2004 DACIA SUPERNOVA Repair Manual

31
FRONT BEARING ELEMENTS
31 - 6
BRAKE GASKETS
NOTE
In order to maintain the brake efficiency,
the replacement of the brake pads shall be
made only in complete kit.
Never fit brake pads of diffe rent makes
and different qualities .
DISMOUNTING
Lift t he vehicle by means of a two columns
elevator;
Dismount the front wheel;
Disconnect the wear sensor wire;
Dismou nt : - the safety of the wedges (1);
- the wedges, by sliding them.
Detach the caliper assembly from the fork
together with the flexible hose;
Remove : - the elastic blades - the brake pads
Remount :- the brake pads their places in the fork;
- the elastic blades;
- the caliper;
- the wedges and their locks.
Reconnect the wear sensor wire.
Pr ess several times the brake pedal.
Mount the wheels.
Get down the vehicle from the elevator the
ground. NOTE
It
is forbidden to push the brake pedal
after the calipers were dismounted from
the fork. If the brake pads are not fully used but
on their friction surface, especially i n the
middle pad c hannel, there are material
traces, i t i s recommended t he cleaning of
these surfaces in order to avoid the noise
when braking.
REMOUNTING
Push the c aliper pi ston by means of the
FR 500 s pecial t ool.
SPECIAL TOOLS
FR 500 Pushing piston device
FR 500
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FRONT BEARING ELEMENTS
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BRAKE CALIPER
DISMOUNTING
Lift the vehicle by means of a two columns
elevator.
Dismount the wheel.
Disconnect the wear sensor wire
Drain the brake fluid from the reservoir
Remove the locks and the caliper wedges;
Unscrew the rigid duct screw from the brake
flexible hose and detach the caliper assemb ly.
NOTE
If it is necessary to dismount the
caliper fork, unscrew the two attachment
s crews M 12.
When remounting the fork, replace the
Grower washers, tighten the screws at the
r equired moment of 6.5 daNm then seal
them with FIXAMED R 58. REPAIR
ING
Dismount the protection gasket.
Extract the piston using a wooden wedge and
a compressed air source. Remove the sealing gasket from its seat in the
caliper groove by means of a steel blade. Clean with alcohol the parts, replace t he
damaged ones, mounting being performed in the
dismounting reverse order, after previously all
parts have been oiled with brake fluid.
NOTE
Before remounting to t he wheel, c heck
the sealing of the caliper assembly.
TIGHTENING MOMENTS (daNm)
Wheel nuts 7,5
Rigid duct on front flexible screw 1,5
Purging screw 1
Flexible hose - caliper 2
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FRONT BEARING ELEMENTS
31 - 8
BRAKE CALIPER
REMOUNTING
Perform the dismounting operations in the reverse order plus the following operations : - fill the caliper with brake fluid in order to facilitate the brake system purging;
- purging the brake system.
BRAKE CALIPER SEALING CHECKING
Connect to the caliper, a pressure gauge attached to a compressed air source.
P lace a wooden wedge in order to block the piston.
Create a 0,3 bars pressure in the caliper.
Dip the caliper into a vessel with alcohol.
Move the piston several times to remove the air from the sealing gasket seat.
Check the sealing of the brake caliper at various pressu res, without exceeding the pressure of 2 bars.
If the brake shows air leaks by the piston, perform at its dismounting.
Replace the piston, the ga sket, or the caliper body, as the c ase stands.
Perform again the sealing test.
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FRONT BEARING ELEMENTS
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DISMOUNTING
Lift the vehicle by means of a two col-
umns elevator.
Dismou nt :
- the wheel;
- the two attachment screws M 12 ( B)
of the brake disk assemb ly on the steering knuckle;
- the brake pads;
- the t wo sunk screws attaching t he
disk on the hub. BRAKE DISK
The brake disks can be not rectified.
A bigger wear or an important mark on the brake disk braking surfaces impose obligatory its
replacement.
- The minimal accepted thickness : 19 mm
- The maximum accepted axial deviation 0,1 mm on a diameter of F 215.
TIGHTENI NG MOMENTS (daNm)
steering nuckle 6,5
Disk attachment screw on the hub 2,5
Front wheel steering knuckle nut 21
Wheel screws 7,5
Before remounting, check:
- the wear of the flexible hose;
- the wear of the bra ke pa ds and
replace them if necessary. REMOUNTING
Remount :
- the disk on the hub by means of the two
sunk screws M8 and tighten them to the required
moment; - the brake disk assembly on the steering
knuckle, tightening the M 12 screws at t he
required moment. Press the brake pedal several times, in order
to bring the piston in contact with the brake pads.
NOTE :
In case of replacing the brake disk it is ab-
s olutely necessary to replace the brake pads.
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FRONT BEARING ELEMENTS
31 - 10
SPECIAL TOOLS
Hub disk extractor PF600
Ball joint extractor PF476
DISMOUNTING
Disconnect the battery.
Lift the vehicle by means of an elevator with
two column. Dismou nt :
- the wheel
- the brake disk assembly together with
the flexible connection;.
- the transmission gear nut.
- the brake disk a ssembly by means by
means of the PF 600 extractor.
Continue by dismounting t he steering
knuckle, observing the operations sequence: - dismount the steering ball joint nut;
- depre ss the steeri ng ball joint by
means of the PF 476 extractor;
- dismount the t wo screws that attach
the steering knuckle on the shock absorber; - dismount the attachment screws that
attach the steering ball joint – steering knuckle;
- detach the steering knuckle.
TIGHTENING MOMENTS (daNm)
Wheel attachment screw 7,5
Steering ball joint nut 3,5
Transmission nut 21
Attachment fork screw on steering knuckle 6,5
The screw nut of the steering knuckle
attachment with the shock absorber leg 7,5
The attachment screw nut of the ball
joint with the steering knuckle 5,5
STEERING KNUCKLE
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FRONT BEARING ELEMENTS
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STEERING KNUCKLE
REMOUNTING
NOTE :
Before remounting check the wear of the bearing.
The bearing shall be replaced when t he grease is fl own.
Position and press the steering knuckle together with the “ hub – disk “assembly , performing
the operations in the reverse order, after previously having greased the steering knuckle grooves.
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FRONT BEARING ELEMENTS
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STEERING KNUCKLE BEARING (35 x 65 x 35)
DISMOUNTING
Dismount the steering knuckle (see chapter
“Dis mounting steering knuckle)
Remove the safety ring from the interior of
the steering knuckle; Depress the bi-c onical bearing, using a F 50 mm
outer diam eter rod.
Place the steering rod using a bushing with inner
diameter F 67 mm.
REMOUNTING
Introduce in the steering knuckle the bearing
support washer
Press the bearing in the steering knuckle, by
means of a 63 mm diameter bushing.
Mount the safety ring in the steering knuckle
NOTE:
The operation shall be performed so that
bushing is no t pressed on the bearing
support washer, in order to perform a correct
mounting and not to damage the bearing. The steering knuckle-bearing a ssembly
shall be placed above the hub – disk assembly
and after centering the support washer, press
the bearing on the hub, using a bushing with
the inner diameter of F 36 mm and an exterior
diameter of F 40 mm.
Continue with the mounting of the steering
knuckle assembly on t he vehicle (see the
chapter “Remounting steering knuckle”)
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FRONT BEARING ELEMENTS
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Helical spr
ings, hydraulic shock absorber with double effect and anti-roll bar.FRONT SUSPENSION
6 daNm
2 daNm
7,5 daNm 2,7 daN m
3,5 daNm
7,5 daNm 7,5 daN
m 21 daNm
7,5 daN
m
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