alternator DACIA SOLENZA 2004 Repair Manual

CHARACTERISTICS
Engine – Clutch - Gearbox .................................. 01-1
Ve hicle identification .......................................... 01-2
LIFTING MEANS
M obile jack – Adjustable supports ..................... 02-1
Elevator positioned under vehic le body .............. 02-2
TOWING
All types .............................................................. 03-1
LUBRICANTS – INGREDIENTS
C ondition ............................................................ 04-1
DRAINING – FILLING
Engine.................................................................. 05-1
Gearbox .............................................................. 05-2
P ower steering ..................................................... 05-3
VALUES AND ADJUSTMENTS
Dimensions .......................................................... 07-1
Weights (kg) ........................................................ 07-2
C apacity - Quality ................................................ 07-3
Accessories belts tension ..................................... 07-4
Wheels, Tires ....................................................... 07-5
Br akes.................................................................. 07-6
Dimensions under carriage body ......................... 07-7
Checking values of the front axle angles .............. 07-8
Checking values of the rear axle angle s .............. 07-9
ENGINE ASSEMBLY
Ingredie nts............................................................ 10-1
Oil consumption ................................................. 10-2
Oil pressur e ......................................................... 10-3
Power tr ain group................................................. 10-4
Sepa ration - Gearbox .......................................... 10-9
Se para tion – Unfitting ......................................... 10-10
Tightening moments ........................................... 10-11
S pecial tools ......................................................... 10-12
C haracteristics ..................................................... 10-13
Dismounting – Remounting ................................. 10-20
Lower casing ...................................................... 10-39
Oil pump .............................................................. 10-41
Mul ti-purpose support ......................................... 10-42
DISTR IBUTIO N SYSTEM
Dis t rib ution belt ........................................................ 11-1
Cy l inder head gasket ............................................... 11-3 FUEL MIX TURE
Characteri stics .......................................................... 1 2 -1
Bo d y valve ................................................................. 1 2 -4
In let man ifo ld ........................................................... 1 2 -5
Exh aust man i fold ...................................................... 1 2 -6
Air fi l ter .................................................................... 1 2 -7 FUEL SUPPLY
Su p ply interruptio n .................................................. 1 3 -1
Fu el ramp .................................................................. 1 3 -2
Pu mp capaci ty ........................................................... 1 3 -3
Su p ply pressure ......................................................... 1 3 -4 ANTI-POLLUTIO N
Pet rol vapors re-as p irat ion ...................................... 1 4 -1
Oil vapors re-as p irat ion ............................................ 1 4 -4 ALTERNATOR – STARTER
Alternat or ................................................................. 1 6 -1
Starter ........................................................................ 1 6 -6 IGNIT ION AND INJECTION
Ig nition system ......................................................... 1 7 -1
Sp ark pl ags ............................................................... 1 7 -3
In ject ion system ....................................................... 1 7 -4
Characteri stics .......................................................... 1 7 -10
In ject ion / ai r co nditioning strat egy ......................... 1 7 -11
Id ling reg ime co rrection ........................................... 1 7 -12
Id ling reg ime ad aptive co rrection ............................ 1 7 -13
Enri ching ad justment ............................................... 1 7 -14
Enri ching ad aptive co rrection .................................. 1 7 -16
“On Board Diagnostic” system ch aracterist ics ....... 1 7 -18
“On Board Diag nostic” li ghting conditions ............. 1 7 -19
“On Board Diag nostic” di agnostic conditions ......... 1 7 -20
Diag nostic of co mbustion mis fires det ection ............ 1 7 -21
Cat alyst diag nostic .................................................... 1 7 -22
Oxy gen sensor diag nostic ......................................... 1 7 -23
Diag nostic – Gen eral ................................................. 1 7 -25
Diag nostic – Fai l ures interp retat ion ......................... 1 7 -26
Diag nostic – Hel p ...................................................... 1 7 -60
Diag nostic – Confo rmity ch ecking ............................ 1 7 -61
Diag nostic – Stat es interpret ation ............................ 1 7 -69
Diag nostic – Paramet ers interp retat ion .................. 1 7 -75
Fai l ure locat ing al gorithm ........................................ 1 7 -83 COOLING - EXHAUST - TANK
Characteri stics .......................................................... 1 9 -1
Fi l ling - Purging ........................................................ 1 9 -2
Checking ................................................................... 1 9 -3
Co o ling system diagram ........................................... 1 9 -4
Rad i ato r ..................................................................... 1 9 -5
Co o ling engine fan fo r vehicles
wit h out ai r co nditioning ............................................ 1 9 -7
Diag nostic – fai lures in terp retat ion at vehicles
wit hout ai r co nditioning ............................................. 1 9 -8
Co o ling engine fan fo r vehicles
General poinds vehicle0
01
02
03
04
05
07
Engine and péripheriques1
10
11
12
13
14
16
17
19
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VA LUES AND ADJUSTMENTS
07
07 - 4
Accessories belts tension
Belts tensioning values are:
- alternator belt 253 – 273 Hz
- compressor belt 150 – 155 Hz
- power steering pumps belt 151 – 161 Hz
- compressor belt / DA pump 222 ± 8 Hz
A ccessories belt tensioning method.
Belt tensioning is to be performed with cold engine.
Mount the new belt.
Tighten the belt till obtaining the prescribed mounting tensioning.
Block the tensioner.
Perform three engine crankshaft rotations. P lace t he reading head of the MOT 1505 device i n the m easurement area and check if the
belt tensioning is within the mounting prescribed values; restore is necessary.
REMARK :
Once a belt is dismounted, is not to be remounted, but replaced.
A – crankshaft C – Compressor T – Tensioner pulley.
B – alternator D – Power steeri ng pump – Tensioning checking point.
B
A
A D
TA C
T
T
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 10
ENGINE UNFITTING
Dismo
unt :
- alternator and its belt;
- oil dipper guide;
- induction coil, after its electric co nnector
and spark plugs cables have been disconnected.
ENGINE FITTING
Perform the dismounting operations in the
reverse order.
Tighten the screws and nuts to the required
moment.
Se paration – Unfitting
Di sconnect the electri c connectors and
dismount the engine wiring.
Dismou nt then:
- valve body;
- injection ramp;
-clutch disc and mechanism;
-e ngine flywh eel;
- intake manifold;
- thermal screen and exhaust manifold;
- water inlet pipe;
- thermostat support.
For the veh i cles equi ppe d wi t h a i r
conditioning unit and /or power steeri ng
d ismount additionally:
-driving belt tensioner;
- compressor belt;
- compressor electric connector;
- compressor;
- compressor support and intermedi ary
support.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 21
CYLINDER HEA D DISMOUNTING
Drain the oil from the engine.
Dismount :
- wiring from the engine;
- compressor and/or power steering pump ( for vehicles equipped with air conditioning
unit and/or power steering); -compressor support and/or power steering pump support;
- alternator and its belt.
Dismounting – Remounting
Block the engine flywheel by means of the
MOT 582 device .
Dismou nt :
- oil dipper rod support;
- alternator belt tightening clamp;
-cr ankshaft pulley or pulleys ;
- pulley hub;
- distribution belt casings.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 38
2. Camshaft gear with marks
Rotate the engine until is reaching the Upper
Dead Point (cylinder 1 at ignition), and then con-
tinue until first item:
- adjust : exhaust 1
exhaust 3
- at second item :
-adjust : admission 1
admission 3
- at third item :
- adjust : exhaust 2
exhaust 4
- at fourth item :
- adjust : admission 2
admission 4
Dismounting – Remounting
Continue to mount:
- cylinder head cover equipped with a ne w cylinder head gasket, tighten the attachment
sc rews to the required moment of 1 daNm;
- water inlet pipe and the oil dipper guide (with new sealing rings);
- distribution casings;
-cr ankshaft pulley or pulleys; tighten the pulley hub screw to the required moment of 2
daN m, then to 68° ± 6°.
ATTENTION!
If the screw is not properly tighten, this may unloose, which may lead to the oil pump
no n-drive and to the distribution derangement, consequently to engine damaging.
- intake manifold and exhaust manifold, tighten the attachmen t screws to the required mo-
ment of 2.5 daNm;
- compressor and/or power steering support;
- alternator (see chapter 16”Alternator”);
- compressor- for vehicles equipped with air conditioning (see chapter 62 “Air condition-
ing”); -power steering pump-for vehicles equipped with power steering (see chapter 36 “Power
steering pump”);
-belt or accessories belt according to the method described in chapter 07” Accessories
b elt tensioning”.
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ENGINE E7J-26211
11 - 1
DISTRIBUTION SYSTEMDistribution belt
DISMOUNTIN G
Place the vehicle on a two-column eleva-
tor.
Mount between chassis and cylinder casing,
the MOT. 545 device for sustainin g front part
engine.
TIGHTENING MOMENTS (daNm)
Wheels screws 7.5
C rankshaft pulley screw 2+68
0 ± 60
Te nsioning roller nut 5
R ight support screws 6.2
Hydro-elastic buffer nut 3.7
Dismo unt :
-r ight front wheel;
-r ight pendular suspension support;-
accessories belt ( for vehicles provided
with air conditioning and/or power steering; -alternator’s belt;
-cr ankshaft’s pulley or pulleys and their
hub ; -distribution casings.
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ENGINE E7J-26211
11 - 2
DISTRIBUTION SYSTEMDistribution belt
Set the engine at setting poi nt (see method described in chapter 10 “ Engine assembly”,
page 10 –19). Loosen the tensioning roller nut.
Dismount the distribution belt.
REMOU NT I NG
Mount a new distribution belt.
Tension the distribution belt to a value of 145 – 185 Hz by means of the MOT 1505 device
(see the method described in c hapter 10 “ Engine assembly”, page 10 –33 ).
Perform the dismounting operations in the reverse order.
Tighten to the required moment the screws.
Remount the pulley for accessories belt (for vehicles equipped with air conditioning and/or
power steering). Obligatory tighten the screw of the crankshaft pulley hub to the required moment of 2 daNm
plus an angle of 68° ± 6 °
Mount and tension the alternator belt and the accessories belt, observing the method for belts
tensioning described in chapter 07 “ Accessories belts tensioning “.
The belts te nsioning values are:
Alternator belt 253 – 273 Hz
Co mpressor belt 150 – 155 Hz
Power steering pump belt 151 – 161 Hz
Co mpressor / power steering pump belt 214 – 230 Hz
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ENGINE E7J-26211
11 - 4
DISTRIBUTION SYSTEM
56
Cylinder head gasket
Dismount the hoses from the thermostat sup-
port.
Dismou nt :
- compressor (see chapter 62 “Air con-
ditioning”); -power steering pump (see chapter 36”
Power steering pump );
- alternator (see chapter 1 6 “Alterna-
tor” ); -
oil gauge guide;
- thermal screen;
- multi-purpose support;
- exhaust manifold.
Dismo unt :
- cylinder head screws except the screw
corresponding to A position, which is to be
loosen, then rotate the cylinder head around the
screw remained not-dismounted; - cylinder head.
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16ENGINE E7J-262
16 - 1
ALTERNATOR – STARTER
IDENTIFICATION
ENGINE ALTERNATOR INTENSITY
VALEO A11 VI 87 75A
E7J - 262
VALEO A13 VI 212 80A
CHECKING
After 15 minutes of heating under a 13.5 V tension.
ENGINE RPM ALTERNATOR 75 AALTERNATOR 8 0A
(rot/min) (A)(A)
10004654
2000 6875
3000 7180
4000 7282
OPERATION / DIAGNOSTIC
These vehicles are equipped with alternators with internal ventilation, incorporated voltage
regulator, and charging indicator on the instrument panel, which must operate as follows:
-w hen the contact is set on, the indicator is on;
-af ter engine starting, the indicator is off;
-i f indicator goes on during engine running, then it shows a charging failure.
INCIDENTS SEEKING
A. The indicator is not lighting when setting the contact on
Check : -the electric connections must be well done;
- the indicator bulb is not worn (when the circuit is mass connected, the bulb must be on).
Alternator
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ENGINE E7J-26216
16 - 2
ALTERNATOR – STARTER
B. The indicator is lighting, engine being running.
This shows a charging failure, which may be caused by:
- alternator driving belt broken, charging wire connected to alternator is broken (+ per-
manent);
-alternator failure(rotor, stator, diodes or brushes);
- voltage regulator failure;
- an over voltage.
C. Client is claiming a charging defect, but the luminous indicator is correctly oper-
ating.
If the adjusted voltage is smaller than 13.5 V, check the alternator.
The defect may be caused by : -worn diode;
-b roken phase;
- collector wear or coal dust.
VOLTAGE CHECKING
Connect a voltmeter to the battery plugs and read its voltage value.
Start the engine and speed the e ngine till the voltmeter needle i s set on the adjusted voltage.
This voltage must be between 13.5 V and 14.8 V
Connect maximum of consumers; the voltage must still between 13.5 V and 14.8 V.
AT T E N T I O N !
In case electric arch welding is performed on vehicle obligatory disconnect the bat-
tery and the voltage controller (alternator).
Alternator
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