power DACIA SOLENZA 2004 Service Manual

36
STEERING ASSEMBLY
36 - 7
General
CONSTANT POWER STEERING (CPS)
1. Power steering pump
2. Power steering box
3. High pressure piping
4. Low pressure piping
5. Oil reservoir
6. Rotary valve
7. Pressure controller
8. Accessories belt
9. Rigid ducts
10. Steering box working
chambers
The working principle of the Constant Power Steering (CPS ) system, consists in steering
hydraulic assistance by hydraulic fluid (oil) passing through a drawer (the two chambers ( 10)
from steering box) with double effect and through a rotary valve ( 6) that is distributing the fluid
through two pipes (9) towards the steering box ( 2) subject t o the full turni ng direction of the
directing wheels. The hydraulic assistance is ensured by a pressure controller ( 7) attached on the high pressure
pipe (3) and connected to the injection computer.
The injection computer is receiving information, during power steering operation, about the
pressure value in “high pressure circuit” ( which may be seen by means of the CLIP tester). The
pressure value in “high pressure circuit” is depending of the pomp conducted pressure as well as
of the used oil fluidity. The more pressure is high, the power steering pump is absorbing more additional energy.
The power steering pump ( 1) is continuously providing in the circuit a constant hydraulic fluid
(oil) flow, regardless the engine RPM, based on the fact t hat pump is driven by the accessories
belt (8). In this case, the system has the generic denomination of “ Open Center System “
REMARK:
The steering is not to be ful ly locked at maximum m ore than 45 seconds at an engine
RPM of 2500 rot/min (risk of power steering pump damaging).
36054
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36
STEERING ASSEMBLY
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SPECIAL TOOLS
MOT 453 Flexible piping pliers
P. F. 476 Device for ball joi nt depressing
TIGHTENING MOMENTS (daNm)
Pow er steering box
DA-CA supply pipe attachment screw on power train 0.4
A ttachment screw of steering box high pressure pipe-pump 2.1
Wheels screws 9
St eering ball joint nut 4
St eering box attachment screws on cross-member 5
S crews for pipes clamps attachment on power train 0.77
S crews for clamps attachment on steering box supports 3
Con nection screws of the steering column lower shaft joint 1.4
DISMOUNTIN G
Dismount the battery.
Lift the ve hicle by means of a t wo-column
elevator.
PF 476
Dismo unt :
- engine shield;
- steering rods funnels ball joints by means
of the PF 476 device;
- connection screw between the steering
column lower shaft joint and the steering box gear
shaft, marking the joint position.
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36
STEERING ASSEMBLY
36 - 10
R
EMARK :
It is forbidden to dismount from the power
st eering box the pipes between the rotary
valve and the steering box.
Whe n dismounti ng, the high and low
p ressure pipes are to be positioned with the
connection screws downward oriented, i n
order to avoid contaminants penetration.
R EMOU NT I NG
Mount :
-steering box
-s teering rods ball j oints in t he steeri ng
knuckle arms; - exhaust
-anti-rocking steering rod;
- cardan joint in the position marke d at
dismounting;
-high and low pressure pipes (remove
MOT 453 pliers), ob serving t he re qui re d
tightening moments; -piping attachment collars;
- wheels;
- battery.
Refill the circuit with oil ( full reservoir).
With stopped engine, easy a ct upon the
steering wheel in both directions, so that rack
is performing a complete double stroke.
Repeat the operation with started engine
(oil pump operatin g), then fill up to the MAXI
mark, the oil level in the reservoir.
Check and eventually adjust the
parallelism.
Pow er steering box
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36
STEERING ASSEMBLY
36 - 11
Power steering box pusher
When an excessive rack clearance,
followed by clattering in the steering box is
occurring, before replacing the steering box,
the pusher with rack is to be adjusted. 1. Noise (clattering) identification.
Lift the vehicle by means of a two-column
elevator; On the pusher side:
- dismount the bellows attachment clip
on the steering box casing;
- push the bellow towards the steering
rod; - hold by hand the rack rod and check
the transversal clearance (up- down). A clearance followed by a noise (clatt ering)
is leading to a pusher noise, during driving. 2. Adjustment
Straigh ten th e caulking (A) of t he
adjustment nut bead (1).
By means of a 10 mm hexagonal wrench,
tighten the adjustment nut until there is no more
clearance.
AT T E N T I O N !
Do not tighten the nut more than 3
teeth.Check if the rack is freely moving all the
length. Bend the adjustment nut bead in the two
opposite slots of the steering box casing, ensuring
in this way its unscrewing.
Positio n the bellows on the steering box casing
and mount a new attachment clip.
Lower the vehicle from the elevator with
wheels on the ground.
Check, during driving if the steering wheel is
coming back to the steering center point.
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36
STEERING ASSEMBLY
36 - 12
Power steering pump
SPECIAL TOOLS
MOT 453 Flexible piping pliers
DIR 1083-01 Device for PDA pul ley remounting
PS 1094 Bearing extractor
TIGHTENING MOMENTS (daNm)
Screws for D.A. pump attachme nt 5
Screws for D.A. pump pulley attachment 0.8
Place the vehicle on a two-column elevator.
DISMOUNTIN G
Disconnect the battery.
Drain the oil from DA circuit
Loosen the attachment screws ( S
1) of the
tightening clamp. Dism ount t he a dj ust m ent sc re w ( S
2)
allowin g the tightening clamp lowering.
Dismount the accessories belt.
Dismou nt the three pulley attachment screws
to the hub and extract the pulley.
Disconnect from the power steering pump
the supply piping and the high pressure piping. Dism oun t t he po we r st e e ri n g p um p
attachment screws to the support: -f
our screws in case of the DA/CA pump.
-Three screws in case of the DA pump
without CA
R EMOU NT I NG
Perform the dismounting operations in the
reverse order, observing the following:
- the screws tightening sequence, i.e. :
-1-2- 3-4 - i n c a se of t he DA/ CA
pump; -1-2-3 - i n c ase of t he DA pum p
w ithout CA, a s we l l a s the t ighte ni ng
moments. Mount a new accessories belt.
Adjust the belt tension (see the method
described in chapter 07 – Tensioning, belts,
accessories).
Perform t he fi lling of t he DA unit, then
perform the unit purging ( method described
in chapter 05).
S2
S1
S1
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36
STEERING ASSEMBLY
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Power steering pump
REMARK :
The replacement of the PDA hub is to
be performed at working bench, by means
of the Special tools previously described.
PULLEY HUB REPLACEMENT
Catch the pump in the working bench vice.
Attach the arms of the PS 1094 device on
the hub.
Depress the hub.
REMARK :
Inse rt a screw (1) between the pump
sha f t and the pushing rod of the
depressing device.
Place the new hub on the pump shaft and
press it by means of the DIR 1083-01 device.
Gr ease previously the shaft with a thin layer
of UM 185 Li2 M type grease to facilitate
the remounting.
REMARK :
Insert between DIR 1083-01 device and
the hub, one spacer (2) of about 25 mm.
length.
Di r. 1083-01
PS 1094
1 2
A – Hub
B – Power steering pump
Press the hub on the pump shaft, observing
the va lue X = 49.67 ± 0.2 mm.
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36
STEERING ASSEMBLY
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Steering column
REMOU NT I NG
1. Manual steering column
Pass the cardan joint of the lower shaft
through the cowl panel whole.
2. Power steering column
Pass the cardan joint of the l ower shaft as
well as the protection bellows through the cowl
panel whole, having previously bound with a
piece of cord, both the cardan joint end and
the bellows eyes.
Cut the piece of cord, position the bellows
on the cowl panel. In both situatio ns, continue with:
In the engine compartment:
Position the cardan joint end of the steering
column lower shaft on the steering box gear
shaft. Fix in th e p o si tion marked when
dismounting, the connection screw between the
s teering column lower shaft and the steering
box gear shaft, without tightening to the required
moment.
In the passengers compartment :
Fix and tighten to the required moment the
six screws attaching the steering column to the
driving post. Return in the engine compart ment for
tight e ni ng t o t he re qui r e d m om e nt , t he
connection screw between the steering column
lower shaft and the steering box gear shaft. For the other parts, remounting is done by
performing the dismounting operations in the
reverse order. Take c are when mounting the i nstrument
panel , t o correct l y connect t he electri cal
connectors.
Characteristics of the steering column
mounting.
The straig ht in line driving position is ensured
by unique positioning of the steering wheel on
the column shaft. Replace the steeri ng wheel attachment
screw after each dismountin g.
Observe the required tightening moment for
the steering wheel attachment screw ( 4.4
daNm).
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36
STEERING ASSEMBLY
36 - 17
Steering connecting rods ........................................................................\
............................... .36 - 1
Manual steering box ........................................................................\
.................................... ... 36 - 3
St eering box pusher ........................................................................\
........................................ 36 - 4
N oise absorbant bushing ........................................................................\
................................ 36 - 5
Bellows ........................................................................\
............................................................ 36 - 6
General ........................................................................\
............................................................ 36 - 7
Power steering box ........................................................................\
..................................... .... 36 - 8
Power steering box pusher ........................................................................\
........................... 36 - 11
Power steering pump ........................................................................\
.................................... 36 - 12
Steering column ........................................................................\
............................................ 36 - 14
36 36 - 1 STEERING ASSEMBLY Steering connecting rods
36 36 - 2 STEERING ASSEMBLY Steering connecting rods
36 36 - 3 STEERING ASSEMBLY Manual steering box
36 36 - 4STEERING ASSEMBLY Steering box pusher
36 36 - 5 STEERING ASSEMBLY Noise absorbant bushing
36 36 - 6 STEERING ASSEMBLY Bellows
36 36 - 7 STEERING ASSEMBLY General
36 36 - 8 STEERING ASSEMBLY Power steering box
36 36 - 10 STEERING ASSEMBLY Power steering box
36 36 - 11 STEERING ASSEMBLY Power steering box pusher
36 36 - 12 STEERING ASSEMBLY Power steering pum p
36 36 - 13 STEERING ASSEMBLY Power steering pum p
36 36 - 14 STEERING ASSEMBLY Steering column
36 36 - 16 STEERING ASSEMBLY Steering column
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40
GENERAL
40 - 15
Collision diagnosis
POWER-TRAIN SUPPORT ASSEMBLY CHECKING
FLOOR FRAME CHECKING
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40
GENERAL
40 - 20
21
65
43
pict. 10
pict. 11
pict. 12
Power train frame attachment on the lower cross member
The specifi c supports (1 ) and (2) are used in front straightening, front m echanic elements
being dismounted, enabling the positioning of
the lower cross member, consequently the front
attachment of the power train frame (pict. 10).
REMARK :
Thes e holes are destined as main
re ference for the vehicle front part.
Centering under front longitudinal girder
The specifi c supports (3) and (4) are used
for positionin g, centering, and alignment of the front longitudinal girders. They are to be used for
all reparation cases because they are a main reference of vehicle setting on the bench. (pict. 11).
Upper attachment on front shock ab-
sorber (shock absorber column)
S pecific supports (5) and (6) are used in
front strengthening, mechanical elements
dismounted, enabling the positioning of the
shock absorbers ends, consequently the front
linings positioning (pict. 12).
Their centering in the shock absorbers ends
is performed by means of the centering washers
(1)- (fig 13).
The center i ng washers are used when
str aightening a carriage body a nd also when
Carriage body checking
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