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Dacia 1304 2004, Repair Manual

The Dacia 1304 2004 repair manual is a comprehensive guide that provides step-by-step instructions for maintaining and repairing your vehicle. Available for free download at manualshive.com, this manual is a valuable resource for DIY enthusiasts and professional mechanics. Get all the essential information you need to keep your Dacia running smoothly and efficiently.

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10

10 - 10

ENGINE AND LOWER ENGINE UNITS

PARTICULARS ON REMOUNTING

Check the existance of the two bushings by means of which the clutch casing is centered on

the block.

Slightly grease ( thin coat) the clutch shaft grooves with 

Li Ca Pb type II

 grease.

Adjust the stroke of the acceleration pedal.
Perform:

- the filling with oil of the engine;
- the filling and aeration of the cooling circuit.

     Adjust the engine running (ignition ,carburation).
     Tighten the fixing nuts and screws according to the tightening moments given in the bellow
table:

E

NGINE

 

MOUNTING

 - 

DISMOUNTING

Caps to bearings

           

5,50 - 6,50

Caps to connecting rods

         

  4,00 - 4,50

Flywheel

     5

Cylinder head to casing ( at cold)

           

5,50 - 6,50

Cylinder head cap

           

0,15 - 0,45

Tilter shaft support

           

1,50 - 1,75

Camshaft pinion

           

2,70 - 3,20

Camshaft clip

           

0,80 - 1,00

Oil pump on casing

           

0,70 - 1,00

Lower casing

        

1,20 +/- 0,40

Clutch mechanism 

φ

 

180 DBR

           

1,00 - 1,20

Clutch mechanism

 

φ

 200 DBR/ 

φ

 200 GR

1,50 - 2,00

Distribution cap

           

0,70 - 1,00

Oil emptying plug

           

max. 3,5

Pump and water pump cap

                 

0,70

Fan

2,00 - 2,50

Starter    screen

    2 - 3

Fuel pump

1,50 - 2,00

Thermocontact

1,50 - 2,00

Oil pressure trasmitter

    2

Carburettor

1,50 - 2,00

Crankshaft pulley

       6,50

Alternator support

1,00 - 1,75

ENGINE DISMOUNTING - REMOUNTING

F

IXING

 

    T

IGHTENING

 

MOMENTS

                                           (daN.m)

vnx.su

Summary of Contents for 1304 2004

Page 1: ...blished 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 AUT...

Page 2: ...seal 10 55 Distribution cap 10 56 Tightener and distribution chain 10 59 Camshaft 10 61 Lower crankcase 10 64 Oil pump 10 66 12 FUEL MIXTURE Characteristics 12 1 Injector valve body 12 2 Inlet exhaust manifold 12 3 13 PUMP SUPPLY Fuel filter injection engine 13 1 14 ANTIPOLLUTION Gasoline vapours reaspiration 14 1 Carbon can 14 2 Carbon can valve 14 3 16 STARTINGAND CHARGING Alternator 16 1 Starte...

Page 3: ...knuckle bearing 31 24 Characteristics of front suspension main elements 31 26 Suspension Tightening moments 31 27 Front shock absorber 31 28 Front suspension spring 31 32 Front stabilizer rod 31 33 33 REAR BEARING ELEMENTS Plate drive rear axle 33 1 Brake drum 33 4 Brake cylinder 33 6 Brake shoes 33 8 Bearing 39 x 68 x 37 33 10 Plate drive rear axle differential 33 11 Non drive plate rear axle 33 ...

Page 4: ...119 D 47169 D 2S119 D 4S169 D 16119 D 17119 D 1S119 D 2F719 D 1F119 D 4F769 106 02 106 10 106 02 106 10 106 02 106 10 106 02 106 10 102 14 106 02 106 10 106 02 106 10 106 02 106 10 1557 1557 1557 1557 1557 1557 1557 1557 1397 1557 1557 1557 1557 1557 1557 200 GR 200 DBR 200 GR 200 DBR 200 GR 200 DBR 200 GR 200 DBR 200 GR 200 DBR 200 GR 200 DBR 200 GR 200 DBR 50 C 51 C 50 C 51 C 50 C 51 C 365 365 3...

Page 5: ...nplaceof thehomologationnumber for the importer country h Location placeof VIS sign one character for theyearmodel 7 charactersfor thechassis manufacture series 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 MANUF ACTURERPLATE ...

Page 6: ...frontengine and front drive 2 longitudinal frontengine and rear drive 4 longitudinal frontengine and integral drive optional front coupling chassis type 6 type carosserie 6 PICK UP 7 DROP SIDE S KING CAB F PICK UP doble cabine 7 payload location 1 two front places bed body 7 5 front places 2 fixed rear bench for 3 places bed body 8 gearbox type 1 gearbox with 5 1 steps 6 gearbox with 5 1 steps and...

Page 7: ...ale Pick Up Drop Side King Cab Double Cab U 75 B U 75 C U 75 D 1305 Ri 1304 Ri 1304 4 WD Ri E 75 B E 75 C E 75 D 1305 Ri 1304 Ri 1304 4 WD Ri M 75 B M 75 C M 75 D 1305 Ri 1304 Ri 1304 4 WD Ri H 75 B H 75 C H 75 D 1307 FRi 1307 Ri 1307 4 WD Ri Note U E M H express the carriage body type B C D express the C type engine 1557 cmc front transmission type rear and consequently 4x4 75 the code for R12 al...

Page 8: ...out pre filter M Mechanical steering system R Without adjustable shock absorber T Without plate corrector V Without wheels ABS anti blocking ATTENTION Do not unstuck or damage the label of the right side part surface of the dashboard This label represents the only way of vehicle identification needed by the after sale services for a period of 8 eight years from the purchasing date UNITLTHEDATEOF 2...

Page 9: ...SPECIFICATIONS 01 01 6 Fig 2 1 Vehicle identification MANUFACTURER SPLATEDISPOSALTYPESELF ADHESIVE STARTINGWITHTHEDATEOF26 06 2003 vnx su ...

Page 10: ...TURER SIDENTIFICA TION DATA A Manufacturer sname B Community reception number or homologation number C Identificationnumber D Total authorized weight of the loaded vehicle E Totalauthorizedrunningweight F Totalweight on front axle G Totalweight on rear axle H Additionalinscription I Manufacturing dateinscription J Consignmentnumber TheMANUFACTURERPLATE self adhesivetype hasthebellowpresentedconfig...

Page 11: ...body LIFTING THE FRONT PART OF THE CAR For lifting the rolling jack and the CHA 280 hold are used in order to protect the body and mechanical item of the car which are placed on longitudinal girders on wheels axle LIFTING THE CAR FROM ONE SIDE For lifting the car from one side the rolling jack and the CHA 280 hold shall be usedwhichareplaced on thethresholdon the front door Theedgeof the threshold...

Page 12: ...fting place the elevator buffers on the same points where the car jack of the vehicle is usually placed The edge ofthe threshold shall be placed correctly in the buffer channel ELEVATORPOSITIONEDUNDERTHECARRIAGE BODY vnx su ...

Page 13: ...TOWING USING FRONT TRANSMISSION The towing of the cars on wheels must be obligatory done by means of the unique towing points These points cannot be anyhowused for drawing out the carfrom a trench hole for a similar intervention or for direct or indirect lifting of the car FRONT REAR vnx su ...

Page 14: ...III Grease 22 Grease U100 Ca 4 5 Clutchshaftgroves Pinions groves of front transmission Gear box control lever Pressure bearing Cardan flange sealing ring Front transmission Front wheel steering stub groves Cardanic transmission Front transmission Front wheel bearing Suspension ball joints Rear axle differential Wheels screws Steering gear pinion rack gear bearings Rubber gaskets of the steering g...

Page 15: ...opellershaft pins Half crankcase Clutch crankcase Fuel pump with membrane Cover palier 1 Rear axle Thread of the reverse lamp contact Gear box plug M 16 Rear axle Differential rear axle SOLDERING FIXAMEDM28 Screwsofflywheelfixin g Screws of crank shaft pulley CLEANING DECAPJOINT S E DERO 100 Thesurfaceof cylinderheadgasket Washing of steel cast iron aluminum parts vnx su ...

Page 16: ...DRAINING AND FILLING 05 05 1 ENGINE Draining plug 2 Filling plug 1 Necessary special tools wrench for draining plug CV 514 vnx su ...

Page 17: ...DRAINING AND FILLING 05 05 2 GEARBOX Draining plug 2 Filling plug 1 vnx su ...

Page 18: ...DRAINING AND FILLING 05 05 3 REAR AXLE DIFFERENTIAL Draining plug 2 Filling plug 1 vnx su ...

Page 19: ...rack width Ground clearance Empty Loaded Turn radius Between footways Between walls Unloaded vehicle weight On the front axle On the rear axle Total Maximum authorized load On the front axle On the rear axle Total Authorized payload Load with trailer with own brake Load with trailer without own brake 4674 1636 1550 1450 2675 1334 1320 165 5600 5800 600 480 1080 760 1550 2250 1000 3225 2630 vnx su ...

Page 20: ...heel track width Ground clearance Empty Loaded Turn radius Between footways Between walls Unloaded vehicle weight On the front axle On the rear axle Total Maximum authorized load On the front axle On the rear axle Total Authorized payload Load with own brake trailer Load without own brake trailer 4599 1615 1550 1450 2675 1334 1320 165 5600 5800 595 520 1115 760 1550 2230 1000 3225 2630 vnx su ...

Page 21: ...Rear wheel track width Ground clearance Empty Loaded Turn radius Between footways Between walls Unloaded vehicle weight On the front axle On the rear axle Total Maximum authorized load On the front axle On the rear axle Total Authorized payload Weight on towing hook 4794 2636 1525 2795 1310 1334 165 5600 5800 635 540 1175 820 1550 2230 680 1055 max 50 vnx su ...

Page 22: ...GL5 SAE 80 W 90 API GL 5 SAE J 1703 DOT 4 Tip C Tip D GLACEOL RX from 26 11 2001 HFC 134 a PAG SP 10 3 2 3 2 0 3 6 0 700 kg 265 cmc CHARACTERISTICS Mixture 50 concentrate antifreeze 50 distilled water On the expansion vessel a label is stacked specifying the use of this type of cooling fluid Engine oil quality 30 C 20 C 10 C 0 C 10 C 20 C 30 C 15 C 15 W 40 15 W 50 10 W 40 10 W 50 10 W 30 5 W 30 5 ...

Page 23: ...cale at the arrow imposed value 2mm 4 5mm 3 5 mm or 7 5 mm for the belts 1 2 3 or 4 place the small O ring on the scale at zero value place a metallic graduated rule on both pulleys place the device at half and vertical on the rule 1 distance between pulleys axles BELT ARROW f mm FORCE N N MOUNTING AFTER 5 min AFTER 500 km 1 2 3 4 between compressor alternator between crankshaft compressor between...

Page 24: ...he imposed range the belt tightening is good if the read value is bigger or smaller than the imposed value perform the adjustment of the distance between pulleys axles re tighten the belt until obtaining a value within the imposed range start the engine run it for five minutes check again the belt tension and compare it with the imposed value and adjust it if necessary check the tension andcorrect...

Page 25: ...the tightening sequence from the drawing CYLINDER HEAD RE TIGHTENING Retightening of the cylinder head is performed as follows for new vehicles at the 800 1000 km check u in case of engine repairing which implies the cylinder head dismounting after 800 1000 km driving every 10 000 km For retightening loose the screw 1 with 1 4 rotation after that retighten it to the require moment 6 5 daNm at warm...

Page 26: ...PR 8 175 R 14 PR 8 1920 25 1920 25 1 9 2 0 4 2 4 5 Tightening moment of the wheels nuts screws 9 daNm Axial run out max 1 2 mm Radial run out max 1 2 mm Pressure in tires to be checked at cold The increase of tire temperature during running implies a growth of pressure with 0 2 0 3 bar In case of checking the tires pressure at warm consider this growth of pressure The tires are TUBELESS type witho...

Page 27: ...n aerated Minimal disk thickness aerated Brake pad thickness the support included Minimal brake pad thickness the support included Disk axial run out measured at Φ215 mm Φ 48 mm Φ 54 mm 10 mm 20 mm 9 mm 19 mm 14 mm 7 mm 0 1 mm Wheel braking cylinder diameter New drum diameter Maximum drum diameter after grinding Braking lining width Braking lining thickness Minimal accepted braking lining height a...

Page 28: ...ncemeasuredfromthewheelscentertotheground H2 thedistancemeasuredfromthelongitudinalgirderlowerparttotheground H5 the distance measuredfrom the jointaxis of the front leaf springto theground measuredintheareaof thelowerarmattachment C thisvalue is showingthepositionwheretherack mustreach inorderto obtain the middlepointfor thesteeringrack vnx su ...

Page 29: ...0 45 30 20 02 20 19 20 36 20 52 Maximum Le ft Right difference 10 10 22 10 21 10 20 10 18 30 10 17 10 15 10 14 Maximum Le ft Right difference 10 80 01 80 02 80 03 80 04 30 80 05 80 07 80 08 Maximum Le ft Right difference 10 Opening toe in 00 10 10 for one wheel 0005 05 ANGLES CASTER CAMBER BALL JOINT TOTALPARALLELISM ELASTIC JOINTS BLOCKING H5 H2 260 H5 H2 250 H5 H2 240 H5 H2 230 H5 H2 220 H5 H2 2...

Page 30: ...eering box positioning 6 7 75 on the scale By means of T F 246 eccentrics Steering rack central C 65mm By means of the point steering whe el rot ation ANGLES POSITION OF THE VEHICLE ADJ USTMENTS 1304 1307 VALUES OTHER STEERING SYSTEM VALUES TO BE RESPECTED vnx su ...

Page 31: ...Empty Empty 10 11 10 29 10 46 30 20 02 20 19 20 36 20 53 Maximum Left Right difference 10 10 21 10 20 10 19 10 18 30 10 16 10 15 10 13 Maximum Left Right difference 10 80 01 80 02 80 03 80 04 30 80 05 80 07 80 08 Maximum Left Right difference 10 Opening toe in 00 160 100 for one wheel 00 08 05 ANGLES CASTER CAMBER PIVOT TOTALPARALLELISM ELASTIC JOINTS BLOCKING H5 H2 260 H5 H2 250 H5 H2 240 H5 H2 2...

Page 32: ...eering box positioning 6 7 75 on the scale By means of T F 246 eccentrics Steering rack central C 65mm By means of the point steering whe el rot ation ANGLES POSITION OF THE VEHICLE ADJ USTMENTS 1304 1307 VALUES OTHER STEERING SYSTEM VALUES TO BE RESPECTED vnx su ...

Page 33: ...E OFREARAXLEANGLES Not adjustable Not adjustable Empty Empty Empty Empty 00 34 30 For two wheels Toe out 00 34 30 ANGLES CAMBER PARALLELISM ELASTI CJOINTS BLOCKI NG COMMERCIAL U 75 DRIVE 1304 1307 VALUES VEHIC LE POSITI ON ADJUSTMENTS vnx su ...

Page 34: ...sitionedwiththewheelson benchrotatingplatesbeinginhorizontaldirection brakedensured suspensiontested for vehiclesettingatitsfreeheight steeringbroughtatcentralpointandsteeringrackblockedinthisposition Theseoperationsaretobe followedby optical deviceattachmenton vehicle observingthe prescriptionsof thesteeringmeasurementbenchmanufacturer COMMERCIAL U 75 4 X 4 DRIVE 1304 1307 Not adjustable Not adju...

Page 35: ...Oilsumpanddistributioncap LOCTITE 518 Petrol pump sealaing membrane type andcap of bearing no 1 OMNI FIT RAPID FIXAMEDM 28 Flywheelattachementscrews bearings capscrews OIL SUPER 15 W 40API SJ Enginelubrication partslubrication whenmounting S E DERO 100 Washingof steel aluminiu mandcast iron parts vnx su ...

Page 36: ... GEAR BOX DISPLACEMENT BORE STROKE COMPRESS cm 3 mm mm ION RA TIO 1304 Pick up 365 1304 Drop side 106 10 50 C 1557 77 83 6 8 5 1 1304 King cab 51C 1305 Pick up 365 1305 Drop side 106 02 50 C 1557 77 83 6 8 5 1 1305 King cab 51 C 1307 365 1397 76 77 8 5 1 102 14 50 C vnx su ...

Page 37: ...10 10 3 ENGINE AND LOWER ENGINE UNITS Theengineidentificationisdoneby meansof aplateattachedtothecylinderblock above theoilfilter 1 Typeof engine 2 Enginemanufactur eseries IDENTIFICATION vnx su ...

Page 38: ...vesselwhichcanbeusedbothforfillingand drainingofthe oil Mounttheemptyingplug Weighthevesselwith theollectedoilby meansof ascale Mark thisvalueG1 Theoilisfilledbackintheengine directellyfromthespecialvesel Checkthesealingof theemptyingplug Keepthevesselwiththeoiltracesremainedafteroilfilling ROADTEST Drivingconditionstobeconstantasfaras speedandchargeareconcerned equivalentwith a80 km hspeedon a ho...

Page 39: ...tion G1 G2 ADMISSIBLE CONSUMPTION Theadmissibleconsumptionisdeterminatedby theweargeneralconditionoftheengine theoilquality drivingstyle rpm enginetuning carburattion Theengineswithaoilconsumptiongreaterof 100 gramsat100 kmneedtobeadjusted Forthecarswithinthewarranty period themaximumadmissibleoilconsumptionis75grams at 100km MEASUREMENT OFOIL CONSUMPTION vnx su ...

Page 40: ... ifthe oilisunsuitable used itshalbereplaced starttheengineandletitrun untiltheoiltemperaturereach80 ºC stoptheengineanddismounttheoilpressur etransmitter mounttheMOT73 01 manometer connectarotationmeter starttheengine andcheckthe pressure Therecommendedpressureis 750 800 rpm 0 7 bars 4000 rpm 3 5 4 bars stop the engine dismount the MOT 73 01 manometer and mount the oil pressure transmitter disonn...

Page 41: ...EMOUNTING Lubricatethegasketof thenewfilterwithoil Tightenthefilterby handuntilltheasketcomesinthecontactwiththeblock Tighten1 2rotationmoreby meansof theMOT445wrench Loosenthefilter bring thegasketintocontactwiththeblockand tighten1 2 3 4morerotations Checkandfillwithoilup totherequiredlevelintheengine OILFILTERREPLACEMENT vnx su ...

Page 42: ...oolingcircuit dismounttheradiatorplug dismountthecylindersblockplug Dismountthewatterandfuelducts Dismounttheradiator Dismo untthefan thebeltandthefanpulley of thewatterpump Disconecttheelectricwires alternator thermocouplings oil pressure transmitter co il breaker Dismountthecables accelerationandshock Dismountthethrottlevalvespring Dismounttheairfilter Dismountthestarterprotection Dismountthesta...

Page 43: ...nplateoftheclutch Dismountthepulleyof thecrakshaft Dismounttheattachmen tringofthe dischargetube Unscrew the nuts that attach the engine supportstothebuffers Deposerlesecrousdefixationdes supports moteurautampon Place a jack underthe gearbox in order to maintainitintherightposition Mounttheliftingdevice Displacetheengineforward andliftit Placetheengineon thesupport REMOUNTING Thedismountingoperati...

Page 44: ...UNTING Caps to bearings 5 50 6 50 Caps to connecting rods 4 00 4 50 Flywheel 5 Cylinder head to casing at cold 5 50 6 50 Cylinder head cap 0 15 0 45 Tilter shaft support 1 50 1 75 Camshaft pinion 2 70 3 20 Camshaft clip 0 80 1 00 Oil pump on casing 0 70 1 00 Lower casing 1 20 0 40 Clutch mechanism φ 180 DBR 1 00 1 20 Clutch mechanism φ 200 DBR φ 200 GR 1 50 2 00 Distribution c ap 0 70 1 00 Oil emp...

Page 45: ...r dismountingof thescrewsfixingthegearboxtotheengine Performadditionally dismountin g of theclutchcable DISMOUNTING underthecar dismountin g ofclutchprotectionplate dismountingthenutsoffixing thegearb ox totheengine Performadditionally gearbox oildraining disconnecting the wires of the baking connector Dismountthespeedometercable Dismount the fixing bolt of the speeds connectin g rod Dismoun tthef...

Page 46: ...els Dismo unttheuppersuspenssionballjointsand theballjointsof thesteeringconnectingrod Disconnectthetransmissions Placea jackunderthegearboxtomaintainit intherightposition Dismountthebackcrossbarof thegearbox Dismo untthefixingnutsoftheenginesupports ENGINE AND GEARBOX DISMOUNTING REMOUNTING vnx su ...

Page 47: ...lershallbeplacedattheends ofthepins for sealing Adjusttheclutchstroke 2 5 3 mm Perform oilfillup of thegearbox and theengine fillingandaeration ofthecooling system Adjusttheenginerunning ignitionand carburation Adjustthespeedscommand seechapter37 Speedscommand Tightenthefixing nutsandscrewsaccordingtothemomentsmentionedinthebellowtable FIXING TIGHTENING MOMENTS daNm Gearbox controlconnectingrod 4 ...

Page 48: ...10 10 14 ENGINE AND LOWER ENGINE UNITS TIGHTENINGBY SCREWINGUPMOMENTS vnx su ...

Page 49: ... Maxrpm Fuel 1397 76 77 8 5 1 42 6 KW DIN at5000 rpm 10 2 daNm at3500 rpm 750 800rpm cold warm 0 15 0 18 0 20 0 25 0 4 57 30 63 3 0 10 1 3 4 2 line 5500 rpm Petrol CO Rmin90 1557 77 83 6 8 5 1 50 KW DIN at5000 rpm 11 9 daNm at2500 rpm 750 850rpm cold warm 0 15 0 18 0 20 0 25 0 4 57 30 63 3 0 10 1 3 4 2 line 5500 rpm Petrol CO Rmin95 87 1557 77 83 6 8 5 1 50 KW DIN at5000 rpm 11 5 daNm at2500 rpm 7...

Page 50: ...102 14 5 5 6 5 6 5 74 40 73 90 0 50 0 05 41 80 0 5 1400 8 5 106 10 5 5 6 5 6 5 74 20 73 70 0 50 0 05 46 6 0 5 1557 8 5 106 02 5 5 6 5 6 5 74 20 73 70 0 50 0 05 46 6 0 5 1557 8 5 50 minutesaftertheengineis stopped Thedifferencebetweentheignitionchambersvolumesof thesamecylinderhead max 0 5 cmc VALVE SPRINGS Thevalvespringsareidenticalfor theinletandfortheoutlet Uponassembling thetightcoilsshallbeto...

Page 51: ...lve guide mm inlet outlet 102 14 7 90 0 90 0 33 5 30 3 0 03 0 08 106 02 106 10 7 90 0 90 0 34 6 30 3 0 03 0 08 VALVESSEATS Thespecialcastiron valves warmpressed nottobereplaced TYPE OF ENGINE Angle of the seat inlet outlet Width of support side mm inlet outlet Outside diameter mm inlet outlet 102 14 90 0 900 1 1 1 4 1 4 1 7 34 5 31 3 106 02 106 10 90 0 900 1 1 1 4 1 4 1 7 35 7 31 3 CHARACTERISTICS...

Page 52: ...s per seat mm inlet outlet 102 14 7 11 11 10 11 25 17 0 26 5 26 2 106 02 106 10 7 11 11 10 11 25 17 0 27 4 26 1 TYPE OF THE ENGINE ALL TYPES Nomber of bearings 4 Axial clearance mm measured at the adjustment strap 0 06 0 11 Distribution dia gram inlet opening lead 22 0 inlet closing delay 62 0 outlet opening lead 60 0 outlet closing delayay 20 0 CAMSHAFT ROCKERACTUATORS STEMS TYPE OF THE ENGINE AL...

Page 53: ...ue red yellow Diametre for centering in the block mm Jackets heights over the level of the gasket mm Thikness of the sealing gaskets on the block mm 102 14 76 000 76 010 76 010 76 020 76 020 76 030 76 030 76 040 80 6 0 02 0 09 Without ring gasket 0 0 05 0 13 With Cu gasket Rubber φ 1 25 1 45 Copper 0 1 106 02 106 10 77 000 77 010 77 010 77 020 77 020 77 030 77 030 77 040 80 6 0 02 0 09 Without rin...

Page 54: ...ess of washers thrust for axial clearance adjustment mm half bushings Sliding bloc k bearings Nominal diameter mm Repair diameter mm Grindingtolerance mm Conicité et ovalité de l axe mm Sliding bloc k device Normal diameter mm Repair diameter mm Grindingtolerance mm Coussinets de paliers Normal diameter Repair diameter ALL TYPES 5 aluminium stanium 5 5 6 5 0 05 0 23 2 28 2 38 2 43 54 795 54 575 0 ...

Page 55: ...MOTEUR Piston diameter mm A Piston marking mm B C D Piston axle bore i nside diameter Piston marki ng Piston shaftoutside diameter mm Piston marking Piston axle length mm Pistonaxle assembling Piston assembling in the block Rings thickness slot mm compression ring sealing ring l ubricating ring Mounting position of the rings 102 14 75 945 75 955 75 955 75 965 75 965 75 975 75 975 75 985 106 02 106...

Page 56: ...Yellow Z Blue TYPE OF THE ENGINE ALL TYPES Oilpressurea80 0 C bars for iddlerunning 750 800 rpm minimum0 7 for 4000 rpm minimum3 5 4 FUELPUMP Diaphragmpump forengineswithcarburettor Staticpressure pumpdoes notwork bars minimum 0 170 maximum 0 265 Electric pump forenginewith injection Admissibleminimumflow 65 l h Pression 1 bar at 12V CHARACTERISTICS vnx su ...

Page 57: ...le thefuelpump theoilfilter theoildipstick theoilpressuiretransmitter theengineleftsidesupportandtheelasticbuffer Mounts theboltsof MOT460 on the engineblock Place the engine on theMOT 460 support Dismo unt therubberhoses theinlet outletcolector thecolectorgasket thepressureplateandtheclutchdisk DISMOUNTING MOUNTING vnx su ...

Page 58: ...order toremove the gasket use a rubber or plastichammertoslightlyhitthecylinderhead extremities then easy turn the cylinder head aroundtheundismountedscrew Mountthejacketsclampingdevice MOT 484 Takeoutthetiltersshaftsandthepushersand puttheminorder Dismoun tthe pinionof thebreakerdistributor Turntheengineat1800 anddismount thecrankshaftpulley theoilcasing thedistributioncap Takeoutthesealinggasket...

Page 59: ...n chaintightener Straightenthelockwasherandunscrewthe camshaftpinionfixing screw Takeoutthecamshaftpinionandthe distributionchain Dismountthescrewsof thecamshaftclip Take outthe camshaft Takeoutthe crankshaftpinionby meansof the MOT 49 DISMOUNTING MOUNTING vnx su ...

Page 60: ...marked from 1 to 5 number1towardstheflywheel Dismountthebearingcapsandthehalfbush ingsandplacetheminorder Dismountthecrankshaft Dismountthehalfbushingsfromthe connectingrodandfromtheblockandplacethem inorder Removetheaxialclearanceadjustmentthrust washers Takeoutthebearingannularoilseal Rotatetheengineby 180 dismountthe MOT484 deviceand takeout theengineshield thegaskets atthe bottomof thejackets ...

Page 61: ...los for the others screws inthetighteningorderspecified inthe figure After re tightening the screws adjust the tilters ADJUSTMENTOFTHETILTERS Beforeadjustingthetilterscheckthe tighteningoftheplatform The tighteningmomentof theplatformfixing screws 1 5 1 75 daNm When adjustingthetilters thegear box shall beinthedead point The adjustment oftilters is tobedoneas per methodof thecompletelyopenedvalve ...

Page 62: ...let 0 25 mm Thecheckingof thedistancebetweenthetilterandthevalveis doneby meansof adistance calliper spy atthecorrespondingdimensionof theconstructivecleranace Thecallippershouldglidewitheasyfrictionbetweensurfaces for acorrectchecking CYLINDERHEAD DISMOUNTING Disconnectthebattery Dismounttheairfilter Empty drain thecooling system dismounttheradiatorplug dismountthecylindersblockplug Dismountthebr...

Page 63: ...om In ordertoremovethegasketturnthecylinderheadaround theunscrewedscrew Forcylinder headdisplacementusearubberor plastichammer Unscrewthefixingscrew Dismountthecylinderhead MounttheMOT484devicefor jacketsmaintenance Cleanthecontactsurfacesof thegasket cylinderblockandcylinderhead IMPORTANT It is forbiden the cleaning of the aluminium surfaces with the scrapper For cleaning the rests of the gasket ...

Page 64: ...laneiscorrectedbygrinding Beforegrindingwaterpumpandtiltersplatformaretobedismounted Thecylinderheadshallbecarefullypositionedonthegrindingmachinein ordertoobservethe parallelismof thesurfaces Themaximumaddition thatmaybeground 0 5mm If by grinding theminimumacceptedheightis exceeded thecylinderheadistobereplaced becauseby reducingtheheight thecompressionratioisaltered MOUNTING Performthedismounti...

Page 65: ...egasketwiththemarking HAUT or TOP upwards Checkiftheholeinthegasketcorrectlyoverlapsthelubricationchannelintheblock Setthecylinderheadandthefixingscrews Tightenthescrewsattherequiredmoment 6 5 daNm Mountthetiltersshafts intheholeswheretheyhavebeendismounted Adjust theaccelerationpedalstroke Fillandaeratethecoolingsystem Checkandadjusttheenginerunning CYLINDERHEADREPLACEMENT Dismountthecylinderhead...

Page 66: ...an and airblow the newcylinder head Checkthepresenceof thelubricatingchannelsandvalvesstate Performthelappingof thevalveson thecylinderhead guiding thisoperationis also tobe performedwhenreplacingthevalves Mountthevalvesinthecylinderheadandplacethe MOT320valvessupportplate Placeintheirpreviou spositions sealinggasketsof thevalvesshafts thelowervalveheads thevalvesprings halfcotters NOTE The valve ...

Page 67: ...eratethecoolingsystem Checkand adjusttheengine ignition carburation Retightemthecylinderheadafter800 kmof driving VALVE SPRINGREPLACEENT on car Disconnectthebattery Disconnecttheaccelerationcable Dismountthetilterscap Dismountthespark plug MounttheMOT61 devicefor valve maintainingintheplaceofthespark plug Dismountthetiltershaft Compressthespringby meansof the MOT382compressingdeviceandtakeoutthe l...

Page 68: ...LVESHAFTSEALINGRING Disconnectthebattery Dismounttheaccelerationcable Dismountthetilterscap Dismountthespark plug MounttheMOT61 valvesupprtdevicein theplace ofthespark plug Dismountthetilter sshaft Compress thespring bymeans of the MOT 382 compression device and take out the lock halfcotters Remove theuppertray thespring Cleantheseatof thelowertray Dismo unttheseal ingringofthevalveshaftusing the ...

Page 69: ...61 andmountthespark plug Checkand adjusttheengine ignition carburation TILTERSPLATFORM on car DISMOUNTING Disconnecttheaccelerationcable Dismountthetilterscap Dismoun ttheplatformfromthecylinderhead Dismountthelockclipfromtheshafthead ATTENTION Upon distension of springs the parts should not spring from the shaft Dismounttheparts fromthe shaftandplace theminorder Washthepartsobser vingthedismounti...

Page 70: ...tthecylinderheadfromthe engine Dismo untfromthecylinderheadthefollowings thewaterpump thevalves thevalvesshaftssealing rings thetiltersplatform theattachmentboltsof thecap thespark plugs Placethecylinder headonthe MOT 121 support plate and by means of the MOT148 devicechuck 1 depress the guiding onahydraulicpress Mountthetilterscover Mounttheaccelerationcableandadjusttheaccelerationpedalstroke Che...

Page 71: ...ondening valueof thenewguie Introducethe chuck 1 inthe lockbushing 2 at one or the otherside depending on the guiding being pressed andtheguiding isplaced on theend ofthe chuck 1 Lubricatetheuidingwithoilandpressitwith ahydraulic pressobservin g thefollowingsvalues Inlet A 26 5 mm Oulet B 26 2mm Thesevaluesareobtainedduringpressing if in the moment when the shoulder of the chuck 1 reach esclosethe...

Page 72: ...olts thevalvesshaftssealingrings thevalves intheplaceswheretheyhavebeenremovedfrom thetiltersplatform thewaterpump thewaterpumppulley thespark plugs Mountthecylinderheadwithanewgasketobservingthemountingprescriptions Mounttheaccelerationcableandadjusttheaccelerationpedalstroke Performthefillingandaeration ofthecoolingsystem Performthecheckingand adjustementoftheenginerunning ignitio n carburation ...

Page 73: ...tethevalve takeit outandcheckthemark leftby thevalve accordingtothemark left thesurface 2 by meansof the150 or surface 3 isground by meansof the 70ºcutteruntiltheworkingsurfaceisthe prescribedone 1 1 1 4 mm for inletand 1 4 1 7 mmfor outlet andthemarklefton thevalveishalfwaythe workingsurfaceof thelatter Performthelappingof thevalveor ofthevalves thenplacethem inordersothattheycanbe mountedinthepl...

Page 74: ...no 1 istheoneon theflywheelside Themarking of theconnectingrods isdoneon thesideoppositethecamshaft Dismo unt theconnectingrods caps thebushings theenginekit jackets pistons connectingrods NOTE The caps and the bushings shall be placed in order so that they may be mounted in the places where they have been removed from Cleanandairblowtheparts itisforbiddenthecleaningof thealuminiu mpartsby meansof...

Page 75: ...perpen dicular plane with external flattenings For calculation of the piston jacket clearance the average diameter D is to be considered D D1 D2 2 For the engines with the sealing of the cylinder jackets by 0 ring thechecking is done without the gasket At these engines the rubber gasket is used only for sealing The height of the jackets over the level of the gasket is 0 02 0 09 mm Place the jacket...

Page 76: ...hintheprescribedlimits thejacket blockassemblingvaluesareto bechecked DISMOUNTING OF THE PISTON SHAFT Thedismounting and mountingofthepiston shafts is performedby meansof theMOT255 device madeof supportbushingofthepistonupon dismountin g thepiston A support bushing of the piston upon mounting B extractormandrel 3 mountingmandrel 1 centeringmandrel 2 connectingrod checkingmandrel 4 washer 5 Placeth...

Page 77: ...nt the centering mandrel 2 on the mountingmandrel 1 Grease the mandrel piston shaft assembly withspecialgreasecontainingMoS2 PISTON CONNECTING Useanelectric plateof 1500 W electricoven Heat the crosshead end of the connectingrod inthefurnace ata temperatureof about 250 C 10 15 minutes inordertoincreasethebor ingoftheconnectin g rodcrossheadendby dila tation Thetemperatureischeckedby placingapiece ...

Page 78: ...rodsreachedthetem peratureof 250 C thetinis melted remove thetinfrom thecrossheadend of theconnectingrod place the connecting rod in the piston observin g theposition ingindicati onsof thelatter quicklyintrodu cethemountingmandrel 1 withthepistonshaftuntilthe lattercomesintocontactwiththebottomof the supportbushing dismountthechuckfromthepistonshaft checkifthepistonshaftremainsretractedas to thepi...

Page 79: ...der 1 towards theflywheel themarkingon theconnectingrod oppositetothecamshaft thearrow on thepistonheadshallbeorientedtowardstheflywheel MountthethejacketsmaintainingdeviceMOT484 Oilthethebushingsandthecrankshaf twithfreshoil Placetheconnectingrodson thebearingsand mountthecaps Tihtenthecapnutsattherequiredmomentof 4 5 daNm with dynamometricwrench Checkthecorrectrotationof themobileassembly Dismou...

Page 80: ...theplugs 1 intheirseatsintheblock andclampthemby meansof the MOT111A rivetset REPLACEMENT OFTHECRANKSHAFTBEARINGANNULAROIL SEAL DISMOUNTING Disconnectthebattery Dismount gearbox clutchmechanismand thedisk flywheelandthewornannularoilseal REMOUNTING Placethenewannularoilsealon the MOT259 01 mountingdevice Lubricatewithoiltheexteriordiameterof the annularoilseal ATTENTION The edge of the annular oil...

Page 81: ...rotectthechuckby placingaworn annular oilsealon it Mounttheflywheel thescrewswillbe lubricatedwith FIXAMEDM28 Tightenthescrewsata 5daNmmoment Centerthediskby meansof thecenteringchuckandmounttheclutchmechanism Mountthegearbox Checkallthefluidfillingsandperformallnecessar y adjustments REPLACEMENTOFTHECLUTCHSHAFTCENTERINGBUSHING DISMOUNTING Disconnectthebattery Dismo unt gear box clutchmechanismand...

Page 82: ...necessar y adjustments REMOUNTING CRANKSHAFTREPLACEMENT DISMOUNTING Dismounttheenginefromthecar Mounttheengineon theMOT369 support Draintheoilofftheengine Dismo unt thealternatorandtheattachmentclip thefuelpump theoilfilter theoildipstick thebreaker distributtorandtheignitioncables thecontactandoilpressuretransmitter theleftsidesupportandtheelasticbuffer MounttheMOT460 device boltson the engineblo...

Page 83: ...atetheengineby180 º anddismountthe following parts thecrankshaftpulley theoilcasing theoilpump thedistributioncap Take outthe sealing gaskets of the dismounted itemsorremo vetheseala ntmaterialbyscrappimg it forthosewithsealantsealing Dismount the distribution chain tightening device Strainthelockwasherandunscrewthecam shaftpinion fixin g screw Takeoutthecamshaftpinionandthe distributionchain DISM...

Page 84: ...ckthemarking of theconnectingrods no 1towards theflywheel andopposite tothecamshaft Unscrew theconnectingrod capsnuts Dismounttheconnecting rodscasandthehalf bushingsandplacetheminorder Dismountthecrankshaft Dismounttheconnectingbearingandthehalf bushingsandplacetheminorder Dismountthecrankshaft DISMOUNTING MOUNTING vnx su ...

Page 85: ...Mountthehalfbushingsof thebearingsintheblck thehalfbushingswithlubricatin g holes NOTE The half bushings of bearings 1 and 3 on one hand and the ones for bearings 2 4 and 5 on the other hand are identical In case crankshaft is replaced it is obligatory to change also the connecting rod bearings crankshaft bearings and the distribution and bearing annular oil seals Mountthecrankshaftpinionontheshaf...

Page 86: ...tscrewsof thecapsat 5 5 6 5 daNmmomentusing Checkthefreerotationof thecrankshaft Mountasupportwithmagnetic bottomand by meansof acomparator checktheaxialclear ance ofthecrank shaftwhichmustbewithin0 05 and0 23 mm If theclearanceisnotasrequired replacethe axialhalfbushings Theaxialhalfbushingshavevario usthickneses suchas 2 28 2 38 2 43 mm Mount the bearing annular oil seal on the MOT259 01 chuck L...

Page 87: ...elusingnewscrews Befor e mountinglubricatewith FIXAMEDM28the screws Tighten the screws at a 5 daNm moment using Mountthesupportwithmagneticbottomand by meansofacomparatorchecktheaxialrunout of theflywheel Themaximumadmittedrunout 0 06 mm Mountthehalfbushingsintheconnecting rods caps Lubricate the half bushings and the bearings with oil and mount the connecting rod caps Tightenthescrewsata 4 5 daNm...

Page 88: ...desupportandelasticbuffer theanometerandtheoilpressuretransmitter theoilfilter theoildipstick thedrivepinionof thebreaker distributtor the breaker distributtorandthespark plugscables thefuelpump theattachmentclipandthealternator Mounttheengineon thevehicle Perform theoilfilling of theengine thefilingandaerationofthecooling circuit enginecheckingandadjustment ignition carburation DISMOUNTING MOUNTI...

Page 89: ...aroilsealby meansof the MOT457 A device REPLACEMENTOFTHEDISTRIBUTIONANNULAROILSEAL DISMOUNTING Mountthenewannularoilsealon themount ingchuckof the MOT457 Adevice Lubricatetheoutsideof theannularoilseal withoilandplaceit onthecap Tightenthenutuntilthechuckcomesinto contactwiththecap Mount thecrankshaftpulleyafterthe surface betweenthepulleyhub andthe distributtion pinionhasbeenlubricatedwith LOCTIT...

Page 90: ...gineshield Dismoun ttheoilsump adjusttheenginewith no 1 and4 pistonsinthelowerdeadpoint rotate thefrontpartof theoilsumptowardstheleftand lowerit Dismountthecrankshaftpulley Dismountthedistribution cap Dismounttheannularoilsealfromthecap Cleanthe contactsurfacesof thegasketsor thosewheresealantmaterial hasbeen applied engineblock oilsump distribution cap DISTRIBUTIONCAP vnx su ...

Page 91: ...ial is used thisis tobeappliedas perbellowdescribedprocedure Mounttheoilsumptakingcarenottodisplacethegasketsotthesealantmaterial Tightentheattachmentscrewsfromthecentertowardstheedges Remounttheengineshield Performthefillingwithoiloftheengine For enginesfittedafter 01 06 1999 thesealaingof thedistributioncapis donewithsealant material insteadof thedistributioncapgasket thenecessar y quantityofsea...

Page 92: ...ent ATTENTION Mounting of the distribution cap on engine casing must be done in maximum 5 minutes from the sealant material application At the distribution cap which is mounted with sealant material the drawings of the contact surface are towards the exterior see chapter A A different from the ones mounted with gaskets where the drawings are towards the interior The distribution cap mounted with s...

Page 93: ...wthetightenerfixingscrew Dismountthetightener ATTENTION Do notletspring the crossheadshoeand the spring Straighten thelockwasherandunscrew the camshaftpinionfixing screw Takeoutthecamshaftpinionandthe distributionchain Cleanthecontactsurfacesof thegaskets engineblock oilsump distributioncap REMOUNTING Distributionadjustment Mountthecamshaftpinionsothatmarkings on the pinions tobe placed one infron...

Page 94: ...Fixingscrew andwasher Remount thedistribution capandtheoilsumpwithnewgaskets usingsealan tmaterialfor engines usingthissealin g withsealin g material thecrankshaf tpulley thesurfacebetweenthepulleyhub and thedistribution pinionwill begreasedwithLOCTITE518 thewater pumppulleyandthefan theelasticbushingsfixingattachmen tsnutsof thestabilizerrod thecrossbarbetweenthelongitudinalgirders theengineshiel...

Page 95: ...have been removedfrom MountthejacketsmaintainingdeviceMOT484 Dismountthefuelpumpwithoutdisconnectingthehoses thecontrolpinion of thebreaker distributorwithacylinderheadattachementscrew theengineshield thecrossbarbetweenthe longitudinalgirders theelasticbushingsattachementnutsof thestabilizerrod theoilsump the alternatorbelt thewaterpumppulleyand thefan thecrankshaftpulley the distribution cap thed...

Page 96: ...equiredone replacetheclip Dismountthecamshaftpinion Lubricatewithoilthecamshaftandmountitinitsplace Tightenthescrewsof camshaftclipfixing ata2 daNmmoment Remount thecamshaftpinionand thedistributionchain thedistributionchaintightener the distributioncapwithanewgasketorsealantmaterial the crankshaftpulley thewaterpumppulley and the fan the oil sump with new gaskets or sealant material for engines a...

Page 97: ...le andthe larger part D is oriented towards the flywheel Remountthepusherslubricatedwithfreshoil thecylinderhead thetiltersshafts Adjustthetilters thermalclearance atcold inlet 0 15 mm outlet 0 20 mm Mountthetilterscap Mountthefuelpump thebreaker distributor Remounttheradiator thefrontgrill theairfilter Mountthealternatorbeltandadjustitstightening Perform oilfilling of theengine filling and aerati...

Page 98: ...gasketsof thebearings thesidegasketsof thesump sealantmaterial on oilsumpfor enginesfitted after 01 06 1996 placetheoil sumpsothatthegasketsor sealantmateriallayerarenotdisplaced tightenthesumpattach ementscrewsfrom themiddletowardsedges tightentheoilsumpattachmentnuts performtheoilfillingof theengine For enginesfittedafter 01 06 1996 thesealingof theoilsumpis doneby meansof sealant material inste...

Page 99: ...interiorpartof theoil sumpcontactsurface takingcarenottoobturateitsfixingholes Mounttheoilsumpandtightentheattachementscrewsattherequiredmoment ATTENTION The oil sump mounting on engine casing must be done inmaximum 5 minutes from sealuing matterial application For the oil sump which is sealed with sealant material the drawings of the contact surface are towards the exterior different from the one...

Page 100: ... the antirolling shaftand theoilpump Unscrew theattachement s crewsandtakeouttheoilpump Cleanthecontactsurfacesof thegasketsor thosewithsealantmaterial engineblocandoil sump REMOUNTING Mountthenewoilpumpwithanewgasket Τightentheattachmentscrews Remount theoilsump thebearingattachementnutstostabilizerrod thecrossbarbetweenthelongitudinalgirders theengineshield Performtheoilfillingof theengine OIL P...

Page 101: ...d the ball may spring up Washtheparts andcheckthemaximumclearancewearbetweenthepinionsandthepump body tobe0 2 mm If clearanceis bigger replacethepinions REMOUNTING Mountinthebodyof thepumpthefollowings thefreepinion thedrivepinion thespringtray thespring thevalveball Mountthecapby compressi ng thedischargevalvespring Tightentheattachementscrews OIL PUMP vnx su ...

Page 102: ...lve potentiometer Oxygen senzor Can purging valve PARTICULARITIES Monomotronic M A 1 7 Connector with 35 pins Monopoint Bosch type Monomotronic M A 1 7 Static controlled by computer R1 2 650 1100 Ω at 200 C Spark plugs electrode distance 0 8 Tightening moment 2 5 3 daNm Mounted under the vehicle in front the fuel tank Replacement at every scheduled checking or at max running 20000 Km Electrical im...

Page 103: ... order not to damage the air temperature sensor and the injector protect the injector valve body against hits Their protection cover shall be removed only after fixing the injector valve body on the flange Avoid dirtying with impurities the connectors contacts and the valve body socket contacts in order to achieve perfect electrical connections Taking into consideration that in the feeding system ...

Page 104: ...et exhaust manifold Extract the inlet exhaust manifold REMOUNTING Perform in reverse order the dismounting operations Clean the assembly surface Replace the gasket of the inlet exhaust manifold Replace the gasket of the tube Tighten the nuts at the required moment INLET EXHAUST MANIFOLD TIGHTENING TORQUES daNm Inlet exhaust manifold nuts 1 8 Attachment nuts of the tube on the inlet exhaust manifol...

Page 105: ...tain the eventual impurities and stop them to reach the pressure regulator and injector ATTENTION The fuel filter is provided at the exit with a very fine metallic cloth which can retain possible filtering paper particles from it Therefore upon mounting attention must be paid at the arrow marked on the fuel filter body which shows the flow direction of the fuel The filter is to be changed at maxim...

Page 106: ...n at thepurging valve 3 The electric valve opening is done bythe electronic control unit pin 29 in certain operation conditions of the engine Check this circuit as far as its sealing is concerned its valve operation as well as the free cycling of the vapours between the fuel tank and the carbon can Takeinto consideration whenvalvemounting theflow directionof thegasolinevapours whichmustbeaccording...

Page 107: ...to the can and disconnect the hoses REMOUNTING Perform in reverse order the dismounting operations ATTENTION Take into consideration when mounting about the hoses connection direction the gasoline vapour cycling is from the duct to the carbon canpurge valve Use goodring clips which must be well tightened 14 2 CARBONCAN vnx su ...

Page 108: ...pushing the lock 1 after that disconnecting the connector Dismount the fixing clips of the hoses to the purging valve and disconnect the hoses REMOUNTING 14 3 Performinreverseorderthedismountingoperations The can purging valve shall be mounted so that the arrow marked on its body to be oriented from the can to the injector valve body 1 CARBONCANVALVE vnx su ...

Page 109: ...measures at N 4 rpm are performed when engine is cold The checking of the values at rpm N1 N2 N3 N5 are performed when the engine is warm i e afterthe alternatorhas beenworkingfor aboutonehour on voltage14 0 1 V After measuring the value of the current at rpm N5 adjust the exciter voltage at 10 0 1 V and the voltage at the plugs level at 14 0 1 V Adjust rpm NN at 6000 60 rpm and measure the corres...

Page 110: ...agrams and the curves of theload characteristic of the alternator type 1180 are the followings A CHECKING OF THE CURRENT INTENSITY A Unstable operating conditions B Stable operating conditions Tip 1114 200 Tip 1180 GENERATOR ROTATION SPEED rot min GENERATOR ROTATION SPEED rot min ALTERNATOR vnx su ...

Page 111: ...king the adjusted voltage perform an assembly similar to next diagram After starting the engine accelerate until rpm is300 rot min then increase the alternator current from 10A to43 A the voltage must be between 13 8 and14 5 V at a temperature of 22 5 C If this condition isnot accomplished check the voltage ifalso this is correct replace the electronicregulatorandcheckagain If defectpersists check...

Page 112: ... and disconnection of the battery during running connection of the alternator before checking if the battery is correct connected minusatthechassis ground becausecontrary the builtin electronicregulator is instanta neouslydestroyed reversing of the two wires connected at the regulator connecting at chassis ground of the supply plug of the electronic regulator performingelectric welding withoutprev...

Page 113: ...B the belt the tightening screw A Tighten the belt Connect wires to the alternator and the battery NOTE The belt will be tighten so to obtain the maximum arrow of 7 5 mm at half distance between the water pump pulley and the alternator pulley The excessive tightening of the belt may lead to a premature wear of the water pump bearings and of the alternator bearings ALTERNATOR vnx su ...

Page 114: ...STARTING AND CHARGING 16 16 6 ALTERNATOR TYPE 1180 ALTERNATOR vnx su ...

Page 115: ...crew 1 REMOUNTING Mount attachment screw 1 the V belt the tightening screw 2 and the tightener 3 NOTE For dismounting re mounting the alternator type 1180 perform same operations as for alternator type 1114 200 For tightening and checking of the belt tightening see chapt 07 ATTENTION Do not tension exaggeratedly the belt Danger of premature wear both of alternator bearings and of water pump bearin...

Page 116: ...r to the battery plugs At rpm of 2000 rot min without consumers the voltage read on the instrument must be about 14 6 0 1 V At same rpm 2000 rot min with consumers headlights air conditioner windscreen wipers thevoltagereadon theinstrumentmustbebetween13 5 and14 5 V If themeasured values are not correct perform the checking of the alternator on bench ALTERNATOR vnx su ...

Page 117: ...ent the needle of the voltmeter on the instrument board must be placed in the left side of the central area For a voltage of13 5 V read on instrument the needle of the voltmeter on the instrument board must be placed in the middle of the central area white area For a voltage of15 6 V read on instrument the needle of the voltmeter on the instrument board must be placed in the right side of the cent...

Page 118: ...ided with an old belt to avoid its faulting Unscrew the fixing nut of the pulley Dismount the pulley the pulley wedge the fan Dismount the brushes supports Unscrew the alternator assembly screws Dismount the rotorand the front bearing by means of ascrewdriver placedbetween the stator and the front bearing ATTENTION Do not insert the screwdriver more than 2 mm The rotor coiling may be damaged ALTER...

Page 119: ...with a piece of wood Unscrew the attachment screws of the sustaining shield of the front bearing The dismounting operation of the front bearing is performed only in case of front bearing replacement Check the aspect ofthe coiling damaged insulation scratched rings broken wires ALTERNATOR vnx su ...

Page 120: ...ternator on the vehicle Connect the battery NOTE Tightening moment for thepulley nut3 3 5 daNm for type 1114 200 or 7 daNm for type 1180 terminal B 0 3 da Nm The belt shall be tighten to obtain a maximum arrow of 7 5 mm for a pushing force of about 3 daNm at half distance between the water pump pulley and the alternator pulley Exaggerate tensioning of the belt may lead to the premature wear of the...

Page 121: ... three attachment screws of the bearing cap and take out the bearing Mountthenewbearing inthedriveshieldand fixthebearingcapby meansofthethreescrews Perform in reverse order the dismounting operations of the alternator B REARBEARINGREPLACEMENT Dismount pulley washers and Grower washer fan pulley wedge brushes support and front bearing rotor assembly Extract the bearing by means of the CV 28 A extr...

Page 122: ...Connect the battery ALTERNATOR BRUSHESREPLACEMENT DISMOUNTING Disconnectthebattery Unscrew the attachment screws of the brushes support Dismount the used brushes off the support REMOUNTING Mountthenewbrushesintheir support Check theslidingof thebrushes intheir support the insulation between brushes the continuity from the brushes contact point with the collector up to the contacts withchassisgroun...

Page 123: ...pand thecondenser Check on the bench the alternator DIODEREPLACEMENTS The diodes having a diode support type housing made oftwo parts are not replaceable A burnt diode decreases the current intensity by about A DISMOUNTING Dismount the diode support off the alternator Check diodes by means of a control lamp connected to a 12 V direct current source Connectthe controllampin onesensethan reverse the...

Page 124: ... positive cable of the ohmmeter on the support in d point then the black terminal negative cable in sequence in a point b point and c point After reversing the cables and repeating the checking the ohmmeter needle must not deviate resistance B CHECKING OF THE NEGATIVE DIODES Place the negative terminal of the ohmmeter on the support then on e point after that the red terminal in sequence on a poin...

Page 125: ... INSULATION Afterplacing the ohmmeter terminals on chassis ground on I point and onone ofthe three terminals marked with f g h the ohmmeter needle must not deviate resistance B CHECKINGOFTHECOILRESISTANCE Place in sequence the terminalson thecoils extremities f and g g and h f and h the valuesof the measured resistances must be equal in the thr ee cases the maximum allowed variation being of 5 ALT...

Page 126: ...place the ohmmeter terminals on M and N collector rings the measuredresistancemust be 4 6 0 1 Ù at 20 o C If the valueof the resistance is very high the rotor coiling is burnt and if the resistance is zero there is a short circuit VOLTAGE REGULATOR RELAY The pick up vehiclesequipped with alte rnator type 1114 200 have the voltage r egulator fixed on the left front inner wing the alternator type 11...

Page 127: ...e and the excitation wire of the voltage regulator by unscrewing the fixing nut Unscrew the right side nut loosen the left side one and dismount the relay REMOUNTING Place in its place the regulator and tighten the fixing screws Connect the supply cable the excitation wire by tightening the nut the battery ALTERNATOR vnx su ...

Page 128: ...Nm Minimum rpm n min s 1400 rot min Voltage Ub 7 5 V Coupling Cb 0 95 daNm Absorption current Ia 425 A PINION CHARACTERISTICS CHARACTERISTICS IN LOAD BLOCKED COUPLING bendix to be blocked Thestarteris anengineof continuoscurrentwithserialexcitationprovidedwitharollsidle runningmechanismandgearing commendedby sideelectromagnet A ELECTRIC DIAGRAM OF THE STARTER TYPE 2146 1 Battery 2 Contact switch 3...

Page 129: ...ply voltage RPM and coupling B ELECTRIC DIAGRAM OF THE 2600 TYPE STARTER The starter type 2600 is an engine of continuos current with excitation by constant magnets having a coupling mechanism with rolls and gearing commended by side electromagnet 1 Battery 2 Contact switch 3 Starter solenoid 4 Starter rotor and magnets Characteristics of load at temperature of 23 0 5 0 C Minimal curves 1 2 3 4 ST...

Page 130: ...STARTING AND CHARGING 16 16 22 Test must not be done more than 4 5 secondsTo lay out these characteristics measure the absorbed current supply voltage RPM and coupling STARTER STARTER vnx su ...

Page 131: ...estarterlet itsend down untilcomesintocontactwith the exhaustpipe rotate the starter by 90 and take it out REMOUNTING Place the starter with its end up lower it until it comes in contact with the engine support Rotate the starter by 90 until the end comes in contact with the exhaust pipe bring out the starter then place it in its seat Remount attachment screws supply wires protection screen air fi...

Page 132: ...ke Check the state of the coupling mechanism bendix andof thebrushes the insulation of the brush support the state of the bushings in the two bearings replace them is necessary REMOUNTING Lubricate with bearing oil the bushing of the support bearing and introduce the rotor of the assembled solenoid with the coupling fork Tighten the attachment nuts of the solenoid and introduce the fork shaft Moun...

Page 133: ...reasewitha thin coat ofUM185 Li2 greasethegrooves theareabetweenthe grooves andthesupport ringthe fork shaft andthe rolling areaof the couplingmechanismwith the fork Remount the rotor and adjust the fork stroke BRUSHES REPLACEMENT Dismountthestartertakeoutthecollectorbearingandthestator Take out the old brushes The minimum length of the brushes is 7 mm Stick the new brushes check the rotor and re ...

Page 134: ...rter from the vehicle DISMOUNTING Dismount the stator and the rotor Dismount the solenoid Unscrew the A screw and recover the fork which can be used again if it is in good state REMOUNTING Mount the fork on solenoid shaft Tighten the screw A Assembly the starter and adjust the fork stroke STARTER vnx su ...

Page 135: ...arance H is between 1 0 5 mm For adjustment act on the adjustment nut 1 until clearances F and H are correct By loosening the nut the clearance H is reduced NOTE When mounting remounting the 2600 type starter it isforbidden its hitting with the hammer of some other hard thing which might cause the breaking of the stator magnets The maintenance operations are to be performed on a clean table in ord...

Page 136: ...attery clean and tighten Terminals Check if solenoid is supplied when switch on contact with the key Solenoid is not supplied Check the ignition contact Ignition contact does not work replace the ignition contact Solenoid is supplied dismount the starter and check it Ignition contact working the supplied wire of the solenoid is interrupted or disconnected STARTER vnx su ...

Page 137: ... Thespark plugs maybecheckedon theengineitselfby means of aspecialtesterfor spark plugsorby testingtheinducingvoltage Mount he spark plug on the tester increase the pressure to 12 13 bars and observe the spark aspect thesparkplugshouldbereplacedasinadequate incasethesparkisreddishanddispersed or incasethereis anexternaldischarge thespark plugis adequateincasethespark is blueandis betweenthe electr...

Page 138: ...erminalthread 3 Anti powerhazard protectionstep 4 Insulator 5 Conductingmaterial 6 Internalgasket 7 Ventilationroom 8 Connectionrod 9 Insuringarea 10 Sealin gring 11 Insulatingbulb 12 Central electrode 13 Mass electrode 1 1 1 1 3 4 5 6 7 2 8 9 10 11 12 13 vnx su ...

Page 139: ...corrected depending upon the variation of the parameters with lent evolution T engine T suction air lambda value ë battery voltage The electronic control unit does the ignition advance calculation and the ignition coil control for the MONO MOTRONIC injection system taking into account the evolution of the parameters T engine T air n engine rotation The system is available and does not require adju...

Page 140: ...2 Electronic control unit computer for injection and ignition 13 Induction coil 14 Engine sensor T 15 Rotation sensor 16 Oxygen sensor Lambda 17 Catalytic convertor 18 Ignition control cables with plug for system diagnosis The drawing also indicates 2 Fuel tank 7 Air filter The fuel supply circuit consists of tank fuel electric pump fuel filter injection central unit supply and back feed pipes Cen...

Page 141: ...nnected to the fuel input connection into the valve body the pump is supply by starting the engine or by shunting the terminals 30 and 87 of the relay R1 with both engine and contact OFF AIR TEMPERATURE SENSOR AIR T The air T sensor 5 drawing 4 measures the temperature of the air sucked by the engine Knowing that the air density decreases with the temperature increasing the electronic control unit...

Page 142: ...ctioning the electronic control unit will correct the injection time for an air fuel optimal report ë 1 In case ofa lowvoltageatstartthevalue ti shouldbe increasedin orderto compensate the lower flow of the fuel electric pump The simple testing of the injector is done by means of stroboscopic lamp The air pipe above the injection unit is to be dismounted the engine is to be started and the sprayin...

Page 143: ... admitted when supplying the fuel pump by shunting the terminals 30 and 87 of the relay R1 with lose contact VALVE POTENTIOMETER The valve potentiometer drawing 4 position B is fixed on the injection unit at the end of the valve axle and consists of a potentiometer a double way This is supplied with 5 V from the pin 25 computer and sends to the later a voltage signal proportional with its position...

Page 144: ... In can be checked by means of means of an oscilloscope as follows engine on contact manual moving of the control clutch lever oscilloscope contacted to the pins 1 and 2 of the connector if the displayed sign looks likea row of horizontal straightlines withno interactionsthepotentiometer is ready to use drawing 10 In caseof damage the potentiometeris notto berepaired the lower part oftheinjection ...

Page 145: ...34 The regulator will position the valve in order to obtain the idle rotation 800 50 rot min Components 1 Electric motor step by step 2 Endless screw 3 Endless screwed wheel 4 Switch 5 Protection buffer The switch connector and the idle motion actuator consist of 1 2 Actuatorsupply pin 32 pin 34 computer 3 Idle motion switch pin 8 computer 4 Mass By connecting an ohmmeter to the connectorwires 3 a...

Page 146: ... is checked as follows engine on contact idle motion regulator supplied according to the diagram bya continuous source having U 5 6 5 V necessary to lead it at the end of its way the voltage U v and the partial voltage U 1 are measures on the potentiometer the point with U v U 1 coordinates is marked on the diagram drawing 6 in case of a correct setting the point will appear on the shaded area of ...

Page 147: ... is not fulfilled we can adjust it by the screw B NOTE The distance between the screw 3 and the axle 2 should be 1 mm at cold in order to avoid the idle rotation increasing when the engine is hot The rotation sensor is of inductive type and consists of 1 Permanent magnet 2 Insulator body 4 Ferite core 5 Coil The drawing also indicates 3 gearbox clutch casing 6 flywheel for rotation sensor The flyw...

Page 148: ...ng The sensor functioning can be checked by connecting the connector pins 1 and2 or the computer pins 3 and21 to an oscilloscope A good sensor will generate a signal shaped as in drawing 8 during the engine functioning in which we can identify the following A gear toothed area rotation signal B the 2 missing teeth area C the first tooth area reference signal The rotation sensor is not to be repair...

Page 149: ...ge of the cold engine should be U 5 V thisvoltage decreases according to the heatingof the engine In casethere isa shortcircuit the voltage will drop first slowly then suddenly This is a very precise diagnosis as it is done under running The engine sensor T is not to be repaired but replaced Reference values R sensor 1450 3300 Ω la 15 30 0 C R sensor 2500 125 Ω la 20 0 C The report between the sen...

Page 150: ...ires shouldhave a specialconstruction accordingthenew conceptof anti electricinterference Whentheengine ison contactthecoilis supplied witha DC voltage it iscontrolled by the electronic control unit as follows for spark plugs 1 and 4 pin 1 for spark plugs 2 and 3 pin 19 The secondary circuit isclosedby the two spark plugs the spark voltage atthecylinder under compression is about 20 KV the auxilia...

Page 151: ...tages can be viewed through an oscilloscope and an adapter Fig 10 Fig 11 The reference values measured at the ignition coil connector are as follows for secondary windings R1 4 R1 3 10 16 KÙ at 20 C for primary windings R1 2 R3 4 0 4 0 6 Ù at 20 C The reference values for spark plugs wires R 3000 7000 Ù at an environmental temperature of 20 C DESCRIPTIONOFTHESYSTEM vnx su ...

Page 152: ...ol cablesthrough a 35pins connector The information track between the control unit andthe system componentsis as follows Fuel electric pump Carbon canister purging valve Air T EngineT Battery U Oxygen sensor λ λ λ λ ELECTRONIC CONTROL UNIT Oxygen heating sensor Induction coil Injector Valve potentiometer α α α α Idle motion regulator Idle switch Rotation sensor n DESCRIPTIONOFTHESYSTEM vnx su ...

Page 153: ...ts should be according to the Table 1 page 17 29 and to the afferent electric diagram Takingintoconsideration thespecialconstruction of the connectors usedfor thiscabling system their disconnection should be done only after interrupting the contact to the engine by pushing the fuse and then by disconnecting it The connection should be done carefully the fuse should assure a perfect fixing and elec...

Page 154: ...nition and injection system The system takes into consideration the wearing in time of the engine introducing the necessary correction factors for engine functioning under optimal parameters When reconnecting the battery thecomputer rememorizes allthe datasent by the sensors andthe possible damages of the system after about 20 minutes of engine running The pins 33 and 18 are very important they en...

Page 155: ...15 Not connected 16 Permanent supply clamp 30 17 Supply after contact relay R2 clamp 87 18 Mass clamp 31 19 Control ignition coil cylinders 2 and 3 1 20 Mass clamp 31 21 Signal rotation sensor 1 22 Control air conditioning 23 Mass clamp 31 24 Speed meter 25 Valve potentiometer supply 5 V 5 26 Not connected Mass valve potentiometer 1 27 Mass engine temperature sensor 2 Mass air temperature sensor 4...

Page 156: ...atures within 300 800 C The external area of the ceramic element is in contact with the burned exhausted gases while its internal area is in contact with the fresh air As a consequence there will be a voltage signal between these two ceramic areas this signal will betransmitted totheelectronic control unit pin 9 pin 10 According to the size of this signal the computer will control the ignition and...

Page 157: ...are damaged in case of overheating caused by a difficult starting up or by an improper functioning of the engine The correlation between the value ë and the dosing of the mixture is indicated in the diagram here under The voltage limit values are U ë 0 9 V for a rich mixture and U ë 0 1 V for a poor mixture The value U ë 0 45 V existing between these two is the reference voltage existing in the co...

Page 158: ...inless steelcase resistingtohigh temperaturesandenvironmentalagentaction WARNING Knowing that the catalytic converter reaches high temperatures during the func tioning it is forbidden to install it in areas storing inflammable materials fire hazard In order not to damage the catalyst during a difficult engine starting do not insist in repetitiously trying to start the engine pushing the vehicle it...

Page 159: ...otareasor withthemovingpartsof theengine In caseof chargingthebattery formaredresser thebattery shouldbefirstdisconnectedfromthe electricsystemof thevehicle WARNING 1 Only fuel without lead should be supplied otherwise the catalytic converter will be damaged Use only fuel or oil additives recommended by the constructor 2 You should avoid bumping the catalytic converter 3 The engine should be fit f...

Page 160: ...or supplyingthecomputer pin 17 andtheinjectionwitness of thevehicle frontpanel relayR3 forcontrollingtheairconditioning compressor Theplatefuses are10 A theyare placed onthesupplyingcircuit ofthefuelelectricpump S1 andof theoxygenrod S2 NECESSARYDEVICES FORDIAGNOSISANDMEASUREMENTS OFTHE SYSTEMPARAMETERS Voltmeter ohmmeter class20000 Ù V Manometerfor liquids 0 4 bar withT connection Tester SAGEM CL...

Page 161: ...yingpoints 12 V atstarter Theexhaustingtrackshouldbesealedmainlybetweentheevacuationgallery downtube and ë rod CONNECTINGTHEDIAGNOSISTESTER Thediagnosistesteris connectedtothevehicleinjectioncables providedwiththetwoways connector AMP type code282189 1 This connectoris placedon the left frontmudguard coatingnexttotherelayandfusesblockandfixedby asealingclip The connector isprovidedwithaprotectiong...

Page 162: ...Tester KTS 300 Bosch ThetesterKTS300 executesthefollowingoperations processingof thecommunicationstructures processingof thecommunicationby electroniccontrolunit computer selectionof thememorizeddamages selectionofhelping menu HELP processingof damagecodeby comparingtherealand thesetup values checkingofactingelements actuatorstest Thetesterisprovidedwiththefollowingkeys the keys 1 2 3 are used for...

Page 163: ...n be identified Eachtimeonepressesthekey N thepreviousmessagewillbedisplayed After displaying the data about the last damage of the list by pressing the key the computersendsa messagetotheuser askingifthedamagehas beenrectified Thefollowin goptionsaredisplayed press key 1 for YES press key 3 for NO Whenpressingkey 1 amessageconcerningthememorizeddamageswillbedisplayed withtwooptions press key 1 fo...

Page 164: ...its In caseofchoosingthedisplayin g oftherealvaluesofthemeasuredcheckingtwooptionsfor realvaluesselectionwillbedisplayedby pressingthekey 2 press key 1 for selectingthreeparameters witreal values press key 2 for exploringoneparameterina raw startingwiththefirstone presskey for selectingthenextitemof thelist presskey N forreturningtothesub menu displayingtherealvaluesofthemeasured elemen ts Further...

Page 165: ...s 0206 Valvepotentiometer Shortcircuitatmass 0206 Valvepotentiometer Stopping Shortcircuitatplus 020A Enginetemperaturesensor Stopping Shortcircuitatplus 020A Enginetemperaturesensor Shortcircuitatmass 020A Enginetemperaturesensor Unrealsignal 020B Airtemperaturesensor Stopping Shortcircuitatplus 020B Airtemperaturesensor Shortcircuitatmass 020D Oxygensensor Shortcircuitatmass 010D Oxygensensor Sh...

Page 166: ...ectroniccontrolunitontherightbumpercolumnaredismounted REMOUNTING Reversetheabovementionedoperations Functio ningtests systemtesting WARNING When manipulating the electronic control unit you should avoid mechanic shocks and above 85 C heating You should also avoid any dust or other impurities on the contacts of the control unit and of the connector these could lead to signal errors The control uni...

Page 167: ...ted Thefixingscrew of thesensoron theclutch caseis dismounted REMOUNTING Reversetheabovementionedoperations Functionin g tests testingoftherotationsensorfunctioning WARNING In order toavoid its damaging thesensor shouldbe placed in theclutch case by pushing not by hammering The tightening strength of the fixing screw 8 2 Nm 1 ROTATION SENSOR vnx su ...

Page 168: ...ountingit Thesensorisdismounted REMOUNTING Reversetheabovementionedoperations Thecoolingandthechecking of thecoolingliquid levelinthegas vesselaretobedone Functionin g tests testingoftheenginetemperatur esensorfunctioning WARNING Avoid bumping the sensor The tightening of the sensor to the couple max 18 Nm 1 ENGINETEMPERATURE SENSOR vnx su ...

Page 169: ...nfixingtherod itsthreadshouldbelubricated with12 g anti grippinggrease Function ingtests testingof theoxygensensorfunctioning WARNING In order to avoid its damaging the sensor should be protected against mechanical shocks The tightening of the sensor to the couple 40 60 Nm Seal the gasket between the rod and the primary down tube The evacuation tubes of the burned gases should be tightened up othe...

Page 170: ...he corresponding engine cylinder The high voltage inthe primary and secondary circuits of the coil isvery dangerous Disconnectthebattery terminal Disconnect the connector of fuel injection controlcablesfromthecoilasfollows push thelock 1 arrow sense disconnecttheconnectorfromthecoil Disconnectthespark plugs cables fromthe coil Disconnectthecoilfixingscrewson thecyl inderheadclosingplate 1 DISMOUNT...

Page 171: ...hecablestothespark plugsandtothecorrespondingplotsoftheinductioncoil Function ingtests testingof ignition system WARNING When mounting the cables they should be connected to the cylinder corresponding to the number marked near the coil plot Tightening couple for the spark plugs 20 40 Nm SPARKPLUGSSET vnx su ...

Page 172: ...rm countries 76 87 7 Cold and temperate 87 100 7 5 countries NOTE The vehicles which are using the type D cooling fluid have a label stacked on the expansion vessel as follows ATTENTION Use only cooling fluid type DACIA GLACEOL RX type D The D type antifreeze has a yellow colour For theenginesvariants withtypeC antifreeze itis forbiddentheuseof typeDantifreeze because the type D antifreeze is dama...

Page 173: ...iator hose purges Fill the expansion vessel 30 mm over the maximum level mark Lock the radiator expansion vessel hose by means of the MOT 453 device Pour fluid in the device and fill the radiator and the circuit Start the engine accelerate it up to about 1500 rpm Continue the filling of the circuit till the fluid flows in a continuous jet without air bubbles through the aeration purges In this sit...

Page 174: ...trate antifreeze fluid 65 distilled water for a protection up to 40º 50 concentrate antifreeze fluid 50 distilled water The protection temperature of the fluid is decreasing in case antifreeze fluid rate is over 60 Remove the radiator plug and take out a certain quantity of the liquid Read on densimeter or refractometer scale the protection temperature of the liquid Dependingtheliquidtemperature p...

Page 175: ...ze IMPORTANT Do not use for cooling purpose waterwithout antifreeze fluid addition The water pump may be thus damaged Protection up to 210 C Warm countries The value of protection temperature red on thermal densimeter The fluid quantity liters which is replaced with concentrated antifreeze 50 C 100 C 150 C 200 C 1 6 1 1 0 7 0 2 Protection up to 400 C Cold countries 50 C 100 C 150 C 200 C 250 C 300...

Page 176: ...he radiator the water pump the cylinder head Lock the pump heating radiator ducts Create pressure in the circuit ifthepressureis not decreasing it means thatheating radiator is defective check it and replace it if required if the pressure is decreasing dismount the oil sump create pressure in the circuit and check if there are any fluid leaks at the bottom of the jackets if there are any leaks rep...

Page 177: ...reatepressurein thecircuit value of the pressureshall be 0 1bar higher that thevalue marked on the valve In this situation the pressure must decrease If the pressure does not decrease the valve is blocked and shall be replaced The valve shall be also be replaced in case it permits the fluidpassing Themark on theexpansionvesselvalveis inmilibars 800 0 8 bars CONTROL vnx su ...

Page 178: ...d Dismount the radiator hoses Unscrew thefixing screw andtakeout the radiator REMOUNTING Check the presence of the lower buffers Mount the radiator Mount the upperbuffer and tighten the fixing screw Mount the hoses and tighten the collars Dismount the MOT 453 device Perform the filling and aeration of the cooling circuit DISMOUNTING COOLINGRADIATOR vnx su ...

Page 179: ...DisconnecttheG M Vconnector Dismounttheradiatorattachmentscrewson thevehiclebody Detach theradiator condenser coolingGMVassembly DismounttheG M Vattachmentscrews onthecondenser Takeout theG M V REMOUNTING Performthesameoperationsinthereverseorder Fillup theA C systemwith freon refrigerant andcheckfor leakage Perform operationtestswithrunningengineafterA Cstarting COOLINGG M V vnx su ...

Page 180: ...ncouplingat 90 C stageII between theposts B andC couplingat105 Canduncouplingat100 C In ordertocheckthecorrectoperationof thethermocou ple therearenecessar y thefollo wings abattery 1 acoolingfluidvessel 2 athermometerfor fluidsbetween0 200 C 3 acontrollamp 4 aheat source Makeanassemblyaccordingtothea m diagram Heatthefluidinthevessel Whentheliquidtemperaturereachesto95 Cthelamp connectedbetweenth...

Page 181: ...hammer The water pump is not to be repaired DISMOUNTING Cleanthecontactsurfaceof the gasket and mount a new gasket on the pump Mount the water pump pulley and the fan Mountthehosesandtightenthecollars Mountthebeltandadjustthetightness maximum sag of 7 5 mm at a pushing force of about 3 daNm The belt shall not be overtightened so that pump and alternator bearings are not forced Connect the battery ...

Page 182: ...ump pulley Unscrew the fixing screws of the coverand take out the cover by slightly tapping it with a plastic hammer REMOUNTING Clean the contact surface of the gasket and mount the cover with a new gasket Mount the water pump pulley and the fan Connect the battery Perform the filling and aeration of the cooling circuit WATER PUMPCOVER vnx su ...

Page 183: ...G END 0 Warm countries 76 87 7 Cold and 87 100 7 5 temperate countries DISMOUNTING Loosen the tightening ring and dismount the pump hose Loosen the tightening ring of the thermostat and dismount the thermostat REMOUNTING Mountthe thermostat in the hoseand tighten the fixing ring The thermostat is placed in the hose with the cylindrical part Mount the hose on the pump and tighten the fixing ring Pe...

Page 184: ...Dismountthesilencerby trowittowardsback To dismounttheintermediatepipe 3 performthefollowingoperations Loosenthecollar 4 of fixingtheintermediatepipewiththeexpansionchamber 8 Dismountthetwoelasticrings 5 for attachin g theintermediatepipeandtakeitoutbyturning andpullingitback To dismounttheexpansionchamberassemblyperformthefollowingoperations Loosenthecollar 9 betweentheexpansion chamberassembly 8...

Page 185: ...COOLING EXHAUST FUEL TANK 19 19 14 REMOUNTING Performinreverseorderthedismountingoperations 9 10 11 8 7 6 5 4 3 1 2 EXHAUSTASSEMBLY vnx su ...

Page 186: ... 2 Dismountthehosefixingring 3 on theairexhaustduct 4 for Dacia1304 Pick up respectivelythesealing gasket 8 for Dacia1304 Dropside Dismountthefixingcollar 5 of thefuelductonthelowerfillinghole Dismounttheanti turningvalve 6 Dismountthefixingwashers 7 of thefueltankon thecarbody REMOUNTING Performinreverseorderthedismountingoperations Dacia 1304Pk Dacia1304 Pl 4 5 3 6 2 1 7 4 5 8 6 2 7 1 FUELTANKAS...

Page 187: ...of aninsufficientflowmaybethe lowfeedingtensionof thepumpor adirtyfuelfilter In caseit is defectivethe pumpis nottoberepairedbutreplaced ATTENTION In the feeding system the fuel remains under pressure even after stopping of the engine in case of hoses disconnecting place a cloth material next to the connection so that fuel does not reach the hot areas of the engine Theflowmeasurementis doneasfollo...

Page 188: ...herwithsupportwith theelectricpumpandthefuelleveltransmitter Disconnectthefeedingwiringfrompumpandfuelleveltransmitter Dismountthefixingring ofthehosegoingtothepump Unscrew thefixingscrewsof upperandlowerringsof thefuelpump Takeoutthepumpfromthecollarswithgaskets REMOUNTING Performinreverseorderthedismountingoperations ATTENTION When mounting good fixing rings are to be used and these will be well...

Page 189: ...utfromthetankitscaptogetherwithsupportwith theelectricpumpandthefuelleveltransmitter Disconnectthewiringof thefuellevelsensor Unscrewthesensorfixingscrews REMOUNTING Performinreverseorderthedismountingoperations ATTENTION When mounting good fixing rings are to be used and these will be well tightened The feeding wiring terminals of the pump and of the fuel level transmitter shall be well fixed to ...

Page 190: ...CLUTCH 20 CHARACTERISTICS Dry single disk clutch Membrane mechanism Clutch disk with elastic hub Disk thickness 7 4 mm Clutchstrokeattheleverend 2 5 3 5 mm 20 1 vnx su ...

Page 191: ...CLUTCH 20 IDENTIFICATION The clutch type is marked on the front side of the mechanism Φ Φ Φ Φ 180 DBR CLUTCH Φ Φ Φ Φ 200 DBR CLUTCH Φ Φ Φ Φ 200 GR CLUTCH 20 2 vnx su ...

Page 192: ...equired moment M7 1 1 2 daNm M8 1 5 2 daNm Slightly grease the diaphragm with grease UM170 Li Ca Pb 2M on the area where it comes into contact with the pressurebearing Remount the gearbox on the vehicle Adjust the clutch stroke 2 5 3 5 mm at the end of control lever DISMOUNTING ATTENTION For theinjectionengines beforegearbox dismounting from the vehicle dismount the RPM transducer in order to avoi...

Page 193: ...UNTING Grease the bearing guide and the clutch forksendswithgreaseUM170LiCaPb2M Place the new bearing Place the springby introducing the ends in the bearing holes Slightly grease the contact surface betweenthediaphragmandthebearingwith grease UM 170Li Ca Pb 2M Remount the gearbox Adjusttheclutchstroke 2 5 3 5 mm at the end of control lever 20 4 CLUTCHDISK MECHANISM vnx su ...

Page 194: ...ns by means of the AMB 384 A device observing the value D 1mm Mount the pressure bearing Remount the gearbox Adjust the clutch stroke 2 5 3 5 mm to end of control lever REMOUNTING 20 5 DISMOUNTING Dismountthegearboxfromthevehicle Dismount the pressure bearing Extract the attachment shaft of the clutch fork by means of the AMB 384 A extractor Dismounttheforkspringandrecoverthe fork and the spring v...

Page 195: ...rbox is done by means of a rectangular plate attached to the clutch housing of the gearbox with a 3 5 mm POP rivet On therectangular plate thetype variant andfabrication serial numbers of the gearbox are marked Type G B Var 365 50C 51C 0000000 IDENTIFICATION vnx su ...

Page 196: ...MANUAL GEARBOX 21 21 2 GEARBOX 50C SECTIONS vnx su ...

Page 197: ...MANUAL GEARBOX 21 21 3 SECTIONS GEARBOX 51C vnx su ...

Page 198: ...MANUAL GEARBOX 21 21 4 GEARBOX 365 SECTIONS vnx su ...

Page 199: ...MANUAL GEARBOX 21 21 5 DIFFERENTIAL 51C DIFFERENTIAL 365 SECTIONS vnx su ...

Page 200: ...o pinion and gear synchro hub springs and wedges coupling gears of the pinion and the sliding gear B IMPOSSIBILITY OF GEAR COUPLING AFTER CLUTCH CHECKING Check gear linkage Adjust gear linkage Check the wear of linkage gear Dismount the gearbox Check gear shifting and coupling of the velocity steps Check synchro cones and wedges Replace defective parts Adjust gear linkage BAD GOOD GOOD BAD DIAGNOS...

Page 201: ...k shifter fork contact surfaces with shifter sleeves Check roller attachment system Replace defective parts Replace defective parts of the gear linkage Adjust the gear linkage GOOD GOOD BAD BAD Check adjustment of the gearbox control Check the state of the parts composing the gearbox control Adjust gearbox control Dismount the gearbox and check shifting and coupling mechanism shift fork axle assem...

Page 202: ...tch control system Replace defective parts Check the level of the gearbox oil Fill to proper level if needed Repair the transmission The noise stops Check the wear of wheels bearings Declutching press the clutch pedal to end of stroke STOP The noise stops Replace the wheels bearings Dismount the gearbox and set it in working state Search for noise source at the engine assembly level YES YES YES NO...

Page 203: ...EDO ME TER RATIO RATIO ENGINE CLUTCH 50C 30 32 33 78 6X13 I 42X11 II 38X17 III 34X23 IV 29X28 V 29X38 M Î 40X13 3 81 2 23 1 47 1 03 0 76 3 07 51C 31 37 38 73 76 9X41 102 106 106 106 102 106 102 106 106 106 102 106 Φ200 GR Φ200 DBR Φ200 DBR Φ180 DBR Φ200 GR Φ200 GR Φ200 DBR Φ200 DBR Φ180 DBR Φ200 GR 365 32 37 13 17 8X33 6X12 I 42X11 II 38X17 III 34X23 IV 29X28 V 31X36 M Î 40X13 I 42X11 II 38X17 III...

Page 204: ...ent screws 1 1 4 Clutch housing attachment screws M8 2 2 8 M10 3 2 4 Reverse drive selector shaft nut 2 2 5 Crown attachment screws 9 11 Speedometer endless screws 10 12 Primary shaft nut 6 Differential gear nut lock screws 2 4 Filling or emptying plug 2 2 8 Lock nut of the speedometer fixing screw 0 1 0 3 Backing contactor 2 3 Base plate attachment screws M6 1 1 4 M7 1 1 4 Breather valve 1 1 9 Sh...

Page 205: ...6 Grease UM 170 Li Ca Pb 2M Lubrication of knuckles and contact parts MAINTENANCE The maintenance of the 365 50 C 51 C type gearboxes consists in repeatedly performing certain revisions according to the performed mileage as mentioned bellow gearbox oil replacement is done after covering the first 800 1000 km and than periodically every 20 000 km checking ofgearbox oil level periodically every 5000...

Page 206: ...achment screws of the gearbox upper part on the engine block Dismount the clutch cable MountthecrossbarTF509 for maintaining thehalf frontaxe betweenthe shockabsorber and the suspension lower arm shaft GB 365 GB 51 C Place the vehicle on the elevator and lift it Drain the oil from the gearbox by unscrewing the threaded plug and recover it Dismount the front wheels Dismount the transmission lock pi...

Page 207: ...Unscrew the attachment nut of the exhaust pipe Disconnect the backward driving contact wire Disconnect the speedometer cable Lift the back part of the gearbox by means of a jack Dismount the three crossbar attachment screws to the gearbox the two crossbar attachment nuts to the longitudinal girders Dismount the crossbar Dismount the clutch protection plate Dismountthe two nuts attachmentgear box T...

Page 208: ...back drive connector Connect the propeller shaft and tighten at the required moment 5 daNm the 4 attachment screws M10 G B 50 and G B 51 Connect the speedometer cable the velocity steps control Connect thevacuumhoses and the electricalconnector of vacuum capsule G B 51 C Grease thepropellershaftgrooveswithgrease UM170 LiCaPb2M G B 365 and51 C Position the transmission in correspondence with the pr...

Page 209: ...n thewheels nuts at the required moment 9 daNm Dismount the TF 509 support cross bar Mount the clutch cable with its support Adjust the clutch stroke 2 5 3 5 mm to the end of shifter shaft Adjust the velocity steps gearing see chapt Velocity steps control adjustment Mount the starter and the protection shield Connect the starter power cable the coupling relay supply wire Fill up the gearbox with o...

Page 210: ...sher 2 of the control lever fixing Dismountthecontrol lever 3 of thefront 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 theattachmentdifferentialcover screws 6 on half crankcase Take out the differential cover assembly and its paper gasket Dismountthebearing...

Page 211: ... 11 Take out the claw 12 and the pins housing 13 REPAIR DISMOUNT THE VELOCITY STEP V Dismount the flange attachment nut flange onsecondary shaft and take outthe flange G B 50C 51 C Bringthe gearbox tothe 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 spee...

Page 212: ...Dismount the distance plate For G B 365 and 51 C Dismount the nuts lock washers for the differential gear adjustment Dismount the adjustment 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 thedifferential gear G B 365 and51 C the secondary shaft and the ...

Page 213: ...ttachment spring of the speed V fork shaft Dismount the elastic pin of fork III IV by meansof 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 meansof the CV 31 B mandrel Dismounttheshaftandthefork recover the attachment spring and ball Dismount the reverse selector the reverse ...

Page 214: ...k ring the shaft the pinion the friction ring the guiding wedge Recoverthespringandtheattachmentball 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 vnx su ...

Page 215: ...by means of the CV 39mandrelandseparate 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 vnx su ...

Page 216: ...ones gear the velocity step IV pinion and its synchronizing ring the synchronizer tooth gear sliding mechanism III IV DismountthespeedsIII IV synchronizer hub on a press by means of the TS 65 extractor Dismount thewedgeof thelock ringof the speed III pinion the lock ring of speed III pinion the speed III free pinion and its synchronizer ring vnx su ...

Page 217: ...he position of the gear sliding corresponding to that of the synchronizer hub Dismount on a press the hub of the velocitysteps I IIsynchronizer by means of the TS 65 extractor Dismount the lock ringof 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 secondary shaft ...

Page 218: ...edcrown DismountthebearingsbymeansoftheCV28Aextractor providedwiththeCV48grippers Dismountthetoothedcrown thescrews may notbere used Dismounttheelasticattachmentpin of the pinionsshaft by meansof theCV 31 B mandrel Dismo unt thedifferentialpinionsshaft thedifferentpinions thefrictionwashers thepropellershaftpinion vnx su ...

Page 219: ...endof therocking lever takeouttheshaft Dismount the plug of the V velocity step pusher recover thespring the pusherandthe gasket Dismounttheelasticpinfromtheend of the controlshaft by meansof theCV344 mandrel Dismountthelockringoftherocking levershaft dismountthe shaftandtherocking lever Dismo unt thesealinggasket thecontrolshaftbushing ifitisworn vnx su ...

Page 220: ... parts will be lubricated with 80W 90 oil before bein mounted Mounton thesecondary shaft the velocity step I pinion together withitssynchroniserring thelockwasherof thevelocitystepI pinion a false wedge made from a normal wedge withacurvedend thefalsewedgeis introducedinachannelwhichhasalubricatin g hole Remove the maintaining device of the bearingouterring Mountthevelocitysteps I IIsynchroniserhu...

Page 221: ...t therefor about 15 minutes toheatit 2 Withoutdifferenceof temperature for gearbox made after 26 04 1999 series 172321 Thepressing forcefor thehubs I II and III IV willbemax 2000 daN Presstheassembledhub untilitcomes into contactwiththevelocitystepIpinionlock Centerthethreewedgesinthesynchronising ringgrooves Removethefalsewedge Mountthehub I IIwasher MountthevelocitystepIIpinion togetherwith itss...

Page 222: ...ich has a lubricatinghole Mounton thevelocitysteps III IVsynchroniserhub thethree wedges thetwo springs thetoothgearslidingmechanism withitsgrooveoppositetothegroovehub Presstheassembledhub until itcomesinto contactwiththelockwasherof thevelocitystep IIIpinion thegrooveinthehub shallbeorien ted towardsthevelocitystepIII pinion Centrethethree wedges inthesynchroniser ringgrooves REPAIR vnx su ...

Page 223: ...ice Engagegearbox inspeedI Tightenattherequiredmoment 10 12 daN thesecondary shaftflange nutor speedometerendlessscrewby meansof theCV 204 wrench Thespeedometerendlessscrew shallnotbe lockedbystraininginordertoenableadjustment of theconicaldistance Check the clearance J between the synchronisingringsof thevelocitystepsI and II and the sides of the hub J min 0 2 mm Thecheckshallbeperformedas follow...

Page 224: ... Presstheneedle rollerbearinginnerring Mounttheoutsidebearingringtogetherwithitsrollerscasing Mountthelockwasher Mounttheclutchshaft place anew compensationwasherbetweentheendof theshaft in ordertopreventthenoise Mounttheelasticpinby meansof the C V 31B mandrel REPAIR vnx su ...

Page 225: ...ifferentialpinion isvery big thepropellershaftpinion lubricatedwithoil thefrictionwashersof thedifferentialpinions thedifferentialpinions Mountthedifferentialpinionsshaftandcenterthepinshaftwiththeoneinthecasing Mounttheelasticpinby meansof theG B 31B mandrel thepinshallbeintroduced about 5 mminthedifferentialgearcasing Lubricatethesecondpropellershaftpinionwithoilandplaceitinthecasing Mountthetoo...

Page 226: ...ness between thebiconicalbearing 2 andthedifferenti aldrive pinion shoulder 3 CASEXCEPTIONEL There maybesituationswhenthevalueA 5 9 mmisnotcorrectvaluefor thepinion positioning Thedifference X betweentheactual valueandthevalueA 59 mmismarkedon the frontsideof thepinionnearthenumbermarked for pairingwiththetoothedcrown Thevalueisgiveninhundredthsof mm EXAMPLE X 20 0 2 mm In this situation thedistan...

Page 227: ...seattherequiredcouple Introduce the CV 239 01 control device Place the CV 239 02 spacer at theend of thedifferentialdrivepinion Measureby meansof a thickness gauge thedistance X betweenthespacerand the deviceshaft 1 Thedistancevaluemeasuredis smaller thanthenormalone 0 5 mm In thiscase replaceadjustmentwasherfor thedistance betweentheconicalmechanismswithathinner one 2 Thedistancevaluemeasuredisbi...

Page 228: ...re mounting the annular oil rings will be immersed in oil 80W 90 Mounttheouterringsof thedifferentialgear bearing inthehalfcrankcases so that they are protrudingas comparedtotheinnersideof the halfcrankcase Placethedifferentialgearintherightsidehalf crankcase Placetheleftsidehalfcrankcaseand assembleitby meansof screws Tighten the screw to the required moment observing thetightening orderspecified...

Page 229: ...ening Tightentheadjustmentnuts untilthebearings showacertainresistancetorotating Check the pre tightening of the bearings as follows rotatethe differentialgear severaltimes in ordertosetthebearings placeathreadaround thedifferentialgear casing and draw the thread by means of a dynamometer thedifferentialgearshouldrotate at a 1 3 daN force NOTE For both types of bearings the nut 1 in the right side...

Page 230: ...hereversedriveselectorinthenotchofthereversedrivingshaft Tightenattherequiredcouple 2 3 daNm thereversedrivingselector shaft Placetheattachmentspringandballof thevelocitystepsI II fork shaft Introducetheshaft AssemblythevelocitystepsI IIfork withthehub towards thebacksideof thegearbox Introducetheelasticpin REPAIR NOTE Upon remounting the elastic pins shall be positioned with the slot towards the ...

Page 231: ...locitystepsIIIIV fork shaft Introducetheshaft MountthevelocitystepsIII IVfork withthehub towards frontsideof thebox Introducetheelasticpin Placetheattachmentballandspringof thefork shaftvelocitystepV Place theblockingballof forks shafts velocitystepsVandIII IV IntroducevelocitystepVfork shaft REPAIR vnx su ...

Page 232: ...the attachment springandball ofthe shaftintheleftsidehalfcrankcase NOTE The spring is black painted to be differentfromlockingspringof forks shafts Introducethereversedrivingpinionshaft Mount thereversedrivingpinion withthehub directedtowards thefrontof thegearbox thefrictionwasher withthebronzeside towardsthepinion Introducetheguidingwedge inits seatand completelyintroducetheshaft Mountthesafetyr...

Page 233: ...cerandtightenitsattachment screwsattherequiredmoment 1 1 4 daNm Tighten the assembling screws of the half crankcases attherequired moment observing thetighteningorderspecifiedinthedrawing M 7 1 9 2 4 daNm M 8 2 8 3 3 daNm VELOCITYSTEPV PINIONREMOUNTING Placethefollowingpartson theprimaryshaft the spacer theinnerbushingandneedlecasings thefreepinionof velocitystepV thesynchronizerassemblytogetherwi...

Page 234: ...actwiththehub thesynchronizingringin contactwith the pinioncon Couplethereversedriving andthevelocity stepV Tightenattherequiredcouple REPAIR thenutof theprimary shaft 6 daNm the speedometerendless screw 10 12 daNm G B 365 Securethelockingnutandthespeedometerendless screw GEAR CLEARANCE ADJUSTMENT G B 365 51C In ordertoadjusttheclearanceof thegear loosenthenut 1 fromtherightsidehalf crankcaseandti...

Page 235: ... 25 mm Adjustthenutsuntilcorrectclearanceis obtained Mountthenutslocks BACK CAP ASSEMBLING Mountthecontrolshaftannularoilseal Assembletherocking leverwithitsshaft Mounttogether theassembledrockinglevershaft thecontrolshaft Tighten the attachment nut of the return rockinglever 4 4 5 daNm Mounttherubberprotection Mounton thecontrolshaft theprotectionbellows thecontrolshaftend theelasticpin REPAIR vn...

Page 236: ...t Placethe backcapgasketlubricatewith oil Placethebackcap positionthevelocitysteps selector intheforksshafts notches Tightenattherequiredmoment 1 1 4daNm the backcapattachmentscrews For G B 50C and 51C Fillthe contact surfacebetweenthe annular sealandtheflangewithgreaseUM170 LiCa Pb 2M Mounttheflangeof propellershaft transmission Place the washer and tighten at required moment 10 12daNm theflangea...

Page 237: ...agedpartswithnewones Mount the pins housing 13 and the claw 12 Mountusingapress bymeansof ametallic strap thebearingon thedifferentialhub ifthis waspreviouslydismounted Mount the assembly hub the tooth gear slidingmechanism 10 togetherwithcoupling shaftandfork 11 Placethewasherrut 9 Mountthesafetyring 8 on thepropellershaft pinion Mountthecover 7 REPAIR withmechanismscrankcase Mounttheclutchcasing...

Page 238: ...enthe flange anddifferentialhub withsealingpasteLOCTITE 518 Necessary quantity 2ml Mounttheflangeanddeflector Tightenthescrewsat therequired moment differentialcap 1 2 daNm differentialflange 2 4 daNm Mountthe threaded plug 4 for limiting the stroke Mount the control lever 3 and secure with safetyring 2 positio n theend of leverinthenotch of thecontrolshaft Check the front transmission engagement ...

Page 239: ...TE The velocity step V fork shaft shall not be dismounted because the interlocking ball may fall their mounting implies dismounting the whole gearbox REMOUNTING Cleanthecontactsurfaceof thegasket Place a new paper gasket after it was lubricatedwithoil Placethe backcap positionthevelocity stepsselectorintheforksshafts grooves Place the cap attachment screws and tighten them at the required moment o...

Page 240: ... Dismountthewormannularoilseal DISMOUNTING REMOUNTING Mountthenew annularoilseal after itwas immersedin 80W90 oil Mounttogether therockinglevershaft the control shaft Tightentheattachmentnutof therockingle vershaft attherequiredcouple 4 4 5daNm Mounttherubberprotection Mounton thecontrolshaft theprotectionbellow thecontrolshaftend theelasticpin Mountthebackcapwithanew lubricated gasket Mountthebac...

Page 241: ...rawthehand brake Dismountthespeedometerendlessscrew by meansof theCV 204 wrench REMOUNTING Mount the speedometer new endless screwby means of thewrench CV 204 and tighten at the required moment 10 12 daNm andsecureitby straining G B 365 Mountthenewspeedometerpinionin thebackcap NOTE Before mounting the speedometer pinion shall be immersed in 80W 90 Mountthebackcap withanew gasket Mountthebackcross...

Page 242: ...hanism andvelocitystep Vhub 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 REMOUNTING Place thefork on thegeartoothgearsliding mechanism Mount the velocity step V synchronizer assemblytogetherwiththefork ontheprimary shaft Mountthefork elasticpin by means of the 31 B ma...

Page 243: ...mersed in 80W 90 oil Mountthenewannularoilsealby meansof theCV 488 device composedof apipe 1 for mountingtheannular seal oil apipe 2 for protection of the annular sealoil Cleantheassemblingsurfaceclutchcasing withthehalfcrankcasesandapplyalayerof sealingpasteLOCTITE518 Mounttheclutchcasing usingthe protector 2 for protectionof theannularseal oil Tightenthescrews attherequiredmoment M8 2 2 8 daNm M...

Page 244: ...wheels Draintheoilfromthegearbox Takeouttheattachmentpinsof the transmissionby meansof theCV31 mandrel Disconn ect thesteeringjoint theuppersuspensionjoint by meansof the TF476extractor Rock the steering knuckle support and removethetransmission fromthepropellershaft pinion Observethepositionof thenutcorresponding tothecrankcase PROPELLERSHAFTANNULAR OILREPLACEMENT on vehicle vnx su ...

Page 245: ...newannularoilsealandtighteningring Mountthenut observing thenumberofrotationsand thedismountingmarking Greasethepropellershaftpiniongrooves withgreaseUM170 LiCa Pb 2 M Positionthetransmissiongearincorresponden cewiththepinion centerthetransmissionby meansof theCV 31B mandrel Introducethenewelasticpins Thepinsnotchesshallbeorientedtowardsthewheel Thepins ends shallbesealedwith RHODORSEAL5661 Mount ...

Page 246: ... andtheone from the wheel consisting in a steering knuckle casing witha 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 2or ELF C...

Page 247: ...ctor PF 476 Mandrel C V 31 B Hub immobiliser PF 235 A Device for mounting transmission in the hub PF 236 FRONT CROSS TRANSMISSION TIGHTENING MOMENTS daNm Suspension upper joint nut 5 Steering joint nut 4 Transmission nut 23 Wheels nut 9 29 2 vnx su ...

Page 248: ...actor theuppersuspensionballjoint 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 suspensi on off the propeller shaft pinion Temporarily mount the steering ball joi...

Page 249: ...s at the required couple Fixthehub by meansof the PF 235A 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 thebrakepedal several times inorder to bringthe brake pistonin contact with...

Page 250: ...missionoffthe vehicle Dismountthecollar 5 maintainingthe 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 Thesliding blocksand th...

Page 251: ...pon theshaft 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 ...

Page 252: ...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 thebellowsreinforcementsinthest...

Page 253: ... areasthere 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 M10x 1 25 35 assembling the cardanic flanges tothe 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 positi...

Page 254: ...es tightening screws M 8 x 1 25 1 5 2 5 CARDANIC TRANSMISSION MAINTENANCE In ordertoavoid arisingof same problemsinexploitation suchas noise jointclearance nooses gutter wear it is necessary to perform the greasing of the cardanic transmission every 5000 km The operationis performed within adjustin within the periodical technical revisions by means of the Tecalemit grease gun This to be applied on...

Page 255: ...ms type The brake disks are aerated for the wheels with 5 attachment screws and non aerated for wheels with 3 attachment screws 30 1 4 5 6 12 14 3 2 1 15 13 16 12 14 10 11 17 9 7 8 14 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 ...

Page 256: ...GENERAL 30 TIGHTENING MOMENTS daNm FRONT DRIVING AXLE 30 2 1 5 6 4 4 5 9 23 5 6 5 11 9 5 8 vnx su ...

Page 257: ...GENERAL 30 TIGHTENING MOMENTS daNm FRONT NON DRIVING AXLE 30 3 1 5 5 11 9 5 8 5 9 23 4 4 5 6 5 vnx su ...

Page 258: ...GENERAL 30 TIGHTENING MOMENTS daNm REAR DRIVING AXLE 30 4 1 54 2 5 24 6 3 vnx su ...

Page 259: ...GENERAL 30 TIGHTENING MOMENTS daNm REAR UNDRIVING AXLE 30 5 2 5 9 6 5 24 1 54 vnx su ...

Page 260: ...nt screw disk to the hub Front wheel steering knuckle nut Wheel attachment screw Wheel fixing nuts Main brake cylinder fixing nut with servobrake I C P transducer Servobrake on bridge floor The screw connection of the rigid linkage on main brake cylinder pressure limiter rear wheel cylinder flexible hose TIGHTENING MOMENT 1 1 2 2 1 5 6 5 2 23 9 9 1 3 2 2 1 5 30 6 vnx su ...

Page 261: ...er after grinding 255 Braking lining width 50 Braking lining thickness 5 Minimal accepted braking lining height above rivets 0 5 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 thicknessnon aerate 9 Minimal disk thickness aerated 19 Braking pad thickn...

Page 262: ...ans 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 The cupping shape of the copper or steel ducts A The shape of the threaded lengths on parts B Connections of ducts C 30 8 A B C vnx su ...

Page 263: ...ty and Maintenance Booklet for brake fluid change COMPLETION OF THE BRAKE FLUID LEVEL The wearof 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 bell...

Page 264: ... 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 otherpurging 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 PR...

Page 265: ...ke brokenmembrane Check the integrity of the depression pipe consequently of the retain ingvalve thesealingofthedepressionpipe attheserv obrake consequentlyatthe vacuumpump inletmanifold Istheengine regimechanging whenbraking The engine pedal is rigid from time to time 1 Is theconnection shaftbetweenthe servobrake fork andthepedal grabed Attheservobrake entrance is the depression the imposedone I ...

Page 266: ...onescorrectly gliding STOP Replacethedefectiveparts withGenuineSpareParts Replacethebrakepads conse quentlythebrakeshoes see bellowsitua tions Arethebrakepads consequentlytheshoes gasketingood condition The brake linings are to be replaced when theyare greasy sh iny not in accordance with the manufacturer s prescriptions genuine Spare Parts havenotbeenused Yes Yes No No No DIAGNOSTIC 30 12 vnx su ...

Page 267: ...vepushingonthebrakepedal inordertovacuumtheservobrake Locate and repair or replace the item where a brake fluid leak is established Yes No Isthebra kefl uid levellowe r comp are dtothe re quire done Replacethe brake pump becausethe pressuregas ket sealing betweentheprimary circuitandthesec ondarycircuitisdefective STOP DIAGNOSTIC 30 13 vnx su ...

Page 268: ...t Floorpedal Thetestis tobeperformedwithstopped vehicleand cutengine REMARK Perform five consecutive pressings on thebrakepedal in order to vacuum the servobrake before taking into consideration thetest result POSSIBLECAUSES Assistance defect Brakelinings greasy stacking tothedisk non conform heating prolongedbrakingwithconstant pedalpress Stuck piston Rigidductnarrowed flattening Airpresenceinthe...

Page 269: ...nliningsanddisk Front axle suspension steering to be checked Stuck piston Tires wear inflation pressure Rigidductnarrowed flattening Stuck piston Automaticadjustment handbrakecablevery tighten REMARK Automatic recovering is performed by means of the brake pedal if there is no ab normal tension in the hand brake cable when released hand brake released Returnspring Insufficient hydraulicstrokeof the...

Page 270: ...n1 betweenthetwoangles leftsideandrightside leadsto thedeviationtothetrajectory thatmustbeadjustedby meansof thesteeringwheel irregularwearof thetires STEERINGGEARBOX POSITION Thesteeringgearbox shouldbeplacedatacertainheightfromtheattachmentpointsof the steeringauxiliaryconnectingrodballjoints Thepositionof thesteeringgearbox influencesthevariationof theparallelism Thesteeringbox ismountedinthepo...

Page 271: ...e tires towards the interior A too much closing causes the wear of the tires towards the exterior THETRANSVERSALINCLINATIONANGLEOFTHEBALL JOINTT 80 30 Itisformedby theballjointaxleandthevertical measuredintransversalplane Thepurposeofthisangleisthesamewiththeoneof thecasterangle retrievethewheelsafter turning inthecorresponding positionfor rectilin eardrivingandtomaintainthismovement Thisangleisno...

Page 272: ...has been dismountedDIR487 PRELIMINARYCHECKINGS Beforechecking and adjustmentof thefrontaxlegeometry performthefollowin gsoperations Thecheckingof tiresconcerning dimensions airpressure thestate ofwear NOTE The tires must be of same type with the same state of wear air pressured at the prescribedpressure Thecheckof joints thewearof elasticbushings balljointsclearance connectingrodclearance wheelsbe...

Page 273: ...ttoobservethefollowingsequence placingthevehicleon rotatingplates brakedvehicle checksuspensionfor placingthevehicleatitsfreeheight establishingof thesteeringcentralpointandsteeringbox lock fixingof theopticaldeviceson thevehicle aspermanufacturerinstructions ESTABLISHINGOFTHESTEERINGCENTRALPOINT In orderto establish thesteering box centralpoint bring gear rod in theposition whereC 65 mm Thisvalue...

Page 274: ...GENERAL 30 31 20 Checktheconnectingrodssymmetry X Readthevalue A on thescale REPARTITION CHECKINGANDADJUSTMENT FRONT AXLECHECKING ADJUSTMENT vnx su ...

Page 275: ... fixedposition Actupon therod ofsteeringconnecting rod takingintoaccounttherotationsenseof latterin ordertoobtaintheconvergenceor divergenceandalsothefact thatoneof its completerotationleadsto anaxialdisplace mentof 1 5 mm After obtaining the correct parallelism tightenthelocknutatamomentof 5 daNm OBSERVATION Three situations may appear PARALLELISM REPARTITION CORRECTION WHICH MUST PERFORMED 1 COR...

Page 276: ...symmetry Requiredconditions arerespected Correctthedeficients The deviation persists Controlfinished Checkandadjustthefront axle Controlfinished The deviation persists Checktheparallelismand alignment Frontaxle adjustment Replacedamaged Controlfinished The deviation persists Controlfinished Control Operatingefectue LEGENDE Tiresrotation NO NO NO NO NO YES YES YES YES YES 31 22 DIAGNOSTIC vnx su ...

Page 277: ... the vehicle on the elevator Onthepart wherethe upperarm isdismounted the followingoperations areperformed 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 ...

Page 278: ...t 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...

Page 279: ...metric wrench 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 UPPER ARM vnx su ...

Page 280: ...476 Dynamometric wrench MOT 50 Dismounttheupperarm ofthesuspension Dismount on a press the worn bushing using a rod with the outer diameter of D 26mm Pressthenewbushing Onpressing observe the value A 6mm Mount the upperarm on the vehicle BALL JOINT REPLACEMENT SPECIAL TOOLS DENOMINATION CODE Front axle support cross bar PF 509 Ball joint extractor PF 476 Dynamometric wrench MOT 50 vnx su ...

Page 281: ... rod with the ball joint and place it on the arm ELASTIC BUSHING UPPER ARM BALL JOINT 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...

Page 282: ...c wrench 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 vnx su ...

Page 283: ... 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 Mountthe wheel takedownthevehiclefromtheelevatorandremovethe PF5...

Page 284: ...ecking device PF 502 Dynamometric wrench MOT 50 LOWER ARM Dismount the suspension lower arm Mountthe lowerarmchecking device PF502 on the lower arm andintroduce 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 vnx su ...

Page 285: ...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 ...

Page 286: ... by means of the PF 476 extractor Dismount the suspension lower arm Boreand removetheball jointattachment rivets Mountthenew balljointand attachit 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 ELASTIC BUSHING LOWER ARM BALL JOINT vnx s...

Page 287: ... 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 housin...

Page 288: ...s 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 vnx su ...

Page 289: ...erage connection from the brake flexible hose Remove the safety washer of the flexible connectionfrom thestopperanddismountthe caliper 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 g...

Page 290: ...nce 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 en...

Page 291: ...all 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 c...

Page 292: ...n 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...

Page 293: ...el 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 φ φ φ 215 NOTE The maximum axial deviation is 0 2 mm If the thickn...

Page 294: ...kthehub by meanstheof thePF235 A deviceandunscrew thesteeringknucklenut Unscrewthethreeattachmentscrewsof thehub disk locatedat120 oneof another mount intheir placethe RO482 01 extractor Placea screwneartheattachmentnutof thebearingclosingplateandbringthethreescrews incontact withthesteeringknuckle Alternativelytightenthethreescrewsuntildismountingthe hub disk assembly Dismountthediskoffthehub BRA...

Page 295: ...yon thesteeringknuckle Mountthe hub disk assemblyon thesteeringknuckleby meansof thePF236 device Mountthesteeringknucklenutandtightenat23 daNmmomentby meansof the MOT50 wrench Mount thecalipersupportwiththescrews greasedwith FIXAMED R 58andnew Grower washer thebrake pads thebrakecaliper thewheel Getthevehicledownfromtheelevator Press thebrake pedal severaltimes inorder tobring the pistonin contact...

Page 296: ...thesteering knucklethebrakecalipersupport REMOUNTING NOTE Upon remounting greasethescrews with FIXAMED R 58 and replacetheGrower washers Place thebrakecalipersupportintherightposition Tightenthescrews M12 x 1 25 attherequiredmomentof 6 5 daNm Tightenthescrews M6 x 1 that attach theprotectorat therequiredmomentof 1 3 daNm Mount thebrake pads thebrakecalipersupport thewheel Takedownthevehiclefromthe...

Page 297: ... Dynamometricwrench MOT 50 TIGHTENING MOMENTS Upperballjointnut 5 daN m Lowerballjointnut 5 daN m Steeringball jointnut 4 daN m Transmissionnut 23 daN m Wheels nut 9 daN m Caliper support attachment screws 6 5 daN m DISMOUNTING Liftthevehicleby meansof anelevator Mountthe PF509 supportcross bar Dismo unt thewheel thebrakecalipertogetherwithflexible connection the brakecalipersupport andthe mud fla...

Page 298: ... hub disk steeringknuckle assembly by couplingtheballjointsandtighten theirnutstotherequiredmoment Mountthetransmissiongearby meansof the PF236 device Mountandtighten thetransmission nut thebrakecalipersupportandthemudflap thebrakecaliper Mountthewheel getthevehicledown fromtheelevator recoverthe PF509crossbar Pressthebrakepedalseveraltimesinordertobringthebrakecaliperpistonincontactwith thebrakep...

Page 299: ...ingknuckleisdismountedoffthemotorcar Dismounttheinnerbearingof thesteeringknuckle In itsseat placethepin C of thePF496 checkingdevice andplacemandrels A and B inthesuspensionballjointseats In thissituation theside E of thesteeringknuckleshouldbeparalleltothecheckingdevice frontside andtheseat ofthesteeringballjoint shouldgetintothedevicebore vnx su ...

Page 300: ... 476 Shaftprotectionbushing RO 15 01 Bearingsextractor CV 28 A Dynamometricwrench MOT 50 Dismountthesteeringknuckleoff thevehicleanddismountthesealingplate INNER BEARING DISMOUNTING Place the steering knuckle on a 80 mm innerdiametertubeanddepresstheinner bearing usinga 45mm outer diameter rod OUTER BEARINGDISMOUNTING Once the hub disk assembly being dismounted mounttheRO15 01 protectionsleeveandd...

Page 301: ...G Mountbearing by pressingit on thehub usinga 36 mm inside diameterrod Thisshall besupportedandshallpresstheinnerringof thebearing PutgreaseLiCaPbtypeUM180 Li2 inthesteeringknuckle Introducethebearingspacer Positionthebearingtogetherwiththesteeringknuckleon the hub disk assembly Thisis pressedon the hub usingarod thatshallrest ontheinnerring and that shallhavethe followingdimensions outerdiameter ...

Page 302: ...ENSIONMAIN ELEMENTS FRONT SUSPENSION Withhelicalsprings hydraulicshockabsorberwithdoubleeffect withincorporatedlock buffersandstabilizerrod Thehelicalsprings haveaflatsupportareaat theupperpart andaflatsupportareaatthe lowerpart FRONT SUSPENSION section vnx su ...

Page 303: ...RTANT Since the shock absorbers are stored in the spare parts warehouses in horizontal position it is possible that they get depressed That is why before mounting on the motor car the shock absorbers shall be pressed by shifting the rod upwards and downwards the shock absorber in vertical position SUSPENSION TIGHTENINGMOMENTS STABILIZERROD VEHICLE TYPE DIAMETER mm Pick up 1304 1305 1307 19 NOTE Ma...

Page 304: ...sorberlowerattachmentshaftand thesuspensionlowerarmshaft Lift the engine by means of a 2 columns elevator Removetheplasticshutter mountedon the shockabsorbercolumn Dismountthewheel MounttheSUS478 01deviceon thewing doublelining reinforcemen t Place the threaded rod and compress the spring Loosenthestabilizerrod shaftnut Unscrew theshockabsorberupperlocknutandnut theshockabsorberlowerlocknut Rotate...

Page 305: ...sorberintothelowerjoint Pulltheshockabsorberrod by meansof the SUS513 device Positiontherubberbuffers andthecrossbar Tightentheuppernutattherequiredmoment Tightenthelocknut Tightenattherequiredcouple thelowerlocknut thestabilizerrod shaftnut Dismount the SUS478 01device Mountthewheel Lowerthevehiclefromtheelevator Removethe PF509 supportcrossbar FRONT SHOCKABSORBER vnx su ...

Page 306: ...dof thegrippers hook thegripperstothelastbutoneup percoilof theshockabsorberspring placethelowerplateof thedevice slight lytightenthenuts mount the lock collaratthemiddle of thesprings compressthespringby alternatelytight eningthenuts until thespringraises fromthe shockabsorberflange Dismo unt theshockabsorberuppernutand lock nut theshockabsorberlowerlocknut Rotatetheshockabsorberandremoveitfrom t...

Page 307: ...rewtheshockabsorberintothelowerjoint Pulltheshockabsorberrod by meansof the SUS513 device Positiontherubberbuffers andthecrossbar Tightentheuppernutattherequiredmoment Tightenthelocknut Tightenattherequiredcouple thelowerlocknut thestabilizer rod shaft nut DepressthespringanddismounttheSUS478device Mountthewheel Lowerthevehiclefromtheelevator Removethe PF509 supportcrossbar vnx su ...

Page 308: ...he spring untiltheSUS478 deviceis released DismounttheSUS478 device Depressthespringandremoveit REMOUNTING NOTE The lower end of the spring must be in contact with the plate and aligned with the SUS 478 device support slot DismounttheSUS480 device Mountthe device spring shockabsorber assembly Placethe newspringon theSUS480 device Pressthespring observingitsmountingpo sitio n MounttheSUS478 device ...

Page 309: ...hestateof theelasticbushings if itshowsmarks of wear replacethe auxilia ry connectingrod REMOUNTING Mounttheauxiliaryconnectingrodson thestabilizerrod Greasetheauxiliary connectingrod shaftwithspecialMoS2grease Mounttheassembledstabilizerrod Press thefrontaxle at adistance D 45mmby meansof the TAV238 02 device Tightenattherequiredmoment casingattach mentnut auxiliaryconnecting rodsshaftnuts thenut...

Page 310: ...id gear between the pinion and the rim The differential is symmetrical simple with four conical differential pinions ATTENTION After fixing the tighten nut of the cardanic flange shall be lock by straining IDENTIFITION On the rear part of the axle casing it is marked by stamping mark or symbol of the manufacturer manufacture series week year month year The characters height is at least 5 mm The mi...

Page 311: ...angle 00 Not adjustable Pressing position of the leave spring G 162 mm TIGHTENING MOMENTS Shock absorber lower nut 3 daN m Axle attachment nut 11 daN m Wheel nut 9 daN m DRIVE REAR AXLE DISMOUNTING Lift the rear axle by means of a two columns elevator Dismount the wheels Disconnect the brake limiter control vnx su ...

Page 312: ...g and the level one to speed draining REMOUNTING Perform the same operation in reverse order attention should be paid to the fact that the axle may overturn when lifting it to mount the clips NOTE The steps performed when dismounting remounting the rear axle as assembly are similar for all types of pick ups Dismount the four screws of the cardanic flange at the side towards the differential gear t...

Page 313: ...um implying the same operation for the other one SPECIAL TOOLS Depress bearing closing assemble device PS 65 TIGHTENING MOMENTS Wheels nuts 9 daN m Slotted nut 24 daN m Theattachmentscrews of the assembly drum axle brakeplate 6 3 daN m Theconnectingscrew propeller shaft drumhub assembly 1 54 daN m 6 5 4 1 2 3 7 vnx su ...

Page 314: ... AI 68 depress the bearing casing assembly from the hub by meansof the PS 65 device REMOUNTING Clean of dust the drum and brake shoes by means of a cleaner vacuum cleaner for brake For remounting perform the mounting operations in reverse order respecting the required tightening moments The clearance adjustment shall be perform as follows by means of a wrench rotate the eccentric downwards until t...

Page 315: ...he hand brake lever the brake drum see corresponding chapter The brake plate being placed on bench dismount the upper return spring see the corresponding paragraph the assembly rod assembled with the hand brake lever Distance the shoes in the cylinder area Unscrew the two cylinder attachment screws on the plate by dismounting it Check the state of the shoes linings and if oil trace are present rep...

Page 316: ...ts of the bellows and of the pistons Any trace of wear oxidation or scratches implies the replacement of brake cylinder assembly If the cylinder components are in a good state lubricate the parts with brake fluid and mount them in the reverse order of dismounting Check the easy moving of the pistons in the cylinder Mount the brake cylinder on the vehicle Check the adjustment of the hand brake Perf...

Page 317: ...ary cable with the hand brake lever the brake drum see the corresponding paragraph separating it from the brake plate The brake plate being placed on a bench dismount the shoes maintaining clips on the brake plate the upperreturn spring by means of a nipper for brake shoes the assembled connecting rod with the hand brake lever the assembled shoes with the lower return spring the lower return sprin...

Page 318: ...he upper return spring Mount the brake shoes maintaining clips Apply a sealant layer ROMTIX 1502 in the areas of the maintain clips with the brake plate Assembly the brake plate with the drum hub assembly Tighten at therequiredmoment the attachment screw of the assembly drum rear axle brake plate Drum clearance adjustment rotate downward the eccentric until the drum is locked than rotate it upward...

Page 319: ... with the hand brake lever the assembly hub drum brake plate Take out from the assembled bearing casing the safety ring by means of adequate nippers the bearing by means of a tube REMOUNTING Clean the inside of the bearing casing Mount the bearing by means of a tube and a press Set in its place the safety ring for boring by means of special nippers Press the bearing casing on the hub drum assembly...

Page 320: ...m the vehicle placed onan universal support having its propeller shaft removed DISMOUNTING Dismount the flage nut 1 the washer 2 the cardanic flange 3 the sealing ring 4 annular oil ring 42 x 72 x 12 the deflector 5 the bearing 6 the inner ring with balls 30 x 72 x 28 75 the adjustment bushing set 7 vnx su ...

Page 321: ...ngs half casings 3 Remove the centering bushing and unscrew the stub bolts Together with the conical balls bearings remove the differential assembly detaching it from the front part of the drive pinion Remove the differential drive pinion together with the conical balls bearing from the differential casing Dismount two rim attachment screws on opposite sides Depress the bearings by means of the CV...

Page 322: ...lements f rom thedifferential casing shall be lubricated with T 90 or T80 oil Mount the following items in the casing the propeller shaft pinion opposite to the rim after attaching the support washer on the former putin the four differential pinions and their respectivebushings oriented with the lock notch in the casing seat putin the balljointthedifferential pinionsshaft and half shafts so thatth...

Page 323: ...tment nuts in correspondence with the casing Check the mark on the bearings in correspondence with the casing To remount the main transmission observe the following 1 The pairing of the conical gear The pinion and the rim are lapped together They are inseparable Replacing one of the parts implies obligatory replacing of the other one There is a common corresponding mark both on the rim and on the ...

Page 324: ...he deflector the 42 x 72 x 12 annular oil seal Attach and tighten the washer the flange nut NOTE When assembling the cardanic flange check the wear degree of the surface in contact with the annular oil seal After remounting the rear axle must be sealed The sealing test is performed by blowing air at a 0 15 0 20 bars pressure through the aeration valve seat No air leaking is accepted TIGHTENING MOM...

Page 325: ...e to the initial tightening of the differential bearings without differential drive pinion shall be between 0 12 0 15 daNm measured within the range of the gear clearance 5 The rotation moment of the differential drive pinion without the mounted rim is 0 15 0 20 daN m DIFFERENTIAL ADJUSTMENT To be performed before and upon remounting This implies three operations 1 Adjustment ofthe conical distanc...

Page 326: ... the device choose a washer of A value value A is the onewritten on the differential pinion for example 185 means A 1 85 mm for negative values example 0 05 choose a washer of A value 0 05 mm for positive values example 0 05 choose a washer of A value 0 05 mm Remove the bearing Place the adjustment washer on the differential drive pinion and press the bearing The differential drive pinion a nd the...

Page 327: ...e performed Place in the differential drive pinion casing the casing rim assembly mount the bearing casings the adjustment nuts observing the marking made upon dismounting Tighten the bearings casings nuts at a moment of a 4 5 daNm Screw the adjustment nuts until the clearance value of the gear may be estimated by hand Mount a dial compar ator with the tester perpendicular on the rim tooth flank a...

Page 328: ...ormed as follows Rotate the differential rim several times so that the bearings get in their seats Winda stringaround the differentialgearcasingand pull the end ofthe string bymeans of a dynamometer The force that allows the rotation of the differential is between 2 3 daNm PLATE DRIVE REARAXLE DIFFERENTIAL If the force measured is not within the specified range tighten or loosen the nuts Mark the ...

Page 329: ...RACTERISTICS Itisrigid drawntype Fromthemanufacturingpointof view itlooksliketheplatedriveaxle Thecentral andannularpartis sealedby meansof acap Providedfor DACIA1305 1307 F Valuesof thesteeringangels parallelism 0 0 pivotcross indicatorangle 0 0 tighteningpositionof theleafsprings G 162 mm vnx su ...

Page 330: ...our M10 screwsattachingthebi conicalbearingcasingtotheaxleend Removethehub bearing casingassembly Dismo unt theslotted nutandthespacerwhich attachthebearingcasingon theinnerpart theinsidesafetyring Depressthehub fromthebearingcasingby meansof thePS 65device REMOUNTING Performthedismountingoperationsinthereverseorder Thetighteningmomentshavethesamevaluesas thosefor thehub of thedriveplateaxle vnx s...

Page 331: ...he parallelismand thepivotcross inclinationanglearenotadjustable WHEELHUB DISMOUNTING NOTE It is assumed that the axle is dismounted and fixed on the support Dismountthewheel Detach thedrumfromthewheelhub by unscrewingthethreeM8 sunk screws Dismountthedrumcapby meansof theRO441tongues Straightenthenutretainerandunscrewthesteeringknucklenut Takeout theretainer thesupportwasher Extract thehub by mea...

Page 332: ...33 REAR BEARING ELEMENTS 33 23 REMOUNTING Performthedismountingoperationsinthereverseorder NON DRIVEPIPEREAR AXLE vnx su ...

Page 333: ... type with hypoid gearing between the pinion and the rim Thedifferentialissymme trical simple withtwodifferentialconicalpinions IMPORTANT The interchangeability of the cast drive axle with the pipe axle assembled axle is depenedent of the replacement of the shock absorbers springs attachment plates attachment clips from the springs and shock absorbers buffers NOTE The dismounting remounting steps ...

Page 334: ...re movethepropellershaft Straightentheretainerbladewhichisfound on thenutgroove Unscrew theslottednutandremove thenutretainer thebearingsupportwasher Takeoutthefirstbearingof thehub Extractthehub andthesecond bearing REMOUNTING Performthedismountingoperation sinthe reverseorder observing thefollowing technicalconditions put grease in the central part of the hub greasethebearingswithgreasetype LiCa...

Page 335: ...DRIVE AXLE CASTIRON Therearaxleassemblyisdismountedfromthevehicle placedonanuniversalsupport having itspropellershaftsdismounted DIFFERENTIAL DISMOUNTING Onsideof cardanicflange dismount thenutretainer thenutretainer thecardanicflange thesealingring annularoilsealingring 42 x 72x 12 theoildeflector thebearing theinnerringwithconicalballs 30 x 72 x 28 75 theadjustmentwasher thedifferentialdrivepini...

Page 336: ...etainers mark ing the position of the nuts in correspondence withthecasing Unscrewthebearingsnuts Dismountthebearingshalfcasingsby unscrewingtheM10 screws Removethedifferentialgearassemblyfrom the rear axle casing together withthetwo bi conicalballsbearings Fromthebackpart of the axlealso remove thedifferentialdrivepiniontogetherwiththe35 x 80 x 32 75conical ballsbearing Dismountthetwooppositescre...

Page 337: ...on oppositetotherim DIFFERENTIAL REMOUNTING Performthedismountingoperationsinthereverseorder toremountthedifferential Beforemounting thecomponentpartsinthedifferentialcasingshallbelubricatedwithT 80 or T 90 oil Mountthefollowingpartsinthecasing thepropellershaftpinionoppositetotherim afterattachingon the formerthesupport washer placethetwodifferentialpinionstogetherwiththeirrespectiv ebushingsorie...

Page 338: ...ountingandperformingtherequiredadjustmentoperations makethesealingtest andthanfillup withT 90oilthedriveaxledifferentialcasing TIGHTENING MOMENTS Axlecap attachmentscrews 1 5 2daN m Toothrimattachment screws 9 11 daN m Thescrewsof thedifferentialadjustmentnuts retainers 2 daN m Thedifferentialdrive pinionnut 9 11 daN m Thetwoconicalballsbearingsshallbemountedby pressingon thedifferentialcasing Pre...

Page 339: ...ringsshallbeincorrespondencewithdifferentialcasing DIFFERENTIALADJUSTMENT Itisperformedbeforeandupon remountingandassumestheperformanceof thethreetypes of adjustment 1 Checkandcorrectionof theconicaldistance 2 Adjustmentof thedifferentialdrivepinion 3 Adjustmentof therimgearingclearance 1 ADJUSTMENTOFTHECONICALDISTANCE Itconsists inthemeasurementand correctionof the distancebetweenthefrontfaceof t...

Page 340: ...aratordialtozero 1 ADJUSTMENT OFTHECONICALDISTANCE Nowsetthe18 mmspacerC infrontof thedifferentialdrivepinionandthechuckM inthe halfcasingsofthebearings By meansof thecomparatordial measurethe differencebetweentherealvalue themea suredone andthevalueA Dependingon thevalueof thisdifference selectthewasherof therequiredthickness Thewashershallbeplaced undertheouterringof thebigbearing CASTIRON REARD...

Page 341: ...naviceandplaceon itsshaft thefollowingparts thefrontbearingwasher thebearinginnerring theflan ge thenut Tightenthenutata 9 11 daNm momentandplace thesupportwith thecomparator dial againon theflange measuringthedifferencebetweentheaxisandthedifferentialdrivepinion frontside Thevalueof thisdifferencecorrespondstothevalueof the adjustmentwasherthickness Dismountthefollowingsfromthepinion theflange th...

Page 342: ... ment of 4 5 daNm Screwtheadjustmentnutsuntilthegearclear ancemaybeestimatedby hand Mount the compar ator dial with the sensor perpendicularon therimtoothflankandcheck theclearanceof thegearing itshouldbe between 0 12 and 0 25 mm Themeasurementshallbeperformedinthreeequidistantpoints Thecorrectionof theclearanceshallbeperformedby meansof theadjustmentnuts Thedifferentialbearingsclearanceiscorrecti...

Page 343: ... Leafspringfrontattachmentnut 11 daNm Leafspringrearattachment nut 7 5 daNm Thenutthatattachtheclipof theleaf springon therearaxle 8 5 daNm REARSHOCKABSORBER for DACIA 1305 1304 1307 vehicles DISMOUNTING Liftthepickup on atwocolumnselevator Dismounttherearwheels Unscrew thenuts thatattachtheshock absorberatthe lowerandupper parts Removetheshockabsorber 11 daNm 8 5 daNm 8 5 daNm 7 5 daNm 7 5 daNm v...

Page 344: ...ments DISMOUNTING Unscrew thenutsof rearwheels Liftthepickup on atwocolumnelevator Dismounttherearwheels Dismountthenuts 1 of therodsthat attachthe leafsprings 2 tothefrontpart Lifttheback axleby meansof ajackin ordertofacilitatethedismountin g ofthe 3 nuts fixingtheleafspringtotheclip 4 thatattaches thespringtotheaxleintherear part Unscrewthenuts 5 thatattachtheleafspring on therearaxle Removethe...

Page 345: ...ntirollrod 1 withconnectingrods 2 Dismounttheconnections 3 of therearantirollrod withtherearaxle Dismounttheantirollrod REMONTING Greasetheattachmentscrews oftheantiroll rod withspecialgrease MoS2 Mounttheantirollrod on therearaxle Attach theantirollrod totheconnectingrods Tightenat therequiredmoments theantirollrod auxiliary connectingrodconnectionaxles nuts andscrews antirollrod attachmentscrews...

Page 346: ...3 CH 48 or simplified Example 5 J 14 A B C D E F Wheels Width The rim φ Nominal Number of Tire Offset type in inches edge profile in inches fixing points staffing in mm Under tire bead profile 5 J14 5 J 14 3 CH 48 3CH48 5 J14 5 J 14 5 CH 48 5CH48 The wheel bolts studs are situated on a diameter of 100 mm Maximum axial runout 1 2 mm measured on the rim edge in G Maximum radial runout 1 2 mm measure...

Page 347: ... 14 83 S 175 70 R 14 83 S 1 2 4 5 6 1 175 Tire width in mm 1 2 70 Ratio h height l width 4 R Radial structure 5 14 Inner diameter in inches φ This is corresponding with the rim diameter 6 83 Charging index 3 3 S Speed index max 180 km h max 35 2 CHARACTERISTICS vnx su ...

Page 348: ...J 14 175 R 14 1920 25 1 9 4 2 D 1307 with 48 mm PR 8 offset D1307 4 WD 5 J 14 175 R 14 1920 25 2 0 4 5 D 1305 with 48 mm PR 8 D1304 4 WD offset The nuts screws tightening moment of the wheels 9 daNm The inflating pressure must be checked at cold The temperature raising during driving leads to a pressure increase from 0 2 to 0 3 bars In case temperature checking is done at warm take into account th...

Page 349: ...WHEELS AND TYRES 35 WHEELSBALANCING BALANCINGWEIGHTS Useexclusivelytheweightsdeliveredasspareparts fixedby meansof clampson steelrims clampsincludedinweights 35 4 vnx su ...

Page 350: ...plication ratio in the steering box is 20 1 The steering wheel number of rotations corresponding to passing from one end to the other of the rack 3 5 The central point of the steering gear is c 65 mm The diameter of the turning circle between pavement 11 2 m walls 11 6 m LONGITUDINAL SECTION 36 1 1 3daNm 3 5daNm 4 5daNm vnx su ...

Page 351: ...or the attachment of the box on the cross rod 2 5 daNm Steering ball joint nut 4 daNm Elastic coupling nut 1 3 daNm Steering auxiliary connecting rod shaft nut 3 5 daNm Steering wheel shaft nut 4 5 daNm Steering cardan nut 3 5 daNm Corp articulaπie pe cremalierã 5daNm CROSS SECTION vnx su ...

Page 352: ...der to avoid measurement errors occurrence STEERING GEAR BOX The replacement of the steering gear box implies the adjustment of the steering gear height and the parallelism adjustment DISMOUNTING Disconnect the battery Dismount the battery and the battery support Dismount the steering gear auxiliary connecting rods shaft nuts Remove the ball joints of the auxiliary connecting rods using the PF476 ...

Page 353: ...ismounting operations in the reverse order Grease the ball joints with Li Ca Pb Hp2 grease Check the state and the attachment of the protection bellows of the steering box Tighten the steering gear auxiliary connecting rods shafts nuts to the required moment Tighten the elastic coupling nuts to the required moment Check and adjust the steering gear box height after which the screws by meansof whic...

Page 354: ...g 36 5 Place the car on the elevator Dismount the wheel on the noise absorber bearing side right side Dismount the steering auxiliary connecting rod the protection bellows Rotate the steering wheel until the rack is withdrawn Dismount the safety ring the outer washer Remove by means of a screw driver the elastic rings the worn noise absorber bearing NOISE ABSORBER BEARING vnx su ...

Page 355: ...t washer the old noise absorber support Temporarily tighten the joint body of the steering auxiliary connecting rod Rotate the steering wheel until the rack is completely withdrawn in this way the new noise absorber bearing gets into its seat Dismount the articulation body the worn noise absorber bearing Check if the noise absorber bearing got into its seat and if the outer washer does not cover t...

Page 356: ...washer 5 Pusher The operation shall be performed after removing the steering gear box off the vehicle ADJUSTMENT METHOD Clamp the steering gear box in the vice Dismount the pusher cap 1 the adjustment washers 4 the elastic washer 2 the spring 3 the pusher 5 Carefully clean the pusher seat and the parts that have been dismounted Grease the parts with special grease containing MoS2 Mount the parts i...

Page 357: ...is established by measuringthedifferencebetweenthemaximum andminimumvalues ontherack inthecentral area Attach the comparator support instead of the cap Bringthe feelerin contactwith the pusher Mark pointsA and B in the central area of therack correspondingtothebox extremity The measurements are always performed from point A towards point B Bring the rack to point A and set the comparator to zero S...

Page 358: ...EMENT OF DISTANCE D ABOVE THE PUSHER In the position previously set rotate the rack by means of a fixed wrench without forcing untilthe pushercomes into contact withtheadjustment washers the rotationmust be done in both directions Read the displacement value on the comparator and note the highest value PUSHER ADJUSTMENT 36 9 vnx su ...

Page 359: ...elastic washer 2 in contact with the pusher 5 and the adjustment washers 4 in contact with the cap 1 Observe the mounting sense of the elastic washer Place the set of washers established by measurement above the pusher CHECKING Place the set of the washers established by measurement above the pusher Measure the distance between the pusher and the adjustment washers this distance shouldbeequaltothe...

Page 360: ...ULAR CASE It may happen that value found for the adjustment washers thickness is negative EXAMPLE The distance between the pusher and the adjustment washers D 1 17 mm Free height of the elastic washer H 1 35 mm Thickness of the adjustment spacer E D 0 06 H 1 17 0 06 1 35 E 0 12 mm In this case take out a 0 15mm thick washer from the washers set after which perform measurement again to establish th...

Page 361: ...aNm Bendthesafetywasher in the opposite part to the pin in at leastone ofthecuts made on the ball joint body Mount the bellows in its channel from the steering casing Mount the bellows collar Mount the auxiliary connecting rod funnel in the steering knuckle support Check the tightening of the nut 5 at a moment of 4daNm on the vehicle 36 12 DISMOUNTING UnscrewTheattachment nutof thefunnelto thestee...

Page 362: ...tachment nut of the auxiliary connecting rod funnel ball joint on the steering knuckle support Depress the funnel ball joint from the steering knuckle support Loosen the nut 5 Unscrew the auxiliary connecting rod funnel from the assembled auxiliary connecting rod end REMOUNTING Remount the new funnel performing the dismounting operations in the reverse order See that the nut 5 is tightened to the ...

Page 363: ...ng wheel lights control switch windscreen washer control switch the steering cardan upper bushing safety ring the ignition starting contact Push the steering wheel shaft by means of a bronze mandrel and a plastic hammer until the lower bushing gets out of the steering gear support Take out the upper bushing STEERING WHEEL SHAFT BUSHING vnx su ...

Page 364: ...half casing the ignition starting contact REMOUNTING Place an old lower bushing with the diameter diminished by 2mm under the new lower bushing 1 Push the steering wheel shaft 3 upwards until the lower bushing gets in its seat Push downwards the steering wheel shaft and recover the old bushing Mount the new upper bushing 2 by means of a pipe Check the correct positioning of the bushings in their r...

Page 365: ...ing cardan the servo brake attachment nuts the servo brake Disconnect the brake pedal pushing rod and the clutch cable Unscrew the two attachment nuts of the steering column and dismount the column REPAIR Check the parts steering wheel shaft steering wheel shaft bushing steering column Replace the defective or worn parts REMOUNTING It shall be performed in the reverse order as to the dismounting T...

Page 366: ...ringon thesecondary piston andthe other part of the brake fluid shall penetrate through the ducts to the upper floor towards both exits leading to the front brake calipers THE FRONT BRAKE CIRCUIT The secondary piston is continuing its movement conducting the brake fluid under pressure through the ducts to the upper floor towards the exit to the pressure reducing valve b DE BRAKING After effort end...

Page 367: ...mally operate The secondary piston reaches its respective pin but the pressure will decrease due to the failure BRAKE PUMP DISMOUNTING Drain the brake fluid reservoir Disconnect the pump from the ICP transducer Dismount the four pipes from central pump Unscrew the attachment nuts of the pump on the servobrake Dismount the pump BRAKE PUMP REMONUTING Before remounting check the stroke of the servobr...

Page 368: ...NTING Dismount the brake fluid reservoir recovering the two gaskets Dismount the transducer and the purging screw Clamp a 3 5 mm drill in the vice Introduce the drill in the elastic pin of the primary piston Rotate and draw the pump until the pin is extracted Extract the secondary piston elastic pin in the same way BRAKE PUMP 37 3 vnx su ...

Page 369: ...n Pp and those ofthe secondary piston Ps cannotbe repaired In case one of these parts is damaged replace the whole primary piston and secondary piston assembly REMOUNTING Before remounting the parts and the pump bore will be lubricated with brake fluid Mount the secondary piston retained spring and primary piston assemble Compressthepistons andintroducethe elastic pins theelastic pinsslotshallbe o...

Page 370: ...paired The only items which are to be replaced are the air filter and the retainer valve SERVOBRAKE TIGHTENING COUPLE daNm Servobrake on the iron brake 2 The attachment nut of the central pump with servobrake 1 3 CHARACTERISTICS TheMaster Vac servobrakeis abrake booster withthe objectiveof reducingthedriver efforton thebrake pedaland may beof 152 mm or 177 5 mm witha minimal boosterrate of 1 9 37 ...

Page 371: ...of theservobrake on the iron plate Dismount the servobrake REMOUNTING Before remounting check the adjustment of the main cylinder stroke which is obtained by acting on the pushingrod P nutin orderto obtainvalue X 9mm between the pushingrod end andthe rest surface of the main cylinder theadjustmentin ordertoobtainthevalue L 131 mm is performedby screwingor unscrewing the fork C followed by blocking...

Page 372: ... it idle run for 1min Block the air suction hose by means of the MOT 453 device Stop the engine Read the indicator SERVOBRAKE If air suction lowers with more than 33 mbar 25 Hg in 15 period it means there is a loss at the retainer valve replace the valve or at the servobrake membrane replace the servobrake Dismount the MOT 453 device Dismount the vacuum hose Connect the air suction hose to the ser...

Page 373: ... the lock nut on the fork Mount the servobrake on the vehicle Purge the braking circuit if necessary SERVOBRAKE RETAINER VALVE REPLACEMENT The operation shall be performed without dismounting the servobrake off the vehicle DISMOUNTING Disconnect the air suction hose Dismount the valve by rotating and then pulling it Dismount the retainer valve gasket REMOUNTING Check the state of the retainer valv...

Page 374: ...eels suspended and hand brake lever released tighten the castle nut M until the shoes gaskets come lightly into contact with the brake drum Tighten the lock nut N at the required moment Theadjustmentshallbe performed so that is insuringahand brake leverstroke ofmin 7 teeth until the blocking of all wheels The adjustment shall be performed anytime the shoes wear is requiring it The hand brake adjus...

Page 375: ...se Dismount the screws that attach the hand brake lever to the floor Release the hand brake lever Dismount thelockingring of the primary cablefork shaft the primary fork shaft the hand brake lever REMOUNTING Grease the primary cable fork shaft with special MoS2 grease Connect the primary cable Mount the hand brake lever Mount the hand brake ornament case Adjust the hand brake Get down the vehicle ...

Page 376: ...NG Dismount the hand brake lever Disconnectthe primary cable from the rocking joint Dismountthestopsheathof theprimary cable REMOUNTING Place a sealant material layer between the floor and the primary cable case Mount the primary cable Mount the stop sheath Mount the hand brake lever Adjust the hand brake 37 11 vnx su ...

Page 377: ...crew the nuts M and N Release the secondary cable from the control levers Dismount the sheathes stops from the plate and from the floor Dismount the secondary cable REMOUNTING Position the secondary cable Connect the secondary cable in the floor the sheaths stops from the plate the sheaths stops floor Adjust the hand brake Tighten to the required moment the nut N HANDBRAKEPRIMARYANDSECONDARYCABLE ...

Page 378: ... the place ofthepurgingscrew of the brake cylinder the F R 214 02 checking manometer Dismount the fork from the big spring After 3 4 successively pressings the brake pedal remains pressed Read the value of the pressure which must be 20 bars In order to obtain this value strain by bending the limiter support slide from the base Z area for lower the pressure to inner side BRAKE LIMITER 0 2 37 13 vnx...

Page 379: ...ver In this moment block the passing fork by means of the screw 1 and the nut 2 Release the brake pedal and purge the braking circuit Dismount the manometer and the adjustment is considered ready OBSERVATION If with the limiter being mounted the pressure of 20 bars can not be obtained proceed to the limiter replacement Repairing of the limiter is forbidden 0 2 0 2 37 14 O1 O2 O vnx su ...

Page 380: ...edal REMOUNTING Greasetheshaft A withspecialgrease containing MoS2 Mount in the following order the brake pedal F the washer C Place the shaft A together with the elastic pin B in the pedal support Place the shaft in the second support bore then place the following items the washer D the clutch pedal E Check that the elastic pin B is well set in its seat Mount the safety lock 1 Attach the followin...

Page 381: ...e the spring 2 and the shaft 3 of the fork Dismount the fork Release the cable f rom the housing stopper on the pedal support and dismount it REMOUNTING Perform the dismounting operations in the reverse order Grease the pedal shaft the fork shaft Adjust the clutch stroke CLUTCH GEAR STROKE ADJUSTMENT Loosen the lock nut 1 Tighten or unscrew the nut 2 until obtaining the 2 5 3 5 mm stroke at the le...

Page 382: ... DISMOUNTING Dismount the throttle brake and clutch pedals Dismount the attachment screws 2 of the steering column mounting 1 on the wall metal REMOUNTING Perform the dismounting operations in the reverse order by screws tightening at the moment of 1 5 2 5 daNm 37 17 2 1 vnx su ...

Page 383: ...ximum position of the valve which is obtained by pedal pressing till its calibration on the limiter 4 and by threaded pin adjustment 5 in this position THROTTLE CONTROL CABLE REPLACEMENT DISMOUNTING Dismount the attachment screw of the cable 1 from the throttle control lever then remove the clips 8 the washer 7 and the pedal shaft 6 releasing the attachment throttle pedal REMOUNTING Performthe dis...

Page 384: ... 4 Dismount the safety ring from the lever end Dismount the control lever from control rod and recover the two elastic washers and the flat washers Dismount the four screws M7 of control box assembly 5 with its support Dismount the ring and the protection bellows 6 Dismount the elastic ring D68 7 Take out assembled bellows spring elastic ring elastic washer the cap and the ball bearing Take out th...

Page 385: ...nthe velocity step IV Place in contact the plug of the control lever with an adjustment washer of13 0 5 mm placed between the control box wall and the plug observing also the value W 56 1 Tighten at the required moment the strap attachment screws 1 8 1 9 daNm and the elastic joints at the control shaft end 1 1 1 9 daNm observingthe value L 10 The strap must be in horizontal position with the screw...

Page 386: ...tment on the right wing lining These are destined to open or close the vacuum route between the inlet manifold and the two vacuum capsule compartments 4x4 switch is placed on dashboard When this is operated the fronttransmission coupling is controlled intermediary relay is placedunderthedashboard on theleftsideanditiscontrolling thelightingof the 4 x 4 warninglight onthe instrumentspanel whenfront...

Page 387: ...m is working based onthe vacuum from the inlet manifold 1 which during enginerunning is actingon themembraneseparatingthetwovacuumcapsulecompartments 12 This will impose the longitudinal movement of the capsule axle which by meansof the control lever 6 will act upon the f ront transmission coupling control axle 7 placed in the gearbox right front part 1 In this way isperformed the front transmissi...

Page 388: ...f thefronttransmission theuncouplingconditionisperformed whenthefrontrightwheelwillbefreelyturningandinthegearbox no gearsengagementnoises canbe heard Blockthethreadedbushingpositionfromthecapsuleaxleby means ofthenearby nut Forthegood operationof thissystem in case ofthereparation thefollowing requirements mustbeobserved Thesystemsealingcondition piping vacuumtank electricvalves vacuum capsule mu...

Page 389: ...y andthepipefrom the opposite part of the capsule axle is to be connected to the electric valve having the pipes on the same side of its body The connecting mode ofthe electrovacuumatic coupling control wiring is as pernext diagram where the following components may be identified 1 Intermediary relay 2 Instruments panel 3 Right connection plate DC 4 4 x 4 switch 5 Electric valves connectors 6 Vacu...

Page 390: ...in and remove the bolt which is connecting the capsule axle with the GB control lever Dismount the capsule attachment nuts on the support 38 5 VACUUM CAPSULE REMOUNTING Perform the dismounting operations in reverse order NOTE Observe the connecting position of the hoses to the capsule from corresponding electric valves After capsule replacement perform the electrovacuumatic control adjustment vnx ...

Page 391: ...e electric valve Disconnect the hoses from the electric valve Dismount the electric valve attachment screw REMOUNTING Perform the dismounting operations in the reverse order NOTE Observe the connec tion position ofthe hosesto the electric valve bef ore disconnec ting 38 6 ELECTROV AL VE vnx su ...

Page 392: ...shed 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 AUTOMO...

Page 393: ...ront lower panel 43 3 Middle pillar 43 4 REAR UPPER STRUCTURE Side panel Dacia 1304 Pick Up 1307 44 1 Side panel Dacia 1304 Drop Side 44 2 Rear wheel passage 44 3 Rear plate 44 4 TOP OF BODY Roof 45 1 SIDE OPPENING ELEMENTS Front door 47 1 Front door outside panel 47 2 NON SIDE OPPENING ELEMENTS Front bonnet 48 1 Drop Side Dacia 1304 platform 48 2 Drop Side Dacia 1304 Pick Up 1307 48 3 SIDE OPPENI...

Page 394: ...member 2 Upper longitudinal girder assembly 3 Steering cross member 4 Lower longitudinal girder assembly 5 Longitudinal girder closing plate 6 Intermediary longitudinal girder 7 Rear unit assembly 8 Rear longitudinal girder 9 Rear cross member DESIGNATION OFPARTS BLOW UP vnx su ...

Page 395: ...40 GENERAL 40 2 1 Pedals floor 2 Cabin closing panel 3 Central floor panel LOWER STRUCTURE COMPOSING ELEMENTS DACIA 1304 PICK UP DROP SYDE 2 1 DESIGNATION OFPARTS BLOW UP vnx su ...

Page 396: ...l girder assembly 3 Steering cross member 4 Lower longitudinal girder assembly 5 Longitudinalgirderclosingplate 6 Intermediary longitudinal girder 7 Rear unit assembly 8 Rear longitudinal girder 9 Rear cross member 1 Front side plate 2 Central floor 3 Rear floor 2 3 1 DESIGNATION OFPARTS BLOW UP vnx su ...

Page 397: ...imple 11 Ceiling 3 Front wing lining 12 Windscreen frame 4 Front pillar lining 13 Lower cross member 5 Front pillar 14 Climate control box 6 Buffer 15 Iron plate 7 Middle pillar 16 Upper radiator cross bar 8 Front part belt 9 Side windscreen lining 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DESIGNATION OFPARTS BLOW UP vnx su ...

Page 398: ...anel 2 Side panel upper part 3 Front extensor 4 Rear lamp lining 1 Side panel 2 Side panel 3 Rear wheel passage 2 1 7 3 6 5 4 1 2 3 DACIA 1304 PICK UP 1307 5 Rear extensor 6 Rear wheel passage 7 Rear plate DACIA 1304 DROP SIDE DESIGNATION OFPARTS BLOW UP vnx su ...

Page 399: ...wing 4 Rear drop side 2 Front door 5 Aerating grill 3 Rear door 6 Front bonnet DACIA 1304 DROP SIDE 1 Front drop side 3 Rear drop side 2 Left drop side 4 Right drop side 2 3 4 1 3 2 1 4 5 6 DACIA 1304 PICK UP 1307 DESIGNATION OFPARTS BLOW UP vnx su ...

Page 400: ...40 GENERAL 40 7 OPENINGS CLEARANCES vnx su ...

Page 401: ...ng of the body elements is performed as follows witha well sharpen chisel this methodmaylead toparts deformation or even parts breaking by using some extractors equipped with steel cutter type BRENDEO or PICKVANT max 6 mm having the cutting head as per shape shown in fig 1 1 Centering point 2 Sharpen slope 3 Drill acting edges 4 Gap for catching the welding material P cca 4mm Whatever method is us...

Page 402: ... time per Tightening force daNm 0 5 6 5 5 130 0 8 8 0 8 200 1 0 9 5 10 250 1 25 10 5 10 295 1 5 10 0 14 310 2 0 12 0 16 350 NOTE 1 period 1 50 part of a second 2 Weldingparametersfor theweldinginprotectorgasfor carbon steelplates orlowalloyed steel Horizontal welding position fig 1 Plate thickness mm 0 6 1 0 1 5 2 0 Electrode diameter mm 0 6 0 8 0 8 1 0 0 8 1 0 0 8 1 0 Welding wire speed m min 2 5...

Page 403: ... fig 2 Plate thickness mm 0 6 12 2 0 Electrode diameter mm 0 6 0 8 0 8 1 0 0 8 1 0 Welding wire speed m min 2 5 1 9 3 3 3 2 5 7 4 4 Welding current A 35 35 70 100 100 130 Welding speed m min 0 25 0 25 0 38 0 48 0 50 0 50 Welding voltage V 17 17 18 18 20 20 Protection gas flow l min 12 17 Electron free lenght mm 6 12 WELDING TYPES AND PARAMETERS vnx su ...

Page 404: ...ed areas Checking with the bar control gauge consisting in comparing the measurements doneinsymmetricpoints CHECKINGOFTHELONGITUDINALGIRDERSPOSITION Thecheckingof thelongitudinal girders positionconsistincomparing themeasurements done on symmetric points Thechecking of B B H H pointsis affecting themechanicalpartof the half front axles and of the rear axle Certainly the distances between the point...

Page 405: ...which the checking starts The checking points are Holes A F F A and consequently H H and B B FRONT LONGITUDINAL GIRDERS CHECKING Checking points are B B for lower longitudinal girders and G G for upper longitudinal girders Lower longitudinal girders Comparethediagonaldistance A B with diagonal A B Upper longitudinal girders Comparethediagonaldistance F G with the diagonal F G H F vnx su ...

Page 406: ...agonals continuos line with A H diagonal broken line and the A C diagonal continuos line with A C diagonal broken line Thesefour holesbeing closesttotherear axle mustbefirstchecked Comparediagonals H D and H E continuos line with diagonals H D and H E straight line FLOOR FRAME CHECKING NOTE The values marked are for Dacia 1307 vnx su ...

Page 407: ...four wheels four parts for vehicle anchoring one traction arm of 10 t type CAIMAN CAR 502 set modularcross bars CAR 503 22 towers MZ CAR 504 set accessories for traction CAR 505 set of specific supports for DACIA Bl Bk CAR 506 set of specific supports for DACIA 1304 1307 CAR 507 set of specific supports forDACIA NOVA 1 CAR 501 The mobile bench 1 is provided with four anchoring parts 2 fig 1 which ...

Page 408: ...ts composition five modular cross bars fig 3 as follows two front cross bars A and B T shaped there are always ready in the same position towards front of bench fig 4 two straight cross bars C1 andC2 andone D cross bar U shaped which may be placed in different positions subject to vehicle type Themarkedfigures 14 36 areengravedon themobilebench every mounting being supplied with a drawing indicati...

Page 409: ...ator to achieve different anchoring when a body strengthening is performed fig 5 4 SET OF SPECIFIC SUPPORTSFOR DACIA 1304 1307 CAR 506 Themountingof the specific supports for DACIA vehicles1304 1307 shallbeperformed accordingwiththemountingdiagramwhichissuppliedwiththisKIT fig 6 7 8 9 10 11 This is a compact mounting sys tem fig 6 fig 7 Dacia 1304 1307 Dacia 1304 1307 fig 5 vnx su ...

Page 410: ... BENCH TYPE CELETTE fig 8 fig 10 Dacia 1304 Dacia 1307 Dacia 1304 Dacia 1307 fig 9 fig 11 Each support is identified by a plateshowing the CELETTEspecific item number the mounting direction and its orientation on the bench fig 12 13 fig 12 vnx su ...

Page 411: ...e positioning of the front longitudinal girders extremity fig 14 fig 14 fig 15 Front suspension lower arm supports fixing Supports 3 4 5 and 6 are used in front straightening They enable the positioning and centering of the front longi tudinal girders fig 15 and consequently the vehicle front alignment on the bench attachment on the bench right side orientation direction towards front attachment o...

Page 412: ...entering under front longitudinal girder Supports 29 30 and 31 are used mainly in rear strengthening for position ing and centering the rear unit or the rear longitudinal girders In thesametime they may also be used for vehicle alignment in the front straightening when vehicle front part is replaced fig 18 fig 19 Rear spring front supports fixing Supports 32 33 and 34 are used mainlyinrearstrength...

Page 413: ...of a steel cutter for detaching the welding points Detach the welding points of the lower longitudinal girder with the upper longitudinal girder in areas 1 2 3 REMOUNTING Position and center the new element Perform a spot welding in the areas 1 2 3 where the lower longitudinal girder is in contact with the upper longitudinal girder and a protection gas welding in the area connection with the upper...

Page 414: ...ith the longitudinal girder Detach the welding points of the longitu dinal girder 1 which are in connection with the front cross bar in the area 2 thefrontwingliningon theoutline 3 thesteering cross barin the areas 4 5 the gusset in the area 6 the pedal and central floor in the area 7 the iron plate in the area 8 Detach the damaged element Straighten the areas resulted by dismounting Grind the are...

Page 415: ...area 4 connecting the longitudinal girder with the steering cross bar in the area 6 connecting the longitudinal girder with fixing gusset inthe area 7 connecting thepedal floor and central floor in the area 8 connecting the longitudinal girder with the iron plate Performa hardening gaswelding inthe areas 5 and 9 connectingthelongitudinal girder with steering cross bar Protectthenew elementwithacor...

Page 416: ...ing with the longitudinal girder in the area 4 the pedal floor in the area 2 the lateral cross bar in the area 3 the central floor in the area 5 rear longitudinal girder in the area 7 Straighten the areas resulted by dismounting Grind the areas resulted by dismounting Position and center the new element Check the correct positioning of the intermediary longitudinal girder Weld the intermediary lon...

Page 417: ...Straighten the areas resulted by dismounting Grindtheareas resultedby dismounting REMOUNTING Position and center the new element Checkthecorrectpositioningof therear longitudinal girder Weld the rear longitudinal girder 1 after the assembling outliners 2 3 4 5 6 7 8 9 10 Performtwo C0 2 welding layers inthe connecting area of the rear longitudinal girder with the front cross bar central middle and...

Page 418: ...n the areas resulted by dismounting Grind the areas resulted by dismounting REMOUNTING Position and center the new element Check the correct positioning of the rear longitudinal girder Weld the rear longitudinal girder 1 following the assembling outliners 2 3 4 5 6 7 8 9 10 Perform two welding layers in the connecting areas of the rear longitudinal girder with the front cross bar central middle an...

Page 419: ...connection of the wing with the front pillar it is not necessary dismounting of the front door in 4 at the lower part of the body PREPARATION Applyby means ofabrusha layerof thermo weldableproductclass 33 B CS 4603 202 on the contact areas of front wing with front wing lining front grill and front pillar Apply a sealant material layer type 223 in the contact area of the front wing with the front w...

Page 420: ... the left right lateral cross bar in 4 joining a rea of thefront long itudinal girders with theintermediary longitudinal girders in 5 joining area of the front wing linings with the iron plate in 6 joining area of the cover reinforce ments and climate control box in 7 joining area of the front wing linings with the front pillar linings in 8 joining a rea of thefront long itudinal girder with the i...

Page 421: ... are in contact with the front grill in the 5 area the upper longitudinal girder in 6 area the iron plate in the 3 area the steering cross bar in the 4 area the climate control box in the 2 area Straighten the areas resulted by dismounting Grind the areas resulted by dismounting REMOUNTING Position and center the new element Check the correct positioning of the front wing lining Weld the front win...

Page 422: ...part of the front wing lining in the area 5 the front wing lining in the lateral part in the 6 area Straighten the areas resulted by dismounting Grind the areas resulted by dismounting REMOUNTING Position and center the new element Check the correct positioning of the head lamp support Weld the headlamp support 1 following the assembling outliners 2 3 4 5 6 Protect the welding with a corrosion pre...

Page 423: ...amp support 7 the reinforcement in the 8 area Straighten the areas resulted by dismounting Grind the areas resulted by dismounting REMOUNTING Position and center the new element Check the correct positioning of the radiator upper cross member Weld the tank mask assembly 2 after the assembling outliners 7 8 Protect the welds with a corrosion preventing product Mount the elements which are in connec...

Page 424: ...of the wind screen washer Dismount the attachment screws 2 of the aeration grill Take out the clips 3 from the front grill grippers taking care to prevent their distortion or damaging REMOUNTING The mounting shall be done by performing the dismounting operationsin reverse order vnx su ...

Page 425: ...edge inthe area 10 climate controlbox endin the area 11 iron plate in the area 12 Straighten the areas resulted by dismounting Grindtheareasresultedby dismounting REMOUNTING Position and center the new element Check the correct positioning of the front pillar lining Weldthefrontpillarlining 1 following the assembling outliner s 4 5 8 9 10 11 12 Protect the new element with a corrosion preventing a...

Page 426: ...lar lining in area 4 and 5 upper spacer and the lower windscreen lining in the areas 6 and 7 Straighten the areas resulted by dismounting Grind the areas resulted by dismounting REMOUNTING Position and center the new element Check the correct positioning of the front pillar Weld the front pillar 2 following the assembling outliners 3 4 5 6 7 Protect the new element witha corrosion preventing and n...

Page 427: ...anel in the area 5 central pillar in the area 6 Straighten the areas resulted by dismounting Grind the areas resulted by dismounting REMOUNTING Position and center the new element Check the correct positioning of the front lower panel Weld the front lower panel 1 following the assembling outliners 2 3 4 5 6 Straighten with the autogenous welding the 3 are a with the frontpillar the 6 area with the...

Page 428: ...s resulted by dismounting Grindtheareasresultedby dismounting REMOUNTING Fittemporarily the middlepillar 3 by introducing the pillar lining under the upperframe 7 and underthelowerpanel plate 6 Check the correct pillar positioning using the door as geometric gauge Welding themiddle pillar followingthe welding outliner 1 and 2 Perform a straightening gas protection welding in the areas 4 and 5 Remo...

Page 429: ...as resulted by dismounting Grindtheareas resultedby dismounting REMOUNTING Apply a layer of 5322 material on the jointsareas 7 of theside panelwith front rear extensor lowerpanel sideplate rear side floor cabin rear plate Position and center the new element Checkthecorrectpositioningof theside panel Weldthelateral panel 1 followingthe assembling outliners 2 3 4 5 6 Apply a sealant material layer P...

Page 430: ...by dismounting Grind the areas resulted by dismounting REMOUNTING Apply a layer of 5322 a secured stripping on thejointsareas 3 and 7 of thesidepanel with lower panel and cabin closing plate Position and center the new element Check the correct positioning of the side panel Weld the side panel 1 following the assembling outliners 2 4 5 6 Protect the welding with a corrosion preventing product SIDE...

Page 431: ... Grindtheareas resultedby dismounting REMOUNTING Position and center the new element Checkthecorrect positioningof therear wheel passage Weld the rear wheel passage 1 following the assembling outliners 2 3 4 Protect the welding with a corrosion preventing product Apply a sealant material layer PLASTISOL 4 in thecontact areas 5 of the rear wheel passage with platform floor front extensor and rear e...

Page 432: ... the area 3 Straighten the areas resulted from dismounting Grindtheareas resultedfromdismounting REMOUNTNG Position and center the new element Check the correct positioning of the rear plate Apply a secured stripping in the joint area 4 of the rear plate with the rear extreme crossbar Weld the rear plate 1 following the outliners 2 and 3 Protect the welding with a corrosion preventive product REAR...

Page 433: ...cross bar in 2 area front pillar in 3 area front safety belt front side in the 4 area windscreen pillar lining in the 5 area front safety belt rear side in the 6 area Upper border of the separating wall in the 7 area REMOUNTING Position and center the new element Check the correct positioning of the roof Weld the roof 1 following the assembling outliners 2 3 4 5 6 7 Mount in the reverse order the ...

Page 434: ...1 and pushing out the hinge pins b by removing the attachment screws 2 on the front pillar 47 1 REMOUNTING Perform the dismounting operations in the reverse order ADJUSTMENT a Horizontally adjustment bush C are to be used b Vertically the front pillar holes are to be used 1 2 2 1 2 C LATERAL OPENING 47 vnx su ...

Page 435: ...joint of outside panel glass frame Adjust if necessary the extensor 3 FRONT DOOR OUTSIDE PANEL REMOUNTING Apply a strip of zinc on the caisson Apply a sealant material layer in the area 4 Position the new outside plate and weld in the 2 area Fit the outside panel on the door caisson by folding in the area 5 Remount the elements which are in connection with the front door 47 2 2 5 4 1 3 M M vnx su ...

Page 436: ...48 NON SIDE OPENING ELEMENTS DISMOUNTING Dismount the attachment screws 1 of the hinges the front bonnet REMOUNTING Perform the dismounting operations in the reverse order FRONT BONNET 48 1 1 vnx su ...

Page 437: ... ELEMENTS 48 DISMOUNTING Dismount the attachment screws 1 of the hinges 2 the rear drop side the drop side REMOUNTING Perform the dismounting operations in the reverse order DROPSIDE DACIA1304 PLATFORM 48 2 1 2 vnx su ...

Page 438: ...the rear drop side dismounting may be performed in two different ways a extract the safety ring 2 and the hinge shaft 3 b unscrew thescrews 4 of the hinges 5 Dismount the rear drop side REMOUNTING Perform the dismounting operations in the reverse order DROPSIDE DACIA 1304 P ick Up 1307 48 3 1 6 3 4 2 5 vnx su ...

Page 439: ... door 1 Dismount the attachment screws 3 of the front rear door lock Release the control lever 2 of the outside opening flap Release the distance control lever 4 by taking out the clips bracket 5 Dismount the attachment screws 6 of outside opening flap releasing the flap Dismount the front rear door lock from the door frame REMOUNTING Perform in reverse order the mounting operations DOOR LOCK FRON...

Page 440: ...k control remove thedoor paneland leavethe window in the lift position Dismount opening knob 1 ornament 3 attachment screws 2 the attachment screw 4 of opening mechanism 5 control lever 6 off the hinge releasing the opening mechanism REMOUNTING Perform the dismounting operations in reverse order 1 3 4 2 5 6 vnx su ...

Page 441: ...wing operations Place in it housing the outside wiper 15 assembled with bracket 15 Easy bend the window regulator window assembly take out the supports 12 the slidesfrom the window base 13 and the glass slide 14 In ordertoremounttheglass slide easy curve it in F and G ensuring a correct attachment in the door frame Lift the window regulator in the position J 40mm introducing the glass through the ...

Page 442: ...d attachment nuts 10 Place the supports 12 at the glass bottom and perform a first sliding test Grease the window regulatorhinges and supports and perform the others operations in reverse order PREPARING THE GLASS BASE When fitting the bottom edge and at the glass positioningintheslide bars observethe value of 92 mm FRONT DOORWINDOWREGULATOR vnx su ...

Page 443: ...OWREGULATOR REMOUNTING For remounting the operations shall be performed in the reverse order Replace the channel support in the rear inner side of the door place the assembly inside the doorframe then remove again the frame to allow the placing ofthe window in the channel support Replacethe window regulator mechanism 19 andtemporally attach itssealingwasher R The window placed in the channel suppo...

Page 444: ...NG Release the cable of front hood 1 from the connection with lock 3 and take out by lock hook rod 4 Dismount the attachment front hood lock nuts 2 REMOUNTING Perform in the reverse order the dismounting operations FRONT HOOD LOCK 52 1 3 2 1 4 vnx su ...

Page 445: ... rear drop side lock 1 unscrew the screws 2 of the closing hook 3 and the screws 4 of the assembled lock 5 52 2 REAR DROP SIDE LOCKING SYSTEM DACIA 1304 Pk 1307 REMOUNTING Perform in the reverse order the dismounting operations 1 4 3 2 REARDROPSIDELOCKINGSYSTEM vnx su ...

Page 446: ...n the reverse order 52 3 DISMOUNTING Dismount the screws 1 and 2 of the end of the stopper chain 3 the lock attachment screws 4 of the side panel the lock attachment screws 5 of the rear drop side panel REAR DROPSIDELOCKINGSYSTEMDACIA1304platform 5 4 1 2 3 REARDROPSIDELOCKINGSYSTEM vnx su ...

Page 447: ...me more 20 cm of cord and between the ends the distance shall not be more than 10 cm MOUNTING OF WINDSCREEN AND REAR WINDOW Thewindscreen gasket cordassembly is placed on the frame for mounting so that the cord ends are placed towards the inside of carriage body 54 1 From the inside of the vehicle successively draw the ends of the cord beginning with the lower parts in this way the window gasket e...

Page 448: ...the attachment screw 1 and 3 of the front bumper 2 on the front wings the nuts 4 which attach the bumper supports 5 on the front grill release the front bumper REMOUNTING Performthedismountingoperationsinthereverseorder 55 1 2 FRONT BUMPER vnx su ...

Page 449: ...tions in the reverse order 55 2 DISMOUNTING Dismount the protectors 1 and the side attachment screws 2 of the rear bumper 3 the attachment screws 4 of the rear bumper on side panels the attachment screws 5 of the rear bumper supports 6 on the rear girders release the rear bumper 2 6 5 4 1 3 REAR BUMPER vnx su ...

Page 450: ...TING Perform the dismounting operations in the reverse order 55 3 DISMOUNTING Dismount the attachment screws 3 of the rear bumper 2 on the end rear cross bar the attachment screws 4 of the rear bumper supports on the rear girders release the rear bumper 1 2 3 REAR BUMPER vnx su ...

Page 451: ...REMOUNTING Perform the dismounting operations in the reverse order 56 1 DISMOUNTING Detach the protector of the outside rear view mirror 3 Dismount the attachment screws 2 of outside rear view mirror 1 Release the outside rear view mirror 1 2 3 vnx su ...

Page 452: ... 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 o...

Page 453: ...pper side panel lining 71 4 Cabin wall lining 71 5 Ceiling covering 71 6 Floor noise absorbent mats 71 7 72 SIDE OPENING ELEMENTS TRIM Front door panel 72 1 Dacia 1307 rear door panel 72 2 75 FRONT SEATS FRAMES ANDRUNNERS Front seats 75 1 Front seat frames 75 2 Front seat slide guides 75 3 76 REAR SEATS FRAMESAND RUNNERS Back rest armature 76 1 Rear bench seat armature 76 2 77 FRONT SEAT TRIM Seat...

Page 454: ... Diagnostic 85 7 89 ELECTRICAL DIAGRAMS Generalites 89 1 Functional diagrams list 89 6 Electric components index 89 8 Couplings list Mass index 89 9 Location of electric coupling on the vehicle 89 10 Fixation of electric mass on the vehicle 89 11 Electric components location on the vehicle 89 12 Cockpit fuse box 89 15 Engine compartment fuse box 89 16 Wire functions index in connectors and couplin...

Page 455: ...e windshield lower frame cross member Dismount the headlamp adjustment switch 5 and the two attachment screws Dismount from the engine compartment the control cable from the climate control valve the vacuum hose from the servobrake valve Detach the dashboard and swing it over in order to have access to the wiring discon necting Disconnect the following connectors dashboard fog lamp switch hazard s...

Page 456: ...board from cockpit Dismount the followings the instrument panel the hazard switch 7 the climate control unit the documents compartment 6 see page 57 3 the radio cassettes player and its support 4 the coupling bar 13 attached on the dashboard by means of the screw 14 the electronic clock the lighter 2 the ashtray 3 the windscreen wiper timer 15 the fog headlamps switch 16 the 4 X 4 switch 1 the fog...

Page 457: ...imate maintenance block speedometer cable from the instrument board the attachment screws 11 dashboard on the windscreen lower cross the attached nuts 8 dash board on the lateral support 9 the attachment screws 10 dash board on the left right pillar three front wire connection boxes from the dashboard with RPM Disconnect the lighting wire of the cigarette lighter 4 Disconnect and dismount the haza...

Page 458: ...ter cable from the instrument board the attachment screws 11 dashboard on the windscreen lower cross the attached nuts 8 dashboard on the lateral support 9 the attachment screws 10 dashboard on the left right pillar three front wire connection boxes from the dashboard with RPM Disconnect the lighting wire of the cigarette lighter 4 Disconnect and dismount the hazard warning switch 3 Dismount headl...

Page 459: ...ery Dismount the diagnostic socket Dismount the documents compartment attachment screws 2 on the dashboard Disconnect the documents compartment lighting wires Extract the documents compartment from the dashboard REMOUNTING Perform the dismounting operations in the reverse order 1 2 vnx su ...

Page 460: ... CASIN AND GEARBOX LEVER ORNAMENT DISMOUNTING Dismounting the screws 1 and release the gearbox lever ornament 2 Dismounting the screws 3 and release the handbrake casing 4 REMOUNTING Perform the dismounting operations in reverse order 1 2 4 3 vnx su ...

Page 461: ...smount the rubber buffer 2 Detach from clips the sun visors rod from the inside rear view mirror support Release the inside rear view mirror 3 by dismounting the attachmentscrews 4 REMOUNTING Perform the dismounting operations in reverse order INSIDE REAR VIEW MIRROR 1 1 2 3 4 vnx su ...

Page 462: ...out inside rear view support protector Detach the sun visors 2 rod from the inside rear view mirror support Release the sun visors 2 by dismount the attachment screws 1 REMOUNTING Perform the dismounting operations in reverse order 1 2 SUN VISORS vnx su ...

Page 463: ...ERNAL ACCESSORIES 57 9 REMOUNTING Perform the dismounting operations in reverse order 2 1 TURN HANDLES DISMOUNTING Dismount the turn handles 1 attachment screws 2 from the stretcher Dismount the turn handles vnx su ...

Page 464: ... 57 57 10 DOORS THRESHOLDS DISMOUNTING Dismount the screws 1 from the cable supports 3 Release the front doors 2 respectively rear doors thresholds REMOUNTING Perform the dismounting operations in the reverse order 1 3 2 vnx su ...

Page 465: ...lar pos 1 the attachments front safety belts screws on the lower middle pillar pos 2 the attachment screw of lock front safety belts on thefront plate protection pos 3 of fixing front belt on middle pillar lower part front safety belt REMOUNTING Perform the dismounting operations in reverse order 59 1 DISMOUNTING 1 3 2 vnx su ...

Page 466: ...t screw on the upper part of lateral panel pos 1 the attachment rear safety belt screw on the inner lateral frame pos 2 the attachment screws of the rear belt lock on central floor pos 3 rear safety belt REMOUNTING Perform the dismounting operations in reverse order 59 2 DISMOUNTING 1 3 2 vnx su ...

Page 467: ...one other the levers 1 and 2 to the left leaving a clearance of 3 4 mm the cable sheath being attached in this position by means of a clip and check the correct operation of the lever and the flap closing the control cable 6 of the climatecontrol valve 7 is mounted to the lever 3 so that the valve is set in the open position the arrow direction and the lever 3 is moved towards right leaving a clea...

Page 468: ...plate 2 Disconnect the connections of the luminous plate and the vacuum hoses Dismount the attachment screws 3 of the climate control Take out the climate control block from its housing Disconnect the climate control valve cable 4 and the climate control cable REMOUNTING Perform the dismounting operations in the reverse order CLIMATE CONTROLBLOCK 1 2 3 4 vnx su ...

Page 469: ...ps andmixing flaps from the control levers and the recycling flaps cable from the climate control panel Dismount the ducts of the heating valve and the aeration connection Dismounttheattachmentnuts of theclimate control unit 4 positions 1 2 and 3 Detach the climatecontrolunitthrough insidecockpit togetherwith the ducts through the iron plate shutter REMOUNTING Perform the dismounting operations in...

Page 470: ...ons in the reverse order observing the following conditions the valve control cable is mounted at the valve control lever so that valve is set in open position and the control lever is moved to the right leaving a clearance of 3 4 mm In this position attach the cable sheath by means of clip than check the correct operation of the lever and valve closing after remounting the climate control valve t...

Page 471: ...t connection plate DC Dismounttheattachment screws of the GMV on the iron plate REMOUNTING Performthe dismounting operations in the reverse order B COMMERCIALS EQUIPPED WITH DASHBOARD TYPE 1325 The climate control GMV is mounted in the climate control unit It is located under the dashboard in the central zone being attached on the iron plate and it has 4 rotation steps Dismount the GMV after previ...

Page 472: ...tfusebox Is itblown Replacethefuse Supplywiredisconnectedor broken Fixit Checkiftheblowerissupplied Replacetheblower Is theblowermassconnected Istheblower switchmassconnected Replacetheblowerswitch Masswiredisconnectedor broken Fixit Yes No Yes No No No Yes Yes DIAGNOSTIC vnx su ...

Page 473: ...ngerscompartmentandtomaintainthistemperatureatan inferiorvaluecomparedtothe environmentone reducinginthesametimetheairmoisture Basically theACunitisoperatinginaclosedcircuitand itiscomposedof thefollowingmain elements evaporator compressor condenser thermostaticexpansionvalve connectionpipes GENERALITI ES vnx su ...

Page 474: ...ernatorattachmentscrewon support 2 4 Pressurecontrollercouple 0 7 TIGHTENING MOMENTS daNm DRAINING FILLING REFRIGERANT CIRCUIT DRAINING Connectthechargingequipmentpiping tothefilling drainingvalves Performthevacuuming oftheaircondition system recoveringtheoilandtherefrigerantfluid Closethehosesvalves Disconnectthecharging equipmentpiping andstoptheequipment FILLING Attachthedraining fillinghosesof...

Page 475: ...AIR CONDITIONING 62 62 3 A C CIRCUITOPERATINGDIAGRAM Warning grup vnx su ...

Page 476: ... temperatures higher than 80 grd C It is absolutely forbidden to perform welding on the elements of the air condition circuits It is essential using the type of the refrigerating agent and of the compressor oil prescribed by the producer The filling of the conditioning system can be performed only in authorized service stations observing the producer s instructions For mechanical or body operation...

Page 477: ...glassairbubblescannotbeseen theunitisingood operation butifairbubblesareoccurringandtheyremainduringoperation thisshowsthelackof refrigerantfluid If therearenotairbubblesandtheair conditioningsystemis notoperating therefrigerant fluidmustbechecked Thelackof refrigerantfluidcanbeconfirmedby measuringthecircuitpressure ata filling station IMPORTANT When starting each time the compressor air bubbles ...

Page 478: ...dairpenetrationnottobe stopped Also thecondenserpipesmustnotshow deformations DISMOUNTING Disconnectthebattery Drainthecooling circuit Dismounttheradiator Draintherefrigerantcircuit Dismountthepipes 1 and 2 connectedtothecondenser Disconnecttheelectricconnectorof thecoolingGMV Dismountthecondenserattachmentscrew 3 on theuppercrossbar Detach thecondenser SeparatetheGMVfromthecondenser ATTENTION Avo...

Page 479: ...nttherefrigerantfluidpipes 1 and 2 Disconnecttheelectricconnectorof thepressurecontroller Dismountingthepressurecontroller 3 Loosentheattachmentringof thetankfilter 4 Replacethereceivertankfilter REMOUNTING Performthedismountingoperationsinthereverseorder Tightenattherequiredmoment 0 4daNm thetankfilterattachmentnut Tightenattherequiredmoment 1 6daNm therefrigerantfluidpipesconnection s Filltheref...

Page 480: ...ineblockby meansof two supports ATTENTION During handling the compressor oil reduce to minimum the oil contact with the air which contains moisture DISMOUNTING Disconnectthebattery Draintherefrigerantcircuit Disconnectthepipes 1 and 2 fromthecompressor Dismountthetensioningclip 3 andthealternatorbelt Disconnecttheelectricconnectors of thealternatorandtheelectricconnectorof thecom pressor Dismountt...

Page 481: ...etightenerscrew seechapt Beltstighteningcheckingandtensioning thenlockit by tighteningthetightenernutatthe requiredmoment 3 5daNm Tensionthealternatorbelt seechapt Beltstighteningcheckingandtensioning andtighten atthe required moment 1 25 daNm thealternator clampattachmentnut and theclamp for alternatorbelttightener Tightenattherequiredmomentthealternatorattachmentscrewon thesupport 2 4 daNm Mount...

Page 482: ...T556on theupperand lowersupportsandslightlytightenits attachment scr ewson thesupports Tightenattherequiredmoment 1 9daNm theuppersupportattac hmentscrewsinthefoll owing order lowerleft upperright Tightenattherequiredmomentthelowersupportattachmentscrewsinthefollowingorder upperleft 3 daNm lowerleft 1 9 daNm upperright 3 5 daNm Dismounttheadjustmentdevice Performthe otheroperationsasdismountingint...

Page 483: ...atorconsists of apackagewithslottedaluminumplates separatedby anempty U shape space wheretherefrigerantfluidflowispushed Theevaporatorismountedon theiron plate intherightside underthedashboard rightside underthedashboard DISMOUNTING Disconnectthebattery Draintherefrigerantcircuit Dismountingthedashboard Removeanti condensesealingmaterial Disconnectthepipesevaporator compressorandevaporator tankfil...

Page 484: ...good operationof theclimatecontrolsystem NOTE Ensure that evaporator finned plates are not deformed and they are not excessive dirty ATTENTION For mounting or remounting the piping connections from refrigerant circuit use two wrenches to balance the tightening moment in order to avoid the piping spin ning EVAPORATOR vnx su ...

Page 485: ...oroilandfillup withcompressoroil Thesystemfillinganddraining valvesareplacedon thecompressorpipingandhavedifferent diameters so thattheycannotbereversed Whenoneairconditioning pipeisreplaced itiscompulsorythatitsmountingtobeperformed immediatelyafterdismountingtheprotectio n cover Pipingcompressor condenser 13 32 Pipingcompressor evaporator 1 2 Pipingcondenser tankfilter 5 16 Pipingtankfilter evap...

Page 486: ...fluid pipes from the thermostatic expansionvalve Thermostaticexpansionvalve allowsthereductionof therefrigerantliquidwhichis comingfromthecondenser passingthrough thetank filterand iscontinuouslyadjustingthe refrigerantflowfromtheevaporator toreachthecompressoringaseousshape Thegood operationoftheairconditioningsystemis ensuredby adryerfiltertankwhichhas thepurposetoprotect theunitby absorbingthee...

Page 487: ...ressur einthehighpressurecircuitismore than27 bars starts thecoolingGMV whenthepressureinthehighpressurecircuitis morethan 16 barsandcutsoff theGMVwhenthepressureis loweringmorethan12 bars PRESSURE CONTROLLER REPLACEMENT DISMOUNTING Thedismountingof pressurecontrollermaybeperformedwithoutdrainingtherefrigerant circu it Disconnectthebattery Disconnecttheconnector 1 of thepressurecontroller Dismount...

Page 488: ...ationand theairducts integrity Compressor belt tensioning is good conditioning Yes Yes No Any refrigerant fluid leakage in the system No Yes Yes Is clutch supplied witch 12V No Yes No Clutch is coupling the compressor Replace the thermostatic Expansion valve Yes No Check the electic circuit for supplying and control Detect the refrigerant fluid leakage cause Perform refilling Pressure controller i...

Page 489: ... the wir ing between F01 and relay 584 No Restore the wiring between pole 4 of 584 relay and pole 2 of 238 relay No The wiring between injection compu ter and the pole 6 of 584 relay is broken Yes Repair the wiring Yes No Injection computer defective Replace it Injection computer does not receive AC actuation Yes Check the switch electric circuit Pressure controller is working No Replace the switc...

Page 490: ...t bonnet gasket 3 4 wing chute gaskets 5 6 rear front doors frames gaskets Manually dismount by pulling one end toward applying area external REMOUNTING To be mounted by hammer tapping Cut the extra ends Tighten the clipping areas FRAMESEALINGGASKETS 65 1 5 4 3 6 2 1 vnx su ...

Page 491: ...egasketsfromthedoorprofile by pullingthemtowardsexterior followingthe dooroutline REMOUNTING Performthedismountingoperationsinthereverseorder Mountingof thesealinggasketson thedoorframesisperformedby plastichammer tapping 65 2 DOORSEALINGGASKETS vnx su ...

Page 492: ...f the vehicle Clean the rubber gasket if it will be reused or replace it with a new one REMOUNTING Place the rubber gasket around the glass on all its contour where previously has been introduced a cotton rope 4 with the diameterof 3 4 mm leaving some 20cm of free rope at each end 3 but no more than 10 cm between ends GLASSES SEALING GASKETS 66 1 For glasses dismounting remounting please see s cha...

Page 493: ...e arm rest at the upper part Dismount the window regulator handle and the inner opening mechanism Dismount the panel by removing it from clips and take out the inner wiper REMOUNTING Performthedismountingoperationsinthereverseorder 66 2 INNERWIPERS vnx su ...

Page 494: ...NS DISMOUNTING Lower the window to the minimum position Thedismounting ofthe outsidewiper is performedby removing it fromthefixing clips REMOUNTING Perform the dismounting operations in the reverse order 66 3 OUTSIDEWIPERS vnx su ...

Page 495: ...ever ornament the front rear doors thresholds Dismount by hand the molded carpet REMOUNTING Perform the dismounting operations in the reverse order UNDER BENCH CARPETS DACIA DOUBLE CAB DISMOUNTING Dismount the rear bench the rear safety belts locks that are attached on the intermediary floor Dismount by hand the carpet under the bench REMOUNTING Perform in the reverse order the dismounting operati...

Page 496: ...ering 5 upper side panel lining 6 side panel covering 7 cabin wall lining 8 plate screw 9 flat washer REPLACEMENT OF THE WINDSCREEN COVERING DISMOUNTING Dismount the windscreen partially the front doors weather strip Unstuck the windscreen covering REMOUNTING Perform the dismounting operations in the reverse order 6 8 9 7 5 4 3 2 1 vnx su ...

Page 497: ...ss at the middle pillar Dismount the front thresholds partially the front rear doors weather strips the front safety belts at their upper lower part attachment on the middle pillar Unstuck in the reverse order of the dismounting operations REMOUNTING Perform the dismounting operations in the reverse order MIDDLE PILLAR LINING vnx su ...

Page 498: ...ING DISMOUNTING Swing over the rear bench back Dismount the rear safety belts at the upper part partially the rear doors weather strip Unstuck the upperside panel lining REMOUNTING Perform the dismounting operations in the reverse order UPPER SIDE PANEL LINING vnx su ...

Page 499: ... WALLLINING DISMOUNTING Swing over the rear bench back Dismount the rear glass grill the rear cabin glass the screws and washers attaching the cabin wall lining REMOUNTING Perform the dismounting operations in the reverse order CABIN WALL LINING vnx su ...

Page 500: ...he cabin rear glass in the contact areas with the ceiling covering Remove the rods 1 assembled with the plasticbushings 2 arch ends fromtheside taps Release the covering 3 by unstuck it and remove the rods from the corresponding sleeves REMOUNTING Perform the dismounting operations in the reverse order by consecutive mounting of the rods positioning and stacking of the ceiling covering edges on th...

Page 501: ...ed mat 3 Remove unstuck front cross member noise absorbents 4 8 thecowlpanelnoise absorbent 5 the front wheel noise absorbents 6 7 and the gearbox casing noiseabsorbent 9 REMOUNTING Perform the dismounting operations in the reverse order the stacking of the elements no 3 4 5 6 7 8 9beingdonewith adhesive 1 2 3 4 5 6 7 8 9 vnx su ...

Page 502: ...control cover 8 by dismounting the attachment screw theinnerwiper 5 fromtheclips 6 the store box 9 Detach the front door panel from its clips Pull toward exterior to enable the panel releasing from the attachment done by clips 7 DISMOUNTING REMOUNTING Perform the dismounting operations in the reverse order 7 6 5 8 4 3 2 1 FRONT DOORPANEL vnx su ...

Page 503: ...owregulatorhandle thedistance controlcover 5 by dismountingtheattachmen tscrew theinnerwiper 4 fromtheclips 6 the storebox 9 Detach thereardoor panelfromitsclips Pulltoward exteriorto enablethe panel re leasingfromtheattachmentdonebyclips 7 REMOUNTING Performthedismountingoperationsinthereverseorder 1 7 6 5 4 3 2 vnx su ...

Page 504: ... position is obtained by using the button M DISMOUNTING In order to dismount the seat perform the following operations Lift the control lever L bring the seat in the front position and dismount the screws 5 as well as the seat attachment cross pieces 6 on the central floor the rear part Bring the seat in the back position and dismount the seat attachments screws 2 and cross pieces 1 on the central...

Page 505: ...EMENT DISMOUNTING Dismount the seat off the vehicle Dismount the slide guides from the front seat Remove the upholstery and the clothing from the armature REMOUNTING Perform the dismounting operations in the reverse order FRONT SEATS FRAMES vnx su ...

Page 506: ...at attachment screws 5 and cross pieces 3 and 6 on the central floor theslide guides 1 and 2 attachment screw 4 on the seat armature release the slide guides 1 and 2 REMOUNTING Perform the dismounting operations in thereverseorder 1 3 5 6 2 4 FRONT SEATS SLIDE GUIDES vnx su ...

Page 507: ...t the closing plate 1 by removing it from the clips of the rear bench back rest Dismount the upholstery and clothing from the rear bench back rest 2 REMOUNTING Perform the dismounting operations in the reverse order 76 1 3 4 2 1 BACKRESTARMATURE vnx su ...

Page 508: ...DISMOUNTING The rear bench seat 4 is dismounted by rocking it in the supports 3 Remove the upholstery from the seat clothing REMOUNTING Perform the dismounting operations in the reverse order 76 2 3 4 2 1 REAR BENCHSEATARMATURE vnx su ...

Page 509: ...the seat upholstery 7 attachment clips 4 on the clothing 14 Take out the rods 6 from the attachment clips 5 with the front seat armature 77 1 REMOUNTING Performthedismountingoperationsinthereverseorder 13 14 2 1 4 5 6 7 8 9 10 11 12 3 SEATSUPHOLSTERY vnx su ...

Page 510: ...mthepipes 1 weldedon thefrontseatarmature Take out the rods 9 from the clips 8 Take out at the second criss cross arch level the rod 11 from the attachment clips 10 of thebackrest upholster y 12 on theclothing 13 andremovethebackrest upholster y REMOUNTING Perform the dismounting operations in the reverse order 13 14 2 1 4 5 6 7 8 9 10 11 12 3 BACKRESTUPHOLSTERY vnx su ...

Page 511: ...at upholstery 4 with the seat clothing Dismounttherods 3 from the chains 5 consequently theattachmentclips fromthe bench seat armature rod Remove the upholstery from the seat clothing 78 1 REMOUNTING Perform the dismounting operations in the reverse order 4 1 5 3 2 SEATSUPHOLSTER Y vnx su ...

Page 512: ...st plate from its plastic clips Take out from clips the rods 2 at the lower part and the side ends rods 1 from the clips 4 Releasethe clippingrods 5 fromtheattachment withthebackrest clothing by means of the chains 3 Remove the back rest upholstery from the bench back rest clothing 1 3 2 4 5 BENCHBACKRESTUPHOLSTERY vnx su ...

Page 513: ...ed on vehicle body disconnect the battery terminals and the connections plugs to the alternator Some external or functional factors have a direct impact on the electric equipment which has as effect the modification in time of the nominal parameters of the component elements of the electric equipment affecting their reliability and operating safety The main affecting factors are Temperature someel...

Page 514: ... table ELECTROLYTE PREPARATION The electrolyte is obtained from sulfuric acid for batteries STAS 164 75and distilled or free of minerals water without impurities When preparing the electrolyte use vessels and funnels made of materials resistant to acids lead glass ceramics that not made impurities orelements that should discharged early the battery When preparing the electrolyte pour the acid into...

Page 515: ... thebattery and the terminal at the terminal of the battery The charging shall be performed only when the electrolyte temperature is not higher than 30 C and the battery will be immersed in a cooling vessel with the level at 2 3 from the battery height The battery charging is performed in two s tages the battery without plugs as follows stageI adjust the charging current II to 10 of the battery no...

Page 516: ... 2 3 hours duringwhich the electrolytepenetratesthe plates checkagain thelevel the level andrefill it with electrolyte of same density then batteries can be put it in operation This type of batteries are submitted to a charging processus by mean of a voltage rectifier having the charging current value set in second stage II in the follow situations batteries stored for more than 6 monthsfrom the m...

Page 517: ...he headlight and signaling lamp connectors Push the headlight forward REMOUNTING Place bypressingthe adjustmentscrews in the headlight seats by pushing towards the engine compartment of the headlight Mount the headlight corrector control screw C Insure the headlight by means of the attachment clip B Connect the battery and adjust the headlights HEADLIGHT BULBS REPLACEMENT vnx su ...

Page 518: ...lb REMOUNTING Perform the dismounting operations in the reverse order NOTE After headlight or bulb replacement it is recommended the adjustment checking FRONTSIGNALING BULBREPLACEMENT Disconnect the wires from the signaling lamp Rotate the lamp holder 3 and then remove it draw it Replace the bulb Place the lamp holder 3 in the signaling lamp and fix it by rotation LAMPS vnx su ...

Page 519: ...ps courtesy lamp glove box lamp Instruments panel lighting and warnings Two phases bulb R2 12 V 40 45W holder with flange P 45 t 41 Bulb 12 V 4W with holder B A9 s Bulb 12 V 21W colored with holderBAU 15 s Halogen bulb H3 12 V 55 W with holder P 16225 Bulb12 V 21 5 W with holder B AY 15 d Bulb 12 V 21W with holder BA 15 s Bulb 12 V 21W with holder BA 15 s Bulb SOFIT 10x35 type AS02 12V 5W wholder ...

Page 520: ...NG REMOUNTING Disconnect the battery Detach the projector supply wires from the front wiring Dismount the attachment screws of the projector from front bumper Mounting is done by performing in the reverse order the dismounting operations FOG PROJECTOR vnx su ...

Page 521: ...ssure the dynamic adjustment switch in position empty without load rotate it to the right The adjustment is performed with a special headlights adjustment device ADJUSTMENT OF MEETING BEAM LOW BEAM This is performed by actuating the screw C or V adjustmentin thevertical plan By screwing up the light beam descends andby unscrewingit thebeam goes up Check if the lighted area is centered on the verti...

Page 522: ...on to coincide with the adjustment made for the low beam and the lightening fascicle shall be uniform distributed between the two vertically lines on the panel When checking the high beam the lightening center of the ellipse must be situated on the cross sign marking the screen center If a major deviation compared to the short beam is noticed it is recommended the replacement of the bulb this one ...

Page 523: ... dismounting operations in the reverse order REAR LAMP DISMOUNTING REMOUNTING Dismount the screws that attach the protector DACIA 1304 Pick up Dismount the screws that attach the lamp body on the vehicle body DACIA 1304 Pick up Dismount the nutsthat attach the lamp body on the vehiclebody DACIA 1304 Drop Side Disconnect the lamp from the vehicle wiring Perform the dismounting operations in the rev...

Page 524: ...replace it between The bulb is not burnt the supply wire lamps is broken or not connected REAR RIGHT FOGG LAMP WORKING THE WARNING IS NOT WORKING Check if the warning bulb is not burnt The bulb is burnt replace it The bulb is not burnt The bulb supply or the instrument panel mass are broken 80 2 DIAGNOSTIC vnx su ...

Page 525: ...central aerator Theantistartingelectroniccontrolunit UCE isconnectedatthefrontwiringof thevehicle by means of a 10ways connector whichis attached by meansof agearbehindtheleft side dashboard Theanti startingreceiver is connectedto antistartingUCEby meansof a4 ways connector andhas adoublepurpose transferring theinformationreceivedfromtheelectronickeytotheUCEantistarting showingtheactiveornotactive...

Page 526: ...ntified 1 UCEantistarting 2 Antistartingreceiver 2 a electronickeycontact 2 b antistartingLEDindicator 3 Insidefusebox 4 Leftconnectionplate I C 5 Antitheftdevice starting ignitioncontact 6 Rear frontwiringconnection 7 Electricfuelpump 8 Leftsidedashboard ground 9 Front fuelinjectionwiringconnection 82 2 PRESENTATION vnx su ...

Page 527: ...been turnedoff andthevehiclestartingisnowauthorised If theLEDindicatordoesnotlightoff thentheelectronickeydoesnotbelong tothevehicleor thereisadefectintheantistartingsystem ATTENTION The system activation may be also obtained without waiting the 30 seconds timing after engine stopping To do that it is necessary the bringing of the electronic key end in contact with the anti starting receiver in th...

Page 528: ...ctronic keys may be re programmed 82 4 ELECTRONICKEYSPROGRAMMINGPROCEDURE ELECTRONICKEYSPROGRAMMINGPROCEDURE Thisis tobeappliedwhenthereplacementof theelectronickeysis neededandtheprocedureis asfollows bringtheswitch 1 of theUCEantistartinginposition ON placetheendof thefirstelectronickeyincontactwiththeantistartingreceiver afteronesecond placetheendofthesecondelectronickeyincontactwiththeantistar...

Page 529: ...83 INSTRUMENT PANEL 83 1 INSTRUMENTS PANEL SERIES 5136 SÃCELE vnx su ...

Page 530: ...backof thepanelinstrument Dimountingthetimerof windscreenwiperswindscreen Dimountingthecontrolreglagefhares Dimountingthousefour screwswhichfixtheframefixationdevice twoaresituatedinfront of thepicture twoareundertheashtrayof panelinstrument Removetheframefixationdevice onwhichisthepanelinstrument Kickawaybothlateralclips 4 whichfixthepanelinstrumenttothepanelinstrument Takeouttheinstrumentspanel ...

Page 531: ...rewarning light 4 Mass 5 Turnsignallights 6 Fuellevelindicator 7 Watertemperaturewarninglight 8 Temperatur eindicatorwarninglight 9 Lowfuellevelwarning light Subjecttothevehicleequippingstatus thefunctionof someindicatorsshallbemodifiedas follows CONNECTORA 1 Hazard warninglight 2 Headlig htmainbeamwarninglight 3 Sidelightswarninglight 4 Mass 5 Revolutionscounter RPM 6 Supply DC aftercontactswitch...

Page 532: ...arburetor 4x4 Standard equipment 2 2 4 4 3 Chokewarninglight Chokewarninglight Rearwindowheating light Defrostfieldglass indicator Batterychargin g light Fuelinjectionwarning light Fuelinjectionwarning light 4x4 coupling warning light 4x4 coupling warning light 120 km h speed warn ing light CONNECTORS SERIES5136 SÃCELE vnx su ...

Page 533: ...ninglamp 2 Headlig htmain beamwarninglight 3 Free 4 Mass 5 Revolutionscounter RPM 6 Supply DC aftercontactswitch 7 Foglightswarninglight 8 Mass CONNECTORB 1 Handbrakewarninglight 2 Chokewarning lightorfuelinjection 3 Free 4 Rearwindowheatingwarninglightor 4x 4 5 Dashboa rdlightening 6 Brakingsystemfailurewarning light CONNECTORC 1 Supply DC aftercontactswitch 2 Free 3 Oilpressurewarninglight 4 Mas...

Page 534: ...ated on the speedometer cable will act on the indic ator relay 4 through which the 120 km h warninglightfromtheinstrumentspanelislighted INCLUDEDELEMENTS Onthecircuitdiagramthefollowingcomponentselementsmaybenoticed 1 Rightconnectionplate DC 2 Vehicle speedsensor on speedometercable 3 Left dash board mass 4 Speedlimitwarninglightrelay Dashboard warninglight120km h 120 Km h SPEEDWARNING vnx su ...

Page 535: ...ight 4 Mass 4 4x4 warninglight 5 Revolutionscounter RPM 5 Rheostatlighteningboard 6 Supply DC 6 Brakingsystemfailurewarninglight 7 Foglightswarninglight I C P and wear of brake pads 8 Mass INSTRUMENTS PANEL CommercialsequippedwithC A C 1 Supply DC 2 3 Oilpressurewarning1 4 Mass 5 Turnsignalwarnin g light 6 Fuellevelgauge 7 8 Watertemperaturewarninglight 9 Lowfuellevelwarning light vnx su ...

Page 536: ...TINGDIAGRAM Thefollowingcomponentselementsmaybeidentified 1 Safetybeltswarninglightboardlamps 2 Safetybeltscontacts 3 Rightconnectionplate DC 4 Mass athandbrake attachment Asitcanbeseenfromthisdiagram whentheignitioncontactison thewarninglight 1 shall belightedifthesafetybeltis notfasten andafterdriverfastenitssafetybelt thewarninglight mustturn off confirmingthecorrectattachmentof thesafetybelt F...

Page 537: ...tercable Dismountthehalfhousingsofthesteering wheel Dismounttheheadlightadjustmentcontrol Dismountthescrewsthatattachthe instrumentframe Releasethetwosideattachmentclipsthat attachtheinstrumentpanelon thedashboard Takeouttheinstrumentspanel REMOUNTING Performinreverseorderthedismountingoperations VEHICLEWITHDASHBOARDTYPE1325 REPLACEMENT vnx su ...

Page 538: ...ilcircuit Thepressureis correct replacetheoilpressureswitch OILPRESUREWARNINGLIGHTIS NOTON WHEN CONTACT SWITCHON Placethewirefromtheoilpressureswitch tothemass Warninglightison replacetheoilpressure switch Warning lightisnoton Bulbisnotburnt checkthebulb supplywiringandrepairit Burntbulb replacethebulb Checkifthebulbisnotburnt DIAGNOSTIC vnx su ...

Page 539: ...ELLEVELINDICATORNOTSHOWINGCORRECTLY Disconnecttheconnectionwiretothe probe The indicator does not come to zero check possibility of a mass short circuit of the connection wire to the probe Thereisnotshort circuit Theindicatorisdefect The indicator comes back to zero Placeatthemass thewire connectiontotheprobe Theindicatordoesnotshowfull theprobeconnectionwireis not connectedor broken Theindicator ...

Page 540: ...the probe Theindicatordoes notwork Replace theprobe Theindicatordoes notwork Checktheindicatorsupplyand mass Notcorrect Repairthemass wiringor probesupply Iff correct Placeat mass the connectionwiretotheprobe Indicatordoes notwork Repairthewiringbetweentheprobeandindicator DIAGNOSTIC vnx su ...

Page 541: ...earbox andpullthecable Detachthecablefromtheattachmentclipson thelongitudinalgirder REMOUNTING Centerthespeedometercableintheinstrumentpanelsocket thenpushinthedirectionofD arrow untila click isheard confirmingthecoupling Center thecable inthespeedometer endless screw tightenthescrew and lock itwith the lockingnut Positio nitintheattachmentclipsofthelongitudinalgirder observin gthecurve Rmin 150mm...

Page 542: ...rce a0 1 bars manometer acontrollamp Makeanassemblyaccordingtothe diagram Whentheairisoff thecontrollamp shouldbelighted If thelampdoesnotlight replacetheoilpressureswitch When the air is open and the pressure is over 0 35 0 08 bars the control lamp shouldgo off If thelamp does notgo off atall or does notgo off at the required pressure replace theoilpressureswitch OIL PRESSURE SWITCHCHECKING vnx s...

Page 543: ...er a 0 200 C thermometer acontrollamp a heatsource Makeanassemblyaccordingtothe diagram Whenthetemperatureof thefluidis low thecontrollampshouldbeoff Ifthelampis on replacethethermocouple Warmup thefluidinthevessel Whenthefluidtemperatur ereachesthetemperaturerequired for thethermocouplecontact 180 C thecontrollampshouldbelighted If thelampdoesnot lightup replacethethermocouple Thecouplingtemperat...

Page 544: ...thecheckingtherearenecessary avesselwithcoolingfluid antifreeze distilledwater a thermometer0 200 C aheatsource anohmmeter Makeanassemblyaccordin g tothediagram Thevariation of theresistance R infunctio n of thetemperature T mustbeaccordingtothefollowingtable T 0 C 60 0 5 0 90 0 4 0 120 0 5 0 R Ω Ω Ω Ω 1010 342 139 TEMPERATURETRANSMITTER CHECKING vnx su ...

Page 545: ...tachmentflangeanti clockwiseby about1 3rotation Takeoutthetransmitterfromthetank by liftitcarefully REMOUNTING Performinthereverseorderthedismountingoperations NOTE When remounting pay attention that rubber sealing gasket of the transmitterto be in good state and flange to tightly fix it on the tank FUELLEVELTRANSMITTER vnx su ...

Page 546: ...sition accessories are voltage supplied protected by means of a bridge fuse F 02 This position enables the removing of the anti theft mechanism after its attachment screw on the steer ing column has been dismounted and the mechanism blocking pin has been pressed In this position the steering is not blocked and all consumers are voltage supplied protected by means of the bridge fuse F 01 inside fus...

Page 547: ...crew 1 Connect the contact switch the battery Check the contact switch operation Mount the steering wheel housings and the contact switch cover CONNECTING PLUGS REPLACEMENT Theoperationsareto beperformedafterdismountingthecontact switchfromthevehicle DISMOUNTING Dismount the attachment screws of the blocking wedge guiding Dismount the connecting plugs REMOUNTING Position and mount the connecting p...

Page 548: ...he steering wheel column Disconnect the switch connector to the front wiring the wires attached by the nut Unscrew the attachment screw of the light control switch off the steering wheel column Disconnect the switch REMOUNTING Tighten the attachment screw Connect the wire attached by nuts the switch connector to the front wiring Position and tie the wire bundle with a new plastic ring Connect the ...

Page 549: ...he connecting screws of the signaling switch off the steering wheel column Remove the switch REMOUNTING Mount the switch Tighten the switch attachment screws Connect the connecting coupling to the front wiring Position and tie the wire bundle with a new plastic ring Connect the battery Check the operation of the signaling switch Mount the lower half casing of the steering wheel 84 4 UNDERWHEELCONT...

Page 550: ...on lights 2 Foglampscommandrelay 4 Position lights 5 Mass FOGLIGHTSSWITCH Pos Destination 1 High beams Road lights 2 Foglampscommand 4 Position lights 5 Mass Pos Destination 1 Windscreenwiperspumpcontrol 2 Windscreenwiperstimercommand 3 Mass 4 Windscreenwipersmallspeed command 5 Supply battery TEMPORISATEURESSUIE GLACES PARE BRISE forvehicles madeafter 02 04 2003 84 5 vnx su ...

Page 551: ...lights 6 Mass 7 Supply signalisati on rela y 8 Supply aftercontact 9 Supply permanent Pos Destination 1 Mass 2 Positionlights 3 ACcommand 4 Supply accessories Pos Destination 2 GMVclimatcontrolspeed3 3 GMVclimatcontrolspeed1 4 GMVclimatcontrolspeed4 5 GMVclimatcontrolspeed2 6 Supply accessories HEATINGSWITCH CASWITCH forvehicles madeafter 02 04 2003 84 6 vnx su ...

Page 552: ... mechanism dismounting shall be perform differ ently Accordingtothetypeof thevehicleequipment withor without windscreenwipertimer the windscreenwiperisconnectedtoitswiringasperfollowingdiagrams a withwindscreenwipertimer b withoutwindscreenwipertimer Onthesediagramsthefollowingelementsmaybeidentified 1 Windscreenwipermotor 2 Rightconnectionplate DC 3 Windscreenwiperwasherpump 4 Washer wiperswitch ...

Page 553: ...bberwashers andbushings Dismountthedashboard Disconnectthewiringconnectorfromthewindscreenwiperdrivemotor Unscrew theattachmentscrewsof themechanismon theplate Drawthemechanismbackwardsandthentakeitoutfromtherightsideof thesteeringwheel REMOUNTING Performthedismountingoperationsinthereverseorder NOTE When mounting the windscreen wiper arms the wiper drive engine must be in position stop at fixe po...

Page 554: ...smounttheshafts 1 off themechanismsupport 2 Depressthegroovedbushing Dismounttheshaft recoverthebushingandtherubbergaskets REMOUNTING Checkthestateof the rubbergaskets Cleanthe parts tobefree of oxides Greasetheparts withgreaseLiCa Pb typeII Remount therubbergasketon theshaft therubbergasketshaftand thebushing Pressthegroovedbushing Mounttheshaftson themechanismsupport Greasethejointswithgreasetyp...

Page 555: ...NOTE When remounting the auxiliary connecting rods A and B shall be aligned the drive motor being stopped at fix position WINDSCREENWIPER DRIVE MOTORREPAIRING Windscreendrivemotor componentspartsdrawing DISMOUNTING Dismountthewindscreenwiperdrivemotoroffthemechanismsupport 1 Reduction geardismounting unscrew theattachmentscrews of thecap B Theoperationshallbeperformedafterdismountingthemechanismof...

Page 556: ...cle DISMOUNTING Dismountthedrivemotorfromthe windscreenwipermechanism Dismount thereductiongearandtherotor Disconnectthecoalbrushesterminals A B E Dismountthecoalbrushes REMOUNTING Checkthestateof the collector anditschan nels Mountthenew coalbrushes check thefree displacementof thecoalbrushesinthesupports Mounttherotorandthereductiongear Adjust the axial clearance of the rotor by meansof theadjus...

Page 557: ...connectthebattery thentheconnectingwiresfromwasherpumps Disconnecttheaspirationandexhausttubesfromthecouplingsandadjustablenozzles Dismounttheattachmentscrewsof washerreservoirsupport Dismountthewasherpumpsfromtheleftwinglining orfromthereservoir according withthe manufactu revariant REMOUNTING Performthedismountin g operationsinreverseorder Checktheoperatingandeventuallyadjustby means of a needle...

Page 558: ...mass wirebrokenor notconnected Thepumpisnotworking replacethe pump Thepumpisnotworking Thepumpisworking Performmadirectsupplyof thepump Checkif whenleveris acted thecontactendis voltagesupplied Thecontactendisvoltagesupplied thepump supplywireis brokenor not connected Thecontactendisnotvoltagesupplied Replacethecontact DIAGNOSTIC vnx su ...

Page 559: ...ass 12 V voltageexistingatthe contact end motorisnotworking Checkifthe motorissupplied Themotorisnotworking Thewires arenot supplied replacethecontact Checkifthesupplywiresof the motorarevoltagesuppliedatthe contactexit The motor is not supplied motor supplyingwires brokenor notconnected Themotorissupplied Replacethemotor DIAGNOSTIC vnx su ...

Page 560: ...pplied Themotorisnotsupplied thesupply wireis brokenor notconnected Checkthemotorsupply WINDSCREENWIPER NOTWORKINGAT LOWSPEED ITDOES NOT STOPATFIX POINT THEPUMPIS WORKING Checkthegreenwiresupplyingfromthe wiringplugconnectedtothemotor Thewireisnotvoltagesupplied replacethe contactor repairtheelectric wiring tothecontact Theengineisvoltagesupplied replacethemotor Thewireisvoltagesupplying Themotori...

Page 561: ... atthewhitewire fromthewiper Checkpresenceof 12V atthe blackwireon thereturn wiring Checkthecorrect operationof the timerandswitch Repairtheelectricwiringright connectionplate wipermotor Bothworkingcorrectly Check electric connectionsandrepairit Replacethe wiperelectricmotor Yes No Botharedefective Replace them No Yes DIAGNOSTIC vnx su ...

Page 562: ...ons markedbytheletterMfollowedby figuresor letters theyareindicated inChapter4 Eachwireof the electricdiagramsis markedby analphanumeric code representingthe wire function followedby agroup of lettersrepresentingthewirecolour Chapter11 includestheconnectorsandcouplingsbetweenthewires Thesearedrawnfromthe wires inlettotheconnector coupling Thewires enteringeachconnectorsocketareidentifiedby meansof...

Page 563: ...connectiongraphicalrepresentation 16 symbol pagescontainingfunctio naldiagrams 17 wirefunctioncode 18 wirecolour 19 functionaldiagramnumber OBSERVATION 1 Theelectricconnectors 5 thecouplings 13 andwires 18 aresymbolise dbythefollowingcolours BA white GR grey SA salmonpink BE blue MA brown VE green BJ beige NO black VI violet CY white OR orange GR grey RG red 2 Thezone 4 specifiesthedifferentiation...

Page 564: ...89 ELECTRICAL DIAGRAMS 89 3 ANTISTARTING GENERALITI ES vnx su ...

Page 565: ...mponenttowhomthedescribedconnectoris tobe connected 9 connectorcolour 10 connectorsymbol 11 indicationof theconnectorsocket 12 wiresectioning mm 13 wirefunctionalcode 14 wire destination 15 chapternumberandconnectordrawingnumber NOTE Concerning position 6 we point out that we are to mark one X for one wire and two Xs for two wires The colour of the wire is to be symbolized only in case the electri...

Page 566: ...tion Destination 1 0 5 3CM DETONATION SENSOR MASS 2 0 5 3S DETONATION INFO INJECTION COMPUTER ENGINEWIRING X 75 03 DETONA TION SENSOR 11 12 13 2 5 3 4 6 14 7 8 9 10 13 07 15 1 1 1 1 1 2 3CM 3S N X CY2AE MA 146 147 3CM 3F 3D N AS G A B C ZW3DT VE GENERALITI ES vnx su ...

Page 567: ...lt witness additional wire mass DAIF S S S S Speed limit alarm wire mass DAIF S S S S Front wire mass dashboard CHAUFO S S S S Front wire mass dashboard CA O O O O Front wire mass dashboard ANTIDID CA O O O O Engine wire mass S S S S Cockpit fuses box S S S S Coupling plates CA O O O O Coupling plates 4x4 O O O O Coupling plates DAIF O O O O Coupling plates CA 4x4 O O O O Coupling plates DAIF 4x4 ...

Page 568: ...ghts S S S Backward running lights S Position lights S S S Position lights S Road lights S S S S STOP lights S S S STOP lights S Signalisation and break down lights S S S Signalisation and break down lights S 44 45 46 47 48 49 50 51 52 53 54 55 56 No Electric diagrams denomination U75 H75 E75 M75 NOTA S equipment series O opπional equipment vnx su ...

Page 569: ...elay Injection water temperat ure sensor Board panel Vehicle speed transducer Water thermo contact 2 steps Front right signalising light Front left signalising light GMV cooling and AC Right front side signalisation light Left front side signalisation light Water temperature transmitter Injection air temperat ure sensor Climate control lights Air conditioning control push button andswitch GMV resi...

Page 570: ... WINDSCREEN WIPER N FRONT WIRES COUPLING R107 BOARD PANEL B FRONT WIRES COUPLING R111 GMV CLIMATE CONTROL H BOARD PANEL WIRES COUPLING R112 DECODER U C E F FRONT WIRES COUPLING R122 FRONT WIRES COUPLING FOG LIGHTS R212 ENGINE G FRONT WIRES COUPLING R217 REAR R FRONT WIRES COUPLING R265 REAR A FRONT WIRES COUPLING R318 BOARD PANEL P FRONT WIRES COUPLING MASS LIST MA RIGHTFRONT BODY ELECTRIC MASS MB...

Page 571: ...AGRAMS 89 10 LOCATION OFELECTRICCOUPLINGON THEVEHICLE A for U75 Pick up M75 King Cab B for E75 Drop Side C for H75 Double Cab K L N F M A E D G C H J BP K L F M A D G N H J P B E C Κ Κ Κ Κ L H J F N A E G D C M vnx su ...

Page 572: ...89 ELECTRICAL DIAGRAMS 89 11 FIXATION OFELECTRICMASSON THEVEHICLE A for U75 Pick up M75 King Cab B for E75 Drop Side C for H75 Double Cab MU MF MG MB MA MN MA MB MN MU MF MG MA MB MN MU MG MF vnx su ...

Page 573: ...Breakdown switch Fog lights switch Safety belt witness Fog headlights switch Air heater switch Anti starter receptor Air conditioning control pusch button switch Indicating relay for over limit speed 120km h Rotation sensor Vacuum capsule contact Supplyinig plate DC Windscreen wiper motor Climate control GMV Cockpit GMV2 for A C Oxygen rod Signalisation relay Braking system ICP Supplying plate IC ...

Page 574: ... 36 46 47 65 48 66 49 60 50 51 52 53 54 55 56 57 58 59 29 27 28 25 26 30 64 24 15 10 62 9 13 14 31 32 33 34 35 39 7 12 41 42 43 44 45 40 23 22 7 20 19 21 4 3 2 1 5 6 8 39 16 18 61 11 17 63 38 37 36 46 47 65 48 66 49 60 50 51 52 53 54 55 56 57 58 59 29 27 28 25 26 30 64 24 15 10 62 9 13 14 31 32 33 34 35 12 ELECTRICCOMPONENTSLOCA TION ONTHEVEHICLE vnx su ...

Page 575: ...ouble Cab 40 23 22 20 19 21 4 3 2 12 56 8 16 18 61 11 17 63 38 37 36 46 47 65 48 66 49 60 50 51 52 53 54 55 56 57 58 59 29 27 28 25 26 30 64 24 15 10 62 9 13 14 31 32 33 34 35 39 7 41 42 43 44 45 1 ELECTRICCOMPONENTSLOCA TION ONTHEVEHICLE vnx su ...

Page 576: ... 15 A Rearlightsandboard panelsupply STOPlights F 02 15 A 4x4 electro vacuumcontrol climatecontrolwithCA speedover l imit120km hindicat orrel ay vehi clespeedtrans ducer F 03 15 A GMVclimatecontrol clock F 04 8 A Foglights ceiling light ashtray windscreenwiper cleaner F 05 8 A Directionandbreak downsignalisation F 06 8 A Positionlights lightingof theboardpanel ashtray lighter gloves box clock swit...

Page 577: ...fixedon theleftmudguardcoating Electriccircuitsprotectedby fusesandrelays FUSE NUMBER FUSE TYPE PROTECTED CIRCUIT F01 10 A Fuelelectricpump F02 10 A Oxygenrod F03 15 A Foglights R 1 Oxygenrod fuelelectricpump R 2 Injectioncomputer injectionwitness R 3 Foglights RELAY PROTECTED CIRCUIT ENGINECOMPARTMENT FUSE BOX forvehiclewithfog lights vnx su ...

Page 578: ...10 A Oxygenrod F03 10 A Fuelelectricpump F04 30 A G M V cooling F05 15 A Foglights RELAY PROTECTED CIRCUIT R 1 Oxygenrod fuelelectricpump R 2 A C compressor R 3 Injectioncomputer injectionwitness R 4 Foglights R 5 G M V cooling R 6 Injectioncomputer thermo protectionA C FUSE NUMBER FUSE TYPE PROTECTED CIRCUIT D 1 6 A A C compressor D 2 6 A A C pressure gauge anti return DIODE TYPE DESTINATION forv...

Page 579: ...CTOR 89 109 163BA ST ARTER 89 120 163AB ST ARTER 89 120 163DB ST ARTER EXCIT ATION 89 120 166 REGISTRA TIONNUMBERRIGHTLIGHT 89 129 167 REGISTRA TIONNUMBERLEFTLIGHT 89 129 168 GLOVESBOXLIGHTS 171 A C COM PRESSOR CLUTCH 89 100 172 RIGHTREARLIGHT 89 131 173 LEFTREARLIGHT 89 131 176 RIGHTFOGLIGHT 89 113 177 LEFTFOGLIGHT 89 113 184 RIGHTFRONT POSITION LIGHT 89 112 185 LEFTFRONT POSITION LIGHT 89 112 19...

Page 580: ...A TURE TRANSM ITTER 89 117 272 AIRTEMPERA TURESENSOR INJ ECTOR 89 92 298 CLIMA TECONTROL LIGHTI NG 89 128 326 SPEED OVER LIMIT INDICA TOR RELA Y 120km h 89 136 329 RIGHTFRONTCEILINGLIGHT 89 137 333 DRYVERSAFETYBELTCONT ACTOR 89 138 335 GMV CLIMATE CONTROLRELA Y 89 122 371 CANISTERPURGINGVALVE 89 94 411 A C PRESSURE GAUGE PRESSURE ROD 89 109 474 A C RELAY board 89 122 484 4x4COUPL INGELECTRO V ALVE...

Page 581: ...ER 89 155 R112 FRONTWIRECOUPLING DECODE RU C E 89 143 R122 REARWIRECOUPLING FOG LIGHTS 89 163 R212 FRONTWIRECOUPLING ENGIN E 89 160 R265 FRONT REAR WIRE COUPLING 89 151 R318 FRONTWIRE COUPLING BOARD P ANEL 89 144 MA FRONTRIGHTBODYELECTRICMASS MB FRONTLEFTBODYELECTRICMASS OBSERV ATION connectors andcouplingsarerepresentedbackwards fromwires forward someelectric componentsarenot connected tothevehic...

Page 582: ... TURE SENSOR 14 0 75 3C SIGNAL W A TER TEM PERA TURE SENSOR 16 0 75 B BATTERY 17 1 0 3BR SUPPLY D C MAIN RELA Y 18 0 5 ML MASS 19 1 5 3CW CONTROL 2 3CYLINDERS IGN ITIONCOIL 20 2 5 ML MASS 21 0 35 3BG ENGINE ROT ATION SIGNAL ROT ATION SENSOR 22 0 5 49F AIR CONDITIONING CONTROL 23 0 75 MB MASS 25 0 75 3AQ SUPPL Y VALVEPOTEN TIOMETE R 27 1 5 NF SENSORSMASS WA TER AIR POTENTIOM ETER 28 0 75 3AC CONTRO...

Page 583: ... X X X X X X N X X X X X Vi N X X As M X X N X 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 3AM 3BV ML 3BU 3FH 38R 3BB 3AC NF 3AQ MB 49F 3BG ML 3CW ROTATION SENSOR Position Sectioning Destination 1 0 35 3BG ENGINE ROT ATION SIGNAL ROT ATION SENSOR 2 0 35 3BL SIGNAL ENGINE ROT ATION ROT ATION SENSOR 3 0 35 M SCRE ENING WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 584: ...DIAGRAMS 89 23 ENGINE WIRING X75 03 A C COMPRESSOR CLUTCH forA C providedvehicles Position Sectioning Destination 1 0 7 5 38R CONTROL A C COM PRESSOR CLUTCH NO 171 38R X WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 585: ...OTENTIOMETER MASS 2 0 75 3LS SIGNAL POTENTIOMETE R 1 3 4 0 75 3LW SIGNAL POTENTIOMETE R 2 5 0 75 3AQ SUPPL Y VALVEPOTENT IOMETER ENGINE WIRING X75 03 DIAGNOSIS PLUG Position Sectioning Destination 1 0 7 5 HK LINE KDIAGNOSIS SIGNA L 2 0 5 ML MASS WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 586: ...ONTROL2IDLEMOTION REG ULA TOR 3 0 75 3AY IDLE MOTION SWITCH M ASS SIGNAL 4 0 75 ML MASS FUELPUMPCONTROLRELAY Position Sectioning Destination 2 1 0 3NR INJECTOR FUELPUMP RELA Y 4 0 75 AP29 AFTER PROTECTED CONT ACT 6 0 75 3AC CONTROL FUELPUMPRELA Y 8 2 5 B BATTERY NO 2 X OR AP29 8 3 A C 3NR 4 6 B G R CS6P 236 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 587: ... AP29 AFTER PROTECTED CONT ACT 6 1 0 B BATTERY 8 0 75 ML MASS ENGINE WIRING X75 03 NO 2 N OR AP29 ML 3BR 4 6 B G R CS6P 238 8 INJECTIONWATERTEMPERATURESENSOR Destination 1 0 75 3C SIGNAL WATERTEMPERA TURE SENSOR 2 0 5 NF MASSWATER TEMPERA TURE SENSOR Sectioning Position WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 588: ...ination 1 0 75 3B SIGNAL AIRTEMPERA TURE SENSOR 2 1 0 3NR INJECTOR FUELPUMP RELA Y 3 1 0 3AM CONTROL INJECTOR 4 0 5 NF AIRTEMPERA TURE SENSOR M ASS CANISTERPURGINGVALVE Position Sectioning Destination 1 0 7 5 3BB CANISTERPURGINGV AL VECONTROL 2 0 7 5 B BATTERY WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 589: ...ENGINE WIRING X75 03 2 0 7 5 38R CONTROL A C COM PRESSOR CLUTCH 4 0 5 3BR AFTER CONT ACT MAIN RELAY 6 0 75 B BATTERY 8 0 75 38R CONTROL A C COMP RESS ORCLUTCH COMP UTER Position Sectioning Destination NO CS6P 584 2 X X 3BR 8 38R 38R 4 6 B G R WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 590: ...SE INPUT 2 1 0 3 PP OXYGEN ROD HEATING CONTROL F02 1 1 5 3NR INJECTOR F03 FUSE INPUT 2 1 5 3N FUEL PUM P F04 1 2 0 B BATTERY 2 2 0 BP5 4 BA TTER Y FOG HE ADLIGHTRELA Y ENGINE WIRING X75 03 NO 597 238 R AS 236 R A 3NR 1 2 3PP F01 R A 3NR 1 2 3N R G F02 231 R B 1 2 BP54 R F03 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 591: ...CONTROL 2 3CYLINDERS IGNITIO NCOIL B 2 AP29 AFTER PROTECTING CONT ACT D 1 5 3CV CONTROL 1 4 CYLINDE RSIGNITIONCOIL Position Sectioning Destination 1 1 0 3PP OXYGEN ROD HEATING CONTROL 2 1 0 ML MASS 3 0 5 3GK UPSTREAM OXYGE N RODSIGNAL 4 0 5 3GH UPSTREAMOXYGENROD MASS L WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 592: ... X75 03 ALTERNA TOR Position Sectioning Destination 1 7 0 B BATTER Y 103 HA B R BA R A 103 HB ALTERNATOR EXCITATION Position Destination 1 0 7 5 A CONTROL CHARGE WITNESS AFTER CONT ACT Sectioning WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 593: ... 0 S SUPPL Y ACCESSORIES A2 3 0 A SUPPLY AFTER CONT ACT A2 1 5 A SUPPLY AFTER CONT ACT B1 3 0 B BA TTERY B2 3 0 D CONTROL ST ARTER B A BA 2 1 X R M D B A S 104 G Position Sectioning Destination 1 0 7 5 67A CONTROL ACOUSTIC ALARM ACOUSTIC ALARM BA 105 X 67A WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 594: ...P PROTECTED SIGN ALISA TION LIGHT 2 0 75 64B CONTROL SIGNALISA TION 4 0 5 MB MASS Position Sectioning Destination BACKWARDSRUNNING CONTACTOR Position Sectioning Destination 1 0 5 AP43 AFTER PROTECTED CONT ACT 2 0 5 H66P CONTROL BACKW ARDS RUNNING LIGHTS BA G X H66P 155 AP43 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 595: ...Position Sectioning Destination 1 0 6 SP16 PROTECTED ACCESSORIES 2 1 0 65A CONTROL STOP LIGHTS STARTER Position Sectioning Destination 1 16 0 B BATTER Y Position Sectioning Destination 1 16 0 ML BATTER Y ELECTRIC M ASS 163BA B N 163AB ML N WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 596: ...tion 1 3 0 D CONTROL ST ARTER STAR TEREXCITATION BA 163 DB A D FRONT WIRING X75 03 RIGHTFRONTPOSITION LIGHT Position Sectioning Destination 1 0 3 5 LPG POSITIONLIG HTS PROTECTE D 2 0 35 MA MASS BA 184 X N MA LPG WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 597: ...ICAL DIAGRAMS 89 36 FRONT WIRING X75 03 BA X N MB 185 LPG LEFTFRONTPOSITIONLIGHT 1 0 35 LPG POSITION LIGHTSPROTECTED 2 0 35 ML MASS Position Sectioning Destination WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 598: ...205 28A X HORNANDLIGHTSSWITCH BA R C L X X X 209 A 11A 9M 67 A X X X 1 2 3 A B A1 1 4 R DRIVING LIGHTS A2 1 4 C HIGH BEAM S A3 1 0 LPG PROTECTEDPOSITIONLIGHTS B1 0 35 11A CONTROL DRIVING LIGHTS B2 0 6 9M SHUNT FOG LIGHTS SWITCH B3 1 0 67A CONTROL ACOUSTIC ALARM Position Sectioning Destination WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 599: ...1 0 64B CONTROL SIGNALISATION 4 1 0 64B CONTROL SIGNALISATION SHUNT BA X X 1 2 64C 64D X X 209B B A 3 4 64B Position Sectioning Destination LEFTFRONTBRAKEPLATE Destination 1 0 35 H1 CONTROL I C P BRAKING SY STEM WITNESS NO H1 X 217 RIGHTFRONTBRAKEPLATE Destination 1 0 35 H1 CONTROL I C P BRAKING SY STEM WITNESS NO H1 X 216 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 600: ...DSCREEN CLEANER PUMP 2 0 5 M MASS 2 0 5 M MASS BA 16A X M N N 221 FRONT WIRING X75 03 RIGHTHEADLI GHT Destination 1 1 4 MA MASS 2 1 0 CPD PROTECTED RIGHT HIGH BEAMS 3 1 0 RPD PROTECTED RIGHT DRIVING LIGHTS BA N 1 MA 2 X 3 RPD CD8F CPD X 226 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 601: ... LIGHTS BA N 1 MB 2 X 3 RPG CD8F CPG X 227 GMV COOLING CONTROLRELAY forA C providedvehicles NO 5 X 3 49B 1 4 2 49C MA R AS N CS6P BP2 7 R 234 Position Sectioning Destination 1 0 35 49C C ONTROL GMVCOOLINGRELA Y TERM OCONT ACT PRESOST AT 2 0 3 5 MA MASS 3 1 5 BP2 7 PROTECTED BA TTERY 5 1 0 49B CONTROL GMV COOLING WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 602: ...WITNESS 6 0 35 H1 CONTROL I C P BRAKING SYSTEM WITNESS BA 6 5 4 3 2 1 H1 LPG 85L 3FH 27A X X X X X X X X 247 FRONT WIRING X75 03 1 0 3 5 64F CONTROL BREAKDOWN WITNESS 2 0 35 11A CONTROL DRIVINGLIGHTS 4 0 35 M B MASS 4 0 35 M B MASS SH UNT 6 0 35 AP43 AFTER PROTECTED CONT ACT 6 0 35 AP43 AFTER PROTECTED CONTACT SHUNT 7 0 35 9C CONTROL REAR FOG L IGHTS WITN ESS 8 0 35 M B MASS SH UNT BA 8 7 6 5 4 3 ...

Page 603: ...TER PROTECTED CONT ACT 2 0 35 28A CONTROL OILPRESSURE WITNESS 3 0 35 M B MASS 4 0 35 64D CONTROL RIGHT SIGNALISA TION WITNESS 5 0 35 64C CONTROL LEFT SIGNALISA TIONWITNESS 6 0 6 41A SIGNAL FUELLEVELTRANSMITTER 7 0 35 2A CONTROL AL TERNA TOR CHARGE WITNESS 8 0 35 31A SIGNAL WATER TEMPERA TURE 8 0 35 47A ALARM FUEL MINIMALLEVEL WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 604: ...OOLINGRELA Y PRESSURE GAU GE 1 0 35 49C CONTROL GMVCOOLINGRELA Y PRESSURE GAU GE 2 0 35 38K A C STOPPING CONTROL 3 0 35 BP2 7 PROTECTED BATTERY NO 251 R AS 3 BP27 R R G 38K 1 49C GR G 2 RIGHTFRONTSIGNALISATION LIGHT Destination 1 0 6 64D RIGHT SIGNALISATION LIGHTS CONTROL 2 0 6 M MASS BA N 64D MA X 255 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 605: ...S CONTROL 2 0 75 MB MASS BA N 64C MB X 256 GMVCOOLING forA C providedvehicles Position Sectioning Destination A 1 0 49B CONTROL GMV COOLING B 1 5 M B MASS RIGHTFRONTSIDESIGNALISATION LIGHT Destination 1 0 35 64D RIGHT SIGNALISATION LIGHTS CONTROL 2 0 35 MB MASS BA N 64D MB X 267 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 606: ...A SIGNAL WATER TEMPERA TURE BA 42A 271 X G M VCLIMATECONTROLRELAY forA C providedvehicles 1 0 5 49F AIR CONDITIONIN GCONTROL PRESSUREGAUGE 1 0 5 49F AIR CONDITIONING CONTROL A C CONTROL PUSH BUTTON 2 0 5 MN MASS 2 0 5 MN MASS A C CONTROL PUSH BUTTON 3 2 5 BP1 1 PROTECTE DBATTER Y 5 1 0 38AH CONTROL G M V SPEED1 Position Sectioning Destination NO 5 X 3 38A H 1 4 2 49F MN N CS6P 335 V N V N BP11 R W...

Page 607: ...Position Sectioning Destination 1 0 5 49F AIR CONDITIONING CONT ROL GMV CONTROL RELA Y 2 0 5 49F AIRCONDITIONIN G CONT ROL GMVSTOPPING RELA Y 3 0 5 AP40 SUPPLY PROTECTED ACCESSORIES 4 0 5 49C CONTROL GMV COOLING RELAY FRONT WIRING X75 03 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 608: ...M V 2AIR CONDITIONING COCKPIT Position Sectioning Destination NO 5 X 3 38H Q 1 4 2 AP40 M N CS6P 474 R GR N R GR N BP11 R FRONT WIRING X75 03 BA 654 1 2 3 4 X X N R 80T 80X MB BP 11 ANTI STARTERRECEPTOR for anti starterprovided vehicles 1 1 5 80T CONTROL ANTI ST ARTER WITNESS 2 1 5 80X ANTI ST ARTER SIGNAL W AY 3 1 5 MB MASS 4 1 5 B P11 PROTECTE D BA TTER Y Position Sectioning Destination WIRE FUN...

Page 609: ... NO 5 3 1 4 2 38K 49F MA R G X N CS6P 720 49F X Position Sectioning Destination 1 0 35 38K A C STOPPING CONTROL THERMO CONT ACT 2 0 35 MA MASS 3 0 35 49F AIRCONDITION INGCONTROL PRESSURE GAUGE 4 0 35 49F AIR CONDITIONING CONTROL U C E IN JECTION WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 610: ... 0 BP1 1 PROTECTE DBATTER Y F04 1 4 BP1 1 PROTECTED BA TTER Y ANTIST ARTING F05 1 0 64A SUPPL Y SIGNALISA TION F05 1 0 64B CONTROL SIGNALISA TION F06 1 0 L POSITION LIGHTS F06 1 0 LPG PROTECTEDLEFTPOSITIONLIGHTS F07 1 4 R ROAD L IGHTS F07 1 0 RP G PROTECTEDLEFTROADLIGHTS F08 1 0 RPD PROTECTEDRIGHTROADLIGHTS F09 1 4 C HIGH BEAMS F09 1 0 CP G PROTECTED L EFT HIG H BEAMS F10 1 0 CPD PROTECTED RIGHT H...

Page 611: ...AMS 89 50 FRONT WIRING X75 03 BA L G SP22 LPG S F02 1016 CPD X F10 A F01 G AP43 G G X R X X RPD RPG F07 F08 X X F06 64A X 64B F05 X C X CPG F09 M SP16 F03 B R BP11 R R F04 X WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 612: ...KI NG SYSTE M WI TNESS BA H1 X 1091 FRONT RIGHT BODY ELECTRIC MASS Position Sect ioning Destination 1 3 0 MA MASS RIGHT L IGHT RIGHT FRONT POSITION LIGHT RIGHTFRONTSIGNAL ISA TIONLIGHT GMVCOOLINGCONTROL RELA Y A C ST OPPING RELA Y COMPR ESSEURCLUT CHDIODE MA MA N WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 613: ...IGHT L EFTFRONT SIGNAL ISA TIONLIGHT WINDSCREEN CLEA NER PUMP BACKWINDSCREEN CLEANE RPUMP 1 3 0 MB MASS ECU INJECTION SEGNALISA TIONRELA Y LEFT RIGHT FRONTSIDE SIGNA LISA TION L IGHT BOARDPANEL LIGHTING GLOVEBOX CLOCK ELECTRICLIGHTER ASHTRA Y HEATINGCONTROL SWITCHES 1 1 0 MB MASS GM VCOOLING AND CA MB MB N N N WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 614: ... BATTERY TERMINAL Position Sectioning Destination 1 16 0 B BA TTERY STAR TER 2 6 0 B BATTER Y BATTERY TERMINAL NO 107AA B AS N NO 107AB ML N Position Sectioning Destination 1 16 0 ML BATTERY EL ECTRICMASS WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 615: ... DBATTER Y PositionSectioning Destination BA M 101 N N L BP11 AS X BOARD PANEL WIRING X75 03 FOGHEADLIGHTSSWITCH 1 0 6 9M SHUNT 2 0 6 9D CONTROL REARFOGLIGHTS RELAY 4 0 35 LPG PROTECTED POSITIONLIGHTS 5 0 35 M B MASS Position Sectioning Destination BA 1 2 9M 9D 121 4 5 3 LPG MB X N X X N WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 616: ...LIGHTS 1 0 3 5 LPG POSITION LIGHTS SHUNT 2 0 3 5 8L CONTROL REARFOG LIGHTSRELA Y 4 0 35 LPG POSITION LIGHTS 5 0 35 M B MASS Position Sectioning Destination BA 1 2 LPG 8L 121 4 5 3 LPG MB X N X X N BOARD PANEL WIRING X75 03 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 617: ...NALISA TIONLIGHTSCONTROL 4 0 35 64F CONTROL BREAKDOWN WITNESS 5 0 35 LPG PROTECTEDPOSITIONLIGHTS 6 0 35 MB MASS 7 1 0 64A SUPPL Y SIGNALISA TION 8 1 0 A AFTER CONT ACT 9 1 0 B BA TTER Y 9 0 35 B BA TTERY CLOCK Position Sectioning Destination BA 7 9 64A B 6 8 MB A GR R R N M 3 1 64D 64B X X 4 5 2 64F LPG 64C X X X 125 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 618: ...Section Destination 1 0 35 MB MASS 2 0 35 LPG PROTECTEDPOSITIONLIGHTS ELECTRONIC CLOCK BA 6 5 4 3 2 1 N R G X 210 Position Section Destination 1 0 35 LPG PROTECTED POSITIONLIGHTS 2 0 35 AP40 AFTER PROTECTED CONT ACT 3 0 35 B BATTER Y 4 0 35 MB MASS 5 6 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 619: ...DPOSITIONLIGHTS 4 0 5 9B CONTROL REAR FOG LIGHTS 5 0 5 BP1 1 PROTECTE DBATTER Y Position Sectioning Destination NO 5 R 3 BP11 1 4 2 9D 9B MB OR X N CS6P 230 LPG X CLIMATECONTROLLIGHTING Position Sectioning Destination 1 0 35 LPG PROTECTED POSITIO N LIG HTS 2 0 35 MB MASS BA MB 298 N X LPG WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 620: ...L DIAGRAMS 89 59 BOARD PANEL WIRING X75 03 FRONTASHTRA YLIGHTING BA MB 1335 N X LPG Position Sectioning Destination 1 0 3 5 MB MASS 2 0 35 LPG PROTECTED POSITIONLIGHTS WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 621: ...GHT WIRING X75 03 BA BCP3 329 13A N R FRONTRIGHTCEILINGLIGHT Destination 1 0 6 BCP3 PROTECT EDBA TTERYCEILING LIGHTING LEFT COUPLI NGPLA TE 2 0 6 13A CONTROL CEILING LIGHTING LEFTDOORCONT ACTOR WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 622: ...EFTFOGHEADLIGHT BA MB N 8B X 176 BA MB N 8B X 177 Position Sectioning Destination 1 1 0 8B FOGHEADLIGH TS FOGHEADLIGHT SRELA Y 2 1 0 MB MASS Position Sectioning Destination 1 1 0 8B FOGHEADLIGH TS FOGHEADLIGHT SRELA Y 2 1 0 MB MASS WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 623: ...IGHTSCONTROLRELAY 1 0 6 MB MASS 2 0 6 8L CONTROL FOGHEADLI GHTSRELA Y 3 1 0 8B FOGHEADLIGH TS LEFTFOGHEADLIGH T 3 1 0 8B FOGHEADLI GHTS RELA Y 5 2 0 B P54 PROTECTE DBATTER Y Position Sectioning Destination FOG HEADLIGHTS WIRING X75 03 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 624: ...B 14C 5 BP11 X N X X 1 113 16A A BA 1 2 3 4 5 14B BP11 14A 14D 16A X A X X X X 145 WINDSCREEN WIPER CLEANER SWITCH Position Sectioning Destination 1 0 6 14B CONTROL WINDSCREEN WIPERHIGH SPEE D 2 0 75 BP1 1 PROTECTED BATTER Y 3 0 6 14A CONTROL WINDSCR EEN WIPER LOW SPEED 4 0 6 14D CONTROL WINDSCR EEN WIPER TIM ER LOW SPEED 5 0 6 16A CONTROL WINDSCREEN CLEANE R PUMP TIMER 5 0 5 16A CONTROL WINDSCREE...

Page 625: ...ation 1 0 6 14A CONTROL WINDSCREEN WIPER LOW SPEED 2 0 6 14C CONTROL WINDSCREEN WIPERTIMER 3 0 6 14B CONTROL WINDSCREEN WIPERHIGH SPEED 4 0 75 BP1 1 PROTECTEDBATTERY 4 0 5 BP1 1 PROTECTED BATTERY WINDSCREEN WIPER TIMER BA X X X 3 4 1 2 14A 14C 14B BP11 212 A A WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 626: ...D POSITION LI GHTS LEFTREGISTRA TION NUMBERLIGHT for U75 M75 H75 Position Sectioning Destination 1 0 3 5 LPG PROTECTEDPOSITIONLIGHTS RIGHREGISTRA TION NUMBERLIGHT for U75 M75 H75 PositionSectioning Destination 1 0 3 5 27A CONTROL HA NDBRAKE WITNESS HANDBRAKECONTACTOR X NO 27A 156 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 627: ...NG LIGH TS 2 0 3 5 LPG PROTECTEDPOSITIONLIGHTS LEFTREGISTRA TIONNUMBERLIGHT forE75 Position Sectioning Destination 1 0 6 H66P CONTROL BACKW ARDS RUNNING LIGH TS 2 0 3 5 LPG PROTECTEDPOSITIONLIGHTS RIGHREGISTRATIONNUMBERLIGHT forE75 BA X 9B LPG X 167 BA 166 X H66P LPG X WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 628: ...HTS B3 0 6 9 C CONTROL REAR PROTE CTEDFOG L IGHTS BA B A X X X 3 2 1 9P H66P 64C 172 65A MG LPG X N X REAR RIGHTLIGHT for U75 M75 H75 Position Sectioning Destination A1 0 35 LPG PROTECTEDPOSITIONLIGHTS A2 1 0 MF MASS A3 0 6 65A CONTROL STO PLIGHTS B1 0 6 64D RIGHTSIGNAL ISA TIONLIGHTS CONTROL B2 0 6 H66P CONTROL BACKW ARDS RUNNING LIG HTS B3 0 6 9 C CONTROL REAR PROCTE D FOGLIGHTS BA B A X X X 3 2...

Page 629: ...ARRIGHTLIGHT forE75 Position Sectioning Destination BA X LPG MF N X 64D X 65A 172 1 0 35 LPG PROTECTEDPOSITIONLIGHTS 2 0 6 65A CONTROL STO PLIGHTS 3 0 6 64D RIGHTSIGNAL ISA TIONLIGHTS CONTROL 4 1 0 MF MASS WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 630: ...TIONLIGHTS 2 0 6 65A CONTROL STO PLIGHTS 3 0 6 64C LEFTSIGNAL ISA TIONLIGHTSCONTROL 4 1 0 MF MASS ELECTRIC PUMPANDFUELLEVELTRANSMITTER Position Sectioning Destination 1 0 5 47A FUEL MINIMALLEVELALARM 2 1 5 3N FUEL PUM P 3 0 5 41A SIGNAL FUELLEVELTRANSMITTER 4 1 5 MG MASS BA X N X R G 3 4 1 2 47A 3N 41A MG 199 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 631: ...5 AP40 SUPPL Y PROTECTED ACCESSORIES SHUNT 3 0 5 85L 4X4 WITNESS CONTROL 4 5 0 75 AP40 SUPPL Y PROTECTED ACCESSORIES 5 0 5 AP40 SUPPL Y PROTECTED ACCESSORIES SHUNT Position Sectioning Destination VACUUMCAPSULECONTACT A1 1 0 MB MASS B2 0 75 85G 4X4COUPLINGRELA YCONTROL Position Sectioning Destination BA N 85G A 1187 B A 2 1 MB WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 632: ...TCH 1 0 75 A3 SUPPL Y PROTECTED ACCESSORIES 2 0 75 MB MASS Position Sectioning Destination BA 2 1 MB A3 N R 484 BA N AP40 M R AP40 478 R A 1 0 75 AP40 SUPPL Y PROTECTED ACCESSORIES 2 0 75 A3 PROTECTED ACCESSORIES 4 0 35 LPG POSITION LIGHTS 5 0 35 MB MASS WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 633: ...ectioning Destination 1 0 35 AP40 SUPPL Y PROTECTED ACCESSORIES 2 0 35 47F VEHICL ESPEEDSIGNAL ISA TION 3 0 35 MN MASS SAFETYBELTWITNESS forDAIF Position Sectioning Destination 4 0 6 AP40 SUPPL Y PROTECTEDACCESORIES 5 0 6 96A CONTROL SAFETY BEL TWITNESS BA 1 2 247 4 5 3 AP40 96A R X WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 634: ...40 SUPPL Y PROTECTED ACCESSORIES 2 0 35 MN MASS 4 0 35 47F VEHICL ESPEEDSIGNAL ISA TION 5 0 35 97A CONTROL SPEED WITNESS 120KM H Position Sectioning Destination SAFETYBELTWITNESS forDAIF Position Sectioning Destination 4 0 6 96A CONTROL SAFETY BEL TWITNESS 5 0 5 MN MASS BA 1 2 333 4 5 3 96A MN R X WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 635: ... 0 75 49F AIRCONDITIONIN GCONTROL PRESSUREGAUGE B 0 5 AP40 SUPPL Y PROTE CTEDACCESSORIES COUPLINGS X75 03 ADDITIONALBOARDPANELWIRES COUPLING Position Sectioning Destination A 0 5 49F AIR CONDITIONING CONTROL G M V RELA Y B 0 5 AP40 SUPPL Y PROTE CTEDACCESSORIES ADDITIONALFRONTWIRES COUPLING WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 636: ...75 03 Position Sectioning Destination 1 7 0 B BATTER Y FRONTWIRES COUPLING BATTERY R BA B R25 Position Sectioning Destination 1 7 0 B BATTER Y BATTERYWIRESCOUPLING R BA B R25 FRONTWIRES COUPLING WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 637: ...FRONTWIRES COUPLING Position Sectioning Destination 1 0 75 49F AIR CONDITION ING CONT ROL G M V RELA Y 2 0 35 49F AIR CONDITIONING CONTROL C A RELA Y DIAVIAADDITIONALFRONTWIRES COUPLING Position Sectioning Destination 1 0 5 49F AIR CONDITIONING CONTROL 2 0 5 49F AIR CONDITIONING CONTROL WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 638: ...ONTROL CONTROL PUSH BUTTON 4 0 5 AP40 SUPPL Y PROTECTE DACCESSORIES ADDITIONALBOARDPANELWIRES COUPLING A C CONTROL forA C providedvehicles ADDITIONALBOARDPANELWIRES COUPLING Position Sectioning Destination 1 0 5 MN MASS 2 0 5 LPG PROTECTED POSITIONLIGHTS 3 0 5 49F AIR CONDITIONING CONTROL RELA Y 4 0 5 AP40 SUPPL Y PROTE CTEDACCESSORIES BA 1 2 3 4 R82 MN LPG 49F AP40 N X V R GR WIRE FUNCTIOSIN CONN...

Page 639: ...D 3 BA X X N X 4 3 R93 2 1 MN 38AH 38AK 38AJ COUPLINGS X75 01 ADDITIONALBOARD PANELWIRES COUPLING GMV2 COCKPIT forA C providedvehicles ADDITIONALBOARDPANELWIRES COUPLING Position Sectioning Destination 1 1 0 38AH CONTROL G M V MOTOR SPEED 1 2 2 5 MN MASS 3 1 5 38AJ CONTROL G M V MOTOR SPEED 2 4 2 5 38AK CONTROL G M V MOTOR SPEED 3 BA X X X N 3 4 38AJ 38AK R93 1 2 38AH MN WIRE FUNCTIOSIN CONNECTORS...

Page 640: ...ONTROL GMV CLIMA TECONTROLSPEED4 5 1 0 38AJ CONTROL GMV CLIMA TECONTROLSPEED 2 6 1 5 SP3 PROTECTED ACCESSORIES CLIM ATE CONTROL Position Sectioning Destination 2 1 0 38AK CONTROL GM VCLIMA TE CONT ROLSPEED 3 3 0 6 38AH CONTROL GMV CLIMA TECONTROLSPEED1 4 1 5 38AL CONTROL GMV CLIMA TECONTROLSPEED4 5 1 0 38AJ CONTROL GMV CLIMA TECONTROLSPEED2 6 1 5 SP3 PROTECTED ACCESSORIES CLIM ATE CONTROL Position...

Page 641: ... BA 16A R106 Position Sectioning Destination 1 0 6 16A CONT ROL WINDSCREEN CLEANER PUMP Position Sectioning Destination 1 0 6 16A CONTROL WINDSCR EENCLEANE RPUMP FRONTWIRES COUPLING WINDSCREENWIPER FRONTWIRES COUPLING X BA 16A R106 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 642: ... B A R107 A1 3 0 MB MASS A2 2 0 AP40 AFTER PROTECTED CONT ACT A3 0 6 LPG PROTECTEDPOSITIONLIGHTS B1 2 0 8A AFTER PROTECTED CONT ACT B2 0 6 9B CONTROL PROTECTE D REAR FOGLIGHTS B2 0 35 9B CONTROL PROTECTED REAR FOG LIGHTS WITNESS B3 0 6 9M SHUNT LIGHT S CONTROL SYSTEM B4 1 0 BP1 1 PROTECTED BA TTER Y Position Sectioning Destination WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 643: ... 0 AP40 AFTERPROTECTEDCONTACT WINDSCRE ENWIPERCONTROL A3 1 0 L PROTECTEDPOSITIONLIGHTS A3 1 0 L PROTECTEDPOSITIONLIGHTS FOGLIGHTSRELA Y B1 2 0 AP43 AFTER PROTECTED CONT ACT B2 0 6 9B CONTROL PROTECTEDREAR FOG L IGHTS B3 0 6 9M SHUNT FOG LIGHTS SWITCH B4 1 4 BP1 1 PROTECTED BA TTER Y ELECTRICLIGHTER B4 0 6 BP1 1 PROTECTED BA TTER Y FOG LIG HTS RELA Y Position Sectioning Destination G G WIRE FUNCTIO...

Page 644: ...ES G M V CLIM A TE CONT ROL G M V CLIMATECONTROLWIRES COUPLING BA R111 D 3 BOARD PANELWIRES COUPLING G M V CLIMATECONTROL G BA AP43 R111 D 3 BOARDPANELWIRES COUPLING Position Sectioning Destination 1 2 0 AP40 PROTECTED ACCESSORIES G M V CLIM A TE CONT ROL G AP43 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 645: ... BP11 PROTECTEDBATTER Y B2 1 5 A SUPPLY AFTER CONT ACT B4 1 5 3N FUELPUMP B5 1 5 A SUPPLY AFTER CONT ACT BA PositionSectioning Destination A1 1 5 MB MASS A2 1 5 MB MASS A4 1 5 3N FUELPUMP U C E DECODER A5 1 5 AP29 AFTER PROTECTED CONT ACT B1 1 5 BP1 1 PROTECTED BA TTER Y B2 1 5 A SUPPLY AFTER CONT ACT B4 1 5 3N FUEL PUMP U C E DECODER INPUT B5 1 5 A SUPPLY AFTER CONT ACT FRONTWIRES COUPLING U C E ...

Page 646: ...OUPLING FOG LIGHTS FRONTWIRES COUPLING Position Sectioning Destination 1 0 6 8L CONTROL POSITIONLIGHTS FOGLIGHTS WIRES COUPLING Position Sectioning Destination 1 0 6 8L POSITION LIGHTS BA R122 8L O R BA 8L R122 X WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 647: ... AIR CONDITIONING CONTROL A C RELAY 3 1 0 38R CONTROL A C COM PRESSOR CLUTCH 4 0 6 MB MASS 7 0 35 3FH CONTROL INJECTION DAMAGEWITNESS 9 1 4 3N FUELPUMP U C E DECODER 9 1 4 3N FUEL PUMP 10 1 4 AP29 AFTER PROTECTED CONT ACT 10 1 4 AP29 AFTER PROTECTED CONT ACT Position Sectioning Destination FRONTWIRES COUPLING WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 648: ... E INJECTION 3 1 0 38R CONTROL A C COM PRESSOR CLUTCH 4 0 6 MB MASS 7 0 35 3FH CONTROL INJECTION DAMAGEWITNESS 9 1 4 3N FUEL PUMP 10 1 4 AP29 AFTER PROTECTED CONT ACT Position Sectioning Destination 49F AP29 38R M B 3N 3FH X V X N G X BA R 212 1 8 2 3 4 7 6 10 9 5 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 649: ...EDPOSITIONLIGHTS A2 1 4 3N FUEL PUM P ANTIST ARTING A2 1 4 3N FUEL PUM P A4 0 6 H66P CONTROL BACKW ARDRUNNINGLIGHTS A5 0 6 9B CONTROL PROTECTE DREARFOGLIGHTS B1 0 6 64C LEFTSIGNALISA TIONLIGHTSCONTROL B2 0 35 47A ALARMFOR FUELMINIMAL L EVEL B3 0 35 H1 CONTROL H ANDBRAKE WITNE SS B4 0 6 41A SIGNAL FUELLEVELTRANSMITTER B5 0 6 64D LEFTSIGNALISA TIONLIGHTSCONTROL X X WIRE FUNCTIOSIN CONNECTORS ANDCOUP...

Page 650: ...G PROTECTEDPOSITIONLIGHTS A2 1 4 3N FUEL PUM P A4 0 6 H66P CONTROL BACKW ARDRUNNINGLIGHTS A5 0 6 9B CONTROL PROTECTE DREARFOGLIGHTS B1 0 6 64C LEFTSIGNALISA TIONLIGHTSCONTROL B2 0 35 47A ALARMFOR FUELMINIMAL L EVEL B3 0 6 H1 CONTROL H ANDBRAKE WITNE SS B4 0 6 41A SIGNAL FUELLEVELTRANSMITTER B5 0 6 64D LEFTSIGNALISA TIONLIGHTSCONTROL WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 651: ...ioning Destination A1 1 0 64D RIGHTSIGNALISA TIONLIGHTSCONTROL A2 1 0 64B CONTROL SIGNALISA TION A3 1 6 B BATTE RY A4 0 6 8L CONTROL FOG LIGHTS RELAY B1 0 35 64F CONTROL BREAKDOWN WITNESS B2 1 0 64A SUPPL Y SIGNALISA TION B3 1 0 A SUPPLY AFTER CONTACT B4 1 0 64C RIGHTSIGNALISA TIONLIGHTSCONTROL COUPLINGS X75 03 WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 652: ...Sectioning Destination A1 1 0 64D RIGHTSIGNALISA TIONLIGHTSCONTROL A2 1 0 64B CONTROL SIGNALISA TION A3 1 0 B BATTE RY A4 0 35 8L CONTROL FOG LIGHTS RELAY B1 0 35 64F CONTROL BREAKDOWN WITNESS B2 1 0 64A SUPPL Y SIGNALISA TION B3 1 0 A SUPPLY AFTER CONTACT B4 1 0 64C RIGHTSIGNALISA TIONLIGHTSCONTROL WIRE FUNCTIOSIN CONNECTORS ANDCOUPLINGS vnx su ...

Page 653: ...RIGHT REAR ELECTRI CMASS MG LEFT REAR ELECTRI C MASS ML BATTER Y ELECTRI C MASS MN LEFTWINDSCR EEN C ROSSELECTRIC MASS MU HANDB RAKEMASS NF MASS AI R W ATER TEMPERA TURE SENSORS POTENTI OMETER R RUNNINGSLIGHTS RPD RIGHT PROTECTED RUNNI NG LIGHTS RPG LEFT PROTECTED RUNNI NG LIGHTS S ACCESSORIES SP16 PROTECTED ACCESS ORIES SP22 SUPPLY P ROTECTED ACCESSORIES SP3 PROTECTED ACCESSORIES GM V CLIMATE CON...

Page 654: ...ESS 31A CONTROL WATER TEMPERA TURE WITNESS 38AH CONTROL GMV C LIMATE CONTROL SPEED 1 38AJ CONTROL GMV C LIMATE CONTROL SPEED 2 38AK CONTROL GMV C LIMATE CONTROL SPEED 3 38AL CONTROL GMV C LIMATE CONTROL SPEED 4 38HQ CONTROL FOR GMV 2 AI RCONDITIONING COCKP IT 38K A C STOPPI NG CONTROL THE RMO CONTACT 38R CONTRPL A C COMPRESSORCLUTCH 41A SIGNAL F UEL LEVEL TRANSMI TTER 42A SIGNAL W ATER TEMPERA TUR...

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