ABS DACIA SOLENZA 2004 Workshop Manual

33
REAR A XLES ELEMENTS
33 - 6
Spring
DISMOUNTING
Place the l ocking clamp of the SU S 600 de-
vice, in order to maintain the spring compressed.
Loosen the screws of the wheel on the side
where the dismounting is performed.
Lift the vehicle by means of a two-column
elevator. Dismount the wheel.
Di smount the shock absorber lower attach-
ment nut and screw.
Push the axle and remove the spring.
REMOU NT I NG
Perform the dismounting operations in the
reverse order.
REMARK:
Make sure that springs mounted on
axle have the same characteristics.
SPECIAL TOOLS
Devi ce SUS 600
TIGHTENINBG MOMENTS (daNm)
Wheel attachment screw 7.5
Shock absorber lower attachment nut 7.5
Rear axle spring coil diameter is of φ 16+ 0,08 mm.-0
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36
STEERING ASSEMBLY
36 - 5
Noise absorbant bushing
DISMOUNTIN G
Loosen the screws of the right front wheel.
Lift the vehicle by means of a two-column elevator.
Dismount the right front wheel.
Dismou nt :
-steering box casing protection bellows-left steering rod end;
-the right steering connected rod.
Rotate the steering wheel t o the right (complete turn), the rack is withdrawing towards left.
Remove, by means of a screwdriver the used noise absorber bearing.
R EMOU NT I NG
Carefully clean t he rack and the noise absorber bearing seat and grease with special grease
containing MoS2 and then mount the new noise absorber bearing.
Position the pins (A) in their casing seats.
Rotate the steering wheel to the left until t he rack stands out the bearing.
Remount on the rack: - the steering c onnecting rod (safety washer and limiter washer a re t o be obligatory
positioned on the threaded side of the joint body); -protection bellows.
Check and adjust the parallelism, if necessary.
A
A
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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
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 - 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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41
41 - 4
LOWER STRUCTURE
1
Rear longitudinal girder
REPLAC EMEN T
This operation shall be performed only on the repair/checking bench.. For the specific sup-
ports mounting on the bench, please see the 40 chapter.
DISMOUNTIN G
Dismount the damaged elements, which are
in contact with the rear longitudinal girder. Proceed to a straightening on the body
checking/ straightening until bringing the ve-
hicle as closed as possible to the initial shape.
D etach the welding points of the rear
longitudinal girder (1), which are i n contact
with:
- central floor in the area ( 2);
- rear floor in the are a ( 3);
- rear extreme cross member in the area ( 4);
- tank front cross member in the area ( 5);
- tank rear cross member in the area ( 6);
- inner wheel passage in the area ( 7);
- rear towing hock in t he area ( 9).
Detach the welding points between the rear
s ide cross member, re ar floor a nd threshold
closing plate in the area ( 8).
Strai ghten the areas resulted after dismounting.
Grind the areas resulted after dismounting.

R EMOUNTIN G
Position and center the new element by
means of the repairing bench. Weld the rear longitudinal girder following
the assembling outlines 2,3,4,5,6,7, 8 and
9(spots and under gas protection welding) Grind the performed welding.
Protect the performed welding with an
anticorrosive product.
Protect the replaced element with a noise
absorbent product. Mount the co nn ect i on e l eme n ts b y
performing the dismounting operations in the
reverse order.
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42
42 - 2
FRONT U PPER STRUCTURE
Front wing lining
2
45
6 7 8
3
RE PLAC EMEN T
This operation shall be performed only on the c hecking/repair bench. For the specific sup-
ports mounting on the bench, please see the 40 sub-chapter.
DISMOUNTING
Dismount t he damaged elements, which are
in contact with the front wing lining. Detach the welding points of the front wing
lining (1), which are in contact with :
- upper longitudinal girder in (2) area;
- front cross member in the area ( 3);
- headlamp support in the area ( 4);
- closing plate in the area ( 5) ;
- front floor in the area (6);
- cowl panel in the area ( 7);
- climate control box in the area ( 8)
Str aig h ten the area resulted from
dismounting. Grind the area resulted from dismounting.
REMOU NT I NG
Position and center the new element by
means of the repairing bench. Weld the front wing lining (1) following the
assembling outlines 2, 3, 4, 5, 6, 7 and 8.
Pr otect th e perfo rmed welding with a
corrosion-preventing product.
Protect the front wing lining with a noise
absorbent product and paint the a ffected area
in the carriage body color. Mount the connection elements by pe rform-
ing the dismounting operations in the reverse
order.
1
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NON – LATERAL OPPENINGS
48
48 -2
Hatchback
DISMOUNTIN G
Dismount the hatchback wiring (1) and
remove it t hrough the e xistent hole in the
hatchback lining. Dismou nt :
- safety locks (2) of the balancing shock
absorbers on the hatchback - attachment screws (3) of the balancing
s hock-absorbers on the hatchback;
- attachment screws (4) of the hinges on
the hatchback;
- hatchback.
REMOU NT I NG
Perform the dismounting operations in the
reverse order. Grease the hi nge s wi th whi t e gre a se
(Teroson).
3
4
1
2
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INSIDE ACCESSORIES
Dashboa rd .......................................................... 57-1
Inside rear view mirror ..................................... 57-8
S un visors ........................................................... 57-9
Central console ................................................. 57-10
Handbrake case ................................................ 57-11
Turning handle .................................................. 57-12
SECU RITY ELEMENTS
Fr ont safety belts ............................................... 59 - 1
Re ar safety belts ............................................... 59 - 2
HEATING
General .............................................................. 61-1
Operating principle ........................................... 61-2
C limate c ontrol unit .......................................... 61-4
Ve n t ilation- climate control air
distributor (RACV) .......................................... 61-5
Heating radiator ................................................ 61-6
C ontrol panel ..................................................... 61-7
C ontrol cable s ................................................... 61-9
Motor fan control resistance............................ 61-10
Diagnose ............................................................. 61-11
AIR CONDITIONING
General ............................................................... 62-1
Draining – filling the refrigerant circuit ......... 62-3
Air conditioning unit operating diagram ........ 62-4
Operating principle ........................................... 62-5
Part icles filter .................................................... 62-7
Cold ai r blowing device (DSAF) ...................... 62-8
Evaporator ........................................................ 62-10
Control panel ..................................................... 62-11
Comp ressor ........................................................ 62-12
C ondenser .......................................................... 62-13
Pressu re controller ............................................ 62-14
F ilter reser voir ................................................... 62-15
Unit piping ......................................................... 62-16
Thermostatic expansion valve ......................... 62-19
C limate c ontrol blower ..................................... 62-20
Blow er control resistance .................................. 62-21
Rec ycling flap motor fan ................................. 62-22
Diagnose ............................................................. 62-23
CARRIAGE BODY SEALING
Ca rriage body se aling ....................................... 64 - 1 OPENINGS SEALING
Opennings sealing ............................................. 65 - 1 GLASSES SEALING
Glasses gaskets .................................................. 66 - 1
Inside wipers ..................................................... 66 - 2
Outside wipers ................................................... 66 - 3
Fr ont door glass channel ................................. 66 - 4
Rear door gla ss run channel ............................ 66 - 5
CARRIAGE BODY INSIDE TRIMS
C arriage body inside trims ............................. 71-1
Upper front pillar trim ..................................... 71-2
Mi ddle pillar trim ............................................. 71-3
Rear quarter panel tr im ................................... 71-4
R oof lining ......................................................... 71-5
Trunk carpet ...................................................... 71-6
Cowl panel noise absor bent ............................. 71-7
Cockpit carpet ................................................... 71-8
LATERAL OPENINGS TRIMS
Fr ont door panel ................................................ 72-1
R ear door panel ................................................. 72-2
REAR TABLE
Lateral table ....................................................... 74-1 FRONT SEATS SLIDES GUIDES
Fr ont seat ........................................................... 75-1
Fr ont seats slides guide s ................................... 75-2
SEATS / R EAR BENCH
R ear bench ......................................................... 76-1
BATTERY - FRONT HEADLIGHTS
Battery ... ............................................................ 80-1
Headlamp assembly .......................................... 80-4
F og projectors ................................................... 80-5
Bulbs ... ................................................................ 80-6
Headlamps adjustment .................................... 80-9
Repl acement of the headlamps mechanic
adjustment control ........................................... 80-1157
Mechanisms and accesoires5
59
61
62
Climatisation6
64
65
66
71
72
74
75
76
80
Echuipment electr ique8
Garnishing and tack room7
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62
AIR CONDITIONING
62 - 1
General
The purpose of the air conditioning unit is to produce a decrease of the tempera ture in t he
passengers compartment a nd to obt ain a l ower value tempera ture c ompare d to the e xterna l
environment one, reducing in the same time the air moisture.
MAINTENANCE
For a vehicle equipped with air conditioning, during the year it is recommended:-the checking of the refrigerant fluid filling;
- the cleaning and the air-blowing of the condenser and the cooling radiator fins;
- the checking of the condensation removal pipe on order not to be clogged.
For important leakage repair, for any components replacement (compressor, condenser, etc)
and if moisture was noticed in the air conditioning circuit, replace the dryer filter tank and drain
the unit; the same is valid also in case the conditioning circuit remains open without protection
covers more than 10 minutes.
IMPORTANT !
During winter, it is recommended the frequent start of the system, in order to prolong
the lifetime of t he compressor and of the whole system.
T he vehicle equipped with an air c onditioning system shall be not exposed for more
than 20 minutes i n painting c abin where there are temperatures higher than 80 °C.
It is obligatory the use of t he refrigerating agent and compressor oil type prescribed
by the manufacturer.
It is absolutely forbidden to perform welding works on the elements of the ai r condition
circ uits.
The fi lling of the air c onditioning system c an be pe rformed only by means of c harging
units and observing the instructions of the manufacturer. For mechanical or body
operations it is recommended piping protection in order to avoid t heir disconnection
by accident.
Avoid the drip of the oil compressor on the painted vehicle carriage body.
For component replacement implying t he circuit draining, it is absolutely necessary
the use of new parts and of a special oil for compressor.
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