REPAIR MANUAL DACIA COMMERCIAL RM 502-1 MECHANICS ENGINE: C3L GERBOX: NG1; NG7 TAPV: U75B; U75F ‘The reparation methods preseribed by the manufactrer in the present document are established subject © 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 ts vehicles All ights 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. A AN Ref: 6001999452 NOVEMBER 2004 English version[_ General poinds vehicle a SPECIFICATIONS Engine ~ Clutch - Gearbox ont Vehicle identification o12 LIFTING Mobile jack and protection route 021 Elevator positioned under the earriage body... 02-2 Ba TOWING Alltypes 03-1 LUBRICANTS CONSUMABLES Conditions 041 DRAINING AND FILLING Engine Fearbox Rearaxle differential [ilysivrs axosernvos ‘Dimensions orl Capacity - Qualities ort Driving belts tightening and tightening checking : ors Cylinder head tightening and raightening ... 07-7 Wheeles and tyres, 078. Brakes 079) Heights under carriage body... 07-10 Control values ofthe front axle angles 5.0711 Control values ofthe rear axle angles 07-15 [H Engine and peripheries NGINE AND LOWER ENGINE UNITS Ingredients . cennnnnnnne 10-1 lentifieation soon sens 10D Measurement of oil consumption wosrnnnn 10-4 Oil presure checking .. sarnenener 106 if filter replacement «mene 10-7 Engine Dismounting - Remounting sono 10-8 Engine and gearbox Dismounting - Remounting ... 10-11 Tightening by serewing up moments jun. 10-14 Characteristics. : 10-15 Dismounting - Mounting 00. 10-23 Replacement of the distribution annular oil seal — 10-55 Distribution cap -....0 - 10-56 Tightener and distribution chain ......0enn 10-59 Camshaft nnn vena 10-61 Lower erankeas 10-64 Ol pump sear nnn 10-66 FUEL MIXTURE Characteristics Injector valve body Inlet exhaust manifold PUMP SUPPLY Fuel filter (injection engine) ANTIPOLLUTION Gasoline vapours reaspiration Carbon can Carbon can valve STARTINGAND CHARGING Alternator Starter IGNITION AND INIECTION Spark plugs Operation principle Description of the system Diagnostic Electronic Control Unit Rotation sensor Engine temperature sensor Oxygen sensor Induction coil, Spark plugs set COOLING - EXHAUST - FUEL TANK Characteristics Filling and aeration of the cooling system Control Cooling radiator Cooling GMLY. .. Cooling G.M.Y. thermocouple checking (for Pick-Up with C.A.) ‘Water pump ‘Water pump cover ‘Thermostat Exhaust assemby Fuel tank asembly Electric fuel pump ..n Fuel level sensor ‘Transmi CLUTCH CCharacteristies Identification CCluteh disk-mechanism Clute fork placement 41 14.2 143 16-1 16.20 1 173 14 17.23 1730 1731 17-32 1733 1734 1735 19-1 19.2 19.3, 19.7 198 19.9 19-10 19-11 19-12 19-13 19-15 19-16 19-18MANUAL GEARBOX Identification. Sections Diagnostics Characterst Tightening moments Ingredients. Dismountin; Repair. Back cap... ‘Control shaft annular oil seal replacement Speedometer endless serew pinion replacement Velocity step V syneroniser replacement (Clutch shaft annular ol seal replacement Propeller shaft annular oil replacement Remounting Bowe siarrs Foo ras Belows towards tothe guru Bellows tvarsthe wheel Langa rnin (aa) EL Chassis B GENERAL General principle schedule of a brake circuit in parallel with by-pass circuit Tightening moments (daN) ‘The dimensions of main braking clements| Brake connections and sewerage .. Brake fluid . Braking circuit purging ... Diagnostic ‘The influence of anges... Steering preliminary checkings and adjustment possibilities Front axle checking-adjustment Diagnostic BH FRONT BEARING ELEMENTS Upper arm Elastic bushing, upperarm ball joint Lower arm Elastic bushing, lower arm ball joint Brake gaskets. Brake caliper. Brake disk, Brake caliper support Steering knuckk. Steering knuckle bearing. Characteristics of front suspension ‘main elements Suspension - Tightening moments Front shock absorber Front suspension spring Front stabilizer rod. [Beran orarin evenents Dine re ear le Brat Brakes Briteshoes Boone O68) Pacer ave cea Nonatve pt raraale= Nontinepsssarank Canim ale Canton uri ale dire Shock barker rene Rowan i wneers ano rvees Charcterts Wheels tance 20 hols 307 istecenso assemony 25 He Creetrsios heing cokes Setting the steering gear central point Noise absorber bearing Pusher adjustment Adjustable steering auxiliary pe eae cafe cere een ag oe nerd td ae 528!6 Bilyecnavea,exanenrscoxreots on ees a eee ee a So | eee at Brake limiter Brake pedal and clutch Clutch cab - Clutch stroke adjustment ‘The steering column support assy and fire wall ‘Throttle pedal Gearbox control mechanism 4X4 COUPLING Presentation Elecrovacuumatic control adjustment ‘Vacuum capsule Elecyovalve 36-12 36-14 36-16 37-1 37.5 37.8 37.9 37-10 37-11 37-13 37-15 37-16 37-17 37-18 37-19 [ietecrrovacuumaric controt svsteM 38-1 38:3 38-5 38-6SPECIFICATIONS ENGINE-CLUTCH-GEARBOX Gearnox 1304 Pick-Up | 5 96119 D 46169 200 GR 200 DBR 1304 Drop-Side | 1 57119 D 47169 106 -02 106 -10 200 GR 200 DBR 1304 King-Cab | 1 96139 D 48169 106 -02, 106 -10 200 GR 200 DBR 200 GR 1305 Pick-Up 200 DBR D 16119 102-14 106 -02 1557 106 -10 1557 200 GR 200 DBR 1305 Drop-Side | 1 17119 1305 King-Cab | is119 | 196-02 | 1557 106 -10 200 GR 200 DBR D 2719 DIFII9 D4F769 1307 200 GR 200 DBR o1-1SPECIFICATIONS VEHICLE IDENTIFICATION UNITLTHE DATEOF 26.06.2003 Manufacturer plate Tentfication-number_VIN MANUFACTURERPLATE a. Manufactureridentificationcade; b. Code of the vehic ¢. Gear box type code; Engine type code and driving device location (according to VIN code structure); e.Vehicle code; f,Maximum authorized weight without braking system; g. Locationplaceof the homologationnumber for the importer country; h. Location place of VIS sign; one chameter for the yearmodel +7 characters for the chassis manufacture seties ; i, Maximum technical admissible weight of the loaded car; j-Maximum ads with braking system; k. Maximum technical admissible weight on front axle; 1.Maximum technical admissible weight on rear axle. ible weight with trailer 01-2SPECIFICATIONS VEHICLE IDENTIFIC. ION UNITLTHE DATE OF 26.06.2003 IDENTIFICATION NUMBER VIN Posrriof 1 23 4 5 6 7 8 9 10 1 12 13 14 15 16 17 cop [uulbieit* ** * * © #* # @ cop juu1D1i71* * * # © # # # oo cop juulD 4g 1% «© © # © © # # # # co juu1tp261* © * © © © # # @ ® co |juu1p271* © # © * # # # # # co juvu1p2S 1% * * * # © # # # # cop juu1D 461 * * * # # # # e & of cop juu1p 471% * * # # * # # # # cop juuip 48 1% * * # # # # # oe # cop juuip iF 7 * # # # # # 8 He co |uulp2RF7* *# © * # # # eH ee cop |uuip 4F 7% * © # # we He ow POSITION] — CHARACTERS EXPLANATION 1-3] - manufacturer identification UUI - AUTOMOBILE DACIA S.A, ROMANIA 4 = vehicle ype D-merchandise transportation vehicle 5 + engine-gearbox unit location longitudinal frontengine and front drive 2-longitudinal frontengine and rear drive 44-longitudinal frontengine and integral drive (optional front coupling) ~ chassis type 6 “ype carosserie 6 - PICK-UP 7-DROP - SIDE S-KING CAB F - PICK-UP, doble cabine 7 = payload location 1 - two front places + bed body 7-5 front places: 2 fied rear bench for 3 places + bed body 8 = gearbox type 1 gearbox with $1 steps 6 gearbox with $+ 1 seps and 4x4 coupling 9 ~ engine code and car driving location 9 1600 cme engine, spark ignition, left hand drive 10 | - year model code = - 2000: 1 - 2001; 2 - 2002 u-17 | chasis manufacturing series o1- 3SPECIFICATIONS VEHICLE IDENTIFICATION UNITLTHE DATEOF 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 vehicke type and itsequipment, being used exclusively for the after sale activity. OVAL PLATE INSTRUCTIONS ‘Tue INTERPRETATION OF THE CODES MARI ON THE OVAL TYPE PLATE Law Line1 1.1 Vehicle type code after sale: ick-Up Double Cab 1305 Ri 1307 FRI 1304 Ri 1307 Ri 304.4 WD Rij 1307 4 WD Ri Note: U,E, M, H = express the carriage body type B,C.D = express the C type engine, 1557 cme, front transmission type, rear and consequently 4x4 75. =the code for R12 alternatives Line2 2.1 Equipping level: E1,CA (airconditioning) 2.2 Country code: ROUM (Romania, with EU 96) o1- 4SPECIFICATIONS VEHICLE IDENTIFICATION UNITLTHEDATE OF 26.06.2003 OVAL TYPE PLATE LABEL Line 4 4.1 Tehnical definition code, driving post: $2: 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 R: Without adjustable shock absorber T: Without plate corrector V: Without wheels ABS (anti-blocking ) ATTENTION! Do not unstuck or damage the label of the right side part surface of the dashboard.This label represents the only way of vehicle identification, needed by the after-sale services, for a period of 8 ( eight ) years from the purchasing date.