cooling 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 - 3
Capacity - Quality
DE NOM I NAT ION QUAL ITYCAPACITY (l)
(a pproximate )*
Engine oil DACIA OIL EXTRA SAE 10 W 40; API SJ 2,9*
Gearbox oil SAE 75 W 80 W; API GL 5 3,5
DACIA OIL EXTRAGEAR
Breaking fluid SAE J 1703 DOT 4 0,450
Cooling fluid 50% antigel GLACEOL RX typeD
50% distilled water 6
Refrigerant AC HFC – 134 a 0,600 kg
Compressor oil PA G S P 10 or SP 20 135 cm
3
* to be adjusted at dipstick
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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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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 - 8
Power train group
REMOU NT I NG
Perform the dismounting operations in the reverse order.
Tighten the screws and nuts to the required moment.
Perform: -filling and purging of the cooling circuit (see chapter 19”Filling a nd purging”);
-f illing with oil of the engine and gearbox;
-f illing of the power steering circuit (see chapter 05 “ Draining-Filling)- for vehicles
equipped with power steering;
-filling of the air conditioning circuit with refrigerant fluid HFC 134a (see chapter 62 “Air
conditioning”). Adjust the clutch pedal stroke (see chapter 37”Clutch control adjustment”).
REMARK:
At each operation implying battery dismounting, when reconnecting the battery,
introduce the radio code, which is written on the vehicle-purchasing invoice.
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ENGINE E7J-26211
11 - 3
DISTRIBUTION SYSTEM
3
1
42
Cylinder head gasket
N
ecessary Special Tools
MOT 1202-01 Pliers for e lastic collars
MOT 1505 Belt te nsioning measurement device
MOT 484 Jackets clamping device Wrench for angle tightening
Wrench for “CLIC” collars
TIGHTENING MOMENTS ( daNm )
Te nsioning roller nut 5
Crankshaft pulley screw 2 + 68° ± 6°
Pendular suspension support screws 6.2
Hydro-elastic buffer nut 3.7
Wheels screws 7.5
C ylinder head screws ( see cylinder head tightening method)
DISMOUNTIN G
Place the vehicle on a two-columns eleva-
tor. Disc onnect the battery.
Dr ain the cooling circ uit by the radiator
lower part hose.
Dismount the distribution belt (see chap-
ter 11 “ D i s t ribution belt “)
Dismount t he air filter
Disconnect : - acceleration cable from the valve con-
trol lever; -valve position potentiometer connec-
tor (1);
-atmospheric pressure sensor connec-
tor (2);
-step-by-step engine connector( 3);
- temperature sensor connector ( 4)
from the inlet manifold .
Disconnect :
-induction coil connector ( 5);
-f uel hoses (supply/return);
- injectors connectors;
- spark plugs cables.
Dismount the three attachment screws of the
induction coil ( 6).
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ENGINE E7J-26211
11 - 5
DISTRIBUTION SYSTEM
MOT 484
Cylinder head gasket
Mount the MOT 484 device or MOT
588 clamps for jackets maintenance.
Check the cylinder head smoothness using
a lineal a nd a set of templates. The maximal admissible deformation: 0.05
mm. The cylinder head is not to be rectified!REMOU NT I NG
Clean the gasket-seating surface of the cyl-
inder head.
Mount the cylinder head with a new gasket.
Perform the dismounting operation s in the re-
verse order.
Tighten the cylinder head observing the cyl-
inder head tightening method described in chap-
ter 10 “Dismounting-Remounting” .
Mount the distribution belt ( see chapter 11
”Distribution belt”).
Adjust the tilters.
Perform the cooling circuit filling and purging
(see chapter 19 “ Filling and Purging” ).
REMARK:
At each operation implying battery dis-
mounting,
when reconnecting it, introduce the radio
code t hat is written on the vehicle-purchas-
ing invoice.
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IGNITION AND INJECTION
17
17 - 7
Injection system
In the fuse box located in the engine compartment, the following relays may be identified:
A. Co mpressor relay
B. Engine c ooling fan relay, step I
C. Engine cooling fan relay, step II
D. UCE injection relay, canister-purging valve
E. Fog projectors relay
H. Fuel pump and ignition coil relay
14. C arbon canister with purging valve
included
;
16.
Power steering pressure controller; 12.
Oxygen sensor;
15.
A ir conditioning pressure controller.
1
15
12
1614
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IGNITION AND INJECTION
17
17 - 8
Injection system
WATER TEMPERATURE SENSOR
The water temperature sensor ( 1) is sending to UCE injection the information regarding water tempera-
tu re, and another information is sent to the indicator from the instrument panel, which will show the water
tem perature.
In case of an alert regarding the water temperature, UCE injection will control the lightening of
the water temperature indicator from the instrument panel.
Subject to water temperature, UCE injection will control:
- injection system;
- relays for controlling the engine cooling fan.
When setting the contact on, the water temperature indicator located on the instrument panel,
will be lighted for 3 seconds, then it will turn off.
1
1
If after the contact is set off, in the next 2 minutes from engine stopping, the water temperature
is reaching 102 °C, and t hen the injection computer i s control ling t he starting of the e ngine
cooling fan at low speed. When the temperature is lowering at 95°C, the engine cooling fan stopping will be controlled;
its operation must not exceed 10 minutes after engine stopping.
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IGNITION AND INJECTION
17
17 - 27
DF003
P RESENT
OR
MEMORIZEDAIR TEMPERATURE SENSOR CIRCUIT
1. DEF : Open circuit or short-circuit
RECOMMENDATIONS
AF TER
REPARATION
C heck the connection and the state of the air temperature sensor connector.
R eplace the sensor ’s connector if necessary.
C heck that resistance of air temperature se nsor is not zero or infinite (sensor sur e failure).
(Use chapter “Help” in order to compare the measured resistance values compared with
recommend ed ones).
R eplace the air te mperature se nsor if necessary.
C onnect the 90 w ays terminal box instead of the injection c omputer then c heck the insulation,
continuity and absence of the parasite resistance on lines: Pin 77 injection computer > pin 1 air temperature sensor
Pin 49 injection computer > pin 2 air temperature sensor
Fix if necessary
C heck the correct evolution of the sensor resistance subject to ai r temperature.
R eplace the air te mperature se nsor if necessary.
If the problem is persisting after these checking, fix the other failures the n perform the conformity
checking.
Diagnostic – Failures interpretation
If failure “DF345 : Supply 5 volts potentiometers or transducers” is present
or memorized, this must be treated with priority.
C onditions for failure detection by the computer:
- Set the contact on
- If the failure is only memorized, st art the engine in order to obtain a temperature
variation ( an engine cooling fan starting).
(The failure must pass to the present state, but it may become again memorized
i mmediately after finishing performing the previous operations).
* If the failure is memorized with OBD indicator on, check in the context part,
if state “ET274 : Air tempe rature se nsor circuit” corresponding to the OBD
i ndicator lighting request is affirmative. In this case, proceed as per bellow
m entioned method.
Perform the operations from “recommendations” for reparation confirmation.
Fix a ny other possible failures.
Erase the failures memoriz ed by the injection computer.
Perform a conformity checking by means of the CLIP tester.
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