ECU DACIA SOLENZA 2004 Repair Manual

IGNITION AND INJECTION
17
17 - 19
CONDITIONS OF OBD INDI CATOR L IGHTING
During driving it is possible that certain functions are not subject to diagnostic (for instance due
to crowded traffic driving).
Indicator lighting -it is occurring if the same OBD failure is detected during three consecutive driving or
fu rther to an electric failure.
Indicator blinking -it is occurring if combustion misfires are detected, that may cause the catalyst damage.
Indicator off
- it is occurring if the OBD failure is not happening during three consecutive driving, but the
fa ilure in cause will remain memorized by the UCE injection.
In orde r to cancel the failures memorized by the UCE injection, failures must not be detected
du ring 40 consecutive tests (or to perform the erasing of the memorized failures, by means of the
CLIP te st er).
O BSERVATION : if a previously detected failure has been not detected again, then the cause
may be: -driving type performed by the end-user, not driving exactly in the conditions imposed for
fa ilure detection;
-rando m character (non-permanent) of the respective failure.
“On Board Diagnostic” lighting conditions
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IGNITION AND INJECTION
17
17 - 21
This diagnostic may detect:
-spark plug fouling or smoking,
-fou ling or modification from the normal value of the injectors flow,
-f uel supply system abnormalities (pressure controller, fuel pump,..)
-pr oblems with the electric connections for controlling fuel supply circuits and the injection.
Th e di ag nostic is performed by variations measurement of the engine prompt rotation speed.
Notice of a couple decrease is allowing the defective combustion recognition as failure cause.
Th is diagnostic is done almost permanently during driving. Non accomplishment of the diagnos-
tic or recognition of the existence of failure, is leading to other OBD diagnostics inhibition. This diagnostic is enabling the identification of two types of failures:
-de structive combustion misfires, which are causing the catalyst damage. These are gener-
ating the immediate blinking of the OBD indicator. -Polluting combustion misfires, leading to e xceeding a pre-established OBD pollution limit.
These ar e generating the permanent lighting of the OBD indicator, if the cause detection is
taken place during three consecutive running.
DE T ECT ION CONDITIONS
At the beginning, it must be checked if the “learning” stages of the adaptive values by the UCE
injection have been correctly performed. Also the preliminary conditions imposed when setting the
co ntact on and those from checking moment, must be accomplished.
Check by means of the CLIP tester if the bellow mentioned states are in the following configu-
ration:
ET0 14 Cylinder 1 recognition----------------------------------------------------------------- DONE
ET2 02 OBD diagnostic of combustion misfires taken into consideration--------------AC TIVE
Detection is accomplished after the water temperature is exceeding 75°C, at three rotation
steps, between idling and 4500 rot/min. It is also possible, test performing by maintaining the engine
at idling for a period of time of 11 minutes.
ATTENTION: after performing this test, the contact set ting on is imposed (key in M
position) before reading the r esults by means of the CLI P t ester. Any contact set ting off
be fore reading the test results, will lead to their wrong interpretation.
If after test performing, the CLIP tester is noticing the presence of the combustion mis-
f ires, refer to the diagnostic method related to this symptom.
CONFIRM ATION OF THE RE PARATION PE RFORM ING
-Check by m eans of the CLIP tester, the bellow states, which must have the following
c onfiguration:
ET0 14 Cylinder 1 recognition -------------------------------------------------------------------- DONE
ET2 02 OBD diagnostic of combustion misfires taken into consideration ----------------- AC TIVE
-N o failures is detected by the CLIP tester, and the OBD indicator must be off.
Diagnostic of combustion misfires detection
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IGNITION AND INJECTION
17
17 - 22
The purpose of the catalyst diagnostic is the detection of the disturbances leading to exceeding
an OBD step due to HC pollution emissions.
Th e ca talyst storage capacity of the oxygen is the indicator of its condition. When the catalyst is
beginnin g to ”age”, the storage capacity of the oxygen is diminishing, in the same time with the
dimin ishing of the treatment capacity of the pollution gases.
IMPOSED CONDITIONS FOR DIAGNOSTIC STARTING
Th e ca talyst diagnostic can be not performed but after a certain time of engine operation and
on ly if the preliminary conditions, when setting the contact on, are accomplished and preserved:
-no electr ic failure
-c ylinder’s recognition performed
-n o detected combustion misfire.
-n on-performing of the catalyst diagnostic after contact setting on.
-correct performing of the “learnings” by the UCE injection.
-water temper ature to be over 75°C
Catalyst diagnostic
Engine Speed Regime Manifold pressure Stabilization period Time before authorization
(Km/h) (rot/min) (mbar) (s ec) (min)
E7J 63-130 1792-4000 430-739 1117
FAILURES DETECT ION
Th e diagnostic is to be performed on a stabilized range in the fifth gear, at the speed of 70 Km/h.
When the diagnostic starting conditions are accomplished, excitation peaks are applied, which is
le ad ing to th e oxygen bubbles sending to the catalyst. If the catalyst is good, it w ill absorb the
ox ygen and the tension of the downstream oxygen sensor will remain at an average value. If the
catalyst is used, it will reject the oxygen and the oxygen sensor will wrongly define the phenom-
en on. The oxygen sensor tension will fluctuate. If the failures is three consecutively times con-
firmed, th e OBD indicator would be on.
Th e test duration will be not exceeding 52 seconds.
ATTENTION: after performing this tes t, the contact s etting on is imposed (key in M
position) before reading the res ults by means of the C LIP tester. Any contact sett ing off
be fore reading the test results, will lead to their wrong interpretation.
If after test performing, the CLIP tester is noticing the presence of the combustion mis-
f ires, refer to the diagnostic method related to this symptom.
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19
19 - 17
COOLING - EXHAUST - TANKFuel tank
DISMOUNTIN G
Drain the fuel tank ( 4)
Disconnect the battery.
Remove the trunk carpet.
Di smount the tank visiting cover from the
three attachment screws.
Di sconnect the e lectric connector f the fuel
pump assembly a nd detach from clips the
connection from the fuel supply pipe. Take out the spare wheel and release it
together with its support.
Remove the filling cap ( 2) and dismount the
two attachment screws of the upper filling cap.
Lift the vehicle on a two columns elevator.
Dismount the four-attachment screws (6) of
the fuel tank on the carriage body, then maintained
in tilted position, disconnect the rapid coupling
on the anti-overturning valve ( 7).
D etach from clips collar ( 3) of the aerating
pipe on the upper filling cap.
Release the fuel tank together with the aerating
connection. Dismount the thermal screen ( 5) off the three
maintaining clips. Dismount the attachment clip ( 1) of the filling
cap muff on the lower filling cap.
Dism ount t he fue l pum p a sse mbly by
dismounting the attachment nut by means of the
MOT 1397 device.
REMOUNTIN G
Perform the dismounting operatio ns in the
reverse order. The t ightening moment of t he fuel tank
attachment screws on the carriage body is of
2.1 daNm and the tightening moment for fuel
pump assembly attachment nut, is of minimal
7daNm .
REMARK :
Collar (1) is for single use only.
When remounting, use a new click collar
(1 ), for the attachmen t of the lower filling cap
connection on the fuel tank.
REMARK:
At remonting, for each 2 back screws
at t ac he ment fue l tank, ap l y 0.002 kg
FIXAMED M 28, for to realise security
moment.
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GENERAL
30 - 10
30Braking system diagnostic
I. CO NSTANT EFFECT TO THE PEDAL
EFFECTS
T ough pedal:
High effort for small deceleration.
Elastic pedal
In order to di agnose, an i ncident where
the use was normal is to be analyzed and two
tests are to be pe rformed:
1. While driving the vehicle :
Interpretation test: pedal stroke/ deceleration
rate.
2. While vehicle i s stopped, engine c ut.
A dditional test of brake pedal press:
Pe rform five c onsecutive pressings on the
brake pedal in order to vacuum the
servobrake, before taking into consideration
the test result.
Long pedal
The test i s to be performed with stopped
vehicle and cut engine.
REMARK:
It is neces sary to perform five
consecutive pressings on the brake pedal,
in order to vacuum the servobrake before
taking into consideration the test result.
Floor pedal
The test i s to be performed with stopped
vehicle and cut engine.
REMARK :
Perform five consecutive pressings on
the brake pedal, i n order to vacuum the
s ervobrake before takin g into
consideration the test result. POSSIBLE CAUSES
- Assi stance defect
- Brake linings:
- greasy
- stacking to t he disk ( non-c onform )
- heating, prolonged bra king with c onstant
pedal press
- Stuck piston
- R igid duct narrowed (flattening)
- Air presence in the circuit: defective purging
- Internal leak in the braking circuit.
- Leak of fluid from reservoir (external fluid
leak from braking circuit).
Automatic adjustment : ha nd brake c able too
tighten. - Important and asymmetric wear of the
b rake linings
- St roke too ample between the servobrake
pushing rod and the brake pump
- Brake fluid having high temperature.
- Hydraulic l eak (check the sealing of the
b raking system components)
- Sealing gaskets defects of the two brake
pump circuits.
- Brake fluid having high temperature
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36
STEERING ASSEMBLY
36 - 2
St eering connecting rods
REMOU NT I NG
At each dismounting, it is OBLIGATORY the replacement of the limiter washer( 1) as well
as of the safety washer ( 2).
M ount in the rack : j oint body ( 3), not before positioning the safety washer ( 2), the limiter
w asher (1) and oiling the t hreaded pa rt ( 4) of the j oint body with FIXAMED R 58-C.S.1/82
(not excessively).
After tightening to t he required m oment of the axial ball joint on the rack, bend the safety
w asher over one of the cuts made on the joint body.
By means of the DIR 1306 , lock up the rack in regard to t he steering box casing.
Tighten to the required moment of 5 daNm, the joint body in the rack by means of the
DIR 505 wrench.
M ount the funnel ball joint in the steering knuckle arm, then tighten the nut to the required
moment of 4 daNm.
P osition the steering at the middle point ( wheels being in straight line position) in order to
balance the air from bellows. Mount the bellows in its c hannel from the steering box casing and secure it using a clip.
CHECKING
S lightly tighten by hand one of the bellows in order to check the other one inflation, in this
way, the good air circulation inside the steering box is checked. Check the steering geometry and adjust the parallelism if necessary.
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36
STEERING ASSEMBLY
36 - 4
Steering box pusher
ADJUSTMENT
When a noise is found in the area of the
st eering box pusher, it is obligatory to per-
form its correct adjustment.
1. Noise identification (clattering).
Hold by ha nd the rack in pusher’s side and
check the tra nsversal c leara nce (up-down). A
noise in the pusher’s area might occur while driv-
ing, caused by a clearance followed by a noi se
(clattering). If the clearance at the pusher is bigger than
0.31 mm, adjust the cleara nce and/or dismount
the steering box and eliminate the cause.
2. Checking and adjustment of the
push er’s clearance.
The pusher adjustmen t is to be performed tak-
ing into consideration both the rack wear and the
pusher’s wear:
- bring t he ra ck i n the minimum radial
runout position; - position the fe eler of a comparative
gauge on the cylindrical part of the rack ( oppo-
site to the threaded part) in the area of rack exit
from casing ( gear side); - rotate the gear on the whole rack length
and establish the minimal runout point, where the
value read on the gauge is minimal; - adjust the comparing gauge to zero;
- by means of a 17 mm fi xed wrench,
rotate the rack from the opposite end unt il the
pusher is in contact with the thre aded plug( a
higher wrench effort may be noticed for a re-
duced movement red on the comparing gauge);
- read the value shown by the comparing
gauge which must be smaller than 0.31 mm.
The pusher clearance adjustment is performed in
the minimal runout point by rotating the threaded
plug ( 4) to a moment of 1± 0.2 daNm and un-screwing ˘ rotations, then secure it by bead-
ing (caulking) in “S” area.
When mounting, put 23 ± 5 cm
3 grease
UM 185 Li2M for : rack, gear, sealing ring
and pusher’s spring, inner surface of t he
threaded plug. Check the operation and check also during
driving if the steering wheel is returning at the
straight line driving position (steering central
point).
1. Pusher
2. “O” ring
3. Spring
4. Threaded plug
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THE M ECHANICAL ELEMENTS CONTROLS
37
37 - 11
Brake flexible hoses
IMPOSED PRECAUTIONS TO BE RESPECTED WHEN
DISMOUNTIN G – REMOUNTING A RECEIVER
OR A BRAKE FLEXIBLE HOSE
Due to security reasons, in order to avoid brake flexible hose twisting and the risk to get i n
contact with the suspension elements, it is necessary to observe the following operations sequence,
as well as the flexible attachment on the wing lining by means of a stopper, positioned at 135 ± 2
mm, value to be measured from the connection screw of the rigid pipe with the flexible hose.
DISMOUNTIN G
Dismount the connection ( 1) of the rigid pipe (6) from the flexible hose ( 2) till the moment
when the spring (3) is relaxed, having releasing the splinted area (4) of the sustaining support (5).
TIGHTENING MOMENTS (daNm)
X (flexible on caliper) 2.0
Y (attachment screw of the rigid pipe on the flexible 1.5
135 ± 2
1
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40
GENERAL
40 - 9
Repairing general conditions
The replacement (reparation) operations of the weldable elements described in this chapter
are specified subject to: cutting out of the parts to be replaced, access to the welded elements,
tools and checking devices accessibility , etc.
In case the vehicle body has suffered important deformations it is recommended the straight-
ening of the damaged body elements, by means of some hydraulic presses.
For this range of vehicles, the elements resistance structure which are affecting the vehicle
s ecurity, are not to be partially replaced (not to be cut), but entirely.
After welding detaching, the body elements must remain straight, without breakage or cracks,
the possible holes being covered out with filling material or by tinning. The body elements sur-
faces are to be pickled ( to eliminate possible oxidation marks), dried and initially applied a paint
layer. The electric welding detaching of the body elements, may be performed as follows:
- with a well sharpen c hisel, t his method may lead t o parts de formation or e ven pa rts
breaking. - by using some extractors equipped with steel cutter type Brendeo or Pickvant (max. 6
mm) having the cutting head shaped as shown in pict.1.
1. Centering point
2. Sharpen slope
3. Drill acting edges
4. Gap for catching the welding material
P = aprox. 0.4 mm
Whatever m ethod is used, the remaining element must be in good order and to a llow per-
forming of a good quality welding point.
The plates cutting it is recommended to be performed (subject of importance and thickness)
using manual scissors or pneumatic portable tools for plates cutting. During cutting or welding of the body elements it is necessary to protect the electric wiring
from the interior of the body structure. The cutting, welding, or strengthening operation done on body welded elements, are to be
performed on body checking/ straightening benches recommended by the producer.
IMP ORTANT !
When removing or straightening the body resistance elements, it i s forbidden the
total or partial heating, in order to avoid the mechanical resistance and metal elastic-
ity de creasing.
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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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