIGN ALISATION LIGHT 64 B CONTROL + SIGNALISA TION MB MASS CS6P NO 1 2 5 64AP X 137 4 64B X MB X 3 BACKWARDS RUNNING CONTACTOR Position Sectioning 1 2 0,5 0,5 Destination AP43 H66P + AFTER PROTECTED CONT ACT CONTROL+ BACKWARDS RUNNINGLIGHTS BA AP43 G H66P 155 X 89 - 33 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING STOP CONTACTOR Destination Position Sectioning 1 2 0,6 1,0 SP16 65A +PROTECTED ACCESSORIES CONTROL + STOP LIGHTS BA SP16 G 65A 160 M STARTER Position Sectioning 1 16,0 Destination B +BATTERY B 163BA N Position Sectioning 1 16,0 Destination ML BATTERY ELECTRIC MASS ML 163AB N 89 - 34 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING STARTER EXCITATION Position Sectioning 1 3,0 Destination D CONTROL+ STARTER BA D 163 DB A RIGHT FRONT POSITION LIGHT Destination Position Sectioning 1 2 0,35 0,35 LPG MA + POSITIONLIGHTS PROTECTED MASS BA LPG X MA 184 N 89 - 35 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING LEFT FRONT POSITION LIGHT Position Sectioning 1 2 0,35 0,35 Destination LPG ML + POSITIONLIGHTSPROTECTED MASS BA LPG X MB 185 N 89 - 36 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING MANUAL CONTACT Destination Position Sectioning 1 0,35 28A CONTROL -OIL PRESSURE WIT NESS BA 28A X 205 HORN AND LIGHTS SWITCH Position Sectioning A1 A2 A3 B1 B2 B3 1,4 1,4 1,0 0,35 0,6 1,0 Destination R C LPG 11A 9M 67A + DRIVING LIGHTS + HIGH-BEAMS + PROTECTEDPOSITIONLIGHTS CONTROL +DRIVING LIGHTS SHUNT > FOGLIGHTS SWITCH CONTROL + ACOUSTIC ALARM BA 209 A R C L X X X 11A 9M 67 A X X X 1 2 3
89 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING DIRECTION SIGNALISATION SWITCH Position Sectioning 1 2 2 4 1,0 1,0 1,0 1,0 Destination 64C 64D 64B 64B LEFT SIGNALISATION LIGHTS CONTROL RIGHTSIGNALISATION LIGHTS CONTROL CONTROL + SIGNALISATION CONTROL + SIGNALISATION>SHUNT BA 1 64C X 209B 2 64D X 64B X X 3 B A 4 RIGHT FRONTBRAKEPLATE NO Destination 1 0,35 H1 CONTROL - I.C.P.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING WINDSCREEN CLEANER PUMP Destination 1 2 2 0,5 0,5 0,5 16A CONTROL + WINDSCREEN CLEANER PUMP M MASS M MASS BA 16A X M 221 N N RIGHTHEADLIGHT Destination 1 2 3 1,4 1,0 1,0 MA MASS CPD + PROTECTED RIGHT HIGH-BEAMS RPD + PROTECTED RIGHT DRIVING LIGHTS 89 - 39 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING LEFTHEADLIGHT CD8F Destination 1 2 3 1,4 1,0 1,0 MB MASS CPG + PROTECTED LEFT HIGH-BEAMS RPG + PROTECTED LEFT DRIVING LIGHTS 227 BA 2 CPG X 1 3 MB RPG N X GMV COOLING CONTROL RELAY (for A.C.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING BOARD PANEL Destination Position Sectioning 1 2 3 4 5 6 6 0,35 0,35 0,35 0,35 0,35 0,35 0,35 25A 25A 3FH 85L LPG H1 H1 CONTROL -HANDBRAKE PLA TE WEAR WITNESS CONTROL -HANDBRAKE PLA TE WEAR WITNESS CONTROL -INJECTIONDAMAGE WITNESS CONTROL- 4x4 WITNESS + PROTECTEDLEFTPOSITIONLIGHTS CONTROL - I.C.P. BRAKING SYSTEMWITNESS CONTROL - I.C.P.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING Destination Position Sectioning 1 2 3 4 5 6 7 8 8 0,6 0,35 0,35 0,35 0,35 0,6 0,35 0,35 0,35 AP43 28A M B 64D 64C 41A 2A 31A 47A +AFTER PROTECTEDCONTACT CONTROL - OILPRESSURE WITNESS MASS CONTROL + RIGHTSIGNALISA TION WITNESS CONTROL + LEFTSIGNALISA TIONWITNESS SIGNAL + FUELLEVELTRANSMITTER CONTROL-ALTERNATOR CHARGEWITNESS SIGNAL +WATER TEMPERATURE - ALARM FUELMINIMALLEVEL BA 247 9 47A 8 31A 7 2A 6 41A 5 64C
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING WATER THERMO-CONTACT (for A.C. providedvehicles) Position Sectioning 1 1 2 3 0,35 0,35 0,35 0,35 Destination 49C 49C 38K BP27 CONTROL+ GMVCOOLINGRELAY > PRESSURE GAU GE CONTROL+ GMVCOOLINGRELAY > PRESSURE GAU GE A.C.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING LEFT FRONT SIGNALISATION LIGHT BA 64C Destination X 1 2 0,6 64C LEFT SIGNALISATION LIGHTS CONTROL 0,75 MB MASS MB N 256 GMV COOLING (for A.C.provided vehicles) Destination Position Sectioning A B 1,0 1,5 49B MB CONTROL + GMV COOLING MASS RIGHT FRONTSIDE SIGNALISATION LIGHT BA 64D Destination X 1 0,35 2 0,35 64D RIGHT SIGNALISATION LIGHTS CONTROL MB MB MASS N 267 89 - 44 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING LEFT FRONT SIDE SIGNALISATION LIGHT BA 64C Destination X 1 2 0,35 64C LEFT SIGNALISATION LIGHTS CONTROL 0,35 MB MASS MB 268 WATERTEMPERATURE TRANSMITTER Destination Position Sectioning 1 0,35 42A SIGNAL +WATER TEMPERATURE BA 42A 271 X G.M.V CLIMATE CONTROL RELAY(for A.C.
89 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING AIR CONDITIONING PRESSURE GAUGE (forA.C.provided vehicles) Position Sectioning 1 2 3 4 0,5 0,5 0,5 0,5 Destination 49F 49F AP40 49C +AIR CONDITIONING CONT ROL > GMV CONTROL RELAY + AIRCONDITIONING CONTROL > GMV STOPPING RELA Y SUPPLY + PROTECTED ACCESSORIES CONTROL + GMV COOLING RELAY 89 - 46 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING A.C. RELAY (on bord - for A.C vehicles) Destination Position Sectioning 1 1 2 2 3 5 0,5 0,5 0,5 0,5 2,5 1,0 AP40 AP40 M M BP11 38HQ SUPPLY + PROTECTEDACCESSORIES SUPPLY + PROTECTEDACCESSORIES MASS MASS > G.M.V CONTROL RELAY + PROTECTED BATTERY G.M.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING A.C. STOPPING RELAY (for A.C. provided vehicles) Destination Position Sectioning 1 2 3 4 0,35 0,35 0,35 0,35 38K MA 49F 49F A.C. STOPPING CONTROL > THERMO-CONTACT MASS + AIRCONDITIONINGCONTROL> PRESSUREGAUGE + AIR CONDITIONING CONTROL> U.C.E. IN JECTION CS6P NO 5 1 38K 720 4 49F 2 MA X N R-G 49F X 3 89 - 48 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING CUTIE SIGURANπE HABITACLU Designation F01 5,0 F01 2,0 F02 2,0 F02 2,0 F03 0,35 F04 2,0 F04 1,0 F04* 1,4 F05 1,0 F05 1,0 F06 1,0 F06 1,0 F07 1,4 F07 1,0 F08 1,0 F09 1,4 F09 1,0 F10 1,0 A AP43 S SP22 SP16 B BP11 BP11 64A 64B L LPG R RPG RPD C CPG CPD SUPPLY + DC + PROTECTEDAFTER CONTACT SUPPLY +ACCESORIES SUPPLY + PROTECTE D ACCESORIES + PROTECTEDACCESORIES > HEATING + BATTERY + PROTECTED BATTERY + PROTECTED BA TTERY >ANTISTARTING
89 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING BA A G AP43 F01 S G G SP22 F02 G SP16 F03 B R F04 64A X F05 X LPG F06 X RPG R X BP11 R R 64B L X M F07 X RPD F08 CPG C X X F09 X CPD 1016 F10 89 - 50 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 FRONT WIRING I.C.P. BRAKING SYSTEM BA Destination 1 0,35 H1 H1 CONTROL- I.C.P. BRAKI NG SYSTEM WITNESS 1091 X FRONT RIGHT BODY ELECTRIC MASS Destination Position Sectioning 1 3,0 MA MASS > RIGHT ILGHT, RIGHT FRONTPOSITION LIGHT, RIGHTFRONTSIGNALISATIONLIGHT, GMVCOOLINGCONTROLRELAY, A.C. STOPPING RELAY,COMPRESSEURCLUTCHDIODE MA MA N 89 - 51 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING X75 03 LEFT FRONT BODY ELECTRIC MASS Destination Position Sectioning 1 3,0 MB 1 3,0 MB 1 1,0 MB MASS > LEFTLIGHT, LEFTFRONT POSITION LIGHT, LEFTFRONT SIGNALISATIONLIGHT, WINDSCREEN CLEA NER PUMP,BACKWINDSCREEN CLEANER PUMP MASS > ECUINJECTION,SEGNALISATION RELAY, LEFT-RIGHT FRONTSIDE SIGNALISATION LIGHT, BOARDPANEL, LIGHTING:GLOVEBOX,CLOCK, ELECTRICLIGHTER,ASHTRAY, HEATINGCONTROL, SWITCHES MASS > GMV COOLING ANDCA
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 BATTERY WIRING BATTERY TERMINAL (+) Position Sectioning 1 2 16,0 6,0 Destination B B + BATTERY > +STARTER +BATTERY NO B 107AA AS,N BATTERY TERMINAL ( -) Position Sectioning 1 16,0 Destination ML BATTERY ELECTRIC MASS NO ML 107AB N 89 - 53 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 BOARD PANEL WIRING ELECTRIC LIGHTER Destination PositionSectioning 1 1 2 3 1,0 0,35 0,35 1,5 M M L BP11 MASS MASS >ASHTRAYLIGHTING + POSITIONLIGHTS + PROTECTED BATTERY BA M N N L X 101 BP1 1 AS FOG HEADLIGHTS SWITCH Destination Position Sectioning 1 2 4 5 0,6 0,6 0,35 0,35 9M 9D LPG M B SHUNT CONTROL +REAR FOG LIGHTS > RELAY + PROTECTED POSITION LIGHTS MASS BA 121 1 9M 2 9D X X N 4 5 LPG MB X N 89 - 54 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 BOARD PANEL WIRING FOG HEADLIGHTS SWITCH Position Sectioning 1 1 2 4 5 0,6 0,35 0,35 0,35 0,35 Destination LPG LPG 8L LPG M B POSITION LIGHTS POSITION LIGHTS>SHUNT CONTROL +REAR FOG LIGHTS RELAY + POSITION LIGHTS MASS BA 121 1 LPG 2 8L X X N 4 5 LPG MB X N 89 - 55 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 BOARD PANEL WIRING BREAKDOWN SWITCH Position Sectioning 1 2 3 4 5 6 7 8 9 9 1,0 1,0 1,0 0,35 0,35 0,35 1,0 1,0 1,0 0,35 Destination 64B 64C 64D 64F LPG MB 64A A B B CONTROL + SIGNALISATION LEFTSIGNALISATIONLIGHTS CONTROL RIGHTSIGNALISATIONLIGHTS CONTROL CONTROL+ BREAKDOWN WITNESS + PROTECTEDPOSITIONLIGHTS MASS SUPPLY + SIGNALISA TION + AFTER CONT ACT + BATTERY + BATTERY>CLOCK BA 7 64A 9 B GR R R 6 MB N 125 4 64F 5 LPG X
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 BOARD PANEL WIRING GLOVES BOX LIGHT Position Section 1 2 Destination 0,35 0,35 MB LPG MASS + PROTECTEDPOSITIONLIGHTS BA MB N LPG 168 X ELECTRONIC CLOCK Position Section 1 2 3 4 5 6 Destination 0,35 0,35 0,35 0,35 LPG AP40 B MB + PROTECTEDPOSITIONLIGHTS + AFTER PROTECTED CONT ACT + BATTERY MASS BA 6 5 4 3 2 1 N R G X 210 89 - 57 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BOARD PANEL WIRING FOG LIGHTS RELAY Destination Position Sectioning 1 2 3 4 5 0,5 0,5 0,5 0,5 0,5 9D M LPG 9B BP11 CONTROL+ REAR FOGLIGHTS MASS + PROTECTEDPOSITIONLIGHTS CONTROL+ REAR FOGLIGHTS + PROTECTED BATTERY CS6P NO 5 BP11 R 230 1 9D 4 9B 2 MB OR X N LPG X 3 CLIMATE CONTROLLIGHTING Position Sectioning 1 2 0,35 0,35 Destination LPG MB + PROTECTED POSITIO N LIGHTS MASS BA MB N LPG 298 X 89 - 58 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 BOARD PANEL WIRING FRONT ASHTRAY LIGHTING Destination Position Sectioning 1 2 0,35 0,35 MB LPG MASS +PROTECTEDPOSITIONLIGHTS BA MB N LPG 1335 X 89 - 59 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS CEILING LIGHT WIRING X75 03 FRONT RIGHT CEILING LIGHT Destination 1 2 0,6 0,6 BCP3 + PROTECTED BATTERY CEILINGLIGHTING>LEFTCOUPLING PLATE 13A CONTROL- CEILINGLIGHTING > LEFT DOORCONTACTOR BA BCP3 R 13A 329 N 89 - 60 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FOG HEADLIGHTS WIRING RIGHTFOG HEADLIGHT Position Sectioning 1 2 1,0 1,0 Destination 8B MB + FOGHEADLIGHTS>FOGHEADLIGHTS RELAY MASS BA 8B X MB 176 N LEFTFOG HEADLIGHT Position Sectioning 1 2 1,0 1,0 Destination 8B MB + FOGHEADLIGHTS>FOGHEADLIGHTS RELAY MASS BA 8B X MB 177 N 89 - 61 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FOG HEADLIGHTS WIRING FOG HEADLIGHTS CONTROL RELAY Destination Position Sectioning 1 2 3 3 5 0,6 0,6 1,0 1,0 2,0 MB 8L 8B 8B B P54 MASS CONTROL+ FOGHEADLIGHTSRELAY + FOGHEADLIGHTS>LEFTFOGHEADLIGHT + FOGHEADLIGHTS>RELAY + PROTECTED BATTERY CS6P NO 5 BP54 R 1 MB 231 4 N 2 8L X 8B 3 89 - 62 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS 89 X75 03 WINDSCREEN WIPER WIRING WINDSCREEN WIPER TIMER Destination Position Sectioning 1 2 3 4 5 0,6 0,6 0,5 0,6 0,5 16A 14C MB 14D BP11 CONTROL+ WINDSCREEN CLEANER PUMP CONTROL + WINDSCREEN WIPER TIMER MASS CONTROL WINDSCREEN WIPER TIMER LOW-SPEED + PROTECTED BATTERY NO 1 16A X 4 14D 3 MB 2 14C X N X 5 BP11 113 A WINDSCREEN WIPER CLEANER SWITCH Position Sectioning 1 2 3 4 5 5 0,6 0,75 0,6 0,6 0,6 0,5 Destination 14B BP11 1
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS WINSCREEN WIPER WIRING X75 03 WINDSCREEN WIPER MOTOR Destination Position Sectioning 1 2 3 4 4 0,6 0,6 0,6 0,75 0,5 14A 14C 14B BP11 BP11 CONTROL + WINDSCREEN WIPER LOW-SPEED CONTROL + WINDSCREEN WIPER TIMER CONTROL + WINDSCREEN WIPER HIGH-SPEED + PROTECTED BATTERY + PROTECTED BATTERY >WINDSCREEN WIPER TIMER BA 212 3 14B 4 BP11 X A A 1 14A 2 14C X X 89 - 64 vnx.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 REAR WIRING HANDBRAKE CONTACTOR Destination PositionSectioning 1 0,35 27A CONTROL - HA NDBRAKE WITNESS NO 27A 156 X RIGH REGISTRATION NUMBER LIGHT (for U75, M75, H75) Position Sectioning 1 0,35 Destination LPG +PROTECTEDPOSITIONLIGHTS BA LPG 166 X LEFT REGISTRATION NUMBER LIGHT (for U75, M75, H75) Position Sectioning 1 0,35 Destination LPG + PROTECTEDPOSITION LIGHTS BA LPG 167 X 89 - 65 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 REAR WIRING RIGH REGISTRATION NUMBER LIGHT (for E75) Position Sectioning 1 2 Destination 0,6 0,35 +CONTROL+ BACKW ARDS RUNNINGLIGHTS +PROTECTEDPOSITIONLIGHTS H66P LPG BA H6 6 P X LPG 166 X LEFT REGISTRATION NUMBER LIGHT (for E75) Position Sectioning 1 2 0,6 0,35 Destination H66P LPG +CONTROL+ BACKW ARDS RUNNINGLIGHTS +PROTECTEDPOSITIONLIGHTS BA 9B X LPG X 167 89 - 66 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 REAR WIRING REAR RIGHT LIGHT(for U75, M75, H75) Destination Position Sectioning A1 A2 A3 B1 B2 B3 0,35 1,0 0,6 0,6 0,6 0,6 LPG MF 65A 64D H66P 9C + PROTECTEDPOSITIONLIGHTS MASS CONTROL+ STOP LIGHTS RIGHTSIGNALISATIONLIGHTS CONTROL CONTROL + BACKW ARDS RUNNING LIG HTS CONTROL+ REAR PROCTE D FOGLIGHTS BA 9P H66P 64D B X X X 65A MF LPG X N X 3 2 1 173 A REAR LEFT LIGHT (for U75, M75, H75) Position Sectioning A1
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 REAR WIRING REAR RIGHTLIGHT(for E75) Position Sectioning 1 2 3 4 0,35 0,6 0,6 1,0 Destination LPG 65A 64D MF + PROTECTEDPOSITIONLIGHTS CONTROL+ STOP LIGHTS RIGHTSIGNALISATIONLIGHTS CONTROL MASS BA LPG X 65A X 64D X MF 172 N 89 - 68 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 REAR WIRING REAR LEFTLIGHT(for E75) Destination Position Sectioning 1 2 3 4 0,35 0,6 0,6 1,0 LPG 65A 64C MF + PROTECTEDPOSITIONLIGHTS CONTROL+ STOP LIGHTS LEFT SIGNALISATIONLIGHTSCONTROL MASS BA LPG X 65A X 64C X MF 173 N ELECTRIC PUMP AND FUEL LEVEL TRANSMITTER Destination Position Sectioning 1 2 3 4 0,5 1,5 0,5 1,5 47A 3N 41A MG - FUEL MINIMALLEVEL ALARM + FUEL PUMP SIGNAL+ FUELLEVEL TRANSMITTER MASS BA 199 3 41A
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS 4X4 CONTROL WIRING X75 03 4X4 WITNESS CONTROL RELAY Destination Position Sectioning 1 2 3 4 5 5 0,75 0,5 0,5 85G AP40 85L 4X4 COUPLING RELAY CONTROL SUPPLY + PROTECTEDACCESSORIES>SHUNT 4X4 WITNESS CONTROL 0,75 0,5 AP40 AP40 SUPPLY + PROTECTEDACCESSORIES SUPPLY +PROTECTEDACCESSORIES>SHUNT NO CS6P 1 85G 1155 5 AP4 0 R R 4 2 AP40 A R 85L X 3 VACUUM CAPSULE CONTACT Destination Position Sectioning A1 B2 1,0 0,75 MB 85G MASS
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS 4X4 CONTROL WIRING 4X4 COUPLING ELECTRO-VALVE Position Sectioning 1 2 0,75 0,75 Destination A3 MB SUPPLY + PROTECTEDACCESSORIES MASS BA 2 MB 484 N 1 A3 R 4X4 SWITCH Destination 1 2 4 5 0,75 0,75 0,35 0,35 AP40 A3 LPG MB SUPPLY+ PROTECTEDACCESSORIES + PROTECTEDACCESSORIES + POSITIONLIGHTS MASS BA AP4 0 R-A M N AP40 478 R 89 - 71 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 OVER - SPEED WIRING SAFETYBELT WITNESS (for DAIF) Position Sectioning 4 5 0,6 0,6 Destination AP40 96A SUPPLY+ PROTECTEDACCESORIES CONTROL - SAFETYBELT WITNESS BA 1 247 2 4 AP40 5 96A R X 3 VEHICLE SPEED TRANSDUCER (for DAIF) Position Sectioning 1 2 3 0,35 0,35 0,35 Destination AP40 47F MN SUPPLY + PROTECTEDACCESSORIES VEHICLE SPEEDSIGNALISATION MASS BA AP4 0 R-A 1 47F 250 X 2 MN N 89 - 72 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 OVER - SPEED WIRING OVER - SPEED INDICATOR RELAY (for DAIF) Position Sectioning 1 2 4 5 0,35 0,35 0,35 0,35 Destination AP40 MN 47F 97A SUPPLY + PROTECTEDACCESSORIES MASS VEHICLE SPEEDSIGNALISATION CONTROL - SPEEDWITNESS 120KM/H NO CS6P 5 97A X 326 1 AP40 4 47F R X 2 MN N 3 SAFETYBELT WITNESS (for DAIF) Position Sectioning 4 5 0,6 0,5 Destination 96A MN CONTROL - SAFETYBELT WITNESS MASS BA 1 333 4 96A R 89 -
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS ADDITIONAL FRONT/ADDITIONAL BOARD PANELWIRES COUPLING (for A.C. providedvehicles) ADDITIONAL FRONT WIRES COUPLING Position Sectioning A B 0,75 0,5 Destination 49F AP40 AIRCONDITIONING CONTROL> PRESSUREGAUGE SUPPLY + PROTE CTEDACCESSORIES ADDITIONALBOARD PANELWIRES COUPLING Destination Position Sectioning A B 0,5 0,5 49F AP40 + AIR CONDITIONINGCONTROL> G.M.V. RELAY SUPPLY + PROTE CTEDACCESSORIES 89 - 74 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONTWIRES COUPLING/BATTERY FRONT WIRES COUPLING Destination Position Sectioning 1 7,0 B + BATTERY BA B R25 R BATTERYWIRES COUPLING Destination Position Sectioning 1 7,0 B + BATTERY BA B R R25 89 - 75 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS ADDITIONALFRONT/DIAVIAADDITIONAL FRONT WIRES COUPLING (for A.C. providedvehicles) ADDITIONAL FRONT WIRES COUPLING Destination Position Sectioning 1 2 0,75 0,35 49F 49F + AIR CONDITION ING CONTROL > G.M.V . RELAY + AIR CONDITIONING CONTROL C.A. > RELAY DIAVIAADDITIONAL FRONT WIRES COUPLING Destination Position Sectioning 1 2 0,5 0,5 49F 49F + AIR CONDITIONINGCONTROL + AIR CONDITIONINGCONTROL 89 - 76 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS ADDITIONAL BOARD PANEL WIRES COUPLING/ A.C.CONTROL (for A.C. providedvehicles) ADDITIONALBOARD PANELWIRES COUPLING Position Sectioning 1 2 3 4 0,5 0,5 0,5 0,5 Destination MN LPG 49F AP40 MASS +PROTECTEDPOSITIONLIGHTS + AIR CONDITIONINGCONTROL> RELAY SUPPLY + PROTE CTEDACCESSORIES BA 1 MN R82 2 LPG N X 3 49F V 4 AP40 R-GR A.C.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 01 COUPLINGS ADDITIONAL BOARD PANELWIRES COUPLING/GMV 2 COCKPIT (for A.C. providedvehicles) ADDITIONALBOARD PANELWIRES COUPLING Destination Position Sectioning 1 2 3 4 1,0 2,5 1,5 2,5 38AH MN 38AJ 38AK CONTROL +G.M.V. MOTOR SPEED 1 MASS CONTROL +G.M.V. MOTOR SPEED 2 CONTROL +G.M.V. MOTOR SPEED 3 BA 3 38AJ X R93 4 38AK X 1 38AH X 2 MN N G.M.V.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS CLIMATE CONTROL SWITCH WIRES COUPLING/ GMVCLIMATE CONTROL CLIMATE CONTROL SWITCH WIRES COUPLING Position Sectioning 2 3 4 5 6 Destination 38AK 38AH 38AL 38AJ SP3 1,0 0,6 1,5 1,0 1,5 CONTROL + GMV CLIMA TE CONTROLSPEED 3 CONTROL + GMV CLIMA TE CONTROLSPEED 1 CONTROL + GMV CLIMA TE CONTROLSPEED 4 CONTROL + GMV CLIMA TE CONTROLSPEED 2 + PROTECTEDACCESSORIES > CLIM ATE CONTROL BA 6 SP3 R 99 5 38AJ R X 3 38AH 2 38AK
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONT WIRES COUPLING/WINDSCREEN WIPER FRONT WIRES COUPLING Position Sectioning 1 0,6 Destination 16A CONTROL+ WINDSCREEN CLEANER PUMP BA 16A R106 X WINDSCREEN WIPER WIRES COUPLING Destination Position Sectioning 1 0,6 16A CONTROL + WINDSCREEN CLEANER PUMP BA 16A R106 X 89 - 80 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONT WIRES COUPLING/BOARD PANEL (for A.C.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS BOARD PANEL WIRES COUPLING Destination Position Sectioning A1 A1 A2 A2 A3 A3 B1 B2 B3 B4 B4 3,0 0,6 2,0 1,0 1,0 1,0 2,0 0,6 0,6 1,4 0,6 MB MB AP40 AP40 L L AP43 9B 9M BP11 BP11 MASS MASS > FOGLIGHTS RELAY + AFTER PROTECTED CONT ACT + AFTER PROTECTEDCONTACT>WINDSCREENWIPER CONTROL + PROTECTEDPOSITIONLIGHTS + PROTECTEDPOSITIONLIGHTS > FOGLIGHTSRELAY +AFTER PROTECTEDCONTACT CONTROL +PROTECTEDREAR FOG LIGHTS SHUNT > FOGL
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS BOARD PANELWIRES COUPLING/G.M.V. CLIMATE CONTROL BOARD PANEL WIRES COUPLING Position Sectioning 1 2,0 Destination AP40 + PROTECTEDACCESSORIES > G.M .V. CLIMATE CONTROL BA AP4 3 R111 G D=3 G.M.V. CLIMATE CONTROL WIRES COUPLING Position Sectioning 1 1,5 Destination AP40 + PROTECTEDACCESSORIES > G.M .V. CLIMATE CONTROL BA AP4 3 R111 G 89 - 83 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONT WIRES COUPLING / U.C.E. DECODER (for DAIF) FRONT WIRES COUPLING Destination Position Sectioning A1 A2 A4 A5 B1 B2 B4 B5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 MB MB 3N AP29 BP11 A 3N A MASS MASS + FUELPUMP + AFTER PROTECTED CONTACT ENGINE + PROTECTEDBATTERY SUPPLY+ AFTER CONT ACT + FUELPUMP SUPPLY+ AFTER CONT ACT SAFETY FUNCTION BA A 3N V X AP29 R 112 3N A BP11 R G MB MB V X N N 5 4 2 1 B A U.C.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONT WIRES COUPLING/FOG LIGHTS FRONT WIRES COUPLING Position Sectioning 1 0,6 Destination 8L CONTROL+ POSITIONLIGHTS BA 8L OR R122 FOG LIGHTS WIRES COUPLING Position Sectioning 1 0,6 Destination 8L +POSITIONLIGHTS BA 8L X R122 89 - 85 vnx.
89 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONT /ENGINE WIRES COUPLING FRONT WIRES COUPLING Destination Position Sectioning 2* 3* 4 7 9 9 10 10 0,35 1,0 0,6 0,35 1,4 1,4 1,4 1,4 49F 38R MB 3FH 3N 3N AP29 AP29 + AIR CONDITIONING CONTROL >A.C. RELAY CONTROL +A.C. COMPRESSOR CLUTCH MASS CONTROL - INJECTION DAMAGE WITNESS + FUELPUMP > U.C.E.
ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS ENGINE WIRING COUPLING Destination Position Sectioning 2* 3* 4 7 9 10 0,35 1,0 0,6 0,35 1,4 1,4 49F 38R MB 3FH 3N AP29 + AIR CONDITION ING CONTROL > U.C.E. INJECTION CONTROL +A.C. COMPRESSOR CLUTCH MASS CONTROL - INJECTION DAMAGE WITNESS + FUEL PUMP + AFTER PROTECTED CONT ACT BA 1 8 7 2 3 49F 3FH X X AP29 3N V G 10 9 6 38R X MB R 212 4 N 89 - 87 vnx.
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONT/REAR WIRES COUPLING FRONT WIRES COUPLING Position Sectioning A1 A2 A2 A4 A5 B1 B2 B3 B4 B5 0,6 1,4 1,4 0,6 0,6 0,6 0,35 0,35 0,6 0,6 Destination LPG 3N 3N H66P 9B 64C 47A H1 41A 64D + PROTECTEDPOSITIONLIGHTS + FUEL PUMP >ANTISTARTING + FUEL PUMP CONTROL+BACKWARDRUNNINGLIGHTS CONTROL+PROTECTED REARFOGLIGHTS LEFTSIGNALISATIONLIGHTS CONTROL - ALARMFOR FUELMINIMAL LEVEL CONTROL - HANDBRAKE WITNE SS SIGNAL+ FUELLEVELT
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS REAR WIRES COUPLING Destination Position Sectioning A1 A2 A4 A5 B1 B2 B3 B4 B5 1,0 1,4 0,6 0,6 0,6 0,35 0,6 0,6 0,6 LPG 3N H66P 9B 64C 47A H1 41A 64D + PROTECTEDPOSITIONLIGHTS + FUEL PUMP CONTROL+BACKWARDRUNNINGLIGHTS CONTROL+PROTECTED REARFOGLIGHTS LEFTSIGNALISATIONLIGHTS CONTROL - ALARMFOR FUELMINIMAL LEVEL CONTROL - HANDBRAKE WITNE SS SIGNAL+ FUELLEVELTRANSMITTER LEFTSIGNALISATIONLIGHTS CONTROL BA B R 265 A 64
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS FRONT WIRES COUPLING / BOARD PANEL FRONT WIRES COUPLING Position Sectioning A1 A2 A3 A4 B1 B2 B3 B4 1,0 1,0 1,6 0,6 0,35 1,0 1,0 1,0 Destination 64D 64B B 8L 64F 64A A 64C RIGHTSIGNALISATIONLIGHTS CONTROL CONTROL+ SIGNALISA TION + BATTERY CONTROL +FOG LIGHTS RELAY CONTROL +BREAKDOWN WITNESS SUPPLY + SIGNALISA TION SUPPLY+AFTER CONTACT RIGHTSIGNALISATIONLIGHTS CONTROL BA B 64F 64A A 64C X X G X 64B B 8L X
ELECTRICAL DIAGRAMS 89 WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS X75 03 COUPLINGS BOARD PANELWIRES COUPLING Position Sectioning A1 A2 A3 A4 B1 B2 B3 B4 1,0 1,0 1,0 0,35 0,35 1,0 1,0 1,0 Destination 64D 64B B 8L 64F 64A A 64C RIGHTSIGNALISATIONLIGHTS CONTROL CONTROL+ SIGNALISA TION + BATTERY CONTROL +FOG LIGHTS RELAY CONTROL +BREAKDOWN WITNESS SUPPLY + SIGNALISA TION SUPPLY+AFTER CONTACT RIGHTSIGNALISATIONLIGHTS CONTROL BA R 318 64C A 64A 64F X G X X 8L B 64B 64D X R X X 4 3 2 1
89 LINK CODES A A3 AP29 AP40 AP43 B BCP3 BP11 BP27 BP54 BP7 C CPD CPG D H1 H66P HK HL L LPG MA MB MF MG ML MN MU NF R RPD RPG S SP16 SP22 SP3 2A 3AC 3AM 3AQ 3AY 3B 3BB 3BG 3BL 3BR 3BU 3BV 3C 3CV 3CW 3FH ELECTRICAL DIAGRAMS WIRE FUNCTIONES EXPLANATION WIRE FUNCTIONS SUPPLY + AFTER CONTACT PROTECTEDACCESORIES + AFTER PROTECTED CONTACT ENGI NE SAFETY FUNCTION SUPPLY + PROTECTEDACCESSORIES + AFTER PROTECTEDCONTACT + BATTERY + PROTECTED BA TTERY CEILING LIGHTING + PROTECTEDBATTERY > COCKPIT 1 + PROTECTED BA TT
ELECTRICAL DIAGRAMS WIRE FUNCTIONES EXPLANATION 3GH 3GK 3LS 3LW 3NA 3NR 3PP 8B 8DP 9A 9B 9C 9D 9M 11A 13A 14A 14B 14C 14D 15B 16A 25A 27A 28A 31A 38AH 38AJ 38AK 38AL 38HQ 38K 38R 41A 42A 47A 47F 49B 49C 49F 64A 64AP 64B 64C 64D 64E 64F 65A 67A 80T 80X 85G 85L 96A 97A UPSTREAMROD O2 MASS UPSTREAMROD O2 SIGNAL SIGNAL + POTENTIOMETER 1 SIGNAL + POTENTIOMETER 2 + FUEL PUMP + INJECTOR > FUEL PUMPRELAY ROD O2 CONTROL + FOG HEADLIGHTS >RELAY CONTROL +FOGHEADLIGHTS RELAY +REARFOG LIGHTSRELAY CONTROL CONTROL +REAR
