bonnet DACIA SOLENZA 2004 Repair Manual

ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 4
Power train group
The power train dismounting-remounting is to be performed on the engine compartment upper
part by means of a mobile lifting device.
The vehicle i s to be placed on a 2–columns
elevator.
Dismo unt :
- battery
- air filter inlet pipe;
- air filter assembly ;
- engine bonnet;
- front wheels.
Disconnect the oxygen sensor ( 1) connector
or the connectors of the two oxyge n sensors
(EURO 00 ).
Di smount : thermal protection screen and
descending tube from the exhaust manifold.
DISMOUNTIN G
Drain:
- the cooling circuit on the water pump
inlet pipe; - oil from gearbox;
- oil from engine if necessary;
- refrigerant fluid to a charging station
(vehicles with AC);
- oil from the power steering circuit
(vehicles with power steering).
- Oil from the power steeri ng circuit
(vehicles with power steering);
Dismo unt :
- engine shield;
- descending tube attachment screws
on support;
TIGHTENING MOMENTS) (daNm)
Right support attachment screw on engine 6.2
Hydr o-elastic buffer attachment nut 3.7
Left elastic buffer attachment nut 6.2
Whe els s c rew s 7.5
Power train- battery attachment screws 2.1
Connecting rod attachment nut on steering cross member support 6.2
Anti-roll connecting rod attachment screw on gearbox connecting rod 10.5
Control bar attachment screw on gearbox connecting rod 2.7
Pipes a ttachme nt s crews on comp ressor 2.1
High pressure pipe on DA pump 2.1
1
23
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IGNITION AND INJECTION
17
17 - 62
Diagnostic – Conformity checking
RECOMMEND AT IONS The values show n on this conformity checking are only as indication.
Performing conditions : St opped engine, contact set on.
Sequence Function Parameter / Controlled state or acti on Visualization Diagnostic
and Observations
3 Anti-starting ET002 : Anti starting PASSIVE In case of a
problemc onsult
t he DF004
diagnostic.
4V alve position Acceleration pedal release d.
potentiometer ET003 : valve pos ition for released pedal. Yes
PR 017 : measured valve pos ition.0 < x < 47
PR008 : position memorized vale for released pedal. 0 < x < 47
Acceleration pedal slightly pressed. In case of a
ET003 : released pedal valve pos ition.NOproblem
ET005 : valve position at maximum accelera tion NO c onsult
Acceleration pedal fully pressed. the DF017
ET003 : valve pos ition for released pedal. NO diagnostic.
ET005 : valve position at maximum accelera tion. YES
PR 017 : measured valve pos ition. 170 < x < 255
5Water In case of a
tem perature PR002 : water temperature X= engine problem
se nsor temperature ± 5°C consult the
PR002
dia gnostic
6Air In case of a
tem perature PR003 : air temperature X = under bonnet problem
se nsor temperature ± 5°C consult
the PR003
dia gnostic
7P ressure PR016 : atmospheric pressure X = atmospheric In case of a
trans duc e r pressure problem
PR001 : manifold pressure X = atmospheric c onsult
pressur e the PR001
dia gnostic
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GENERAL
Lower structure composing elements........... 40-1
Upper structure composing elements........... 40-2
Ca rriage bo dy remo vable elem ents.............. 40-3
Op enings clea rance ...................................... 40-4
Repairing general conditions ...................... 40-9
We ldin g ty pe s an d pa rame ters ..................... 40-10
Collision diagnosis....................................... 40-12
Ca rriage bo dy checking. ............................... 40-16
LOWE R STRUCTURE
Fr on t lo ngitu dina l gird er.............................. 41-1
Fr on t an ti-sh ock cr o ss memb er.................... 41-3
Re ar longitudinal girder............................... 41-4
FRONT UPPER STRUCTURE
Fr on t wi ng .................................................... 42-1
Front wing lining................. ......................... 42-2
Ra diator upper cro ss me mber...................... 42-3
H ead lamp su pport ........................................ 42-4
Wind scre en lowe r cro ss memb er................. 42-5
Dr iving post cro ss memb er.......................... 42-6
SIDE UPPER STRUCTURE
Front pillar ................................................... 43-1
Mi ddle pillar ............................................... 43-2
REAR UPPER STRUCTURE
Rear lower panel ..... .................................... 44-1
Re ar lamp support ....................................... 44-2
In ner wh eel pa ssage..................................... 44-3
Side panel .................................................... 44-4
TOP OF BODY
Ro of ............................................................ 45-1
Wind screen fram e ....................................... 45-2
BODY PROTECTION
Engine shield ............................................... 46-1 LATERAL OPENINGS
Rear door / Front door........ . ......................... 47-1
NON – LATERAL OPPENINGS
Fr on t bo nnet ................................................. 48-1
Ha tchba ck.................................................... 48-2
MECHANISMS OF LATERAL OPENINGS
Front door-opening mechanism withelectric
control .......................................................... 51-1
Front door-opening mechanism withmanual
control .......................................................... 51-2
Rear door-opening mechanism with electric
co ntro l .......................................................... 51-3
Rear door-opening mechanism with manual
co ntro l ........................................................ 51-4
Front door electric window regulator .......... 51-5
Front door manual window regulator .......... 51-6
Re ar door window regulator ........................ 51-7
Lock ............................................................ 51-8
MECHANISMS OF NON LATERAL
OPENINGS
Front bonnet lock..... ..................................... 52-1
Ha tchb ack lock ............................................ 52-2
Pneumatic balancing device .. ..................... 52-3
GLASSES
Wind scre en glass ......................................... 54-1
Ha tchb ack glass ........................................... 54-3
Front door glasses..... .................................... 54-4
Rear door glasses ......................................... 54-5
OUTSIDE PROTECTIONS
Front bumper.......... ....................................... 55-1
Rear bumper.......... ........................................ 55-2
Hatchback handle ornament. ........................ 55-3
Body4
40
41
42
43
44
45
46
47
48
Mechanisms and accesoires5
51
52
55
54
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40
GENERAL
40 - 3
2
34 5
6
1
Carriage body removable elements
1. Side support
2. Front wing
3. Front door
4. Rear door
5. Hatchback
6. Front bonnet
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42
42 - 1
FRONT U PPER STRUCTURE
DISMOUNTING
Dismount the two attachment screws of the bonnet lower half-hinge on the front pillar lining.
Dismount partially the front bumper.
Dismount the attachment screws (1) of the wheel passage fairing.
Dismount the side-signaling lamp from the front wing.
Dismount the attachment screws (2), (3), (4) and (5) of the wing on the front wing lining, front
pillar lining, front bumper attachment side support, front pillars support and side frame lining
(front lower area). Dismount the front wing.
REMOU NT I NG
Perform the dismounting operations in the reverse order, ensuring the sealing by applying a
sealant material layer in the connection area of the wing with the front wing lining, front pillar and
side frame lining.
F ront wing
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42
42 - 5
FRONT U PPER STRUCTURE
Windscreen lower cross member
DISMOUNTIN G
Dismount the elements, which are in con-
tact with the windscreen lower cross member
(front bonnet, windscreen, dashboard, driving
post cross member).
Detach the welding points of the windscreen
lower cross member (1), which are in contact
with :
-windscreen frame in the area (2 );
- side frame lining (left/ right) in the area (3);
- climate c ontrol box in the area (4);
D etach the welding poi nts between the
column support a ssembly and t he c limate
control box in the area (5).
Restore and straighten the outlines resulted
from dismounting. Grin d the outlines resulted from dismounting.
REMOU NT I NG
Position and attach the new element.
Pe rform a spot welding and under
protection gas (SE CO
2), in the connection
areas of the windscreen lower cross member
with : -windscreen frame in the area (2 );
- right/left side frame lining in the area (3);
- climate control box in the area (4).
W eld the column support assembly on the
climate control box in the area (5).
Check and straighten the windscreen frame.
Grind the performed welding.
A ppl y a seal ant materi al laye r in t he
connection area of the windscreen lower cross
member with the right/left side frame lining and
the climate control box.
Mo u n t the connection elements by
performing the dismounting operations in the
reverse order.
1
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43 - 01
43Front pillar
SI DE UPPER STRUCTURE
DISMOUNTIN G
Dismount the elements that are in contact
w ith the front pillar (front door, front bonnet,
front wing). Detach the welding points of the front pillar
(1), which are in connection with :
-side frame lining in the area (3) ;
- windscreen frame in the area (3)
- front pillar lining in the area ( 4).
Straighten the areas resulted by dismount-
ing. Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element on the
side frame lining. Clench in 2-3 points by m eans of sliding
tongs. Joint the front pillar border with side bor-
der of the windscreen frame. Wel d t he fro nt pi l l a r, fo l l owi ng t he
assembling outlines ( 2), (3) and (4) .
Pe rform an additional welding SE CO
2, in
the front pillar connection area with:
- side frame lining (6 weld x 15 mm);
- windscreen frame (4 weld x 15 mm);
- front pillar lining (6 weld x 15 mm).
Mount temporarily the front door, observin g
the openings clearance.
Weld the hinges on the front pillar (continuos
weld on all hinges sides).
Grind the performed welds.
Pr o t ect the perf ormed weld with a
corrosion-preventing product.
Mount the connection elements by
performing the dismounting operations in the
reverse order.
2 3
4
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TOP OF BODY
45
45- 2
Windscreen frame
DISMOUNTING
Dismount the elements in connection with the
windscreen frame (front bonnet, windscreen, left/
right front wing, left/right front door).
Detach the welding points of the windscreen
frame (1), which are in contact with :
- side frame lining and roof belt in the area
(2) left/right; -windscreen lower cross member in the
area (3 );
- front pillar and front pillar lining in the
area (4) left/right
-r oof in the area (5 ).
D etaching is to be performed by means of a
special shar p drill Ø 6 for plate elements.
Straig hten the areas resulted from dismounting
Grind the area resulted from dismounting.
REMOU NT I NG
Position and center the new element on t he
side frame lining (left/right). Clench in 2-3 points by means of sliding tongs.
Joint the front pillar border with windscreen
frame side border (left/right). Perform a spot welding of the windscreen
frame on the outlines (2), (3), (4) and (5).
Perform an additional SE CO
2 welding in the
connection area of the front pillar upper border
with the windscreen frame side border (left/right)
(4 weld x 15 mm).
Check and restore the windscreen frame.
Grind the performed welding.
Protect the performed welding with an anti-
corrosion product. Paint the affected area.
Mount the elements in connection with t he
windscreen frame by performing the dismount-
ing operations in the reverse order.
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48
NON – LATERAL OPPENINGS
48 - 1
Front bonnet
DISMOUNTIN G
Dismount :
- attachment screws (1) and (2) of the
upper half-hinges on the front bonnet lining; -front bonnet.
R EMOU NT I NG
Pr e-attach the screw (1) from the
windscreen frame on the front bonnet lining
(left/right). Place the front bonnet i n the upper half-
hinge (t hrough the channel made in it) a nd
adjust the clearances. Mount the ot her t wo attachment screws
of the upper half-hinges on the front bonnet
lining and tighten all the four screws to the
required moment of 22,44 Nm. Grease the hinges with white grease
(Teroson).
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52
52 - 1
MECHAN ISMS OF NON LATERAL OPENINGS
Front bonnet lock
3
4
2
1
TIGHTENING MOMENTS(daNm)
Attachment screws of the bonnet lock hock
and lock 0.7
-attachment screws (4) of the bonnet
lock on the ra diator upper cross beam. Release the opening control cable (5) from
the lock.
Remove the obturator ( 6) and release the
cable from the opening handle (8).
DISMOUNTING
Dismount :
- attachment screws (2) of the bonnet
lock (1) to the front bonnet lining; Di
smount the attachment screws (7) of the
handle (8) on the side frame lining.
REMOU NT I NG
Perform the di smounting operations in the
reverse order.
Required tightening moment for attachments
screws of the lock hook and lock is of 0,7 daNm.
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