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Dacia - Sandero - Owners Manual - 2013 - 2013
Dacia - Dokker - Owners Manual - 2014 - 2014
Dacia - Logan - Owners Manual - 2015 - 2015
Dacia - Duster - Owners Manual - 2017 - 2017 (Finnish)
Dacia - Lodgy - Workshop Manual - 2012 - 2012
Dacia - Dokker - Wiring Diagram - 2012 - 2012
Dacia - Logan MCV II - Miscellaneous Documents - 2016 - 2016 (Czech)
Dacia - Lodgy - Owners Manual - 2012 - 2020
Dacia - Logan Pick-Up - Workshop Manual - 2008 - 2020 (Czech)
Dacia - Duster - Owners Manual - 2011 - 2011
Dacia - Duster - Sales Brochure - 2017 - 2017 (Danish) (2)
Dacia - Sandero Stpeway - Sales Brochure - 2017 - 2017 (Italian)
Dacia - Logan MCV - Owners Manual - 2014 - 2014
2004 Dacia Solenza Repair Manual
Dacia - Sandero - Sales Brochure - 2014 - 2014
Dacia - Sandero Stpeway - Sales Brochure - 2016 - 2016
Dacia - Duster - Sales Brochure - 2018 - 2018
Dacia - Logan Pick Up - Parts Catalogue - 1924 - 1924
Dacia - Duster - Sales Brochure - 2015 - 2015
Dacia - Sandero Stpeway - Sales Brochure - 2018 - 2018
Dacia - Logan - Miscellaneous Documents - 2016 - 2016
Dacia - Sandero Stpeway - Sales Brochure - 2016 - 2016 (Italian)
Dacia - Sandero Stpeway - Sales Brochure - 2018 - 2018 (Polish)
Dacia - Dokker Stpeway - Sales Brochure - 2018 - 2018 (Czech)
Dacia - Dokker Van - Sales Brochure - 2016 - 2016 (Turkish)
Dacia - Sandero Stpeway - Sales Brochure - 2018 - 2018 (Spanish)
2004 Dacia SupeRNova Repair Manual
Dacia - Duster - Sales Brochure - 2018 - 2018 (Italian)
Dacia - Dokker Stpeway - Sales Brochure - 2017 - 2017 (French)
Dacia - Sandero - Sales Brochure - 2013 - 2013
Dacia - Duster - Sales Brochure - 2018 - 2018 (French)
Dacia - Duster - Sales Brochure - 2014 - 2014 (Czech)
Dacia - Sandero Stpeway - Sales Brochure - 2017 - 2017 (Romanian)
Dacia - Logan MCV - Sales Brochure - 2014 - 2014
Dacia - Duster - Sales Brochure - 2017 - 2017
Dacia - Dokker Van - Sales Brochure - 2018 - 2018 (Spanish)
Dacia - Duster - Sales Brochure - 2018 - 2018 (Greek)
Dacia - Lodgy - Sales Brochure - 2015 - 2015 ( Lithuanian)
Dacia - Logan - Sales Brochure - 2016 - 2016 (Czech)
Dacia - Dokker - Sales Brochure - 2013 - 2013 (Spanish)
Dacia - Duster - Sales Brochure - 2017 - 2017 (2)
Dacia - Duster - Sales Brochure - 2011 - 2011 (Greek)
Dacia - Dokker Van - Sales Brochure - 2014 - 2014 (Finnish)
Dacia - Logan - Sales Brochure - 2011 - 2011 (Bosnian)
Dacia - Logan Pick-Up - Sales Brochure - 2012 - 2012 (French)
Dacia - Sandero Stpeway - Sales Brochure - 2013 - 2013 (Finnish)
Dacia - Duster - Sales Brochure - 2011 - 2011 (Slovenian)
Dacia - Duster - Sales Brochure - 2018 - 2018 (Danish)
Dacia - Duster - Sales Brochure - 2013 - 2013 (Slovenian)
Dacia - Dokker Van - Sales Brochure - 2014 - 2014 (Slovak)
Dacia - Sandero - Sales Brochure - 2016 - 2016 (Dutch) (2)
Dacia - Logan MCV Stpeway - Sales Brochure - 2017 - 2017 (2)
Dacia - Lodgy - Sales Brochure - 2012 - 2012 (Estonian)
Dacia - Dokker Stpeway - Sales Brochure - 2014 - 2014 (Czech)
Dacia - Dokker - Sales Brochure - 2014 - 2014 (Czech)
Dacia - Duster - Sales Brochure - 2017 - 2017 (Dutch)
Dacia - Dokker - Sales Brochure - 2017 - 2017 (French) (2)
Dacia - Dokker Van - Sales Brochure - 2018 - 2018 (Italian)
Dacia - Logan MCV - Sales Brochure - 2017 - 2017
Dacia - Logan MCV - Sales Brochure - 2015 - 2015
Summary of Content
REPAIR MANUAL DACIA COMMERCIAL RM 503-1 MECHANICS ENGINE: F8Q GERBOX: NG1; NG7 TAPV: U75D; U75E; U75G 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. Reproduction or translating even partially of this present document is forbidden without the written authorisation of AUTOMOBILE DACIA S.A. Ref: 6001 999 462 NOVEMBER 2004 vnx.su English version 0 General poinds vehicle 01 SPECIFICATIONS Engine - Clutch - Gearbox ........................... 01-1 Vehicle identification ................................. 01-2 02 LIFTING Mobile jack Protection routes ....................... 02-1 Elevator to be attached under the carriage body .............................................................. 02-2 03 TOWING All types ........................................................ 03-1 04 LUBRICANTS CONSUMABLES Conditions ..................................................... 04-1 05 DRAINING AND FILLING Engine ............................................................ 05-1 Gearbox ......................................................... 05-2 Rear axle differential ..................................... 05-3 07 VALUES AND SETTINGS Dimensions .................................................... 07-1 Capacity - Qualities .......................................07-10 Wheels and tires............................................ 07-11 Brakes ........................................................... 07-12 Heights under carriage body .........................07-13 Control values of the front axle angles ..........07-14 Control values of the rear axle angles ...........07-18 1 Engine and peripherics 10 ENGINE AND LOWER ENGINE UNITS Ingredients .................................................... 10-1 Idetification ................................................... 10-2 Oil consumption ............................................. 10-3 Oil pressure .................................................... 10-4 Dismounting - Remounting engine ............... 10-5 Engine fitting - unfitting ............................... 10-9 Tightening moments......................................10-10 Characteristics .............................................. 10-11 Necesary special tools .................................. 10-16 Dismounting - Remounting............................ 10-17 Lower crankcase............................................ 10-37 Oil pump........................................................ 10-38 Crankshaft sealing gasket towards distribution ................................................... 10-39 Crankshaft sealing towards flyweel............... 10-40 Engine set replacing ......................................10-41 11 UPPER AND FRONT ENGINE UNITS Distribution belt ............................................ 11-1 Cylinder head gasket..................................... 11-4 12 FUEL MIXTURE Intake manifold............................................. 12-1 Exhaust manifold .......................................... 12-2 13 PUMP SUPPLY Fuel stop in case of collision....................... 13-1 Characteristics .............................................. 13-2 Particularities................................................ 13-4 Cleanliness rules ......................................... 13-6 Elements location.......................................... 13-8 Operation ................................................... 13-10 Injection indicator operation ........................ 13-12 Anti-starting function.................................... 13-13 Idle running rotation correction.................... 13-14 Pre / Post –heating control........................... 13-15 Injectors ....................................................... 13-17 Decreased flow electric valve and stop electric valve................................................. 13-18 Increased flow electric valve and advance electric valve................................................. 13-20 Injection pump connector.............................. 13-22 Injection pump.............................................. 13-24 Injection pump pressing on........................... 13-27 Diesel oil filter.............................................. 13-29 Water temperature centralised control (G.C.T.A.)..................................................... 13-30 Acceleration potentiometer........................... 13-31 Diagnosis - Generalities................................ 13-32 Diagnosis - damages interpretation .............. 13-34 Diagnosis – Help........................................... 13-66 Diagnosis - Conformity checking................. 13-67 Breakdown localizing algorithm ................. 13-70 14 ANTIPOLLUTION Oil vapors re-aspiration................................ 14-1 Exhaust gases recycling (E.G.R.) ................. 14-2 16 STARTING AND CHARGING Alternator ..................................................... 16-1 Starter ........................................................... 16-6 19 COOLING - EXHAUST - FUEL TANK Characteristics .............................................. 19-1 Draining – Filling – Purging ........................ 19-2 Checking....................................................... 19-3 Cooling system diagram................................ 19-4 Water pump................................................... 19-5 Radiator......................................................... 19-6 Exhaust assembly.......................................... 19-7 Tank draining................................................. 19-9 Dismounting – Remounting tank................... 19-10 Fuel level transmitter..................................... 19-11 Tightening moments (da Nm)........................ 19-12 vnx.su 2 Transmission 20 CLUTCH Identification................................................. Diagnostic .................................................... Mechanism - Disk ........................................ Engine flywheel............................................ Clutch shaft bearing...................................... 20-1 20-2 20-5 20-6 20-7 21 MANUAL GEARBOX Characteristics.............................................. 21-1 Tightening moments in daNm...................... .21-2 Ingredients ................................................... 21-3 Manual gearbox : Dismounting Remounting................................................... 21-4 Repair............................................................ 21-8 Backcap......................................................... 21-37 Control shaftannular oil seal replacement.... 21-38 Speedometer endless screw pinion replacement .................................................. 21-39 Velocity step synchrontzer replacement ..... 21-40 Clutch shaft annular oil seal replacement... 21-41 Propeller shaft annular oil replacement........ 21-42 29 DRIVE SHAFTS Front cross transmission ............................... Bellows towards to the gearbox ................... Bellows towards the wheel .......................... Longitudinal transmission (cardanic) .......... 3 29-1 29-5 29-7 29-8 Chassis 30 GENERAL General principle schedule of a brake circuit in parallel with by-pass circuit .............................................. Tightening moments (daN) .......................... The dimensions of the main braking elements .......................................... Brake connections and sewerage ................. Brake fluid ................................................... Braking circuit purging ................................ Diagnostic .................................................... 30-1 30-2 30-7 30-8 30-9 30-10 30-11 31 FRONT BEARING ELEMENTS Front axle checking-adjustment ................... 31-1 Diagnostic .................................................... 31-4 Upper arm ..................................................... 31-5 Elastic bushings, upper arm ball joint .......... 31-8 Lower arm .................................................... 31-10 Elastic bushings, lower arm ball joint .......... 31-13 Brake gaskets................................................ 31-15 Brake caliper................................................. 31-17 Brake disk..................................................... 31-21 Brake caliper support ................................... 31-24 Steering knuckle............................................ 31-25 Steering knuckle bearing............................... 31-28 Characteristics of front suspension main elements ............................................... 31-30 Suspension - Tightening moments ............... 31-31 Front shock absorber .................................. 31-32 Front suspension spring .............................. 31-36 Front stabilizer rod ...................................... 31-37 33 REAR BEARING ELEMENTS Plate drive rear axle ..................................... Brake drum................................................... Brake cylinder.............................................. Brake shoes.................................................. Bearing (39 x 68 x 37)................................ Plate drive rear axle differential .................. Non drive plate rear axle ............................. Non drive pipe rear axle ............................. Shock absorber ............................................ Spring .......................................................... Rear antiroll rod .......................................... 33-1 33-4 33-6 33-8 33-10 33-11 33-20 33-22 33-24 33-25 33-26 35 WHEELS AND TYRES Characteristics ............................................. 35-1 Wheels balancing ........................................ 35-4 36 STEERING ASSEMBLY Characteristics, tightening couplers ............ 36-1 Setting the steering gear central point ......... 36-3 Noise absorber bearing ................................ 36-5 Pusher adjustment ........................................ 36-7 Adjustable steering auxiliary connecting rod ............................................ 36-12 Steering wheel shaft bushing ........................ 36-14 Steering gear shaft ....................................... 36-16 37 MECHANICAL ELEMENTS CONTROLS Brake pump.................................................. 37-1 Servobrake................................................... 37-5 Vacuum pump ............................................... 37-8 Air filter – servobrake retainer valve........... 37-9 Handbrake ................................................... 37-10 Handbrake control level .............................. 37-11 Handbrake primary and secondary cable .... 37-12 Brake limiter ............................................... 37-14 Brake pedal and clutch ................................ 37-16 Clutch cable - Clutch stroke adjustment ..... 37-17 The steering column support assy and fire wall ................................................. 37-18 Throttle pedal .............................................. 37-19 Gear box control mechanism ....................... 37-20 38 VACUUM-ELECTRIC CONTROL SYSTEM 4 X 4 COUPLING Presentation.................................................. Electric-vacuumating control adjustment .... Vacuum capsule............................................ Electric valve................................................ vnx.su 38-1 38-2 38-3 38-4 SPECIFICATIONS 01 Engine – Clutch – Gearbox VEHICLE TYPE Pick Up P Pick Up 4x4 CODE VIN D 2611* D 4616* ENGINE TYPE CAPACITY F8Q-636 1870 DRIVE CLUTCH GEARBOX (cm3) NG1-103 rear 4x4 200CPOV 3700 (50C-31) NG7-101 (51C-02) Drop Side P D 2711* NG1-103 rear F8Q-636 Drop Side 4x4 D 4716* 1870 4x4 200CPOV 3700 (50C-31) NG7-101 (51C-02) Pick Up T D 1611* front F8Q-636 1870 200CPOV 3700 Drop Side T D 1711* front F8Q-636 1870 200 CPOV 3700 Double Cab P D 2F71* rear Double Cab T Double Cab 4x4 D 1F11* D 4F76* front (NG1-104) 365-18 (NG1-104) 365-18 (NG1-103) 50C-31 F8Q-636 4x4 1870 200 CPOV 3700 (NG1-104) 365-18 (NG7-101) 51C-02 *(x or 7 or T) – this sign is showing : engine type, engine pollution norm and driving postlocation 01 - 1 vnx.su 01 SPECIFICATIONS Vehicle identification UNITL THE DATE OF 26.06.2003 Manufacturer plate VIN identification number MANUFACTURER PLATE a. Manufacturer identification code; b. Code of the vehicle; c. Gearbox type code; d. Engine type code and driving location (according to VIN code structure); e. Vehicle code; f. Trailer maximum authorized weight without braking system; g. Homologation number for the importer country; h. VIS sign; one character for year model code + 7 characters for the chassis manufacturing number; i. Maximum technical admissible weight of the loaded car; j. Maximum admissible weight with trailer with braking system; k. Maximum technical admissible weight on front axle; l. Maximum technical admissible weight on rear axle. 01 - 2 vnx.su 7 SPECIFICATIONS 01 Vehicle identification UNITL THE DATE OF 26.06.2003 VEHICLE IDENTIFICATION VIN IDENTIFICATION NUMBER Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 CODE CODE CODE CODE CODE CODE CODE CODE CODE U U U U U U U U U U U U U U U U U U 1 1 1 1 1 1 1 1 1 D D D D D D D D D 1 1 2 2 4 4 1 2 4 1 1 1 1 1 1 7 7 7 1 1 1 1 6 6 1 1 6 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * POSITION 1- 3 4 5 6 7 8 9 10 11 - 17 6 7 6 7 6 7 F F F * * * * * * * * * * * * * * * * * * * * * * * * * * * CHARACTERS EXPLANATION - manufacturer identification UU1 - AUTOMOBILE DACIA S.A. ROMÂNIA - vehicle type D - vehicle for goods transportation - engine-gearbox unit location 1 - longitudinal front engine and front drive 2 - longitudinal front engine and rear drive 4 - longitudinal front engine and four wheel drive (front drive coupling optional - carriage body type 6 - PICK UP 7 - DROP SIDE F - PICK UP, DOUBLE CAB - payload location 1 - two front seats + bed body 7 - five places : 2 front places + 3 places rear bench + bed body - gearbox type 1 - gearbox with 5 + 1 steps 6 - gearbox with 5 + 1 steps and 4x4 coupling - engine code and vehicle driving location X - motor 1870 cm3 with ignition by compression, combustibil (Diesel oil), type EURO 2, left hand drive 7 - engine 1870 cm 3 with ignition by compression, combustibil (Diesel oil), type EURO 3, left hand drive T - engine 1870 cm3 with ignition by compression, combustibil (Diesel oil), type 1504, left hand drive - year model code - 2 - 2002 - chassis manufacturing number 01 - 3 vnx.su 01 SPECIFICATIONS Vehicle identification STARTING WITH THE DATE OF 26.06.2003 MANUFACTURER’S PLATE DISPOSAL TYPE SELF-ADHESIVE Fig.2.1 01 - 4 vnx.su SPECIFICATIONS Vehicle identification 01 STARTING WITH THE DATE OF 26.06.2003 The MANUFACTURER PLATE, self-adhesive type, has the bellow presented configuration, 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’s name B. Community reception number or homologation number. C. Identification number. D. Total authorized weight of the loaded vehicle. E. Total authorized running weight F. Total weight on front axle. G. Total weight on rear axle. H. Additional inscription. I. Manufacturing date inscription J. Consignment number. 1.1Code type auto APV 1.2Manufacturing number 2.1 Equipping level code 2.2 Additional code for limited serial definition 2.3 Additional code for special serial definition 3.1 Carriage body color code 3.2 Seats upholstery code 3.3 Interior matching code. 4.1 Technical definition code 4.2 Optional equipping code. 01 - 5 vnx.su LIFTING Mobile jack – Protection routes 02 The use of a mobile jack implies the using of protection intermediary routes. It absolutely forbidden the vehicle lifting using the front or rear suspension arms as supporting points. The mobile jack is not to be used for vehicle lifting in order to perform works under the carriage body (the two columns elevator is to be used). LIFTING THE FRONT PART OF THE VEHICLE In order to lift the front of the vehicle, use the mobile jack and the protection intermediary route Cha 280 ( for protection of the body and mechanical elements) which are placed on the front longitudinal girders in the suspension arms axle. LATERAL LIFTING OF THE VEHICLE For lateral lifting of the vehicle use the mobile jack and the protection intermediary route CHA 280; place it under the threshold at the front door level. The threshold edge shall be correctly positioned in the channel of the protection intermediary route. 02 - 1 vnx.su 02 LIFTING Elevator to be attached under the carriage body For lifting, place the intermediary routes of the elevator arms in the supporting point of the vehicle inbuilt used by jack. The threshold edges shall be correctly positioned in the routes channels. FRONT REAR 02 - 2 vnx.su TOWING Alltypes 03 NEVER USE AS TOWING POINTS, THE TRANSMISSION AXLES (PLANETARY SHAFTS). The towing points, front (1) or rear (2) are to be used only for vehicles hauling on wheels, by towing. These points cannot be anyhow used for drawing out the damaged vehicle from a trench (hole), or for direct or indirect vehicle lifting on a transport platform. FRONT (right) REAR (left) 2 1 03 - 1 vnx.su LUBRICANTS CONSUMABLES Condition PRODUCT 04 PLACE WHERE IT IS USED LUBRICATION (GREASING ) Grease UM 170 Li Ca Pb 2M ELF CARDREXA RNT2 or UM 185 Li 2M Grease UM 185 Li 2M Grease U 95 Ca 2 Grease Li Ca Pb tip II cu MoS2 (or 20 UM Li III) Grease 22 Grease U100 Ca 4-5 Front transmission pinion grooves Gear box control shaft Cardan flange annular oil seal Planetary transmissions Front wheel steering knuckle grooves Cardan transmission Planetary transmission Front wheel bearing Suspension ball joints Rear axle differential Wheels bolts Pressure bearing guide Steering box (gear-rack, bearings) Clutch shaft grooves Pressure bearing Clutch mechanism diaphragm Steering box rubber gaskets Auxiliary steering connecting rod 04 - 1 vnx.su LUBRICANTS CONSUMABLES Condition 04 PRODUCT RHODORSEAL 5661 LOCTITE 518 PLACE WHERE IT IS USED SEALING Camshaft bearing cap no.1 and 5 Crankshaft no.1 bearing cap Planetary transmission pins Gearbox half crankcase Clutch casing Rear axle KIT DURCISSEUR Crankshaft no.1 bearing cap LOCTITE 577 Rear driving contact thread Plug M 16- gearbox Rear axle Sealant material 503 ( mastic) Rear axle differential SOLDERING LOCTITE FRENETANCH Flywheel attachment screws CLEANING DECAPJOINT Cylinder head gasket surface 04 - 2 vnx.su DRAINING AND FILLING Engine ENGINE Necessary special tools - wrench for draining plug : MOT 1018 Draining : plug (2) Filling : plug (1) 1 2 05 - 1 vnx.su 05 05 DRAINING AND FILLING Gearbox GEARBOX Drain : plug (2) Fill : plug (1) 05 - 2 vnx.su DRAINING AND FILLING Rear axle differential REAR AXLE DIFFERENTIAL Draining: plug (2) Filling: plug (1) 05 - 3 vnx.su 05 VALUES AND SETTINGS 07 Dimensions DIMENSIONS DACIA Pick Up P, 4x4 and T 1334 k DACIA Pick Up P, 4x4 end T DIMENSIONS (mm) Total length Total width Total height: - Empty - Loaded Axle base Front wheel track width Rear wheel track width Ground clearance(k): - Loaded Turn radius: - Between footways - Between walls 07 - 1 vnx.su 4674 1636 1550 2675 1334 1320 >140 5600 5800 07 VALUES AND SETTINGS Dimensions WEIGHTS DACIA Pick Up P, 4x4 and T VEHICLES WEIGHTS VEHICLE DENOMINATION DRIVE VIN CODE DACIA DACIA Pick Up P Pick Up 4x4 REAR INTEGRAL D 2611* D4616* DACIA Pick Up T FRONT D 1611* 1. Unloaded vehicle weight ( with 75 Kg. driver): - on the front axle, - on the rear axle, - total. 635 520 1155 645 530 1175 645 480 1125 2. Deadweight (unloaded vehicle weight): - on the front axle, - on the rear axle, - total. 590 490 1080 600 500 1100 600 450 1050 3. Technical admissible maximal weight of the loaded vehicle: - on the front axle, - on the rear axle, - total. 720 1510 2230 740 1510 2250 640 1260 1900 4. Technical admissible maximal weight on each axle: - on the front axle, - on the rear axle. 760 1550 760 1550 760 1300 5. Payload: - on seats, - on bed body, - total. 150 1000 1150 150 1000 1150 150 700 850 07 - 2 vnx.su VALUES AND SETTINGS 07 Dimensions TOWING WEIGHTS DACIA Pick Up P, 4x4 and T TOWING WEIGHTS VEHICLE DACIA DACIA DENOMINATION Pick Up P Pick Up 4x4 DACIA Pick Up T FRONT D 1611* DRIVE VIN CODE 1. Technical admissible maximal weight for towing (trailer with braking system) REAR INTEGRAL D 2611* D 4616* 1095 1075 0 2. Admissible maximalweight of the assembly 3225** 3225** not applicable 3. The vehicle is capable / is not capable for trailer towing capable capable not capable 4. Towing maximal weight without braking system. 450* 450* 0 5. Technical admissible maximal weight on towing coupling point 50 50 - ** By reducing the bed payload with 100 Kg. 07 - 3 vnx.su 07 VALUES AND SETTINGS Dimensions DIMENSIONS DACIA Drop Side P, 4x4 and T 1334 4599 k DACIA Drop Side P, T ºi 4x4 DIMENSIONS (mm) Total length Total width Total height: - Empty - Loaded Axle base Front wheel track width Rear wheel track width Ground clearance (k): - Loaded Turn radius: - Between footways - Between walls 07 - 4 vnx.su 4599 1636 1550 2675 1334 1320 > 140 5600 5800 VALUES AND SETTINGS 07 Dimensions WEIGHTS DACIA Drop Side P, 4x4 and T VEHICLES WEIGHTS VEHICLE DENOMINATION DACIA DACIA DACIA Drop Side P Drop Side 4x4 Drop Side T REAR D 2711* INTEGRAL D 4716* FRONT D 1711* 1. Unloaded vehicle weight (with 75 Kg. driver): - on the front axle, - on the rear axle, - total. 635 555 1190 645 565 1210 645 510 1155 2. Deadweight (unloaded vehicle weight): - on the front axle, - on the rear axle, - total. 590 525 1115 600 535 1135 600 480 1080 3. Technical admissible maximal weight of the loaded vehicle: - on the front axle, - on the rear axle, - total. 690 1540 2230 690 1540 2230 690 1240 1930 4. Technical admissible maximal weight on each axle: - on the front axle, - on the rear axle. 760 1550 760 1550 760 1300 5. Payload: - on seats, - on bed body, - total. 150 965 1115 150 945 1095 150 150 700 DRIVE VIN CODE 07 - 5 vnx.su VALUES AND SETTINGS 07 Dimensions TOWING WEIGHTS DACIA Drop Side P, 4x4 and T TOWING WEIGHTS VEHICLE DENOMINATION DACIA DACIA DACIA Drop Side P Drop Side 4x4 Drop SideT REAR D 2711* INTEGRAL D 4716* FRONT D 1711* 1. Technical admissible maximal weight for towing (trailer with braking system) 1060 1040 0 2. Admissible maximalweight of the assembly 3225** 3225** not applicable 3. The vehicle is capable / is not capable for trailer towing capable capable not capable 4. Towing maximal weight without braking system 450* 450* 0 5. Technical admissible maximal weight on towing coupling point 50 50 - DRIVE VIN CODE ** By reducing the bed payload with 100 Kg. 07 - 6 vnx.su VALUES AND SETTINGS 07 Dimensions DIMENSIONS DACIA Double Cab P, 4x4 and T 1334 k DACIA Double Cab P, 4x4 ºi T DIMENSIONS (mm) Total length Total width Total height: - Empty - Loaded Axle base Front wheel track width Rear wheel track width Ground clearance (k): - Loaded Turn radius: - Between footways - Between walls 07 - 7 vnx.su 4794 1636 1525 2795 1334/1312 1320 >140 5600 5800 07 VALUES AND SETTINGS Dimensions WEIGHTS DACIA Double Cab P, 4x4 and T VEHICLES WEIGHTS VEHICLE DACIA DACIA DACIA DENOMINATION Double Cab P Double Cab 4x4 Double Cab T DRIVE VIN CODE REAR D 2F71* INTEGRAL D 4F76* 1. Unloaded vehicle weight (with 75 Kg. driver): - on the front axle, - on the rear axle, - total. 680 570 1250 690 580 1270 690 530 1120 2. Deadweight (unloaded vehicle weight): - on the front axle, - on the rear axle, - total. 635 540 1175 645 550 1195 645 500 1145 3. Technical admissible maximal weight of the loaded vehicle: - on the front axle, - on the rear axle, - total. 710 1520 2230 730 1520 2250 710 1260 1970 4. Technical admissible maximal weight on each axle: - on the front axle, - on the rear axle. 820 1550 820 1550 820 1300 5. Payload: - on seats, - on bed body, - total. 375 680 1055 375 680 1055 375 450 825 07 - 8 vnx.su FRONT D 1F71* VALUES AND SETTINGS 07 Dimensions TOWING WEIGHTS DACIA Double Cab P, 4x4 and T TOWING WEIGHTS VEHICLE DACIA DACIA DACIA DENOMINATION Double Cab P Double Cab 4x4 Double Cab T DRIVE VIN CODE REAR D 2F71* INTEGRAL D 4F76* FRONT D 1F71* 1095 1075 0 3225** not applicable 1. Technical admissible maximal weight for towing (trailer with braking system) 2. Admissible maximal weight of the assembly 3225** 3. The vehicle is capable / is not capable for trailer towing capable capable not applicable 4. Towing maximal weight without braking system 450** 450** 0 5. Technical admissible maximal weight on towing coupling point 50 50 - ** By reducing the bed payload with 100 Kg. 07 - 9 vnx.su VALUES AND SETTINGS 07 Capacity - Qualities DENOMINATION QUALITY CAPACITY (liters) Engine oil Dacia Oil Diesel SAE API 10W40 ACEA B3 CF 4,6* Gearbox oil DACIA OIL SAE 80 W 90/GL5 2,3 SUPERGEAR The rear axle group oil DACIA SAE 80 W 90 / GL5 OIL SUPERGEAR 2 Brake fluid SAE J 1703 DOT 4 0,450 Cooling fluid ** Type D - GLACEOL RX 6 * To be ajusted at dipstick ** Mixture : 50% concentrated anti-freeze + 50% distilled water. 07 - 10 vnx.su VALUES AND SETTINGS 07 Wheels and tires VEHICLE TYPE DACIA Pick Up T, P ºi 4x4 DACIA Drop SideT, P ºi 4x4 DACIA Double Cab T, P ºi 4x4 RIMS TIRES ROLLING CIRCUMFERENCE PRESSURE (bari) (1) (mm) 5 J 14 175 R 14 PR 8 1920 ± 25 FRONT REAR 2,0 4,5 (1) Using maximum loading, wheels on ground. • Tightening moment of the wheels screws: 9 daNm. • Rim axial run out: maxim 1,2 mm. • Rim radial run out: maxim 1,2 mm. ATTENTION! The increase of tire temperature during running implies a growth of the tire pressure with 0.2 – 0.3 bars compared with the prescribed values. In case of checking the tires pressure immediately after vehicle driving, consider this growth of pressure. 07 - 11 vnx.su VALUES AND SETTINGS 07 Brakes FRONT BRAKES Brake caliper bore diameter (for aerated brake disk) Φ 54 mm Disk thickness aerated 20 mm Minimal disk thickness aerated 19 mm Brake pad thickness ( the support included) 14 mm Minimal brake pad thickness (the support included) 7 mm Disk axial run out, measured at → 215 mm 0,1 mm REAR BRAKES Wheel braking cylinder diameter Φ 25,4 mm New drum diamete Φ 254 mm Maximum drum diameter after grinding Φ 255 mm Braking lining width 50 mm Braking lining thickness 5 mm Minimal accepted braking lining height above rivets 0,5 mm MAIN BRAKE CYLINDER Tandem master cylinder with ICP by pass included Type of main brake cylinder nner diameter Φ 22,2 mm Stroke - primary piston - secondary piston min. 19 mm min. 13 mm • Brake fluid reservoir - double without level warning. • Pressure reducing valve - for parallel circuit. • Brake fluid - norm SAE J 1703 DOT4. • Servobrake - master vac 8" 07 - 12 vnx.su 224 mm VALUES AND SETTINGS Heights under carriage body 07 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 distance measured from the longitudinal girder 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. C – this value is showing the position where the rack must reach in order to obtain the middle point for the steering rack. 07 - 13 vnx.su VALUES AND SETTINGS 07 Control values of front the axle angles COMMERCIAL U 75 DRIVE (1304, 1307) ANGLES VALUES POSITION OF THE VEHICLE CASTER CAMBER BALL JOINT 1 0 11' 10 28' ± 30' 1045' 0 2 02' 20 19' 2036' 2052' Maximum Left / Right difference = 10 10 22' 1021' 10 20' 10 18' ± 30' 10 17' 10 15' 10 14' Maximum Left / Right difference = 10 8 0 01' 80 02' 80 03' 80 04' ±30' 80 05' 80 07' 80 08' Maximum Left / Right difference = 10 ADJUSTMENTS 1307 1304 H5 H5 H5 H5 H5 H5 H5 - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = 260 250 240 230 220 210 200 H5 H5 H5 H5 H5 H5 H5 - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = H1 H1 H1 H1 H1 H1 H1 - H2 = 66 - H2 = 62 - H2 = 58 - H2 = 54 - H2 = 51 - H2 = 47 - H2 = 43 H1 H1 H1 H1 H1 H1 H1 - H2 = 66 - H2 = 62 - H2 = 58 - H2 = 54 - H2 = 51 Not adjustable - H2 = 47 - H2 = 43 H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = 66 62 58 54 51 47 43 H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = H1 - H2 = 265 255 A djustable by 245 modification of 235 the tie-rod 225 length from 215 previous 205 mounting 66 62 58 54 51 Not adjustable 47 43 TOTAL PARALLELISM Opening (toe-in) 0010’ ± 10’ (for one wheel 0005’ ± 05”) Empty Empty Adjustable by means of the tie rods rotation ELASTIC JOINTS BLO CKING - Empty Empty - 07 - 11 vnx.su VALUES AND SETTINGS 07 Control values of the front 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.su ADJUSTMENTS 1307 By means of eccentrics By means ofhet steering whee l rotation VALUES AND SETTINGS 07 Control values of the front 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 modi245 fication of the tie-rod 235 length from previous mounting 22 215 205 1 0 11' 10 29' ± 30' 1046' 0 2 02' 20 19' 2036' 2053' Maximum Left / Right difference = 10 H5 H5 H5 H5 H5 H5 H5 - H2 = 260 - H2 = 250 - H2 = 240 - H2 = 230 - H2 = 220 - H2 = 210 - H2 = 200 1 0 21' 10 20' 10 19' 10 18' ± 30' 10 16' 10 15' 10 13' Maximum Left / Right difference = 10 8 0 01' 80 02' 80 03' 80 04' ±30' 80 05' 80 07' 80 08' Maximum Left / Right difference = 10 H1 H1 H1 H1 H1 H1 H1 - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = 66 62 58 54 51 47 43 H1 H1 H1 H1 H1 H1 H1 - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = 66 62 58 54 51 47 43 H1 H1 H1 H1 H1 H1 H1 - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = 66 62 58 54 51 47 43 H1 H1 H1 H1 H1 H1 H1 - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = - H2 = 66 62 58 54 51 47 43 TOTAL PARALLELISM Opening (toe-in) -00 160 ± 100 (for one wheel -0008’± 05’) Empty ADJUSTMENTS Not adjustable Not adjustable Empty Adjustable by means of the tie rods rotation Empty - ELASTIC JOINTS BLOCKING - vnx.su VALUES AND SETTINGS 07 Control values of the front 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.su ADJUSTMENTS 1307 By means of eccentrics By means ofhet steering whee l rotation VALUES AND SETTINGS 07 Control values of the rear axle angles 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 00 ± 34'30'' ELASTIC JOINTS BLOCKING Not adjustable Empty Empty - - 07 - 15 vnx.su VALUES AND SETTINGS 07 Control values of the rear axle angles 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 adjust the front axle angles values, respectively the rear axle ones, the following must be done: - perform the tires checking concerning: - dimensions - inflating pressure - degree of wear - perform the joints checking: - elastic joints condition - ball joint clearance - wheel bearing clearance The vehicle must be obligatory: - positioned with the wheels on bench rotating plates being in horizontal direction - braked ensured - suspension tested, for vehicle setting at its free height - steering brought at central point and steering rack blocked in this position. These operations are to be followed by optical device attachment on vehicle, observing the prescriptions of the steering measurement bench manufacturer. 07 - 16 vnx.su ENGINE AND LOWER ENGINE UNITS Ingredients TYPE 10 UTILIZATION RHODORSEAL 5661 Front transmission pins, bearing covers (1) and camshaft (5), bearing cover No. (1) and crankshaft OIL 10W40 ACEA B3 API CF Parts lubrication during mounting LOCTITE FRENETANCH Engine flywheel placing area on crankshaft DÉCAPJOINT Cleaning of the cylinder head gasket plane KIT DURCISSEUR Sealing of the bearing cover No.(1) crankshaft Engine oil capacity: 4.6 liter (with filter) Used engine oil quality: Dacia Oil Diesel 10W40 API CF, ACEA B3 10 - 1 vnx.su ENGINE AND LOWER ENGINE UNITS 10 Identification Vehicle Type Cod VIN Type Pick Up P Drop Side P Engine Gearbox (cm3) D 2611X(7;T)* D 2711X(7;T) Bore (mm) Stroke (mm) Volume ratio 80 93 21,5 NG 1-103 (50C-31) D 4616X(7;T) Pick Up 4x4 Drop Side 4x4 D 4716X(7;T) NG7-101 (51C-02) Pick Up T Drop Side T D 1611X(7;T) D 1711X(7;T) Double Cab P D 2F71X(7;T) NG 1-103 (50C-31) Double Cab 4x4 D 4F76X(7;T) NG 7-101 (51C-02) D 1F71X(7;T) NG 1-104 (365-18) Double Cab T Cylinder capacity F8Q-636 NG 1-104 (365-18) 1870 * X (7;T) - According to the pollution norm “X” - Euro 96; “7” - Euro 2000; “T” - 1504. The engine identification is performed by means of a metallic plate, which is stuck on the engine block. A B D E 000 0 0 00 0 000000 G F A – engine type B – engine homologation letter D – “RENAULT” identity code E – engine index F – engine fabrication series G – code for assembling factory 10 - 2 vnx.su ENGINE AND LOWER ENGINE UNITS Oil consumption 10 OIL CONSUMPTION MEASURING a) Oil filling at maximal level This operation is to be performed when the engine is warm (an engine fan rotation) and after a stabilization of 15 minutes, necessary to the oil complete draining into the lower crankshaft. Check the oil at the oil-indicating rod. Fill to the maximal level. Seal the draining and filling taps (mark them with paint, for further checking if these have not been dismounted b) Customer driving time Ask the customer to drive for about 2000 km or until the oil reaches the minimal level. c) Refilling to the maximal level This operation is to be performed when the engine is warm (an engine fan rotation) and after a stabilization of 15 minutes. Check the oil at the oil-indicating rod. Fill to the maximal level. Write down the oil quantity and the driven mileage after filling to the maximal level. d) Oil consumption measuring Oil filled quantity (liter) OIL CONSUMPTION = kilometers (thousand) 10 - 3 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Oil pressure Necessary Special Tools MOT 836 - 05 Oil pressure measuring kit CHECKING The oil pressure is to be checked when the engine is warm (about 80°C). The pressure value should be: 1.2 bars at 1000 rpm 3.5 bars at 3000 rpm 10 - 4 vnx.su ENGINE AND LOWER ENGINE UNITS 10 Dismounting - Remounting engine Necessary Special Tools MOT 1202 - 01 MOT 1311 - 06 Pliers for elastic clips Connections dismounting device Pliers for clips type “CLIC” TIGHTENING MOMENTS (daNm) Engine supports attachment screws Engine elastic supports nuts Gearbox attachment on engine: - upper attachment screws - nuts - lower attachment screws RPM sensor Starter attachment 3.6 2.7 1 a 4.4 4.4 2.1 0.8 4.4 b The vehicle engine is to be dismounted through the engine compartment upper part by means of a mobile lifting device. DISMOUNTING -the oil pressure transmitterconnector (2); -the pre-heating spark plugs cables (3); -the alternator electric connections(4); The vehicle is to be placed on a 2– columns elevator. The battery is to be dismounted. The followings are to be drained: - the cooling circuit, through water pump inlet pipe and radiator lower hose: - the engine oil. The followings are to be dismounted: - the air filter inlet sleeve; - the radiator. 3 1 Disconnect: -the mass wire from the engine lifting clamp; -the injection pump connector (1); lift the flap (a) by means of a screw driver and take out the connector in the direction of arrow (b); 4 2 -the diesel filter connector; - the water temperature sensor connector (5); pull theconnector in the direction ofthe arrow (n) in the same time with clips pushing (m). 10 - 5 vnx.su ENGINE AND LOWER ENGINE UNITS 10 Dismounting - Remounting engine m 5 6 n 5 7 m Dismount the supply connections (A) and fuel return (B). - the temperature sensor connector(6); - the EGR connector (7) : push the valve . in the direction of the arrow (x) and pull the connector in the direction of the arrow (y); y x 7 Remove from clips the fuel ducts from the air filter casing and from the distribution crankcase. Dismount the air filter casing. - The RPM sensor connector. The wiring attachment clip on the clutch crankase is to be dismounted. 10 - 6 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting engine 10 Dismount the RPM sensor from the clutch crankcase of the gearbox Dismount the upper attachment screws of the gearbox on the engine. Disconnect : - the hoses (1) from the expansion vessel; Dismount the side attachment nuts of the - the servobrake connection (2); gearbox on the engine. - the connection (3) of the vacuum tank Lift the vehicle by means of the elevator (4 X 4 vehicles); Dismount the engine shield. - the climate control hoses from the Dismount the lower attachment screws of thermostat box by means of the pliers the gearbox on the engine. MOT 1202-01. 2 3 1 Dismount the starter (see chapter 16 “ Starter “). Dismount the attachment nuts of the descent tube on the exhaust manifold. Dismount the attachment clamp of the descent tube on the engine. Dismount the elastic supports nuts of the engine. 10 - 7 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting engine REMOUNTING Perform the dismounting operations in the reverse order. Perform the cooling circuit filling and purging (see chapter 19 “ Filling and purging “). Perform the engine oil filling Sustain the gearbox by means of a jack. Fix the lifting device on the engine lifting supports. Move forward the engine and lift it. Place the engine on a support. 10 - 8 vnx.su ENGINE AND LOWER ENGINE UNITS Engine fitting - unfitting 10 For thereplacement of the standard engine, the following operations are tobe performed: DISMOUNTING The followings are to be dismounted: - the air filter; - the alternator, the belt and its tightening device; - the alternator support; - the oil rod and its guide; - the clutch disk and mechanism; - the engine flywheel; - the high pressure pipes; - the injection pump gear; - the injection pump, the injectors and the port-injectors; - the vacuum pump; - the water pump pipe; - the water pump; - the pre-heating sparking plugs; - the E.G.R. assembly; - the intake and exhaust collectors; - the distribution crankshafts; - the oil filter; - the thermostat box; - the camshaft gear; - the crankshaft gear and pulley; - the distribution belt tightening roller; - the oil mono-contact. REMOUNTING The worn or damaged parts are to be replaced. Perform the dismounting operations in the reverse order. The attachment screws and nuts are to be tightened according to the required moment. 10 - 9 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Tightening moments TIGHTENING MOMENTS (daNm) Alternator attachment screws - M 10 ……………………………………………………………...……… 3.8 - M 8 ………………………………………………………………………. 1.9 Injectors supply pipes (high pressure) ……………………………….......… 2.5 Injection pipe attachment…………………………………………………… 2.5 Injection pump pulley nut ………………………………………….......…… 5.5 Intake – exhaust manifold fixing ………………………………………..…. 2.7 Air filter attachment ……………………………………………………....… 0.8 Port – injectors ………………………………………………………….....… 7 Incandescent sparking plugs ………………………………………………1.5 ÷ 2 E.G.R. attachment ……………………………………………….......……… 0.8 Gases tube attachment on exhaust manifold …………………….............…1.9 Water pump pipe attachment ………………………………………….....… 3.8 Camshaft gear screw …………………………………………………...…… 5 Cylinder head cover nuts……………………………………………….....… 1.2 Camshaft bearing covers screws……………………………………….…… 2 Engine flywheel screws……………………………………………………. 5 ÷ 5.5 Lower crankcase screws……………………………………………….… 1.2 ÷ 1.5 Connection rods covers screws…………………………………………… 4.5 ÷ 5 Bearing covers screws……………………………………………………...... 6.5 Crankshaft pulley screw…………………………………………..... 2 + 115° ± 15° Water pump attachment screws………………………………….................. 1.6 Water pump pulley screws…………………………………………………... 2 Oil pump attachment screws……………………………………….............. 2 ÷ 2.5 Distribution belt tensioning nut…………………………………………….. 5 Starter attachment screws …………………………………………….......... 4.4 Clutch mechanisme attachment screws …………………………………… 5 10 - 10 vnx.su ENGINE AND LOWER ENGINE UNITS Characteristics CYLINDER HEAD The cylinder head is aluminum made and it is provided with turbulence chambers. Cylinder head height = 159.5 ± 0.2 mm. The cylinder head is not to be rectified. The maximal deformation of the gasket plane is 0.05 mm. Cylinder head moments will by respected the discribed method (see chapter 10 “Dismounting - Remounting”). 10 E = 1.4 mm. B. A one-hole gasket is to be used for an over-height within 0.613 mm (inclusive) and 0.767 mm (exclusive). E = 1.5 mm. C. A three-holes gasket is to be used for an over-height higher than 0.767 mm E = 1.6 mm. TURBULENCE CHAMBERS - over-height compared with the cylinder head: y = 0.01 ÷ 0.04 mm; - cylinder head slot diameter (d): d = 37.5 mm - channel angle compared with the cylinder head (á): á = 35° CYLINDER HEAD GASKET The cylinder head gasket (E) thicknessvaries according to the pistons maximal overheight, as follows: A. A two-holes gasket is to be used for an over-height lower than 0.613 mm 10 - 11 vnx.su NOTICE: The necessary holes for the gasket thickness identification are placed in a 25-mm˝ area as against its edge. Any other hole is not to be taken into consideration, in case it is placed out of the above-mentioned area. The gasket thickness identification mark (R) may be seen even with the cylinder head mounted. 10 ENGINE AND LOWER ENGINE UNITS Characteristics The cylinder head gasket thickness is to be obligatory recalculated according to the pistons over-height in case one of the following elements is replaced: - crankshaft, - cylinders crankcase, - connecting rods - pistons. Otherwise the cylinder head gasket is to be replaced with a same thickness one. VALVES SEATS Sealing face angle (á): - intake - exhaust 120° 90° Sealing face width (X): 1.8 mm External diameter (D): - intake - exhaust 36.8 mm 32.6 mm VALVES Valve rod diameter 8 mm Sealing face angle: - intake - exhaust 120° 90° Tray diameter: - intake - exhaust 35.2 ± 0.1 mm 31.5 ± 0.1 mm 10 - 12 vnx.su ENGINE AND LOWER ENGINE UNITS 10 Characteristics VALVES GUIDES VALVES SPRINGS The valves guides are identical for both intake and exhaust. They are provided with oil-rings for sealing the valves rods. The valves springs are identical for both intake and exhaust. Internal diameter External diameter - nominal - repair (marked with 2 channels) Guides position as against the gasket plane (A) Cylinder head bore for guide - nominal - repair Length in free state 47.2 mm Length under a load of: - 23 ± 2 daNm - 70.5 ± 3.5 daNm 37.9 mm 27.4 mm Length of the stuck coils 25.77 mm Coil diameter 4 mm Internal diameter 21.5 mm 8 mm 13 mm 13.30 mm 43.25 mm 12.9 mm 13.20 mm CAMSHAFT The engine is provided with a camshaft having the cams on its head, mounted in the cylinder head and driven by the distribution belt . The camshaft cams operate the valves by tappets Replacing the tappets, only with cold engine, regulates the thermal clearance. Thermal clearance values: - intake: 0.20 ± 0.05 mm, - exhaust: 0.40 ± 0.05 mm. A Axial clearance (mm) 0,05 ÷ 0,13 Number of bearings 5 ADA ÎÎA ADE ÎÎE Distribution diagram 10 - 13 vnx.su - 2° 45° 45° - 4° 10 ENGINE AND LOWER ENGINE UNITS Characteristics TAPPETS The tappet with conform thickness (y) is to be chosen for getting the thermal clearance. BOLTS The bolts are freely mounted in the connecting rod and piston. They are axially kept by means of a security device. Length (mm) 63 Internal diameter (mm) 13.3 External diameter (mm) 24 RINGS As spare parts, there are 24 classes of tappets, with thickness (y) within 7.550 and 8.150 mm. The thickness increases every 0.025 mm. Tappets external diameter: 35 -0,01 -0,04 mm. PISTONS As spare part , there is only one class (M). The piston is to be mounted: with the turbulence chamber towards the oil filter. The pistons diameter (D) is to be measured at a distance A = 60 mm from the piston head. D = 80 mm. Thickness (mm) - Compression ring - Sealing ring - Oiling ring 2 2 3 The rings are to be mounted with the mark “TOP” towards the piston head and the grooves separated at 120°. Top 10 - 14 vnx.su ENGINE AND LOWER ENGINE UNITS Characteristics 10 CONNECTING RODS OIL PUMP Connecting rod side clearance: 0.22 ÷ 0.40 mm. The connecting rod end is bushed. The bushes are not to be replaced. The oil pump is with gear wheels type, driven by means of a chain by the crankshaft. Oil minimal pressure at 80°C (bars): - at 1000 rpm……………………1.2 - at 3000 rpm……………………3.5 Pistons coolers valves opening pressure: 2.2 ± 0.2 bars. The followings are to be checked: - Clearance A (mm): - minimum 0.100 - maximum 0.240 NOTICE: The connecting rods and their covers are not to be marked by means of punches, but by permanent markers. CRANKSHAFT Number of bearings Bearings nominal diameter (mm) 5 54.795 ± 0.01 Pressure gauges nominal diameter (mm) 48 ÷ 0.02 / ÷ 0 Axial clearance (mm) 0.07 ÷ 0.23 Axial half-bearings thickness (mm) 2.30; 2.35; 2.40; 2.45 - Clearance B (mm): - minimum 0.020 - maximum 0.085 10 - 15 vnx.su 10 SERVICE CODE ENGINE AND LOWER ENGINE UNITS Necesary special tools DENOMINATION MOT 251-01 Comparing support MOT 252-01 Plate for over-height pistons measurement MOT 582 Flywheel immobilizing sector MOT 799-01 Camshaft gear immobilizing device MOT 988-02 Camshaft sealing mounting device MOT 990-03 Crankshaft sealing mounting device towards distribution MOT 991-01 Crankshaft sealing mounting device towards flywheel MOT 997-01 Port – injectors mounting – dismounting device MOT 1054 Rod for engine pressing-on. MOT 1200-01 Injection pump pulley maintaining device MOT 1520 Injection pump blocking rod E.P.I.C. MOT 1522 Injection pump blocking pulley E.P.I.C. MOT 1525 Injection pump pulley extractor MOT 1485-01 Pistons coolers dismounting device MOT 1516-01 Pistons coolers mounting device (used with MOT 1516) MOT 1492 Connecting rods bearings device MOT 1493 Bearings mounting device MOT 1505 Belts tension measurement device MOT 1202-01 Pliersforelastic clips MOT 1516 Mounting device for pistons coolers MOT 1566 Wrench for mounting/dismounting high-pressure ducts 10 - 16 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting CYLINDER HEAD 10 - 17 vnx.su 10 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting DISMOUNTING - drain the oil from the engine. - drain the cooling fluid. The followings are to be dismounted: - the air filter, - the oil vapors recycling system hoses, - the alternator belt and its tensioning device, - the alternator, - the distribution crankcases, - the distribution belt (see Chapter 11 “Distribution Belt”). The followings are to be dismounted: - the injectors supplying pipes, - the incandescent sparking plugs supplying wires, - the injection pump (see Chapter 13 “Injection Pump”), - the depression hose off the vacuum pump, - the intake and exhaust manifold, - the camshaft gear, - the cylinder head cover. The cylinder head attachment screws are to be unscrewed. The cylinder head is to be dismounted without rotate it (the cylinder head is centered by means of two bushes (C)). 10 - 18 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting 10 - the incandescent sparking plugs, - the turbulence chambers, - the thermostat support. The camshaft bearing covers are to be dismounted (the covers order and direction are to be marked prior their dismounting). 5 4 3 2 1 The following are to be dismounted: - the valves springs, - the valves, - the valves oil sealing rings. In order to get a right tightening of the cylinder head screws, the oil that may be in the cylinder head fixing holes is to be extracted by means of a syringe. The followings are to be dismounted: - the camshaft, - the tappets (they are to be marked as against the cylinder head), - the injectors, by means of the MOT 997-01 device, WARNING! Avoid foreign materials introduction into the oil grooves, otherwise the latter will clog, and the camshaft will quickly breakdown. It is very important not to scratch the gasket seating face. The DECAPJOINT is to be used for cleaning the gasket possible stuck bits. Spread out the substance on the area to be cleaned, wait for about 10 minutes, and clean with a wooden spatula. MOT 997-01 During this operation, wear protection gloves. 10 - 19 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The cylinder head flatness is checked by means of a ruler and a kit of gauges. Maximalpermitted deformation: 0.05 mm. The cylinder head is not to be rectified. The valves are to be run-in on their seats. The valves are to be marked as against the cylinder head. The parts are to be oiled with engine oil. The followings are to be mounted in order: - the valves oil-sealing rings (1), by means of a 12 mm tubular wrench, - the valves (2), - the lower hoods (3), - the valve springs (4), (are identical for both intake and exhaust), - the upper hoods (5), the half-cones (6). REMOUNTING The new valves are to be placed on position; the valves return as against the gasket plane is to be checked by means of the MOT 251-01 and MOT 252-01 devices, as follows: - intake: 0.85 ± 0.09 mm - exhaust: 0.97 ± 0.09 mm 4 1 3 2 MOT 251-01 MOT 252-01 10 - 20 vnx.su 5 6 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The turbulence chambers (7) are to be mounted. The port-injectors are to be mounted and tightened at a moment of (6.5 ÷ 7.5 daNm) The thermostat support is to be mounted. MOT 252-01 MOT 251-01 7 Their over-height is to be checked by means of the devices MOT 251-01 and MOT 252-01: x = 0.01 ÷ 0.04 mm The incandescent sparking plugs are to be mounted and tightened at a moment of 1.5 ÷ 2 daNm The anti-flame washers (9) are to be mounted observing their orientation. The anti-flame washers (9) and the gaskets are to be replaced every time the port-injectors are to be dismounted. 9 10 2 10 - 21 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting THERMAL CLEARANCE ADJUSTMENT The comparing gauge is to be set on “zero”. This operation is to be performed only when the engine is cold. The method “In balance” is used when checking the valves clearance (the cylinder valves at the end of the exhaust and the beginning of the intake). MOT 252-01 Cylinder valves in balance 1 3 4 2 The comparing feeler is to be lifted (not to modify the assembly position). The tappet is to be introduced and the value (y) is to be measured. Cylinder valves to be checked 4 2 1 3 The measured values are to be compared with the reference ones: - intake: 0.20 mm - exhaust: 0.40 mm In case the clearance (x) is not according to the requirements, the respective tappet is to be replaced with one having the adequate thickness (y). The value (y) squares with the tappet class (there are 24 classes). The value (y) is to be measured by a MOT 252-01 plate, a magnetic plate support, and a comparing gauge with a precision of 0.001 mm. The value (y) varies every 0.025 mm, from 7.550 to 8.150. 10 - 22 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting 10 The following are to be mounted: - the camshaft, - the camshaft bearings covers, observing the marking performed during the dismounting. A thin layer of RHODORSEAL 5661 is to be applied on the bearings covers (1) and (5), according to the drawing indications. 3 2 - the camshaft-sealing gasket, by means of the MOT 988-02 device. 5 1 The pistons are to be positioned so that neither of them is on its upper dead point, in order to avoid the contact with the valves, during the camshaft covers tightening (the blocking mark on the crankshaft is to be horizontallypositioned). The camshaft bearings covers screws are to be progressively tightened at a required moment of (2 daNm). The camshaft axial clearance is to be checked; the clearance should be within 0.05 and 0.13 mm The followings are to be mounted: - the vacuum pump (2) and its gasket (3), MOT 1505 MOT 988-02 10 - 23 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting - the camshaft gear – its screw (4) is to be tightened at a required moment of 5 daNm. - the injection pump support – its screws are to be tightened at a required moment of (2.5 daNm), 4 - the injection pump – the screws are to be progressively screwed by hand and then tightened at 2.5 daNm (see Chapter 13 “Injection Pump”), - the cylinder head cover, - the injectors pipes, the injection pump gear – it is to be immobilized by means of the MOT 1200-01 device and its nut is to be tightened at 5.5 daNm. MOT 1200-01 10 - 24 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting CYLINDERS CRANKCASE 10 - 25 vnx.su 10 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting CYLINDERS CRANKCASE DISMOUNTING - the water pump, The following are to be dismounted: - the clutch, - the engine flywheel (it is immobilized by means of the MOT 582), - the lower crankcase, - the crankshaft gear, - the distribution belt lower protection plate, - the distribution with oil-sealing ring crankcase, - the oil pump (the two attachment screws are to be unscrewed and the pump is to be turned over). 1 - the crankshaft sealing gasket support, Mark the connecting rod covers compared with the connecting rod body. 10 - 26 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The following are to be dismounted: - the connecting rod covers and bearings, - the pistons – connecting rod assembly (the pistons are to be marked as against the cylinders - No.1 towards the flywheel), - the bearings covers and bearings, - the bearing No.1 oil-sealing ring, - the crankshaft and the bearing for axial clearance adjustment - the bearings on the cylinders crankcase. The piston axle-maintaining locks are to be extracted and the connecting rods are to be dismounted (the axle is freely mounted in the piston and connecting rod). 10 PISTONS COOLERS REPLACEMENT COOLERS DISMOUNTING - the cooler (1) is to be drilled with a Ö 7 mm drill, 1 - extract the stopper (2) and spring (3). NOTICE: The ball (4) is not to be extracted in order to avoid the splinter entering the oil circuit. 2 3 The rings are to be dismounted. 4 The remained splinter is to be removed by means of a brush. 10 - 27 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The MOT 1485–01 is to be screwed in the cooler and the latter is to be extracted. MOT 1485-01 2 1 3 The cooler is introduced in the device rod. PISTONS COOLERS MOUNTING NOTICE: Pay attention when mounting the cooler; the end (4) is to be directed towards the cylinder center. The cooler mounting is performed by means of the MOT 1516-01 device. MOT 1516-01 4 The MOT 1516-01 device plate (3) is to be mounted on the cylinders crankcase and centered by mans of the centering device (2). The screws (1) are to be tightened then the centering device is to be removed. The cooler is to be positioned again and again, until the pressing rod shoulder (5) contacts the plate (3). 10 - 28 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting 10 REMOUNTING 5 3 The cylinders crankcase gasket areas and the crankshaft oiling grooves are to be cleaned. The connecting rod bearings are identical and they are not provided with groin. They are to be mounted by means of the MOT 1492 device. 3 Pay attention to the coolers direction. 2 The bearing support (1) is to be chosen according to the engineshown in position (2). The bearing support is to be mounted in the device slot (3). The connecting rod is to be mounted on the device so that the lower part of the connecting rod leg (4) contacts the centering part. 4 A: coolersdirection for cylinders 2 and 4. B: coolers direction for cylinders 1 and 3. 10 - 29 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The bearing (5) is to be placed on the bearing support (see the following drawing). 5 The bearing support is moved according to the arrow so that the bearing hits the connecting rod. The same operations are to be performed for all the other connecting rods. The followings are to be performed when mounting the connecting rods covers bearings: The connectingrod cover is to be placed on the support so that the latter hits the two studs (6) then the bearing (7) is to be mounted on its support. 7 6 The bearing support is moved according to the arrow so that the bearing hits the cover. The pistons are to be mounted with the bolts and connecting rods. 10 - 30 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The axle / piston keeping locks are to be mounted. The rings are to be mounted on the piston as follows: - the oiling ring (3), - the sealing ring (2) with the “TOP” mark upward, - the compression ring (1) with the “TOP” mark upward. The rings are to be positioned at 120° from one another, with the oiling ring slot in front of one of its channel full. The ring slot is not to be adjusted. 10 The rings – piston – connecting rod assembly is to be oiled and mounted in the cylinders crankcase so that the turbulence chamber is directed towards the oil filter The bearings are not provided with groins The bearings to be mounted in the cylinder crankcase are provided with oiling holes. The MOT 1493 device is to be used for the bearings mounting. MOT 1493 The MOT 1493 device is placed on the cylinders crankcase. MOT 1493 10 - 31 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The bearing is to be mounted in the MOT The bearing-covers (3), (4) and (5) are 1493 device. Then the bearing is to be pushed to mounted and tightened at 6.5 daNm. on the point (A) until it hits the point (B) of The crankshaft axial clearance (j) is the device. to be checked: j = 0.07 ÷ 0.23 mm A B The axial bearings may have: 2.30, 2.35, 2.40 and 2.45 mm. The MOT 1493 device is to be placed on the bearing cover. The bearing is to be mounted in the device. Then the bearing is to be pushed on the point (A) until it hits the point (B) of the MOT 1493 device The oiled crankshaft and the axial bearings are to be mounted (at bearing No.2). The followings are to be mounted: - the bearing cover (2); then it is to be tightened at a required moment of (6.5 daNm), - the connecting rod covers; then they to be tightened at 4.5 ÷ 5 daNm. The bearing (1) is to be sealed by silicon injection. a) Mounting of the gaskets - If the channel thickness is lower to 5 mm, a 5.1 - mm thickness gasket is to be used. - If the channel thickness is greater than 5 mm, a 6 - mm thickness gasket is to be used. The gaskets are to be mounted with channel towards exterior. b) Silicon injection The necessary kit for this operation includes a 50 ml syringe and a 5 ml tube of DURCISSEUR. 10 - 32 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting IMPORTANT: The injection is to last at least 5 minutes, in order to avoid the syringe mixture polymerization. The cylinders crankcase and the bearing cover areas (A) are to be cleaned and degreased with thinner. 10 Thirty milliliters (30 ml) of RHODORSEAL 5661 are to be mixed with one third (1/3) of the tube of DURCISSEUR until obtaining a homogeneous mixture. The mixture is to be introduced into the syringe and then slowly injected into the bearing cover grooves so that the sealing between the bearing cover and the cylinders crankcase is perfect. Wait for the mixture polymerization and remove the excess. A A thin layer of RHODORSEAL 5661 is to be applied on the cylinders crankcase areas (B). BB B B The bearing cover (1) is to be mounted and tightened at 6.5 daNm. 10 - 33 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting The assembly rotation is to be checked. The bearing (1) oil-sealing ring is to be mounted by means of the device MOT 991-01. The crankshaft oil-sealing ring on the distribution side is to be oiled. The oil-sealing ring is to be mounted by means of the device MOT 990-03. MOT 991-01 MOT 990-03 The crankshaft cover centering bushes are to be checked on the distribution side. The oil pump centering bushes presence is to be checked. The oil pump is to be mounted and the attachment screws are to be tightened at a required moment of 2 ÷ 2.5 daNm. The support is to be mounted with a new gasket. 10 - 34 vnx.su ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting 10 CYLINDER HEAD REMOUNTING The engine flywheel supporting area on the crankshaft is to be lubricated with LOCTITE AUTOFORM. The geared sector MOT 582 is to be dismounted. MOT 582 The screws are to be tightened at a required moment of (5 ÷ 5.5 daNm). The geared sector MOT 582 is to be dismounted. The clutch is to be mounted (see the Chapter 20 “The Clu tch”) and its attachment screws are to be tightened at 2 daNm. The lower crankcase is to be provided with a new gasket; its screws are to be tightened at a required moment of (1.2 ÷ 1.5 daNm). - The followings are to be mounted: - The cylinder head centering bushes; - The cylinder head gasket. NOTICE: In case of replacing one of the following elements - the crankshaft, - the cylinders crankcase, - the connecting rods, - the piston, it is obligatory to recalculate the cylinder head gasket thickness according to the pistons area. Otherwise the cylinder head gasket is to be replaced with an identical one. In order to establish the gasket thickness the pistons over-height is to be measured by means of the devices MOT 251-01 and MOT 252-01. The calamine is to be removed from the pistons head. The crankshaft is to be rotated towards the running direction and the piston (1) and its upper dead point. The piston over-height is to be measured. The operation is to be repeated for all the other pistons. 10 - 35 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Dismounting - Remounting NOTICE The measurements are to be performed on the engine longitudinal axe, in order to avoid the errors caused by the piston turning over. IMPORTANT! The cylinder head screws are to be tightened at 3 daNm, then at an angle of 80° ± 4°, observing the order indicated in the drawing. Wait for 3 minutes. ONLY THE MAXIMAL OVER-HEIGHT IS TO BE TAKEN INTO CONSIDERATION. The screws 1 and 2 are to be totally unscrewed and tightened at 2.5 daNm, then at an angle of 213° ± 7°. The same is to be done for the screws 3-4, 5-6, 7-8 and 9-10. The followings are to be used to get a maximal over-height of the piston: - less than 0.613 mm a two-holes gasket is to be used (thickness 1.4 mm), - within 0.613 mm (inclusive) and 0.767 mm (inclusive): a one-hole gasket is to be used (thickness 1.5 mm), - higher than 0.767 mm: a three-holes gasket is to be used (thickness 1.6 mm). The pistons are to be brought at halfstroke, in order to avoid the contact with their valves. The cylinder head is to be centered on the two centering bushes. The cylinder head screws are to be tightened at the required moment and oiled, observing the following method: CYLINDER HEAD TIGHTENING METHOD 1. GASKET PRE-SETTING 2. CYLINDER HEAD TIGHTENING The cylinder head is not to be re-tightened. The distribution belt is to be mounted and tensioned at 61 ± 5 Hz (see Chapter 11 “The Distribution Belt”). The nut of the tightening roller is to be obligatory tightened at 5 daNm. Perform the pressing-on of the injection pump. (see Chapter 13 “Injection Pump Pressing-on”). Then, the followin gs are to be mounted: - the distribution covers, - the crankshaft pulley – its screw is to be tightened at 2 daNm then at an angle of 115° ± 15°, - the intake-exhaust manifold - its screws are to be tightened at 2.7 daNm - the alternator and its belt – the alternator belt is to be tensioned at 127 ± 5 Hz (see Chapter 16 “Alternator”). 10 - 36 vnx.su ENGINE AND LOWER ENGINE UNITS Lower crankcase 10 TIGHTENING MOMENTS (daNm) Lower crankcase attachment screws ............................................................... 1.5 Cross-tie attachment screws............................................................................... 5.7 Attachment screws of the anti-rolling bar on longitudinal girders................. 2 DISMOUNTING The vehicle is to be placed on a two-columns elevator. The battery is to be dismounted. The oil is to be drained from the motor. The following are to be dismounted: - the engine shield, - the engine shield cross-tie, - the attachment screws of the anti-rolling bar on longitudinal girders. The lower crankcase attachment screws are to be dismounted. REMOUNTING The lower crankcase is to be cleaned. The lower crankcase is to be mounted with a new gasket. Perform the dismounting operations in the reverse order. The engine is to be filled with oil (Dacia Oil Diesel 10W40 API CF). 10 - 37 vnx.su ENGINE AND LOWER ENGINE UNITS 10 Oil pump TIGHTENING MOMENTS (daNm) Oil pump attachment screws .......................................... 2 ÷ 2,5 DISMOUNTING The followings are to be dismounted: - the lower crankcase (see Chapter 10 “Lower Crankcase”), - the two attachment screws of the oil pump on the cylinders crankcase. The oil pump is turned over, the driving chain is to be extracted from the gear, and the pump is to be dismounted. The oil pump cover is to be dismounted. The oil pump gear clearance is to be checked (see Chapter 10 “Characteristics”). REMOUNTING Perform the dismounting operations in the reverse order. The engine is to be filled with oil. The oil pressure at 80° is to be checked. - at 1000 rpm…………………1.2 bars - at 3000 rpm ………………...3.5 bars 10 - 38 vnx.su ENGINE AND LOWER ENGINE UNITS 10 Crankshaft sealing gasket towards distribution Necessary Special Tools MOT 1054 MOT 990-03 MOT 1505 Engine pressing-on rod Crankshaft sealing gasket mounting device towards distribution Belts tension measurement device TIGHTENING MOMENTS (daNm) Crankcase pulley screw 2+115°±15° Distribution belt tensioning roller nut 5 Alternator attachment screw 1,9 MOT 990-03 GASKET REPLACEMENT DISMOUNTING The distribution belt is to be dismounted (see Chapter “Distribution Belt”) The gear is to be dismounted from the crankshaft. The crankshaft-sealing gasket is to be extracted. The distribution belt is to be mounted (see the method described in the Chapter “Distribution Belt”). REMOUNTING The new sealing gasket is to be mounted by means of the device MOT 990-03. 10 - 39 vnx.su ENGINE AND LOWER ENGINE UNITS 10 Crankshaft sealing towards flyweel Necessary Special Tools MOT 991-01 MOT 582 Crankshaft sealing mounting device towards flywheel Flywheel immobilization sector REMOUNTING TIGHTENING MOMENTS (daNm) The new sealing gasket is to be mounted by means of the device MOT 991-01. Engine flywheel attachment screws ……5 ÷ 5.5 Clutch attachment screws…..........……… 2 Gearbox attachment screws on engine - upper attachment ……….......……… 4.4 - lower attachment ………........………2.1 MOT 991-01 GASKET REPLACEMENT This operation is to be performed after dismounting the gearbox, the clutch, and the engine flywheel. DISMOUNTING The gearbox is to be dismounted from the vehicle (see Chapter 21 “DismountingRemounting Of The Gearbox”). The clutch is to be dismounted (see Chapter 20 “Clutch Dismounting-Remounting”). The engine flywheel attachment screws are to be dismounted (immobilized by means of the device MOT 582). The crankcase-sealing gasket is to be extracted. The gasket housing is to be cleaned. The holes thread of the flywheel attachment screws is to be cleaned with a dry gaze. The flywheel seating area on the crankshaft is to be degreased. The engine flywheel is to be mounted and to be immobilized with MOT 582. The flywheel seating area is to be applied with LOCTITE AUTOFORM. The stopping sector MOT 582 is to be dismounted. The holes thread of the flywheel attachment screws is to be cleaned with a dry gaze. 10 - 40 vnx.su ENGINE AND LOWER ENGINE UNITS Engine set replacing 10 Necessary Special Tools MOT 251-01 MOT 252-01 MOT 1054 MOT 1505 Comparing support Comparing support plate Engine pressing-on rod Belts tension measurement device TIGHTENING MOMENTS (daNm) Connecting rods attachment screws ............................................. 4.5 ÷ 5 Injectors supplying pipes ……………2.5 Crankcase pulley screw …...… 2 + 115 ± 15° Distribution belt tensioning roller nut.............................................…5 Oil pump attachment screws……… 2 ÷ 2.5 DISMOUNTING The vehicle is to be placed on a twocolumns elevator. The battery is to be dismounted. The oil is to be drained from the motor. The cooling fluid is to be drained. The lower crankcase is to be dismounted (see Chapter 10 “Lower Crankshaft”). The oil pump attachment screw is to be dismounted and the pump is to be extracted by turning it over. The cylind er head is to be dis mounted (see Chapter 10 “Cylinder Head Dismounting-Remounting”). The connecting rods covers are to be dismounted. The connecting rods covers are to be marked as against the connecting rods bodies. The pistons-connecting rods assembly is to be dismounted. The axe piston-maintaining locks are to be extracted and the connecting rods are to be dismounted. 10 - REMONTARE The bearings are to be mounted on the connecting rods bodies and covers (see the method described in Chapter 10 “Cylinders Crankcase Dismounting–Remounting”) The pistons and the bolts – pistons are to be mounted. The axe gear-maintaining locks securities are to be mounted. The pistons rings are to be mounted observing the order: - the oiling ring, - the sealing ring with the mark “TOP” upward, - the compression ring with the mark “TOP” upward. The rings are to be positioned at 120o from one another. 41 vnx.su 10 ENGINE AND LOWER ENGINE UNITS Engine set replacing The rings – piston – connecting rod assembly is to be lubricated with engine oil and mounted in the cylinders crankcase, with the turbulence chamber towards the oil filter. The connecting rods cover are to be mounted, observing the dismounting marks and the screws are to be tightened at the required moment (4.5 ÷ 5 daNm) The piston over-height is to be measured by means of the devices MOT 521-01 and MOT 252 – 01, in order to calculate the thickness of the cylinder head. NOTICE: The measurements are to be performed on the engine longitudinal axle in order to eliminate the errors caused by the piston turning over. For a piston maximal over-height: - less than 0.613 mm : a two – holes gasket is to be used for identification (thickness 1.4 mm), - within 0.613 mm (inclusive) and 0.767 mm (inclusive): a one-hole gasket is to be used for identification (thickness 1.5 mm), - higher than 0.767 mm: a three-holes gasket is to be used for identification (thickness 1.6 mm) The cylinder head is to be mounted (see the Chapter 10 “Dismounting- Remounting”). The oil pump is to be mounted and the attachment screws are to be tightened at the required moment. The lower crankcase is to be mounted (see the Chapter 10 “Lower Carter”). The distribution belt is to be mounted (see Chapter 11 “Distribution Belt”). The alternator belt is to be mounted (see Chapter 16 “Alternator”). The engine is to be filled with oil Dacia Oil Diesel 10W40 API CF. The cooling circuit is to be purged and filled with cooling fluid GLECEOL Rx type D (see C hapter 19 “Filling Purging”). IMPORTANT: ONLY THE MAXIMA L OVERHEIGHT IS TO BE TAKEN INTO CONSIDERATION. 10 - 42 vnx.su UPPER AND FRONT ENGINE UNITS Distribution belt 11 Necessary Special Tools MOT 1054 MOT 1505 Engine pressing-on rod Belt tensioning measurement device Mount the engine pressing-on rod MOT 1054. TIGHTENING MOMENTS (daNm) Crankshaft. pulley screw Tensioning roller nut 2 + 115° 5 MOT 1054 DISMOUNTING Place the vehicle on a two-columns elevator. Disconnect the battery. Drain the cooling circuit by the radiator lower hose. Dismount the radiator. Dismount the accessories belt (see chapter 16 “Alternator”. Rotate de crankshaft in order to line up the mark from the camshaft gear with the pressing-on window ( C). C 11 - 1 vnx.su Dismount : - the crankshaft pulley, - the support of the fuel return pipe, - the distribution crankcases. 11 UPPER AND FRONT ENGINE UNITS Distribution belt Dismount the tensioning roller and remove the distribution belt. Tighten the distribution belt by screwing a screw (A) in the lower distribution crankcase. NOTICE : An unscrewing more than one rotation of the tensioning roller may lead to its falling from the pivoting screw. REMOUNTING Check if the rod MOT 1054 is correctly mounted. Mount a new distribution belt, observing the rotation direction shown by the arrows back of the belt. The belt has marked on the external part three marks and one mark on the internal side for pressing-on; the internal mark is off one external mark. Line up the internal mark from the belt with the mark from the crankshaft gear. Then, line up the marks from the crankshaft gear and the injection pump gear with the corresponding marks from the belt. Place one of the two captors (a) or (b) of the MOT 1505 device reading head at a distance x = 5 – 10 mm of belt in the position shown in the drawing. x a b 1 2 The measurement may be performed on any of the belt face (1) or (2), subject that both captors are not to be in the same time in front of the belt during measurement. 11 - 2 vnx.su UPPER AND FRONT ENGINE UNITS Distribution belt 11 Tighten again the distribution belt (acting upon the A screw) until obtaining the value T2 = 61 ± 5 Hz. A MOT MOT 1505 Make vibrating the belt by means of a finger. The measurement is validated by a device “bip” Tighten the belt until obtaining the value T1 = 68 ± 3 Hz. Block the tensioning roller. Rotate then, four turns the crankshaft and position again the distribution at the upper dead point. Unblock the tensioning roller. The tensioning roller nut is to be obligatory tightened at 5 daNm. If not, this may unloose risking the engine damage. Remount the crankshaft pulley and obligatory tighten its screw at a moment of 2 daNm plus an angle of 115° ± 15°. Check the injection pump pressing-on (see chapter 13 “ Injection Pump Pressing-on”) Remount the other elements performing the dismounting operations in the reverse order. Mount and tension the accessories belt (see chapter 16 “ Alternator”) Perform the filling and purging of the cooling circuit (see chapter 19 “ Cooling circuit filling – purging”). NOTE: Once a belt is dismounted it can not be remounted. 11 - 3 vnx.su UPPER AND FRONT ENGINE UNITS 11 Cylinder head gasket Necessary Special Tools MOT 251-01 MOT 252-02 MOT 1054 MOT 1505 MOT 1202-01 Comparing support Measurement plate for pistons over-height Engine pressing-on rod Belt tensioning measurement device Pliers for elastic collars Wrench for angle tightening TIGHTENING MOMENTS ( daNm ) Tensioning roller nut Crankshaft pulley screw 5 2+115°±15° - disconnect the connector (2) of the electric valve E.G.R. and the connector (3) of the air temperature sensor, - the hoses and the connector of the water temperature sensor from the thermostat box, DISMOUNTING Place the vehicle on a two-columns elevator. Disconnect the battery. Dismount the distribution belt ( see chapter 11 “ Distribution belt “) Drain the cooling circuit by the water pump inlet pipe Dismount : - the exhaust descent pipe, - the vacuum pump connection(1), 1 2 3 4 - the air intake connection, - the connection for oil vapor recycling , - detach from clips the fuel pipes from the air filter case, - dismount the air filter assembly, Disconnect : - the supply wires of the pre-heating spark plugs, - the injectors connectors and the injection pump connector (5), - the fuel supply and return connections in (A) and (B), - the resistance connector for diesel heating from the diesel filter. 11 - 4 vnx.su UPPER AND FRONT ENGINE UNITS Cylinder head gasket 11 A B 5 Dismount the fuel return pipe support (6). Loosen the attachment screws of the distribution lower crankcase in order to facilitate the cylinder head dismounting. Remove by lifting, the cylinder head but without rotating it, because it is centered by means of two bushings (C). 6 The following are to be dismounted: - the alternator driving belt tightener, - the cylinder head screws. 11 - 5 vnx.su 11 UPPER AND FRONT ENGINE UNITS Cylinder head gasket Protect the oil grooves to avoid impurity penetration (addition); penetration of addition in the oil grooves may govern their clogging and consequently induce a fast failure of the crankshaft. It is very important not to scratch the gasket seating face. The DECAPJOINT is to be used for cleaning the gasket possible stuck bits. Spread out the substance on the area to be cleaned, wait for about 10 minutes, and clean with a wooden spatula. Place the MOT 252-01 device on the piston. Place the MOT 251-01 device provided with a comparing device on the support plate of the MOT 252-01. Place the comparing gauge feeler in contact with the cylinders crankcase and look for the piston upper dead point. Measure the pistons over-height. NOTICE: The measurements are to be performed on the engine longitudinal axe, in order to avoid the errors caused by the piston turning over. During cleaning operation, protection gloves are to be worn. The cylinder head flatness is checked by means of a ruler and a kit of gauges. Maximalpermitted deformation:0.05 mm. The cylinder head is not to be rectified. Measurement of the pistons over-height. The calamine is to be removed from the pistons head. The crankshaft is to be rotated towards the running direction for bringing the piston (1) at its upper dead point. ONLY THE PISTON MAXIMAL OVER-HEIGHT IS TO BE TAKEN INTO CONSIDERATION. The followings are to be used to get a maximal over-height of the piston: - less than 0.613 mm: a cylinder head gasket provided with two identification holes. - between 0.613 mm and 0.767 mm, a cylinder head gasket with one identification hole is to be used - higher than 0.767 mm: a cylinder head gasket provided with three identification holes. 11 - 6 vnx.su UPPER AND FRONT ENGINE UNITS Cylinder head gasket 11 Wait for 3 minutes, as stabilizing time. REMOUNTING Mount the corresponding new cylinder head gasket (according to the maximal over-height). This is centered by means of two centering bushings (C). 2. CYLINDER HEAD TIGHTENING The cylinder head tightening is to be performed consecutively for the screws group 1-2, 3-4, 5-6, 7-8 and 9-10 - The screws 1- 2 are to be totally unscrewed. - Tighten the 1-2 screws at 2.5 daNm, then at an angle of 213° ± 7°. - Repeat the dismounting and tightening operation for the screws group 3-4, 5-6, 7-8 and 9-10. The cylinder head is not to be retightened. The pistons are obligatory positioned so that neither one is at the upper dead point, in order to avoid the contact with the valves during cylinder head tightening. The cylinder head is to be centered on the two centering bushings. The cylinder head gasket is to be tightened as follows: 1. GASKET PRE-SETTING The cylinder head screws are to be tightened at 3 daNm, then at an angle of 80° ± 4°, observing the order indicated in the drawing. NOTICE: In order to get a right tightening of the cylinder head screws, the oil that may be in the cylinder head fixing holes is to be extracted by means of a syringe. Before mounting, the screws thread and head are to be lubricated with engine oil. Mount the distribution belt ( see chapter 11 “ Distribution belt “) For remounting perform the dismounting operations in the reverse order. Fill and purge the cooling circuit (see chapter 19 “ Filling – Purging “). 11 - 7 vnx.su FUEL MIXTURE 12 Intake manifold TIGHTENING MOMENTS (daNm) Collectors attachment nuts Air filter case attachment Exhaust gases pipe flange screws 2.7 0.8 1.9 DISMOUNTING Place the vehicle on a two-columns elevator. Disconnect the battery. Dismount under the vehicle, the two attachment nuts of the downward pipe on the exhaust manifold. Dismount the downlead pipe attachment clamp on the engine. Detach from clips the fuel pipes from the air filter case (1). Dismount the three nuts and the attachment screw of the air filter case (2) on the intake manifold. Disconnect the oil vapors recycling connection. Dismount the air filter case attachment screw on the engine lifting support. Disconnect: - sensor of air temperature connector - E.G.R. connector - sensor of water temperature connector Remove the air filter assembly. 1 2 3 4 12 - 1 vnx.su FUEL MIXTURE 12 Exhaust manifold Dismount the exhaust gases recycling pipe. Dismount the diesel return hose support attached on the distribution casing. Dismount by means of a ratchet wrench and an extension, the following: - the upper attachment nuts (A) of the intake manifold and exhaust manifold - the lower attachment nuts (B) of the manifolds - the attachment nuts (C) of the exhaust manifold. Recover the washers. Dismount the two manifolds (intake and exhaust). A C B C REMOUNTING Tighten the attachment nuts of the two manifolds at the required moment ( 2.7 daNm). Replace and correctly place the gaskets (3) and (4). Perform the dismounting operations in the reverse order. 12 - 2 vnx.su PUMP SUPPLY Fuel stop in case of collision 13 PURPOSE The hazard sensor interrupts the fuel supply in case of an accident, thus avoiding the fire hazard due to the fuel losses. OPERATION The hazard sensor (1) is placed in the engine compartment, mounted on the left shock absorber column. 1 1 In case of hazard, the sensor ball leaves its lodgement, thus stopping the injection relay supply (+); the latter supplies the injection computer, the injection pump and the E.G.R. electric valve (exhaust gases recycling). Therefore the pump will neither intake the fuel nor will generate high pressure. The hazard of fire generated by diesel oil projection is thus excluded. HAZARD SENSOR RE-STARTING The upper part of the hazard sensor is to be pushed to re-positionthe ball into its lodgement and thus to re-start the sensor. 13 - 1 vnx.su PUMP SUPPLY 13 Characteristics Engine Vehicle Gearbox Pick Up Drop Side Double Cab NG 1 NG 7 Type Index Bore Stroke (mm) (mm) F8Q 636 80 93 1870 Rotation (rpm) 5175 ± 50 21.5/1 EURO’96 Smoke opacity Idle Maximal (unloaded) Maximal (loaded) running 825 ± 50 De-pollution CylinderCompression standards capacity ratio (cm3) Homologation value Legal maximum 1.0 m-1 (33%) 2.5 m-1 (64%) 4600 ± 100 Denomination Particularities Injection pump LUCAS DIESEL E.P.I.C. Electronic rotary pump, provided with: - increased flow electric valve, - decreased flow electric valve, - advance electric valve, - STOP electric valve, - flow rotor axial position captor (solid), - advance cam position captor (solid). Pump pressing on Increased flow electric valve Decreased flow electric valve Advance electric valve STOP electric valve Advance cam position captor Flow slide position captor Diesel oil temperature captor Pressing on by means of the rod MOT 1520 Resistance: 31 ± 2 Ohms Resistance: 31 ± 2 Ohms Resistance: 31 ± 2 Ohms Resistance: 1.39 ± 0.1 Ohms Resistance: 52 ± 4 Ohms Resistance: 41 ± 4 Ohms Integrated in pump Resistance: 2716 ± 60 Ohms at 20°C Electronic checking unit (U.C.E.) – 90 ways LUCAS RDNOSDC 6751 II Tare: 125 ÷ 140 bars LUCAS LCR 67354 Port-injector tightening: 7daNm Port-injector tightening on cylinder head: 7daNm Injection computer Injectors Port-injectors 13 - 2 ÷ vnx.su PUMP SUPPLY 13 Characteristics Particularities Denomination Discharge lines Pre-heating relay Pre-heating plugs Acceleration potentiometer Engine rotation (RPM) sensor Absolute pressure sensor E.G.R. valve Temperature (°C) ± 1° φ External: 6 mm φ Internal: 2.5 mm Length: 300 mm NAGARES BRE /6-12 Controlled by computer BERU Resistance: 0.6 Ω Tightening moment: 2 daNm CTS Double track potentiometer MGI Resistance ∪ 760 Ω at 20 °C Inserted in computer PIERBURG Electric valve with inserted wheel and position captor Valve resistance: 8 ± 0.5 Ω at 20 °C Resistance: 4 KΩ at 20 °C -10 25 Air temperature sensor 10454  8623 2175  1928 (resistance in Ohms) Water temperature sensor 13588 11332 2364  2140 (resistance in Ohms) 13 - 3 vnx.su 50 80 857  763 325  292 850  773 290  275 PUMP SUPPLY 13 Particularities The pump E.P.I.C. (Electronic Programmed Injection Checking) is an electronic distributive injection pump. The following elements are placed on the pump: - advance electric valve (A), - increased flow electric valve (B), - decreased flow electric valve (C), - STOP electric valve (D), - flow rotor axial position captor (solid) (E), - advance cam angular position captor (solid) (F), - diesel oil temperature probe (solid, placed in the pump body). The increased flow electric valve and the advance one constitute a common body and one cannot separate them. They are placed on the pump upper part. The decreased flow electric valve and the STOP one constitute a common body and one cannot separate them. They are placed on the pump lower part (at its back). One cannot dismount the two captors (the flow and advance ones) since the injection computer is to memorise their position. This operation is to be performed only on an injection bench. The injection pump E.P.I.C. is connected to an U.C.E. injection calculator (Electronic Checking Unit). The latter calculates the flow and the advance and controls the electric valves accordingly. The U.C.E. calculator also controls the exhaust gases recycling(E.G.R.). The cleanliness rules are to be observed both prior and during any intervention on the E.P.I.C. system. B C F A E D 13 - 4 vnx.su PUMP SUPPLY Particularities 13 The engine is to be started and idle run after each intervention on the injection system. The possible diesel oil losses are to be checked. When cutting the contact the engine may run 1 – 2 seconds longer before stopping. When repairing or dismounting the injection pump, the supply connections, the return and the high-pressure ones are to be covered with new adequate obturators, in order to avoid impurities entering into the injection circuit. 13 - 5 vnx.su 13 PUMP SUPPLY Cleanliness rules COMPULSORY CLEANLINESS RULES TO BE OBSERVED WHEN INTERVENING ON E.P.I.C. INJECTION SYSTEM The E.P.I.C. system (Electronic Programmed Injection Checking) is very sensitive to polluting agents. The polluting agents entering into the injection system may cause the followings: - the E.P.I.C. system damages or definitive breakdown, - the elements gripping or unsealing. Any post-selling intervention on the injection system is to be performed in perfect cleanliness conditions. It means that no impurities - small as they may be - are allowed to enter the system or the circuits, during the dismounting or through the fuel connections. The followings may constitute polluting agents: - metallic or plastic chips, - paint, - hard paper, brushes, paper, clothes, gauze fibres, - foreign bodies (hair for instance), - ambient dust particles. ATTENTION! It is definitely forbidden to clean the engine with a high-pressure water jet, due to the connectors damaging hazard. Moreover, the wet connectors may cause electric connections troubles. COMPULSORY RULES TO BE OBSERVED WHEN INTERVENING ON E.P.I.C. INJECTION SYSTEM • Make sure there are enough available obturator caps. The caps are all single use. • Make sure there are enough available plastic bags. They are to be hermetically closed every time the dismounted parts are to be stocked, in order to protect the latter from any impurities. The bags are all single use. • Make sure there are enough available cleaning un-shred cloths. Gauze or common shredding clothsusing is definitelyforbidden, sincethey may cause polluting agents entering into the fuel circuit. COMPULSORY CLEANLINESS RULES TO BE OBSERVED WHEN OPENING THE FUEL CIRCUIT • A brand new diluter is to be used for any intervention (impurities-free). • A brand new and clean brush is to be used for any intervention. • The parts to be dismounted, the Special Tools to be used and the working-bench are to be thinner-cleaned by means of a brush. 13 - 6 vnx.su PUMP SUPPLY Cleanliness rules 13 • The cleaned parts are to be compressed air blown. • The hands are to be washed prior and during any intervention, if necessary. • Only LATEX protection gloves are to be used. RULES TO BE OBSERVED DURING THE INTERVENTIONS • As soon as the supplying circuit is opened, its connections are to be obstructed with adequate caps, in order to avoid impurities (dirt) entering into the circuit. The caps are all single use. • The parts stocking bags are to be hermetically closed, even when they are to be soon re-opened as the ambient air is a polluting factor. • After having obstructed all their orifices with obturator caps, all the injection system dismounted elements are to be stocked in hermetic bags. • After having opened the fuel circuit, the use of brushes, diluter and common gauze is definitely forbidden. • In case of replacing a worn element with a new one, the latter is to be unpacked only when mounting it. 13 - 7 vnx.su PUMP SUPPLY 13 Elements location 9 5 13 3 2 4 7 6 10 11 12 8 1 1. Air filter 2. Intake air temperature sensor 3. E.G.R. Electric valve (exhaust gases recycling) 4. Acceleration pedal position potentiometer 5. U.C.E. Injection computer 6. Injection relay 7. Pre-heating relay 8. Fuel filter 9. Engine rotation (RPM) sensor 10. STOP and decreased flow electric valves 11. Advance and increased flow electric valves 12. E.P.I.C. Injection pump 13. Cooling fluid temperature sensor 13 - 8 vnx.su PUMP SUPPLY 13 Elements location 11 10 14 2. Intake air temperature sensor 3. E.G.R. Electric valve (exhaust gases recycling) 4. Acceleration pedal position potentiometer 7. Pre-heating relay 10. STOP and decreased flow electric valves 11. Advance and increased flow electric valves 13. Cooling fluid temperature sensor 14. Injection pump pressing on rod orifice 4 2 7 13 3 13 - 9 vnx.su 13 PUMP SUPPLY Operation The U.C.E. injection computer permanently checks the system sensor transmitted parameters. The U.C.E. computer controls the electric valves according to these parameters and to the memorised reference values. It also permanently checks the obtained results and performs all their necessary corrections. The E.P.I.C. injection pump is a rotary distributor type one. The supplying pump intakes the diesel oil. The latter is brought to the so-called “transfer pressure” in the pump body. The transfer pressure is obtained by means of the plunger little pistons. Rollers in contact with a cams ring drive these pistons. The precisely processed cams ring determines the injection beginning moment and its duration. The injection computer determines the cams ring position by means of the advance electric valve, thus modifying the plunge pistons movement beginning moment. The cam position captor permanently informs the computer about the injection beginning moment. The plunger pistons stroke defines the injected diesel oil quantity towards each cylinder. The two electric valves (increased and decreased flow) allow the modification of this stroke, therefore of the injected diesel oil quantity. The flow rotor axial positioning captor permanently informs the computer about the injected diesel oil quantity. The diesel oil is then sent to the distributive pump area, which determines the cylinder to be supplied. A rotary piston assures this function. The engine operation steps are as follows: Pre-starting (prior the start-up) The system performs the following checking between the contact putting ON moment and the engine start-up one: - rotor maximal stop position, - advance piston minimal stop position, - increased and decreased flow electric valves operation, - advance electric valve operation. Starting (engine start-up) The computer controls a certain position of the pump rotor and the STOP electric valve supplying during the engine start-up, namely starter driving. Normal operation The computer modifies the diesel oil flow accordingly, by means of the increased and decreased flow electric valves. The flow is adjusted or cut in case of sudden acceleration or deceleration, according to the memorised reference parameters. 13 - 10 vnx.su PUMP SUPPLY Operation 13 Engine stop The computer controls the STOP electric valve closure, then the engine rotation evolution when cutting the contact. The computer drives the decreased flow electric valve until the engine STOP, in case the rotation does not suddenly decrease. 13 - 11 vnx.su 13 PUMP SUPPLY Injection indicator operation INJECTION INDICATOR OPERATION (PRE-HEATING) The instrument panel injectionindicator (luminous), lights under the following situations: - when putting the contact ON, the injection indicator lights and remains lit during the pre-heating step, then turns off. - the indicator lights in case of injection system failure. The indicator flashes for few seconds during the pre-heating step, signalising a break down presence from the contact putting ON. Injection indicator lighting possible causes - computer or injection pump supplying trouble, - damaged rotation sensor, - pump internal memory device damage, - damage: - acceleration pedal position potentiometer, - increased flow electric valve damage, - decreased flow electric valve damage, - STOP electric valve damage, - cam position captor damage, - computer damage. 13 - 12 vnx.su PUMP SUPPLY Anti-starting function 13 The anti-starting code is to be permanently memorised by the injection computer, otherwise the latter does not operate. INJECTION COMPUTER REPLACEMENT When delivered, the new injection computers are un-coded.In case of computer replacement, the new one is to memorise the anti-starting code. Then the anti-starting function viability is to be checked, by putting the contact ON for few seconds (See Chapter 82 “Anti-starting” for details). ANTI-STARTING OPERATION CHECKING The key is to be taken out the contact and, 10 seconds after; the indicator is to flash once per second. See Chapter 82 “ Anti-starting” in case of checking the engine starting-up impossibility. 13 - 13 vnx.su 13 PUMP SUPPLY Idle running rotation correction IDLE RUNNING ROTATION CORRECTION ACCORDING TO WATER TEMPERATURE The idle running rotation is to be increased and sustained at 900 rpm for a cooling fluid temperature of - 23°C. CORRECTION ACCORDING TO THE ELECTRIC BALANCE This correction purpose is to compensate the voltage drop, caused by other consumers operation when the battery is low-loaded. To perform the voltage drop compensation, the idle running rotation is to be increased, thus allowing the alternator higher rotation and the battery voltage consequent increasing. Lower the voltage, higher the correction is. The correction is thus viable and starts when the battery voltage drops under 12 Volts. The idle running rotation is to be stabilized at maximum 900 rpm. IDLE RUNNING ROTATION CORRECTION IN CASE OF POTENTIOMETER DAMAGE In case one of the acceleration pedal potentiometer tracks is damaged, the idle running rotation is to be maintained at 1000 rpm. In case both acceleration pedal potentiometer tracks are damaged, the idle running rotation is to be maintained at 1300 rpm. 13 - 14 vnx.su PUMP SUPPLY 13 Pre / Post –heating control The pre / post-heating function is controlled by means of the pre-heating relay. PRE / POST-HEATING OPERATION PRINCIPLE 2. Starting (Starting-up) 1. Putting the contact – “Pre-heating” a. Variable pre-heating The plugs are supplied during the start-up (starter operation). 3. Started engine – “Pre-heating” The indicator lighting time and the plugs The plugs are continuously supplied supplying one depends upon the cooling fluid during this step, according to the cooling temperature and the atmospheric pressure. fluid temperature and the flow slide position. t timp (s) For the idle running rotation with out actioning the acceleration pedal 180 - 20 T The injection indicator lighting time is never to overcome 15 seconds in any case. b. Fixed pre-heating The plugs remain under supplying for a fixed while of 15 seconds, after the engine stopping. 13 - 15 vnx.su 0 20 40 60 The cooling fluid temperature (°C) 13 PUMP SUPPLY Pre / Post –heating control In case the cooling fluid temperature sensor is damaged, the plugs are supplied as a result of a calculated temperature according to the air temperature timing. In any case the plugs are not to be supplied longer than 180 seconds. 13 - 16 vnx.su PUMP SUPPLY Injectors 13 REMOUNTING TIGHTENING MOMENTS (daNm) Port-injectors on cylinder head High pressure pipes nuts 7 2.5 DISMOUNTING STRI CTLY OSERVE CLEANLINESS RULES ! THE The battery is to be disconnected. The followings are to be dismounted: - the high pressure pipes, - the injectors. The supplying orifices and the injectors’ tops are to be compulsorily obstructed with caps. The anti-flame washers and the underinjectors sealing gaskets are to be replaced. The followings are to be mounted: - the injectors, - the high pressure pipes. The pipes fixing nuts are to be mounted. The followings are to be tightened at moment: - the injectors, - the pipes. The engine is to be started and left in idle running in order to check the diesel oil possible losses. Take all the necessary protection steps to avoid the diesel oil projection on the electric parts, otherwise operation troubles may occur. 13 - 17 vnx.su 13 PUMP SUPPLY Decreased flow electric valve and stop electric valve TIGHTENING MOMENTS Electric valves attachment screws 6 ± 0.6 Nm High pressure pipes nuts 2.5 ± 0.2 daNm DECREASED FLOW AND STOPPING ELECTRIC VALVES DISMOUNTING These electric valves are placed at the E.P.I.C. injection pump lower part and are not to be separately dismounted. STRI CTLY OSERVE CLEANLINESS RULES ! THE The following are to be disconnected: - the battery, - the pump electric connector. The electric connector attachment screws are to be dismounted from the connector support. The decreased flow and the STOP electric valves’ w ires are to be dismounted from the connector (red / white and blue / white) (see Chapter 13 “Pump Connector”). The wires in the connector are to be marked. The electric valves block four attachment screws on the electric valves support are to be unscrewed beginning the external ones. BEWARE OF CLEANLINESS ! The electric valves block and the plastic support are to be dismounted. ATTENTION ! The STOP electric valve core is not associated with the valve itself. Moreover, the core is pushed by the spring mounted behind it. The three gaskets are to be dismounted. The electric valves placing areas are to be cleaned with an un-shredding cloth, with no detergents or air blowing. The injection pump is to be cleaned in the same way. 13 - 18 vnx.su PUMP SUPPLY Decreased flow electric valve and stop electric valve 13 REMOUNTING The worn gaskets are to be replaced with new ones. The new gaskets are to be placed on the pump cover. The gaskets are to be diesel oil soaked for a better adherence on their lodgements. The electric valves and their supports are to be placed near their lodgements, holding them by hand (ATTENTION: the electric valve gaskets, core or springs are not to fall down). The two internal attachmentscrews are to be simultaneously screwed without tightening, so that the electric valves lodge onto the pump body. The two external attachment screws are to be screwed, too. The four screws are to be tightened at moment (6 ± 0.6 Nm). Pay attention when remounting the plugs and the connector: first, the plugs are to be mounted into the intermediary part, in order to get the best catching, then the rest of the connector is to be remounted (see Chapter 13 “Pump Connector”). For all the other remounting operations, it is to be proceeded in reverse the dismounting. The engine is to be started and left in idle running for checking the possible diesel oil losses. NOTICE: The STOP electric valve core pairs its body. In case of replacing the STOP electric valve, pay attention - the new one is to be identical (same item). 13 - 19 vnx.su 13 PUMP SUPPLY Increased flow electric valve and advance electric valve TIGHTENING MOMENTS (Nm) Electric valves attachment screws 6 ± 0.6 INCREASED FLOW AND ADVANCE ELECTRIC VALVES DISMOUNTING The increased flow electric valve and the advance one are placed on the E.P.I.C. injection pump upper part and are not to be separately replaced. STRI CTLY OBSERVE THE CLEANLINESS RULES ! The followings are to be disconnected: - the battery, - the pump electric connector. The electric connector attachment screws are to be unscrewed from the connector support. The electric valves four plugs are to be taken out from the connector (see Chapter 13 “Pump Connector”). Their position in the connector is to be marked. The electric valves block four sustaining screws are to be un-tightened beginning the external ones. BEWARE OF CLEANLINESS ! The electric valves block is to be dismounted and the four gaskets are to be removed. 13 - 20 vnx.su PUMP SUPPLY Increased flow electric valve and advance electric valve 13 The electric valves placing areas are to be cleaned with an un-shredding cloth. The gaskets placing areas on pump or electric valves are not to be detergent cleaned or air blown. REMOUNTING The worn gaskets are to be replaced with new ones. The new gaskets are to be placed on the pump body (they are not to be placed on the electric valves). The electric valves block is to be positioned and the internal and external screws are to be tightened. The electric valves four attachment screws are to be screwed and tightened at moment. Pay attention when remounting the plugs and the connector: first, the plugs are to be mounted into the intermediary part, in order to get the best catching, then the rest of the connector is to be remounted (see Chapter 13 “Pump Connector”). For all the other remounting operations, it is to be proceeded in reverse the dismounting. The engine is to be started and left in idle running for checking the possible diesel oil losses. 13 - 21 vnx.su PUMP SUPPLY 13 Injection pump connector SPECIAL TOOLS ELE 1044-01 Connectors clips dismounting device REMOUNTING INJECTION PUMP CONNECTOR DISMOUNTING STRI CTLY OSERVE CLEANLINESS RULES ! THE In order to dismount the connector, the following are to be dismounted in order: - the black port-connector (A), - the intermediary plate with plugs (B), - the wiring sustaining white clip (C), - the intermediary part (D), - the plugs (E), freeing the blocking pins by means of the device ELE 1044-01 and simultaneously pulling the wire. E C The wires are to be reconnected (the plugs are to be pushed until blocking then slightly pulled for a good fixing). The followings are to be remounted: - the intermediary part (D), - the wiring sustaining white clip (C), - the intermediary plate with plugs (B), The assembly is to be re-positioned onto the black port-connector. D B A 13 - 22 vnx.su PUMP SUPPLY Injection pump connector 13 Plugs marking (positioning). Marking Marking Marking towards towards on the pump the wiring computer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 - 13 13 12 15 11 10 9 8 7 6 5 30 14 12 51 67 36 60 4 + AVC 3 2 1 89 90 9 Wire function Wire colour Green Advance slide position captor position signal Red Advance slide position captor position starting Red Flow slide position captor position starting White-Red STOP electric valve control Yellow Flow slide position captor position signal White Flow slide position captor position compensation Orange Pump memory link Blue Diesel oil temperature common wire and pump Brown memory Diesel oil temperature in pump White-Black Increased flow electric valve control White-Black Increased flow electric valve supply White-Red STOP electric valve supply White-Green Advance electric valve supply White-Blue Decreased flow electric valve supply White-Green Advance electric valve control White-Blue Decreased flow electric valve control Screening 13 - 23 vnx.su PUMP SUPPLY 13 Injection pump INJECTION PUMP BACK SUPPORT REPLACING TIGHTENING MOMENTS (daNm) Closing plate Injection pump back support 0.55 ± 0.05 2.2 ± 0.3 CLOSING PLATE GASKET REPLACING STRI CTLY OSERVE CLEANLINESS RULES ! NOTICE: The back support following dismounting – mounting method is to be observed in case of cylinder head replacing. THE The battery is to be disconnected. The closing plate attachment screws are to be dismounted (P). The gasket is to be replaced. The diesel oil spots are to be wiped put with an un-shredding cloth. The closing plate is to be remounted and the screws are to be tightenedat the required moment. DISMOUNTING The back support is to be dismounted prior dismounting the pump attachment screws, placed behind the driving pulley. REMOUNTING The pump attachment screws are to be repositioned on their place. The back support is to be repositioned and the screws are to be screwed until approaching. The followings are to be tightened: - the pump attachment screws, - the back support screws. 13 - 24 vnx.su PUMP SUPPLY 13 Injection pump SPECIAL TOOLS Pulley sustaining device Engine pressing on rod Injection pump pressing rod Injection pump pressing on knurling tool Pulley extractor MOT 1200-01 MOT 1054 MOT 1520 MOT 1522 MOT 1525 TIGHTENING MOMENTS (daNm) Injectors pipes nuts Back support screws Pump attachment screws Pulley screws 2.5 ± 0.6 2.2 ± 0.3 2.5 ± 0.3 5.5 ± 0.5 DISMOUNTING STRI CTLY OSERVE CLEANLINESS RULES ! THE The following are to be dismounted: - the pump pulley crankcase, - the high pressure pipes, - the injection pump back support, - the diesel oil supply and return pipes. All the open canalisations are to be caps obstructed. The pump electric connector is to be disconnected. The MOT 1200-01 device is to be installed for the pump pulley blocking. The pulley-fixing nut is to be mounted. The battery is to be disconnected. The engine is to be fixed at its upper dead point (P.M.S.) by means of the rod MOT 1054 (see Chap ter 11 “Distribution Belt”). MOT 1200-01 MOT 1054 13 - 25 vnx.su MOT 1525 13 PUMP SUPPLY Injection pump The MOT 1525 is to be mounted and the pump shaft pulley is to be depressed. The pump three attachment screws are to be unscrewed between the pulley arms. The injection pump is to be dismounted after unscrewing all its attachment screws. The pump is to be stocked into a hermetically closed plastic bag in order to protect it from any impurity. REMOUNTING The torric gasket on the pump driving shaft is to be replaced. The high-pressure pipes are to be mounted. Thenuts are to be hand-screwed then tightened at moment. The injections is to be blocked (see Chapter 13 “Pump pressing on”) ATTENTION! Not to forget to dismount the engine rod and the pump pressing-on one. Start and let the engine under idle running condition for checking the possible diesel oil losses. IMPORTANT: The rod MO T 1520 is to be compulsorily kept cleaned and under perfect conditions. The pump blocking rod is to be positioned by turning the pump shaft by means of the knurling tool MOT 1522 (see Chapter 13 “Pump Pressing on”). The injection pump is to be remounted. The pump three attachment screws on its support are to be hand-screwed, without tightening. The pump attachment screws and the back support fixing ones are to be tightened at moment. ATTENTION! The pump attachment screws tightening is very important. All screws are to be handscrewed and then tightened at the required moment. 13 - 26 vnx.su PUMP SUPPLY Injection pump pressing on MOT 1200-01 MOT 1054 MOT 1520 MOT 1522 MOT 1525 SPECIAL TOOLS Pulley sustaining device Engine pressing on rod Injection pump pressing on rod Injection pump pressing on knurling tool Pulley extractor TIGHTENING MOMENTS Pump pulley nut Pump pressing on rod lodge obstructer 13 5.5 ± 0.5 daNm 5 Nm The injection pump driving shaft nut is to be unscrewed The pulley is to be moved on the pump shaft by means of the pulley extractor MOT 1525. MOT 1200-01 MOT 1525 INJECTION PUMP PRESSING ON A complete pump pressi ng on is necessary for checking the blocking itself. ATTENTION! The engine is never to be turned anticlockwise. The injection pump pulley crankcase is to be dismounted. The engine is to be brought at its upper dead point (PMS) and blocked on this position by means of the rod MOT 1054. The injection pump pulley-blocking device MOT 1200-01 is to be fixed. The pressing on knurling tool MOT 1522 is to be mounted on the pump driving shaft end. MOT 1200-01 MOT 1054 MOT 1522 13 - 27 vnx.su MOT 1520 PUMP SUPPLY 13 Injection pump pressing on Place a vess el under the pump for recovering the diesel oil. The pressing on cap is to be taken out from the pump orifice. ATTENTION! There is an important diesel quantity in the injection pump and its connections. Rotate the pump in the direction of its turning by acting upon the knurl MOT 1522, in order to obtain the pressing-on position (the hole from the pump shaft must reach in front of the pressing-on orifice). It is forbidden acting upon the screws (A). ATTENTION ! Any unscrewing of any of these screws implies the pump placing on the reparation bench. By slightly screwing the rod MOT 1520, the pressing on rod maximal entering point into the pump is looked for. When reaching this position the rod blocks the pump shaft. The knurling tool MOT 1522 is to be taken out. When reaching this position the nut on the pump driving shaft is to be tightened in order the block the pinion. The blocking device MOT 1200-01 is to be dismounted. The rods MOT 1054 and MOT 1520 are to be taken out from the engine and injection pump. The pressing on orifices caps are to be mounted. The injection pump pinion cover is to be remounted. ATTENTION ! Not to forget to take out the injection pump and engine blocking rods. The engine is to be started and left under idle running condition for checking the possible diesel oil losses. A IMPORTANT: The rods MOT 1520 and MOT 1054 are to be compulsorily kept cleaned and in good condition. MOT 1520 13 - 28 vnx.su PUMP SUPPLY 13 Diesel oil filter The fuel filter is placed in the engine compartment, on the right front part wing lining It is removable allowing the filtering element replacement. The filter also includes a diesel oil heating resistance. DISMOUNTING STRI CTLY OSERVE CLEANLINESS RULES ! The screw (4) is to be unscrewed and the filtering element is to be removed. THE 5 ATTENTION! Pay attention to the diesel oil quantity and to the residual pressure of the diesel oil canalisation. The followings are to be disconnected from the filter: - the diesel oil heating resistance connector (1), - the injection pump supplying pipe (2), - the fuel supplying pipe (3), The fuel filter is to be dismounted by unclipping it from its support. 4 6 REMOUNTING Perform the dismounting operation in the reverse order. The coupling positions on filter are to be compulsorily observed Pay attention not to obstruct or damage the fuel pipes IMPORTANT: The fuel circuit is to be restarted through the cap (5) by means of the restarting pump. The filter cover position is to be marked as against its body. The water accumulated in the diesel oil filter is to be periodically purged through the purging cap (6) every 10000 km or whenever necessary . 13 - 29 vnx.su 13 PUMP SUPPLY Water temperature centralised control (G.C.T.A.) WATER TEMPERATURE SENSOR LOCATION OPERATION The water temperature sensor (244) informs the injection computer (UCE) about the water temperature The injection computer controls the following according to the water temperature - the injection system, - the exhaust gases recycling, - the cooling motor-fan, - the lighting of the water temperature alarm indicator on the instrument panel. 244 The water temperature sensor (244) is mounted in the thermostat box in the cylinder head rear part. • ENGINE FAN STARTS WHEN THE WATER TEMPERATUR E INC REA SES OV ER 99 o C A ND STOPS WHEN THE TEMPERATURE DECREASES UNDER 96oC. WATER TEMPERATURE INDICATOR The injection computer controls the water temperature indicator. The indicator lights when the water temperature increases over 105 oC. 13 - 30 vnx.su PUMP SUPPLY Acceleration potentiometer Pins location: 13 DISMOUNTING 1. Signal track 2 2. Signal track 1 3. 5 Volts supply track 2 4. Mass track 1 5. Mass track 2 6. 5 Volts supply track 1 The potentiometer box is to be dismounted from the front left wing half-lining. The acceleration cable is to be disconnected from the box. As a spare part the potentiometer is sold only assembled with its box. REMOUNTING Perform the dismounting operations in the reverse order. The potentiometer operation is to be compulsorily checked by means of the tester CLIP. 1 4 3 5 6 2 Ω. Tracks resistance: 1.7 ± 0.5 KΩ NOTICE: When one of the two acceleration pedal position potentiometer tracks is damaged, the normal rotation or the idle running one will modify (see Chapter 13 “Idle Running Rotation Correction”). 13 - 31 vnx.su 13 PUMP SUPPLY Diagnosis - Generalities This documentation is presenting the applicable diagnosis to the computers DCU 3R, having the diagnosis alternative VDIAG 09. The followings are to be used in order to perform the diagnosis of this injection system: - Diagnosis Technical Notice; - Operational Electric Diagram of the respective vehicle; - Technical tester CLIP, 90-way terminal-box (ELE 1497) DIAGNOSIS STEPS - In order to identify the type of the injection computer, the program number and the diagnosis alternative, the tester CLIP is to be connected to the diagnosis socket. - The information are to be identifiedin the diagnosisdocument corresponding to the injection system - The diagnosis documentationincluded working instruction are to be carefully read and observed: - The injection computer memorised damages are to be read by means of the tester CLIP. Their causes are to be identified by means of the Chapter “Damages Interpretation” indications. REMARK: The damages are each interpreted for a particular memorising type (present damage, memorised damage, present or memorised damage). The checking steps described for each damage treatment are not to be applied on the vehicle unless the CLIP declared damage is interpreted in the document for its memorising type. The damage memorising type is to be considered when starting the diagnosis, with contact OFF then ON. In case damage is interpreted when it is declared as being already “memorised”, the diagnosis applying conditions are mentioned in the Chapter “Recommendations”. In case of not-respected conditions, the diagnosis steps are to be performed for checking the incriminated element electric circuit, the damage not being present on the vehicle anymore. The same is to be performed in case the tester CLIP declares damage as being a “memorised”, one but the documentation only interprets it as being a “present” damage. - The checking is to be performed accordingly (the possible wrong functions, not yet declared by the system self-diagnosis) and the associated diagnosis is to be applied following the results interpretation. - The repairs are to be validated (the damage cause is to be eliminated). - In case of persistent problem, the damage location range is to be checked. 13 - 32 vnx.su PUMP SUPPLY Diagnosis - Generalities 13 INTERVENTIONS AND CHECKING NECESSARY EQUIPMENT - Tester SAGEM CLIP; - Multi-meter; 90-way terminal-box ELE 1497 DIAGNOSIS PARTICULARITIES The Diesel injection computer LUCAS DCU 3R displays the information “Damage Type” (CO01, 1DEF) for most of the present damages. This information is systematically limited to “DAMAGE” when one of these damages is declared as being memorised, even if the breakdown is present and the necessary conditions to take it into consideration are not achieved (impossible to obtain 1.DEF or CO.0 for a memorised damage). In this case and if the diagnosis only interprets the damage as “memorised”, the confirmation condition of the breakdown real presence, mentioned in the column “Diagnosis Conditions Applying On A Memorised Damage” - “Recommendations” are to be applied. When the breakdown is present, these recommendations applying will allowthe display of the information “Breakdown Type” on the tester CLIP screen, thus applying the respective breakdown diagnosis. 13 - 33 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF001 present Computer RECOMMENDATION None Replace the injection computer (UCE). Modify the new computer configuration according to the vehicle existing options, if necessary (In order to perform this intervention read Chapter “Help”) AFTER REPAIRS A road test is to be done, followed by a tester CLIP checking. 13 - 34 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF002 present Water temperature sensor circuit 1.DEF: Measured temperature - too low 2.DEF: Measured temperature - too high RECOMMENDATION 1. DEF 13 Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. Resistance at 20°C: 2500 ±100 Ohms (300 - 450 Ohms at 80°C) RECOMMENDATION None Check the water temperature sensor connections. Repair, if necessary. Measure the water temperature sensor resistance, at its connector. Replace the sensor, in case of damage (open circuit or out of tolerance). Check the injection computer connections. Repair, if necessary. Check the continuity and the isolation as compared to +12 V of the connection between: pin 34 injection computer —› pin 3 water temperature sensor Check the continuity on the electric track: pin 66 injection computer—› pin 2 water temperature sensor 2. DEF RECOMMENDATION None Check the water temperature sensor connector. Repair, if necessary. Measure the water temperature sensor resistance, at its connector. Replace the sensor, in case of damage (open circuit or out of tolerance). Check the connecting system at the computer level. Repair, if necessary. Check the isolation as compared to the mass between: pin 34 injection calculator —› pin 3 water temperature sensor Check whether the sensor circuit is short-circuited (wiring short-circuit between the computer connector pins 34 and 66). AFTER REPAIRS The damages memorised by the injection computer are to be erased, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 35 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF003 present Acceleration potentiometer circuit 1.DEF: Measurement track 1 too low / track 2 2.DEF: Measurement track 2 too low / track 1 3.DEF: Measured voltage at track 2 too high 4.DEF: Measured voltage at track 2 too low 5.DEF: Measured voltage at track 1 too high 6.DEF: Measured voltage at track 1 too low 7.DEF: Value of reference voltage no.2 too low 8.DEF: Value of reference voltage no.2 too high RECOMMENDATION Particularities: The terminal-box ELE. 1497 is to be used for any intervention on the injection computer connector. 1.DEF / 2.DEF RECOMMENDATION None Check the acceleration potentiometer and computer connectors. Repair if necessary. The acceleration potentiometer is to be replaced in case the damage persists after all these checking. 3. DEF RECOMMENDATION None Check the acceleration potentiometer and computer connectors. Repair if necessary. Check the injection computer connector. Repair if necessary. Check the isolation as compared to +12 V of the connection between: pin 37 injection computer —› pin 1 acceleration potentiometer Then check this connection isolation as compared to the connection between: pin 41 injection computer —› pin 6 acceleration potentiometer (5 Volts potentiometer) pin 42 injection computer —› pin 3 acceleration potentiometer (2.5 Volts potentiometer) The acceleration potentiometer is to be replaced in case the damage persists after all these checking. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 36 vnx.su PUMP SUPPLY Diagnosis - damages interpretation 13 DF003 continued 4. DEF None RECOMMENDATION Check the acceleration potentiometer connector. Repair if necessary. Check the injection computer connector. Repair if necessary. Check the continuity and isolation as compared to the mass of the connection between: pin 37 injection computer —› pin 1 acceleration potentiometer Then check this connection isolation as compared to the connection between: pin 62 injection computer —› pin 5 acceleration potentiometer (mass track 2 potentiometer) pin 61 injection computer —› pin 4 acceleration potentiometer (mass track 1 potentiometer) The acceleration potentiometer is to be replaced in case the damage persists after all these checking. 5. DEF RECOMMENDATION None Check the acceleration potentiometer connector. Repair if necessary. Check the injection computer connector. Repair if necessary. Check the isolation as compared to +12 V of the connection between: pin 8 injection computer —› pin 2 acceleration potentiometer Then check this connection isolation as compared to the connection between: pin 41 injection computer —› pin 6 acceleration potentiometer (5 Volts potentiometer) Check the continuity on the electric track: pin 61 injection computer —› pin 4 acceleration potentiometer The acceleration potentiometer is to be replaced in case the damage persists after all these checking. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 37 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF003 continued 6. DEF RECOMMENDATION None Check the acceleration potentiometer connectors. Repair if necessary. Check the injection computer connector. Repair if necessary. Check the continuity and the isolation as compared to the mass of the connection between: pin 8 injection computer—› pin 2 acceleration potentiometer Then check this connection isolation as compared to the connection between: pin 62 injection computer —› pin 5 acceleration potentiometer (mass track 2 potentiometer) pin 61 injection computer —› pin 4 acceleration potentiometer (mass track 1 potentiometer) Check the continuity of the connection between: pin 41 injection computer —› pin 6 acceleration potentiometer The acceleration potentiometer is to be replaced in case the damage persists after all these checking. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 38 vnx.su PUMP SUPPLY Diagnosis - damages interpretation 13 DF003 continued 7. DEF / 8. DEF RECOMMENDATION None Check the acceleration potentiometer connectors. Repair if necessary. Disconnect the acceleration potentiometer and measure the voltage between the terminals 3 and 5 of its connector, with the contact ON. Is the measured voltage within 2.15 and 2.85 Volts? NO Check the acceleration potentiometer connectors. Repair if necessary. In case there is a 7.DEF: Check the isolation as compared to the mass of the connection between: pin 42 injection computer —› pin 3 acceleration potentiometer Then check this connection isolation as compared to the connection between: pin 62 injection computer —› pin 5 acceleration potentiometer (mass track 2 potentiometer) Check again for a possible short-circuit of the potentiometer track 2 between: pin 3 potentiometer —› pin 5 acceleration potentiometer In case there is a 8.DEF: Check the continuit y and thesolati i on as compared to12 + V ofhe t connection between: pin 42 injection computer —› pin 3 acceleration potentiometer Then check this connection isolation as compared to the connection between: pin 41 injection computer —› pin 6 acceleration potentiometer (5 Volts potentiometer) Also check the continuity of the connection between: pin 62 injection calculator—› pin 5 acceleration potentiometer YES AFTER REPAIRS The acceleration potentiometer is to be replaced in case the voltage is zero between the terminals 1 and 5 of its connector (rightly checked supply). The computeris to bereplaced in acse of damaged isolation as compared to +12 Vof theconnection between: pin 37 injection computer —› pin 1 acceleration potentiometer (right supply and wiring) The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 39 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF012 present Battery voltage. 1.DEF: Battery voltage too low 2.DEF: Battery voltage too high RECOMMENDATION Particularities: Completely check the charging circuit, by means of the tester CLIP, if necessary. Perform the necessary interventions in order to get the right supply voltage of the computer: 6 Volts < operation voltage < 16.5 Volts - Check the battery charging - Check the circuit charging - Check the battery terminal situation and tightening up - Check the computer electric connection to the mass AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 40 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF014 present or memorised 13 Stopping electric valve circuit. DEF: Memorised damage 1.DEF: Damaged stopping electric valve 2.DEF: Stopping electric valve operational damage Diagnosis applying condition for the memorised damage: RECOMMENDATION The damage is declared as being present during the starting up step. Particularities: Use the terminal-box ELE.1497 for any intervention on the injection computer connector. 1. DEF RECOMMENDA TION None Check the injection pump connector. Repair if necessary. Measure the stopping electric valve resistance between pins 4 and 11 of the pump connector. Replace the stopping electric valve in case its resistance is not 1.4 ± 0.7 ohms. Check the computer connector. Repair if necessary. Check the continuity and the isolation as compared to +12 V of the connection between: pin 30 injection computer —› pin 11 pump connector Check whether there is supply + After Contact at pin 4 of the pump connector 2. DEF RECOMMENDATION None Check yhe pump connector. Repair if necessary. Disconnect the pump connector, he putcontact t ON and me asure the voltage at the connector11. pin * In case the voltage is not within 9 – 10 Volts, cut the contact and check the following: - The situation of the computer connector - The isolation as compared to the mass of the connection between: pin 30 injection computer —› pin 11 pump connector * In case the voltage is within 9 – 10 Volts, use the actuator control “ELECTRIC STOP”, checking the voltage oscillation between 9 – 10 Volts and the battery voltage during the piloting. In case the piloting cycle is rightly performed, replace the stopping electric valve (mechanical trouble / splinter). In case the piloting cycle is not visualized, replace the injection computer. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 41 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF015 present Anti-starting or memorised Diagnosis applying condition for the memorised damage: The diagnosis is to be applied in case the damage is present RECOMMENDATION or memorised. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. Check the anti-starting function. Check / Valid the anti-starting procedure for both keys. In case the damage persists, check the continuity and isolation of the connection between: pin 20 injection computer —› pin A6 decoder U.C.E. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 42 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF017 present or memorised Injection relay circuit 1.DEF: Permanent supply (the relay does not cut the supply) 2.DEF: The relay cuts the supply too soon; therefore it does not keep the supply. RECOMMENDATION 1. DEF 13 Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. RECOMMENDATION None Check the relay connector. Repair if necessary. Try another relay (write down thememorised damages, replace the relay, cancel the memorised damages, cut the contact and wait for 10 seconds, read the possiblememorised damages). Check the computer connector. Repair if necessary. Check the isolation as compared to the mass of the connection between: pin 82 injection computer —› relay connector (coil mass) Assure the isolation as compared to + battery of the connection between: pins 76 and 77 injection computer —› relay connector (outlet + 12 V) In case the damage persists after all the above-mentioned checking, replace the computer (In order to perform this intervention see Chapter “Help”). 2. DEF RECOMMENDATION None Check the injection relay connector. Repair if necessary. Try another relay (write down the memorised damages, replace therelay, cancel thememorised damages, cut the contact and wait for 10 seconds, read the possible memorised damages). Check the computer connector. Repair if necessary. Check the continuity of the connection between: pin 76 and 77 injection computer —› relay connector (power mass) and wiring situation checking Check the continuity of the connection between: pin 82 injection computer —› relay connector (coil outlet) and wiring situation checking In case the damage persists after all the above-mentioned checking, replace the computer (In order to perform this intervention see Chapter “Help”). AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 43 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF021 present Fuel temperature captor circuit 1.DEF: Measured temperature - very low 2.DEF: Measured temperature - very high RECOMMENDATION 1. DEF Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. RECOMMENDATION None Check the injection pump connector. Repair if necessary Measure the fuel temperature captor resistance at the pump connector, between pins 6 and 7. Replace the captor in case of damages (open circuit). Recommended value: 2716 ± 60 Ohms at 25°C. Check the injection computer. Repair if necessary. Checkthe continuityand the isolation as comparedto + 12 Volts of the connection between: pins 36 injection computer —› pin 6 pump connector 2. DEF RECOMMENDATION None Check the injection pump connector. Repair if necessary. Measure the fuel temperature captor resistance at its connector. Replace the captor in case of damages (short-circuit) Check the injection computer. Repair if necessary. Check the isolation as compared to the mass of the connection between: pins 36 injection computer —› pin 6 fuel temperature captor Check whether the captor circuit is short-circuited. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 44 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF022 prezent 13 Air temperature sensor circuit 1.DEF: Measured temperature - too low 2.DEF: Measured temperature - too high Particularities: Use the terminal-box ELE. 1497 for any RECOMMENDATION intervention on the injection computer connector. Resistance at 20°C: 2500 ±100 Ohms (1070 – 1270 Ohms at 40°C) 1. DEF RECOMMENDATION None Check the air temperature sensor connector. Repair if necessary Measure the air temperature sensor resistance at its connector Replace the sensor in case of damages (open circuit). Check the injection computer. Repair if necessary. Check the continuityand the isolation as comparedto +12 Voltsof the connection between: pins 4 injection computer —› pin 1 air temperature sensor Check the continuity of the connection between: pins 65 injection computer —› pin 2 air temperature sensor 2. DEF RECOMMENDATION None Check the air temperature sensor connector. Repair if necessary Measure the air temperature sensor resistance at its connector Replace the sensor in case of damages (short-circuit). Check the injection computer connector. Repair if necessary. Check the isolation as compared to the mass of the connection between: pins 4 injection computer —› pin 1 air temperature sensor Check whether the sensor circuit is in short-circuiting. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 45 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF023 memorised Engine rotation sensor circuit DEF: Memorised damage 1.DEF: Engine acceleration - too high 2.DEF: Engine deceleration - too high 3.DEF: Impossible measurement of the rotation signal 4.DEF: No rotation signal when engine under operation 5.DEF: No rotation signal at starting Application diagnosis condition on the memorised damage: The damage is declared as being present when an engine-starting test is RECOMMENDATION performed supervising the damages displayed on the screen. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector 1.DEF / 2.DEF / 3.DEF RECOMMENDATION Rotation sensor signal damage Check the rotation sensor connector. Repair if necessary. Measure the rotation sensor resistance at its connector. Replace the sensor in case of damage (recommended value: about 650 – 700 Ohms). Check the rotation sensor connector. Repair if necessary Visually check the general situation of the wiring and rotation sensor wiring circuit in order to find the possible micro-ruptures or parasites. Check the continuity (no parasite resistances) and the isolation of the between: pin 11 injection computer —› pin B rotation sensor pin 74 injection computer —› pin A rota tion sensor Also check the continuity between these connections. Dismount the rotation sensor and check its situation (deformations, dirt etc.) Possibly take into consideration the situation and the conformity of the engine steering wheel (as a result of a part replacement or dismounting of vehicles with low mileage (kilometres recording). 4. DEF / 5. DEF RECOMMENDATION No or lost rotation sensor signal Check the rotation sensor connector. Repair if necessary. Measure the rotation sensor resistance at its connector. Replace the sensor in case of damage (recommended value: about 650 – 700 Ohms). Check the rotation sensor connector. Repair if necessary. Check the continuity and the isolation of the following connections between: pin 11 injection computer —› pin B rotation sensor pin 74 injection computer —› pin A rota tion sensor Also check the isolation between these connections. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 46 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF024 present 13 Atmospheric pressure sensor circuit 1.DEF: Measured pressure – too low 2.DEF: Measured pressure – too high RECOMMENDATION None Replace the injection computer. In case it is necessary, modify the new computer configiuration as compared to the vehicle existing options (In order to perform this intervention see Chapter “Help”). AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 47 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF027 present or memorised EGR electric valve circuit DEF: Memorised damage CO.0: Open cir cuit or short-circuit at mass (present damage) CC.1: Short-circuit at +12 Volts (memorised damage) 1.DEF: Electric valve position out of low limit (present damage) 2.DEF: Electric valve position out of high limit (present damage) 3.DEF: Electric valve positioning loop checking (memorised damage) 4.DEF: EGR calibration in close position Application diagnosis condition on the memorised damage: The damage is declared as being present after giving the actuator order “EGR Electric Valve” or after the engine start-up and the checking of RECOMMENDATION the situation “EGR Electric Valve” by means of the tester CLIP (engine condition: air temperature > 15°, water temperature > 15°). In case there is not damage confirmation, apply the diagnosis for DEF. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. CO.0 RECOMMENDATION None Check the EGR electric valve connector. Repair if necessary. Measure EGR electric valve resistance between the connector pins 1 and 5. Replace the EGR electric valve / captor assembly, in case the measured resistance is not within 8 ± 0.5 Ohms. Check the injection computer connector. Repair if necessary. Check the continuity and the isolation as compared to the mass of the connection between: pin 5 injection computer —› pin 5 EGR electric valve Check the +After Contact supply at pin 1 of the EGR electric valve CC.1 RECOMMENDATION None Check the EGR electric valve connector. Repair if necessary. Measure EGR electric valve resistance between the connector pins 1 and 5. Replace the EGR electric valve / captor assembly, in case the measured resistance is not within 8 ± 0.5 Ohms. Check the injection computer connector. Repair if necessary. Check the isolation as compared to +12 Volts of the connection between: pin 59 injection computer —› pin 5 EGR electric valve AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 48 vnx.su PUMP SUPPLY Diagnosis - damages interpretation 13 DF027 continued 1. DEF RECOMMENDATION None Check the EGR electric valve connector. Repair if necessary Check the injection computer connector. Repair if necessary Check the continuity and the isolation of the connection between: pin 35 injection computer —› pin 6 EGR electric valve Check the continuity of the connection between: pin 39 injection computer —› pin 2 EGR electric valve pin 63 injection computer —› pin 4 EGR electric valve In case of ‘EGR ELECTRIC VALVE CIRCUIT” damage reaparition, replace the EGR electric valve / EGR valve positioning captor assembly (In order to perform this intervention read the “Repairs Book”). 2. DEF RECOMMENDA TION None Check the EGR electric valve connector. Repair if necessary Check the injection computer connector. Repair if necessary Check the isolation as compared to +12 Volts of the connection between: pin 35 injection computer —› pin 6 EGR electric valve Also check the isolation of this connection as compared to the connection between: pin 39 injection computer —› pin 2 EGR electric valve (+5 Volts potentiometer) In case of ‘EGR ELECTRIC ALVE V CIRCUIT” dam age reaparition, replace the EGR electric valve / EGR valve positioning captor as sembly (In order to perform this intervention read the Repairs “ Book”) AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 49 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF027 continued 3. DEF RECOMMENDATION None Cancel the memorised damages of the computer. Start the engine and test the situation “EGR ELECTRIC VALVE CONTROL” by means of the tester CLIP. Wait for the EGR electric valve control displaying (engine condition: air temperature > 15° and water temperature > 15°). In case of damage reappearance, dismount the4 electric valve. In case of impossible dismounting, extract the air filter then dismount the electric valve by pushing it from its inside. Pay attention not to damage the valve shaft and valves. Check whether the valve is blocked. - In case it is blocked on intermediary position: Replace the EGR Electric Valve / EGR valve position captor. - In case it is blocked on closed position (valves oxidized seats, electric valve): Try the electric valve unblocking. * In case the valve is still blocked, replace the EGR Electric Valve / EGR valve position captor. * In case the valve unblocks, reconnect the electric valve connector and repeatedly pilot the valve by means of the actuator control “EGR ELECTRIC VALVE”. Clean if necessary. Replace the EGR Electric Valve / EGR valve position captor, in case there are operation troubles. 4. DEF RECOMMENDATION None Check the computer connector. Repair if necssary Measure the resistance of the EGR valve position captor between the computer connector pins 63 and 39 (theoretical resistance = 4 Kohms ± 40%. - In case the resistance is right, replace the EGR Electric Valve / EGR valve position captor (blocked valve). - In case the resistance is wrong, directly measure the resistance of the EGR valve position captor between the pins 2 and 4 of the EGR connector. In case the measured value is wrong, replace the EGR Electric Valve / EGR valve position captor. In case the measured value is right, check the wiring and its connectors. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 50 vnx.su PUMP SUPPLY Diagnosis - damages interpretation 13 DF027 continued DEF RECOMMENDATION None Check the EGR electric valve connector. Repair if necssary. Measure the resistance of the EGR valve between its connector pins 1 and 5. In case the measured value is not within 8 ± 0.5 Ohms, replace the EGR Electric Valve / EGR valve position captor. Check the injection computer connector. Repair if necessary Check the continuity and isolation of the connection between: pin 59 injection computer —› pin 5 EGR electric valve pin 35 injection computer —› pin 6 EGR electric valve pin 39 injection computer —› pin 2 EGR electric valve pin 63 injection computer —› pin 4 EGR electric valve Measure the resistance of the EGR valve position captor between the computer connector pins 63 and 39 (theoretical resistance = 4 Kohms ± 40%. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 51 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation Cooling motor-fan group circuit DEF: Memorised damage CO.0: Open circuit or short-circuit at mass CC.1: Short-circuit at +12 Volts DF 048 present or memorised RECOMMENDATION CO. 0 Application diagnosis condition on the memorised damage: The CC.1 diagnosis is to be applied in case the damage reappears as memorised after Memorised Damages Cancelling and Actuator Control “Motor-fan Group LOW SPEED” Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. RECOMMENDA TION None Measure the GMV relay coil resistance, placed in the engine fuse box. Replace the relay in case the measured resistance is not equal to 65 Ohms. Check the GMV relay connector. Check whether there is + 12 Volts supply at the GMV relay pin 1. Check the injection computer connector. Check thecontinuity and isolation as compared to the massof theconnection between: pin 53 injection computer —› pin 2 GMV relay In case the damage persists after these checking’s, the GMVelay r is to be replaced. CC.1 RECOMMENDATION None Measure the GMV relay coil resistance. Replace the relay in case the measured resistance is not equal to 65 Ohms. Check the isolation as compared to +12 Volts of the connection between: pin 53 injection computer —› pin 2 GMV relay AFTER REPAIRS The damages memorised by the injection computer are to becancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 52 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF053 present 13 Protection circuit RECOMMENDATION None Replace the injection computer. If necessary, modify the new computer configuration, according to the vehicle present options (In order to perform this intervention read the Chapter “Help”). AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 53 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF054 present Pump memory circuit RECOMMENDA TION None Check the pump connector. Repair if necessary. Check the injection computer connector. Repair if necessary Assure the continuity and isolation of the connections between: pin 51 injection computer —› pin 8 pump connector pin 67 injection computer —› pin 7 pump connector In case the first checking do not allow to locate the origin of the damage “PUMP MEMORY CIRCUIT” and if the tester CLIP still declares this damage as being present, all checking are to be done again. In case the damage persists, the pump is to be replaced. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 54 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF056 present or memorised 13 Control circuit of sparking plugs pre-heating relay DEF: Memorised damage CO.0: Open circuit or short-circuit at mass CC.1: Short-circuit at +12 Volts Application diagnosis condition on the memorised damage: The CC.1 diagnosis is to be applied in case the damage reappears RECOMMENDATION as memorised after Memorised Damages Cancelling and Actuator Control “PRE-HEATING RELAY” Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector CO. 0 RECOMMENDATION None Check the two connectors of the sparking plugs pre-heating relay. Repair when necessary. Disconnect the 6-way connector pof the pre-heating relay and check its supply: - Supply presence: + After Contact between pins A1 and A2 of the 6-pins connector - Supply presence: In front of the contact at 3-way connector pin 2 (fuse 70A). Perform the necessary interventions. Check the injection computer connector. Repair if necessary Check the continuity and isolation as compared to the mass of the connections between: pin 52 injection computer —› pin B1 pre-heating relay 6-pins connector CC. 1 RECOMMENDATION None Check the isolation as compared to + 12 Volts of the connections between: pin 52 injection computer—› pin B1 pre-heating relay 6-pins connector AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 55 vnx.su 13 DF058 present PUMP SUPPLY Diagnosis - damages interpretation Captors reference voltage (+5 Volts) 1.DEF: Captors reference voltage – too low 2.DEF: Captors reference voltage – too high RECOMMENDATION Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector 1.DEF RECOMMENDATION None Check the acceleration potentiometer connector. Repair if necessary. Check again a possible short-circuitof the potentiometer track 1 between pins 4 and 6. Check the EGR valve connector. Repair if necessary. Check again a possible short-circuit of the valve potentiometer track 1 between pins 2 and 4. Check the injection computer connector. Repair if necessary Check the isolation as compared to the mass of the connections between: pin 41 injection computer —› pin 6 acceleration potentiometer connector pin 39 injection computer —› pin 2 EGR valve connector In case the first checking do not allow to locate the origin of the damage “CAPTORS REFERENCE VOLTAGE” and if damage persists, all checking are to be done again. In case the damage still persists, the computer is to be replaced 2.DEF RECOMMENDATION None Check the EGR valve computer connector. Repair if necessary. Check the pump connector. Repair if necessary Check the injection computer connector. Repair if necessary Check the isolation as compared to the mass of the connections between: pin 41 injection computer —› pin 6 acceleration potentiometer connector pin 39 injection computer —› pin 2 EGR valve connector pin 12 injection computer —› pin 9 pump connector pin 13 injection computer —› pin 13 pump connector pin 14 injection computer —› pin 10 pump connector pin 15 injection computer —› pin 12 pump connector AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 56 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF059 present or memorised 13 Advance circuit DEF: Memorised damage CO.0: Open cir cuit or short-circuit at mass CC.1: Short-circuit at +12 Volts 1.DEF: Cam position out of low limit 2.DEF: Cam position out of high limit 3.DEF: Wrong cam position 4.DEF: Incoherence between the measured position and the mechanical stopper Application diagnosis condition on the memorised damage: The DEF / 3.DEF / 4.DEF diagnosis is to be applied in case the damage reappears as present or memorised after Memorised Damages Cancelling and Road RECOMMENDATION Testing. Particularities: This damage will not be taken into consideration in case the fuel circuit is re-started by means of the re-starting mechanism (near the diesel oil filter) and the contact ON. Just cancel the memorised damages. Use the terminal-box ELE. 1497 for any intervention on the injection computer connector CO. 0 RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the advance electric valve resistance between pins 3 and 4 of the pump connector. Replace the advance electric valve when the resistance is not equal to 30 ± 2 Ohms. Check the injection computer connector. Repair if necessary. Check the continuity and isolation as compared to the mass of the connection between: pin 89 injection computer —› pin 3 pump connector Check the supply presence + After Contact at the pump connector pin 4 CC. 1 RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the advance electric valve resistance between pins 3 and 4 of the pump connector. Replace the advance electric valve when the resistance is not equal to 30 ± 2 Ohms. Check the injection computer connector. Repair if necessary. Check the continuity and isolation as compared to the mass of the connection between: pin 89 injection computer —› pin 3 pump connector AFTER REPAIRS The damages memorised by the injection computer are to becancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 57 vnx.su 13 PUMP SUPPLY Diagnosis - damages interpretation DF059 continued 1.DEF RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the position captor resistance between pins 13 and 12 of the pump connector. Replace pump when the resistance is not equal to 52 ± 4 Ohms. Check the injection computer connector. Repair if necessary. Check the isolation as compared to the mass of the connection between: pin 12 injection computer —› pin 9 pump connector Check the isolation as compared to the mass of the connection between: pin 14 injection computer —› pin 10 pump connector 2.DEF RECOMMENDATIONNone Check the pump connector. Repair if necessary. Measure the position captor resistance between pins 13 and 12 of the pump connector. Replace pump when the resistance is not equal to 52 ± 4 Ohms. Check the injection computer connector. Repair if necessary. Check the isolation as compared to the mass of the connection between: pin 13 injection computer —› pin 13 pump connector Check the isolation as compared to the mass of the connection between: pin 15 injection computer—› pin 12 pump connector AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 58 vnx.su PUMP SUPPLY Diagnosis - damages interpretation 13 DF059 continued DEF / 3.DEF / 4.DEF RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the advance electric valve resistance between pins 3 and 4 of the pump connector. Replace the advance electric valve when the resistance is not equal to 30 ± 2 Ohms. Measure the position captor resistance between the pump connector pins 12 and 13. Replace the pump when the resistance is not equal to 52 ± 4 Ohms. Check the computer connector. Repair if necessary. Measure the line resistance of the connection between: pin 13 injection computer —› pin 13 pump connector Perform the necessary interventions in case the resistance is abnormally high (when the resistance > 0,2 Ohms) The pump is to be replaced in case the damage persists. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 59 vnx.su 13 DF061 present or memorised PUMP SUPPLY Diagnosis - damages interpretation Pre-heating sparking plugs Application diagnosis condition on the memorised damage: The damage reappears as present for 30 seconds as a result of the RECOMMENDATION contact putting ON before being memorised. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector Check the two connectors of the sparking plugs pre-heating relay. Repair if necessary Check the pre-heating relay supply: +After Contact supply presence between the 6-way connector pins A1 and A2 and + In front Of The Contact supply presence at the 3-way pins connector pin 2 (fuse 70A). Perform the necessary interventions. Check the injection computer connector. Repair if necessary. Check the continuity an isolations of the connection between: pin 49 injection computer —› pin C1 pre-heating relay connector Check the continuity and isolation as compared to the mass of the pre-heating sparking plugs supplying wires. Reconnect the computer and the pre-heating relay. Start the engine and keep it in idle running. Activate the “PRE-HEATING RELAY” actuator control following the voltage on the sparking plugs. - When the piloting cycle is visualized, check and replace the sparking plug / plugs. - When the piloting cycle is not visualized, replace the pre-heating relay. AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 60 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF065 present or memorised 13 Fuel flow actuator circuit 1.DEF: Memorised damage at flow actuator 2.DEF: Memorised damage at flow actuator + 1.CO.0: Open circuit or short-circuit at mass 1.CC.1: Short-circuit at + 12 Volts 2.CO.0: Open circuit or short-circuit at mass 2.CC.1: Short-circuit at + 12 Volts 1.DEF Application diagnosis condition on the memorised damage: The diagnosis CC.1 is to be applied in case the damage reappears as memorised, as the result of cancelling the memorised damages and RECOMMENDA TION actuator control “FLOW ACTUATOR 1” or of the engine-starting step. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. 1.CO. 0 RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the flow electric valve resistance (-) at the pump connector level between pins 2 and 4. Replace the electric valve in case of damage (open circuit). Theoretical value: 30 ± 2 Ohms. Disconnect the pump connector, put the contact ON and measure the voltage at the connector pin 2. * In case the measured voltage is not within 9 – 10 Volts cut the contact and perform the following checking: - Injection computer connector situation - Continuity and isolation as compared to the mass of the connection between: pin 90 injection computer —› pin 2 pump connector - Presence of +After Contact supply at the pump connector pin 4. * In case the measured voltage is within 9 – 10 Volts, use the actuator “FLOW ACTUATOR 1” control, checking the change from the 9 – 10 Volts voltage to the battery voltage during the driving. - In case the piloting is right, replace the flow electric valve (+). - In case the piloting is not visualised, replace the injection computer. Make sure there is + After Contact supply at the pump connector pin 4. 1.CC. 1 RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the flow electric valve resistance (-) at the pump connector level between pins 2 and 4. Replace the electric valve in case of damage (short-circuit). Theoretical value: 30 ± 2 Ohms. Check the injection computer connector. Repair if necessary. Check the isolation as compared to +12 Volts of the connection between: pin 90 injection computer —› pin 2 pump connector AFTER REPAIRS The damages memorised by the injection computer are to becancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 61 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF065 continued 2.DEF 2.CO. 0 Application diagnosis condition on the memorised damage: The diagnosis 2.CO.0 is to be applied in case the damage reappears as memorised as the result of cancelling the memorised damages and actuator RECOMMENDATION control “FLOW ACTUATOR 2”. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the flow electric valve resistance (+) at the pump connector level between pins 2 and 4. Replace the electric valve in case of damage (open circuit). Theoretical value: 30 ± 2 Ohms. Disconnect the pump connector, put the contact ON and measure the voltage at the connector pin 5. * In case the measured voltage is not within 9 – 10 Volts cut the contact and perform the following checking: - Injection computer connector situation - Continuity and isolation as compared to the mass of the connection between: pin 60 injection computer —› pin 5 pump connector - Presence of +After Contact option at the pump connector pin 4. * In case the measured voltage is within 9 – 10 Volts, use the actuator “FLOW ACTUATOR 2” control, checking the change from the 9 – 10 Volts voltage to the battery voltage during the driving. - In case the piloting is right, replace the flow electric valve (+). - In case the piloting is not visualised, replace the injection computer Make sure there is + After Contact option at the pump connector pin 4. 2.CC. 1 RECOMMENDATION Damage of the flow electric valve (+). Check the pump connector. Repair if necessary. Measure the flow electric valve resistance (+) at the pump connector level between pins 5 and 4. Replace the electric valve in case of damage (short-circuit). Theoretical value: 30 ± 2 Ohms. Check the injection computer connector. Repair if necessary. Check the isolation as compared to +12 Volts of the connection between: pin 60 injection computer —› pin 5 pump connector AFTER REPAIRS The damages memorised by the injection computer are to becancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 62 vnx.su PUMP SUPPLY Diagnosis - damages interpretation 13 Fuel flow actuator position DF066 present or memorised DEF: Memorised damage 1.DEF: Flow rotor position captor damage 2.DEF: Incoherence between rotor position and minimal stopper 3.DEF: Incoherence between rotor position and maximal stopper 4.DEF: Loss of fuel flow loop control Treatment priority in case of damagesplurality: In case the damage DF065 or DF023 are declared as being present or memorised, treat them in priority. These damages can be memorised during a vicious operation of the rotation sensor (to be confirmed during the starting step) Application diagnosis condition on the memorised damage: The damage appears as being present or memorised as a result of the followings: RECOMMENDATION - Engine starting step or - Cancelling of the memorised damages and o f actuators “FLOW ACTUATOR 1” and “FLOW ACTUATOR 2” controls or - Running with a deceleration for longer than 4 seconds (engine braking when lifting the foot off the clutch). A too tighten distribution belt could cause the flow rotor captor blocking. The diagnosis DEF / 2.DEF / 3.DEF / 4.DEF is to be applied. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. 1.DEF RECOMMENDATION None Check the pump connector. Repair if necessary. Measure the resistances at the pump connector following pins: - Between pins 10 and 12 : 41.3 ± 4 Ohms - Between pins 9 and 10 : 200 ± 30 Ohms - Between pins 12 and 13 : 52 ± 4 Ohms Replace the pump in case the measured value / values is / are wrong. Check the injection computer connector. Repair if necessary.Check the continuity and isolation as compared to the mass of the following connections between: pin 12 injection computer —› pin 9 pump connector pin 14 injection computer —› pin 10 pump connector pin 15 injection computer —› pin 12 pump connector Check the isolation as compared to the mass of the connections between: pin 13 injection computer —› pin 13 pump connector If the first checking do not allow to locate the “FUEL FLOW CIRCUIT” damage origin and if this damage is still declared as being “present” after diagnosis by means of the tester CLIP, perform all the checking again. In case the damage persists, replace the injection computer. AFTER REPAIRS The damages memorised by the injection computer are to becancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 63 vnx.su PUMP SUPPLY 13 Diagnosis - damages interpretation DF066 continued DEF / 2.DEF / 3.DEF / 4.DEF RECOMMENDATION None Check the pump connector and the situation of the wiring between the pump connector ant the electric valves assembly. Selectively choose the actuators “FLOW ACTUATOR 1” and “FLOW ACTUATOR 2” controls and audio-check the valves operation (regular hammering). Replace the damaged parts. Disconnect the computer. Measure the resistances between the injection computer connector following ways: - Between pins 14 and 15 : 41,3 ± 4 Ohms - Between pins 14 and 12 : 200 ± 30 Ohms Are the measured resistances right? Yes Check the computer connector. Repair if necessary. No Check the pump connector, then measure the resistances between the following pins: - Between pins 10 and 12 : 41,3 ± 4 Ohms - Between pins 10 and 9 : 200 ± 30 Ohms If the measured value/values is/are wrong replace the pump. Check the computer connector. Repair if necessary. Measure the line resistance of the following connections: pin 12 injection computer —› pin 9 pump connector pin 14 injection computer —› pin 10 pump connector pin 15 injection computer —› pin 12 pump connector If the first checking do not allow to locate the “FUEL FLOW CIRCUIT” damage origin and if this damage is sti ll declared as bein g “present ” under the co ndi tion describ ed in Chap ter “Recommendations”, performall the checking again. In case the damage persists, replace the pump. AFTER REPAIRS The damages memorised by the injection computer are to becancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 64 vnx.su PUMP SUPPLY Diagnosis - damages interpretation DF0103 present or memorised 13 Pre-heating indicator circuit injection damage: DEF: Memorised damage CO.0: Open circuit or short-circuit at mass CC.1: Short-circuit at +12 Volts Application diagnosis condition on the memorised damage: The diagnosis CC.1 is to be applied in case the damage reappears as memorised as the result of cancelling the memorised damages RECOMMEND ATION and actuator control “PRE-HEATING INDICATOR”. Particularities: Use the terminal-box ELE. 1497 for any intervention on the injection computer connector. CO. 0 RECOMMENDATIONNone Check the pre-heating indicator lamp situation and the presence of the option + After Contact at this indicator. Check the computer connector and the instrument panel connectors. Check the continuity and isolation as compared to the mass of the connection between: pin 24injection computer —› pre-heating indicator / instrument panel injection damage. CC. 1 RECOMMENDATION None Check the continuity and isolation as compared to +12 Volts of the connection between: pin 24injection computer —› pre-heating indicator / instrument panel injection damage Check the pre-heating indicator lamp (lamp short-circuit). AFTER REPAIRS The damages memorised by the injection computer are to be cancelled, the contact is to be cut and a road test is to be performed. At the end of the operation, check by means of the tester CLIP. 13 - 65 vnx.su 13 PUMP SUPPLY Diagnosis – Help INJECTION COMPUTER REPLACEMENT (Or as a result of a re-programming) The followings are to be performed when the injection computer is to be replaced: - The contact is to be OFF. - Connect the tester CLIP at the diagnosis socket and at the vehicle battery. - Replace the injection computer. - Put the contact ON and wait for 15 seconds (necessary time of data transferring into pump memory). Not to worry if the pre-heating indicator does not light. - Cut the contact and wait for 10 seconds (loss of communication). - Put the contact ON, then start the tester CLIP. - Configure the computer according to the vehicle equipment level. - Cut the contact and wait for 10 seconds (loss of communication). - Check whether the computer configuration is right. - Try to start up the engine (pre-heating function activation). - Cut the contact and wait for 10 seconds (loss of communication). - Put the contact ON and check whether the pre-heating indicator operates. - Start the engine and make sure there is not any damage. INJECTION PUMP REPLACEMENT The followings are to be performed when the injection pump is to be replaced: - The contact is to be OFF. - Replace the pump. - Put the contact ON and wait for 15 seconds (necessary time of data transfer into pump memory). - Cut the contact and wait for 10 seconds (loss of communication). - Start the engine and make sure there is not any damage. 13 - 66 vnx.su PUMP SUPPLY 13 Diagnosis - Conformity checking RECOMMEND ATION Not to perform this conformity checking unless a complete checking was performed by means of the tester CLIP (lack of damages). Current Function number Situation/Parameter Visualization and remarcs Diagnosis 1 ET 051: The engine does not turn at contact Confirmed situation Nothing to refer to PR 004: Computer supplying voltage 11,8 < X < 13,2 V In case of trouble check this parameter diagnosis ET 004: Injection damage indicator Unconfirmed situation. Nothing to refer to ET 008: Superheating indicator Unconfirmed situation. Lit for few seconds when putting the contact ON ET 044: At least one “Degraded mode” activation. Unconfirmed situations Nothing to refer to 2 3 4 Battery voltage Instrument panel indicator Damage absence ET 045: Diminution engine performance 5 ET 040: Started engine Confirmed situation at started engine PR 001: Diesel oil Diesel oil temperature captor temperature - 10° < X < 140°C Water temperature PR 002: Water temperature sensor - 32° < X < 140°C 6 Air temperature sensor PR 003: Air temperature - 32° < X < 140°C 13 - 67 vnx.su Nothing to refer to In case of trouble check the d iagnos is o f th ese parameters PUMP SUPPLY 13 Diagnosis - Conformity checking RECOMMEND ATION Not to perform this conformity checking unless a complete checking was performed by means of the tester CLIP (lack of damages). Current Function number 7 Clutch potentiometer Situation/Parameter Visualization and remarks PR 008: Potentiometer 4 % < X < 96 % voltage, track P1 PR 009: Potentiometer 4 % < X < 56 % voltage, track P2 8 Atmospheric pressure sensor 9 PR 016: atmospheric pressure 420 mbar < X < 1070 mbar ET 021: EGR electric valve control Confirmed situation according to the operation EGR operation PR 024: EGR electric valve RCO 10 11 12 Rotation sensor Injection pump operation PR 006: Engine rotation Control: motor-fan group 13 In case of trouble check the diagnosis of this parameter In case of trouble check the diagnosis of this parameter In case of trouble check the diagnosis of this situation X = / = 0% when E.G.R. is active Engine rotation (rpm): X75 = 875 rpm 250 us < X < 800 us PR 060: Rotor position us = SEEM units measurement Motor-fan group Diagnosis The motor-fan group running is to be heard Flow electric valves Control: flow actuator 1 The actuators rhythmic movement is (flow -) Control: flow actuator 2 to be heard (flow +) 13 - 68 vnx.su In case of trouble check the diagnosis of this parameter In case of trouble check the diagnosis of this parameter In case of trouble check the diagnosis of this control In case of trouble check the diagnosis of this control PUMP SUPPLY 13 Diagnosis - Conformity checking RECOMMENDATION Not to perform this conformity checking unless a complete checking was performed by means of the tester CLIP (lack of damages). Current Function number Situation/ Parameter Visualization and remarks Diagnosis 14 Advance electric valves Control: advance actuator The actuator rhythmic movement is to be heard In case of trouble check the diagnosis of this control 15 Stop electric valve Control: electric stop The actuator rhythmic movement is to be heard In case of trouble check the diagnosis of this control 13 - 69 vnx.su 13 RECOMMENDATION PUMP SUPPLY Breakdown localizing algorithm Not to use this information unless a complete checking was performed by means of the tester CLIP. TESTER – INJECTION COMPUTER IMPOSSIBLE COMUNICATION ALP 1 STARTING TROUBLES (engine does not start or hardly starts) ALP 2 IDLE RUNNING TROUBLES (unstable idle running) ALP 3 SUDDEN ACCELERATION OR DECELERATION (engine fragmented running) ALP 4 13 - 70 vnx.su PUMP SUPPLY Breakdown localizing algorithm ALP 1 13 TESTER – INJECTION COMPUTER COMUNICATION IMPOSIBILITY RECOMMENDATION None Make sure the tester does not cause the damage, trying to communicate with another vehicle computer. In case the tester is right but the communication is not possible with any other vehicle computer, the diagnosis lines K and L may be perturbed by a damaged computer. Successively disconnect the other computers (UCE anti-starting) in order to locate the damaged one. Measure the battery voltage and perform the necessary interventions to obtain the according voltage (7 Volts < battery U < 16 Volts). Check the presence and situation of the injection computer supplying safety fuse (fuse 7,5A), placed into the engine safety fuse box. Check the connection of the computer connector and its connector situation. Check whether the computer is rightly supplied. - presence of connection at Mass at Pins 78 and 79 - supply + After Contact at pin 81 supply + 12 Volts, After the injection relay at pins 76 and 77 Check whether the vehicle diagnosis socket is rightly supplied - supply + In front of the contact at pin 16 - presence of connection at Mass at Pin 5 Check the continuity and isolation of the connecting lines between the diagnosis socket and the injection computer: - between pin 3 injection computer connector and pin 15 diagnosis socket - between pin 33 injection computer connector and pin 7 diagnosis socket In case that the communication cannot be performed after all these checking, the injection calculator is to be replaced (prior this intervention performing read Chapter “Help”. AFTER REPAIRS Repair the possible detected damages when re-establishing the dialogue. 13 - 71 vnx.su PUMP SUPPLY 13 Breakdown localizing algorithm ALP 2 STARTING TROUBLES (engine does not start or hardly starts) RECOMMENDATION Not to use this information unless a complete checking was performed by means of the tester CLIP. In case the tester does not indicate any damage, make sure the trouble is not caused by the antistarting system breakdown. Check the pre-heating operation by means of the tester CLIP. Check the pre-heating sparkling plugs voltage by means of the actuator “PRE-HEATING RELAY” control. - In case any sparking plug is under supply, check the connection of the pre-heating relay 3way connector. Also check the 70A safety fuse situation, placed in the engine fuse box. - In case there is supply only at one sparking plugs group, check the continuity of the electric track between the sparking plugs and the pre-heating relay - In case the sparking plugs are supplied when their connectors are disconnected, check the sparking plugs resistance (it should be within 0,6 ± 0,1 Ohms). - The pre-heating relay is to be replaced in case the damage persists. Check the fuel supplying circuit (of the pump and of the injectors )in case the damage persists. If is necessary, completely check the engine (driving speed starting, pump injection blocking, injectors situation, valves laches, engine compression...) AFTER REPAIRS Perform a road test, then a checking by means of the tester CLIP. Repair the possible detected damages. 13 - 72 vnx.su PUMP SUPPLY Breakdown localizing algorithm ALP 3 13 IDLE RUNNING TROUBLES RECOMMENDATION Do not use this informations unless a complete checking was performed by means of the tester CLIP. In case the tester clip does not indicate any damage, make sure the trouble is not caused by a mechanical trouble of the EGR valve position. Check the fuel conformity. Check for clogging and unsealing on air intake circuit, exhaustion circuit and fuel supplying circuit. In case the trouble persists, completely check the engine (pump blocking, injectors situation, engine compression) Check the motor flywheel. Connect the tester CLIP for the flywheel checking and follow its indications. AFTER REPAIRS Perform a road test, then a checking by means of the tester CLIP. Repair the possible detected damages. 13 - 73 vnx.su PUMP SUPPLY 13 Breakdown localizing algorithm ALP 4 SUDDEN ACCELERATION OR DECELERATION (engine fragmented running) RECOMMENDATION Do not use this informations unless a complete checking was performed by means of the tester CLIP. Check the fuel conformity. Check for clogging and unsealing on air intake circuit, exhaustion circuit and fuel supplying circuit. Check the absence of oil steam re-intake. In case the trouble persists, completely check the engine (injectors, injection pump, engine flywheel). AFTER REPAIRS Perform a road test, then a checking by means of the tester CLIP. Repair the possible detected damages. 13 - 74 vnx.su ANTIPOLLUTION 14 Oil vapors re-aspiration THE CIRCUIT DIAGRAM 4 3 2 1 1. 2. 3. 4. Engine Oil setting tank. Air filter box Intake manifold CHECKING In order to ensure a good operation of the anti-pollution system, the oil vapors reaspiration circuit must be maintained clean and in good condition. 14 - 1 vnx.su ANTIPOLLUTION 14 Exhaust gases recycling (E.G.R.) THE CIRCUIT DIAGRAM 3 1 6 5 2 1. 2. 3. 4. 5. 6. 4 Engine Injection computer Intake manifold Exhaust collector E.G.R. valve Cooling fluid temperature sensor. E.G.R. ELECTRIC VALVE DISMOUNTING The E.G.R. electric valve is mounted in the intake manifold. In order to enable its replacement, it is recommended to dismount first the Air filter assembly. Dismount : -battery, - EGR electric valve connector, -air temperature sensor connector, - connector from thediesel filter, - connection from the vacuum pump. Dismount the air filter assembly. Dismount the EGR attachment screws. Remove the EGR electric valve. 14 - 2 vnx.su ANTIPOLLUTION Exhaust gases recycling (E.G.R.) 14 OPERATION CONDITIONS REMOUNTING Perform the dismounting operations in the reverse order. Tighten the electric valve attachment screws at t he required moment of (0,8 daN). THE E.G.R. PURPOSE T he exhaust gases recycling is performed for reduction of the nitrogen oxide content (N0x) from the exhaust gases. The injection computer is authorizing the passing of the recycled gas towards the intake manifold, by means of an electric valve. THE OPERATION PRINCIPLE The electric valve is controlled by a R.C.O . signal issued by the injection computer.The R.C.O. signal is allowing the valve opening modification and consequently of the exhaust gas quantity diverted towards the intake manifold. The computer is permanently performing a knowledge test of the E.G.R. electric valve flap position. The E.G.R. electric valve activation is governed by the following parameters: - air temperature - cooling fluid temperature - acceleration pedal position - engine RPM - vehicle speed - battery voltage E.G.R is not supplied if : - air temperature is bellow 15° C or above 60°C - cooling fluid temperature is bellow 15° C or above 60° C. - battery voltage is bellow 10V - the atmospheric pressure is bellow 890 mbars - if the RPM/ engine load parameters exceed a certain value imposed by the charts from the computer memory If the a.m. conditions are not accomplished, the electric valve is supplied for a period of 30 s after starting. For exhaust gases recycling at idling, it is necessary that vehicle is running more than 10 Km/h. E.G.R. electric valve is then not supplied for 30 sec. At each return to idling. The injection computeris not controlling E.G.R in case of the damage of one of the following elements: - cooling fluid temperature sensor - air temperature sensor - atmospheric pressure captor - vehicle speed transducer - increased flow electric valve or reduced flow electric valve - E.G.R. electric valve 14 - 3 vnx.su 14 ANTIPOLLUTION Exhaust gases recycling (E.G.R.) 6 5 1 4 2 1. 2. 4. 5. 6. Coil supply Captor supply Captor mass Coil mass Captor exit 14 - 4 vnx.su STARTING AND CHARGING 16 Alternator IDENTIFICATION ENGINE ALTERNATOR F8Q - 636 VALEO A 11 VI 88 INTENSITY 75A CHECKING After 15 minutes of heating under a 13.5 V tension. Engine RPM ( rot/min) Intensity (A) 1000 2000 3000 4000 46 68 71 72 OPERATION / DIAGNOSTIC These vehicles are equipped with alternators with internal ventilation, incorporated voltage regulator, and charging indicator on the instrument panel, which must operate as follows: - when the contact is set on, the luminous indicator is on, - after engine starting, the indicator is off, - if indicator goes on during engine running, then it shows a charging failure. INCIDENTS SEEKING The luminous indicator does not go on when setting the contact on. In this case, check the following: - the electric connections of the alternator and of the instrument panel indicator must be well done. - the indicator bulb is not worn (when the circuit is mass connected, the bulb must be on). The indicator is going on during engine running. This shows a charging failure, which may be caused by: - alternator drive belt broken, charging wire connected to alternator is broken. - alternator failure(rotor, stator, diodes or brushes) - voltage regulator failure. 16 - 1 vnx.su 16 STARTING AND CHARGING Alternator Client is claiming a charging defect, but the luminous indicator is correctly operating. If the adjusted voltage is smaller than 13.5 V, check the alternator. The defect may be caused by : - worn diode, - broken phase, - collector wear. VOLTAGE CHECKING Connect a voltmeter to the battery plugs and read its value. Start the engine and speed the engine till the voltmeter needle is set on the adjusted voltage. This voltage must be between 13.5 V and 14.8 V. Connect maximum of consumers; the voltage must still between 13.5 V and 14.8 V. ATTENTION ! In case electric arch welding is performed on vehicle, obligatory disconnect the battery and the alternator . 16 - 2 vnx.su STARTING AND CHARGING Alternator 16 DIAGNOSTIC SPECIAL TOOLS CLIP-SAGEM tester Accessories for physical measurements CHECKING OF THE CHARGING CIRCUIT CLIP-SAGEM tester is enabling the alternator checking, by measuring the generated voltage and intensity with and without electric consumers. NOTE : The ammeter pliers is of inductive type 0 ÷ 500 A. Its mounting does not imply the battery disconnecting, enabling so the memorized data preserving and the adapting values from the injection computer. Mount the ammeter directly on the alternator charging cable (permanently + ), having the arrow directed towards the alternator. The measurements are to be performed in three stages : - measurement of the battery voltage with contact taken off, without consumers; - measurement without consumers of the adjusted voltage and generated intensity; - measurement, with maximum of consumers, of the adjusted voltage and generated intensity. The values resulting further to the measurements, lead to following interpretations: - voltage battery (without consumers) < 12.3 V – indicating that battery is discharged. Without consumers : - adjusted voltage > 14.8 V – indicating that voltage regulator is defect; - adjusted voltage < 13.2 or charging current < 2 A – indicating there is a charging failure. With consumers: - adjusted voltage > 14.8 – indicating that regulator is defect; adjusted voltage < 12.7 – indicating that alternator charging current must be checked compared with its characteristics: ENGINE INTENSITY(A) F8Q Nominal intensity : Minimal intensity, which must be generated by the alternator to all consumers under operation. 16 - 3 vnx.su 75 55 16 STARTING AND CHARGING Alternator If the measured current is too small, check the following: - alternator wear (brushes, collectors, etc) - battery connections - mass stripe between the gearbox and the right longitudinal girder. - drive belt tension. If the measured current is correct and the adjusted voltage is too small, the cause may be: - the vehicle has too many electric consumers; - the battery is discharged. 16 - 4 vnx.su STARTING AND CHARGING 16 Alternator SPECIAL TOOLS Belt tension measurement device MOT 1505 DISMOUNTING Place the vehicle on a two columns elevator. Disconnect the battery and the alternator electric connections. Loosen the alternator blocking screw (1). Unscrew the tensioning screw (2) and dismount the belt. Rotate the engine by three crankshaft rotations. Place the reading head of the MOT 1505 device, with one of the two captors in front of the belt at a distance of 5 ÷10 mm from the belt, in the position shown in drawing. Make vibrating the belt; the measurement is validated by a device “bip”. A B E 3 1 A 2 Dismount the support (A). Dismount the alternator attachment screw and remove the alternator. REMOUNTING Perform in the reverse order the dismounting operations. Mount the alternator belt. Tighten the belt by acting upon the screw (2) in order to obtain the mounting tension (142). Block the alternator position by means of the screw (1). Tighten the belt until the stipulated value is obtained (127 ± 5 Hz). The belt checking and tightening is to be performed with the cold engine, at the environment temperature. Tighten the alternator attachment screws at the following moment: - screw M 10 – 3.8 daNm, - screw M 8 – 1.9 daNm. Note : Once a belt is dismounted it can not be remounted. 16 - 5 vnx.su 16 STARTING AND CHARGING Starter IDENTIFICATION ENGINE F8Q - 636 STARTER MITSUBISHI DIAGNOSTIC NECESSARY SPECIAL TOOLS CLIP-SAGEM TEHNIC tester The starter diagnostic consists in battery voltage measurement and absorbed current intensity measurement during starting stage. The operation abnormalities, which may be noticed, are the following: - battery failure = large voltage drop on starter during engine starting stage, - blocked starter = the absorbed current is very high, - solenoid failure = the absorbed current is very low. In order to perform the measurements, it is necessary the engine drive by means of the starter, but stopping the engine starting. To do that, remove the injection relay placed in the fuse box from the engine compartment. NOTE : After performing this checking, erase by means of the SAGEM-CLIP tester, the possible failures memorized by the computer. 16 - 6 vnx.su STARTING AND CHARGING Starter 16 TIGHTENING MOMENTS (daNm) Starter attachment screws Starter attachment nuts Air filter attachment Flange attachment screws of the exhaust gases pipe 4,4 2,7 0,8 1,9 2 DISMOUNTING 3 Place the vehicle on a two columns elevator. Disconnect the battery. Suspend the vehicle and dismount: - downward pipe attachment nuts on the exhaust manifold, - starter lower attachment clamp, - starter attachment screw. Lower the vehicle and dismount: - air filter, - inlet manifold and exhaust manifold (see chapter 12 “ Dismounting – Remounting inlet/exhaust manifold”). Disconnect the sta rter electric connections. Dismount the attachment screws. 1 Remove the starter. REMOUNTING Check the presence of the starter centering bushing. Perform the dismounting operations in the reverse order. Tighten the screws and nuts at the prescribed moment. 16 - 7 vnx.su COOLING - EXHAUST - FUEL TANK Characteristics 19 COOLING FLUID QUANTITY AND QUALITY Engine Quantity* (liters) F8Q - 636 6,00 Quality GLACEOL RX (type D) Use only cooling fluid Mixture: concentrated anti-freeze + de-mineralisazed water Characteristics: - Protection up to 33 ° +/-2 for temperate and cold countries (antifreeze 48 %) - Protection up to 40 ° +/-2 for very cold countries (antifreeze 50 %) THERMOSTAT Engine type F8Q Opening beginning (°C) Opening ending (°C) 89 101 19 - 1 vnx.su Stroke (mm) 7,5 19 COOLING - EXHAUST - FUEL TANK Draining – Filling – Purging DRAINING Dismount the expansion vessel cap, the engine having the environment temperature. Open the purges and disconnect the cooling piping connection, in the lowest point (the one from the water pump entrance for engine draining and the radiator lower hose for radiator draining), in order to have the cooling fluid as complete as possible drained. FILLING Open the two purging screws. Fill up the circuit by the expansion vessel hole Tighten the purging screws in the moment when the fluid is flowing in a continuos jet. Start the engine, maintaining it at 2500 rot/min. Adjust the fluid level in the expansion vessel, during about four minutes. Close the cap of the expansion vessel. PURGING Let the engine run for ten minutes at 2500 rot/min, until engine fan starting, necessary period for automatic degasification. Check if the fluid level in the expansion vessel is nearby the mark “Max”. NOTE : Do not open the purging screws with engine running. Retighten the expansion vessel cap with warm engine. 19 - 2 vnx.su COOLING - EXHAUST - FUEL TANK Checking 19 SPECIAL TOOLS M.S. 554-01 M.S. 554-06 M.S. 554-07 Adapter Adapter Assembly for checking the cooling system sealing 1. CIRCUIT SEALING CHECKING Mount the adapter M.S 554 –01 in the expansion vessel valve place . Connect at the adapter, the M.S.554-07 device. Start the engine, let it run till it is warm, then stop it. Pump in order to create pressure in the circuit. Stop pumping at avalue lower with 0.1 bar then the valve calibrating value (1.2 bar). The pressure must not drop, if not, check for leak. Progressively unscrew the device connection by cooling circuit decompressing, then unscrew the device, and mount back the expansion vessel valve. 2. CHECKING VALVE CALIBRATION Mount the M.S. 554-07 device provided with adapter M.S. 554-06 and restore the pressure in the circuit; this must be stabilized at the valve calibration value 1.2 with a tolerance of +/- 0.1 bar. 19 - 3 vnx.su 19 COOLING - EXHAUST - FUEL TANK Cooling system diagram 2 1 3 T X R 6 5 7 4 - Water pump 1. Engine 2. Radiator 3. Expansion vessel 4. Blower 5. Thermostat support 6. Nozzle Ø 3 7. Purging screw T - Thermostat - Purge R X 19 - 4 vnx.su - Heating valve - Thermocouple COOLING - EXHAUST - FUEL TANK Water pump 19 SPECIAL TOOLS MOT 1202 - 01 MOT 1505 Pliers for elastic clips Device for belts tension measurement TIGHTENING MOMENTS (daNm) Water pump screws Water pump pulley screws Crankshaft pulley screw 1,6 2 2+115°±15° DISMOUNTING Place the vehicle on a two columns elevator. Disconnect the battery. Drain the cooling circuit using the lower hose from the water pump. Dismount the radiator from the vehicle: - accessories belt; - crankshaft pulley (A); - water pump pulley (B); - injection pump casing (C); - screw (1) and tilt over the alternator. C 1 CLEANING It is very important not to scratch the surfaces for gaskets of the aluminum parts. In order to dissolve the gasket particles stacked, product “DECAPJOINT” is to be used. Apply the product on the surfaces to be cleaned, leave it for about 10 minutes, then clean using a wood palette knife. During performing this operation, use protection gloves. REMOUNTING A B Dismount the water pump attachment screws and remove the pump. Mount the water pump equipped with a new gasket. Perform the dismounting operations in the reverse order. Mount and tighten the accessories belt by means of the MOT 1505 device ( see the method des cribed in chapter 16 “Alternator”). Fill up and purge the cooling circuit with cooling fluid type D “ GLACEOL RX “ ( see chapter 19 “ Filling – draining”). 19 - 5 vnx.su COOLING - EXHAUST - FUEL TANK 19 Radiator SPECIAL TOOLS MOT 453 MOT 1202 - 01 Hoses clamp Pliers for elastic clips DISMOUNTING Disconnect the battery. Clamp the hoses from radiator by means of MOT 453 device. Dismount the hoses from radiator by means of the pliers for elastic clips MOT 1202-01 and recover the cooling fluid. Disconnect the blower connector. Dismount the side supports from the radiator upper cross bar and remove the radiator assembled with the cooling fan. Dismount the fan lower attachment on the radiator, from the two screws. Dismount the two fan attachment screws on the radiator at the upper part and release the radiator. Drain the radiator and recover the cooling fluid. REMOUNTING Perform in the reverse order the dismounting operations. Perform the cooling circuit filling and purging. NOTE : When mounting, line up the marking from the hose and related parts. 19 - 6 vnx.su COOLING - EXHAUST - FUEL TANK Exhaust assembly 19 The exhaust assembly is ensuring the evacuation of the burnt gas produced during engine running and the reduction of the noise level and of the dangerous emissions. The exhaust assembly is composed of : - downward pipe (1); - expansion chamber (5); - noise silencer (8). DISMOUNTING In order to dismount the noise absorber assembly, perform the following operations: Loosen the clamp (6) between the expansion chamber (5) and the noise silencer(8). Dismount the attachment elastic rings (7) of the noise silencer. Dismount the noise silencer by rotating it and pulling it backwards. In order to dismount the expansion chamber, perform the following operations: Dismount the attachment nuts (3) of the «Matex» coupling between the expansion chamber (5) and the primary downward pipe (1). Loosen the clamp (6) between the expansion chamber (5) and the noise silencer (8). Dismount the expansion chamber. In order to dismount the downward pipe, perform the following operations: Dismount the engine shield. Dismount the coupling bar. Dismount the two screw-nuts (2) of downward pipe attachment on the exhaust gallery flange. Unscrew the attachmentnuts (3) of the «Matex» coupling betweenthe expansion chamber (5) and the primary downward pipe (1). Dismount the elastic buffer RON (4). Extract the downward pipe. 19 - 7 vnx.su COOLING - EXHAUST - FUEL TANK 19 Exhaust assembly 6 4 1 3 5 2 7 8 REMOUNTING Perform the remounting starting from the downward pipe on the exhaust collector and finishing with the noise silencer. ATTENTION ! During operation, the catalyst reaches high temperatures, therefore it is necessary not to stand in areas where combustible materials may come in contact with this one, with danger of fire. 19 - 8 vnx.su COOLING - EXHAUST - FUEL TANK Tank draining 19 Necessary special tools Pneumatic pump for fuel tank draining Pliers for “clic” clips TANK DRAINING The lack of the fuel electric pump in DIESEL version is imposing the use of a pneumatic pump for fuel tank draining. In order to drain the fuel tank, proceed as follows: Disconnect the battery. Dismount the tank visiting cover. Disconnect the supply contact (4) for fuel level transmitter. Disconnect the connection (3) and connect the hose of the pneumatic pump on the exit connection (A). A 2 3 Drain the fuel tank (2). 19 - 9 vnx.su 4 19 COOLING - EXHAUST - FUEL TANK Dismounting – Remounting tank DISMOUNTING In order to dismount the tank, perform the following operations: Disconnect the battery. Dismount the attachment screws of the visiting cover. Disconnect the rear wiring from the tank cover. Dismount the hose attachment clip (3) on the air exhaust (4) connection for Dacia 1304 Pick-Up, consequently the sealing gasket (6) for DACIA 1304 Drop-Side. Dismount the attachment clips of the supply-return hoses. Dismount the attachment clip (5) of the petrol connection on the lower filling cap. Lift the vehicle on a two columns elevator. Dismount the fuel tank (2) attachment screws (1) on the carriage body. Release the tank. 4 3 5 2 1 Dacia 1304 Pick Up 4 6 REMOUNTING Perform in the reverse order the dismounting operations. 5 1 2 Dacia1304 Drop Side,DaciaDouble Cab 19 - 10 vnx.su COOLING - EXHAUST - FUEL TANK Fuel level transmitter 19 DISMOUNTING Disconnect the battery. Dismount the tank visiting cover. Disconnect the connection connector with the rear wiring. Detach the hose clips connected to the tank cover. Turn anti-clockwise the blocking ring (1) of the tank cover, with about 1/3 rotation, until it is released from its attachment shoulders. Remove the immersed assembly (2) from the tank, carefully lifting it. Disconnect the two transmitter wires. Dismount the two transmitter attachment screws from this assembly. 1 3 2 REMOUNTING Perform in the reverse order the dismounting operations. NOTE : When remounting, take care that sealing gasket (3) of the tank cover is in good condition, the flange is tight fixing it on the tank and the hoses connected to the tank are well attached by means of clips. 19 - 11 vnx.su 19 COOLING - EXHAUST - FUEL TANK Tightening moments (daNm) TIGHTENING MOMENTS (daNm) 19 - 12 vnx.su CLUTCH 20 Identification VEHICLE TYPE ENGINE TYPE MECHANISM DISK 26 grooves D = 200 mm E = 6.8 mm Pick Up Drop Side Double Cab V: Green R: Red G: Grey V F8Q E G R D G R V 200 CPOV 3700 CHARACTERISTICS - Single disk dry clutch cable controlled. - Clutch mechanism with diaphragm spring. - Clutch disk with elastic hub. - Pressure bearing with balls permanentlyin contactwith the diaphragm (constant pressing force of 5 daNm). 20 - 1 vnx.su CLUTCH 20 Diagnostic GEARS ENGAGING PROBLEMS Check the clutch disk release (see the checking method bellow described). No Check the declutching fork stroke (see the method bellow described). Is the stroke correct ? Is the release correct ? Yes Check external actuating linkage of the gearbox ( adjust if necessary). No Clutch control pedal problems Yes Check: - pedal return, - control cable. ( repair if necessary). If the problem is persisting. Internal problem inside the gearbox (repair the gearbox). Replace the clutch. CHECKING METHOD “ DISK RELEASE “ The checking is to be performed at idling, warm engine. - declutch, - wait for three seconds, - engage the reverse driving (engagement must be performed without noise). CHECKING METHOD “ DECLUTCHING FORK STROKE “ By means of a lineal perform the following operations: - measure the distance between the fork upper part and the clutch cable support, in the clutched position, - measure the distance between the fork upper part and clutch cable support, in the declutched position, - calculate the difference between the two values (the fork stroke) and compare it with the reference value ( maximum 40 mm). 20 - 2 vnx.su CLUTCH Diagnostic 20 EFFECT OF TREPIDATION Check for oil leaks at the clutch casing level. If there are no leaks. Check the tightening and the condition of the gearbox and engine supports (fix it if necessary). If the incident is persisting. Check the clutch control (fix it if necessary). If the incident is persisting . Check the idle regime ( unstable or correct) Adjust if necessary. If the incident is persisting Replace the clutch. 20 - 3 vnx.su Fix the oil leak and replace the clutch disk if necessary. CLUTCH 20 Diagnostic NOISE AT FREE CLUTCH (low and regular noise subject to engine regime) Check for oil leaks at clutch casing level. Fix the oil leak and replace the clutch disk if necessary. If there are no leaks. Check the idling regime ( unstable or incorrect). Adjust if necessary. If the incident is persisting. Check the tightening and condition of the gearbox and engine supports ( fix it if necessary). If the incident is persisting. Replace the clutch. 20 - 4 vnx.su CLUTCH 20 Mechanism - Disk REPLACEMENT This operation is to be performed after dismounting the gearbox off the vehicle. SPECIAL TOOLS MOT 582 Flywheel immobilizing sector REMOUNTING TIGHTENING MOMENTS (daNm) Clutch mechanism attachment screws Degrease the friction surface of the engine flywheel. Check the disk sliding on the clutch shaft. Mount the clutch disk ( wi th hub protuberance (A ) towards the engine flywheel). 2 DISMOUNTING Mount the immobilizing sector MOT 582. Dism ount the clutch mechanism attachment screws. Dismount the mechanism and the clutch disk. A Center the clutch disk by means of the centering device delivered in the clutch kit. MOT 582 Perform a visual checking of : - the wear of the engine flywheel and of the mechanism plate, - the condition of the starter crown, - the sealing at crankshaft sealing gasket level, - the condition of the bearing from the crankshaft extremity, - the wear of the pressure bearing guide and of the control fork, - the conditions of the clutch shaft grooves. Replace the damaged parts and clean the clutch shaft grooves. Mount the clutch mechanism. Progressively screw “radial way”, the mechanism attachment screws, then tighten them at the required moment. Dismount the immobilizing sector MOT 582. Lubricate with grease UM 170 LiCaPb2M: - the bearing guiding tube, - the declutching fork sliders. 20 - 5 vnx.su CLUTCH 20 Engine flywheel REPLACEMENT This operation is to be performed after dismounting the clutch and gearbox off the vehicle. SPECIAL TOOLS MOT 582 Flywheel immobilizing sector REMOUNTING TIGHTENING MOMENTS (daNm) Flywheel screws 5 ÷ 5.5 DISMOUNTING Mount the immobilizing sector MOT 582 Dismount the flywheel attachment screws The screws are not to be reused. Dismount the engine flywheel. Clean the holes thread from the crankshaft by means of a dry gauze. Degrease the flywheel seating surfaces on the crankshaft. Mount the flywheel with new screws ( the screws thread shall be lubricated with LOCTITE FRENETANCH) Tighten the screws at the required moment. Dismount the immobilizing sector MOT 582. . 20 - 6 vnx.su CLUTCH Clutch shaft bearing 20 REPLACEMENT This operation is to be performed after dismounting the clutch and gearbox. SPECIAL TOOLS Bearing extractor DISMOUNTING Extract the bearing by means of a bearing extractor. REMOUNTING Lubricate the external diameter of the new bearing with LOCTITE 648 Mount the bearing by slightly tapping upon the bearing external ring by means of an adequate tube. 20 - 7 vnx.su MANUAL GEARBOX 21 Characteristics The gearbox NG 1, Ng 7 are monobloc type,mechanical in steps ( five steps for forward driving and one step for reverse driving). The speed steps for forward driving are provided with Borg-Warner synchronizers. The reverse driving step is not synchronized. CONIC MILEAGE GEARBOX GEA RING GEARING TYPE VARIANT 365 (NG1) 18 (104) 8X33 NO OF TEETH RATIO ENGINE CLUTCH F8Q 636 200 CPOV 3700 6X13 I) 50C (NG1) 31 (103) - 6X14 51C (NG7) 02 (101) 9X41 6X14 42 X 11 II ) 38 X 17 III) 34 X 23 IV) 29 X 28 V) 29 X 38 MÎ 40 X 13 3,818 2,235 1,478 1,030 0,760 3,070 Gearbox capacity ( in liters) : CV 365 …....….. 2.3 CV 50C …......… 2.2 CV 51C ………. 2.3 Oil used: DACIA OIL SUPERGEAR 80W 90 API GL5. 21 - 1 vnx.su 21 MANUAL GEARBOX Tightening moments in daNm VALORI DE REGLARE Conic distance : 59 mm. Pre-tightening of the differential bearings: - reused bearings : free, no clearance, - new bearings : 1-3 daNm. Teeth clearance : 0.12 – 0.25 mm. Clearance in the differential gearing : maximum 0.1 mm. TIGHTENING MOMENTS (daNm) - Half-crankcases assembling screws: • M 7 ..................................................................................................... • M 8 ..................................................................................................... Rear cover attachment screws ............................................................. - Clutch crankcase attachment screws: • M 8 ..................................................................................................... • M 10 ................................................................................................... - Reverse driving selector axle nut .......................................................... - Crown attachment screws ...................................................................... - Speedometer endless screw .................................................................... - Primary shaft nut .................................................................................. - Differential nut lock screw ................................................................... - Draining or filling plug ......................................................................... - Counter nut of the speedometer guide attachment screws ............... - Reverse driving contact .......................................................................... - Cross piece attachment screws: • M 6 ..................................................................................................... • M 7 ..................................................................................................... - Aerating valve ......................................................................................... - Return shaft nut .................................................................................... - Plug M 16 ................................................................................................ - Secondary shaft flange nut ................................................................... - M 8 attachment screws of the differential flange 4 x 4 ....................... - M 7 attachment screws of the differential cover 4 x 4 ....................... 21 - 2 vnx.su 1,9 - 2,4 2,8 - 3,3 1 - 1,4 2 - 2,8 3,2 - 4 2 - 2,5 9 -11 10 -12 6 2,4 2 - 2,8 0,1 - 0,3 2 -3 1 - 1,4 1 - 1,4 1 - 1,9 4 - 4,5 1 - 1,5 10 -12 2 - 2,8 1 - 1,4 MANUAL GEARBOX 21 Ingredients MATERIALS The following parts are to be obligatory replaced, if they were dismounted : paper gaskets, oil seal rings, crown attachment screws, speedometer endless screw, elastic pins, primary shaft nut, secondary shaft nut, reverse driving selector axle nut, return axle nut. USE MATERIAL Oil DACIA OIL SUPERGEAR 80W 90 API GL5 LOCTITE 518 RHODORSEAL 5661 LOCTITE 577 Grease UM 170 Li Ca Pb 2M Parts lubrication upon mounting. Sealing : half crankcases; clutch crankcase; flange on the differential hub (4x4). Transmission pins sealing. Reverse driving contact ; plug M 16 Joint and contact parts greasing MAINTENANCE The maintenance of the gearboxes consists in repeatedly performing certain inspections, according to the performed mileage as mentioned bellow : - gearbox oil replacement : is to be performed at the 1 000 km inspection and than periodically, every 20 000 km; - checking of gearbox oil level – periodically, every 10 000 km. The oil in the gearbox is replaced through the emptying (B) and filling (A) plugs. The oil in the gearbox should reach the level of the orifice uncovered by the filling plug (A). If the level is lower than that, add oil until it starts flowing through the orifice. The plugs are tightened at the required moment of 2.4 daNm. 21 - 3 vnx.su 21 MANUAL GEARBOX Manual gearbox : Dismounting – Remounting SPECIAL TOOLS CV 31 B PF 509 PF 476 - Mandrels kit for elastic pins - Maintaining cross pieces - Ball joints extractor TIGHTENING MOMENTS (daNm) Upper attachment nuts and screws of the gearbox on the engine 4,4 Lower attachment screws of the gearbox on the engine 2,1 Cardan transmission attachment screws on the gearbox flange 4,1 RPM sensor attachment screws 0,8 Steering auxiliary connecting rods nuts 4 Piuliπe rotule superioare 5 Upper ball joint nuts 9 Speeds control rod nuts 1,5 DISMOUNTING Place the vehicle on a two columns elevator. Dismount the battery. Drain the oil from the gearbox if this one is going to be disassembled. Dismount the starter ( see chapter 16 “Starter Dismounting-Remounting”) Dismount the clutch cable from the gearbox For the gearbox types 365 and 51C: - mount the crosspieces PF 509, for front half axles maintaining, between the shock absorber attachment axle and the suspension lower arm axle. - Dismount the front wheels. - Remove the transmission pins by means of the mandrel C.V. 31B. 21 - 4 vnx.su MANUAL GEARBOX Manual gearbox : Dismounting – Remounting Dismount by means of the PF 476 extractor : - the steering connecting rods ball joints, - the suspension upper ball joints. Swing over the steering knuckle and remove the transmission from the transmission gear. Disconnect the vacuum hoses and the electric connection of the vacuumcapsule (4x4). Dismount the attachment screws of the cardan transmission on the gearbox flange. 21 Swing over the cardan transmission. Disconnect the gears control from the gearbox. Dismount the nut of the exhaust attachment elastic buffer. Detach the flexible shaft. Disconnect the reverse driving contact connector Sustain the rear part of the gearbox by means of a jack. 21 - 5 vnx.su 21 MANUAL GEARBOX Manual gearbox : Dismounting – Remounting Dismount: - the attachment screws of the rear cross member on the gearbox and recover the stiffening cross pieces. - The attachment nuts of the cross member on the longitudinal girders. Dismount the cross member. Dismount the centering kit lock of the longitudinal transmission by means of a safety pliers. Remove the centering kit. REMOUNTING (PARTICULARITIES) Dismount the lower attachment screws of the gearbox on the engine. Check the presence of the centering bushings on the clutch crankcase. Grease the pressure bearing guiding tube and the transmission gears grooves with UM LiCaPb 2M grease. Position and engage the transmission with the transmission gears, using the mandrel CV 31B for centering. Insert the new elastic pins with the notches oriented towards the wheel and sealthe ends using RHODORSEAL5661. Detach the gearbox off the engine, by backward drawing. When dismounting the gearbox, take care not to catch the clutch mechanism. 21 - 6 vnx.su MANUAL GEARBOX Manual gearbox : Dismounting – Remounting 21 Fill the centering cam place from cardan transmission flange with UM 185 Li 2 grease. Perform the dismounting operations in the reverse order Tighten at the required moment the screws and nuts. Fill up with oil the gearbox. Check the speeds engagement. 21 - 7 vnx.su 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. Dismount the threaded plug (4) for stroke limiting. Unscrew the attachment screws (5) of the deflector and flange on the differential hub. Take out the deflector and flange. Unscrew the attachment differential cover screws (6) on half crankcase. Take out the differential cover assembly and its paper gasket. Dismount the bearing from the differential hub by means of an extractor ( only if this is used and must be replaced ). Take out the annular oil ring from the differential cover by means of a screwdriver. 1 4 3 5 6 2 21 - 8 vnx.su 2 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). Bring the gearbox to the dead point and dismount the back cap. Engage the velocity step V and the reverse one. Unscrew the primary shaft nut. Bring the gearbox to the dead point, then engage velocity step IV. Take out the speedometer spring by means of CV 204 wrench at GB 365. 21 - 9 vnx.su 8 7 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. Rotate the gearbox with the left side upwards. Unscrew the attachment screws of the crankcases. Remove the left half crankcase. Dismount : - the differential gear(G.B.365, and 51 C); - the secondary shaft and the locker pin of the biconical bearing; - the primary shaft. 21 - 10 vnx.su 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. Dismount the elastic pin of fork I – II by means of the CV 31 B mandrel. Dismount the shaft and the fork, recover the attachment spring and ball. Dismount : - the reverse selector; - the reverse driving shaft. 21 - 11 vnx.su 21 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 - 12 vnx.su 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 - 13 vnx.su 21 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. Dismount: - the wedge of the lock ring of the speed III pinion; - the lock ring of speed III pinion; - the speed III free pinion and its synchronizer ring. 21 - 14 vnx.su 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. Dismount: - the lock ring of the speed I pinion; - the synchronizer ring of speed I pinion; - the speed I free pinion. IMPORTANT! Place the maintaining device of the bearing outer ring. The bearing inner ring is stuck to secondar y shaft, s o that the bearing cannot be replaced. 21 - 15 vnx.su 21 21 MANUAL GEARBOX Repair DIFFERENTIAL GEAR DISASSEMBLING ( G.B. 365 ºi 51C ) Unscrew two opposite attachment screws of toothed crown. Dismount the bearings by means of the CV 28 A extractor, provided with the 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 differential pinions shaft; - the different pinions; - the friction washers; - the propeller shaft pinion. 21 - 16 vnx.su MANUAL GEARBOX Repair BACK CAP DISASSEMBLING Dismount : - the speedometer pinion guide and its sealing gasket; - the speedometer pinion. 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 means of the CV 344 mandrel. Dismount the lock ring of the rocking lever shaft; dismount the shaft and the rocking lever. Dismount : - the sealing gasket; - the control shaft bushing (if it is worn). 21 - 17 vnx.su 21 21 MANUAL GEARBOX Repair SECONDARY SHAFT ASSEMBLING For G.B. 365 ºi 51C. The differential drive pinion and the toothed crown are lapped together. Replacing of one part obligatory requires replacing the pair part. A pairing number is marked both on the pinion end and on the toothed crown. No other markings shall be taken into consideration besides the pairing number. NOTE: All spare parts will be lubricated with 80W 90 oil before bein mounted. Mount on the secondary shaft: - the velocity step I pinion together with its synchroniser ring ; - the lock washer of the velocity step I pinion ; - a false wedge, made from a normal wedge ,with a curved end ; the false wedge is introduced in a channel which has a lubricating hole. Remove the maintaining device of the bearing outer ring. Mount the velocity steps I – II synchroniser hub: - the three wedges ; - the two springs ; - the tooth gear sliding mechanism (for the re-used parts, observe the markings made upon dismounting ). 21 - 18 vnx.su 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 velocity steps 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 difference of 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. Press the assembled hub until it comes into contact with the velocity step I pinion lock. Center the three wedges in the synchronising ring grooves. Remove the false wedge. Mount the hub I – II washer. Mount the velocity step II pinion together with its synchroniser ring. Mount the velocity step II pinion washer. 21 - 19 vnx.su 21 21 MANUAL GEARBOX Repair Mount the velocity step III pinion and its synchronising ring. Mount : - the velocity step III pinion lock washer; - the lock wedge of the washers; the wedge is mounted in a channel which has a lubricating hole. Mount on the velocity steps III – IV synchroniser hub : - the three wedges ; - the two springs ; - the tooth gear sliding mechanism , with its groove opposite to the groove hub. Press the assembled hub until itcomes into contact with the lock washer of the velocity step III pinion ; the groove in the hub shall be oriented towards the velocitystep IIIpinion. Centre the three wedges inthe synchroniser ring grooves. 21 - 20 vnx.su MANUAL GEARBOX Repair Mount : - the velocity step IV pinion and its synchroniser ring; - the adjustment washer for the conical mechanism dist ance, recovered upon dismounting; - the biconical bearing; - the spacer; - the velocity step V pinion; - the elastic washer. Mount the speedometer endless screw (G.B. 365). Mount the speedometer endless and flange of the secondary shaft (G.B. 51 C). Tighten the velocity step I, in a soft dies vice. Engage gearbox in speed I. Tighten at the required moment (10-12 daN) the secondary shaft flange nut or speedometer endless screw by means of the CV 204 wrench. The speedometer endless screw shall not be locked by straining in order to enable adjustment of the conical distance. Check the clearance (J) between the synchronising rings of the velocity steps I and II and the sides of the hub : J = min.0,2 mm. The check shall be performed as follows: - the pinion in contact with the hub; - the synchronising ring in contact with the pinion con. Check in the sameway also the clearance of the synchroniser rings of the velocity step III and IV. 21 - 21 vnx.su 21 21 MANUAL GEARBOX Repair PRIMARY SHAFT ASSEMBLING Mount the biconical bearing. Press the needle-roller bearing inner ring. Mount the outside bearing ring together with its rollers casing. Mount the lock washer. Mount the clutch shaft ; place a new compensation washer between the endof the shaft, in order to prevent the noise. Mount the elastic pin by means of the C.V. 31B mandrel. 21 - 22 vnx.su MANUAL GEARBOX Repair 21 DIFFERENTIAL GEAR ASSEMBLING ( G.B. 365 and 51C ) Place the following parts 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 shall be used only if the clearance between the propeller shaft pinion and the differential pinion is very big. - the propeller shaft pinion, lubricated with oil; - the friction washers of the differential pinions; - the differential pinions. Mount the differential pinions shaft and center the pin shaft with the one inthe casing. Mount the elastic pin by means of the G.B. 31 B mandrel; the pin shall be introduced about 5 mm in the differential gear casing. Lubricate the second propeller shaft pinion with oil and place it in the casing. Mount the toothed crown on the differential gear casing with new screws. Tighten the screws at the requiredoment ( 9 –11 daNm ). 21 - 23 vnx.su 21 MANUAL GEARBOX Repair Mount the differential bearings on a press. ADJUSTMENT OF THE CONICAL DISTANCE (G.B.365 AND 51 C) The differential drive 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 the differential drive pinion shoulder(3). CAS EXCEPTIONEL There may be situations when the value A=59 mm is not correct value for the pinion positioning. The difference (X) between the actual value and the value A=59 mm is marked on the front side of the pinion near the number marked for pairing with the toothed crown. The value is given in hundredths of mm. EXAMPLE : X = 20 (0,2 mm) In this situation ,the distance between the conical mechanisms shall be A + X. In a.m. case:A +X = 59 + 0,2 = 59,2 mm 21 - 24 vnx.su 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 means of 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 distance value (X) measured between the spacer and the pinion face shall be: X = 59 mm - 58,5 mm = 0,5 mm (when the actual value is A = 59mm). Attach the right half crankcase on the support, with the separating plane upwards. Place the secondary shaft. Place the left (1) half crankcase and tighten it by means of several screws. Tighten the attachment spacer screws on the half crankcase at the required couple. Introduce the CV 239 -01 control device. Place the CV 239 - 02 spacer at the end of the differential drive pinion Measure by means of a thickness gauge the distance (X) between the spacer and the device shaft : 1. The distance value measured is smaller than the normal one (0,5 mm) .In this case, replace adjustment washer for the distance between the conical mechanisms with a thinner one. 2. The distance value measured is bigger than the normal one (0,5mm).In this case, replace the adjustment washer for the conical distance with a thicker one. The thickness of the adjustment washers is 1,8 - 3,8mm, every 10 hundredths of millimeter. The measurement of the value (X) is performed by means of the speedometer endless screw (G.B. 365 ) or the flange nut (G.B. 51 C ) tightened at the required moment ( 10 -12 daNm). Take out the checking device. Dismount : the spacer; the left half crankcase; secondary shaft. 21 - 25 vnx.su 21 MANUAL GEARBOX Repair DIFFERENTIAL GEAR BEARINGS ADJUSTMENT ( G.B. 365 and 51 C ) 1 2 2 1 The differential gear bearings adjustment is performed by means of the nuts (1) and (2). Mount the annular oil seal rings on the adjustment nuts. Grease the adjustment nuts threads with sealing paste LOCTITE 518 NOTE: Before mounting, the annular oil rings will be immersed in oil 80W/90. Mount the outer rings of the differential gear bearing in the half crankcases so that they are protruding as compared to the inner side of the half crankcase. Place the differential gear in the right side half crankcase. Place the left side half crankcase and assemble it by means of screws. Tighten the screw to the required moment,observing the tightening order specified in the drawing. M 7 : 1,9 - 2,4 daNm M 8 : 2,8 - 3,3 daNm 21 - 26 vnx.su MANUAL GEARBOX Repair 21 Tighten theadjustment nuts by means of the CV 377 wrench, until they come into contact,with the outer rings of the bearings. 1. REUSED BEARINGS The reused bearings shall be mounted freely, without clearance. Tighten the adjustment nuts until the bearings rotate freely, without any clearance. 2. NEW BEARINGS The new bearings shall be mounted by pretightening. Tighten the adjustment nuts until the bearings show a certain resistance to rotating. Check the pre-tightening of the bearings as follows: - rotate the differential gear several times, in order to set the bearings; - place a thread around the differential gear casing and draw the thread by means of a dynamometer; the differential gear should rotate at a 1 - 3 daN force. NOTE: For both types of bearings , the nut (1) in the right side half crankcase shall be tighten more, in order to obtain a bigger clearance of the tooting. 21 - 27 vnx.su 21 MANUAL GEARBOX Repair Noticethe nuts positioncorresponding to the half crankcases. Dismount the left side half crankcase and the differential gear. 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 driving shaft in the right side half crankcase. Position the reverse drive selector in the notch of the reverse driving shaft. Tighten at the required couple ( 2,3 daNm ) the reverse driving selector shaft. Place the attachment spring and ball of the velocity steps I -II fork shaft. Introduce the shaft. Assemblythe velocity steps I -II fork with the hub, towards the back side of the gearbox. Introduce the elastic pin. 21 - 28 vnx.su MANUAL GEARBOX Repair 21 Place the interlocking disk of the forks shafts. Place the attachment spring and ball of the velocity steps III IV fork shaft. Introduce the shaft. Mount the velocity steps III - IV fork with the hub towards front side of the box. Introduce the elastic pin. Place the attachment ball and spring of the fork shaft velocity step V. Place the blocking ball of forks shafts, velocity steps V and III - IV. Introduce velocity step V fork shaft. 21 - 29 vnx.su 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 position until complete mounting 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 locking spr ing of for ks shafts. Introduce the reverse driving pinion shaft Mount : - the reverse driving pinion,with the hub directed towards the front of the gearbox; - the friction washer, with the bronze side towards the pinion. Introduce the guiding wedge in its seat and completely introduce the shaft. Mount the safety ring. 21 - 30 vnx.su MANUAL GEARBOX Repair 21 HALF CRANKCASE ASSEMBLING Place in the right side half crankcase - primary shaft; - secondary shaft together with the lock pin of the biconical bearing 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 the left side half crankcase over the right side half crankcase; position correctly the reverse selector. Place the assembling screws of the half crankcase and slightly tighten them. Mount the spacer and tighten its attachment screws at the required moment (1 - 1,4 daNm). Tighten the assembling screws of the half crankcases at the required moment,observing the tightening order specified in the drawing. M 7 : 1,9-2,4 daNm M 8 : 2,8-3,3 daNm VELOCITY STEP V PINION REMOUNTING Place the following parts on the primary shaft: - the spacer; - the inner bushing and needle casings; - the free pinion of velocity step V; - the synchronizer assembly together with the fork and shaft for velocity step V; - the elastic washer; - the locking nut. Mount the elastic pin of fork for. velocity step V, by means CV 31 B mandrel. NOTE: The synchronizer for velocity step V shall be assembled in the same way as the one for velocity steps I - II; mount additionally the retentive segment. 21 - 31 vnx.su 21 MANUAL GEARBOX Repair Place the following parts on the secondary shaft: - the velocity step V pinion; - the elastic washer; - the speedometer endless. Check the clearance “J” between the synchronizing ring and the surface of the hub : J = min 0,2 mm The checking shall be 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. Tighten at the required couple: - the nut of the primary shaft: 6 daNm - the speedometer endless screw: 10 - 12 daNm ( G.B. 365). Secure the locking nut and the speedometer endless screw. GEAR CLEARANCE ADJUSTMENT (G.B. 365,51C) In order to adjust the clearance of the gear, loosen the nut (1) from the right side half crankcase and tighten the nut (2) from the left side half crankcase by the same value. 2 1 2 1 21 - 32 vnx.su 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. Adjust the 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. Tighten the attachment nut of the return rocking lever (4-4,5 daNm). Mount the rubber protection. Mount on the control shaft: - the protection bellows; - the control shaft end; - the elastic pin. 21 - 33 vnx.su 21 21 MANUAL GEARBOX Repair Mount the speedometer pinion 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 at the 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. Place the back cap; position the velocity steps selector in the forks shafts notches. Tighten at the required moment (1- 1,4daNm ) the back cap attachment screws. For G.B. 50C and 51C: Fill the contact surface between the annular seal and the flange with grease UM 170 Li Ca Pb 2M. Mount the flange of propeller shaft transmission. Place the washer and tighten at required moment (10 - 12daNm) the flange attachment nut (1). 21 - 34 vnx.su MANUAL GEARBOX 21 Repair CLUTCH CASING RE MOUNTING Press in the clutch casing the guiding bushing of 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 mechanisms crankcase. Mount the clutch casing by means the device CV 488 for oil seal ring protection. Tighten the attachment screws of the clutch casing at the required moment. M8 : 2 - 2,8 daNm M10 : 3,2 - 4 daNm Mount the reverse lamp contact, after its thread has been greased with LOCTITE 577 and tighten it at required moment (2,5 daNm). REMOUNTING THE COUPLING MECHANISM 4X4 (G.B. 51 C) Check by visual inspection the state of the mechanism elements and replace damaged parts with new ones. Mount the pins housing (13) and the claw (12). Mount using a press, by means of a metallic strap, the bearing on the differentialhub (if this was previously dismounted). Mount the assembly hub - the tooth gear sliding mechanism (10), together with coupling shaft and fork (11). Place the washer rut (9). Mount the safety ring (8) on the propeller shaft pinion. Mount the cover (7). 21 - 35 vnx.su 11 12 13 10 9 8 7 21 MANUAL GEARBOX Repair Replace the annular oil seal from the differential cap, as follows: - grease the new annular oil seal with gear oil 80W90; - mount the new annular oil seal by slightly tapping by means of the plastic hammer until it came into contact with the support shoulder from the differential cap resulting in this case the dimension of 6 + 0,5 mm. Mount the differential cap assembly with a new lubricated gasket. Grease de contactsurface between the flange and differential hub with sealing pas te LOCTITE 518. Necessary quantity: 2 ml. Mount the flange and deflector. Tighten the screws at the required moment: - differential cap - 1,2 daNm; - differential flange - 2,4 daNm. Mount the threaded plug (4) for limiting the stroke. Mount the control lever (3) and secure with safety ring (2) (position the end of lever in the notch of the control shaft. Check the front transmission engagement and disengagement. Mount the vacuum capsule bracket on the gearbox casing. Mount the connecting bolt (1) between the vacuum capsule shaft and the control lever and secure with the attachment pin. 6+/-0,5 3 4 2 1 21 - 36 vnx.su 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 velocity steps 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. - dismount the secondary shaft flange. Engage the gear velocity step IV Unscrew the back cap attachment screws. Dismount the back cap NOTE: The velocity step V fork shaft shall not be dismounted because the interlocking ball may fall; their mounting implies dismounting the whole gearbox. 21 - 37 vnx.su Clean the contact surface of the gasket. Place a new paper gasket after it was lubricated with oil. Place the back cap; position the velocity steps selector in the forks shafts grooves. Place the cap attachment screws and tighten them at the required moment of 1,2daNm. For G.B. 50C and 51C: - mount the driving flange of cardan transmission and tighten the attachment nut at the required couple (10 -12 daNm); - engage the cardan transmission. Mount the back support of the gearbox. Connect : - the speedometer cable; - the velocity steps control. Fill up the gearbox with oil 80W/90. 21 MANUAL GEARBOX Control shaftannular oil seal replacement (on vehicle ) 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 lever shaft. Dismount the elastic pin from the control shaft end. Dismount together : - the control shaft; - the rocking lever and shaft. Dismount the worm annular oil seal. REMOUNTING Mount the new annular oil seal,after it was immersed in 80W90 oil. Mount together : - the rocking lever shaft; - the control shaft. Tighten the attachmentnut of the rocking lever shaft, at the required couple (4 - 4,5 daNm). Mount the rubber protection. Mount on the control shaft : - the protection bellow; - the control shaft end; - the elastic pin. Mount the back cap with a new lubricated gasket. Mount the back crossbar of the gearbox. Mount the flange of secondary shaft and connect the cardan transmission (G.B.50C,G.B. 51C) Checkthe velocitystepscontrol mechanism. Fill up the gearbox with 80W90 oil. Lower the vehicle from the elevator. 21 - 38 vnx.su MANUAL GEARBOX Speedometer endless screwpinion replacement DISMOUNTING 21 (on vehicle ) REMOUNTING Lift the car on the elevator Drain the oil from the gearbox. Disconnect: - the speedometer cable; - the velocity steps 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). Engage velocity step I and draw the hand brake. Dismount the speedometer endless screw by means of the CV 204 wrench. 21 - 39 vnx.su Mount the speedometer new endless screw by means of the wrench CV 204 and tighten at the required moment (10-12 daNm) and secure it by straining. (G.B. 365). Mount the new speedometer pinion in the back cap. NOTE: Before mounting, the speedometer pinion shall be immersed in 80W/90. Mount the back cap with a new gasket. Mount the back crossbar. Connect: - the speedometer cable; - the velocity steps control. Mount the flange, tighten its nut at the required moment (10 - 12daNm) and connect cardan transmission (G.B.50C,51C). Check the velocity steps control. Fill up the gearbox with 80W90 oil. 21 MANUAL GEARBOX Velocity step synchronizer replacement (on vehicle ) REMOUNTING DISMOUNTING Lift the car on the elevator Drain the oil from the gearbox. Disconnect : - the speedometer cable; - the velocity steps control. Disconnect the cardan transmission and dismount the flange (G.B. 50C,G.B.51C). Dismount the back crossbar of the gearbox. Dismount the back cap. Engage the velocity step V and the reverse driving. Dismount the primary shaft nut. Dismount the elastic pin of the velocity step V fork by means of the CV 31 B mandrel. Dismount the velocity step V fork together with the tooth sliding mechanism and velocity step V hub. Place thefork on the gear tooth gear sliding mechanism; Mount the velocity step V synchronizer assembly together with the fork, on the primary shaft. Mount the fork elastic pin by means of the 31 B mandrel. Mount the primary shaft nut ant tighten at the required moment (6 daNm). NOTE: The velocity step V shaft shall not be dismounted because the interlocking ball and the attachment ball may fall; their mounting implies complete dismounting of the gearbox. Connect : - the speedometer cable; - the velocity step control. Mount the flange, tighten at the required moment (10 - 12daNm) its nut, and connect the cardan transmission (G.B.50C,G.B.51C). Check the velocity steps control mechanism. Fill up the gearbox with 80W/90 oil. 21 - 40 vnx.su MANUAL GEARBOX Clutch shaft annular oil seal replacement 21 (on vehicle ) DISMOUNTING Clutch annular oil seal replacement requires gearbox dismounting from the vehicle. Dismount the gearbox from the vehicle. Dismount the pressure bearing. Dismount the clutch casing. Dismount the annular oil seal clutch shaft. REMOUNTING NOTE: Before mounting ,the annular oil seal shall be immersed in 80W/90 oil. Mount the new annular oil seal by means of the CV 488 device, composed of: - a pipe (1) for mounting the annular seal oil. - a pipe (2) for protection of the annular seal oil. Clean the assembling surface clutch casing with the half crankcases and apply a layer of sealing paste LOCTITE 518. Mount the clutch casing ,using the protector (2) for protection of the annular seal oil. Tighten the screws at the required moment: M8 : 2-2,8 daNm; M10 : 3,2-4 daNm. Mount the pressure bearing. Mount the gearbox on the vehicle. Adjust the clutch stroke (2,5 - 3,5 mm at the declutching lever end). 21 - 41 vnx.su 21 MANUAL GEARBOX Propeller shaft annular oil replacement (on vehicle ) DISMOUNTING Mount the TF 509 support crossbars between the attachment shaft of the shock absorber and the lower suspension arm shaft. Lift the car on the elevator. Dismount the front wheels. Drain the oil from the gearbox. Take out the attachment pins of the transmission by means of the CV 31 mandrel. Disconnect: - the steering joint; - the upper suspension joint, by means of the TF 476 extractor. Rock the steering knuckle support and remove the transmission from the propeller shaft pinion. Observe the positi on of the nut corresponding to the crankcase. 21 - 42 vnx.su MANUAL GEARBOX Propeller shaft annular oil replacement 21 (on vehicle ) Dismount the lock washer. Dismount the adjustment nut by means of the CV 377 wrench; mark the number of rotations of the nut to enable the mounting in the same position, avoiding this way the further adjustment of the differential gear bearings. Dismount the annular oil seal and the tightening ring. Clean the nut. REMOUNTING NOTE: Before mounting, the annular oil seals shall be immersed in 80W/90. Mount the new annular oil seal and tightening ring. Mount the nut, observing the number of rotations and the dismounting marking. Grease the propeller shaft pinion grooves with grease UM 170 Li Ca Pb 2 M. Positionthe transmission gear in correspondence with the pinion ; center the transmission by means of the CV 31 B mandrel. Introduce the new elastic pins. The pins notches shall be oriented towards the wheel. The pins ends shall be sealed with RHODORSEAL 5661 Mount: - the upper suspension joint; - the steering joint. Mount the front wheels. Lower the vehicle from the elevator and tighten the wheels nuts to required moment (9 daNm). Mount the TF 509 support cross bars. Fill up the gearbox with 80W/90 oil. 21 - 43 vnx.su 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. Both couplings are tripod type, the one from the gearbox, consisting in a tulip and GB tripod assembly and the one from the wheel, consisting in a steering knuckle casing with a tripod assembly, which is to be assembled with the propeller shaft tulip, the connection being ensured by the retention star. These couplings allow: the transmission of the rotation motion, an axial sliding movement and accomplishment of the imposed turning angles. The both couplings are working in special grease UM 185 Li 2 or ELF CARDREXA RNT2, being sealed towards exterior by means of a protection bellow. INGREDIENTS GREASE ELF CARDREXA RNT 2 UM 185 LI 2 M ELF CARDREXA RNT 2 UM 185 LI 2 M QUANTITY 14,0 cl. 14,0 cl. 26,0 cl. 26,0 cl. 29 - 1 vnx.su COUPLING JOINT GI JOINT GE 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.su 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. Stuck the hub by means of the PF 235 A device and dismount: - the transmission nut; - the washer. Dismount the brake caliper. Dismount the suspension upper joint nut and the steering joint nut. Take the suspension off the propeller shaft pinion. Temporarily mount the steering ball joint. Remove the transmission from the hub by means of the PF 235 Aextractor. Dismount the steering ball joint and remove the transmission. 29 - 3 vnx.su 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. Tightening the nuts at the required couple. Fix the hub by meansof the PF 235 A device. Mount: - the washer ; - the transmission nut. Tighten the transmission nut at the required moment. Remount: - the brake caliper; - the wheel. Take the vehicle down from the elevator and tighten the wheel nuts at the required moment. Dismount the PF 509 support cross bar. Press the brake pedal several times in order to bring the brake piston in contact with the friction linings. NOTE: If after front brake beginning the brake damage warning light remains on perform the dismounting of the ICP from the brake pump; push three-five times the brake pedal then remount the ICP and the brake damage warning light will not be on again. 29 - 4 vnx.su 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. Remove maximum possible of the grease. By means of a pair tongues, strain the tulip tilt towards the outside in the three zones of the tulip ramps. Dismount the tulip. Dismount the tulip safety ring. Depress the tripod off the shaft. NOTE: The sliding blocks and the needles are in pairs. Do not dismount the sliding off the tulip. Do not ever use solvent for parts washing. 29 - 5 vnx.su 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. Move the tulip until the value A=162 mm is obtained ( the value comprised between the bellows edge and the tulip extremity. In this position take out the bar. Mount the clip. Mount the transmission on the vehicle. 29 - 6 vnx.su 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. For GE joint bellows replacement it will be necessary to dismount the joint parts towards the gearbox (joint JI 69) ( see previously described method). REMOUNTING NOTE: It is absolutely necessary to observe the prescribed grease quantity ( 26,0 cl ). Position:the bellows reinforcementsin the steering knuckle casingchannelsand in the shaft rod channel. Mount the GE joint collars. Remount GI joint parts. 29 - 7 vnx.su 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). It is composed of three asynchronous cardanic joints open type and two longitudinal cardanic shafts, the first one assembled to the gearbox, sustained on a support with intermediary bearing, the second one assembled with the first and with the main transmission, owing an axial compensating coupling (slotted joint). In the cardanic joints areas there are mounted the lubricators G which have the purpose to distribute the grease through the channels made for the access to the four bearings. DISMOUNTING Dismount: - the four bolts M10 x 1,25 - 35 assembling the cardanic flanges to the side towards the drive axle; - the four bolts M10 x 1,25 - 35 assembling the cardanic flanges to the side towards the drive gearbox; - the two bolts M 8 x 1,00 - 25 positioning the transmission relay on the cross bar. Dismount the cardanic transmission off the vehicle. REMOUNTING For remounting, perform in reverse order the dismounting operations. Additionally, observe the following conditions: - before assembly the shaft flanges must not show shocks marks, marks, paint marks, oxides, etc. - when assembling the intermediary support on the cross bar, the screws will be oriented from top to bottom. 29 - 8 vnx.su 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. SIZE CHARACTERISTIS [ mm ] Lt - total length of the cardanic transmission L - lengt of the cardanic shaft with bearing L z - length of the assembled cardanic shaft VEHICLE RANGE DACIA 1304 DACIA 1304 DACIA 1307 DACIA 1307 NUMBER OF GEARS GB 4 TR 5TR 4 TR 5 TR LT L LZ 1970 1950 2080 2060 870 850 980 960 1100 1100 1100 1100 TIGHTENING MOMENTS [ daNm ] - cardanic flanges tightening screws (extremities) - M 10 x 1,5................4 - 6 - cardanic intermediary flanges tightening screws - M 8 x 1,25...........1,5 - 2,5 CARDANIC TRANSMISSION MAINTENANCE In order to avoid arising of same problems in exploitation such as : noise, joint clearance, nooses gutter wear, it is necessary to perform the greasing of the cardanic transmission every 5000 km. The operation is performed within adjust in within the periodical technical revisions by means of the Tecalemit (grease gun). This to be applied on the lubricators from the joints areas (cross-head) and the corresponding lubricator to the gutters. Needle roller bearings and the gutter connection is to be lubricates under pressure using UM 185 Li 2 type grease or its equivalent. Greasing is considered adequate when by the sealing elements (gaskets) the old grease is eliminated and the new one is coming out. The intermediary support does not require maintenance. 29 - 9 vnx.su 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. 4 5 7 6 12 9 14 11 3 14 13 15 10 2 1 16 14 17 12 8 1. Brake pedal 2. Master - Vac amplifier. 3. Master cylinder 4. Front brake disk 5. Front brake caliper 6. Brake pads 7. Brake drum 8. Brake shoes 9. Pressure limiter 10. Warning light 11. STOP contact 12. Front brake hose 13. Rear brake hose 14. Rigid piping 15. Parking brake control lever 16. Parking brake primary cable 17. Parking brake secondary cable 30 - 1 vnx.su 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.su 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.su 5 30 GENERAL TIGHTENING MOMENTS ( daNm ) REAR DRIVING AXLE 2,5 24 1,54 6,3 30 - 4 vnx.su GENERAL TIGHTENING MOMENTS ( daNm ) REAR UNDRIVING AXLE 2,5 9 6,5 24 1,54 30 - 5 vnx.su 30 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. transducer 2 Servobrake on bridge floor 2 The screw-connection of the rigid linkage on: main brake cylinder, pressure limiter, rear wheel cylinder, flexible hose. 30 - 6 vnx.su 1,5 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 braking cylinder diameter 25,4 New drum inner diameter 254 Maximum drum diameter after grinding 255 Braking lining width 50 Braking lining thickness 5 Minimal accepted braking lining height above rivets TANDEM MASTER CYLINDER with I.C.P. BY PASS ÎNCLUDED Inner diameter Max.pump stroke 0,5 20,6 32 BRAKE FLUID TANK Double, with alarm sensor PRESSURE LIMITER For parallel circuit 30 - 7 vnx.su 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.su 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). The current brake fluids suffer in all cases a slight degradations during the first months of use by a slight humidity absorption series (see the Vehicle Warranty and Maintenance Booklet, for brake fluid change) COMPLETION OF THE BRAKE FLUID LEVEL The wear of brakes pads and shoes leads to a gradually diminution of brake fluid level in the brake fluid tank. It is not necessary to compensate this diminution , because the level will be restored when changing the brake pads and shoes. Obviously, in the meantime, the level of brake fluid in tank must not go down bellow the minimal mark. HOMOLOGATED BRAKE FLUIDS The mixture in the braking circuit of two non compatible brake fluids may leads to important risks mainly due to gasket damage In order to avoid such risks, it is important to use brake fluids checked and homologated by our laboratories and which are conformed with Norm SAEJ 1703, DOT 4. 30 - 9 vnx.su 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. During the purging, the brake fluid from the tank must not go down bellow the minimal level marked on the tank. To perform the purging, one person will stay on the driver place, to push the brake pedal and the other one will perform the purging (bleeding) at the wheel using a 500 ml vessel, a transparent plastic tube and brake fluid for completion. PROCEDURE Place on the bleeding (purging )screw, a transparent tube with its end in a vessel with brake fluid and proceed as follows:press the brake pedal slowly, dismount the bleeding screw, maintaining the full stroke of the pedal, then tighten the bleeding screw and slowly release the brake pedal. Repeat the same procedure until complete cease of bubbles. Proceed in the same way also for the other purging places.( Take into consideration the existence all the time of the brake fluid in the tank ). ATTENTION : Before beginning the purging procedure dismount the I.C.P. from the brake pump. It shall be remounted at the end of the operation. PROCEDURE IN PARALLEL SYSTEM It is important to observe the following sequence of the purging points: 1,6. Main cylinder with I.C.P. incorporated; 2. Left rear wheel brake cylinder; 3. Right rear wheel brake cylinder; 4. Caliper of front right wheel; 5. Caliper of front left wheel. O PERATING CONDITIONS The vehicle is on wheels. If the fuel tank is empty, place on the rear bench of the vehicle one or two persons to enable the possibility of the circuit opening ( the passing of a larger fluid flow through the brake limiter). CHECKING THE BRAKE SYSTEM SEALING After purging the front and rear circuits, check if the level of brake fluid in tank is within the prescribed limits, than press the brake pedal for 30 s ,during this time the pedal shall not change its place. Leaking in the brake system is not acceptable. 30 - 10 vnx.su 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. Yes Replace the servobrake (broken membrane) Yes Replace the servobrake (broken membrane) No Is the engine regime changing when braking ? No The engine pedal is rigid from time to time ? No At the servobrake entrance is the depression the imposedone ? No Yes 1 30 - 11 vnx.su Check: - the integrity of the depression pipe, consequently of the retaining valve; - the sealingof thedepressionpipe atthe servobrake, consequentlyat the vacuum pump(inletmanifold). 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). The brake linings are to be replaced when they are: -greasy -shiny -not in accordance with the manufacturer’s prescriptions (genuine Spare Parts have not been used). No 30 - 12 vnx.su 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.su Locate and repair or replace the item where a brake fluid leak is established. 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. the use wasnormal is to be analyzedand two - Leak of fluid from reservoir (external fluid tests are to be performed: leak from braking circuit). 1. While driving the vehicle : Automatic adjustment : hand brake cable too Interpretationtest:pedalstroke/deceleration tighten. rate. 2. While vehicle is stopped, engine cut. Additionaltest of brake pedal press: Perform five consecutivepressings on the brake pedal in order to vacuum the servobrake, before takinginto consideration the testresult. Long pedal The test is to be performed with stopped - Important and asymmetric wear of the brake linings vehicleand cut engine. - Stroke too ample between the servobrake REMARK: I t is neces sary to perform five pushing rod and the brake pump consecutive pressings on the brake pedal, - Brake fluid having high temperature. in orderto vacuumthe servobrake before - Hydraulic leak (check the sealing of the taking into consideration the test result. braking system components) - Sealing gaskets defects of the two brake Floor pedal pump circuits. The test is to be performed with stopped - Brake fluid having high temperature vehicleand cut engine. REMARK : Perform five consecutive pressings on the brake pedal, in order to vacuum the servobrake before takin g into consideration the test result. 30 - 14 vnx.su 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). When braking, the vehicle ( front part) is left/right deviating - Front axle suspension, steering (to be checked); - Stuck piston; - Tires – wear, inflation pressure; - Rigid duct narrowed (flattening). Braking - Stuck piston; Automaticadjustment :hand brake cable very tighten. REMARK : Automatic recovering is performed by means of the brake pedal, if there is no abnormal tension in the hand brake cable when released (hand brake released). - Return spring. Heating brakes - Insufficient hydraulic stroke of the brake pump, not allowing the return at rest of the brakepump pistons ( brakepump remaining under pressure); - Stuck pistons or hardly returning; - Rigid duct narrowed (flattening); - Defective adjustment of the hand brake control. 30 - 15 vnx.su FRONT BEARING ELEMENTS FRONT AXLE CHECKING - ADJUSTMENT 31 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 parallelismbeing directlyinfluenced). The modification of these angles does not happen during vehicleexploitation,butonly as a consequenceof a vehicleaccident. It is important to observe the followingsequence: - placing the vehicleon rotating plates; - braked vehicle; - check suspensionfor placing the vehicleat its free height; - establishing of the steering central point and steering box lock; - fixingof the opticaldeviceson the vehicle,as per manufacturer instructions. ESTABLISHING OF THE STEERING CENTRALPOINT In order to establish the steering box central point, bring gear rod in the positionwhere C = 65 mm. This value is obtained when a rivet of the elasticcoupling is upward orientated. The performingof one checking or adjustingfront axle operation implieslocation of the steering box point in order to avoid errors when measuring. 31 - 1 vnx.su 31 FRONT BEARING ELEMENTS FRONT AXLE CHECKING - ADJUSTMENT REPARTITION CHECKING ANDADJUSTMENT Check the connecting rods symmetry “X”. Read the value “A” on the scale. 31 - 2 vnx.su FRONT BEARING ELEMENTS FRONT AXLE CHECKING - ADJUSTMENT 31 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. Check in order: camber angle, casterangle, parallelism,ball joint angle. PARALLELISM ADJUSTMENT Loosen the locknut (1) maintainingthe tie rod of steering connectingrod (2) in a fixedposition. Act upon the rod of steering connecting rod taking into account the rotation sense of latterin order to obtain the convergence or divergence and also the fact thatone of its completerotation leadsto an axial displacement of 1,5 mm. After obtaining the correct parallelism, tighten the lock nut at a moment of 5 daNm. 2 1 OBSERVATION: Three situations may appear: PARALLELISM 1.CORRECT REPARTITION CORRECTION WHICH MUST PERFORMED It is performed the same number of connecting rod rotation INCORRECT on left side and right side until obtain the same value ”A”. 2.INCORRECT CORRECT Adjustthe parallelismat the samevaluefor left and right side ensuring in the sametime, the samevalue “A”on both sides. First operate on repartition in order to balance the value 3.INCORRECT INCORRECT “A” on each side, than adjust the parallelism (see Case 2}. 31 - 3 vnx.su FRONT BEARING ELEMENTS 31 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. CONTROL POINTS HEIGHT: - symmetry Required conditions are respected NO Correct the deficients YES The deviation persists NO Control finished YES Check and adjust the front axle YES The deviation persists NO Control finished Check the parallelismand alignment YES Front axle adjustment Replacedamaged Control finished The deviation persists LEGENDE: Control Operating efectue NO YES Tires rotation 31 - 4 vnx.su NO Control finished 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. On the part where the upper arm is dismounted , the following operations are performed: - dismount the wheel; - loosen the lower lock nut of the shock absorber; - detach the caster angle rod off the upper part of the arm; - dismount the suspension upper ball joint and the steering ball joint by means of the PF 476 extractor; - dismount the lower joint shaft of the shock absorber; - dismount the upper arm of the shaft; - lift the arm and dismount the lower joint of the shock absorber; - remove the arm. 31 - 5 vnx.su 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. In this position of elastic bushings locking , tighten to the required moment: - the upper arm shaft nut; - the lower joint shaft of the shock absorber; - the caster rod nut; - the upper suspension ball joint nut; - the seering ball joint nut. Mount the wheel and get the vehicle down from the elevator. TIGHTENING MOMENTS - Upper arm shaft nut.................................................... 9,5 daNm - Shock absorber lower shaft nut..................................... 6 daNm - Caster rod nut..................................................................4 daNm - Upper ball joint nut........................................................ 5 daNm - Wheels nut...................................................................... 9 daNm 31 - 6 vnx.su 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. Re mount the suspension upper arm on the vehicle. 31 - 7 vnx.su 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. BALL JOINT REPLACEMENT SPECIAL TOOLS: DENOMINATION CODE Front axle support cross bar Ball joint extractor Dynamometric wrench 31 - 8 vnx.su PF 509 PF 476 MOT 50 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. In case protection below is damaged, replace it with a new one. Attach the ball joint to the arm by replacing the rivets with screws, the latter being mounted with the ends towards the bellow. Mount the caster rod. Couple the ball joint and tighten it to the required moment. Dismount the cross bar PF 509. Mount the wheel and take down the vehicle from the elevator. Check and adjust, if necessary : - the caster angle; - the camber angle; - the steering box position; - the parallelism and the wheels alignment. 31 - 9 vnx.su 31 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. Release the lower ball joint and dismount the arm. 31 - 10 vnx.su 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. Tighten the following to the required moment : - the lower ball joint nut; - the lower arm shaft nut; - the stabilizer rod elastic bushing nut. Mount the wheel, take down the vehicle from the elevator and remove the PF 509 support cross bar. 31 - 11 vnx.su 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. 31 - 12 vnx.su 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. Dismount on a press the other elastic bushings. Press the new bushing ,observing the value A = 151mm. Mount the suspension lower arm on the vehicle. 31 - 13 vnx.su 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. Check and adjust: - the caster angle; - the camber angle; - the steering box position; - the parallelism and repartition. 31 - 14 vnx.su PF 509 PF 476 MOT 50 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. Dismount the calipers without detaching the flexible hoses. NOTE: Do not press the brake pedal Dismount : - the brake pads; - elastic blades. Dismount the protection bellows. Clean with alcohol the housing of bellow and the piston end; blow with compressed air. 31 - 15 vnx.su 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 - 16 vnx.su 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. Unscrew the flexible connection from caliper and the purging screw. REMOUNTING Check: - the state of flexible connection; - the state of brake disk; - the state of brake pads; - the state of protection bellow. Replace the damaged or worn parts. Fill the caliper with brake fluid. Mount on the caliper: - aerating screw; - the flexible connection with a new copper gasket. Push the piston by means of the FR 500 device. 31 - 17 vnx.su 31 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. Fill the tank with brake fluid. Purge the brake circuit. FRONT BRAKE CALIPER REPAIRING Dismount the caliper off the vehicle Dismount: - the flexible connection; - the purging screw; - the protection bellow. Place a wooden wedge between the piston and the caliper. Take out the piston by means of compressed air. Dismount the sealing gasket from the caliper groove by means of a steel blade with round ends. Wash with alcohol the parts and blow them with compressed air; clean attentively the sealing gasket housing. Check the wear of parts; replace the parts showing wear, scratches or ripple-marks, with new, original ones and reassemble for sealing test. 31 - 18 vnx.su 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. Create a 0,3 bars pressure in the brake caliper. Dip the caliper into a vessel with alcohol. Move the piston several times to remove the air from the sealing gasket seat. Place a wooden wedge between the piston and the brake caliper. Check the sealing of the brake caliper at various pressures , without going over 2 bars. 31 - 19 vnx.su 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. Grease the pinion and the inside of the caliper brake grease. Mount: - the sealing gasket; - the piston; - the protection bellow; - the purging screw; - the flexible connection, with a new copper gasket. Fill up the caliper with brake fluid. Mount the caliper brake on the vehicle. Purge the braking circuit. 31 - 20 vnx.su 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............................................................................................ 9 daNm The brake disk shall be not rectified. A bigger wear or important marks on the brake disk impose obligatory replacement of the brake disk. The minimal accepted thickness of not aerate disk .......................................9 mm The minimal accepted thickness of aerate disk.. .........................................19 mm The maximum accepted axial deviation ...................... 0,2 mm on diameter φ 215 NOTE: The maximum axial deviation is 0,2 mm. If the thickness of the disk is smaller than 9 mm or if the wear is not uniform, the disk shall be replaced. 31 - 21 vnx.su 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. Placea screw near the attachmentnut of the bearing closingplate and bring the three screws in contact with the steering knuckle. Alternativelytighten the threescrewsuntil dismountingthe “ hub – disk “ assembly. Dismountthe disk off the hub. 31 - 22 vnx.su 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. Mount: - the caliper support with the screws greased with FIXAMED R 58 and new Grower washer; - the brake pads; - the brake caliper; - the wheel. Get the vehicledown from the elevator. Press the brake pedal several times, in order to bring the piston in contact with the brake pads. 31 - 23 vnx.su 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. Dismount: - the two screws M 6 x 1 that attach the protector on the brake caliper support; - the two screws M 8 x 1,25 that attachthe brake calipersupport on the steering knuckle; - the two screws M 12 x 1,25 that attach the brake calipersupporton the steering knucklethebrake calipersupport. REMOUNTING NOTE: Upon remounting, grease the screws with FIXAMED R 58 and replace the Grower washers. Place thebrake calipersupport in the right position. Tighten the screws M 12 x 1,25 at the required moment of 6,5 daNm. Tighten the screws M 6 x 1 that attach the protector at the required moment of 1,3 daNm. Mount: - the brake pads; - the brake caliper support; - the wheel. Take down the vehiclefrom the elevator. 31 - 24 vnx.su 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..........................................23 daN.m - Wheels nut.....................................................9 daN.m - Caliper support attachment screws................6,5 daN.m DISMOUNTING Lift the vehicleby meansof an elevator. Mount the PF 509 support cross bar. Dismount: - the wheel; - the brake calipertogetherwith flexible connection; - the brake caliper support andthe mud flap; - the transmissiongear nut. 31 - 25 vnx.su 31 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. Mount the transmission gear by meansof the PF 236 device. Mountand tighten: - the transmissionnut; - the brake calipersupport and the mud flap; - the brake caliper. Mount the wheel, get the vehicle down from the elevator,recover the PF 509 crossbar. Press the brake pedal several times in order to bring the brake caliperpiston in contactwith the brake pads When replacing the steering knuckle,check and adjustthe steering box position,the parallelism, distribution. 31 - 26 vnx.su 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. In this situation,the side (E) of the steering knuckle should be parallelto the checking device front side, and the seat ofthe steering ball joint shouldget into the device bore. 31 - 27 vnx.su 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. INNER BEARING DISMOUNTING Place the steering knuckle on a 80 mm → inner diametertube and depressthe inner bearing, using a 45 mm → outer diameter rod. OUTER BEARING DISMOUNTING Once the “hub – disk” assembly being dismounted, mount the RO 15 – 01 protectionsleeve and dismount the bearing by means of the CV 28 A extractor. 31 - 28 vnx.su 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. Put grease LiCaPb type UM 180 Li 2 in the steering knuckle. Introduce the bearing spacer. Positionthe bearing together with the steering knuckle on the “hub – disk” assembly. This is pressed on the hub using a rod that shall rest on the inner ring, and that shall have the followingdimensions:outer diameter: 43 mm and inner diameter 36 mm. Grease the inner bearing sealing gasketedge with grease LiCaPb type UM 180 Li2. Mounting thesealingplate. 31 - 29 vnx.su 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 - 30 vnx.su 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................................................................11 daN.m - Upper ball joint nut...................................................................5 daN.m - Lower ball joint nut...................................................................5 daN.m - Steering ball joint nut................................................................4 daN.m - Stabilizer rod shaft nut..............................................................8 daN.m - Steering connecting rod lower nut.........................................1,5 daN.m - Shock absorber lock nut.........................................................1,5 daN.m - Front shock absorber lock nut...................................................6 daN.m