engine DACIA SOLENZA 2004 Repair Manual

19
19 - 7
COOLING - EXHAUST - TANK
Cooling engine fan for vehicles without air conditioning
DISMOUNTIN G
Disconnect the battery (-) terminal.
Remove the air inlet pipe from the attachment of the battery screen.
Detach from clips the oil reservoir of the power steering from the battery screen.
Disconnect the engine fan connector ( 1) and detach from clips wiring of point ( 2)
Dismount the four attachment screws ( 3) of the engine fan on radiator.
Carefully dismount the engine fan assembly from guiding points (4).
REMOUNTING
Check the condition of the fan impeller and of the engine fan electric motor.
Carefully position the engine fan assembly in the guiding points (4).
Mount the attachment screws ( 3) of the assembly on the radiator.
Connect the engine fan connector ( 1).
Attach in clips the wiring in point ( 2).
Attach in clips the power steering oil reservoir on the battery screen.
Mount the air inlet pipe.
Connect t he battery (-) terminal. In case the vehicle is equipped with programmable
r adio-cassettes player, e lectronic clock, etc, there are t o be re-programmed before returning
the vehicle to the client.
Check the engine fan operation: start the vehicle engine and disconnect the water
temperature sensor. The engine fan must start. Reconnect the water temperature sensor
then by means of the CLIP tester erase the memorized failure corresponding to the water
temperature sensor.
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19
19 - 8
COOLING - EXHAUST - TANK
COOLING ENGINE FAN NOT WORKING
(for vehicles without air conditioning)
Replace fuse
F01
.
Check fuse F01 from engine compartment. Is it good?
Replace water temperature sensor.
Replace the control relay of the cooling engine fan.
Replace the cooling engine fan assembly . Start the vehicle’s
engine.
Disconnect the water
temperature sensor. Is the
cooling engine fan working?
Check the control relay of the cooling engine fan Is it good?
Is any voltage between pins 1
and 2 of the cooling engine fan connector?
The wirin g
is
damaged. Fix it. Stop the vehicle engine.
Check the continuity and resistance
against vehicle mass between:
- pin B2 connector of water temperature sensor pin 13 UCE i njection;
- pin B1 connector of water temperature sensor pin 73 UCE i njection;
- pin 3 connector of cooling engine fan control relay exit fuse F01;
- pin 5 connector of cooling engine fan control relay pin 2 connector of
cooling engine fan
- pin 1 connector of cooling engine fan vehicle mass;
- pin 1 connector of cooling engine fan control relay pin D 5 connector
of actuators relay;
- pin 2 connector of cooling engine fan control relay pin 8 UCE injection.
Ar e they good?
Replace UCE injection.
AT T E N T I O N !
The injection computer damaging i s probably due to an e lectric
shock. Before mounting a new injection computer, the cause of its
damaging must be found.No Ye s
Yes
No No
Ye s Ye s
No
Ye s
Diagnostic – failures interpretation
at vehicles without air conditioning
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19
19 - 9
COOLING - EXHAUST - TANK
Cooling engine fan for vehicles with air conditioning
DISMOUNTIN G
Disconnect the battery (-) terminal.
Remove the air inlet pipe from the attachment of the battery screen.
Detach from clip the power steering oil reservoir from the battery screen.
Disconnect the engine fan connector ( 1)
Detach wiring from clips ( 2) and (3).
Disconnect the connector of the cooling engine fan resistance (4).
Carefully dismount the engine fan assembly from the radiator, from sustaining points (5).
REMOUNTING
Check the condition of the fan impeller and of the engine fan electric motor.
Carefully mount the engine fan assembly in the sustaining points (5).
Connect the connector of the engine fan resistance ( 4).
Connect the cooling engine fan connector ( 1) and attach it in clip (3) then in clip (2).
Attach in clips the power steering oil reservoir on the battery screen. Mount the air inlet
pipe.
Connect the battery (-) terminal. In case the vehicle is equipped with programmable
r adio-cassettes player, electronic clock, etc, there are t o be re-programmed before returning
the vehicle to the client. Check the engine fan operation: start the vehicle engine and disconnect the water
temperature sensor. The engine fan must start. Reconnect the water temperature sensor
then by means of the CLIP tester erase the memorized failure corresponding to the water
temperature sensor.
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19
19 - 11
COOLING - EXHAUST - TANKWa ter pump
DISMOUNTIN G
Place t he vehicle on a two columns elevator
Disconnect the battery
Drain the cooling circuit using the lower hose from the water pump.
Dismount :
- distribution belt ( see chapter 11 “Distribution belt”);
- tightening cam ( 1);
- water pump attachment screws and nut.
Remove the water pump through the upper part of the engine compartment.
TIGHTENING MOMENTS (daNm)
Tightening cam nut5
Crankshaft pulley hub screw2+680± 60
Right pendular support screws6.2
Hydro-elastic buffer nut3.7
W ater pump screws2.2
Water pump nut1
Wheels screws7.5
SPECIAL TOOLS
MOT. 1202-01 Pliers for elastic clips
MOT. 1505 Device for belts tension me asurement
MOT. 1135-01 Device for distribution belt tensioning
MOT. 545 Engine sustaining device
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19
19 - 13
COOLING - EXHAUST - TANKExhaust Assembly
ATTENTION !
Descending pipe in operation, may reach high temperatures and consequently must not
co me in contact with flammable materials which may lead to their auto-ignition.
Catalytic converter is to be mechanical shock protected.
DISMOUNTIN G
In order to di smount the noise a bsorber assembly ( 1), lift t he ve hicle on an elevator and
perform the following operation s:
Loosen the nuts ( 2) of the attachment collar between the expansion chamber ( 3) and the
noise silencer ( 1).
Di smount the thre e a ttachment e lastic supports of the noise a bsorber, on the carri age
body, rear pa rt. Release the noise silencer.
In order to dismount the assembled expansion chamber (3), perform the following operations:
Di smount the c ollar ( 4) and disengage the e xpansion chamber assembled with the de -
scending pipe.
Dismount the three elastic supports of the assembled expansion chamber.
Loosen the attachment collar nuts ( 2) and remove the assembled expansion chamber by
easy rotation and onward pulling.
In order to dismount the descending pipe assembly (6), perform the following operations:
Dismount the engine shield.
Dismoun t the catalytic converter attachment nuts ( 7) on the two studs of the exhaust manifold
flange. Dismount the attachment screws of the converter support ( 5).
For EURO 96, dismount the oxygen sensor located in upstream of the catalytic converter.
For EURO 00, dismount the oxygen sensors located in upstream, consequently, in
downstream of the catalytic converter.
Dismount the collar (4) and disengage the assembled catalytic converter from the assembled
expansion chamber.
Remove the descending pipe.
REMOU NT I NG
Perform the dismounting operations in the reverse order.
Ensure a perfect sealing between the exhaust assembly elements, using sealing paste Wurth,
on the joining area length (inside) between the noise absorber – expansion chamber (0.013 Kg);
The oxygen sensor gasket is to be replaced at each dismounting.
The tightening moment between noise absorber and expansion chamber is: 3.6 daNm.
The tightening moment of descending pipe attachment nuts on the exhaust manifold flange is:
2 daNm. Tightening moment between the catalytic converter and expansion chamber: 2.5 daNm.
All elements are to be assembled having the ambient temperature.
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19
19 - 15
COOLING - EXHAUST - TANKFuel tank
IMPORTANT:
During the int erventi on on the fuel tank
and on the fuel supply circuit, at t he working
place, do not smoke and do not bring near
an y incandescent parts.
Fuel tank draining i s not implying tank
dismountin g. The access is allowed through the
vehicle interior (trunk).
Dismo unt :
-tr unk carpet;
-v isitin g whole cover (by dismounting the
three attachment screws);
- disconnect the rapid coupling A;
- adjust to exit A, an enough long hose to
be introduced in a vessel outside the vehicle.
From the fuse box located inside the engine
compartment, remove the H relay of the petrol
pump and bridge across plugs 3 and 5 of the
relay connector, ensuring the petrol pump
working (12V).
Stop the pum p working when petrol
discontin uous draining s noticed.
Detach the plugs bridge.
Mount the petrol pump relay.
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19
19 - 18
COOLING - EXHAUST - TANK
VEHICLES WI THOUT VISITING CAP
Fuel tank
TIGHTENING MOMENTS (daNm)
Fuel ta nk attachment screws 2.1
IMPORTANT :
Dur ing thi s operation it is
compulsory:
-not smoking and not approaching
with i ncandescent obj ects in t he working
area, -keep awa y from fue l spray i ng
when disc onn ectin g the fu el
connections, protect the sensitive area of
fuel leak.
Dismount :
- protection shield ( 3);
- filling cap attachment clip (5) on tank;
- fuel pump assembly (6).
REMOU NT I NG
Perform the di smounting opera tions in the
reverse order.
Tighten to the required moment the fuel tank
attachment screws (2.1 daNm); the thread of
the two rear attachmen t screws is to be lubricated
before mounting with Fixamed M28 (necessary
quantity – 2 grams).
Re p lace the single use clip ( 5) with a tightening
clip “CAILLAU” .
12
6
5 4
3
DISMOUNTIN G
Place the vehi c le on a t wo-c ol um n
elevator. Disconnect the battery (-) terminal.
Dismount the fuel tank cap.
Drain the fuel tank through the filling cap,
by means of a draining pneumatic or electric
pump. Dismount the a ttachments screws ( 1) of
the upper filling cap.
Lift the vehicle by means of the elevator.
Di smount the four attachment screws of
the fuel tank. Dismount the attachment clip ( 2) of the
aeration hose ( 4) on filling cap.
Carefully lower the tank and disconnect it:
- wiring connector;
- fuel supply pipe;
- petrol vapors re-aspiration pipe (for
petrol engines); - fuel return pipe (for Diesel engines);
Extract the aera tion hose on top of tank
crossbar and dismount the tank.
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19
19 - 25
COOLING - EXHAUST - TANKEngine suspension
TIGHTENING MOMENTS (daNm)
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20
CLUTCH
20 - 1
Identification
CHARACTERISTICS
- Single disk dry clutch cable controlled.
- Clutch mechanism with diaphragm spring.
- Clutch disk with elastic hub.
- Pressure bearing with balls permanently in contact with the diaphragm (constant pressing
force).
Vehicle type Engine
type Mechanism Disk
E7J
S OLENZA
180 CPO 330026 grooves V: Green
D
= 181.5 mm G: Grey
E = 6.8 mm
D
V
G
V
V G V
E
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CLUTCH
20
20 - 2
Diagnostic
GEARS ENGAGING PROBLEMS
Check t he c lutch disk re lease (see the
checking method bellow described.)
Is the release corre ct ?
Check the adjustment of the gearbox
extern c ontrol lever (adjust if ne cessary).
If the problem is persisting.
Check the clutch releasing fork stroke
(see the method bellow descri bed). Is the fork stroke correct?
Int e rna l probl e m i n the ge arbox
(repair t he gearbox) .
Replace the clutch .
Pr
oblems at clutch
control pedal.
Check:
- pedal re turn,
- control cable.
(Fix if necessary).
No
No
Ye s
Ye s
C HECKING METHOD
“ DISK RELEASE “
The checking is to be performed at idling, with warm engine. - release the clutch,
- wait for thre e seconds,
- engage the reverse dri ving (engagement must be performed without noise).
CHECKING METHOD
“ CLUTCH RELEASING FORK STROKE “
By means of a lineal perform the following operations:
- measure the distance between the fork upper part and the clutch cable support, in the
clutched position;
- measure the distance be tween t he fork upper part and c lutch cable support, in t he
clutch releasing position;
- calculate the differe nce between the t wo values (the fork active stroke) and compare i t
with the re ference value ( 29 mm).
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