2004 DACIA SOLENZA Repair Manual

THE M ECHANICAL ELEMENTS CONTROLS
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MASTER VAC 7 " SERVO MECHANISM
The ” Master-Vac 7" ser vobrake is a brake booster destined to reduce the driver’s effort on
the brake pe dal.
AT T E N T I O N !
The servobrake cannot be repaired.
The only items of the servobrake which are to be replaced are the air filter and the retainer
valve.
DISMOUNTIN G
Disconnect the battery.
Drain the brake fluid reservoir.
Servobra ke
OBSERVATION :
In case one circuit is damaged, the pedal stroke shall be longer, the braking being
done only by the circuit still working.
TIGHTENING MOMENTS (daNm)
Brake pump attachment nut on servobrake 1.7
S ervobrake attachment nut on cowl panel 1.7
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REMOU NT I NG
Before remounting, check: and if necessary,
perform the following adjustmen ts:
Detach the connection screws of the rigid
brake ducts from the main brake pump.
Disconnect the electrical contact from ICP
transducer. Dism ount t he m ain pum p fr om t he
ser vobrake.
Disconnec t the suction hose off t he
ser vobrake.
Servobra ke
Dismou nt :
- the connecting shaft ( 1) between the
coupling fork and the pedal ; -the attachment nuts of the servobrake
on cowl panel. Dismount the servobrake .
1.The adjustment of the exit rod (P1) ( brake
pump side) which is obtained by acting on the
nut which is one with the pushing rod, in order to
obtain value X = 9
-0.2 mm.
This value is measured between the pushing rod
end and the rest surface of the main cylinder on
ser vobrake.
2.The adjustment of the pushing rod (P2)
( brake pedal side) in order t o obtain the value
L = 107.7
-0.5
mm , which is obtained as follows:
- unscrew the lock nut E and by;
- act on t he c oupl i ng fork ( C) unt i l
obtaining the value L = 107.7
-0.5 mm;
- lock the lock nut ( E).
The L va lue, is to be measured between the
ax le of t he coup l i ng fork whol e a nd t he
ser vobrake rest surface on cowl panel.
For remounting, perform the dismounting
operations in the reverse order. Dismount the ICP transducer from the brake
pump. Purge the brake circuit.
Mount the I.C.P. transducer
M ount th e electri c con nector t he I.C. P.
transducer.
1 P 2
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ATTENTION !
The tightness of the servobrake is checked on t he vehicle, with t he hydraulic cir-
cuit under operation Connect the vacuum meter between the servobrake and the inlet manifold by means of a “
T ” type connector. The connecting hose of the vacuum meter shall be as long as possible.
Start the engine and let it idle run for 1min.
Block the air suction hose by means of the MOT 453 device.
Stop the engine.
If air suction lowers with more than 33 mbar (25 mm Hg) in a 15 seconds period, it means
there is a loss at t he retainer valve (replace the valve) or at the servobrake membrane (replace
the servobrake). Dismount the MOT 453 device.
Dismount the vacuum hose.
Reinstate the connection between the servobrake and the inlet manifold by means of
the vacuum hose. TIGHTNESS CHECKING
Servobra ke
SPECIAL TOOLS
MOT 453 Obturator
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THE M ECHANICAL ELEMENTS CONTROLS
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DISK FILTER REPLACEMENT
DISMOUNTIN
G
Dismount the servobrake off the vehicle.
Loosen the lock nut ( E) and dismount :
- the coupling fork
- the lock nut.
Remove the disk filter ( F).
REMOU NT I NG
Mount :
-the new disk filter
- the lock nut;
- the coupling fork.
A djust the value L = 107.7
-0.5 mm.
Tighten the lock nut E on the coupling fork.
Mount the servobrake on the vehicle.
Purge the braking circuit.
RETAINER VALVE REPLACEMENT
The ope ra t ion i s pe rform e d without
dismountin g the servobrake off the vehicle.
DISMOUNTIN G
Disconnect the connection of the air suc-
tion hose with the servobrake retainer valve. Dismount the valve by rotating a nd then
pulling it. Dismount the retainer valve gasket.
REMOU NT I NG
Check the state of the retainer valve gasket
and replace it if necessary. Mount the new retainer valve gasket.
Attach and mount the new retainer valve.
Connect the air suction hose.
Air filter – servobrake retainer valve
A
F
E
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THE M ECHANICAL ELEMENTS CONTROLS
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Handbrake - adjustment
The adjustment of the handbrake shall be performed with the vehicle lift on a two-column
elevator. Note :
The adjustment i s obligatory performed anytime t he brake shoes or secondary cables
have been replaced.
Release the control lever of the hand brake (release position)
Tighten the nut ( 1) until the shoes lining come lightly into contact with the brake drum.
The adjustment shall be performed so that is insuring a hand brake lever stroke of min.12
teeth until the blocking of the wheels. Lower the vehicle from the elevator.
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Handbrake control lever
TIGHTENING MOMENTS (daNm)
Attachment screws of the handbrake lever on c entral floor 1.2
DISMOUNTIN G
Disconnect the battery.
Release the hand brake control lever ( released position).
Lift the vehicle by means of a two columns elevator;
Detach the rudder bar fork ( 5) from the end rod (3) by unscrewing the lock nut (1) and
remove the ball-ended washer ( 2).
Remove the secondary cables ends from rudder bar seats.
D etach from clips the rod ( 3) from rudder bar (4)
Lower the vehicle from the elevator and inside the vehicle dismount: - seat;
- carpet attachment clips in the rear side area
- inner attachment of the left/right middle pillars coverings.
M ove the front seats backwards and dismount the a ttachment screw (6) of the handbrake
control on the central floor.
3 4521
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THE M ECHANICAL ELEMENTS CONTROLS
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Move the seats a head and dismount:
- safety belts lower attachment screws;
- attachment screws of the front safety
belts locks and remove them.
Clear the cockpit carpet towards front seats.
Dismount the handbrake control attachment
screw ( 7) on the central floor.
Remove the upper casing of the handbrake
(8).
Han dbrake control lever
Disconnect handbrake contact (9).
Take off the assembly handbrake.
RE MOUNTIN G
Grease the shaft s with UM 185 Li 2M
grease.
Perform the dismounting operations in the
reverse order, taking care to apply a sealant
material layer on the outline of lower casing of
the handbrake lever assembly .
Readjust the handbrake.
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THE M ECHANICAL ELEMENTS CONTROLS
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Handbrake secondary cables
SECONDARY CABLE - REPLACEMENT
DISMOUNTING
Disconnect the battery.
Loosen the rear wheels attachment screws.
Release the ha nd brake control l ever (re-
lease position).
Lift the vehicle by means of a two-column
elevator.
Detach the rudder ba r fork from the end
rod by unscrewing the lock nut (M12 x 1.25)
and remove the ball-ended washer.
Remove the secondary cables ends from
rudder bar seats.
Dismount the two rear wheels.
Dismount the brake drums ( see chapter 33
– Rear axles e leme nts ). Remove the secondary cables stops from
the central floor. Dismount the sheathe stops from the brake
plates. Remove the secondary cables.
REMOU NT I NG
Grease the cable with UM 185 Li 2M
grease
Perform the dismounting operations in the
reverse order.
Adjust the drum clearance ( see chapter 33-
Rear axles elements ”).
Adjust the handbrake control lever stroke.
SPECIAL TOOLS
Ro 441 Wheel drum cover tongs
Fr.600 Hub extractor
TIGHTENING MOMENTS (d aNm)
Wheel attachment screw 7.5
Steering knuckle nut 16.5
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