Dacia 1304 2004 Repair Manual
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Dacia 1304 2004 Repair Manual

Dacia 1304 2004 Repair Manual

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Table of Contents

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The reparation methods prescribed by the manufacturer in the present document are established subject to
technical specifications in force at the document issuing date.
These are subject to modifications brought by the manufacturer at the fabrication of different assemblies,
subassemblies or accessories of its vehicles.
All rights reserved to SC Automobile Dacia SA.
Reproduction or translating even partially of this present document is forbidden without the written
authorisation of AUTOMOBILE DACIA S.A.
Ref: 6001999452
REPAIR MANUAL
DACIA COMMERCIAL
RM 502-1 MECHANICS
ENGINE: C3L
GERBOX: NG1; NG7
TAPV: U75B; U75F
NOVEMBER 2004
English version

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Summary of Contents for Dacia 1304 2004

  • Page 1 These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA. Reproduction or translating even partially of this present document is forbidden without the written authorisation of AUTOMOBILE DACIA S.A.

  • Page 2: Table Of Contents

    General poinds vehicle 12 FUEL MIXTURE Characteristics ..........12-1 01 SPECIFICATIONS Injector valve body ........12-2 Engine – Clutch - Gearbox ......01-1 Inlet exhaust manifold ........12-3 Vehicle identification ......... 01-2 13 PUMP SUPPLY Fuel filter (injection engine) ......13-1 02 LIFTING Mobile jack and protection route ....
  • Page 3 21 MANUAL GEARBOX 33 REAR BEARING ELEMENTS Identification..........21-1 Plate drive rear axle ........33-1 Sections ............21-2 Brake drum........... 33-4 Diagnostics ..........21-6 Brake cylinder..........33-6 Characteristics ..........21-9 Brake shoes..........33-8 Tightening moments ........21-10 Bearing (39 x 68 x 37)........ 33-10 Ingredients..

  • Page 4: Specifications Engine - Clutch - Gearbox

    SPECIFICATIONS ENGINE - CLUTCH - GEARBOX EHICLE NGINE LUTCH EARBOX YLINDER APACITY (cmc) 1304 Pick-Up D 26119 106 -02 1557 200 GR 50 C D 46169 106 -10 1557 200 DBR 51 C 1304 Drop-Side D 27119 106 -02 1557 200 GR 50 C D 47169...

  • Page 5: Vehicle Identification

    SPECIFICATIONS VEHICLE IDENTIFICATION UNITL THE DATE OF 26.06.2003 Manufacturer plate Identification number VIN MANUF ACTURER PLATE a. Manufacturer identification code; b. Code of the vehicle; c. Gear box type code; d. Engine type code and driving device location ( according to VIN code structure); e.Vehicle code;...
  • Page 6 U U 1 POSITION CHARACTERS EXPLANATION 1 - 3 - manufacturer identification UU1 - AUTOMOBILE DACIA S.A. ROMANIA - vehicle type D - merchandise transportation vehicle - engine-gearbox unit location 1 - longitudinal front engine and front drive 2 - longitudinal front engine and rear drive...
  • Page 7 SPECIFICATIONS VEHICLE IDENTIFICATION UNITL THE DATE OF 26.06.2003 OVAL TYPE PLATE LABEL The self-adhesive label is applied on the right part side surface of the dashboard. This enable the identification of the vehicle type and its equipment, being used exclusively for the after sale activity.
  • Page 8 SPECIFICATIONS VEHICLE IDENTIFICATION UNITL THE DATE OF 26.06.2003 OVAL TYPE PLATE LABEL Line 4 4.1 Tehnical definition code, driving post: S2: Left hand drive 4.2 Optional equipping code: A: Normal suspension C: Temperate climate E: Warm climate F: Normal heating G: Air conditioning K: Without pre-filter M: Mechanical steering system...
  • Page 9 SPECIFICATIONS Vehicle identification STARTING WITH THE DATE OF 26.06.2003 MANUFACTURER’S PLATE DISPOSAL TYPE SELF-ADHESIVE Fig.2.1 01 - 6...
  • Page 10 SPECIFICATIONS Vehicle identification STARTING WITH THE DATE OF 26.06.2003 The MANUFACTURER PLATE, self-adhesive type, has the bellow presented configura- tion, with two distinctive areas, presenting :manufacturer’s identification data and APV type identi f icatio n data. APV IDENTIFICATION DATA MANUFACTURER’S IDENTIFICA- TION DATA 1.1Code type auto APV 1.2Manufacturing number...

  • Page 11: Lifting

    LIFTING MOBILE JACK AND PROTECTION ROUTE It absolutely forbidden the vehicle lifting using the front or rear suspension arms as supporting points. The mobile jack shall not be used to lift the car in order to perform certain operations under the carriage body. LIFTING THE FRONT PART OF THE For lifting, the rolling jack and the CHA 280 hold are used, in order to protect...

  • Page 12: Elevator Positioned Under The Carriage Body

    LIFTING ELEVATOR POSITIONED UNDER THE CARRIAGE BODY For lifting, place the elevator buffers on the same points where the car jack of the vehicle is usually placed. The edge of the threshold shall be placed correctly in the buffer channel. 02 - 2...

  • Page 13: Towing All Types

    TOWING ALL TYPES FOR TOWING OBSERVE THE LAW IN FORCE OF EACH COUNTRY NEVER PERFORM TOWING USING FRONT TRANSMISSION The towing of the cars on wheels must be obligatory done by means of the unique towing points These points cannot be anyhow used for drawing out the car from a trench ( hole ), for a similar intervention or for direct or indirect lifting of the car.

  • Page 14: Lubricants Consumables Conditions

    LUBRICANTS CONSUMABLES CONDITIONS RODUCT LACE WHERE IT IS USED REASING Clutch shaft groves Grease Pinions groves of front transmission UM 170 Li Ca Pb 2M Gear box control lever Pressure bearing Cardan flange sealing ring ELF CARDREXA RNT2 Front transmission UM 185 Li 2M Front wheel steering stub groves Cardanic transmission...
  • Page 15 LUBRICANTS CONSUMABLES CONDITIONS LACE WHERE IT IS USED RODUCT EALING Inferior crankcase Distribution cover RHODORSEAL Propeller shaft pins 5661 Half crankcase Clutch crankcase Fuel pump ( with membrane ) Cover palier 1 LOCTITE 518 Rear axle Thread of the reverse lamp contact. Gear box plug M 16 LOCTITE 577 Rear axle...

  • Page 16: Draining And Filling Engine

    DRAINING AND FILLING ENGINE Necessary special tools - wrench for draining plug : CV 514 Draining: plug (2) Filling: plug (1) 05 - 1...

  • Page 17: Gearbox

    DRAINING AND FILLING GEARBOX Draining: plug (2) Filling: plug (1) 05 - 2...

  • Page 18: Rear Axle Differential

    DRAINING AND FILLING REAR AXLE DIFFERENTIAL Draining: plug(2) Filling: plug (1) 05 - 3...

  • Page 19: Values And Settings

    VALUES AND SETTINGS DIMENSIONS DACIA 1304 PICK - UP DACIA 1305 PICK - UP ( mm ) ( kg ) IMENSIONS EIGHT Total length 4674 Unloaded vehicle weight Total width 1636 On the front axle Total height On the rear axle...
  • Page 20 VALUES AND SETTINGS DIMENSIONS DACIA 1304 PLATFORM DACIA 1305 PLATFORM ( kg ) ( mm ) EIGHT IMENSIONS Total length 4599 Unloaded vehicle weight Total width 1615 On the front axle Total height On the rear axle Empty Total 1550...
  • Page 21 VALUES AND SETTINGS DIMENSIONS DACIA 1307 ( kg ) ( mm ) EIGHT IMENSIONS Total length 4794 Unloaded vehicle weight 2636 Total width On the front axle Total height On the rear axle Empty 1525 Total 1175 Loaded Maximum authorized load...

  • Page 22: Capacity - Qualities

    VALUES AND SETTINGS CAPACI TY - QUALITIES (liters) HARACTERISTICS ENOMINATIO APACITY SAE 15 W 40 / API SJ/CF Engine oil SAE 80 W 90 / API GL4/GL5 Gearbox oil SAE 80 W 90 / API GL 5 Differential oil SAE J 1703; DOT 4 Breaking fluid Tip C Cooling fluid *...

  • Page 23: Driving Belts Tightening And Tightening Checking

    VALUES AND SETTINGS DRIVING BELTS TIGHTENING AND TIGHTENING CHECKING The checking of the belt tightening may be done by means of the MOT 557 device which has two scales; one shows the arrow’s value ,and the other implicitly translates the value of the tension ( force ).
  • Page 24 VALUES AND SETTINGS DRIVING BELTS TIGHTENING AND TIGHTENING CHECKING * press on the device until the big “O” ring passes over the rule; ∗ read the value of force N on the scale with small “O” ring; ∗ compare the read value with the imposed value : - if the N force value is within the imposed range, the belt tightening is good;...
  • Page 25 VALUES AND SETTINGS CYLIDER HEAD TIGHTENING AND RETIGHTENING ATTENTION! In order to obtain a correct tightening of the cylinder head screws, clean the attachment holes of the cylinder head of oil or coolant liquid, by means a syringe. Grease the thread of screws with engine oil. CYLINDER HEAD TIGHTENING Tighten at the required moment (6,5 daNm) observing the tightening sequence from the...

  • Page 26: Wheeles And Tyres

    VALUES AND SETTINGS WHEELS AND TYRES RESSURE OLLING (daN/cm ) CIRCUMFERENCE HEELS YRES VEHICLE (mm) RONT 1304 175 R 14 5 J 14 with deport 1920 +/- 25 1307 48 mm PR 8 1307 - 4WD 5 J 14 with deport 175 R 14 1920 +/- 25 1305...

  • Page 27: Brakes

    VALUES AND SETTINGS BRAKES FRONT BRAKES Brake caliper bore diameter (for brake disk non aerated) Φ 48 mm Brake caliper bore diameter (for aerated brake disk) Φ 54 mm Disk thickness non aerated 10 mm 20 mm Disk thickness aerated Minimal disk thickness non aerated 9 mm 19 mm...

  • Page 28: Heights Under Carriage Body

    VALUES AND SETTINGS HEIGHTS UNDER CARRIAGE BODY VALUES UNDER CARRIAGE BODY CONDITIONING THE ADJUSTMENT OP- ERATIONS OF THE STEERING ANGLES. H1 – the distance measured from the wheels center to the ground H2 – the distance measured from the longitudinal girder lower part to the ground H5 –...
  • Page 29 VALUES AND SETTINGS CONTROL VALUE OF FRONT AXLE ANGLES COMMERCIAL U 75 DRIVE (1304, 1307) POSITION OF THE VEHICLE ANGLES VALUES ADJ USTMENTS 1304 1307 H5 - H2 = 260 H5 - H2 = 265 CASTER H5 - H2 = 255 H5 - H2 = 250 djustable by ±...
  • Page 30 VALUES AND SETTINGS CONTROL VALUE OF FRONT AXLE ANGLES OTHER STEERING SYSTEM VALUES TO BE RESPECTED ANGLES VALUES POSITION OF THE VEHICLE ADJ USTMENTS 1304 1307 Steering box positioning 6 – 7,75 on the scale By means of T.F.246 eccentrics C=65mm By means of the Steering rack central...
  • Page 31 VALUES AND SETTINGS CONTROL VALUE OF FRONT AXLE ANGLES COMMERCIAL U 75 / 4X4 DRIVE (1304, 1307) POSITION OF THE VEHICLE ANGLES ADJUSTMENTS VALUES 1307 1304 H5 - H2 = 265 CASTER H5 - H2 = 260 H5 - H2 = 255 Adjustable by modifi- H5 - H2 = 250 cation of the tie-rod...
  • Page 32 VALUES AND SETTINGS CONTROL VALUE OF FRONT AXLE ANGLES OTHER STEERING SYSTEM VALUES TO BE RESPECTED ANGLES VALUES POSITION OF THE VEHICLE ADJ USTMENTS 1307 1304 Steering box positioning 6 – 7,75 on the scale By means of T.F.246 eccentrics C=65mm By means of the Steering rack central...
  • Page 33 VALUES AND SETTINGS CONTROL VALUE OF REAR AXLE ANGLES COMMERCIAL U 75 DRIVE (1304, 1307) VEHIC LE ANGLES VALUES ADJUSTMENTS POSITI O N CAMBER Empty Not adjustable ± 34'30'' PARALLELISM (For two wheels) Empty Not adjustable Toe out ± 34'30'' Empty ELASTI C JOINTS BLOCKI NG Empty...
  • Page 34 VALUES AND SETTINGS CONTROL VALUE OF REAR AXLE ANGLES COMMERCIAL U 75 / 4 X 4 DRIVE (1304, 1307) ADJUSTMENTS ANGLES VEHICLE VALUES POSITION CAMBER Empty Not adjustable ± 19'59'' PARALLE LISM For two wheels) Empty Not adjustable Toe out ±...

  • Page 35: Engine And Lower Engine Units

    ENGINE AND LOWER ENGINE UNITS INGREDIENTS TILISATION RHODORSEAL 5661 Propeller shaft pins. Oil sump and distribution cap. LOCTITE 518 Petrol pump sealaing ( membrane type ) and cap of bearing no. 1. OMNI - FIT RAPID ( FIXAMED M 28 ) Flywheel attachement screws,bearings cap screws.

  • Page 36: Identification

    ENGINE AND LOWER ENGINE UNITS IDENTIFICATION EHICLE TYPE NGINE EAR BOX ISPLACEMENT TROKE OMPRESS ( cm ( mm ) ( mm ) ION RA TIO 1304 Pick-up 1304 Drop-side 106 - 10 50 C 1557 83,6 8,5:1 1304 King-cab 51 C 1305 Pick-up 1305 Drop-side 106 - 02 50 C...
  • Page 37 ENGINE AND LOWER ENGINE UNITS IDENTIFICATION The engine identification is done by means of a plate attached to the cylinder block, above the oil filter. 1. Type of engine. 2. Engine manufactur e series. 10 - 3...

  • Page 38: Measurement Of Oil Consumption

    ENGINE AND LOWER ENGINE UNITS MEASUREMENT OF OIL CONSUMPTION PREPARATION FOR TEST Place the car on the elevator,dismount the engine shield,check the presence of oil leaks. If there are any leaks,eliminate it and then check again. Drain the oil from the engine. Fill the engine with 2,750 l new oil 15 W 40, start the engine and let it run in force ( 1000 - 1200 rpm.
  • Page 39 ENGINE AND LOWER ENGINE UNITS MEASUREMENT OF OIL CONSUMPTION CONSUMPTION CALCULATION The oil consumption is given by the difference between the first weighing and the second weighing. Oil consumption G1 - G2. ADMISSIBLE CONSUMPTION The admissible consumption is determinated by: - the wear general condition of the engine;...

  • Page 40: Oil Pressure Checking

    ENGINE AND LOWER ENGINE UNITS OIL PRESSURE CHECKING The oil pressur e checking is done in the following conditions:oil to be up to the required level and of a adequate quality; oil temperature to be 80 ºC. To check the oil pressure use the following procedure : - check the oil level and fill in until the required level is reached (if this is necessar y);...

  • Page 41: Oil Filter Replacement

    ENGINE AND LOWER ENGINE UNITS OIL FILTER REPLACEMENT ISMOUNTNG Disconnect the battery. Loosen the filter by means of the MOT 445. Hand dismount the filter. EMOUNTING Lubricate the gasket of the new filter with oil. Tighten the filter by hand untill the asket comes in the contact with the block. Tighten 1/2 rotation more by means of the MOT 445 wrench.

  • Page 42: Engine Dismounting - Remounting

    ENGINE AND LOWER ENGINE UNITS ENGINE DISMOUNTING - REMOUNTING The engine may be independently dismounted by taking it out through the upper part of theengine compartment. ( in the engine compartment ) ISMOUNTING Disconnect the battery. Dismount the engine hood. Dismount the plug of the cylinder head cap,the plug of the oil casing and drain the oil from the engine.
  • Page 43 ENGINE AND LOWER ENGINE UNITS ENGINE DISMOUNTING - REMOUNTING (under the car ) ISMOUNTING Dismount the engine shield. Dismount the beam between the longitudinal girders. Dismount the nuts that attach(fix) the bushings to the stabilizer rod. Dismount the nuts that attach the gearbox to the engine.
  • Page 44 ENGINE AND LOWER ENGINE UNITS ENGINE DISMOUNTING - REMOUNTING 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.

  • Page 45: Engine And Gearbox Dismounting - Remounting

    ENGINE AND LOWER ENGINE UNITS ENGINE AND GEARBOX DISMOUNTING - REMOUNTING The engine-gearbox assembly may be dismounted from the car only by taking it out at the uper part of the engine compartment. ( inside the engine compartment ) ISMOUNTING Perform the operations described for the sole engine dismounting,except the following operation s: - dismounting of the starter protection;...
  • Page 46 ENGINE AND LOWER ENGINE UNITS ENGINE AND GEARBOX DISMOUNTING - REMOUNTING Place the cross bars supporting the front axle. Dismount the front wheels. Dismo unt the upper suspenssion ball joints and the ball joints of the steering connecting rod. Disconnect the transmissions. Place a jack under the gearbox to maintain it in the right position .
  • Page 47 ENGINE AND LOWER ENGINE UNITS ENGINE AND GEARBOX DISMOUNTING - REMOUNTING Remove the jack from under the gearbox. Mount the lifting device. Move the engine-gearbox assembly forward,bend it and lift it. Place the engine on support. Dismount the gearbox ( if necessar y). EMOUNTING Perform in the reverse order the operations descibed at the dismounting.

  • Page 48: Tightening By Screwing Up Moments

    ENGINE AND LOWER ENGINE UNITS TIGHTENING BY SCREWING UP MOMENTS 10 - 14...

  • Page 49: Characteristics

    ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS 102 - 14 106 - 02 106 - 10 NGINE TYPE Cylinder (cmc) 1397 1557 1557 Bore (mm) Stroke (mm) 83,6 83,6 Compression ratio 8,5:1 8,5:1 8,5:1 Maximum power 42,6 KW 50 KW 50 KW DIN at 5000 rpm DIN at 5000 rpm DIN at 5000 rpm...
  • Page 50 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS CYLINDER HEAD Aluminiu m alloy cast cylinder head 102 - 14 106 - 10 106 - 02 YPE DU MOTEUR Couple for tightening the attachment screws of the cylinder head (daNm) 5,5 - 6,5 5,5 - 6,5 5,5 - 6,5 - cold engine...
  • Page 51 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS VALVES 106 - 02 102 - 14 YPE OF ENGINE 106 - 10 Diameter of shaft (mm) Angle of the support side - inlet - outlet Diameter of the head (mm) 34,6 33,5 - inlet 30,3 30,3 - outlet...
  • Page 52 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS VALVES GUIDES The cast iron guides ,warm pressed ,may be replaced. 106 - 02 102 - 14 YPE DU MOTEUR 106 - 10 Inner diameter (mm) Outside diameter (mm): - normal 11.10 - 1 st repair (1 channel) 11.10 - 2-nd repair (2 channels)* 11,25...
  • Page 53 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS PUSHERS YPE OF THE ENGINE LL TYPES Outside diameter (mm) - normal - reparation * 19,2 + 0,21 Alesage du trou d’embase (mm) - normal + 0,210 - reparation * Done only upon special request. CYLINDER JACKETS 102 - 14 106 - 02...
  • Page 54 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS * The adimisible clearance between the piston and the cylinder jacket is J = 0,045 - 0,065 mm and is done by corresponding matching as per table : ISTON MARK YLINDER JACKET MARK Green Blue Yellow CRANKSHAFT...
  • Page 55 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS CONNECTING RODS YPE OF ENGINE LL TYPES Tightening by screwing up moment of the bush- ing caps (daNm) Type of bushings aluminium - stanium 0,31- 0,57 Axial clearance of the connecting rod head 20 - 0,029 (mm) - 0,04 1...
  • Page 56 ENGINE AND LOWER ENGINE UNITS CHARACTERISTICS * Matching of the piston with the piston shaft is done as per following table: ISTON MARKING ISTON SHAFT MARKING Yellow Blue OIL PUMP YPE OF THE ENGINE LL TYPES Oil pressure a 80 C ( bars ) - for iddle running ( 750 - 800 rpm ) minimum 0,7 - for 4000 rpm...

  • Page 57: Dismounting - Mounting

    ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismoun t from erngine: - the alternator and the fixinf clip; - the distributor and the ignintion cable; - the fuel pump; - the oil filter; - the oil dip stick; - the oil pressuire transmitter ; - the engine left side support and the elastic buffer.
  • Page 58 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismount the cylineder head and take out the cylinder head gasket. In order to do that, u nscrew the the fixing bolts of the cylinder head,except the central screw,on the side of the breaker-distributor. Because of the thightening, always when dismounting ,the cylinder head gasket is stuck to the casing or the cylinder head the latter shall...
  • Page 59 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismount the distributi o n chain tightener. Straighten the lock washer and unscrew the camshaft pinion fixing screw . Take out the camshaft pinion and the distribution chain. Dismount the screws of the camshaft clip. Take out the camshaft.
  • Page 60 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismoun t the engine flywh eel. Check the marking of the connecting rods: number 1 towards the flywheel ond on the reverse side of the camshaft. Dismount the connecting rods caps and the half bushings and place them in order.
  • Page 61 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING RETIGHTENING OF THE CYLINDER HEAD SCREWS The re tightening of the cylinder head screws is performed: - for new cars.upon revision at 800-1000 - upon an engine checking which requires dismounting of the cylinder head; - after every 10 000 km.
  • Page 62 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Repeat the operation for the cylinders 3 - 4 - 2 according to the table: UTLET VALVE COMPLETELY OPENED ALVE TO BE ADJUSTED NLET UTLET Tilters clearance : at cold - inlet 0,15 mm; - outlet 0,20 mm;...
  • Page 63 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismount the alternator. Dismount the acceleration and shock cables. Disconnect the thermocontacts. Dismount the water hoses(cylinder head- carburator; carburator-water pump; water pump- radiator). Dismoun t the collector from the cylinder head. Dismount the tilters cap. Dismount the tilters shafts.
  • Page 64 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING CHECK OF THE GASKET PLANE DEFORMATION The checking of the deformation of the gasket plane is done by means of a ruler and of a set of gauges. The maximum accepted deformation is: x = 0,05 mm. If the maximum deformation exceeds this value,the gasket plane is corrected by grinding.
  • Page 65 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING PARTICULARITIES UPON RE MOUNTING The contact surfaces of the gasket must be clean. The grease or antifreeze fluid must be removed from the holes of the cylinder head fix- ing screws by means of a. This is necessary in order to obtain a correct thightening of the screws and to avoid the appearance of casing cracks.
  • Page 66 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Dismount the tilters platform. Compress the valves springs by means of the MOT 382 compressing device. Take out the lock half cotters,release the spring,take out the upper tray,the spring and the lower tray. Place the parts in order so that they may be mounted back in the same place where they have been dismounted from.
  • Page 67 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Compress the springs by means of the MOT 382 compression device and mount the lock half cotters. Mount the cylinder head closing plate and the water pump with new gaskets. Mount the alternator support. Mount the cylinder head with new gasket observing the mounting instructions.
  • Page 68 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Compress the spring by means of the MOT 382 device and mount the lock half cotters. Mount the tilter shaft. Adjust the tilter. Mount the tilters cap. The nuts tightening moment: 0,5 – 0,7 daNm. Mount the acceleration cable and adjust the acceleration pedal stroke.
  • Page 69 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Compress the spring by means of the MOT 382 and mount the lock half cotters. Mount the tilters shaft. Mount the tilters cap. The nuts tihtening moment is : 0,5 - 0,7 daNm. Mount the acceleration cable and adjust the acceleration pedal stroke.
  • Page 70 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING EMOUNTING Lubricate the supports,the tilters and the shaft with clean oil. Mount the parts on the shaft in the reverse order of the operation performed for dismounting .Pay attention that attachmen t holes in the supports identify with the sockets on the shaft.
  • Page 71 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Check the diameter of the depressed guiding: - nominal value 11 mm; - value 1-st repair 11,1 mm; - value 2-nd repair 11,25 mm; NOTE: The guiding at the repair value are supplied only by request EMOUNTING Turn the cylinder head on the support plate and bore the seat of the guide at the...
  • Page 72 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Bore the guiding at the value φ 7. Grind the valve seat. Perform the lapping of the valve with the valve seat. Wash carefully the cylinder head and the component parts and blow them with air under pressure. Mount on the cylinder head the following items: - the cap attachment bolts;...
  • Page 73 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING VALVE SEATS GRINDING Dismount the cylinder head from the engine. Dismount from the cylinder head: - the water pump; - the valves; - the valves shafts sealing rings; - the tilters platform; - the cap attachment bolts;...
  • Page 74 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Perform the filling and aeration of the cooling system. Perform the checking and adjustment of engine operation (ignition ,carburation). Re tighten the cylinder head after driving 800 km. ENGINE KIT REPLACEMENT ( on car ) ISMOUNTING Disconnect the battery.
  • Page 75 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING NOTE: The parts contained in the repair kit are in pairs ( jackets-piston-piston shaft ) according to colours. The colour (1) marked on the piston head must correspond to the colour marked on the jacket.
  • Page 76 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING For all types of engines,the jackets shall be positioned as follows: - the maximum difference between the heights of two adjoing jackets shall be maximum 0,02 mm,within the limit of the prescribed tolerance; - the jackets shall be placed in growing order ( by steps ).
  • Page 77 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING NOTE: If wear of the connecting rods is noticed or if the parallelism of the shafts is not correct, the connecting rods shall be corrected or replaced. For the new connecting rods, a check shall be made so that they belong to the same weight class (they shall not have the same colour marked on them).
  • Page 78 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING When assembling the piston with the connecting rod,the following instructions are to be observed: - place the piston with the bladed item on the bushing (B) of the piston shaft mounting device;in this situation the arrow on the piston head shall be upwards oriented;...
  • Page 79 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Lubricate the jackets with fresh oil. Mount in the jackets the piston-connecting rod assembly with the bushing: - MOT 502 for 102 engines; - MOT 655 for 106 engines. When mounting, the connecting rod sides will be parallel with the flattenings made on the jackets.
  • Page 80 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING OIL PLATFORM PLUGS REPLACEMENT ISMOUNTING Dismount the plugs from the block by boring with a φ 10 drill. Wash the block,clean the platform and the channels in the block and blow it with compressed air.
  • Page 81 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Mount the annular oil seal in its place, s lightl y tapping the chuck head until it comes into contact with the crankshaft. The mounting chuck for the annular oil seal shall be kept with care in order to avoid deterioration of the collar on which the annular oil seal is placed.
  • Page 82 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING EMOUNTING Press the new bushing by means of the clutch disk centering chuck. Center the disk by means of the centering chuck. Mount the clutch mechanism. Mount the gear box. Check all the fluid fillings and perform all necessar y adjustments.
  • Page 83 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Place the engine on the MOT 460 suPlace the engine on the MOT 460 support.pport. Dismo unt: - the pressure plate and the clutch disk; - the breaker-distributtor pinion by means of a M 12 x 1,5 screw. Rotate the engine by 180 º...
  • Page 84 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Take out the crankshaft pinion by means of the MOT 49 device. Dismoun t the engine flywhhe. Check the marking of the connecting rods: - no.1 towards the flywheel and opposite to the camshaft. Unscrew the connecting rod caps nuts.
  • Page 85 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING Remove the half bushings from the connecting rod and from the block and put them in order. Dismount the washer thrusts for the axial clearance adjustment. Remove the annular oil seal from the bearing. EMOUNTING Wash and air blow the new crankshaft;...
  • Page 86 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Mount the half bushings on the bearing heads ( the half bushings for caps do not have lubricatin g holes). Lubricate the half bushings with fresh oil and mount the bearing caps at their place according to the marking.
  • Page 87 ENGINE AND LOWER ENGINE UNITS DISMOUNTING – MOUNTING NOTE: In case the old crankshaft is to be mounted, displace the annular oil seal position by inserting a 2 mm thick washer between the chuck and the crankshaft end so that the annular oil seal does not work in its initial position.
  • Page 88 ENGINE AND LOWER ENGINE UNITS DISMOUNTING - MOUNTING Mount : the il pump and the distribution,the oil sump and the distribution cap with new gaskets or sealant, the disk and mechanism clutch. Place the engine on MOT 369 support and mount : - the left side support and elastic buffer;...

  • Page 89: Replacement Of The Distribution Annular Oil Seal

    ENGINE AND LOWER ENGINE UNITS REPLACEMENT OF THE DISTRIBUTION ANNULAR OIL SEAL ISMOUNTING Disconnect the battery. Place the no.1 cylinder at the dead point in orde to avoid the falling of the key from the crankshaft when disounting the crankshaft pul- ley .

  • Page 90: Distribution Cap

    ENGINE AND LOWER ENGINE UNITS DISTRIBUTION CAP DISTRIBUTION CAP REPLACEMENT ISMOUNTING Disconnect the battery. Drain the oil off the engine. Dismount the alternator belt, the water pump pulley and the engine shield. Dismoun t the oil sump: (adjust the engine with no.1 and 4 pistons in the lower dead point), rotate the front part of the oil sump towards the left and lower it.
  • Page 91 ENGINE AND LOWER ENGINE UNITS DISTRIBUTION CAP EMOUNTING Mount the distribution annular oil seal. Place the cap with new gasket or on the block after sealan t material has been applied previously. Center the cap by means of the MOT 457 A device. Attach the cap on the block;...
  • Page 92 ENGINE AND LOWER ENGINE UNITS DISTRIBUTION CAP Clean with 002 solvent the contact surfaces of the engine casing and of the distribution cap . Place a continous sealant material layer of a 3 mm thickness on the lower part of the contact surface of the distribution cap,taking care not to obturate the its fixing holes.

  • Page 93: Tightener And Distribution Chain

    ENGINE AND LOWER ENGINE UNITS TIGHTENER AND DISTRIBUTION CHAIN REPLACEMENT OF TIGHTENER AND DISTRIBUTION CHAIN ISMOUNTING Disconnect the battery. Drain the oil from the engine. Dismount: the engine shield,the cross bar between the longitudinal girders,the elastic bushing nuts of the stabilizer rod,the alternator belt,the fan and the water pump pulley,the oil sump and the distribution cap.
  • Page 94 ENGINE AND LOWER ENGINE UNITS TIGHTENER AND DISTRIBUTION CHAIN Place the new chain on the camshaft pinion and on the crankshaft pinion. Mount the camshaft pinion maintaining the alignement of the markings on the pinions. Tighten the fixing screw at a 2 daNm moment and strain the safety washer.

  • Page 95: Camshaft

    ENGINE AND LOWER ENGINE UNITS CAMSHAFT CAMSHAFT REPLACEENT ISMOUNTING Disconnect the battery. Drain: oil from engine and the cooling circuit. Dismo unt : - air filter,f r ont grill, r adiator,crossbar betwenn the longitudinal girders,the fixing nuts of the elastic bushers from the stabilizer rod. Dismount the breaker- distributtor,the tilters cap,the cylinder head,the tilters shafts and the pushers;arrange them in order so that they may be re mounted in the places they have been removed from.
  • Page 96 ENGINE AND LOWER ENGINE UNITS CAMSHAFT EMOUNTING Mount on the new camshaft : the disk key,a new attachement clip,a new cross piece;tapp the cross piece with a rod until it comes into contact with the camshaft shoulder). Mount the camshaft pinion and tighten the screw at the moment of 3 daNm using. Check the attachement clip clearance ( J ) ;...
  • Page 97 ENGINE AND LOWER ENGINE UNITS CAMSHAFT Mount the control pinion of the breaker distributor. The control pinion is position ed as follows: - place the no.1 cylinder at the upper dead point, on ignition; - mount the pinion with a cylinder head attachement screw so that the slots are perpendicular on the engine longitudinal axle and the larger part (D) is oriented towards the flywheel.

  • Page 98: Lower Crankcase

    ( instead of oil sump gaskets). Any dismountin g of the oil sump requires replacemen t of the sealant material layer. The sealant materials homologated by SC AUTOMOBILE DACIA SA, are the followins: - RHODOR SEAL 5661; - LOCTITE 5900 ( ULTRA BLAKE ).
  • Page 99 ENGINE AND LOWER ENGINE UNITS LOWER CRANKCASE The quantity of sealant material necessar y for one engine is max. 60 grams, of which max. 15 grams for the distribution cap and max. 45 grams for oil sump. Proceed as follows: Remove trhe oil sump.

  • Page 100: Oil Pump

    ENGINE AND LOWER ENGINE UNITS OIL PUMP OIL PUMP DISMOUNTING – REMOUNTING ISMOUNTING Disconnect the battery. Drain the oil off the engine. Dismount :engine shield,crossbar between the longitudinal girders,elastic bushing nuts on the anti rolling shaft and the oil pump. Unscrew the attachement s crews and take out the oil pump.
  • Page 101 ENGINE AND LOWER ENGINE UNITS OIL PUMP REPAIR OF OIL PUMP ISMOUNTING Dismount the pump cap. Dismount: the free pinion and its respective shaft. ATTENTION ! The valve spring and the ball may spring up. Wash the parts and check the maximum clearance wear between the pinions and the pump body to be 0,2 mm.

  • Page 102: Fuel Mixture Characteristics

    FUEL MIXTURE CHARACTERISTICS NGINE HECKING TO BE DONE ON IDLE RUNNING OLLUTION EMISSIONS ( minimum octane NDEX number CO) ( rtm ) Co ( % ) ( % ) AMBDA ( λ λ λ λ ) ( ppm ) Unleaded fuel 775 - 850 max.

  • Page 103: Injector Valve Body

    FUEL MIXTURE INJECTOR VALVE BODY ISMONTING Disconnect the ( - ) battery terminal. Dismount the air duct fixing clips. Dismount the air duct attachment screws. Dismount acceleration cable from the injector valve body. Disconnect the feeding and return hoses and the connecting hose to the can purging electrovalve.

  • Page 104: Inlet Exhaust Manifold

    FUEL MIXTURE INLET EXHAUST MANIFOLD ( daNm ) IGHTENING TORQUES Inlet exhaust manifold nuts ..............1,8 Attachment nuts of the tube on the inlet exhaust manifold ....1,8 ISMOUNTING Disconnect the battery. Dismount the injector valve body ( see chapt.” Replacement of the injector valve body” ). Dismount the starter protection shield.

  • Page 105: Pump Supply

    PUMP SUPPLY FUEL FILTER ( INJECTION ENGINE ) The fuel filter is placed in the fuel feeding circuit after the fuel pump and can be found under the body of the vehicle close to the tank. The filter element is made of paper, with 0,01mm porosity and has the very important function to retain the eventual impurities and stop them to reach the pressure regulator and injector.

  • Page 106: Antipollution

    ANTIPOLLUTION GASOLINE VAPOURS REASPIRATION The cycling circuit of the fuel vapours has as purpose the reduction of the environment pollution with gasoline vapours, and is composed of: 1. Fuel tank, tight 2. Active carbon can 3. Carbon can purging valve 4.

  • Page 107: Carbon Can

    ANTIPOLLUTION CARBON CAN ISMOUNTING Remove the can from its fixing support by pulling up. Dismount the fixing ring clips of the hoses to the can and disconnect the hoses. EMOUNTING Perform in reverse order the dismounting operations. ATTENTION: Take into consideration when mounting, about the hoses connection direction (the gasoline vapour cycling is from the duct to the carbon can purge valve).

  • Page 108: Carbon Can Valve

    ANTIPOLLUTION CARBON CAN VALVE ISMOUNTING Disconnect the ( - ) terminal of the battery. Disconnect the connector of coupling the fuel injection control wiring to the purging valve, pushing the lock (1),after that disconnecting the connector. Dismount the fixing clips of the hoses to the purging valve and disconnect the hoses.

  • Page 109: Starting And Charging Alternator

    Type of relay used 1410;1342 electronic electronic incorporated For vehicles of Dacia range, there are used alternators type 1114.200 and type 1180 (used for vehicles provided with AC). CHECKING ON BENCH ( for alternator type 1114.200 ) LOAD CHARACTERISTIC General electric diagram: I = f (n);...
  • Page 110 STARTING AND CHARGING ALTERNATOR ALTERNATOR CHECKING ( for alternator type 1180 ) The general electric diagrams and the curves of the load characteristic of the alternator type 1180 are the followings: A. CHECKING OF THE CURRENT INTENSITY A - Unstable operating conditions B - Stable operating conditions GENERATOR ROTATION SPEED (rot/min) GENERATOR ROTATION SPEED (rot/min)
  • Page 111 STARTING AND CHARGING ALTERNATOR LOAD CHARACTERISTIC I = f ( n ); U = ct = 13,5 V [ rot/min ] [ A ] REGIM ORRESP ONDING INTENS ITY 1200 > 0 1250 > 10 1500+/- 1% > 20 3000+/- 1% >...
  • Page 112 STARTING AND CHARGING ALTERNATOR MAINTENANCE OF THE ALTERNATOR AND OF THE ELECTRINIC REGULATOR It is recommended the periodical checking of the connections to avoid the loosening of the imperfect connections which may produce electric arc during operation. The followings are forbidden: - rotation of the alternator mounted on the engine without being connected at the battery and disconnection of the battery during running;...
  • Page 113 STARTING AND CHARGING ALTERNATOR ISMOUNTING Disconn ect: - battery; - wires connected to the alternator. Dismount: - tightening screw (A ); - belt; - attachment screw (B). EMOUNTING Mount: attachment screw (B) ,the belt, the tightening screw (A). Tighten the belt. Connect: wires to the alternator and the battery.
  • Page 114 STARTING AND CHARGING ALTERNATOR ALTERNATOR TYPE 1180 16 - 6...
  • Page 115 STARTING AND CHARGING ALTERNATOR ISMOUNTING Disconnect: battery, wires connected to the alternator and the connections box from the voltage electronic regulator. Dismount: tightening screw (2) by acting on the locking nut, the tightened (3) by unscrewing, the belt; pushing down the alternator,take out the alternator belt from the pulley and the alternator attachment screw (1).
  • Page 116 STARTING AND CHARGING ALTERNATOR CHECKING OF THE ALTERNATOR MOUNTED ON THE VEHICLE. The operation of the alternator can be checked on the v ehicle, by connecting a voltmete 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 .
  • Page 117 STARTING AND CHARGING ALTERNATOR CHEKING THE VOLTMETER OF THE INSTRUMENT BOARD Checking is performed by means of a voltmeter connected according to the above diagram,where you can identify: B = battery , V = voltmeter, A = alternator , R = voltage regulator , Key = ignition contact, Tb = instrument board.
  • Page 118 STARTING AND CHARGING ALTERNATOR ALTERNATOR REPAIR ( type 1114.200 ) ISMOUNTING Dismount the alternator from the vehicle. Unscrew the two attachment screws of the brushes support and dismount them. Clamp on vice the pulley provided with an old belt to avoid its faulting. Unscrew the fixing nut of the pulley.
  • Page 119 STARTING AND CHARGING ALTERNATOR Dismount the front bearing from the rotor by tapping the shaft end with a piece of wood. Unscrew the attachment screws of the sustaining shield of the front bearing. The dismounting operation of the front bearing is performed only in case of front bearing replacement.
  • Page 120 STARTING AND CHARGING ALTERNATOR EMUONTING Remount : - the end bearing and the stator; - the front bearing; - the attachment screws; - the pulley wedge; - the fan and the pulley; - the snap ring and the pulley fixing nut; - the brushes support;...
  • Page 121 STARTING AND CHARGING ALTERNATOR ALTERNATOR BEARINGS REPLACEMENT Dismount the alternator from the vehicle. A. FRONT BEARING REPLACEMENT Dismount : pulley, washers and Grower washer, fan, pulley wedge and the drive shield. Place the drive shield in a horizontal position and unscrew the three attachment screws of the bearing cap and take out the bearing.
  • Page 122 STARTING AND CHARGING ALTERNATOR Place the protector RO 15.01 on the rotor shaft end. Mount the new bearing by means of a press and using a tube, which shall rest only on the inner ring of the bearing. Assembly the alternator and then mount it on the vehicle.
  • Page 123 STARTING AND CHARGING ALTERNATOR ALTERNATOR DIODE SUPPORT REPLACEMENT ISMOUNTING Dismount the plastic protection cap and the condenser. Disconnect the terminals: mark the position of the wires so that may be reconected in the same place. Unscrew the attachment nuts;dismount the diode support. EMOUNTING Mount the diode support ;...
  • Page 124 STARTING AND CHARGING ALTERNATOR EMOUNTING Check the new diode. Press the new diode in the diode support observing the marking : red for “ + “ , black for “ - “. Mount the diode support on the alternator. CHECKING OF THE RECTIFYING BRIDGE After dismounting the diode support perform a visual checking of the diodes to avoid defects ( short circuits, broken ) as well as the connections state.
  • Page 125 STARTING AND CHARGING ALTERNATOR CHECKING OF THE ALTERNATOR STATOR After visual checking of the coils which must not show heating or oxidation traces,check the resistance and the insulation of the coils. A.CHECKING OF THE COILS INSULATION After placing the ohmmeter terminals on chassis ground , on “ I point and on one of the three terminals marked with “...
  • Page 126 STARTING AND CHARGING ALTERNATOR CHECKING OF THE ALTERNATOR ROTOR After the visual checking of the coiling (without heating or oxidation traces), check the collecting rings for defects (sometimes it is recommended their polishing with very fine granulation sandpaper). A. CHECKING OF THE COILING INSULATION Place the ohmmeter terminals on chassis ground, on 1 and on one of the M or N collector rings.
  • Page 127 STARTING AND CHARGING ALTERNATOR VOLTAGE REGULATOR ( alternator type 1114.200 ) ISMOUNTING Disconnect: the battery, the ( + ) supply cable and the excitation wire of the voltage regulator by unscrewing the fixing nut. Unscrew the right side nut, loosen the left side one and dismount the relay. EMOUNTING Place in its place the regulator and tighten the fixing screws.

  • Page 128: Starter

    STARTING AND CHARGING STARTER TYPE OF STARTER 2146 MAXIMUM POWER 995 W ( 1,35 CP ) NOMINAL VOLTAGE MINIMUM STARTING ROTATION 150 tr./ min. PINION Number of te eth CHARACTERISTICS 2,116 / 1,1814 Module Pressure angle Voltage ( Us ) 9,5 +/- 0,5 V CHARACTERISTICS Intensity ( Is )
  • Page 129 STARTING AND CHARGING STARTER Characteristics of load at the temperature of 20 C. Average curves: +/- 5 Test must not be done more than 4 – 5 seconds To lay out these characteristics measure the absorbed current, supply voltage,RPM and coupling. B.
  • Page 130 STARTING AND CHARGING STARTER Test must not be done more than 4 – 5 seconds To lay out these characteristics measure the absorbed current, supply voltage,RPM and coupling. STARTER 16 - 22...
  • Page 131 STARTING AND CHARGING STARTER ISMOUNTING Disconnect: battery, starter supply cable,supply wire of the coupling relay. Dismount: air filter, starter protection screen, and the three screws, which attach the starter to the clutch housing. Detach the starter let its end down until comes into contact with the exhaust pipe, rotate the starter by 90°...
  • Page 132 STARTING AND CHARGING STARTER STARTER REPAIR The operation is performed after the starter is dismounted from the vehicle. ISMOUNTING Dismount: sheet cap and the screw from the rotor top (A) electric plug (B), back bearing with brushes support, stator,attachment nuts of the coupling relay, take out the rotor and the solenoid.
  • Page 133 STARTING AND CHARGING STARTER BENDIX REPLACEMENT Dismount the starter. Take out the rotor. Move the stopping bushing by means of a rod. Take out the lock then the bendix. Mount the new bendix , the stopping bushing and the safety ring. Grease with a thin coat of UM 185 Li2 grease the grooves, the area between the grooves and the support ring the fork shaft and the rolling area of the coupling mechanism with the fork.
  • Page 134 STARTING AND CHARGING STARTER SOLENOID REPLACEMENT The operation is performed after dismounting the starter from the vehicle. ISMOUNTING 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.
  • Page 135 STARTING AND CHARGING STARTER FORK STROKE ADJUSTMENT Dismount the protector from the solenoid end. Check the clearance (F) between the screw and the adjustment nut, which must be as small as possible. In this situation the coupling mechanism ( bendix ) must be leaning on the rotor.
  • Page 136 STARTING AND CHARGING STARTER STARTER DOES NOT WORK Check the battery voltage and the terminals state. Dead battery; charge the battery;check Charged battery : clean and tighten the charging circuit. Terminals. Check if solenoid is supplied when switch on contact with the key. Solenoid is supplied;...

  • Page 137: Ignition And Injection Spark Plugs

    IGNITION AND INJECTION SPARK PLUGS The following spark plugs are to be used for Dacia vehicles: The following spark plugs are to be used for Dacia vehicles: The inducing voltage of the spark plug is 4 – 8 KV. The maximum voltage difference between the spark plugs, measured on the engine is 2 KV.
  • Page 138 IGNITION AND INJECTION SPARK PLUGS 1. Termin al nut 2. Terminal thread 3. Anti-power hazard protection step 4. Insulator 5. Conducting material 1 1 1 6. Internal gasket 7. Ventil a tion room 8. Connection rod 9. Insuring area 10. Sealin g ring 11.

  • Page 139: Operation Principle

    IGNITION AND INJECTION OPERATION PRINCIPLE MONO - MOTRONIC INJECTION SYSTEM ( MA 1.7 ) OPERATION PRINCIPLE The BOSCH MONO-MOTRONIC injection system is a (á, n) type, where: á = angle indicating the position of the valve and reading the engine load. n = engine rotation These are the principle information for the electronic control unit (computer), used for determining the basic injection time (t...

  • Page 140: Description Of The System

    IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM DESCRIPTION OF THE SYSTEM AND ITS COMPONENTS The components of the injection system are: (drawing no.1). 1 - Fuel electric pump 3 - Fuel filter 4 - Fuel pressure regulator 5 - Injector Central unit 6 - Air temperature sensor ( injector valve body )
  • Page 141 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM INJECTION CENTRAL UNIT The injection central unit consists of: 1 - The upper part (hydraulic part) 2 - The lower part (body-valve) 3 - Pressure regulator 4 - Injector 5 - Air sensor T 6 - Fuel input ( supply connection ).
  • Page 142 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM INJECTOR The injector (drawing 4) is placed above the valve in order to ensure an optimal supply and homogenous mixture of the fuel. The injector basic function is to ensure a very fine and homogenous spraying of the fuel, shaped as a conic jet.
  • Page 143 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM A sign shaped as follows will be displayed on the oscilloscope screen. It is to be used for the calculation of the injection time = t The injection time value increases when the battery voltage is lower than 12 V. Reference values for the injector: - resistance measured between the wires 2 and 3, R...
  • Page 144 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM The valve potentiometer consists of a first potentiometer, working on the range (0° - 22°) and a second one, working on the range (19° - 90°). A common area is noticed, between (19° - 22°) established for a more precise reading of the load necessary in the partial load area, the most used for the engine exploitation.
  • Page 145 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM REGULATOR OF IDLE RUNNING This regulator (drawing 1, position 9) is used to position the valve in order to obtain the idle rotation. It is mounted into a case together with a switch. The idle running is realized at the moment of switch contact closing (position 4), being necessary to the normal idle functioning or to the engine brake.
  • Page 146 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM IMPORTANT: The connector disconnection and connection is to be done only with contact OFF for the following checking and adjustment. The basic adjustment of the valve (drawing 5) is the correlation between the potentiometer position and the positioning engine of the valve.
  • Page 147 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM EXAMPLE When U v = 5 V, U 1 should be within 3.75 – 4.25 V for a correct adjustment. This adjustment is used in case of changing regulator or of an irregular functioning during the idle motion.
  • Page 148 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM From now on, we can calculate the injection time (t ), the injection moment and the ignition advance moment for each engine cycle. The rotation sensor is fixed on the clutch case of the gearbox therefore it should be at 1 ±...
  • Page 149 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM ENGINE TEMPERATURE SENSOR The engine sensor T is an NTC type (negative temperature coefficient); its internal resistance will decrease with the increasing of the temperature. It is checked with an ohmmeter connected to the sensor terminals or even better with a voltmeter, during the engine running The voltage of the cold engine should be U = 5 V;...
  • Page 150 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM INDUCTION COIL The induction coil is a double-coil with stationary distribution of the voltage without moving elements. The voltage in the secondary circuit of the coil can reach 30 KV, the distance between the spark plugs electrodes should be 0,8 mm and the spark plugs wires should have a special construction according the new concept of anti-electric interference.
  • Page 151 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM EXAMPLE - piston 4 at compression = ignition spark; about 20 KV (drawing 10). - piston 1 evacuation = auxiliary spark; about 300 V (drawing 11). The two voltages can be viewed through an oscilloscope and an adapter. Fig.

  • Page 152: Electronic Control Unit

    IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM ELECTRONIC CONTROL UNIT The electronic control unit is situated in the engine compartment and fixed on the right bumper column. It is connected to the injection control cables through a 35 pins connector. The information track between the control unit and the system components is as follows: Carbon canister purging Rotation...
  • Page 153 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM WARNING! In case of electric welding on the vehicle, the battery the alternator and the electronic control unit should be disconnected. In case of fine painting above 85°C, the electronic control unit should be taken off the vehicle. When remounting the fixing screws of the control unit should be well secured, in order to ensure a perfect electric contact to the vehicle chassis.
  • Page 154 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM The pin 23 should be tightly fixed to the mass. The pin 16 is very important; it ensures a permanent supply (+) to the computer in order to keep in its memory all the damages which might occur during the running and to introduce the necessary connection at starting up for the ignition and injection system.
  • Page 155 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM Pin no. Injection and ignition system component MA 1.7 Wire position in the computer component connector Control ignition coil ( cylinders 1 and 4 ) Not connected Signal rotation sensor Diagnosis plug ( line K ) Not connected Not connected Not connected...
  • Page 156 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM OXYGEN SENSOR ( Lambda ) The oxygen sensor (Lambda) is fixed on the primary down tube, in front of the catalytic converter. Its purpose is to determine the oxygen content of the exhausted gases; this oxygen content value depends upon the dosing of the air-fuel mixture.
  • Page 157 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM For starting the oxygen sensor as soon as possible after the engine start up it should be heated by its electric resistance, type PTC = positive temperature coefficient. The evacuation track of the burned gases should be 100% sealed in the area in front of the ë...
  • Page 158 IGNITION AND INJECTION DESCRIPTION OF THE SYSTEM CATALYTIC CONVERTER The catalytic conver t er (drawing 1, position 17) is placed o n the burned gases evacuation track between the primary down tube and the detector it is three ways type and it is used for simultaneous tr a nsformation of the three gases existing in the evacuation gas, according to the following chemical reactions: C m Hn + ( m+n/4 ) O...
  • Page 159 IGNITION AND INJECTION DIAGNOSTIC WORKING MODE IN CASE OF INTERVENTION ON THE MONO-MOTRONIC INJECTION SYSTEM Prior to the engine start up one should check the correct connection of the battery; the battery should be well loaded and its terminals should be cleaned and well tightened up. The maximum supplying voltage of the system should not excel 15 V.
  • Page 160 - Voltmeter, ohmmeter, class 20000 Ù/V; - Manometer for liquids, 0 – 4 bar, with T-connection; - Tester SAGEM CLIP Dacia, KTS 300 or AT 520 with soft DACIA (MA 1.7) and accessories for series diagnosis; - Marked vessel 0 – 2000 ml.
  • Page 161 IGNITION AND INJECTION DIAGNOSTIC PRELIMINARY CHECKING OPERATIONS PRIOR THE DIAGNOSIS The starting up electric circuit components should be under best conditions: - Starter battery and cables; - Fuel in accordance with the indications (without lead), sufficient quantity (min imum 5 l); - Fuel filter according to the indications and correctly installed;...
  • Page 162 + 12 V supply from the battery terminals and from the lighter plug. The detailed description of the tester as well as the diagnosis soft DACIA installing and their operation mode are written on the CD no.1 joint to the tester purchase.
  • Page 163 IGNITION AND INJECTION DIAGNOSTIC After accessing the diagnosis menu by pressing the key >, a submenu is displayed, with the followin g options: - press key 1 for reading the memorized damages; - press key 2 for displaying the real values of the checked measures; - press key 3 for checking the functioning of the acting items;...
  • Page 164 IGNITION AND INJECTION DIAGNOSTIC The next unit is activated with each pressing of the key “ 1 ”. When pressing key “ 3 ” the working instructions for canceling the malfunctioning cause of the unit will be displayed and by pressing the key “ > ” the unit is reselected. When pressing key “...
  • Page 165 IGNITION AND INJECTION DIAGNOSTIC The diagnosis of the injection system by KTS 300 Tester permits the detection of the system damages components; the damage code is provided in the following table: AMAGE COD AMAGED COMPONENT AMAGE DENOMINATION 011 A Idle motion regulato r Unreal signal 0203 Rotation sensor...
  • Page 166 IGNITION AND INJECTION ELECTRONIC CONTROL UNIT ISMOUNTING Disconnecting of the battery terminal (-). Disconnecting of the connector coupling the control unit to the control cables of the fuel injectio n, as follows: - the lock (1) is pulled arrow-sense; - the connector is turned around point (2), arrow-sense (a), until its disconnection; - the fixin g screws of the electronic control unit on the right bumper column are dismounted.

  • Page 167: Rotation Sensor

    IGNITION AND INJECTION ROTATION SENSOR ISMOUNTING The connector is disconnected from the rotation sensor by pressing the fuse (1), arrow-sense and then it is dismounted. The fixing screw of the sensor on the clutch case is dismounted. EMOUNTING Reverse the above mentioned operations. Functionin g tests (testing of the rotation sensor functioning).

  • Page 168: Engine Temperature Sensor

    IGNITION AND INJECTION ENGINE TEMPERATURE SENSOR ISMOUNTING The injection control cables from the sensor are disconnected by pushing the fuse (1), arrow-sense and by dismounting it. The sensor is dismounted. EMOUNTING Reverse the above mentioned operations. The cooling and the checking of the cooling liquid level in the gas vessel are to be done.

  • Page 169: Oxygen Sensor

    IGNITION AND INJECTION OXYGEN SENSOR ISMOUNTING The sensor coupling connector to the fuel injection control cables is disconnected as follows: - the blocking valve (1) is pulled arrow-sense (a); - the connector is dismounted. The sensor is dismounted from the primary down tube.

  • Page 170: Induction Coil

    IGNITION AND INJECTION INDUCTION COIL ISMOUNTING Disconnect the battery terminal (-) Disconnect the connector of fuel injection control cables from the coil as follows: - push the lock (1) arrow-sense; - disconnect the connector from the coil. Disconnect the spark plugs cables from the coil.

  • Page 171: Spark Plugs Set

    IGNITION AND INJECTION SPARK PLUGS SET ISMOUNTING Disconnect the spark plugs and the coil cables. ISMOUNTING Connect the cables to the spark plugs and to the corresponding plots of the induction coil. Function ing tests (testing of ignition system). WARNING! When mounting the cables, they should be connected to the cylinder corresponding to the number marked near the coil plot.

  • Page 172: Cooling - Exhaust - Fuel T Ank Characteristics

    ATTENTION ! Use only cooling fluid type DACIA GLACEOL RX type D. The D-type antifreeze has a yellow colour. For the engines variants (with type C antifreeze) it is forbidden the use of type D antifreeze because the type D antifreeze is damaging the cooper gaskets from the cylinders jackets lower part and compromising the sealing.

  • Page 173: Filling And Aeration Of The Cooling System

    COOLING - EXHAUST - FUEL TANK FILLING AND AERATION OF THE COOLING SYSTEM Check : - the tightness of the rings; - the tightness of the draining plugs from the engine block and from the radiator. Dismount the radiator plug and mount in its place the MOT 401 filling device. Completely open the air conditioning radiator tap.

  • Page 174: Control

    COOLING - EXHAUST - FUEL TANK CONTROL The cooling circuit is filled with a fluid which ensures the protection against frost,up to - 40º C. The fluid is made up of a mixture of distilled or de mineralised water and antifreeze fluid as follows: - for a protection up to - 21º...
  • Page 175 COOLING - EXHAUST - FUEL TANK CONTROL CHECKING OF THE COOLING FLUID CONCENTRATION Protection up to - 21 Protection up to - 40 Warm countries Cold countries The value of protection The value of protec- The fluid quantity The fluid quantity temperature red on tion temperature red (liters) which is...
  • Page 176 COOLING - EXHAUST - FUEL TANK CONTROL CHECKING OF THE COOLING CIRCUIT TIGHTNESS AND TAR RING OF THE EXPANSION VESSEL VALVE 1.CHECKING OF THE CIRCUIT TIGHTNESS Mount the MS 554 device instead of the radiator plug. Open the heating tap. Warm the engine till the thermostat opens.
  • Page 177 COOLING - EXHAUST - FUEL TANK CONTROL 2. CHECKING OF EXPANSION VESSEL VALVE TARRING After checking the tightness of the cooling circuit, release the radiator-expansion vessel hose. Create pressure in the circuit,value of the pressure shall be 0,1 bar higher that the value marked on the valve.

  • Page 178: Cooling Radiator

    COOLING - EXHAUST - FUEL TANK COOLING RADIATOR ISMOUNTING Disconnect the battery. Clamp the radiator hoses by means of the MOT 453 device. Drain the radiator and recover the cooling fluid. Dismount the radiator hoses. Unscrew the fixing screw and take out the radiator.

  • Page 179: Cooling G.m.v

    COOLING - EXHAUST - FUEL TANK COOLING G.M.V. ( for A.C. ) ISMOUNTING Disconnect the battery. Drain the cooling system. Drain the A.C system. Disconnect the hoses from the radiator. Disconnect the hoses from the condenser. Disconnect the G.M.V connector.. Dismount the radiator attachment screws on the vehicle body..

  • Page 180: Cooling G.m.v. Thermocouple Checking (For Pick-Up With C.a.)

    COOLING - EXHAUST - FUEL TANK COOLING G.M.V. THERMOCOUPLE CHECKING ( for Pick-Up with C.A. ) NOTE: The GMV thermocouple may not be repaired ;I t is located on the radiator. The G.M.V . thermocouple is located on the lateral right side of the radiator, attached on this. The tightening moment is 5 daNm.

  • Page 181: Water Pump

    COOLING - EXHAUST - FUEL TANK WATER PUMP ISMOUNTING Disconnect the battery. Drain the cooling circuit and recover the cooling fluid. Dismount : - the hoses connected to the pump; - the fan belt; - the fan and the water pump pulley. Unscrew the fixing screws of the pump and dismount the pump by tapping it with a plastic hammer.

  • Page 182: Water Pump Cover

    COOLING - EXHAUST - FUEL TANK WATER PUMP COVER ISMOUNTING Disconnect the battery. Drain the cooling circuit. Dismount : the pump belt,the fan and the water pump pulley. Unscrew the fixing screws of the cover and take out the cover by slightly tapping it with a plastic hammer.

  • Page 183: Thermostat

    COOLING - EXHAUST - FUEL TANK THERMOSTAT ISMOUNTING Loosen the tightening ring and dismount the pump hose Loosen the tightening ring of the thermostat and dismount the thermostat. CHECKING OF THE THERMOSTAT OPERATION Pour in a vessel a convenient quantity of cooling fluid. Check the fluid temperature by means of a thermometer.

  • Page 184: Exhaust Assemby

    COOLING - EXHAUST - FUEL TANK EXHAUST ASSEMBLY The exhaust assembly ensure the evacuation of the burnt gases issued during the engine running and reduction of both noise level and dangerous emissions. The assembly is composed of : - downtake pipe (1); - pipe and expansion chamber (8);...
  • Page 185 COOLING - EXHAUST - FUEL TANK EXHAUST ASSEMBLY EMOUNTING Perform in reverse order the dismounting operations. 19 - 14...

  • Page 186: Fuel Tank Assembly

    Disconnect the rear wiring from the tank cap. Dismount the fuel pump (2). Dismount the hose fixing ring (3) on the air exhaust duct (4) for Dacia 1304 Pick-up, respectively the sealing gasket (8) for Dacia 1304 Dropside. Dismount the fixing collar (5) of the fuel duct on the lower filling hole.

  • Page 187: Electric Fuel Pump

    COOLING - EXHAUST - FUEL TANK ELECTRIC FUEL PUMP PARTICULAR ITIES The electric fuel pump (pic ture 2) is fixe d on the tank,being immersed in fuel and is commended by the computer,by means of the fuel pump relay (R1). When contact is on,with the key in the position M (engine),but without starting the engine,the pump will be fed with electricity only for 3-4 sec.The pump will permanently flow only when the computer is receiving signal from the rpm sensor and must ensure a minimum flow of...
  • Page 188 COOLING - EXHAUST - FUEL TANK ELECTRIC FUEL PUMP ( dismounting the tank from the vehicle not required ) ISMOUNTING Unscrew the fixing screws of the fuel tank visiting cap. Disconnect the rear wiring from the tank cap. Dismount the fixing rings of the hoses and disconnect the hoses from the tank cap. Dismount by turning counter clockwisedir ection,the blocking ring of the tank cap.

  • Page 189: Fuel Level Sensor

    COOLING - EXHAUST - FUEL TANK FUEL LEVEL SENSOR ( dismounting the tank from the vehicle not required ) ISMOUNTING Unscrew the fixing screws of the fuel tank visiting cap. Disconnect the rear wiring from the tank cap. Dismount the hoses fixing rings and dismount the hoses from the tank cap. Dismount,by turning counter clockwise direction, t he fixing ring of the tank cap.

  • Page 190: Clutch Characteristics

    CLUTCH CHARACTERISTICS Dry single disk clutch. Membrane mechanism. Clutch disk with elastic hub. Disk thickness: 7,4 mm Clutch stroke at the lever end: 2,5 - 3,5 mm 20 - 1...

  • Page 191: Identification

    CLUTCH 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 GR CLUTCH Φ Φ Φ Φ 200 DBR CLUTCH 20 - 2...

  • Page 192: Clutch Disk-Mechanism

    CLUTCH CLUTCH DISK – MECHANISM CLUTCH DISMOUNTING - REMOUNTING ISMOUNTING Dismount the gearbox. from the vehicle. ATTENTION! For the injection engines, before gearbox dismounting from the vehicle, dismount the RPM transducer in order to avoid its damaging. Unscrew the clutch mechanism attachment screws and dismount the clutch.
  • Page 193 CLUTCH CLUTCH DISK – MECHANISM PRESSURE BEARING REPLACEMENT ISMOUNTING Dismount the gearbox. from the vehicle. Release the spring from the pressure bearing ears. Dismount the pressure bearing. EMOUNTING Grease the bearing guide and the clutch forks ends with grease UM 170 Li Ca Pb 2M. Place the new bearing.

  • Page 194: Clutch Fork Replacement

    CLUTCH CLUTCH FORK REPLACEMENT ISMOUNTING Dismount the gearbox from the vehicle. Dismount the pressure bearing. Extract the attachment shaft of the clutch fork by means of the AMB 384 A extractor. Dismount the fork spring and recover the fork and the spring. EMOUNTING Grease the fork shaft with UM 170 Li Ca Pb 2M.

  • Page 195: Manual Gearbox Identification

    MANUAL GEARBOX IDENTIFICATION IDENTIFICATION Identification of the gearbox is done by means of a rectangular plate, attached to the clutch housing of the gearbox with a 3,5 mm POP rivet. On the rectangular plate, the type ,variant and fabrication serial numbers of the gearbox are marked.

  • Page 196: Sections

    MANUAL GEARBOX SECTIONS GEARBOX 50C 21 - 2...
  • Page 197 MANUAL GEARBOX SECTIONS GEARBOX 51C 21 - 3...
  • Page 198 MANUAL GEARBOX SECTIONS GEARBOX 365 21 - 4...
  • Page 199 MANUAL GEARBOX SECTIONS DIFFERENTIAL 51C DIFFERENTIAL 365 21 - 5...

  • Page 200: Diagnostics

    MANUAL GEARBOX DIAGNOSTICS GLOSSARY Checking Operations to be performed. A. NOISY GEAR SHIFTING (AFTER CLUTCH CHECKING) Dismount the gearbox. Check the sinchro assembly of the velocity step : - friction cones of the synchro pinion and gear; - synchro hub,springs and wedges; - coupling gears of the pinion and the sliding gear.
  • Page 201 MANUAL GEARBOX DIAGNOSTICS C. SLIPS OUT OF VELOCITY STEPS OF GEAR BOX Check the situation of brackets of assembly. GOOD Tighten brackets Checking of the attachment screws wea and adjustment or replace brackets. of the linkage gear GOOD Dismount the gearbox: Replace defective parts Check coupling teeth of the shifter of the gear linkage.
  • Page 202 MANUAL GEARBOX DIAGNOSTICS E. UNUSUAL NOISES DURING DRIVING Stop the vehicle. Bring the gear shifting handle to dead point. Let the engine running. The noise stops. Check the state of clutch stroke. GOOD Check transmission state. Check the clutch Check the level of the control system.

  • Page 203: Characteristics

    MANUAL GEARBOX CHARACTERISTICS The 365, 50C, 51 C gearboxes are monoblock type , mechanical in steps (5 forward steps and one reverse step). The forward driving velocity steps are provided with Borg – Warner synchronizers. The reverse driving step is not synchronized. UMBER ONICAL EARBOX...

  • Page 204: Tightening Moments

    MANUAL GEARBOX TIGHTENING MOMENTS ADJUSTEMENT VALUES Distance between the conical gears: 59 mm. Differential gear bearings pre-tightening : - reused bearings : free, without clearance; - new bearings : 1-3 daN. Gear teeth clearance: 0,12- 0,25 mm; Clearance in differential gear: max. 0,1mm (daNm) IGHTENING MOMENTS - Half crankcases assembling screws :...

  • Page 205: Ingredients

    MANUAL GEARBOX INGREDIENTS MATERIALS Parts that are to be obligatory replaced, if they were dismounted: paper gaskets, annular oil rings, toothed crown attachment screws, speedometer endless screw, elastic pins, primary shaft nut, secondary shaft nut, reverse selector shaft nut, shifter shaft nut. ATERIALS 80W/90;...

  • Page 206: Dismounting - Remounting

    MANUAL GEARBOX DISMOUNTING - REMOUNTING GEARBOX DISMOUNTING – REMOUNTING FROM THE VEHICLE NOTE: For the vehicles equipped with injection system ,first dismount RPM transducer attached on the clutch casing, to avoid its damaging during gearbox dismounting. Disconnect the battery. Disconnect: -starter power cable;...
  • Page 207 MANUAL GEARBOX DISMOUNTING - REMOUNTING Disconnect the vacuum hoses and the electrical connector of the vacuum capsule (G.B. 51 C). Dismount the 4 attachment screws of the secondary shaft flange and rock the transmission (G.B. 51 C; 50 C). Disconnect the speed gear control by unscrewing the control auxiliary rod screws.
  • Page 208 MANUAL GEARBOX DISMOUNTING - REMOUNTING EMOUNTING Check the state of the centering bushing from the crankshaft end. Grease the grooves of the clutch shaft with grease U M 170 Li Ca Pb 2 M. Assembly the gearbox to the engine. ATTENTION ! ! ! ! Do not catch the clutch mechanism.
  • Page 209 MANUAL GEARBOX DISMOUNTING - REMOUNTING Place the new elastic pins. The pins notches shall be oriented towards the wheel. The ends of the pins shall be sealed with RHODORSEAL 5661. Mount (on both sides): a. the upper suspension joint b. the steering joint Mount the front wheels, take the vehicle down from the elevator and tighten the wheels nuts at the required moment (9 daNm).

  • Page 210: Repair

    MANUAL GEARBOX REPAIR Dismount the gearbox off the vehicle Dismount the reverse driving lamp contact. Dismount the clutch casing. DISMOUNTING OF THE COUPLING MECHANISM 4X4 (G.B. 51 C) Dismount the attachment pin of the connection bolt (1) between the vacuum capsule shaft and the control lever and take out the bolt.
  • Page 211 MANUAL GEARBOX REPAIR Clean the annular oil seal place from the differential cover. Take out the cover (7) from the hub differential. Dismount the safety ring (8) from the propeller shaft gear. Take out slotted shim (9). Extract the hub-gear assembly (10) together with fork and shaft (11).
  • Page 212 MANUAL GEARBOX REPAIR Dismount the velocity step V fork pin by means of 31 B mandrel. Observe the hub and the tooth gear sliding mechanism of velocity step V. Dismount: - the synchronizing mechanism and the fork of velocity step V; - the velocity step V pinions.
  • Page 213 MANUAL GEARBOX REPAIR FORKS AND SHAFTS DISMOUNTING Bring the fork III - IV to the dead point. Dismount the speed V fork shaft and recover : - the interlocking ball between forks shafts III -IV and V. - the ball and the attachment spring of the speed V fork shaft;...
  • Page 214 MANUAL GEARBOX REPAIR REVERSE DRIVING PINION DISMOUNTING Dismount: - the lock ring; - the shaft; - the pinion; - the friction ring; - the guiding wedge. Recover the spring and the attachment ball. HALF CRANKCASES DISASSEMBLING Dismount the outer ring of the bearing by means of a trod.
  • Page 215 MANUAL GEARBOX REPAIR PRIMARY SHAFT DISASSEMBLING Dismount the elastic pin by means of the CV 39 mandrel and separate the clutch shaft from the primary shaft. Take out the outer rings of the bearings and the rollers cage. Dismount the bearing inner ring by means of the CV 22 extractor.
  • Page 216 MANUAL GEARBOX REPAIR SECONDARY SHAFT DISASSEMBLING Dismount : - the biconical bearing; - the ring for the adjustment of the distance between the cones gear; - the velocity step IV pinion and its synchronizing ring; - the synchronizer tooth gear sliding mechanism III - IV.
  • Page 217 MANUAL GEARBOX REPAIR Dismount: - the lock ring of the speed II pinion; - the speed II free pinion and its synchronizer ring; - the lock ring of the synchronizer hub speeds I -II; - the synchronizer tooth gear sliding mechanism of speeds I –...
  • Page 218 MANUAL GEARBOX REPAIR DIFFERENTIAL GEAR DISASSEMBLING ( G.B. 365 ºi 51C ) Unscrew two opposite attachment screws of toothed crown. Dismount the bearings by means of the CV 28 A extractor, provided with the CV 48 grippers. Dismount the toothed crown; the screws may not be re-used. Dismount the elastic attachment pin of the pinions shaft, by means of the CV 31 B mandrel.
  • Page 219 MANUAL GEARBOX REPAIR BACK CAP DISASSEMBLING Dismo unt : - the speedometer pinion guide and its sealing gasket; - the speedometer pinion. Dismount the nut at the end of the rocking lever; take out the shaft. Dismount the plug of the V velocity step pusher, recover the spring, the pusher and the gasket.
  • Page 220 MANUAL GEARBOX REPAIR SECONDARY SHAFT ASSEMBLING For G.B. 365 ºi 51C. The differential drive pinion and the toothed crown are lapped together. Replacing of one part obligatory requires replacing the pair part. A pairing number is marked both on the pinion end and on the toothed crown. No other markings shall be taken into consideration besides the pairing number.
  • Page 221 MANUAL GEARBOX REPAIR The mounting of the hub I – II can be performed in two variants : 1.By difference of temperature (for gearbox made until 26.04.1999 , series 172321). Place the velocity steps I – II synchroniser hub on electrical stove , at a 120° C, dgr temperature , and keep it there for about 15 minutes , to heat it.
  • Page 222 MANUAL GEARBOX REPAIR Mount the velocity step III pinion and its synchronising ring. Mount : - the velocity step III pinion lock washer; - the lock wedge of the washers; the wedge is mounted in a channel which has a lubricat i ng hole.
  • Page 223 MANUAL GEARBOX REPAIR Mount : - the velocity step IV pinion and its synchroniser ring; - the adjustment washer for the conical mechanism dist ance, recovered upon dismounting; - the biconical bearing; - the spacer; - the velocity step V pinion; - the elastic washer.
  • Page 224 MANUAL GEARBOX REPAIR PRIMARY SHAFT ASSEMBLING Mount the biconical bearing. Press the needle-roller bearing inner ring. Mount the outside bearing ring together with its rollers casing. Mount the lock washer. Mount the clutch shaft ; place a new compensation washer between the end of the shaft, in order to prevent the noise.
  • Page 225 MANUAL GEARBOX REPAIR DIFFERENTIAL GEAR ASSEMBLING ( G.B. 365 and 51C ) Place the following parts in the casing : - the textolite washer ,with the lubricating grooves directed towards the propeller shaft pinion ; use 1.96 - 2 mm thick washers. The 2.03 - 2.07 mm thick washers shall be used only if the clearance between the propeller shaft pinion and the differential pinion is very big.
  • Page 226 MANUAL GEARBOX REPAIR Mount the differential bearings on a press. ADJUSTMENT OF THE CONICAL DISTANCE (G.B.365 AND 51 C) The differential drive pinion is in the correct position, when its front is at distance A=59 mm from the toothed crown axis. This position is obtained by mounting a washer (1) of the adequate thickness between the biconical bearing (2) and the differenti a l drive...
  • Page 227 MANUAL GEARBOX REPAIR The checking of the conical distance is performed by means of the CV239 - 01 control device, which materializes the toothed crown axis and by means of a spacer CV 239 - 02, with the height H = 48,5 mm. The height (H) of the 48,5 mm spacer plus radius (C) of the device axis of 10 mm represents: 48,5 mm + 10 mm = 58,5 mm.
  • Page 228 MANUAL GEARBOX REPAIR DIFFERENTIAL GEAR BEARINGS ADJUSTMENT ( G.B. 365 and 51 C ) The differential gear bearings adjustment is performed by means of the nuts (1) and (2). Mount the annular oil seal rings on the adjustment nuts. Grease the adjustment nuts threads with sealing paste LOCTITE 518 NOTE: Before mounting, the annular oil rings will be immersed in oil 80W/90.
  • Page 229 MANUAL GEARBOX REPAIR Tighten the adjustment nuts by means of the CV 377 wrench, until they come into contact,with the outer rings of the bearings. 1. REUSED BEARINGS The reused bearings shall be mounted freely, without clearance. Tighten the adjustment nuts until the bearings rotate freely , without any clearance. 2.
  • Page 230 MANUAL GEARBOX REPAIR Notice the nuts position corresponding to the half crankcases. Dismount the left side half crankcase and the differential gear. REMOUNTING OF FORKS AND SHAFTS NOTE: Upon remounting, the elastic pins shall be positioned with the slot towards the back side of the gearbox.
  • Page 231 MANUAL GEARBOX REPAIR Place the interlocking disk of the forks shafts. Place the attachment spring and ball of the velocity steps III IV fork shaft. Introduce the shaft. Mount the velocity steps III - IV fork with the hub towards front side of the box. Introduce the elastic pin.
  • Page 232 MANUAL GEARBOX REPAIR Engage the velocity steps III - IV fork in the position required for the coupling of velocity step IV and keep it in this position until complete mounting of the gearbox. REMOUNTING OF THE REVERSE DRIVING PINION Place the attachment spring and ball of the shaft in the left side half crankcase.
  • Page 233 MANUAL GEARBOX REPAIR HALF CRANKCASE ASSEMBLING Place in the right side half crankcase - primary shaft; - secondary shaft together with the lock pin of the biconical bearing taking care that the assembled forks to be positioned in their seats; - the differential gear (G.B.
  • Page 234 MANUAL GEARBOX REPAIR Place the following parts on the secondary shaft: - the velocity step V pinion; - the elastic washer; - the speedometer endless. Check the clearance “J” between the synchronizing ring and the surface of the hub : J = min 0,2 mm The checking shall be performed as follows: - the pinion in contact with the hub;...
  • Page 235 MANUAL GEARBOX REPAIR Mount a comparing device on the crankcase and place the feeler perpendicularly on the crown tooth flank, as much to the edge of the rim as possible. Check the clearance of the gear which should be: 0,12-0,25 mm. Adjust the nuts until correct clearance is obtained.
  • Page 236 MANUAL GEARBOX REPAIR Mount the speedometer pinion and its guide provided with a sealing gasket. Mount : - the velocity step V pusher; - the spring; - the gasket; - the plug greased with LOCTITE 577 and t i ghten at the r e qui r ed coupl e (1,1- 1,5daNm) BACK CAP RE MOUNTING Bring the forks to the dead point.
  • Page 237 MANUAL GEARBOX REPAIR CLUTCH CASING RE MOUNTING Press in the clutch casing the guiding bushing of the pressure bearing (only if it has previously been dismounted). Mount the annular oil seal of the clutch shaft by means of the device CV 488. NOTE: Before mounting, the annular oil seal shall be immersed in 80W/90.
  • Page 238 MANUAL GEARBOX REPAIR Replace the annular oil seal from the differential cap, as follows: - grease the new annular oil seal with gear oil 80W90; - mount the new annular oil seal by slightly tapping by means of the plastic hammer until it came into contact with the support shoulder from the differential cap resulting in this case the dimension +/-0,5...

  • Page 239: Back Cap

    MANUAL GEARBOX BACK CAP (on vehicle ) ISMOUNTING EMOUNTING Lift the car on the elevator. Clean the contact surface of the gasket. Drain the oil from the gearbox. Place a new paper gasket after it was Disconn ect: lubricated with oil. - the speedometer cable;...

  • Page 240: Control Shaft Annular Oil Seal Replacement

    MANUAL GEARBOX CONTROL SHAFT ANNULAR OIL SEAL REPLACEMENT (on vehicle ) ISMOUNTING EMOUNTING Lift the car on the elevator. Mount the new annular oil seal,after it was Drain the oil from the gearbox. immersed in 80W90 oil. Dismount the back crossbar of the Mount together : gearbox.

  • Page 241: Speedometer Endless Screw Pinion Replacement

    MANUAL GEARBOX SPEEDOMETER ENDLESS SCREW PINION REPLACEMENT (on vehicle ) ISMOUNTING EMOUNTING Lift the car on the elevator Mount the speedometer new endless Drain the oil from the gearbox. screw by means of the wrench CV 204 Disconn ect: and tighten at the required moment - the speedometer cable;...
  • Page 242 MANUAL GEARBOX VELOCITY STEP V SYNCHRONIZER REPLACEMENT (on vehicle ) EMOUNTING ISMOUNTING Place the fork on the gear tooth gear sliding Lift the car on the elevator mechanism; Drain the oil from the gearbox. Mount the velocity step V synchronizer Disconnect : assembly together with the fork, on the primary - the speedometer cable;...

  • Page 243: Clutch Shaft Annular Oil Seal Replacement

    MANUAL GEARBOX CLUTCH SHAFT ANNULAR OIL SEAL REPLACEMENT (on vehicle ) ISMOUNTING Clutch annular oil seal replacement requires gearbox dismounting from the vehicle. Dismount the gearbox from the vehicle. Dismount the pressure bearing. Dismount the clutch casing. Dismount the annular oil seal clutch shaft. EMOUNTING NOTE: Before mounting ,the annular oil seal shall be immersed in 80W/90 oil.

  • Page 244: Propeller Shaft Annular Oil Replacement

    MANUAL GEARBOX PROPELLER SHAFT ANNULAR OIL REPLACEMENT (on vehicle ) ISMOUNTING Mount the TF 509 support crossbars between the attachment shaft of the shock absorber and the lower suspension arm shaft. Lift the car on the elevator. Dismount the front wheels. Drain the oil from the gearbox.
  • Page 245 MANUAL GEARBOX PROPELLER SHAFT ANNULAR OIL REPLACEMENT (on vehicle ) Dismount the lock washer. Dismount the adjustment nut by means of the CV 377 wrench; mark the number of rotations of the nut to enable the mounting in the same position, avoiding this way the further adjustment of the differential gear bearings.

  • Page 246: Drive Shafts

    DRIVE SHAFTS FRONT CROSS TRANSMISSIONS I. FRONT CROSS TRANSMISSION CHARACTERISTICS Transmission of the motion from the gearbox to the front two driving wheels is performed by means of two assembled homo-kinetics transmissions provided at their ends with two joints of the following type: - GE 86 - towards the wheel;...

  • Page 247: Front Cross Transmission

    DRIVE SHAFTS FRONT CROSS TRANSMISSION SPECIAL TOOLS Pivot pins extractor PF 476 Mandrel C.V. 31 B Hub immobiliser PF 235 A Device for mounting transmission in the hub PF 236 ( daNm ) IGHTENING MOMENTS Suspension upper joint nut Steering joint nut Transmission nut Wheels nut 29 - 2...
  • Page 248 DRIVE SHAFTS FRONT CROSS TRANSMISSION ISMOUNTING Mount the TF 509 support cross bar between the shock absorber attachment shaft and the suspension lower arm shaft. Lift the vehicle on the elevator. Dismount the wheel. Loosen: - the attachment nut of the suspension upper ball joint;...
  • Page 249 DRIVE SHAFTS FRONT CROSS TRANSMISSION EMOUNTING Grease the propeller shaft pinion grooves with Li Ca Pb type II. Couple the transmission with the propeller shaft pinion. Introduce the new elastic pins. The pins notches shall be oriented towards the wheel. The pins ends shall be sealed with RODORSIL.

  • Page 250: Bellows Towards To The Gearbox

    DRIVE SHAFTS BELLOWS TOWARDS TO THE GEARBOX GI 69 JOINT BELLOWS REPLACEMENT Joint bellows replacement - the part towards the gearbox – is to be performed with dismounted transmission. 1. Tulip 2. Assembled tripod 3. Assembled type 4. Casing 5. Collar 6.
  • Page 251 DRIVE SHAFTS BELLOWS TOWARDS TO THE GEARBOX EMOUNTING Grease, the transmission shaft, the bellows and the rubber ring with MoS grease. Place on the shaft, the rubber ring and the new bellows. Mount the tulip on the shaft. Mount the safety ring. Mount the tulip on the shaft.
  • Page 252 DRIVE SHAFTS BELLOWS TOWARDS THE WEEL GE 86 JOINT BELLOWS REPLACEMENT Bellows replacement – the wheel side- is to be performed having the transmission dismounted. 1. Steering knuckle casing 2. Retention star 3. Tripod assembly 4. Tulip shaft 5. Collars 6.

  • Page 253: Longitudinal Transmission (Cardanic)

    DRIVE SHAFTS LONGITUDINAL TRANSMISSION ( CARDANIC ) II.LONGITUDINAL TRANSMISSION ( CARDANIC ) CHARACTERISTICS Longitudinal transmission is specific and is equipping the D1304, D 1307 vehicles (rear wheel drive or f.w.d. 4 W D) and has the purpose to transmit the motion from GB to rear axle (drive axle).
  • Page 254 Lt - total length of the cardanic transmission L - lengt of the cardanic shaft with bearing L z - length of the assembled cardanic shaft EHICLE UMBER OF RANGE GEARS DACIA 1304 4 TR 1970 1100 DACIA 1304 1950 1100...

  • Page 255: General

    GENERAL PRINCIPLE SCHEDULE OF A BRAKE CIRCUIT IN PARALLEL WITH BY-PASS CIRCUIT The DACIA commercial vehicles, are equipped with hydraulic braking system, double circuit by-pass brake pump , brake amplifier, pressure limiter in order to avoid the rear wheels blocking.

  • Page 256: Tightening Moments (Dan)

    GENERAL TIGHTENING MOMENTS ( daNm ) FRONT DRIVING AXLE 30 - 2...
  • Page 257 GENERAL TIGHTENING MOMENTS ( daNm ) FRONT NON DRIVING AXLE 6, 5 30 - 3...
  • Page 258 GENERAL TIGHTENING MOMENTS ( daNm ) REAR DRIVING AXLE 1,54 30 - 4...
  • Page 259 GENERAL TIGHTENING MOMENTS ( daNm ) REAR UNDRIVING AXLE 1,54 30 - 5...
  • Page 260 GENERAL TIGHTENING MOMENTS ( în daNm ) IGHTENING MOMENT LEMENT 1 - 1,2 Caliper purging screw Flexible hoses in calipers Rigid tubing linkage in wheel cylinder Pad holder attachment screw Attachment screw disk to the hub Front wheel steering knuckle nut Wheel attachment screw Wheel fixing nuts Main brake cylinder fixing nut with servobrake...

  • Page 261: The Dimensions Of Main Braking Elements

    GENERAL THE DIMENSIONS OF MAIN BRAKING ELEMENTS ( in mm ) FRONT BRAKE Brake caliper bore diameter (for 3 screws wheel) φ 48 Brake caliper bore diameter (for 5 screws wheel) φ 54 Brake disk diameter Disk thickness non aerated Disk thickness aerated Minimal disk thickness non aerate Minimal disk thickness aerated...

  • Page 262: Brake Connections And Sewerage

    GENERAL BRAKE CONNECTIONS AND SEWERAGE The sewerage connection between the brake pump, brake calipers, pressure limiter is performed by means of the sleeves threaded with METRIC PITCH Therefore it is important to use only original spare parts, recommended in the spare parts catalogue specific for this type of vehicle.

  • Page 263: Brake Fluid

    BRAKE FLUID PERIODIC CHANGE OF THE BREAK FLUID The manufacturing conception of the brakes equipping the Dacia vehicles especially the disk brake type (inner empty pistons, low quantity of fluid with cylinder, sliding calipers avoiding existence of a fluid reserve in the less cooled area of the wheel) enable the maxi- mum rejection of fluid vaporization even in case of intensive using of brakes (mountain area).

  • Page 264: Braking Circuit Purging

    GENERAL BRAKING CIRCUIT PURGING AIR ELIMINATION FROM THE HYDRAULIC CIRCUIT ( PURGING ) The air existence in the hydraulic circuit may be noticed by an elastic displacement of the brake pedal, sometimes even, close to the floor. This fact is more evident with the engine stopped.

  • Page 265: Diagnostic

    GENERAL DIAGNOSTIC Rigid ped al: when braking, an I. FAILURE : RIGID PEDAL increased effort for a small decel- eration is performed Is the connection Replace: shaft, pedal or shaft between the servobrake fork. servobrake fork and the pedal, grabed? Is the engine Replace the servobrake regime changing...
  • Page 266 GENERAL DIAGNOSTIC I. FAILURE : RIGID PEDAL (ctd) One of the rigid Replace the corresponding rigid brake pipes is it pipe. smashed ? Dismount the brake caliper or the brake cylinder? Are the brake caliper’s pistons Replace the defective parts or the cylinders (with Genuine Spare Parts) ones correctly...
  • Page 267 GENERAL DIAGNOSTIC II. FAILURE : LONG PEDAL When braking, the brake pedal is slowly moving. Perform a test with the stopped engine, after previously performing five successive pushing on the brake pedal (in order to vacuum the servobrake). Is the bra ke fl u id Locate and repair or replace the level lowe r item where a brake fluid leak is...
  • Page 268 GENERAL DIAGNOSTIC I. CONSTANT EFFECT TO THE PEDAL EFFECTS POSSIBLE CAUSES Tough pedal: - Assistance defect High effort for small decele ration. - Brake linings: - greasy - stacking to the disk ( non-conform ) - heating, prolonged braking with constant pedal press - Stuck piston - Rigid duct narrowed (flattening)
  • Page 269 GENERAL DIAGNOSTIC II. CONSTANT EFFECT AT BEHAVIOUR EFFECTS POSSIBLE CAUSES - Non-uniform worn brake linings (backing Brakes not accomplishing the required braking distance off); - Brake linings slightly greased; - Springs with modified characteristics. - Brake disks with high wobbling; Vibrating brakes - Inconstancy brake disks width;...

  • Page 270: The Influence Of Angles

    GENERAL THE INFLUENCE OF ANGLES FRONT AXLE ANGLES CAMBER ANGLE 1 30’ +/- 30’ It is formed by the wheel plane with the vertical that crosses the wheel axis. A difference higher that 1°between the two camber angles (left side and right side) leads to: - the deviation from the trajectory that must adjusted by means of the steering wheel;...
  • Page 271 The wheels of the front axle are : - divergent for DACIA commercial vehicles with front drive (opening 1 – 4 mm); - convergent for DACIA commercial vehicles with rear drive or four wheels drive (closing 1 – 3 mm).

  • Page 272: Steering Preliminary Checkings And Adjustment Possibilities

    GENERAL STEERING PRELIMINARY CHECKINGS AND ADJUSTMENT POSSIBILITIES ADJUSTMENT POSIBILITIES Only the following parameters may be adjusted: - the caster angle, by means of the rod; - the parallelism and the distribution, from the connecting rod pipe; - the steering gear box position, by means of the eccentrics (positioning will be adjusted only if the steering gear box has been dismounted DIR 487).

  • Page 273: Front Axle Checking-Adjustment

    GENERAL FRONT AXLE CHECKING -ADJUSTMENT THE SEQUENCE OF THE OPERATIONS Due to the geometric conception of the front axle , modification of one side angle (castor angle, camber angle,ball joints) has no major impact on the value of other side angles (the parallelism being directly influenced).
  • Page 274 GENERAL FRONT AXLE CHECKING -ADJUSTMENT REPARTITION CHECKING AND ADJUSTMENT Check the connecting rods symmetry “X”. Read the value “A” on the scale. 31 - 20...
  • Page 275 GENERAL FRONT AXLE CHECKING -ADJUSTMENT Case 1. The symmetry dimension “X” is correct: - the value “A” is equal distributed. Case 2. The symmetry dimension “X” is incorrect: - read the value “A” on each side, mark it, calculate an average value, establishing the value for each side.

  • Page 276: Diagnostic

    GENERAL DIAGNOSTIC THE AXIAL DEVIATION OF THE WHEELS TO THE LEFT OR RIGHT AT STABLE SPEED Prelimin ary checking: (front,rear):- pressure; - bush. HEELS HINGES: - dimensions; - types; - adjusting wheels. : - symmetry CONTROL POINTS HEIGHT Required conditions are respected Correct the deficients The deviation persists...

  • Page 277: Front Bearing Elements

    FRONT BEARING ELEMENTS UPPER ARM SUSPENSION UPPER ARM SPECIAL TOOLS ENOMINATION Front axle support cross bars PF 509 Ball joints extractor PF 476 Dynamometric wrench MOT 50 ISMOUNTING The operation that where performed on a half axle are identical to those performed on the other one.
  • Page 278 FRONT BEARING ELEMENTS UPPER ARM EMOUNTING Position the arm and clamp the lower joint of the shock absorber. Couple the upper suspension ball joint with the steering knuckle and slightly tighten the nut. Mount , without tightening ; - the upper arm shaft; - the lower joint shaft of the shock absorber;...
  • Page 279 FRONT BEARING ELEMENTS UPPER ARM CHECKING SPECIAL TOOLS ENOMINATION Front axle support cross bars PF 509 Ball joints extractor PF 476 Upper arm checking device PF 502 Dynamometric 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).

  • Page 280: Elastic Bushing, Upper Arm Ball Joint

    FRONT BEARING ELEMENTS ELASTIC BUSHING, UPPER ARM BALL JOINT ELASTIC BUSHING REPLACEMENT SPECIAL TOOLS ENOMINATION Front axle support cross bar PF 509 Ball joint extractor PF 476 Dynamometric wrench MOT 50 Dismount the upper arm of the suspension. Dismount on a press the worn bushing, using a rod with the outer diameter of D = 26mm.
  • Page 281 FRONT BEARING ELEMENTS ELASTIC BUSHING,UPPER ARM BALL JOINT Lift the vehicle using a two columns elevator. Dismount the wheel, mounting the PF 509 crossbar, between the lower arm shaft and the shock absorber joint shaft. Release the ball joint from the steering knuckle by means of the PF 476 extractor.

  • Page 282: Lower Arm

    FRONT BEARING ELEMENTS LOWER ARM SUSPENSION LOWER ARM SPECIAL TOOLS ENOMINATION Front axle support cross bar PF 509 Ball joint extractor PF 476 Dynamometric wrench MOT 50 ISMOUNTING 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.
  • Page 283 FRONT BEARING ELEMENTS LOWER ARM EMOUNTING Mount the lower ball joint in the steering knuckle and slightly tighten the nut. Lift the half-front axle by means of a jack. Position the arm, grease it with special MoS2 grease and mount it. Mount the elastic bushings of the stabilizer rod.
  • Page 284 FRONT BEARING ELEMENTS LOWER ARM CHECKING SPECIAL TOOLS ENOMINATION Front axle support cross bar PF 509 Ball joint extractor PF 476 Lower arm checking device PF 502 Dynamometric wrench MOT 50 Dismount the suspension lower arm. Mount the lower arm checking device PF 502 on the lower arm and introduce the shaft. By means of the pin (D) placed on the arm, measure the distance between the pins (A,B,C) and arm, which should be between 0 and 1 mm .

  • Page 285: Elastic Bushing, Lower Arm Ball Joint

    FRONT BEARING ELEMENTS ELASTIC BUSHING, LOWER ARM BALL JOINT ELASTIC BUSHING REPLACEMENT SPECIAL TOOLS ENOMINATION Front axle support cross bar PF 509 Ball joint extractor PF 476 Dynamometric wrench MOT 50 This operation implies bushings replacement one by one ,in order to maintain their position as to the arm shaft.
  • Page 286 FRONT BEARING ELEMENTS ELASTIC BUSHING, LOWER ARM BALL JOINT BALL JOINT REPLACEMENT SPECIAL TOOLS ENOMINATION Front axle support cross bar PF 509 Ball joint extractor PF 476 Dynamometric wrench MOT 50 Release the ball joint by means of the PF 476 extractor. Dismount the suspension lower arm.

  • Page 287: Brake Gaskets

    FRONT BEARING ELEMENTS BRAKE GASKETS : Pushing piston device FR 500 SPECIAL TOOLS FRONT BRAKE PADS REPLACEMENT NOTE: In order to maintain the brake efficiency, the replacement of the brake pads shall be made only in complete kit; never fit brake pads of different makes and different qualities.The replacement is made when the pad thickness is less than 7 mm (support included).
  • Page 288 FRONT BEARING ELEMENTS BRAKE GASKETS EMOUNTING Mount the protection bellow. Check : - the wear of brake disk; - the wear of flexible hoses. Push the piston by means of the FR 500 device. Mount: - the protection bellows; - the elastic blades; - the new brake pads;...

  • Page 289: Brake Caliper

    FRONT BEARING ELEMENTS BRAKE CALIPER ( daNm ) IGHTENING MOMENTS Wheel nuts Rigid sewerage-connection screws ISMOUNTING Drain the brake fluid tank. Lift the vehicle by means of a two columns elevator Dismount the wheel. Dismount: -safety wedges; -the wedges (B) by lateral sliding. Disconnect the brake wear sensor.
  • Page 290 FRONT BEARING ELEMENTS BRAKE CALIPER Clean and grease the sliding surfaces of the caliper, wedges and pads holder. Mount the caliper on the pad holder. Mount the lower wedge, which must smoothly slide. Introduce a screwdriver between upper caliper part and pad holder and press the screw- driver.
  • Page 291 FRONT BEARING ELEMENTS BRAKE CALIPER TEMPORARY REMOUNTING FOR TESTING Lubricate the caliper groove and the sealing gasket with brake fluid. Mount the sealing gasket in its seat. Lubricate the piston with brake fluid and introduce it in the brake caliper. The piston should be displaced easily by hand;...
  • Page 292 FRONT BEARING ELEMENTS BRAKE CALIPER If the brake caliper lets the air flow by the piston, dismount the caliper brake once more. If the piston has been reused, it shall be replaced, and if has been replaced, it shall be recovered and the brake caliper shall be replaced with a new assembly.

  • Page 293: Brake Disk

    FRONT BEARING ELEMENTS BRAKE DISK FRONT BRAKE DISK SPECIAL TOOLS ENOMINATION Caliper piston pusher FR 500 Dynamometric wrench MOT 30 IGHTENING MOMENTS - Brake caliper fork attachment screw on steering knuckle....6,5 daNm - Disk attachment screw on the hub............. 2 daNm - Steering knuckle front wheel nut............
  • Page 294 FRONT BEARING ELEMENTS BRAKE DISK ISMOUNTING Lift the vehicle on the elevator Dismo unt : - the wheel; - the front wheel steering knuckle nut; - the caliper without disconnecting the flexible connection; - the brake pads; - the caliper support. Lock the hub by means the of the PF 235 A device and unscrew the steering knuckle nut.
  • Page 295 FRONT BEARING ELEMENTS BRAKE DISK EMOUNTING Check the state of the flexible hose and of the brake pads; replace them if necessary. Attach the disk to the hub. Grease the bearing with LiCaPb type II grease. Mount the cross bar on the hub and place the “hub – disk” assembly on the steering knuckle. Mount the “...

  • Page 296: Brake Caliper Support

    FRONT BEARING ELEMENTS BRAKE CALIPER SUPPORT ( în daNm ) IGHTENING MOMENTS The attachment caliper support screw on steering knuckle ..6,5 The attachment protector screw on the caliper support....1,3 The attachment protector screw on the steering knuckle....2 ISMOUNTING Lift the vehicle on a two columns elevator;...

  • Page 297: Steering Knuckle

    FRONT BEARING ELEMENTS STEERING KNUCKLE ISMOUNTING SPECIAL TOOLS ENOMINATION Transmission gear and hub extractor PF 235 A Transmission gear mounting device PF 236 Ball joints extractor PF 476 Front axle support cross bar PF 509 Dynamometric wrench MOT 50 IGHTENING MOMENTS - Upper ball joint nut........5 daN.m - Lower ball joint nut........5 daN.m - Steering ball joint nut........4 daN.m...
  • Page 298 FRONT BEARING ELEMENTS STEERING KNUCKLE Mount the PF 235 A extractor on the hub; Depress the “hub – disc” assembly; Dismount the three ball joints by means PF 476 and take out the steering knuckle. EMOUNTING Position and press the steering knuckle on the “ hub – disk “assembly ,after previou sly having introduced a grease supply.
  • Page 299 FRONT BEARING ELEMENTS STEERING KNUKLE STEERING KNUKLE - CHECKING SPECIAL TOOLS ENOMINATION Steering knuckle checking device PF 496 The steering knuckle is dismounted off the motor car. Dismount the inner bearing of the steering knuckle. In its seat, place the pin (C) of the PF 496 checking device, and place mandrels (A) and (B) in the suspension ball joint seats.

  • Page 300: Steering Knuckle Bearing

    FRONT BEARING ELEMENTS STEERING KNUCKLE BEARING STEERING KNUCKLE - BEARINGS REPLACEMENT SPECIAL TOOLS ENOMINATION Front axle support crossbar PF509 Transmission gear and hub extractor PF 235 A Transmission gear mounting device PF 236 Ball joint extractor PF 476 Shaft protection bushing RO 15 - 01 Bearings extractor CV 28 A...
  • Page 301 FRONT BEARING ELEMENTS STEERING KNUKLE BEARING INNER BEARING REMOUNTING Mount the new bearing by means of a press, using a bushing having the outer diameter of 71 mm and the inner diameter of 66 mm. The bushing shall be supported and shall be pressed on the bearing outer ring. NOTE: Do not deteriorate the bearing sealing gasket ! OUTER BEARING REMOUNTING Mount bearing by pressing it on the hub, using a 36 mm inside diameter rod.

  • Page 302: Characteristics Of Front Suspension Main Elements

    FRONT BEARING ELEMENTS CHARACTERISTICS OF FRONT SUSPENSION MAIN ELEMENTS FRONT SUSPENSION ( section) FRONT SUSPENSION With helical springs, hydraulic shock absorber with double effect, with incorporated lock buffers and stabilizer rod. The helical springs have a flat support area at the upper part, and a flat support area at the lower part.

  • Page 303: Suspension - Tightening Moments

    FRONT BEARING ELEMENTS SUSPENSION - TIGHTENING MOMENTS NOTE: Make sure the suspension springs of each axle have the same characteris- tics. OIL DIAMETER REE LENGHT ( mm ) daN/mm OF MOTOR CARE UNDER LOAD RONT SPRINGS Pick - up 1304, 1305,1307 14,5 410 / 250 STABILIZER ROD...

  • Page 304: Front Shock Absorber

    FRONT BEARING ELEMENTS FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER REPLACEMENT BY MEANS OF THE SUS 478 - 01 DEVICE The front shock absorber may be dismounted as follows: - single, using the SUS 478 – 01 device; - together with the spring, using the SUS 478 device. ISMOUNTING Mount the PF 509 support crossbar between the shock absorber lower attachment shaft and...
  • Page 305 FRONT BEARING ELEMENTS FRONT SHOCK ABSORBER EMOUNTING Grease the threaded parts of the shock absorber with special MoS2 grease. Press the rod , tilt and place the shock absorber. Fully screw the shock absorber into the lower joint. Pull the shock absorber rod by means of the SUS 513 device. Position the rubber buffers and the crossbar.
  • Page 306 FRONT BEARING ELEMENTS FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER REPLACEMENT BY MEANS OF THE SUS 478 DEVICE ISMOUNTING Mount the PF 509 support crossbar. Lift the vehicle by means of a 2 columns el- evator. Dismount the wheel. Take the SUS 478 device and perform the following operatio ns: - grease the thread of the grippers;...
  • Page 307 FRONT BEARING ELEMENTS FRONT SHOCK ABSORBER EMOUNTING Grease the threaded parts of the shock absorber with special MoS2 grease. Place the “ device – spring – shock absorber “ assembly . Fully screw the shock absorber into the lower joint. Pull the shock absorber rod by means of the SUS 513 device.

  • Page 308: Front Suspension Spring

    FRONT BEARING ELEMENTS FRONT SUSPENSION SPRING ISMOUNTING Dismount the shock absorber and the spring by means of the SUS 478 device. Clamp the SUS 480 device into the vice. Place the “ SUS 478 device – spring “ assembly on the SUS 480 device. Place the upper plate and press the spring until the SUS 478 device is released.

  • Page 309: Front Stabilizer Rod

    FRONT BEARING ELEMENTS FRONT STABILIZER ROD ISMOUNTING Unscrew : - the attachment nuts (1)and (2) of the casing on the longitudinal girder; - the nuts (3) of the stabilizer rod aux- iliary connecting rod. Dismount the stabilizer rod together with the auxiliary connecting rod.

  • Page 310: Rear Bearing Elements Plate Drive Rear Axle

    REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE PLATE DRIVE REAR AXLE DACIA 1304,1307 CHARACTERISTICS It is a rigid type axle made of plate, with differential gear and propeller shafts. It is attached to the chassis by means of semi elliptic springs and hydraulic shock absorbers.
  • Page 311 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE ANGLES ALUE DJUSTMENT Parallelism Not adjustable Camber angle 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 ISMOUNTING...
  • Page 312 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE Dismount : - the four screws of the cardanic flange at the side towards the differential gear; - the shaft nut that attaches the shock absorber; - the clamping clips of the half-elliptic spring. Detach the brake cable from the hand brake levers.

  • Page 313: Brake Drum

    REAR BEARING ELEMENTS BRAKE DRUM The two rear brake drums must have the same diameter, the rectifying of one drum implying the same operation for the other one. PECIAL TOOLS Depress bearing closing assemble device PS 65 IGHTENING MOMENTS - Wheels nuts ....................9 daN.m - Slotted nut ....................24 daN.m - The attachment screws of the assembly “...
  • Page 314 REAR BEARING ELEMENTS BRAKE DRUM ISMOUNTING Dismount the M 8 x 1,25 - ( 1 ) screw. Dismount the elastic ring 32 and washer 8,1 x 12,7 - ( 3 ). Dismount the four 4 screws M 10 x 1,5 - ( 4 ). Dismount the “...

  • Page 315: Brake Cylinder

    REAR BEARING ELEMENTS BRAKE CYLINDER IGHTENING MOMENTS - Wheels nuts ....................9 daN.m - Slotted nut .....................24 daN.m - Attachment screws of the assembly “ drum – axle brake plate “…....6,3 daN.m - Connecting screw propeller shaft – drum hub assembly ......1,54 daN.m - Connection screw of the rigid duct..............1,5 daN.m - Cylinder attachment screws on the brake plate .......0,53...0,99 daN.m ISMOUNTING...
  • Page 316 REAR BEARING ELEMENTS BRAKE CYLINDER REPAIRING Dismount the cylinder off the vehicle. Dismount: the protection bellows assembled with pistons, the pressure gaskets, and the purging screw. Check the state of cylinder boring, pressure gaskets of the bellows and of the pistons. Any trace of wear, oxidation or scratches implies the replacement of brake cylinder assembly.

  • Page 317: Brake Shoes

    REAR BEARING ELEMENTS BRAKE SHOES IGHTENING MOMENTS - Wheels nuts ....................9 daN.m - Attachment screws of the assembly “ drum – axle brake plate “....6,3 daN.m - Slotted nut ....................24 daN.m - Connecting screw propeller shaft – hub drum ........1,54 daN.m The brake components with adjustment by eccentrics: A - tightening shoe...
  • Page 318 REAR BEARING ELEMENTS BRAKE SHOES EMOUNTING The shoes assembled with the lower return spring is attached on the plate ( the shoes P foots in contact with supporting plate C). Remount the auxiliary connecting rod assembled with the hand brake lever. By means of a brake shoes nipper, set the upper connection of shoes by means of the upper return spring.

  • Page 319: Bearing ( 39X68X37 )

    REAR BEARING ELEMENTS BEARING ( 39X68X37 ) PECIAL TOOLS Depressing device for bearing casing assembly PS 702 IGHTENING MOMENTS - Wheels nuts ...................9 daN.m - Slotted nut ....................24 daN.m - Attachment screws of the assembly “drum axle brake plate” .....6,3 daN.m - Connecting screw propeller shaft –...

  • Page 320: Plate Drive Rear Axle Differential

    REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL The rear axle assembly is dismounted from the vehicle, placed on an universal support, having its propeller shaft removed. ISMOUNTING Dismount: - the flage nut (1); - the washer (2); - the cardanic flange (3); - the sealing ring (4) ( annular oil ring ) 42 x 72 x 12;...
  • Page 321 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL Remove the differential assembly by unscrew the eight screws of the casing. Dismount : - the screws that attach the differential nuts lock washers (1); - the differential adjustment nuts (2); - the stub bolts nuts that attach the bearings half casings (3); Remove the centering bushing and unscrew the stub bolts.
  • Page 322 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL Dismount the elastic pin that attaches the differential pinions shaft by means of the mandrel CV 31 B. Dismount: - the differential pinions lock washer; - the differential pinions shaft, the ball joint;...
  • Page 323 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL The two conical ball bearing shall be mounted by pressing in the differential casing. Press the two outer rings of the differential drive pinion bearing in the differential casing. Put the differential drive pinion in the casing; the former has the adjustment washer mounted on it and the 30 x 80 x 32,75 conical balls bearing pressed on.
  • Page 324 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL - place continuos sealant material layer on the whole contact surface of the rear axle taking care not to close the attachment wholes of differential casing; - mount the differential assembly and tighten the screws at the required couple of 2 - 2,5 daNm.
  • Page 325 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL MOUNTING CONDITIONS mm between the rim axis and the front 1. Adjustment of the conical distance 54 - 0,1 surface of the pinion head. 2. The propeller shafts and the differential pinions shall be selected so that a maximum 0,1 mm clearance is obtained in the whole differential assembly, one propeller shaft being locked, the moment required for the rotation of the propeller shaft should be maximum 1 daN.m.
  • Page 326 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL Check the distance 90 +/- 0,015 mm by reading the value shown by the device. OBSERVATION: Regarding the mounting conditions: - in case there are accidental deviations from the absolute value 54, on the front side of differential drive pinion it will be marked the effective deviation in hundredth;...
  • Page 327 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 2. ADJUSTMENTOF THE PINION – RIM GEARING CLEARANCE Checking of the clearance of the conical assembly gear is performed initially by estimation, by hand. If the clearance felt is too big, act upon the nut on the side of the casing; by unscrewing it a number of rotations, until a smaller clearance in the conical assembly gear is obtained, or, perform the opposite operation clearance is too small.
  • Page 328 REAR BEARING ELEMENTS PLATE DRIVE REAR AXLE DIFFERENTIAL 3. DIFFERENTIAL GEAR BEARINGS ADJUSTMENT It is performed by means of the adjustment nuts until the bearing opposes a certain resistance. The bearing clearance is correct if upon rotation of the differential, without differential drive pinion, the resistant moment shall have values between 0,10 –...

  • Page 329: Non Drive Plate Rear Axle

    From the manufacturing point of view, it looks like the plate drive axle. The central and annular part is sealed by means of a cap. Provided for : DACIA 1305 ,1307 F. Values of the steering angels: - parallelism ..............0 - pivot cross indicator angle ..........0...
  • Page 330 REAR BEARING ELEMENTS NON DRIVE PLATE REAR AXLE WHEEL HUB ISMOUNTING NOTE: It is assumed that the axle is dismounted and fixed on the support. Dismount the wheel. Unscrew the M8 sunk screw. Unscrew the four M 10 screws attaching the bi-conical bearing casing to the axle end. Remove the hub –...

  • Page 331: Non Drive Pipe Rear Axle

    It is a drawn, rigid type axle. Attachment to the chassis is performed by means of the half axial blades springs and of the hydraulic shock absorbers. Provided for Dacia 1305, 1307 F. Values of steering angles: - parallelism......0 - pivot cross angle....0 - tightening positio n of the leaf spring s .........G = 162 mm...
  • Page 332 REAR BEARING ELEMENTS NON DRIVE PIPE REAR AXLE EMOUNTING Perform the dismounting operations in the reverse order. 33 - 23...

  • Page 333: Cast Iron Rear Drive Axle

    REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE REAR DRIVE AXLE OF CAST IRON DACIA 1304, 1307 ( supplier ARO CÂMPULUNG ) CHARACTER ISTICS It is a rigid type cast iron axle, with differential and propeller shafts. It is attached to the chassis by means of the half-elliptical springs and the hydraulic shock absorbers.
  • Page 334 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE WHEEL HUB ISMOUNTING NOTE: It is assumed that the axle is dismounted and fixed on the support. EMOUNTING Dismount the wheel. Perform the dismounting operation s in the Detach the drum from the wheel hub by un- reverse order, observing the following screwing the three M8 sunk screws.
  • Page 335 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE IGHTENING MOMENTS - Screws assembling the propeller shaft flange....2,5 daN.m - The sunk screw ..........0,8 +/- 0,3 daN.m - The rear wheel stud bolt nut..........7 daN.m THE DIFFERENTIAL OF THE REAR DRIVE AXLE CAST IRON The rear axle assembly is dismounted from the vehicle, placed on an universal support;...

  • Page 336: Cast Iron Rear Drive Axle Differential

    REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL From the back part of the axle dismount the cap of the axle , by unscrewing the fourteen M 8 screws. Remove the G 3 – 36 and G 5 – 36 elastic pins of the slotted bushing , by means of the 31 B set of mandrels, marking the position of the bushing and shifting it towards the exterior.
  • Page 337 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL Dismount the attachment elastic pin of the differential pinions shaft by means of the φ φ φ φ 5 CV 31 B mandrel. Dismo unt: - the differential pinions shaft ; - the differential pinions;...
  • Page 338 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL By means of a → 5 mandrel, attach and push the G 5 – 40 elastic pin. Mount the second propeller shaft pinion in the rim. Mount the rim on the casing by means of the ten M 11 x 22 screws ( use new ,self locking screws).
  • Page 339 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL NOTE: Check the marks on the axes in correspondence with the casing. Mark the adjustment nuts in correspondence with the casing. When remou nting the main transmission, observe the following technical conditions: 1.
  • Page 340 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL Working procedure: Temporarily mount the inner ring with balls of the back bearing on the pinion, and introduce it in the casing , without mounting the adjustment washer. Tighten the flange nut at a moment of 3 – 4 daNm. Set the comparator dial to zero.
  • Page 341 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL 2. ADJUSTMENT OF THE DRIVE PINION BEARINGS The drive pinion is mounted in the casing together with the two bearings, without the adjustmen t washer. Mount the cardanic flange and tighten the nut at a moment of about 0,20 daNm, so that the pinion rotates easily at a load between 2 and 3 daNm.
  • Page 342 REAR BEARING ELEMENTS CAST IRON REAR DRIVE AXLE DIFFERENTIAL 3. ADJUSTMENT OF THE DIFFERENTIAL DRIVE PINION AND DIFFERENTIAL RIM CLEARANCE In a first phase, the clearance of the conical group gearing is measured by hand. The checking and the exact correction are performed using the comparator dial. Working procedure: Place the differential drive pinion, the rim –...

  • Page 343: Shock Absorber

    11 daNm 7,5 daNm 8,5 daNm REAR SHOCK ABSORBER ( for DACIA 1305 , 1304 , 1307 vehicles ) ISMOUNTING Lift the pick up on a two columns elevator. Dismount the rear wheels. Unscrew the nuts that attach the shock absorber at the lower and upper parts.

  • Page 344: Spring

    - lower attachment nut ………………………..8,5 daNm REAR SPRING Dacia 1304, 1305, 1307, light trucks are provided with leaf springs. The leaf springs suspension has the advantage that it undertakes in the same time with the vertical forces, the longitudinal and the cross ones; these are the forces that occur upon contact between tire and road, without requiring additional guiding elements.

  • Page 345: Rear Antiroll Rod

    REAR BEARING ELEMENTS REAR ANTIROLL ROD IGHTENING MOMENTS - Anti roll rod shaft attachment screw..........1,5 daN.m - Anti roll rod-auxiliary connecting rod connection axles nut ... 8 daN.m ISMOUNTING Loose the rear wheels nuts. Lift the vehicle on a two columns elevator. Dismount the rear wheels nuts.

  • Page 346: Wheels And Tyres

    WHEELS AND TYRES CHARACTERISTICS RIMS The wheels identification marking is represented in two ways: - engraved marking for steel rims; - cast marking for aluminum rims. The marking enables acknowledgment of the main wheels dimensions criteria. This marking may be: - complete.
  • Page 347 WHEELS AND TYRES CHARACTERISTICS TIRES Identification marking examples: 175/70 R 14 83 S - 175 - Tire width in mm ( 1 ) - 70 - Ratio h height l width - R - Radial structure - 14 - Inner diameter in inches ( φ ): This is corresponding with the rim diameter - 83 - Charging index - S - Speed index max.
  • Page 348 WHEELS AND TYRES CHARACTERISTICS Some speed markings: Max. speed Km/h ZR bigger than 240 Structure types: Diagonal No marking Radial Diagonally belted RIMS - TIRES [bars] IR FILLING PRESSURE UTER AT COLD EHICLE IRES [mm] DIAMETER RONT D 1304 5 J 14 175 R 14 1920+/- 25 D 1307...

  • Page 349: Wheels Balancing

    WHEELS AND TYRES WHEELS BALANCING BALANCING WEIGHTS Use exclusively the weights delivered as spare parts : - fixed by means of clamps on steel rims (clamps included in weights). 35 - 4...

  • Page 350: Steering Assembly

    STEERING ASSEMBLY CHARACTERISTICS, TIGHTENING COUPLERS CHARACTERISTICS The steering mechanism is rack-and-gear drive. The multiplication ratio in the steering box is: 20:1. The steering wheel number of rotations, corresponding to passing from one end to the other of the rack: 3,5. The central point of the steering gear is: c = 65 mm The diameter of the turning circle between: - pavement......11,2 m...
  • Page 351 STEERING ASSEMBLY CHARACTERISTICS, TIGHTENING COUPLERS CROSS SECTION IGHTENING MOMENTS - Screws for the attachment of the box on the cross rod......2,5 daNm - Steering ball joint nut................4 daNm - Elastic coupling nut................1 ,3 daNm - Steering auxiliary connecting rod shaft nut........3,5 daNm - Steering wheel shaft nut..............

  • Page 352: Setting The Steering Gear Central Point

    STEERING ASSEMBLY SETTING THE STEERING GEAR CENTRAL POINT In order to set the steering gear central point, bring the rack in the position in which the value C = 65mm. This position is obtained when a rivet of the elastic coupling is oriented upwards. Performing of a checking and adjustment operation of the front axle, impose the identification of the steering gear central point in order to avoid measurement errors occurrence.
  • Page 353 STEERING ASSEMBLY SETTING THE STEERING GEAR CENTRAL POINT Dismount: - the attachment screws of the elastic coupling; - the steering box attachment screws on the cross rod. NOTE: If the steering gear box is not replaced, do not dismount the eccentrics safety rings, so that, after remounting, it will not be necessary to adjust the height of the steering gear box.

  • Page 354: Noise Absorber Bearing

    STEERING ASSEMBLY NOISE ABSORBER BEARING REPLACEMENT OF THE NOISE ABSORBER BEARING ISMOUNTING 1. Noise absorber bearing 2. Elastic bushings 3. Inside support washer 4. Outside support washer 5. Safety ring Place the car on the elevator. Dismount the wheel on the noise absorber bearing side (right side). Dismount: - the steering auxiliary connecting rod;...
  • Page 355 STEERING ASSEMBLY NOISE ABSORBER BEARING EMOUNTING Carefully clean the rack and the noise absorber bearing seat and grease with a special grease containing MoS2. Mount the elastic rings on the noise absorber bearing. Rotate the steering wheel towards the left until the rack is on the extreme right position. Mount the following parts on the rack: - the new noise absorber bearing;...

  • Page 356: Pusher Adjustment

    STEERING ASSEMBLY PUSHER ADJUSTMENT The pusher clearance adjustment shall be performed taking into account the wear degree of the following parts: rack, pusher, casing. The adjustment method shall be observed every time it is necessary to alter the spacers clearance, in order to maintain a normal operation of the steering gear box.
  • Page 357 STEERING ASSEMBLY PUSHER ADJUSTMENT MEASUREMENT OF THE FREE HEIGHT “ H “ OF THE ELASTIC WASHER Place the washer on a straight plate and measure its height by means of a comparator, using a set of spacers with a known thickness. Note the average value.
  • Page 358 STEERING ASSEMBLY PUSHER ADJUSTMENT Move the rack up to the point where the value is the highest. In this point, reset the comparator to zero. MEASUREMENT OF DISTANCE ( D ) ABOVE THE PUSHER In the position previously set, rotate the rack by means of a fixed wrench, without forcing, until the pusher comes into contact with the adjustment washers;the rotation must be done in both directions.
  • Page 359 STEERING ASSEMBLY PUSHER ADJUSTMENT SETTING OF THE ADJUSTMENT WASHERS THICKNESS The thickness of the adjustment washers shall be measured for the lowest point of the rack, so that a pre compression of the washer is obtained: E = ( D + 0,06 mm ) - H E - washers thickness;...
  • Page 360 STEERING ASSEMBLY PUSHER ADJUSTMENT DJUSTMENT XAMPLE The distance between the pusher and the adjustment washers: D = 1,48 mm Free height of the elastic washer: H = 1,32 mm Thickness of the adjustment spacer: E = ( D + 0,06 ) - H = ( 1,48 + 0,06 ) - 1,32 E = 0,22 mm ARTICULAR CASE It may happen that value found for the adjustment washers thickness is negative.

  • Page 361: Adjustable Steering Auxiliary Connecting Rod

    STEERING ASSEMBLY ADJUSTABLE STEERING AUXILIARY CONNECTING ROD ISMOUNTING Unscrew The attachment nut of the funnel to the steering knuckle support and depress the auxiliary connecting rod ball joint. Take out the attachment collar of the bellows on the casing box. Detach bellows (2) from the steering box.
  • Page 362 STEERING ASSEMBLY ADJUSTABLE AUXILIARY CONNECTING ROD The tightening at the moment of 5 daNm shall be performed with the 6902-4105 special wrench. AUXILIARY CONNECTING ROD FUNNEL In case only the auxiliary connecting rod funnel is worn, this may be replaced. ISMOUNTING Dismount the attachment nut of the auxiliary connecting rod funnel ball joint on the steering knuckle support.

  • Page 363: Steering Wheel Shaft Bushing

    STEERING ASSEMBLY STEERING WHEEL SHAFT BUSHING STEERING WHELL SHAFT BUSHINGS REPLACEMENT ISMOUNTING Disconnect the battery. Dismount: - the lower half case; - the steering wheel; - lights control switch; - windscreen washer control switch; - the steering cardan; - upper bushing safety ring; - the ignition/starting contact.
  • Page 364 STEERING ASSEMBLY STEERING WHEEL SHAFT BUSHING EMOUNTING 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.

  • Page 365: Steering Gear Shaft

    STEERING ASSEMBLY STEERING GEAR SHAFT ISMOUNTING Disconnect the battery. Dismount: - the lower half casing; - the steering wheel; - the lights control switch; - the turn lights relay. Disconnect the stop lamp switch and the ignition/starting contact. Dismount: - the steering cardan; - the servo brake attachment nuts;...

  • Page 366: Mechanical Elements Controls

    MECHANICAL ELEMENTS CONTROLS BRAKE PUMP DOUBLE BRAKE PUMP WITH PRESSURE DROP INDICATOR ( ICP ) INCLUDED ( daNm ) IGHTENING MOMENTS The hydraulic ducts guides The attachment nuts brake pump with servobrake OMPONENTS 1. Assembled primary piston with gaskets 2. Assembled secondary piston with gaskets 3.
  • Page 367 MECHANICAL ELEMENTS CONTROLS BRAKE PUMP PRIMARY CIRCUIT – PRESSURE LOOSING Lack of pressure in the primary circuit leads to the following situation: The primary piston advances up to the pin, so it controls mechanically the secondary piston.. The secondary piston reaches a fluid pressure that shall operate on the piston – linings assembly moving it to the right, opening also the second exit of the rear circuit (the by-pass circuit) increasing the pressure in this circuit.
  • Page 368 MECHANICAL ELEMENTS CONTROLS BRAKE PUMP BRAKE PUMP REPAIRING The operation is performed after dismounting the central pump off the vehicle. ISMOUNTING 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.
  • Page 369 MECHANICAL ELEMENTS CONTROLS BRAKE PUMP Remove from the pump bore : - the primary piston assembled with Pp gaskets; - the primary piston return spring; - the secondary piston assembled with Ps gaskets; - the secondary piston return spring. Wash the parts with alcohol and blow them with compressed air. Check: - the pump bore;...

  • Page 370: Servobrake

    MECHANICAL ELEMENTS CONTROLS SERVOBRAKE MASTER - VAC SERVOBRAKE ( daNm ) IGHTENING COUPLE Servobrake on the iron brake The attachment nut of the central pump with servobrake CHARACTERISTICS The Master-Vac servobrake is a brake booster with the objective of reducing the driver effort on the brake pedal and may be of 152 mm or 177,5 mm with a minimal booster rate of 1,9.
  • Page 371 MECHANICAL ELEMENTS CONTROLS SERVOBRAKE ISMOUNTING Drain the liquid out of the reservoir. Detach the four brake ducts from the pump. Disconnect the electrical contact from ICP transducer. Dismount the central pump from the servobrake. Disconnect t he suction hose of the servobrake.
  • Page 372 MECHANICAL ELEMENTS CONTROLS SERVOBRAKE TIGHTNESS CHECKING The tightness of the servobrake is checked on the vehicle, with the hydraulic circuit under operation. Connect the vacuum meter between the servobrake and the inlet collector by means of a “ T ” type connector. The connecting hose of the vacuum meter shall be as short as possible.

  • Page 373: Air Filter - Servobrake Retainer Valve

    MECHANICAL ELEMENTS CONTROLS AIR FILTER - SERVOBRAKE RETAINER VALVE AIR FILTER REPLACEMENT ISMOUNTING Dismount the servobrake off the vehicle. Loosen the lock nut and dismount : the coupling brake and the lock nut. Remove the old filter, F. EMOUNTING Mount the new filter. Mount: - the lock nut;...

  • Page 374: Handbrake

    MECHANICAL ELEMENTS CONTROLS HAND BRAKE Lever on floor, mechanical controlled, operating on the rear wheels. ( daNm ) IGHTENING MOMENTS The attachment screws of the hand brake lever assembly on the floor The primary cable tightening nut on swing bar ADJUSTMENT With rear wheels suspended and hand brake lever released ,tighten the castle nut M until the shoes gaskets come lightly into contact with the brake drum.
  • Page 375 MECHANICAL ELEMENTS CONTROLS HANDBRAKE CONTROL LEVEL ISMOUNTING Disconnect the battery. Lift the vehicle by means of an elevator. Release the hand brake. Disconnect the primary cable from the rocking joint. Dismount the hand brake ornament case. Dismount the screws that attach the hand brake lever to the floor.

  • Page 376: Handbrake Primary And Secondary Cable

    MECHANICAL ELEMENTS CONTROLS HANDBRAKE PRIMARY AND SECONDARY CABLE THE HAND BRAKE SECONDARY CABLE REPLACEMENT ISMOUNTING Dismount the hand brake lever. Disconnect the primary cable from the rocking joint. Dismount the stop sheath of the primary cable. EMOUNTING Place a sealant material layer between the floor and the primary cable case. Mount the primary cable.
  • Page 377 MECHANICAL ELEMENTS CONTROLS HANDBRAKE PRIMARY AND SECONDARY CABLE HAND BRAKE SECONDARY CABLE REPLACEMENT ISMOUNTING Disconnect the battery. Release the primary cable from the rocking joint. Dismount the drums. Lift the motor-car by means of a jack. Unscrew the nuts M and N. Release the secondary cable from the control levers.

  • Page 378: Brake Limiter

    MECHANICAL ELEMENTS CONTROLS BRAKE LIMITER BRAKE LIMITER CHECKING-ADJUSTMENT Place the vehicle on the checking bench so that wheels are in contact with the ground (unloaded pick up and one person on board ). Mount in the place of the purging screw of the brake cylinder, the F R 214 – 02 checking manometer.
  • Page 379 MECHANICAL ELEMENTS CONTROLS BRAKE LIMITER After obtaining the pressure of 20 bars, with the brake pedal pressed, slide the passing fork (3) until the contact with the limiter control lever. In this moment block the passing fork by means of the screw (1) and the nut (2). Release the brake pedal and purge the braking circuit.

  • Page 380: Brake Pedal And Clutch

    MECHANICAL ELEMENTS CONTROLS BRAKE PEDAL AND CLUTCH ISMOUNTING Remove the safety clip (1). Detach the spring (2) of the clutch cable shaft. Remove the pins and the shaft (3) of the main cylinder pushing rod. Remove the clutch pedal from the pedals shaft.

  • Page 381: Clutch Cable - Clutch Stroke Adjustment

    MECHANICAL ELEMENTS CONTROLS CLUTCH CABLE – CLUTCH STROKE ADJUSTMENT CLUTCH CABLE REPLACEMENT ISMOUNTING Dismount the clutch lever cable. Dismount the attachment clip (1) of the pedal. Push the shaft rightward and take out the pedal. Release the spring (2) and the shaft (3) of the fork.

  • Page 382: The Steering Column Support Assy And Fire Wall

    MECHANICAL ELEMENTS CONTROLS THE STEERING COLUMN SUPPORT ASSY AND FIRE WALL ISMOUNTING Dismount the throttle, brake and clutch pedals. Dismount the attachment screws (2) of the steering column mounting (1) on the wall metal. EMOUNTING Perform the dismounting operations in the reverse order by screws tightening at the moment of 1,5 –...

  • Page 383: Throttle Pedal

    MECHANICAL ELEMENTS CONTROLS THROTTLE PEDAL THROTTLE PEDAL REPLACING ISMOUNTING Release the throttle pedal by dismounting the clip (8),the washer (7) and support shaft (6). Dismount the attachment nuts of the pedal support (2) and release the throttle pedal (3). EMOUNTING Perform the dismounting operations in the reverse order then adjust the throttle stroke at the “...

  • Page 384: Gearbox Control Mechanism

    MECHANICAL ELEMENTS CONTROLS GEARBOX CONTROL MECHANISM ISMOUNTING Dismount the return spring (1). Dismount the control auxiliary connecting rod screw. Dismount the four attachment support nuts M8 (2) of the gearbox control case. Dismount the attachment screws M7 of the bellow control lever. Remove from the vehicle, the gears control assembly .
  • Page 385 MECHANICAL ELEMENTS CONTROLS GEARBOX CONTROL MECHANISM EMOUNTING Re mounting is done by performing in the reverse order, the dismounting operations. Before mounting grease the parts with grease UM 170LiCa Pb Tighten at the required moment the attachment nuts and screws: - nuts M8 ......1,5 - 2 daNm - screws M7 ......

  • Page 386: Electrovacuumatic Control System 4X4 Coupling Presentation

    ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING PRESENTATION It is used for the Dacia 1304, 1307 vehicles equipped with 51 C type gearbox, for front transmission coupling. This is allowed after vehicle stopping or during driving, at a speed of max.10 km/h, after declutching.
  • Page 387 ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING PRESENTATION - one-way vacuum valve ( 2 ) – is placed on the connection hose between the inlet manifold and the electric valves. - “ 4x4 ” coupling control wiring – is performing the connection of the system components to the vehicle electrical equipment.

  • Page 388: Electrovacuumatic Control Adjustment

    ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING ELECTROV ACUUMATIC CONTROL ADJUSTMENT Suspend the vehicle on an elevator. Dismount the fixing lock pin of the connection bolt (8) between the capsule axle and the control lever (6), then remove the bolt from its place. Rotate the front right wheel and set the positions coupled-uncoupled acting upon the front transmission control axle.
  • Page 389 ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING ELECTROV ACUUMATIC CONTROL ADJUSTMENT -The vacuum piping connecting mode between the electric valves and the vacuum capsule is according to the drawing: the pipe from the vacuum capsule axle is connected to the electric valve having the pipes on both sides of its body, and the pipe from the opposite part of the capsule axle is to be connected to the electric valve having the pipes on the same side of its body.

  • Page 390: Vacuum Capsule

    ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING VACUUM CAPSULE ISMOUNTING Suspend the vehicle on an elevator. Disconnect the vacuum capsule connector. Disconnect the vacuum hoses from the capsule. Dismount the lock pin and remove the bolt which is connecting the capsule axle with the GB control lever.

  • Page 391: Electrovalve

    ELECTROVACUUMATIC CONTROL SYSTEM 4X4 COUPLING ELECTROV AL VE ISMOUNTING Disconnect the connector from the electric valve. Disconnect the hoses from the electric valve. Dismount the electric valve attachment screw. EMOUNTING Perform the dismounting operations in the reverse order. NOTE: Observe the connec tion position of the hoses to the electric valve, bef ore disconnec ting. 38 - 6...
  • Page 392 These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA. Reproduction or translating even partially of this present document is forbidden without the written authorisation of AUTOMOBILE DACIA S.A.
  • Page 393 NON SIDE OPPENING ELEMENTS Body Front bonnet ............48-1 GENERAL Drop Side Dacia 1304 platform ......48-2 Drop Side Dacia 1304 Pick-Up, 1307 ....48-3 Designation of parts (blow-up) ......40-1 Openings clearances ........40-7 Mechanisms and accessories Repairing general conditions ......

  • Page 394: General

    GENERAL DESIGNATION OF PARTS (BLOW-UP) LOWER STRUCTURE COMPOSING ELEMENTS DACIA 1304 1. Front cross member 2. Upper longitudinal girder assembly 3. Steering cross member 4. Lower longitudinal girder assembly 5. Longitudinal girder closing plate 6. Intermediary longitudinal girder 7. Rear unit assembly 8.
  • Page 395 GENERAL DESIGNATION OF PARTS (BLOW-UP) LOWER STRUCTURE COMPOSING ELEMENTS DACIA 1304 PICK-UP, DROP - SYDE 1. Pedals floor 2. Cabin closing panel 3. Central floor panel 40 - 2...
  • Page 396 GENERAL DESIGNATION OF PARTS (BLOW-UP) LOWER STRUCTURE COMPOSING ELEMENTS DACIA 1307 6. Intermediary longitudinal girder 1. Front cross member 2. Upper longitudinal girder assembly 7. Rear unit assembly 3. Steering cross member 8. Rear longitudinal girder 4. Lower longitudinal girder assembly 9.
  • Page 397 GENERAL DESIGNATION OF PARTS (BLOW-UP) UPPER STRUCTURE COMPOSING ELEMENTS DACIA 1304, 1307 1. Headlamp support 10. Separating wall 2. Front grill simple 11. Ceiling 3. Front wing lining 12. Windscreen frame 4. Front pillar lining 13. Lower cross member 5. Front pillar 14.
  • Page 398 GENERAL DESIGNATION OF PARTS (BLOW-UP) UPPER STRUCTURE COMPOSING ELEMENTS DACIA 1304 PICK - UP, 1307 5. Rear extensor 1. Side panel 6. Rear wheel passage 2. Side panel upper part 7. Rear plate 3. Front extensor 4. Rear lamp lining DACIA 1304 DROP - SIDE 1.
  • Page 399 GENERAL DESIGNATION OF PARTS (BLOW-UP) BODY REMOVABLE ELEMENTS DACIA 1304 PICK - UP, 1307 1. Front wing 4. Rear drop side 2. Front door 5. Aerating grill 3. Rear door 6. Front bonnet DROP - SIDE DACIA 1304 1. Front drop side 3.

  • Page 400: Openings Clearances

    GENERAL OPENINGS CLEARANCES 40 - 7...

  • Page 401: Repairing General Conditions

    GENERAL REPAIRING GENERAL CONDITIONS The replacement ( reparation ) operations of the weldable elements described in this chapter are specified subject to: removing of the parts to be replaced, access to the welded elements, tools and checking devices accessibility, etc. In case the vehicle body has suffered important deformations it is recommended the straightening of the damaged body elements, by means of some hydraulic presses, the operation being performed slowly and at cold.

  • Page 402: Welding Types And Parameters

    GENERAL WELDING TYPES AND PARAMETERS At the reparation of the welded body elements, three welding categories may be used: protection gas welding (CO2), electric spot welding and filling materials welding (autogenous). At the autogenous welding, it is recommended that flame must be slightly inclined so that arch can be seen and the flame extremity to be maintained at aprox.
  • Page 403 GENERAL WELDING TYPES AND PARAMETERS NOTE: In case of using Ar + CO mixture, the welding voltage will decrease with 2 V. Vertical welding position (obligatory from top to bottom) fig. 2 Plate thickness (mm) Electrode diameter (mm) 0,8 0,8 1,0 0,8 Welding wire speed (m/min) 1,9 3,3...

  • Page 404: Collision Diagnosis

    GENERAL COLLISION DIAGNOSIS During the vehicle exploitation, the body may suffer different distortions, that lead many times to the wheels setting angles change, body elements breakage, vibrations or even mechanical parts wear. In these conditions, before performing the vehicle body reparation, some checking is necessary: Visual checking - consisting in the examination of the mechanics elements attachments and of the distortions that occur in the damaged areas.
  • Page 405 GENERAL COLLISION DIAGNOSIS CHECKING WITH THE BAR GAUGE CENTRAL PART CHECKING It is performed in the purpose to establish if one of the distortions is not affecting this part, from which the checking starts. F’ The checking points are : Holes A – F – F’ – A’ and consequently H – H’ and B – B’. FRONT LONGITUDINAL GIRDERS CHECKING Checking points are: B –...
  • Page 406 These four holes being closest to the rear axle, must be first checked. Compare diagonals H’ – D and H’ – E continuos line with diagonals H – D’ and H – E’ straight line. FLOOR FRAME CHECKING NOTE: The values marked * are for Dacia 1307. 40 - 13...

  • Page 407: Body Checking/Straightening Bench Type Celette

    -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 can be used when a body checking / straightening operation is performed.
  • Page 408 GENERAL BODY CHECKING / STRAIGHTENING BENCH TYPE CELETTE To straighten the vehicle body, CELETTE bench is provided with a traction arm of 10 tons, Caiman type, 250 mm stroke of the hydraulic cylinder, with rapid anchorage on any side of the mobile bench ( fig. 2 ) stands is. one..
  • Page 409 (fig. 5). ( fig. 5) 4. SET OF SPECIFIC SUPPORTS FOR DACIA 1304, 1307 ( CAR 506 ) The mounting of the specific supports for DACIA vehicles 1304,1307 shall be performed according with the mounting diagram which is supplied with this KIT (fig.
  • Page 410 GENERAL BODY CHECKING / STRENGTHENING BENCH TYPE CELETTE Dacia 1304 Dacia 1307 ( fig. 8 ) ( fig. 10 ) Dacia 1307 Dacia 1304 ( fig. 9 ) ( fig. 11 ) Each support is identified by a plate showing the CELETTE specific item number, the mounting direction and its orientation on the bench.
  • Page 411 ( fig. 13 ) - with dismounted mechanic elements - with or without dismounted mechanic elements. REFERENCE POINTS ON VEHICLE ( DACIA 1304, 1307 ) Front longitudinal girder extremity supports fixing Supports (1) and (2) are used in front straightening, front mechanic elements dismounted.
  • Page 412 GENERAL BODY CHECKING / STRAIGHTENING BENCH TYPE CELETTE Front suspension upper arm supports fixing Supports (7) and (8) are used in front straightening. They enable the positioning and centering of the upper longitudinal girders- ( fig. 16 ). ( fig. 16 ) Centering under front longitudinal girder Supports (27) and (28) are used for centering and alignment of the front...

  • Page 413: Lower Structure

    LOWER STRUCTURE LOWER LONGITUDINAL GIRDER REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. ISMOUNTING Dismount the damaged elements that are in contact with lower longitudinal girder. Straighten the areas resulted from disassembling.

  • Page 414: Assembled Front Longitudinal Girder

    LOWER STRUCTURE ASSEMBLED FRONT LONGITUDINAL GIRDER REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. ISMOUNTING Dismount the damaged elements, which are in contact with the longitudinal girder. Detach the welding points of the longitu- dinal girder (1) which are in connection with:...
  • Page 415 LOWER STRUCTURE ASSEMBLED FRONT LONGITUDINAL GIRDER EMOUNTING Position the new element. Perform an electric spot welding as follow: - in the area (2) connecting the longitudinal girder with the front cross bar; - in the area (3) connecting the longitudinal girder with the front wing lining;...

  • Page 416: Intermediary Longitudinal Girder

    LOWER STRUCTURE INTERMEDIARY LONGITUDINAL GIRDER REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. ISMOUNTING Dismount the elements, which are in contact with the intermediary longitudinal girder. Detach the welding points of the intermediary longitudinal girder (1) that are connecting with: - the longitudinal girder in the area (4);...

  • Page 417: Rear Longitudinal Girder (Dacia 1304)

    LOWER STRUCTURE REAR LONGITUDINAL GIRDER ( Dacia 1304 ) REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. ISMOUNTING Dismount the elements, which are in contact with the rear longitudinal girder.

  • Page 418: Rear Longitudinal Girder (Dacia 1307)

    LOWER STRUCTURE REAR LONGITUDINAL GIRDER ( Dacia 1307 ) REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter ISMOUNTING Dismount the elements which are in contact with the rear longitudinal girder.

  • Page 419: Upper Front Structure

    UPPER FRONT STRUCTURE FRONT WING ISMOUNTING Dismount the elements which are in contact with the front wing ( front bumper, the turning lamp from the wing). Dismount from the front wing the following screws: - in (1) at the upper part; - in (2) at the connection of the wing with the front grill, at the lower part;...

  • Page 420: Front Unit Carriage Body

    UPPER FRONT STRUCTURE FRONT UNIT CARRIAGE BODY REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. ISMOUNTING Dismount the damaged elements, which are in contact with the front part body. Perform a checking redressing on the check- ing/repairing bench, until bringing the carriage body almost at the initial shape.

  • Page 421: Front Wing Lining

    UPPER FRONT STRUCTURE FRONT WING LINING REPLACEMENT This operation shall be performed only on the repair bench. For the specific supports mounting on the bench, please see the 40 chapter. ISMOUNTING Dismount the damaged elements, which are in contact with the front wing lining. Detach the welding points from to the front wing lining (1) which are in contact with - the front grill in the (5) area;...

  • Page 422: Head Lamp Support

    UPPER FRONT STRUCTURE HEAD LAMP SUPPORT ISMOUNTING Dismount the elements, which are in contact with the headlamp support. Detach the welding points of the head lamp (1) support which are in connection with : - the radiator upper cross member in the area (3);...

  • Page 423: Radiator Upper Cross Member

    UPPER FRONT STRUCTURE RADIA TOR UPPER CROSS MEMBER ISMOUNTING Dismount the elements, which are in contact with the radiator upper cross-member. Detach the welding points of the radiator upper cross member (2) which are in connection with: - the head lamp support (7); - the reinforcement in the (8) area.

  • Page 424: Aeration Grill

    UPPER FRONT STRUCTURE AERA TION GRILL ISMOUNTING Dismount the two nozzles (1) 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.

  • Page 425: Upper Side Structure

    UPPER SIDE STRUCTURE FRONT PILLAR LINING ISMOUNTING Dismount the elements which are in contact with the front pillar lining. Detach the welding points of the front pillar lining (1) which are in connection with: - front pillar in the area (4) and (5); - floor closing plate in the area (8);...

  • Page 426: Front Pillar

    UPPER SIDE STRUCTURE FRONT PILLAR ISMOUNTING Dismount the elements which are in contact with the front pillar . Detach the welding points of the front pillar (2) which are in connection with : - lateral frame in the areas (3); - front pillar lining in area (4) and (5);...

  • Page 427: Front Lower Panel

    UPPER SIDE STRUCTURE FRONT LOWER PANEL ISMOUNTING Dismount the elements which are in contact with the front lower panel . Detach the welding points of the front lower panel (1) which are in connection with : - floor closing plate in the area (2); - front pillar in the (3) area;...

  • Page 428: Middle Pillar

    UPPER SIDE STRUCTURE MIDDLE PILLAR ISMOUNTING Dismount the damaged elements which are in contact with the middle pillar. Detach the welding points of the middle pillar which are in connection with: Ceiling in the area (1). Front lower panel in the (2) area. Straighten the areas resulted by dismounting.

  • Page 429: Rear Upper Structure

    REAR UPPER STRUCTURE SIDE PANEL DACIA 1304 PICK - UP, 1307 ISMOUNTING Dismount the elements which are in contact with the side panel. Detach the welding points of the side panel (1) which are in connection with: - middle pillar in the area (2);...

  • Page 430: Side Panel Dacia 1304 Drop-Side

    REAR UPPER STRUCTURE SIDE PANEL DACIA 1304 DROP - SIDE ISMOUNTING Dismount the elements which are in contact with the side panel. Detach the welding points of the side panel (1) which are in connection with : - middle pillar in the area (2);...

  • Page 431: Rear Wheel Passage

    REAR UPPER STRUCTURE REAR WHEEL PASSAGE ISMOUNTING Dismount the elements which are in contact with the rear wheel passage. Detach the welding points of the rear wheel passage (1) which are in connection with : - platform floor in the area (2); - front extensor in the (3) area;...

  • Page 432: Rear Plate

    REAR UPPER STRUCTURE REAR PLATE ISMOUNTING Dismount the elements which are in contact with the rear plate. Detach the welding points of the rear plate (1) which are in connection with: - platform floor rear edge in area (2); - corner plate edge in the area (3). Straighten the areas resulted from dismounting.

  • Page 433: Top Of Body

    TOP OF BODY ROOF ISMOUNTING Dismount the elements which are in contact with the roof ( doors, front wings, windscreen, cabin glass, roof sealing of the ceiling and win- dows gaskets). Detach the welding points of roof (1) which are in connection with : - windscreen lower cross-bar in (2) area;...

  • Page 434: Front Door

    LATERAL OPENING FRONT DOOR ISMOUNTING Front door dismounting may be performed in two different ways: a) by removing the clips (1) and pushing out the hinge pins. b) by removing the attachment screws (2) on the front pillar. EMOUNTING Perform the dismounting operations in the reverse order. ADJUSTMENT a) Horizontally, adjustment bush C are to be used.

  • Page 435: Front Door Outside Panel

    SIDE OPENING ELEMENTS FRONT DOOR OUTSIDE PANEL ISMOUNTING Dismount the front door and the elements which are in contact with this. Cut the outside panel of the door following the outliner (1). Unscrew the screws (2) from the joint of outside panel-glass frame. Adjust, if necessary, the extensor (3).

  • Page 436: Non Side Oppening Elements

    NON SIDE OPENING ELEMENTS FRONT BONNET ISMOUNTING Dismount : - the attachment screws (1) of the hinges; - the front bonnet. EMOUNTING Perform the dismounting operations in the reverse order. 48 - 1...

  • Page 437: Drop Side Dacia 1304 Platform

    NON SIDE OPENING ELEMENTS DROP SIDE DACIA 1304 PLATFORM ISMOUNTING Dismount : - the attachment screws (1) of the hinges (2); - the rear drop side (the drop side). EMOUNTING Perform the dismounting operations in the reverse order. 48 - 2...

  • Page 438: Drop Side Dacia 1304 Pick-Up, 1307

    NON SIDE OPENING ELEMENTS DROP SIDE DACIA 1304 P ick - Up, 1307 ISMOUNTING Dismount : - the screws (1) from the end of the limiting mechanism (6). Then, the rear drop side dismounting may be performed in two different ways: a) extract the safety ring (2) and the hinge shaft (3).

  • Page 439: Side Oppening Elements Mechanisms

    SIDE OPENING ELEMENTS MECHANISMS DOOR LOCK FRONT / REAR ISMOUNTING Dismount the arm rest, the window regulator , the locking knob and the front/rear door panel. Detach the door panel from the door frame. Dismount the lock control of the front/rear door (1). Dismount the attachment screws (3) of the front/rear door lock.

  • Page 440: Front/Rear Door Opening Mechanism

    SIDE OPENING ELEMENTS MECHANISMS FRONT/REAR DOOR OPENING MECHANISM ISMOUNTING Before dismounting the door lock control , remove the door panel and leave the window in the lift position. Dismount: - opening knob (1); - ornament (3) attachment screws (2); - the attachment screw (4) of opening mechanism (5); - control lever (6)off the hinge, releasing the opening mechanism.

  • Page 441: Front Door Window Regulator

    SIDE OPENING ELEMENTS MECHANISMS FRONT DOOR WINDOW REGULATOR ISMOUNTING To dismount the door window regulator assembly, perform the following operations: Bring the window in the position P = 85 mm. Unscrew the attachment nuts (10), press the shaft (11) for releasing the window regulator towards the inner side.
  • Page 442 SIDE OPENING ELEMENTS MECHANISMS FRONT DOOR WINDOW REGULATOR Put in its place the window regulator , introducing the shaft (11) in the frame than the attachment washer (17) and attachment nuts (10). Place the supports (12) at the glass bottom and perform a first sliding test. Grease the window regulator hinges and supports and perform the others operations in reverse order.

  • Page 443: Rear Door Window Regulator

    SIDE OPENING ELEMENTS MECHANISMS REAR DOOR WINDOW REGULATOR ISMOUNTING In order to dismount a door window and the window regulator of the back door window, perform the following operations: Remove the screws (11) and (12). Using the technological opening (14) in the inner side of the door , remove the elastic washer and the safety washer (20), which make the connection with the window slide-bar,...

  • Page 444: Non Side Oppening Elements Mechanisms

    NON SIDE OPENING ELEMENTS MECHANISMS FRONT HOOD LOCK ISMOUNTING 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). EMOUNTING Perform in the reverse order the dismounting operations. 52 - 1...

  • Page 445: Rear Drop Side Locking System

    NON SIDE OPENING ELEMENTS MECHANISMS REAR DROP SIDE LOCKING SYSTEM REAR DROP SIDE LOCKING SYSTEM DACIA 1304 Pk, 1307 ISMOUNTING To dismount the rear drop side lock (1) unscrew the screws (2) of the closing hook (3) and the screws (4) of the assembled lock (5).
  • Page 446 NON SIDE OPENING ELEMENTS MECHANISMS REAR DROP SIDE LOCKING SYSTEM REAR DROP SIDE LOCKING SYSTEM DACIA 1304 platform ISMOUNTING 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.

  • Page 447: Windows

    WINDOWS WINDOWS WINDSCREEN AND CAB REAR WINDOW The replacement of these windows is performed in case they are broken, when they are not according to the required overall dimensions or have manufacturing defects (image distortions,cracks, etc). DISMOUNTING OF A BROKEN WINDOW If the window or part of it did not fall, the window gasket shall be dismounted and the pieces of broken window shall be removed from it easier by sticking a sheet of paper on each surface.

  • Page 448: External Protections

    EXTERNAL PROTECTIONS FRONT BUMPER ISMOUNTING Dismount : - the attachment screw (1) and (3) of the front bumper (2) on the front wings; - the nuts (4) which attach the bumper supports (5) on the front grill; - release the front bumper. EMOUNTING Perform the dismounting operations in the reverse order.

  • Page 449: Rear Bumper

    EXTERNAL PROTECTIONS REAR BUMPER REAR BUMPER ( for vehicles Dacia 1304 Pk., 1307 ) ISMOUNTING 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 ;...
  • Page 450 EXTERNAL PROTECTIONS REAR BUMPER REAR BUMPER ( for Dacia 1304 platform drop side ) ISMOUNTING 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;...

  • Page 451: External Accessories

    EXTERNAL ACCESSORIES OUTSIDE REAR VIEW MIRROR ISMOUNTING 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. EMOUNTING Perform the dismounting operations in the reverse order. 56 - 1...
  • Page 452 These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA. Reproduction or translating even partially of this present document is forbidden without the written authorisation of AUTOMOBILE DACIA S.A.
  • Page 453 Mechanisms and accessories 72 SIDE OPENING ELEMENTS TRIM Front door panel ........... 72-1 57 LOWER INTERNAL ACCESSORIES Dacia 1307 rear door panel ......72-2 Dashboard ............57-1 Documents compartment ........57-5 75 FRONT SEATS FRAMES AND RUNNERS The hand brake casin and gearbox lever Front seats ............
  • Page 454 Temperature transmitter checking ....83-16 Fuel level transmitter ........83-17 84 CONTROLS - SIGNALLING Starting-ignition switch ......... 84-1 Under wheel control module ......84-3 Switches dashboard ........84-5 85 WINDSCREEN WIPERS Windscreen wiper mechanism ...... 85-1 Windscreen wiper drive motor ..... 85-4 Windscreen washer assembly .......

  • Page 455: Lower Internal Accessories

    LOWER INTERNAL ACCESSORIES DASHBOARD DISMOUNTING Dismount the battery Dismount: - the windscreen, - the steering wheel and the lower/upper casing. Dismount the attachment nut (12) of the coupling bar for dashboard sustaining. Dismount the dashboard attachment screws (8) on the side support (9). Dismount the dashboard attachment screws (11) on the windshield lower frame cross member.
  • Page 456 LOWER INTERNAL ACCESSORIES DASHBOARD - fog headlamps switch, - windscreen wiper timer, - radio-cassettes player. Disconnect the following wires: - lighter lighting, - climate control lighting, - ashtray lighting, - documents compartment lighting. Dismount the followings: diagnostic socket and the three hoses from the climate con- trol unit, observing the corresponding positions.
  • Page 457 LOWER INTERNAL ACCESSORIES DASHBOARD DASHBOARD TYPE DACIA 1325 ISMOUNTING In order the dismount the dashboard, perform the following operation : Dismount: - the steering wheel and the upper-lower steering wheel half cases; - the ash try (5); - wiper timer by dismounting the control knob (2), disconnecting the wiper timer wires and the attachment nuts on dashboard;...
  • Page 458 LOWER INTERNAL ACCESSORIES DASHBOARD DASHBOARD TYPE DACIA 1325 ISMOUNTING 12 1 In order the dismount the dashboard, perform the following operation : Dismount : - the steering wheel and the upper-lower steering wheel half cases; - the ash try (5);...

  • Page 459: Documents Compartment

    LOWER INTERNAL ACCESSORIES DOCUMENTS COMPARTMENT DISMOUNTING Disconnect the battery. Dismount the diagnostic socket. Dismount the documents compartment attachment screws (2) on the dashboard. Disconnect the documents compartment lighting wires. Extract the documents compartment from the dashboard. REMOUNTING Perform the dismounting operations in the reverse order. 57 - 5...

  • Page 460: The Handbrake Casin And Gearbox Lever Ornament

    LOWER INTERNAL ACCESSORIES THE HANDBRAKE CASIN AND GEARBOX LEVER ORNAMENT ISMOUNTING Dismounting the screws (1) and release the gearbox lever ornament (2). Dismounting the screws (3) and release the handbrake casing (4). EMOUNTING Perform the dismounting operations in reverse order. 57 - 6...

  • Page 461: Inside Rear View Mirror

    LOWER INTERNAL ACCESSORIES INSIDE REAR VIEW MIRROR ISMOUNTING Dismount the protector support (1). Dismount the rubber buffer (2). Detach from clips the sun visors rod from the inside rear view mirror support. Release the inside rear view mirror (3) by dismounting the attachment screws (4). EMOUNTING Perform the dismounting operations in reverse order.

  • Page 462: Sun Visors

    LOWER INTERNAL ACCESSORIES SUN VISORS ISMOUNTING Take out inside rear view support protector. Detach the sun visors (2) rod from the inside rear view mirror support. Release the sun visors (2) by dismount the attachment screws (1). EMOUNTING Perform the dismounting operations in reverse order. 57 - 8...

  • Page 463: Turn Handles

    LOWER INTERNAL ACCESSORIES TURN HANDLES ISMOUNTING Dismount the turn handles (1) attachment screws (2) from the stretcher. Dismount the turn handles. EMOUNTING Perform the dismounting operations in reverse order. 57 - 9...

  • Page 464: Doors Thresholds

    LOWER INTERNAL ACCESSORIES 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. 57 - 10...

  • Page 465: Safety Elements

    SAFETY ELEMENTS FRONT SAFETY BELTS ISMOUNTING Dismount : - the protector and attachments front safety belts screws on the upper middle pillar (pos. 1); - the attachments front safety belts screws on the lower middle pillar (pos.2); - the attachment screw of lock front safety belts on the front plate protection (pos.3) of fixing front belt on middle pillar –...

  • Page 466: Rear Safety Belts

    SAFETY ELEMENTS REAR SAFETY BELTS ISMOUNTING Dismount : - the protector and the attachment rear safety belt screw on the upper part of lateral panel (pos.1); - the attachment rear safety belt screw on the inner lateral frame (pos. 2); - the attachment screws of the rear belt lock on central floor (pos.3);...

  • Page 467: Heating

    HEATING CLIMATE CONTROL BLOCK ISMOUNTING Disconnect the battery. Dismount the ash try from the dash board. Dismount the attachment screws (4) of the block on the dash board and detach the block from its place. Disconnect: - the control cables (5) of the flaps; - the control cable (6) of the climate control valve.
  • Page 468 HEATING CLIMATE CONTROL BLOCK ( for the commercials with dashboard type 1325 ) ISMOUNTING Disconnect the battery. Dismount the switch knob (1), the climate control switch and the luminous plate (2). Disconnect the connections of the luminous plate and the vacuum hoses. Dismount the attachment screws (3) of the climate control.

  • Page 469: Climate Control Unit

    HEATING CLIMATE CONTROL UNIT ISMOUNTING In case AC system can not be used, the classis climate control system may be used according to necessities. Dismount the dashboard. Disconnect the wires from the dashboard wiring. Dismount the control cables of the distribution flaps and mixing flaps from the control levers and the recycling flaps cable from the climate control panel.

  • Page 470: Climate Control Valve

    HEATING CLIMATE CONTROL VALVE ISMOUNTING Clamp the heating hoses (1) , (2) by means of the clamp (3) – MOT 453 and dismount the hoses from the valve. Dismount the control cable (4) of the valve (5) and bring the valve in the OF F position. Dismount the climate control valve.

  • Page 471: Climate Control G.m.v

    HEATING CLIMATE CONTROL G.M.V. A.COMMERCIALS EQUIPPED WITH DASH BOARD TYPE SERIES Climate control GMV is located under the dashboard, in the right side and can be with one or two rotation steps. ISMOUNTING Disconnect the battery. Disconnect the GMV connectors from the right connection plate (+DC).

  • Page 472: Diagnostic

    HEATING DIAGNOSTIC CLIMATE CONTROL BLOWER NOT WORKING Check the F02 fuse from the cockpit fuse box. Is it blown ? Replace the fuse. Check if the blower is supplied. Supply wire disconnected or broken. Fix it. Is the blower mass connected? Is the blower switch mass connected? Replace the blower Replace the blower switch...

  • Page 473: Air Conditioning Generalities

    AIR CONDITIONING GENERALITI ES The purpose of the air conditioning unit is to produce a decrease of the temperature in the passengers compartment and to maintain this temperature at an inferior value compared to the environment one, reducing in the same time the air moisture. Basically , the AC unit is operating in a closed circuit and it is composed of the following main elements: - evaporator...
  • Page 474 AIR CONDITIONING GENERALITI ES DRAINING – FILLING REFRIGERANT CIRCUIT DRAINING Connect the charging equipment piping to the filling-draining valves. Perform the vacuuming of the air condition system, recovering the oil and the refrigerant fluid. Close the hoses valves. Disconnect the charging equipment piping and stop the equipment. TIGHTENING MOMENTS FILLING Attach the draining –...
  • Page 475 AIR CONDITIONING A.C. CIRCUIT OPERATING DIAGRAM Warning grup 62 - 3...

  • Page 476: Maintenance

    AIR CONDITIONING MAINTENANCE For important leakage removal, for any components replacement (compressor, condenser, etc ) and if moisture was noticed in the air conditioning circuit, the dryer filter tank is to be replaced and the unit draining is to be done. The same is valid also when the conditioning circuit still open without protection covers more than 10 minutes.
  • Page 477 AIR CONDITIONING DETECTION OF REFRIGERANT FLUID LEAKAGE In order to detect the refrigerant liquid leakage, the detector INFICON type HDL 300 (or similar) may be used, calibrated to detect leakage of aprox. 9gr./an. Start the engine and switch on the air conditioning unit. Check through the sight glass of the dryer filter tank if there are any air bubbles;...

  • Page 478: Condenser

    AIR CONDITIONING CONDENSER Condenser has the purpose to achieve the second heat exchange, where the refrigerant fluid by condensation, is transmitting outside the abstracted heat. When coming out from the con- denser, the refrigerant fluid is liquid, at high pressure. The condenser is made of aluminum, Harrison type, with parallel flows.

  • Page 479: Dryer Filter Tank

    AIR CONDITIONING DRYER FIL TER TANK The dryer filter tank is mounted by means of a support, on the front wing lining and it has a triple purpose in the air conditioning system: - filtering the refrigerant fluid from the system; - absorbing the moisture from the system;...

  • Page 480: Compressor

    AIR CONDITIONING COMPRESSOR Compressor is absorbing the vapors coming from the evaporator at low pressure and tem- perature, is compressing them and convey the gas at high temperature and pressure to the con- denser. The compressor is type Harrison V5, alternating , with pistons and variable cylinders capacity . Compressor oil used PAG SP 10 Quantity of compressor oil used 265 cmc The compressor is mounted on the left side of the engine block by means of two supports.
  • Page 481 AIR CONDITIONING COMPRESSOR EMOUNTING Position the compressor on the attachment supports. Tighten the compressor on the supports, by means of 3 screws, which are to be initial screwed in the following order : front upper left, rear lower right, front lower left. Position and tighten the tie rod on the compressor upper support and on the cylinders hous- ing.
  • Page 482 AIR CONDITIONING COMPRESSOR COMPRESSOR SUPPORTS ISMOUNTING Dismount the compressor (see “ Compressor replacement “). Dismount the upper support. Dismount the lower support. EMOUNTING Position the lower support (1) of the compressor on the cylinder housing and initial tighten its attachment screws. Position the upper support (2) of the compressor on the cylinder head and initial tightening its attachment screws.

  • Page 483: Evaporator

    AIR CONDITIONING EVAPORATOR Evaporator has the purpose to transfer to the refrigerant liquid the air heat, which is passing through it. The cooled air, is so conveyed in the passengers compartment, progressively reducing the temperature. The refrigerant fluid which goes into the evaporator, absorbs the passengers compartment heat, cycled transmitted by the GMV-AC at constant temperature and is trans- forming it from liquid into vapors.
  • Page 484 AIR CONDITIONING EVAPORATOR EMOUNTING Perform the dismounting operations in the reverse order. Fill the refrigerant circuit and check the good operation of the climate control system. NOTE : Ensure that evaporator finned plates are not deformed and they are not excessive dirty.

  • Page 485: System Piping

    AIR CONDITIONING SYSTEM PIPING The air conditioning system piping ensure the refrigerant fluid circulation between the system components. When pipes are replaced, check the existence of the protective covers. Lubricate the con- nections and gaskets with compressor oil and fill up with compressor oil. The system filling and draining valves are placed on the compressor piping and have different diameters, so that they can not be reversed.
  • Page 486 AIR CONDITIONING THERMOSTATIC EXPANSION VALVE Thermostatic expansion valve – allows the reduction of the refrigerant liquid which is coming from the condenser, passing through the tank filter and is continuously adjusting the refrigerant flow from the evaporator, to reach the compressor in gaseous shape. The good operation of the air conditioning system is ensured by a dryer filter tank which has the purpose to protect the unit by absorbing the eventually solid particles found in the oil and refrigerant liquid circulation, if not, these might block the operation of the thermostatic expansion...

  • Page 487: Pressure Controller

    AIR CONDITIONING PRESSURE CONTROLLER PRESSURE CONTROLLER The pressure controller is mounted on the dryer filter tank. The pressure controller is an electric/mechanical device, which has the purpose to protect the air conditioning unit and it has the follo wing funct i ons: - cuts off the compressor operation, when the pressure in the high pressure circuit is low- ering more than 2,5 bars.

  • Page 488: Diagnostic

    AIR CONDITIONING DIAGNOSTIC Defective cooling. Is GMV working? Check the GMV fuse. Replace them. Adequate air flow Are they defective? and relay? Supply the Change GMV GMV at (+12V). Does it Check the air flow flaps GMV works? engine.Operation and the air ducts integrity .
  • Page 489 AIR CONDITIONING DIAGNOSTIC Correct A.C. system filling. Compressor does not work. Is +12V at pole 2 of 584 relay ? Check the clutch coil ? Is +12V at pole 8 of 584 relay? Broken, short-circuit ? Restore the electric circuit Re pla ce the Is +12V at pole between E and clutch.

  • Page 490: Sealing Opening Elements

    SEALING OPENING ELEMENTS FRAME SEALING GASKETS ISMOUNTING 1 - gasket under front grill 2 - front bonnet gasket 3,4 - wing chute gaskets 5,6 - rear/front doors frames gaskets Manually dismount by pulling one end toward applying area external. EMOUNTING To be mounted by hammer tapping.

  • Page 491: Door Sealing Gaskets

    SEALING OPENING ELEMENTS DOOR SEALING GASKETS ISMOUNTING Dismount the gaskets from the door profile, by pulling them towards exterior, following the door outline. EMOUNTING Perform the dismounting operations in the reverse order. Mounting of the sealing gaskets on the door frames is performed by plastic hammer tapping.

  • Page 492: Sealing Windows And Screens

    SEALING WINDOWS AND SCREENS GLASSES SEALING GASKETS 1 - Side glass rubber gasket ( D 1304 King - cab ) 2 - Separating wall glass rubber gasket 3 - Windshield rubber gasket ISMOUNTING Remove the glass together with the rubber gasket, by pushing it from the interior of the vehicle.

  • Page 493: Inner Wipers

    SEALING WINDOWS AND SCREENS INNER WIPERS ISMOUNTING Dismount the arm rest at the upper part. Dismount the window regulator handle and the inner opening mechanism. Dismount the panel by removing it from clips and take out the inner wiper. EMOUNTING Perform the dismounting operations in the reverse order.

  • Page 494: Outside Wipers

    SEALING WINDOWS AND SCREENS OUTSIDE WIPERS ISMOUNTING Lower the window to the minimum position The dismounting of the outside wiper is performed by removing it from the fixing clips. EMOUNTING Perform the dismounting operations in the reverse order. 66 - 3...

  • Page 495: Internal Body Trim

    INTERNAL BODY TRIM FLOOR CARPETS 1. molded carpet 2. under bench carpet ( Dacia Double Cab) 3. platform carpet ( bed mat) MOLDED CARPET DISMOUNTING Dismount: - the front seats - the front safety belts locks - the gearbox lever ornament - the front/rear doors thresholds.

  • Page 496: Windscreen Coverings

    INTERNAL BODY TRIM WINDSCREEN COVERING 1. front pillar covering 2. windscreen covering 3. middle pillar lining 4. side lining lower covering 5. upper side panel lining 6. side panel covering 7. cabin wall lining 8. plate screw 9. flat washer REPLACEMENT OF THE WINDSCREEN COVERING DISMOUNTING Dismount :...

  • Page 497: Middle Pillar Lining

    INTERNAL BODY TRIM MIDDLE PILLAR LINING REPLACEMENT OF THE MIDDLE PILLAR LINING DISMOUNTING Move ahead the front seat, in order to enable the access at the middle pillar. Dismount : - the front thresholds - partially the front/rear doors weather-strips - the front safety belts at their upper/lower part attachment on the middle pillar.

  • Page 498: Upper Side Panel Lining

    INTERNAL BODY TRIM UPPER SIDE PANEL LINING REPLACEMENT OF THE UPPER SIDE PANEL LINING DISMOUNTING Swing over the rear bench back Dismount : - the rear safety belts at the upper part. - partially the rear doors weather-strip. Unstuck the upper side panel lining. REMOUNTING Perform the dismounting operations in the reverse order.

  • Page 499: Cabin Wall Lining

    INTERNAL BODY TRIM CABIN WALL LINING REPLACEMENT OF THE CABIN WALL LINING DISMOUNTING Swing over the rear bench back Dismount : - the rear glass grill - the rear cabin glass - the screws and washers attaching the cabin wall lining. REMOUNTING Perform the dismounting operations in the reverse order.

  • Page 500: Ceiling Covering

    Perform the dismounting operations in the reverse order, by consecutive mounting of the rods, positioning and stacking of the ceiling covering edges on the windshield fixing frame, on the front and rear ( Dacia Double Cab ) upper frames and creating the access for the side lamps.
  • Page 501 INTERNAL BODY TRIM FLOOR NOISE ABSORBENT MATS ISMOUNTING Dismount by hand the floor mat (1 ) the under bench mat (2) and the molded mat (3). Remove (unstuck): front cross member noise absorbents (4),(8),the cowl panel noise absorbent (5), the front wheel noise absorbents (6) ,(7) and the gearbox casing noise absorbent (9).

  • Page 502: Side Opening Elements Trim

    SIDE OPENING ELEMENTS TRIM FRONT DOOR PANEL ISMOUNTING Dismount: - the arm rest connection (3); - the arm rest (2) from the screws (1); - the window regulator handle; - the distance control cover (8) by dismounting the attachment screw; - the inner wiper (5) from the clips (6);...

  • Page 503: Dacia 1307 Rear Door Panel

    SIDE OPENING ELEMENTS TRIM DACIA 1307 REAR DOOR PANEL ISMOUNTING Dismo unt: - the arm rest (2) from the screws (1); - the window regulator handle; - the distance control cover (5) by dismounting the attachmen t screw; - the inner wiper (4) from the clips (6);...

  • Page 504: Front Seats Frames And Runners

    FRONT SEATS FRAMES AND RUNNERS FRONT SEATS DJUSTMENTS The front seats equipping the Dacia vehicles offer the following adjustment possibilities: - longitudinal displacement back and forth which may be performed by using the control lever (L). - the back rest rocking until the horizontal position is obtained by using the button (M).
  • Page 505 FRONT SEATS FRAMES AND RUNNERS FRONT SEATS FRAMES REPLACEMENT ISMOUNTING Dismount the seat off the vehicle. Dismount the slide guides from the front seat. Remove the upholstery and the clothing from the armature. EMOUNTING Perform the dismounting operations in the reverse order. 75 - 2...
  • Page 506 FRONT SEATS FRAMES AND RUNNERS FRONT SEATS SLIDE GUIDES ISMOUNTING Dismount: - the front seat attachment screws (5) and cross- pieces (3) and (6)on the central floor; - the slide guides (1) and (2) attachment screw (4) on the seat armature; - release the slide guides (1) and (2).

  • Page 507: Rear Seats Frames And Runners

    REAR SEAT FRAMES AND RUNNERS BACK REST ARMATURE ISMOUNTING Dismount the closing plate (1) by removing it from the clips of the rear bench back rest. Dismount the upholstery and clothing from the rear bench back rest (2). EMOUNTING Perform the dismounting operations in the reverse order 76 - 1...

  • Page 508: Rear Bench Seat Armature

    REAR SEAT FRAMES AND RUNNERS REAR BENCH SEAT ARMATURE ISMOUNTING The rear bench seat (4) is dismounted by rocking it in the supports (3). Remove the upholstery from the seat clothing. EMOUNTING Perform the dismounting operations in the reverse order . 76 - 2...

  • Page 509: Front Seat Trim

    FRONT SEAT TRIM SEATS UPHOLSTERY ISMOUNTING Take out the rods (3) from the seat upholstery (7) attachment clips (4) on the clothing (14). Take out the rods (6) from the attachment clips (5) with the front seat armature. EMOUNTING Perform the dismounting operations in the reverse order. 77 - 1...

  • Page 510: Back Rest Upholstery

    FRONT SEAT TRIM BACK REST UPHOLSTERY ISMOUNTING Dismount the back rest control button (2) releasing the screw, the washer, the plate and the counter plate. Remove the sleeves for the headrest from the pipes (1) welded on the front seat armature. Take out the rods (9) from the clips (8).

  • Page 511: Rear Seat Trim

    REAR SEAT TRIM SEATS UPHOLSTER Y ISMOUNTING Take out the rods (1) from the attachment clips (2) of the seat upholstery (4) with the seat clothing. Dismount the rods (3) from the chains (5) , consequently the attachment clips from the bench seat armature rod.
  • Page 512 REAR SEAT TRIM BENCH BACK REST UPHOLSTERY ISMOUNTING Dismount the back rest plate from its plastic clips. Take out from clips the rods (2) at the lower part and the side ends rods (1) from the clips (4) Release the clipping rods (5) from the attachment with the back rest clothing, by means of the chains (3).

  • Page 513: Electric Equipment

    BATTERY - FRONT HEADLIGHTS BATTERY ELECTRIC EQUIPMENT PROTECTION When performing a reparation at the vehicle, a set of actions must be taken to protect the electric equipments of damages or to avoid a short-circuit which may lead to vehicle burning.The battery is always disconnected by first disconnecting the negative terminal and then the positive one.The connecting is done in reverse order.
  • Page 514 BATTERY HARACTERISTICS The DACIA vehicles are equipped with the f o llowing types of batteries:12V/45 Ah , 55 Ah, and 60 Ah. The battery is attached to its support by means of a clip, supported by two bars. The battery is connected to the vehicle electric system with the negative terminal to the mass.
  • Page 515 BATTERY - FRONT HEADLIGHTS BATTERY LECTROLYTE QUANTITY OF [ g/cm [ cm DENSITY SULFURIC ACID 1,23 1,25 1,27 1,29 To prepare electrolyte of a certain density, for each liter of distilled water, add a quantity of sulfuric acid as per a.m. table. BATTERY CHARGING The batteries are charged in special rooms, well ventilated, where the working temperature shall be of 20 –...
  • Page 516 BATTERY - FRONT HEADLIGHTS BATTERY The charging currents of the batteries are showed in the following table: YPE OF BATTERY OMINAL VOLT AGE HARGING CURRENT [ V ] [ A ] [ A ] 12 V - 45 Ah 2,25 12 V - 55 Ah 2,75 12 V - 66 Ah...

  • Page 517: Headlight Bulbs Replacement

    BATTERY - FRONT HEADLIGHTS HEADLIGHT BULBS REPLACEMENT ISMOUNTING Disconnect the battery. Take out the headlight corrector attachment clip (B). Unscrew the headlight corrector control screw (C). Disconnect the headlight and signaling lamp connectors. Push the headlight forward. EMOUNTING Place by pressing the adjustment screws in the headlight seats (by pushing towards the engine compartment of the headlight).

  • Page 518: Lamps

    BATTERY - FRONT HEADLIGHTS LAMPS HEADLIGHT BULB REPLACEMENT ISMOUNTING Disconnect the connector (1). Take out the protector (2). Release the springs sustaining the bulb. Replace the bulb. EMOUNTING Perform the dismounting operations in the reverse order. NOTE: After headlight or bulb replacement it is recommended the adjustment checking. FRONT SIGNALING BULB REPLACEMENT Disconnect the wires from the signaling lamp.
  • Page 519 BATTERY - FRONT HEADLIGHTS LAMPS BULBS BULBS Headlights Two phases bulb R2 - 12 V - 40/45 W, holder with flange P 45 t 41. Front parking, side signaling lamp, trunk lighting Bulb 12 V - 4W with holder B A9 s. Front turn signal lamps Bulb 12 V - 21W (colored) with holder BAU 15 s.

  • Page 520: Fog Projector

    BATTERY - FRONT HEADLIGHTS FOG PROJECTOR FOG PROJECTOR DISMOUNTING – REMOUNTING Disconnect the battery. Detach the projector supply wires from the front wiring. Dismount the attachment screws of the projector from front bumper. Mounting is done by performing in the reverse order the dismounting operations. 80 - 8...

  • Page 521: Headlights Adjustment

    BATTERY - FRONT HEADLIGHTS HEADLIGHTS ADJUSTMENT The DACIA pick ups are equipped with two rectangular headlights. The headlights adjustment is performed observing the following conditions : - the vehicle shall be placed on a horizontal surface; - the vehicle shall be empty (without load or passengers on board);...
  • Page 522 BATTERY - FRONT HEADLIGHTS HEADLIGHTS ADJUSTMENT A lightening fascicle deviated to the left side is shown as in ( figure a ), and a lightening fascicle deviated to the right is shown as in ( figure b ). ( fig a ) ( fig a ) HIGH BEAM ADJUSTMENT ( LONG BEAM ) Check that the position to coincide with...

  • Page 523: Rear And Interior Lighting

    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 nuts that attach the lamp body on the vehicle body ( DACIA 1304 Drop- Side ) Disconnect the lamp from the vehicle wiring.

  • Page 524: Diagnostic

    REAR AND INTERIOR LIGHTING DIAGNOSTIC REAR RIGHT FOGG LAMP NOR WORKING Check if the bulb is not burnt. The bulb is burnt; replace it The bulb is not burnt; the supply wire lamps between. is broken or not connected. REAR RIGHT FOGG LAMP WORKING; THE WARNING IS NOT WORKING Check if the warning bulb is not burnt.

  • Page 525: Horn - Engine Immobiliser

    HORN - ENGINE IMMOBILISER PRESENTATION PRESENTATION This anti starting system ( type 0802) is composed of the following components elements: - UCE anti starting (1) attached by means of three screws on the side wall of the left side dashboard; - anti starting electronic keys (2) are attached to the vehicle keys;...
  • Page 526 HORN - ENGINE IMMOBILISER PRESENTATION CIRCUIT DIAGRAM On the circuit diagram of the system type 0802, the following s component elemen ts may be identified : 1. UCE anti starting 2. Anti starting receiver (2 a = electronic key contact, 2 b = anti starting LED indicator) 3.
  • Page 527 HORN - ENGINE IMMOBILISER PRESENTATION OPERATING CONDITIONS The anti starting has the purpose to block the supply of the electric fuel pump and the ignition and injection system. The anti starting system is automatically armed after 30 seconds from the ignition contact off.( bringing the key on “S”...

  • Page 528: Electronic Keys Programming Procedure

    HORN - ENGINE IMMOBILISER ELECTRONIC KEYS PROGRAMMING PROCEDURE ELECTRONIC KEYS PROGRAMMING PROCEDURE This is to be applied when the replacement of the electronic keys is needed and the procedure is as follows: - bring the switch (1) of the UCE anti starting in position “ON”; - place the end of the first electronic key in contact with the anti starting receiver;...

  • Page 529: Instrument Panel

    INSTRUMENT PANEL INSTRUMENTS PANEL - SERIES 5136 ( SÃCELE ) 83 - 1...

  • Page 530: Replacement Of Instrument Panel

    INSTRUMENT PANEL REPLACEMENT OF INSTRUMENT PANEL ( for vehicles made after 02.04.2003) The instruments panel dismountin g does not imply dashboard dismounting. ISMOUNTING Disconnect the battery. Disconnect the speedometer cable from the instruments panel. Disconnect connectors from the instruments panel. (1, 2 and 3). Disconnect connectors of the switches from the instruments panel.

  • Page 531: Connectors-Series 5136 (Sacele)

    INSTRUMENT PANEL CONNECTORS - SERIES 5136 ( SÃCELE ) Connectors disposal – front view of instruments panel: CONNECTOR A 1. Hazard warning light 2. Headlig ht main beam warning light 3. Side lights warning light 4. Mass ( - ) 5.
  • Page 532 INSTRUMENT PANEL CONNECTORS - SERIES 5136 ( SÃCELE ) EHICLE OSITION NITIAL ECOMING EQUIPMENT IN CONNECTOR 4x2 BOSCH Choke warning light Fuel injection warning inject i on Choke warning light light Rear window heating Fuel injection warning 4x4 BOSCH light light injection Defrost field glass...

  • Page 533: Connectors Type Takosan

    INSTRUMENT PANEL CONNECTORS TYPE TAKOSAN Beginning with 01.01.2000 the DACIA type pick-ups have been equipped with instruments panel SACELE type, where the oil pressure indicator and the water temperature warning light were suppressed i.e. the corresponding positions 2 and 7 from connector C.
  • Page 534 INSTRUMENT PANEL 120 Km/h SPEED WARNING RESENTATION This indicator, located on the instruments panel, has the warning purpose for the driver when the vehicle is running with over 120 km/h. The signal generated from the RPM sensor (2), located on the speedometer cable will act on the indic ator relay (4) through which the “120 km/h” warning light from the instruments panel is lighted.

  • Page 535: Instruments Panel (Commercial Equipped With Ca)

    INSTRUMENT PANEL INSTRUMENTS PANEL ( Commercials equipped with C.A. ) A: 1. Hazard warning light B: 1. Hand brake warning light 2. Headlight s main beam warning light 2. Fuel injection warning light 3. Side lights warning light 3. 120 km/h speed warning light 4.

  • Page 536: Fasten Safety Belts Warning Lights

    INSTRUMENT PANEL FASTEN SAFETY BELTS WARNING LIGHT PRESENTATION This function is activated after switch on the ignition contact (engine starting) and is warning if the driver has not fasten its safety belt, by means of the safety belts warning light, located on the central dashboard.

  • Page 537: Vehicle With Dashboard Type 1325 Replacement

    INSTRUMENT PANEL VEHICLE WITH DASHBOARD TYPE 1325 REPLACEMENT ISMOUNTING Disconnect the battery. Disconnect the speedometer cable from the dash board. Disconnect the connectors and the speedometer cable. Dismount the half housings of the steering wheel. Dismount the headlight adjustment control. Dismount the screws that attach the instrument frame.

  • Page 538: Diagnostic

    INSTRUMENT PANEL DIAGNOSTIC OIL PRESSURE WARNING LIGHT STILL ON AFTER ENGINE STARTING Check the oil pressure. The pressure is not correct; there is The pressure is correct; a failure in the oil circuit. replace the oil pressure switch. OIL PRESURE WARNING LIGHT IS NOT ON WHEN CONTACT SWITCH ON Place the wire from the oil pressure switch to the mass.
  • Page 539 INSTRUMENT PANEL DIAGNOSTIC FUEL LEVEL INDICATOR SHOWING ALWAYS FULL Disconnect the connection wire to the probe. The indicator comes back to zero; replace the probe. The indicator does not come to zero; Is there any mass short-circuit of the connection wire to the probe? Yes.
  • Page 540 INSTRUMENT PANEL DIAGNOSTIC FUEL LEVEL INDICA TOR NOT OPERATING Place at mass the connection wire to the probe. The indicator does not work. The indicator does not work; Replace the probe. Check the indicator supply and mass. Iff correct. Place at mass the connection wire to the probe.

  • Page 541: Flexible Cable

    INSTRUMENT PANEL FLEXIBLE CABLE Dismountin g of the speedomete r cable does not imply the dismounting of the instrument panel from the dashboard. DISMOUNTING Push in the direction of A and B arrows, then pull in the C direction. Loosen the attachment screw E at the gearbox and pull the cable. Detach the cable from the attachment clips on the longitudinal girder.

  • Page 542: Oil Pressure Switch Checking

    INSTRUMENT PANEL OIL PRESSURE SWITCH CHECKING NOTE: The oil pressure switch may not be repaired. It is placed on the left side of the engine block. To check the oil pressure switch, the following items are required: - a compressed air source; - a 0 –...

  • Page 543: Thermocouple Checking

    INSTRUMENT PANEL THERMOCOUPLE CHECKING NOTE: The thermocouple may not be repaired. It is located on closing plate of the cylinder head. In order to check the thermocouple, there are necessary : a vessel with cooling liquid( antifreeze + distilled water ), a 0 –...

  • Page 544: Temperature Transmitter Checking

    INSTRUMENT PANEL TEMPERATURE TRANSMITTER CHECKING NOTE: The temperature transmitter may not be repaired. It is attached on the clos- ing plate of the cylinder head. In order to perform the checking there are necessary: a vessel with cooling fluid (antifreeze + distilled water ), a thermometer 0 – 200° C, a heat source, an ohm meter. Make an assembly accordin g to the diagram.

  • Page 545: Fuel Level Transmitter

    INSTRUMENT PANEL FUEL LEVEL TRANSMITTER ISMOUNTING Disconnect the battery. Disconnect the transmitter connector from the rear wiring. Rotate the gauge attachment flange anti-clockwise by about 1/3 rotation. Take out the transmitter from the tank, by lift it carefully. EMOUNTING Perform in the reverse order the dismounting operations. NOTE: When remounting, pay attention that rubber sealing gasket of the transmitter to be in good state and flange to tightly fix it on the tank.

  • Page 546: Controls - Signalling

    CONTROLS - SIGNALLING STARTING - IGNITION SWITCH ANTI THEFT MECHANISM REPLACEMENT STARTING IGNITION SWITCH The anti theft mechanism is placed on the right part of the steering column and has the purpose to starter control when electric wiring is connected, being provided in the same time also with a steering locking device, with anti theft lock.
  • Page 547 CONTROLS - SIGNALLING STARTING - IGNITION SWITCH ISMOUNTING Disconnect the battery Dismount the half steering wheel housings. Disconnects the connecting plugs of the contact switch. Bring the key in G position. Unscrew the attachment screw (1). Press the mobile pin (2) and draw the contact backwards.

  • Page 548: Under Wheel Control Module

    CONTROLS - SIGNALLING UNDER WHEEL CONTROL MODULE LIGHTS CONTROL SWITCH The DACIA vehicles are provided with a lights control switch shown in the bellow drawing. NOTE: The lights control switch may not be repaired. ISMOUNTING Disconnect the battery. Dismount the lower half housing of the steering wheel.
  • Page 549 CONTROLS - SIGNALLING UNDER WHEEL CONTROL MODULE TURN SIGNALING SWITCH ISMOUNTING Disconnect the battery. Dismount the lower housing of the steering wheel. Cut the plastic ring. Disconnect the connecting coupling to the front wiring. Unscrew the connecting screws of the signaling switch off the steering wheel column. Remove the switch.

  • Page 550: Switches Dashboard

    CONTROLS - SIGNALLING SWITCHES DASHBOARD for vehicles made after 02.04.2003 FOG LAMPS SWITCH 4X4 SWITCH Pos. Destination Pos. Destination Supply + accessories High - beams Road lights Fog lamps command 4x4 coupling command Position lights Position lights Mass Mass TEMPORISATEUR ESSUIE-GLACES FOG LIGHTS SWITCH PARE-BRISE Pos.
  • Page 551 CONTROLS - SIGNALLING SWITCHES DASHBOARD for vehicles made after 02.04.2003 CA SWITCH HEATING SWITCH Pos. Destination Pos. Destination GMV climat control speed 3 Mass + Position lights GMV climat control speed 1 GMV climat control speed 4 AC command GMV climat control speed 2 Supply + accessories Supply + accessories DAMAGE SWITCH...

  • Page 552: Windscreen Wipers

    The windscreen wiper mechanism which is equipping the DACIA pick-ups and its components may be seen in the following detailed drawing. Subject to the type of dashboard which the DACIA pick-ups are equipped with (restyled dashboard or dash board type CN) the mechanism dismounting shall be perform differ ently.
  • Page 553 WINDSCREEN WIPERS WINDSCREEN WIPER MECHANIS M VEHICLE WITH DASH BOARD TYPE 1325 ISMOUNTING Disconnect the battery. Dismount the attachment nuts of the windscreen wiper arms and the blades. Unscrew the attachment nuts of the shafts on the lower frame of the windscreen, recover the rubber washers and bushings.
  • Page 554 WINDSCREEN WIPERS WINDSCREEN WIPER MECHANIS M WINDSCREEN WIPER DRIVE SHAFT REPAIR This operation shall be performed for Dacia vehicles, as per the following drawing, after dismounting the mechanism from the vehicle. ISMOUNTING Disconnect the auxiliary connecting rods (A) and (B) off the shafts.

  • Page 555: Windscreen Wiper Drive Motor

    WINDSCREEN WIPERS WINDSCREEN WIPER DRIVE MOTOR The operation shall be performed after dismounting the mechanism off the vehicle. ISMOUNTING Unscrew the attac hment nut of the control auxiliary connecting rod, ( B ) on the drive motor shaft. Unscrew the attachment screws of the drive motor on the mechanism support. EMOUNTING Perform the dismountin g operations in reverse order.
  • Page 556 WINDSCREEN WIPERS WINDSCREEN WIPER DRIVE MOTOR - loosen the adjustment screw of the rotor axial clearance. Dismount: the reduction gear cap, the pinion. 2. Rotor dismountin g: - unscrew the attachment screws (A) of the reduction gear casing, on the drive engine. Dismount: the reduction gear casing, the bearing at the back of the motor and the rotor.

  • Page 557: Windscreen Washer Assembly

    WINDSCREEN WIPERS WINDSCREEN WASHER ASSEMBLY The windscreen washer assembly is placed in the engine compartment, being attached on the left front wing lining. According to the manufacture variant, this may have the electric pumps attached on the front wing lining (fig. a) or on the washer reservoir (fig. b). ( fig.a ) ( fig.b ) ISMOUNTING...

  • Page 558: Diagnostic

    WINDSCREEN WIPERS DIAGNOSTIC THE WINDSCREEN WIPER IS WORKING THE WASHER PUMP IS NOT WORKING Place the plug (-) of the pump at the mass. The pump is not working. The pump is working; the mass wire broken or not connected. Performm a direct supply of the pump.
  • Page 559 WINDSCREEN WIPERS DIAGNOSTIC THE WINDSCREEN WIPER IS NOT WORKING THE PUMP IS WORKING Connect the pump motor casing at the mass. The motor is not working. The motor is working; repair the mass. Check if the supply wires of the motor are voltage supplied at the contact exit.
  • Page 560 WINDSCREEN WIPERS DIAGNOSTIC WINDSCREEN WIPER NOT WORKING AT HIGH SPEED; THE PUMP IS WORKING Check the gray wire supplying from the wiring plug connected to the drive motor. The wire is not voltage supplied; replace. The wire is voltage supplied. The plug or repair the wiring to the plug.
  • Page 561 WINDSCREEN WIPERS DIAGNOSTIC WINDSCREEN WIPER WORKING ON BOTH SPEEDS, BUT IT DOES NOT STOP AT FIX POINT; THE PUMP IS WORKING Check existence of + 12V at the white wire from the wiper? Repair the electric wiring right Check presence of + 12V at the connection plate - wiper motor.

  • Page 562: Electrical Diagrams

    ELECTRICAL DIAGRAMS GENERALITI ES GENERAL PRESENTATION From the electric point of view, the electric diagrams of the vehicle have been structured as Applied Principle Schemes (APS), which are presented according to each function of the systems. These APS diagrams also contain detail concer ning the internal function of some simple electric components (contacts, relays) , thus contributing to a better understandin g of the system functioning and of the incident good diagnosis.
  • Page 563 - DAIF coutry group with SASO standards - 4X4 – for vehicles provided with 4X4 traction - U75 – representing DACIA 1304 Pick-Up - M75 – representing DACIA 1304 King Cab - E75 – representing DACIA 1304 Drop-Side - H75 – representing DACIA 1307 Double Cab...
  • Page 564 ELECTRICAL DIAGRAMS GENERALITI ES ANTISTARTING 89 - 3...
  • Page 565 ELECTRICAL DIAGRAMS GENERALITI ES INTERPRETATION OF CONNECTORS WIRES FUNCTION INDEX The information concerning the function of the wires in connecters and couplings included in Chapter 1, are to be interpreted taking into account the explanations based upon the following example: 1 = symbol of the pages containing connectors and couplings 2 = connector destination 3 = vehicle class...
  • Page 566 ELECTRICAL DIAGRAMS GENERALITI ES X 75 ENGINE WIRING DETONA TION SENSOR 1 1 1 1 CY2AE 3 CM Position Section Destination DETONATION SENSOR MASS DETONATION INFO INJECTION COMPUTER ATMOSPHERE PRESSURE SENSOR ZW3DT 13 - 07 89 - 5...

  • Page 567: Functional Diagrams List

    ELECTRICAL DIAGRAMS FUNCTIONAL DIAGRAMS LIST Electric diagrams denomination Antistarting Speed limit alarm (DAIF) Lighter Climate control system Climate control system and air conditioning Ashtray lighting Ceiling lamp Documents compartment lighting lamp(CHAUFO) Documents compartment lighting lamp Transmission 4x4 Starting circuit GMV cooling(CA) Electronic injection (CHAUFO) Electronic injection(CA) Charging circuit...
  • Page 568 ELECTRICAL DIAGRAMS FUNCTIONAL DIAGRAMS LIST Electric diagrams denomination Rear fog lights Rear fog lights Fog lights High - beams Backward running lights Backward running lights Position lights Position lights Road lights STOP lights STOP lights Signalisation and break down lights Signalisation and break down lights NOTA : S = equipment series;...

  • Page 569: Electric Components Index

    ELECTRICAL DIAGRAMS ELECTRIC COMPONENTS INDEX COMPONENT DENOMI NATION COMPONENT DENOMI NATION Fuel pump control relay Electric lighter Main relay Alternator Injection water temperat u re sensor Anti - theft system Board panel Acoustic alarm Vehicle speed transducer Battery Water thermo-contact, 2 steps Windscreen wiper timer Front right signalising light Injection computer (UCE)

  • Page 570: Couplings List. Mass Index

    ELECTRICAL DIAGRAMS COUPLINGS LIST. MASS INDEX COUPLING LIST R 9 = ADDITIONAL BOARD PANEL (E)/ ADDITIONAL FRONT WIRES COUPLING R 25 = BATTERY (C)/ FRONT WIRES COUPLING R 67 = DIAVIA (D)/ADDITIONAL FRONT/ADDITIONAL FRONT WIRES COUPLING R 82 = AC CONTROL (L)/ADDITIONAL BOARD PANEL WIRES COUPLING R 93 = COCKPIT GMV 2(K)/ ADDITIONAL BOARD PANEL WIRES COUPLING R 99 =...

  • Page 571: Location Of Electric Coupling On The Vehicle

    ELECTRICAL DIAGRAMS LOCATION OF ELECTRIC COUPLING ON THE VEHICLE A. for U75 (Pick-up), M75 (King Cab) Κ Κ Κ Κ B. for E75 (Drop -Side) C. for H75 (Double Cab) 89 - 10...

  • Page 572: Fixation Of Electric Mass On The Vehicle

    ELECTRICAL DIAGRAMS FIXATION OF ELECTRIC MASS ON THE VEHICLE A. for U75 (Pick-up), M75 (King Cab) B. for E75 (Drop -Side) C. for H75 (Double Cab) 89 - 11...

  • Page 573: Electric Components Location On The Vehicle

    ELECTRICAL DIAGRAMS ELECTRIC COMPONENTS LOCA TION ON THE VEHICLE Breakdown switch Electronic clock Fog lights switch Left front door contact Safety belt witness Cockpit fuses box Fog headlights switch Decoder UCE Air heater switch Control relay for cl i mate GMV - step1 Anti-starter receptor Right front ceiling light Fuel level transmitte r and electric pump...
  • Page 574 ELECTRICAL DIAGRAMS ELECTRIC COMPONENTS LOCA TION ON THE VEHICLE A. PENTRU U75 (Pick-up), M75 (King Cab) 31 32 33 B. PENTRU E75 (Drop -Side) 31 32 33 89 - 13...
  • Page 575 ELECTRICAL DIAGRAMS ELECTRIC COMPONENTS LOCA TION ON THE VEHICLE C. PENTRU H75 (Double Cab) 31 32 33 89 - 14...

  • Page 576: Cockpit Fuse Box

    ELECTRICAL DIAGRAMS COCKPIT FUSE BOX The DACIA commercial vehicles are provided with a fuses box (10 safety fuses) situated in the cockpit, under the board, left side. In case of electric system damage, before other interventions we must first check the fuses and connection s of the equipment, power off.

  • Page 577: Engine Compartment Fuse Box

    ELECTRICAL DIAGRAMS ENGINE COMPARTMENT FUSE BOX The electric equipment of DACIA commercial vehicles is provided with safety fuses and relay, situated in the engine compartment and fixed on the left mudguard coating. Electric circuits protected by fuses and relays: NUMBER...
  • Page 578 ELECTRICAL DIAGRAMS ENGINE COMPARTMENT FUSE BOX The vehicles provided with AC system, the fuse box situated in the engine compartment is fixed on the left mudguard coating, having the following configu ration. NUMBER USE TYPE PROTECTED CIRCUIT 10 A A.C. compressor 10 A Oxygen rod 10 A...
  • Page 579 ELECTRICAL DIAGRAMS WIRE FUNCTIONS INDEX IN CONNECTORS AND COUPLINGS ONNECTOR ENOMINATION ELECTRIC LIGHTER 89 - 123 103 HA ALTERNA TOR 89 - 121 103 HB ALTERNA TOR EXCIT ATION 89 - 121 ANTI- T HEFT SYSTEM 89 - 114 ACOUSTIC ALARM 89 - 108 107AA BA TTERY TERMINAL (+)
  • Page 580 ELECTRICAL DIAGRAMS WIRE FUNCTIONS INDEX IN CONNECTORS AND COUPLINGS DIAGN OSIS PLUG 89 - 95 RIGHTS HEADLIGHT 89 - 102 LEFT HEADLIGHT 89 - 102 IDLE MOTION REGULA TOR 89 - 92 FOG LIGHTS RELAY 89 - 123 FOG LIGHTS CONTROL RELA Y 89 - 107 GMV RÃCIRE COOLING CONT ROL RELA Y 89 - 111...
  • Page 581 ELECTRICAL DIAGRAMS WIRE FUNCTIONS INDEX IN CONNECTORS AND COUPLINGS ADDITIONAL FRONT WIRES COUPLING/ADDITIONAL BOARD P ANEL 89 -158 R 25 FRONT WIRES COUPLING /BA TTERY 89 -153 R 67 ADITTIONAL FRONT WIRES C OUPLING/ADITTIONAL FRONT DIA VIA 89 -159 R 82 ADITTIONAL BOARD P A NEL WIRE COUPLING/AC CONTROL 89 -157 R 93...
  • Page 582 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING INJECTION U.C.E. Position Section Destination CONTROL - 1-4 CYLINDERS IGNITIO N COIL 0,35 SIGNAL - E NGINE ROT ATION > ROT A TION SENSOR 0,75 LINE K DIAGNOSIS SIGNAL 0,75 IDLE MOTION SWITCH M ASS SIGNAL UPSTREAM OXYGEN E ROD SIGNAL UPSTREAM OXYGENE ROD MASS...
  • Page 583 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING M INTI 18 17 ML 3BR B 3B 3LS 3LW 3GH 3GK 3AY HK 3BL 31 30 22 21 3AM 3BV ML 3BU 3FH 38R 3BB 3AC NF MB 49F 3BG ML 3CW Vi-N X As-M X ROTATION SENSOR...
  • Page 584 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING A.C. COMPRESSOR CLUTCH (for A.C. provided vehicles) Position Sectioning Destination 0,7 5 CONTROL + A.C. COM PRESSOR CLUTCH 89 - 23...
  • Page 585 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING VALVE POTENTIOMETER Destination Position Sectioning POTENTIOMETER MASS 0,75 SIGNAL + POTENTIOMETE R 1 0,75 SIGNAL + POTENTIOMETE R 2 0,75 SUPPL Y + VALVE POTENT IOMETER DIAGNOSIS PLUG Position Sectioning Destination 0,7 5 LINE K DIAGNOSIS SIGNA L...
  • Page 586 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING IDLE MOTION REGULATOR Position Sectioning Destination CONTROL 1 IDLE MOTION REG ULA TOR CONTROL 2 IDLE MOTION REG ULA TOR 0,75 IDLE MOTION SWITCH M ASS SIGNAL 0,75 MASS FUEL PUMP CONTROL RELAY Destination Position Sectioning + INJECTOR >...
  • Page 587 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING MAIN RELAY Position Sectioning Destination + AFTER CONT ACT > M AIN RELA Y 0,75 AP29 + AFTER PROTECTED CONT ACT + BATTERY 0,75 MASS CS6P AP29 INJECTION WATER TEMPERATURE SENSOR Position Sectioning Destination...
  • Page 588 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING INJECTOR / AIR TEMPERA TURE SENSOR Destination Position Sectioning 0,75 SIGNAL + AIR TEMPERA TURE SENSOR + INJECTOR > FUEL PUMP RELA Y CONTROL - INJECTOR AIR TEMPERA TURE SENSOR M ASS CANISTER PURGING VALVE Position Sectioning Destination...
  • Page 589 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING A.C.COMPRESSOR CLUTCH CONTROL RELAY (For A.C. provided vehicles) Position Sectioning Destination 0,7 5 CONTROL + A.C. COM PRESSOR CLUTCH + AFTER CONT A CT > MAIN RELAY 0,75 + BATTERY 0,75 CONTROL + A.
  • Page 590 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING ENGINE RELAYS AND SAFETY FUSES BOX PositionSectioning Destination 3 NR +INJECTOR > F02 FUSE INPUT 3 PP OXYGEN ROD HEATING CONTROL + INJECTOR > F03 FUSE INPUT + FUEL PUM P + BATTERY BP5 4 + BA TTER Y >...
  • Page 591 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS ENGINE WIRING IGNITION COIL Destination Positin Sectioning CONTROL - 2-3 CYLINDERS IGNITIO N COIL AP29 + AFTER PROTECTING CONT ACT CONTROL - 1-4 CYLINDE RS IGNITION COIL OXYGEN ROD Position Sectioning Destination OXYGEN ROD HEATING CONTROL MASS UPSTREAM OXYGE N ROD SIGNAL...
  • Page 592 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING ALTERNA TOR Position Sectioning Destination + BATTER Y 103 HA ALTERNATOR EXCITATION Sectioning Destination Position 0,7 5 CONTROL-CHARGE WITNESS + AFTER CONT ACT 103 HB 89 - 31...
  • Page 593 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING ANTI -THEFT SYSTEM Destination Position Sectioning SUPPL Y + ACCESSORIES SUPPLY + + AFTER CONT ACT SUPPLY + + AFTER CONT ACT + BA TTERY CONTROL + ST ARTER ACOUSTIC ALARM Position Sectioning Destination 0,7 5...
  • Page 594 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING SIGNALISATION RELAY Position Sectioning Destination 0,75 64 AP + PROTECTED SIGN A LISA TION LIGHT 0,75 64 B CONTROL + SIGNALISA TION MASS CS6P 64AP BACKWARDS RUNNING CONTACTOR Position Sectioning Destination AP43 + AFTER PROTECTED CONT ACT...
  • Page 595 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING STOP CONTACTOR Destination Position Sectioning SP16 + PROTECTED ACCESSORIES CONTROL + STOP LIGHTS SP16 STARTER Position Sectioning Destination 16,0 + BATTER Y 163BA Position Sectioning Destination 16,0 BATTER Y ELECTRIC M ASS 163AB 89 - 34...
  • Page 596 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING STAR TER EXCITATION Position Sectioning Destination CONTROL + ST ARTER 163 DB RIGHT FRONT POSITION LIGHT Destination Position Sectioning 0,3 5 + POSITION LIG HTS PROTECTE D 0,35 MASS 89 - 35...
  • Page 597 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING LEFT FRONT POSITION LIGHT Position Sectioning Destination 0,35 + POSITION LIGHTS PROTECTED 0,35 MASS 89 - 36...
  • Page 598 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING MANUAL CONTACT Destination Position Sectioning 0,35 CONTROL - OIL PRESSURE WIT N ESS 2 8 A HORN AND LIGHTS SWITCH Position Sectioning Destination + DRIVING LIGHTS + HIGH-BEAM S + PROTECTED POSITION LIGHTS 0,35 CONTROL + DRIVING LIGHTS SHUNT >...
  • Page 599 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING DIRECTION SIGNALISATION SWITCH Position Sectioning Destination LEFT SIGNALISATION LIGHTS CONTROL RIGHT SIGNALISATION LIGHTS CONTROL CONTROL + SIGNALISATION CONTROL + SIGNALISATION>SHUNT 6 4 D 209B RIGHT FRONT BRAKE PLATE Destination CONTROL - I.C.P. BRAKING SY STEM 0,35 H1 WITNESS LEFT FRONT BRAKE PLATE...
  • Page 600 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING WINDSCREEN CLEANER PUMP Destination 16A CONTROL + WINDSCREEN CLEANER PUMP MASS MASS RIGHT HEADLI GHT CD8F Destination MA MASS CPD + PROTECTED RIGHT HIGH-BEAMS RPD + PROTECTED RIGHT DRIVING LIGHTS 89 - 39...
  • Page 601 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING LEFT HEADLI GHT CD8F Destination MB MASS CPG + PROTECTED LEFT HIGH-BEAMS RPG + PROTECTED LEFT DRIVING LIGHTS GMV COOLING CONTROL RELAY (for A.C. provided vehicles) Position Sectioning Destination 0,35 C ONTROL + GMV COOLING RELA Y >TERM OCONT ACT >...
  • Page 602 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING BOARD PANEL Destination Position Sectioning 0,35 CONTROL - HANDBRAKE PLA TE WEAR WITNESS 0,35 CONTROL - HANDBRAKE PLA TE WEAR WITNESS 0,35 CONTROL - INJECTION DAMAGE WITNESS 0,35 CONTROL- 4x4 WITNESS 0,35 + PROTECTED LEFT POSITION LIGHTS 0,35...
  • Page 603 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING Destination Position Sectioning AP43 +AFTER PROTECTED CONT ACT 0,35 CONTROL - OIL PRESSURE WITNESS 0,35 MASS 0,35 CONTROL + RIGHT SIGNALISA TION WITNESS 0,35 CONTROL + LEFT SIGNALISA TION WITNESS SIGNAL + FUEL LEVEL TRANSMITTER 0,35 CONTROL-AL TERNA TOR CHARGE WITNESS...
  • Page 604 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING WATER THERMO-CONTACT (for A.C. provided vehicles) Position Sectioning Destination 0,35 CONTROL + GMV COOLING RELA Y > PRESSURE GAU G E 0,35 CONTROL + GMV COOLING RELA Y > PRESSURE GAU G E 0,35 A.C.
  • Page 605 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING LEFT FRONT SIGNALISATION LIGHT Destination 64C LEFT SIGNALISATION LIGHTS CONTROL 0,75 MB MASS GMV COOLING (for A.C.provided vehicles) Destination Position Sectioning CONTROL + GMV COOLING MASS RIGHT FRONT SIDE SIGNALISATION LIGHT Destination 0,35 64D RIGHT SIGNALISATION LIGHTS CONTROL...
  • Page 606 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING LEFT FRONT SIDE SIGNALISA TION LIGHT Destination 0,35 64C LEFT SIGNALISATION LIGHTS CONTROL 0,35 MB MASS WATER TEMPERA TURE TRANSMITTER Destination Position Sectioning 0,3 5 SIGNAL + WATER TEMPERA TURE 4 2 A G.M.V CLIMATE CONTROL RELAY (for A.C.provided vehicles) Destination...
  • Page 607 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING AIR CONDITIONING PRESSURE GAUGE (forA.C. p rovided vehicles) Position Sectioning Destination + AIR CONDITIONING CONT ROL > GMV CONTROL RELA Y + AIR CONDITIONIN G CONT ROL > GMV STOPPING RELA Y AP40 SUPPLY + PROTECTED ACCESSORIES CONTROL + GMV COOLING RELAY...
  • Page 608 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING A.C. RELAY (on bord - for A.C vehicles) Destination Position Sectioning AP40 SUPPL Y + PROTECTED ACCESSORIES AP40 SUPPL Y + PROTECTED ACCESSORIES MASS MASS > G.M.V CONTROL RELA Y BP1 1 + PROTECTE D BATTER Y 38HQ...
  • Page 609 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING A.C. STOPPING RELAY (for A.C. provided vehicles) Destination Position Sectioning 0,35 A.C. STOPPING CONTROL > THERMO-CONT ACT 0,35 MASS 0,35 + AIR CONDITION ING CONTROL > PRESSURE GAUGE 0,35 + AIR CONDITIONING CONTROL > U.C.E. IN JECTION CS6P 89 - 48...
  • Page 610 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING CUTIE SIGURANπE HABITACLU Designation F01 5,0 SUPPL Y + DC F01 2,0 AP43 + PROTECTED AFTER CONT ACT F02 2,0 SUPPL Y + ACCESORIES F02 2,0 SP2 2 SUPPL Y + PROTECTE D ACCESORIES F03 0,35 SP1 6 + PROTECTED ACCESORIES >...
  • Page 611 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING AP43 SP22 SP16 BP11 6 4 A 1016 89 - 50...
  • Page 612 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING I.C.P. BRAKING SYSTEM Destination 1091 0,35 CONTROL - I . C.P. BRAKI NG SYSTE M WI T NESS FRONT RIGHT BODY ELECTRIC MASS Destination Position Sect i oni n g MASS >...
  • Page 613 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FRONT WIRING LEFT FRONT BODY ELECTRIC MASS Destination Position Sect i oni n g MASS > LEFT LIGHT, LEFT FRONT POSITION LIGHT, L EFT FRONT SIGNAL ISA TION LIGHT, WINDSCREEN CLEA NER PUMP , BACK WINDSCREEN CLEANE R PUMP MASS >...
  • Page 614 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BATTERY WIRING BATTERY TERMINAL (+) Position Sectioning Destination 16,0 + BA TTERY > + STAR TER + BATTER Y 107AA AS,N BATTERY TERMINAL ( -) Position Sectioning Destination 16,0 BATTERY EL ECTRIC MASS 107AB 89 - 53...
  • Page 615 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BOARD PANEL WIRING ELECTRIC LIGHTER Destination PositionSectioning MASS 0,35 MASS > ASHTRAY LIGHTING 0,35 + POSITION LIGHTS BP11 + PROTECTE D BATTER Y BP1 1 FOG HEADLIGHTS SWITCH Destination Position Sectioning SHUNT CONTROL + REAR FOG LIGHTS >...
  • Page 616 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BOARD PANEL WIRING FOG HEADLIGHTS SWITCH Position Sectioning Destination POSITION LIGHTS 0,3 5 POSITION LIGHTS>SHUNT 0,3 5 CONTROL + REAR FOG LIGHTS RELA Y 0,35 + POSITION LIGHTS 0,35 MASS LPG MB 89 - 55...
  • Page 617 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BOARD PANEL WIRING BREAKDOWN SWITCH Position Sectioning Destination CONTROL + SIGNALISATION LEFT SIGNALISA TION LIGHTS CONTROL RIGHT SIGNALISA TION LIGHTS CONTROL 0,35 CONTROL + BREAKDOWN WITNESS 0,35 + PROTECTED POSITION LIGHTS 0,35 MASS SUPPL Y + SIGNALISA T ION + AFTER CONT A CT...
  • Page 618 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BOARD PANEL WIRING GLOVES BOX LIGHT Position Section Destination 0,35 MASS 0,35 + PROTECTED POSITION LIGHTS ELECTRONIC CLOCK Position Section Destination 0,35 + PROTECTED POSITION LIGHTS 0,35 AP40 + AFTER PROTECTED CONT ACT 0,35 + BATTER Y 0,35...
  • Page 619 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BOARD PANEL WIRING FOG LIGHTS RELAY Destination Position Sectioning CONTROL + REAR FOG LIGHTS MASS + PROTECTED POSITION LIGHTS CONTROL + REAR FOG LIGHTS BP1 1 + PROTECTE D BATTER Y CS6P BP11 CLIMATE CONTROL LIGHTING Position Sectioning...
  • Page 620 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS BOARD PANEL WIRING FRONT ASHTRA Y LIGHTING Destination Position Sectioning 0,3 5 MASS 0,35 +PROTECTED POSITION LIGHTS 1335 89 - 59...
  • Page 621 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS CEILING LIGHT WIRING FRONT RIGHT CEILING LIGHT Destination BCP3 + PROTECT ED BA TTERY CEILING LIGHTING>LEFT COUPLI N G PLA TE 13A CONTROL - CEILING LIGHTING > LEFT DOOR CONT ACTOR BCP3 1 3 A 89 - 60...
  • Page 622 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FOG HEADLIGHTS WIRING RIGHT FOG HEADLIGHT Position Sectioning Destination + FOG HEADLIGH TS>FOG HEADLIGHT S RELA Y MASS LEFT FOG HEADLIGHT Position Sectioning Destination + FOG HEADLIGH TS>FOG HEADLIGHT S RELA Y MASS 89 - 61...
  • Page 623 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS FOG HEADLIGHTS WIRING FOG HEADLIGHTS CONTROL RELAY Destination Position Sectioning MASS CONTROL + FOG HEADLI GHTS RELA Y + FOG HEADLIGH TS>LEFT FOG HEADLIGH T + FOG HEADLI GHTS>RELA Y B P 54 + PROTECTE D BATTER Y CS6P BP5 4...
  • Page 624 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS WINDSCREEN WIPER WIRING WINDSCREEN WIPER TIMER Destination Position Sectioning CONTROL + WINDSCR EEN CLEANE R PUMP CONTROL + WINDSCREEN WIPER TIMER MASS CONTROL WINDSCREEN WIPER TIMER LOW-SP EED BP1 1 + PROTECTED BATTERY 1 6 A BP11 WINDSCREEN WIPER CLEANER SWITCH...
  • Page 625 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS WINSCREEN WIPER WIRING WINDSCREEN WIPER MOTOR Destination Position Sectioning CONTROL + WINDSCREEN WIPER LOW-SPEED CONTROL WINDSCREEN WIPER TIMER CONTROL + WINDSCREEN WIPER HIGH-SPEED 0,75 BP1 1 + PROTECTED BATTERY BP1 1 + PROTECTED BATTERY > WINDSCREEN WIPER TIMER BP11 89 - 64...
  • Page 626 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS REAR WIRING HANDBRAKE CONTACTOR Destination PositionSectioning 0,3 5 CONTROL - HA NDBRAKE WITNESS 2 7 A RIGH REGISTRA TION NUMBER LIGHT (for U75, M75, H75) Position Sectioning Destination 0,3 5 +PROTECTED POSITION LIGHTS LEFT REGISTRA TION NUMBER LIGHT (for U75, M75, H75) Position Sectioning Destination...
  • Page 627 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS REAR WIRING RIGH REGISTRATION NUMBER LIGHT (for E75) Position Sectioning Destination H66P +CONTROL+ BACKW ARDS RUNNING LIGH TS 0,3 5 +PROTECTED POSITION LIGHTS H6 6 P LEFT REGISTRA TION NUMBER LIGHT (for E75) Position Sectioning Destination H66P...
  • Page 628 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS REAR WIRING REAR RIGHT LIGHT(for U75, M75, H75) Destination Position Sectioning 0,35 + PROTECTED POSITION LIGHTS MASS CONTROL + STO P LIGHTS RIGHT SIGNAL ISA TION LIGHTS CONTROL H66P CONTROL + BACKW ARDS RUNNING LIG H TS CONTROL + REAR PROCTE D FOG LIGHTS H66P 6 4 D...
  • Page 629 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS REAR WIRING REAR RIGHT LIGHT(for E75) Position Sectioning Destination 0,35 + PROTECTED POSITION LIGHTS CONTROL + STO P LIGHTS RIGHT SIGNAL ISA TION LIGHTS CONTROL MASS 6 5 A 6 4 D 89 - 68...
  • Page 630 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS REAR WIRING REAR LEFT LIGHT(for E75) Destination Position Sectioning 0,35 + PROTECTED POSITION LIGHTS CONTROL + STO P LIGHTS LEFT SIGNAL ISA TION LIGHTS CONTROL MASS 6 5 A ELECTRIC PUMP AND FUEL LEVEL TRANSMITTER Destination Position Sectioning - FUEL MINIMAL LEVEL ALARM...
  • Page 631 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS 4X4 CONTROL WIRING 4X4 WITNESS CONTROL RELAY Destination Position Sectioning 0,75 4X4 COUPLING RELA Y CONTROL AP40 SUPPL Y + PROTECTED ACCESSORIES >SHUNT 4X4 WITNESS CONTROL 0,75 AP40 SUPPL Y + PROTECTED ACCESSORIES AP40 SUPPL Y +PROTECTED ACCESSORIES >SHUNT CS6P...
  • Page 632 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS 4X4 CONTROL WIRING 4X4 COUPLING ELECTRO-VALVE Position Sectioning Destination 0,75 SUPPL Y + PROTECTED ACCESSORIES 0,75 MASS 4X4 SWITCH Destination 0,75 AP40 SUPPL Y+ PROTECTED ACCESSORIES 0,75 + PROTECTED ACCESSORIES 0,35 + POSITION LIGHTS 0,35 MASS AP4 0...
  • Page 633 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS OVER - SPEED WIRING SAFETY BELT WITNESS (for DAIF) Position Sectioning Destination AP40 SUPPL Y + PROTECTED ACCESORIES CONTROL - SAFETY BEL T WITNESS AP40 VEHICLE SPEED TRANSDUCER (for DAIF) Position Sectioning Destination SUPPL Y + PROTECTED ACCESSORIES 0,35...
  • Page 634 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS OVER - SPEED WIRING OVER - SPEED INDICATOR RELAY (for DAIF) Position Sectioning Destination 0,35 AP40 SUPPL Y + PROTECTED ACCESSORIES 0,35 MASS 0,35 VEHICL E SPEED SIGNAL ISA TION 0,35 CONTROL - SPEED WITNESS 120 KM/H CS6P AP40 SAFETY BELT WITNESS...
  • Page 635 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS ADDITIONAL FRONT/ADDITIONAL BOARD PANEL WIRES COUPLING (for A.C. provided vehicles) ADDITIONAL FRONT WIRES COUPLING Position Sectioning Destination 0,75 AIR CONDITIONIN G CONTROL > PRESSURE GAUGE AP40 SUPPL Y + PROTE CTED ACCESSORIES ADDITIONAL BOARD PANEL WIRES COUPLING Destination Position Sectioning...
  • Page 636 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT WIRES COUPLING/BATTERY FRONT WIRES COUPLING Destination Position Sectioning + BATTER Y BATTERY WIRES COUPLING Destination Position Sectioning + BATTER Y 89 - 75...
  • Page 637 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS ADDITIONAL FRONT/DIAVIA ADDITIONAL FRONT WIRES COUPLING (for A.C. provided vehicles) ADDITIONAL FRONT WIRES COUPLING Destination Position Sectioning 0,75 + AIR CONDITION ING CONT ROL > G.M.V . RELA Y 0,35 + AIR CONDITIONING CONTROL > C.A. RELA Y DIAVIA ADDITIONAL FRONT WIRES COUPLING Destination Position Sectioning...
  • Page 638 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS ADDITIONAL BOARD PANEL WIRES COUPLING/ A.C.CONTROL (for A.C. provided vehicles) ADDITIONAL BOARD PANEL WIRES COUPLING Position Sectioning Destination MASS +PROTECTED POSITION LIGHTS + AIR CONDITIONING CONTROL > RELA Y AP40 SUPPL Y + PROTE CTED ACCESSORIES AP40 R-GR A.C.
  • Page 639 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS ADDITIONAL BOARD PANEL WIRES COUPLING/GMV 2 COCKPIT (for A.C. provided vehicles) ADDITIONAL BOARD PANEL WIRES COUPLING Destination Position Sectioning 38AH CONTROL + G.M.V . MOTOR SPEED 1 MASS 38AJ CONTROL + G.M.V . MOTOR SPEED 2 38AK CONTROL + G.M.V .
  • Page 640 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS CLIMATE CONTROL SWITCH WIRES COUPLING/ GMV CLIMATE CONTROL CLIMATE CONTROL SWITCH WIRES COUPLING Position Sectioning Destination 38AK CONTROL + GMV CLIMA TE CONTROL SPEED 3 38AH CONTROL + GMV CLIMA TE CONTROL SPEED 1 38AL CONTROL + GMV CLIMA TE CONTROL SPEED 4 38AJ...
  • Page 641 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT WIRES COUPLING/WINDSCREEN WIPER FRONT WIRES COUPLING Position Sectioning Destination CONTROL + WINDSCR EEN CLEANE R PUMP R106 WINDSCREEN WIPER WIRES COUPLING Destination Position Sectioning CONT ROL + WINDSCREEN CLEANER PUMP 1 6 A R106 89 - 80...
  • Page 642 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT WIRES COUPLING/BOARD P ANEL (for A.C. provided vehicles) FRONT WIRES COUPLING Destination Position Sectioning MASS AP40 +AFTER PROTECTED CONT ACT + PROTECTED POSITION LIGHTS + AFTER PROTECTED CONT ACT CONTROL + PROTECTE D REAR FOG LIGHTS 0,35 CONTROL + PROTECTED REAR FOG LIGHTS >...
  • Page 643 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS BOARD PANEL WIRES COUPLING Destination Position Sectioning MASS MASS > FOG LIGHTS RELA Y AP40 + AFTER PROTECTED CONT ACT AP40 + AFTER PROTECTED CONTACT> WINDSCRE EN WIPER CONTROL + PROTECTED POSITION LIGHTS + PROTECTED POSITION LIGHTS >...
  • Page 644 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS BOARD PANEL WIRES COUPLING/G.M.V. CLIMATE CONTROL BOARD PANEL WIRES COUPLING Position Sectioning Destination AP40 + PROTECTED ACCESSORIES > G.M .V. CLIM A TE CONT ROL AP4 3 D = 3 R111 G.M.V.
  • Page 645 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT WIRES COUPLING / U.C.E. DECODER (for DAIF) FRONT WIRES COUPLING Destination Position Sectioning MASS MASS + FUEL PUMP AP29 AFTER PROTECTED CONTACT ENGINE SAFETY FUNCTION BP11 + PROTECTED BATTER Y SUPPLY + AFTER CONT A CT + FUEL PUMP SUPPLY + AFTER CONT A CT...
  • Page 646 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT WIRES COUPLING/FOG LIGHTS FRONT WIRES COUPLING Position Sectioning Destination CONTROL + POSITION LIGHTS R122 FOG LIGHTS WIRES COUPLING Position Sectioning Destination +POSITION LIGHTS R122 89 - 85...
  • Page 647 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT /ENGINE WIRES COUPLING FRONT WIRES COUPLING Destination Position Sectioning 0,35 + AIR CONDITIONING CONTROL > A.C. RELAY CONTROL + A.C. COM PRESSOR CLUTCH MASS 0,35 CONTROL - INJECTION DAMAGE WITNESS + FUEL PUMP >...
  • Page 648 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS ENGINE WIRING COUPLING Destination Position Sectioning 0,35 + AIR CONDITION I NG CONT ROL > U.C.E. INJECTION CONTROL + A.C. COM PRESSOR CLUTCH MASS 0,35 CONTROL - INJECTION DAMAGE WITNESS + FUEL PUMP AP29 + AFTER PROTECTED CONT ACT AP29...
  • Page 649 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT/REAR WIRES COUPLING FRONT WIRES COUPLING Position Sectioning Destination + PROTECTED POSITION LIGHTS + FUEL PUM P > ANTIST ARTING + FUEL PUM P H66P CONTROL+ BACKW ARD RUNNING LIGHTS CONTROL+ PROTECTE D REAR FOG LIGHTS LEFT SIGNALISA TION LIGHTS CONTROL 0,35 - ALARM FOR FUEL MINIMAL L EVEL...
  • Page 650 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS REAR WIRES COUPLING Destination Position Sectioning + PROTECTED POSITION LIGHTS + FUEL PUM P H66P CONTROL+ BACKW ARD RUNNING LIGHTS CONTROL+ PROTECTE D REAR FOG LIGHTS LEFT SIGNALISA TION LIGHTS CONTROL 0,35 - ALARM FOR FUEL MINIMAL L EVEL CONTROL - H ANDBRAKE WITNE S S...
  • Page 651 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS FRONT WIRES COUPLING / BOARD PANEL FRONT WIRES COUPLING Position Sectioning Destination RIGHT SIGNALISA TION LIGHTS CONTROL CONTROL + SIGNALISA TION + BATTE RY CONTROL +FOG LIGHTS RELAY 0,35 CONTROL + BREAKDOWN WITNESS SUPPL Y + SIGNALISA T ION SUPPLY + AFTER CONTACT RIGHT SIGNALISA TION LIGHTS CONTROL...
  • Page 652 ELECTRICAL DIAGRAMS WIRE FUNCTIOS IN CONNECTORS AND COUPLINGS COUPLINGS BOARD PANEL WIRES COUPLING Position Sectioning Destination RIGHT SIGNALISA TION LIGHTS CONTROL CONTROL + SIGNALISA TION + BATTE RY 0,35 CONTROL +FOG LIGHTS RELAY 0,35 CONTROL + BREAKDOWN WITNESS SUPPL Y + SIGNALISA T ION SUPPLY + AFTER CONTACT RIGHT SIGNALISA TION LIGHTS CONTROL R 318...
  • Page 653 ELECTRICAL DIAGRAMS WIRE FUNCTIONES EXPLANATION LINK WIRE FU NCTIONS CODES SUPPL Y + AFTER CONTACT PROTECTED ACCES ORIES AP29 + AFTER PROTECTED CONTACT ENGI NE SAFETY FUNCTI O N AP40 SUPPL Y + PROTECTED ACCESSORIES AP43 + AFTER PROTECTED CONTACT + BA TTERY BCP3 + PROTECTED BA TTERY CEI L ING LIGHTING...
  • Page 654 ELECTRICAL DIAGRAMS WIRE FUNCTIONES EXPLANATION UPSTREAM ROD O2 MASS UPSTREAM ROD O2 SIGNAL SIGNAL + POTE NTIOMETER 1 SIGNAL + POTE NTIOMETER 2 + FUEL PUMP + INJECTOR > FUEL PUMP RELA Y ROD O2 CONTROL + FOG HEADLI G HTS > RELA Y CONTROL + FOG HEADLI G HTS RELA Y +REAR FOG LIGHTS RELA Y CONTROL CONTROL + REAR FOG LIGHTS...

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