DACIA SOLENZA 2004 Repair Manual

FRONT AX LES ELEMENTS
31
31 - 10
Brake caliper
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of a two-column
elevator Dismount the wheel.
Drain the brake fluid from the reservoir
Remove the locks and the caliper wedges.
Un screw the rigid duct screw from the
brake flexible hose and detach the caliper
assembly.
REMARK :
If it is necessary to dismount the
cali per fork, di sm ount the at tachm ent
sc rews on the caliper fork.
When remounting the fork, replace the
Grower washers, tighten the screws to the
r equired moment of 6.5 daNm then seal
them with FIXAMED R 58.
RE PAI R ING
Dismount the protection gasket.
Extract the piston using a wooden wedge and
a compressed air source.
Remove the sealing gasket from its seat in the
caliper groove by means of a blade. Clean with alcohol the parts, replace t he
damaged ones, mounting being performed in the
dismounting reverse order, after previously all
parts have been oiled with brake fluid.
REMARK :
Before remounting on the fork, check the
sealing of t he assembled caliper.
TIGHTENING MOMENTS (d aNm)
Wheel screws 7.5
Rigid duct on fr ont flexible screw 1.5
Purging screw 1
Flexible hose - caliper 1.7
vnx.su

FRONT AX LES ELEMENTS
31
31 - 11
Brake caliper
REMOU NT I NG
Perform the dismounting operations in the reverse order plus the following operations:
- filling of the caliper with brake fluid in order to facilitate the brake system purging;
- purging the brake system.
BRAKE CALIPER SEALING CHECKING
Connect to the caliper, a pressure gauge attached to a compressed air source.
Place a wooden wedge in order to block the piston
Create a 0.3 bars pressure in the caliper
Dip the caliper into a vessel with alcohol.
Move the piston several times to remove the air from the sealing gasket seat.
Check the sealing at various pressures, without exceeding the pressure of 2 bars.
If the brake shows air leaks by the piston, perform its dismounting.
Replace the piston, the ga sket, or the caliper body, as the c ase stands.
Perform again the sealing test.
vnx.su

FRONT AX LES ELEMENTS
31
31 - 12
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of a two col-
umns elevator Dismou nt :
- the wheel;
- the two attachment screws (A) of
the brake disk assembly on the steering
knuckle ; -the two sunk screws (B) attaching the
disk on the hub.
Brake disk
REMARK :
The brake disks can be not rectified.
A bigger wear or an important mark on the brake disk braking surfaces impose obligatory its
replacement.
- The minimal accepted thickness: 19 mm;
- The maximum accepted axial deviation 0.04 mm on a diameter of Ø 215.
TIGHTENING MOMENTS (daNm)
Brake caliper fork attachment screw on steering knuckle 6.5
Di sk attachment screw on the hub 1.4
Front wheel steering knuckle nut 28
Wheel screws 7.5
R EMOU NT I NG
Remount :
- the disk on the hub by means of the two
sunk screws (B) and tighten them to the required
moment; - the brake disk assembled on the steering
knuckle, tightening the ( A) screws to the required
moment. Press the brake pedal several times, in order
to bring the piston in contact with the brake pads.
REMARK :
In case of replacing the brake disk it is
absolutely necessary to replace the brake
pads ( TEXTAR brand).
A
B
Di sm ount the brake disk. Before
remounting, check :
- the wear of the brake flexible hoses;
- t he we ar of t he bra ke pa ds and
replace them if necessary.
vnx.su

FRONT AX LES ELEMENTS
31
31 - 13
SPECIAL TOOLS
Hub disk extractor PF 600
Ball joint extractor PF 476
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of an elevator with
two columns
Dismou nt :
- the wheel
- the bra ke disk a ssembly together with
the flexible connection;.
- the transmission gear nut;
- the bra ke disk assembly by means of
the PF 600 extractor.
Continue by dismounting t he steering
knuckle, observing the operations sequence: - dismount the steering ball joint nut;
- depress the steeri ng ball joint by
means of the PF 476 extractor;
- dismount the two screws that attach
the steering knuckle on the shock absorber
leg;
- dismount the attachmen t screw of the
steering ball joint – steering knuckle;
- detach the steering knuckle.
TIGHTENING MOMENTS (d aNm)
Wheel attachment screw 7.5
Steering ball joint nut 4.0
Transmission nut 28.0
Attachment fork screw on steering knuckle 6.5
Screw nut of the steering knuckle
attachment with the shock absorber leg 10.5
Attachment screw nut of the b all
joint with the steering knuckle 6.2
Steering knuckle
PF 476
PF 600
vnx.su

FRONT AX LES ELEMENTS
31
31 - 14
Steering knuckle
REMOU NT I NG
REMARK :
Before remounting check t he wear of the be aring, that shall be replaced if t he grease
is flown.
Position and press the steering knuckle together with the hub – disk assembly, performing the
operations in the reverse order, after previously having greased the steering knuckle grooves.
vnx.su

FRONT AX LES ELEMENTS
31
31 - 15
Steering knuckle bearing (35 x 65 x 35)
DISMOUNTIN G
Dismount the steering knuckle (see method
“Dismoun ting steering knuckle).
Remove the safety ring ( bore ring) from the
interior of the steering knuckle.
De pre ss t he biconi cal be a ring, usi ng a
→ 50 mm outer diameter rod.
P lace t he steeri ng rod using a bushing with
inner diameter → 67 mm.
R EMOU NT I NG
Introduce in the steering knuckle the bearing
support washer
Press the bearing in the steering knuckle, by
means of a → 63 mm diameter bushing.
Mount the safety ring in the channel of t he
steering knuckle bore.
REMARK:
The operation shall be performed so that
bushing is not pressed on the bearing
support washer, in order to perform a correct
mounting and not to damage the bearing. The steering knuckle-bearing assembly
is
to be placed above the hub and after centering
the support washer, press the bearing on the
hub, using a bushing with the inner diameter
of Ø 36 mm and an e xteri or diameter of Ø
40 mm. Continue with the mounting of the steering
knuckle assembly on t he vehicle (see the
method “ Remounting steering knuckle ”)
REMARK :
When replacing the bearing, its spacer
is also t o be obligatory replaced.
ΦΦ ΦΦ
50
ΦΦΦΦ

67
ΦΦΦΦ

64
Φ 40
A
ΦΦΦΦ

40
ΦΦΦΦ

36
vnx.su

FRONT AX LES ELEMENTS
31
31 - 16
CROSS SECTION
F
ront suspension
6 daNm
2 daNm
10.5 daNm 2.7 daN m
4 daNm
10.5 daNm 7....7.5 daNm 28 daNm
7.5 daN
m
51.4
6.2
vnx.su

FRONT AX LES ELEMENTS
31
31 - 17
Shock absorber, Spring
TIGHTENING MOMENTS (d aNm)
Shock absorber rod nut 6
Shock absorber lower attachment nut 10.5
Shock absorber upper attachment screws 2
The shock absorbers are stored in horizontal
position. In these conditions, it is possible that
s hock absorbe rs working vert ically, to get
depressed.
Therefore, before mounting on the vehicle, it
is necessary to perform the shock absorbers
pressing, by alternatively shifting the shock
absorber rod (upwards a nd downwards), the
shock absorber being in vertical position. S
HOCK ABSORBER
1. Upper attachment nut
2. Lower attachment screw
3. Filtering block
4. Upper plate
5. Shock buffer
6. Lower plate
7. Axial bearing
The coil diameter of the front axle spring is Ø 13,1+ 0,0 8 mm.
REMARK :
Make sure that springs of every axle have the same characteristics.- 0
3
4
5
6
7
2 1
vnx.su

FRONT AX LES ELEMENTS
31
31 - 18
Spring – shock absorber assembly
DISMOUNTING SPRING-SHO CK ABSORBER ASSEMBLY OF F THE VEHICLE
Loosen the front wheel attachment screws.
Lift the vehicle by means of a two-column
elevator. Dismo unt :
- the wheel;
-t he st eeri ng knuc kle attachment
screws (1) to the shock a bsorber leg;
- the two upper attachment screws (2 )
of the shock absorber on the carriage body.
Take out the spring – shock a bsorber
assembly, by pressing on the l ower arm, in
order to avoid the shock absorber getting in
contact with the transmission bellows.
SPRING DETACHMENT FROM SHOCK ABSORBER
Place t he shoc k absorbe r on t he shoc k
absorber support (4), of the base plate (3 ) of
the SU S 600 device.
Place the compression plate (7) on the filtering
block and position the rods grips (8) on the spring
lower last but one coil. Com p re ss t he sp ri ng by a l t e rna t i ve l y
tightening the nuts (9) till release it from the lower
plate of t he shock absorber.
Dismount the upper attachment nut of the
s hock absorbe r by means of the SUS 601
combined wrench.
Take out the spring
Place the spring on the SUS 600 device shaft
(2).
Place on the shaft the lock bushing (6), the spacer (5), and tighten the crank ( 1) to the
required moment till the lock bushing (6) comes into contact with the filtering block of the shock
absorber. Loosen alternatively t he nuts (9) and take out the plate (7) and the rods grips (8).
Release the spring by means of the crank (1) and detach from the shaft (2), the filtering block
of the shock absorber, the upper plate, a nd the spring.
1 2
SSPECIAL TOOLS
Devi
ce SUS 600
Combined wrench SUS 601
vnx.su

FRONT AX LES ELEMENTS
31
31 - 19
Spring – shock absorber assembly
SP RING-SHOCK ABSORBER ASSEMBLY REMOUNTING ON THE VEHICLE
P lace the spring on the SUS 600 device shaft (2).
Position on the spring the upper plate and the filtering block of the shock absorber.
P ut on the shaft the lock bushing (6) and the spacer (5).
Compress the spring by means of the crank (1).
P lace the c ompression plate (7 ) on the filteri ng block and position the rods grips (8) on the
spring last but one coil. Tighten the nuts (9) till the rods grips (2) came in contact with the spring coil.
D etach the crank (1) and remove the compressed spring from the shaft (2).
P lace the shock absorber in the support (4).
P lace on the shock absorber the axial bearing, the lower plate, the buffer, and the spring.
M ount the upper attachment nut of the shock absorber by means of the SUS 601 combined
wrench and tighten to the required moment. Loosen the nuts (9) and take out the plate (7) with the rods grips (8).
Mount the spring-shock absorber assembly on the vehicle, in the reverse order of dismounting.
2
6
1
3
5
vnx.su