brake DACIA SOLENZA 2004 Repair Manual

wit h ai r co nditioning ..................................... .............. 1 9 -9
Diag nostic – fai l ures interp retat ion
at vehicles wit h ai r co nditioning ............................... 1 9 -10
Wat er pump ............................................................... 1 9 -11
Exhau st Assemb ly...................................................... 1 9 -13
Fu el tan k .................................................................... 1 9 -15
Fu el pump ................................................................. 1 9 -22
Fu el filter ................................................................... 1 9 -24
Eng ine susp ension ..................................................... 1 9 -25
CLUTCH
Identifi cation ............................................................. 2 0 -1
Diag nostic .................................................................. 2 0 -2
Cl u tch di sk – Mechan ism ......................................... 2 0 -5
Pres s ure bearing – Clutch rel eas ing fo rk ................ 2 0 -7
Engine flywheel ................................................. 20-8 MECHANICAL GEARBOX
Se ctional view .................................................... 21-1
Identification ...................................................... 21-2
Tightening moments in daNm .......................... 21-3
Parti curarities .................................................... 21-4
Ratios ...... ............................................................ 21-5
Ingredie nts .......................................................... 21-6
C apacity, lubricants .......................................... 21-7
Parts t hat are replaced afte r
each dismonting ................................................. 21-8
Necessary special tools ...................................... 21-9
Gearbox dismounting ........................................ 21-10
R eplacement of the planetary se aling
gasket (on the vehicle) ....................................... 21-30
R eplacement of the 5-th gear synchroniser
and pinion (on the vehicle) .................................. 21-32
TRANSMISSION
Fr ont transversa l transmission ........................ 29-1
Bell ows - Bearing asse mbly to
the gearbox (left) ............................................... 29-4
Bell ows to wheel (left) ....................................... 29-7
Be llows to gearbox (right) ................................. 29-12
Bell ows to wheel (right) .................................... 29-15
GENERAL
General principle sc hedule
of the brake circuit ............................................ 30-1
Tightening moments (in daNm) ....................... 30-2
Com position and dimensions
of the ma in braking system elements ............... 30-6
Br aking system diagnostic ................................ 30-7
Br ake connections and ducts ............................ 30-12
Br ake fluid ......................................................... 30-13
Br aking system purging .................................... 30-14
The influe nce of angles ...................................... 30-16
Angles checking princ iple ................................. 30-17
Fr ont axles checking and adjustment ............. 30-18 FR
ONT AXLES ELEMEN TS
C haracteristics ..................................................... 31-1
Sus pension arm ................................................. 31-2
Elastic bushings of the suspension arm ........... 31-5
Sus pension ball joint .......................................... 31-6
Br ake lining (pads) ............................................ 31-7
Checking the brake pads wear ......................... 31-9
Br ake caliper ...................................................... 31-10
Br ake disk ........................................................... 31-12
St eering knuckle ................................................. 31-13
St eering knuckle bearing (35 x 65 x 35) ......... 31-15
Fr ont suspension ................................................ 31-16
Shock absor ber, Spring ...................................... 31-17
Sp ring – shock absorber assembly ................... 31-18
Anti roll bar ........................................................ 31-20
Power tr ain support .......................................... 31-21
REAR AXLES ELEMENTS
C haracteristics ................................................... 33-1
Re ar axle ............................................................. 33-2
Re ar suspension ................................................. 33-4
Shock absor ber ................................................... 33-5
Spring ...... ........................................................... 33-6
Br ake drum ........................................................ 33-7
Br ake cylinder .................................................... 33-8
Br ake shoes ......................................................... 33-10
Be aring ................................................................ 33-13
WHEELS AND TIRES
C haracteristics ................................................... 35-1
Wheels balancing ............................................... 35-4
STEERING ASSEMBLY
St eering connecting rods .................................. 36-1
Manual steering box .......................................... 36-3
St eering box pushe r ........................................... 36-4
Noise absorbant bushing .................................. 36-5
Bell ows ................................................................ 36-6
General .............................................................. 36-7
Power steering box ............................................ 36-8
P ower steering box pusher ............................... 36-11
Power steering pump ......................................... 36-12
Ste ering column ................................................. 36-14
THE MECHANICAL ELEMEN TS CONTROLS
Br ake pump........................................................ 37-1
S ervobrake ......................................................... 37-3
Air filter – se rvobrake reta iner valve .............. 37-6
Handbrake - adjustment ................................... 37-7
Handbrake control lever ................................... 37-8
Handbrake secondary cables ............................ 37-10
Br ake flexible hoses ........................................... 37-11
Br ake pressure controller .................................. 37-13
Gears control ..................................................... 37-15
Cl utch and brake pedals ................................... 37-17
Clutch cable ........................................................ 37-18
Pe dals support ................................................... 37-20
Acceleration control .......................................... 37-21
20
21
29
30
31
33
35
36
37
Transmission2
Chasis3
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VA LUES AND ADJUSTMENTS
07
07 - 6
Brakes
Veh icl e
Normal
20 Minim
19 Normal
228 Minim
229 Front
0.04 Rear
-
Brake disk width and drums diameter (mm) Front Rear Maxi
m disk
axia l run out
Veh icl e
Normal
14 Minim
7 Normal
5 Minim
0.5 mm
above the
rivets SAE J 1703
DOT 4
Gaskets thickness (mm)
Front Rear Bra ke fluid
SOLENZ A
SOLENZ A
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 5
Power train group
Sw ing over the steeri ng knuckle and
extract the pl anetary t ransmission from the
planetary pinion of the gearbox. Dismount the left planetary transmission,
as follows: - dismount the steering knuckle nut;
- dismount the planetary transmission
attachment screws on the gearbox;
- dismount the brake calliper assembly ;
- dismount the shock absorber two
attachment screws on steering knuckle;
- swing over the steering knuckle and
dismount the planetary transmission. Dismount t he fuse box from the engine
compartment.
5
6
- collar ( 2) between the descending
tube and expansion chamber, remove the
descending tube; -anti-roll connecting rod.
Di sconnect the re verse dri ving contact
connector. Disenga ge the right planetary transmission,
as follows:
-dismount the brake calliper assembly ;
- dismount t he shock absorber t wo
attachment screw (4) on steering knuckle. Disconnect:
- connector (5 ) from the UCE (pull flap
(6) and then disengage); - engine wiring from engine fuse box;
4
- shock sensor connector;
- cooling engine fan connector;
- DA pressure sensor connector;
- mass wire from the gearbox
Dismount the battery protection shield.
Disconnect by means of the elastic clips pliers
MOT.1202-01 :
- hoses from radiator;
- hoses from thermostat support and from
water pump inlet pipe;
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 6To
be uncoupled:
- acceleration cable end ( 7) from the
valve control lever and extract it from the
sleeve ( 8) from support;
Po wer train group
Dismount the connection screw between the
gears control rod and gearbox control connecting
rod.
- hoses from gases evacuation vessel;
- petrol vapors recycling pipes from the
carbon can and from can purging valve; - fuel supply pipes (supply and return) from
injection ramp by means of the MOT.1311-06
device.
7
- speedometer cable from the gearbox
(push the two clamps and extract it); -cable for right headlamp adjustment
and place it near carriage body. Disconnect the servobrake pipe from the
intake manifold.
Di
smount the clutch control cable from
gearbox.
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IGNITION AND INJECTION
17
17 - 73
ET039IDLING ADJUSTMENT
RECOMMEND AT IONS No failure must be prese nt or memorized.
Attention to the recommended value of idling RPM: PR041
C heck the connection and condition of the idling regulator connector.
R eplace the connector if necessary.
C heck the resistance of the idling regulator.
R eplace the idling regulator if necessary
C heck the in su la t ion and continuity of the connections between:
Pin 12 inj ection computer >pin B idling regulator
Pin 41 inj ection computer >pin A idling regulator
Pin 42 inj ection computer >pin C idling regulator
Pin 72 inj ection computer >pin D idling regulator
M end if necessary.
Idling regime
< minimal limit RECOMMENDAT IONS The idling RPM is too low
- Check the enriching adjustment operation.
- Clean the air supply circuit (valve body, idling regulator), which may be clogged.
- Check the engine oil level ( too high ? bubbling).
- Check the engine compressions.
- Check the valves clearances and the distribution setting.
- Check the ignition.
- Check the injectors.
If all checked eleme nts are correct, replace the idling regula tor
Idling regime
> maximal limit RECOMMEND AT IONS The idling RPM is too high
- Check the oil level
- Check the good operations of the atmospheric pressure sensor.
- Check possible leaks at piping connected to the inlet manifold.
- Check the electric valve s with pneumatic control.
- Check the manifold gaskets.
- Check the gaskets of the valve body.
- Check tightening at servo-brake.
- Check the presence of nozzles in the connection hose s of the oil vapors re-aspiration circuit.
- Check the valves clearance and the distribution setting.
If all checked eleme nts are correct, replace the idling regula tor AFTER Restart the conformity checking from the beginning.
REPARATION
Diagnostic – States interpretation
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IGNITION AND INJECTION
17
17 - 86
ALP 3 IDLING PROBLEMS (unstable idling)
RECOMMEND AT IONS Do not consult this diagnostic but before performing a complete
checking by means of the CLI P tester.
C heck if there is petrol in the fuel tank (fuel indicator failure)
C heck if the vehic le is supplied with adequate fuel
C heck tha t supply cir cuit hoses are not broken (espe cially further to a dismounting)
C heck the condition of the fuel filter
C heck the condition of the fuel tank
C heck that fuel tank aeration is taking place.
C heck the connection and the condition of the idling regulator connector.
Re place the connector if necessary.
C heck the motor of the idling regulator
In order to unblock it, you may slightly hit it.
Disconnect the connection hose between the canister purging valve and the intake manifold.
Cl amp the connection hose in order to stop the air passing.
If there are no more disturbances, the cause is the canister purging valve.
C heck the spark plugs and ignition coil condition
C heck tha t these eleme nts are specific to that vehicle.
C heck that the exhaust route is not clogged and the catalyst is not clogged.
Check, by means of the oil dipstick, that oil level is not too high.
C heck for lack of sealing at servo-brake (noise).
C heck the intake manifold condition
C heck if the valve body is not clogged
C heck the engine compressions.
C heck the engine flywheel condition
C heck the distribution setting on.
AFTER Perform a checking by means of the CLI P tester.
REPARATION
Fa ilure locating algorithm
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IGNITION AND INJECTION
17
17 - 87
ALP 4 INTEMP ERATE ACCELERATION OR DECELERATION
(engine unstable running)
RECOMMEND AT IONS Do not consult this diagnostic but before a complete checking by
means of the CLIP tester
Ch eck if air filter is not deformed.
Ch eck if there is petrol in the fuel tank (fuel indicator failure)
Ch eck if the vehic le is supplied with adequate fuel
Ch eck tha t supply cir cuit hoses are not broken (espe cially further to a dismounting)
Ch eck the condition of the fuel filter
Ch eck the condition of the fuel tank
Ch eck that fuel tank aeration is taking place.
Disconnect the connection hose between the canister purging valve and the intake manifold.
Cl amp the connection hose in order to stop the air passing.
If there are no more disturbances, the cause is the canister purging valve.
Ch eck the spark plugs and ignition coil condition
Ch eck tha t these eleme nts are specific to that vehicle.
Ch eck that the exhaust route is not clogged and the catalyst is not clogged.
Ch eck the se aling of the exhaust manifold.
Ch eck, by means of the oil dipstick, that oil level is not too high.
Ch eck for lack of sealing at servo-brake (noise).
Ch eck the intake manifold condition
Ch eck if the valve body is not clogged
Ch eck the engine compressions.
Ch eck tha t brake calipers, drums and bearings are not gripped.
Ch eck that tires are inflated
Ch eck the engine flywheel condition
Ch eck tha t cooling system is properly operating
AFTER Perform a checking by means of the CLI P tester.
REPARATION
Fa ilure locating algorithm
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TRANSM ISSION
29
29 - 1
Front transversal transmission
DISMOUNTING - THE SIDE TO W HEEL
Loosen the left wheel screws.
Lift the vehicle on an elevator with two columns.
Dismount the wheels.
Dismount the screws that attach the brake disk assembly on the steering knuckle.
U nscrew the transmission nut by means of the RO 604 – 01 device.
Dismou nt :
- the nut of the steering ball joint;
- steering ball j oint from the steering knuckle, by means of the PF 476 extractor;
- the attachment screws of the steering knuckle on the shock absorber end. SPECIAL TOOLS
RO 604-01 Hub immobilizing device
PF 476 Ball joint extractor
TIGHTENING MOMENTS (daN/m)
T ransmission nut 28
S crew for fixing the bellows lid on the gearbox 2,5
Wheels attachment screw 7,5
Screws, nuts for fixing the stee ring knuckle on the shock absorber 10,5
S crew for fi xing the caliper on the steering knuckle 6,5
Nut for steering ball joint 4
Push the transmission in the steering knuckle and incline the latter.
Dismount the transmission, the wheel side.
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TRANSM ISSION
29
29 - 3
Front transversal transmission
REMOUNTING – THE SIDE TO THE GEARBOX
The left side
Engage the transmission GI joint in the gearbox (the transmission position as horizontally as
possible).
Mount the three attachment screws of the bellows l id on the gearbox.
The right side
Grease the tulip frame grooves (the grooves area) and the transmission shaft of the gearbox
with transmission oil.
Engage t he tra nsmission GI joint (t he tulip) on the transmission shaft of the ge arbox (the
transmission position must be as horizontally as possible).
REMOUNTING – THE SIDE TO THE WHEEL
For both sides
Engage the transmission in the steering knuckle, this one being necessary to freely enter, so that
threaded area of the steering knuckle is allowin g to remounting the transmission nut.
Perform then the dismounting operations in the reverse order.
Observe the tightening moments.
Remount the brake disk assembly.
Refill the gearbox with oil.
Press several times the brake pedal to enable caliper piston coming in contact with the brake
pads.
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GENERAL
30 - 1
30
GENERAL PRIN CI PLE SCHEDULE OF B RAKE CIRC UIT I N PARALLEL,
WITH BY – PASS CIRCUIT
BRAKING IN PARALLEL, WITH BRAKE LIMITER
General principle schedule of the brake circuit
DACIA SOLENZA vehicles, are equipped with hydraulic braking system, brake pump with
by-pass double circuit, braking booster, brake limiter in order to avoid the rear wheels blocking
Fr ont brakes are disc type and rear brakes are hub type.
Brake discs are ventilated.
Front brake circuit
Rear brake circuit
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