dimensions 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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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 - 1
Dimensions
Dimensions (mm)
Total length: 4083
T otal width:G = 1664
Total height:
* emptyH = 1379
*
loaded (authorized maximum total weight)1329
Wheel base* emptyA =2476
*
loaded2479
Front wheel track width, ground level measurement:
* empty E = 1429
* loaded1428
Rear wheel track width, ground level measurement F = 1348
Gr ound clearance (K)
*
empty-
*
loaded120
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VA LUES AND ADJUSTMENTS
07
07 - 7
Dimensions under c arriage body
DIMENSIONS UNDER CARRIAGE BODY CONDITIONING
ADJUSTMENT OPERATIONS OF THE STEERING ANGLES
H1, H4 - to be measured in front wheel axle, consequently rear wheel axle.
H2 - to be measured between the lower side of t he power train support.
H5 – to be measured between the elastic joint axle of the rear a xle arm and the ground.
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VA LUES AND ADJUSTMENTS
07
07 - 9
Checking values of the rear axle angles
ADJUSTMENTS
Not adjustable
N ot adjustable
VEHICLE
POSITION
Unloaded
Unloaded
Unloaded
VA L U ES
0030' ± 10'
(For two wheels) Cl osing
0
030' ± 10'
2,9 mm ± 1 mm
ANG L E S
CAMBER
PARALLELISM
ELASTIC BUSHINGS TIGHTENING
PRELIMINARY OPERATIONS TO BE OBSERVED BEFORE
CHECKING THE STEERING ANGLES
1. Area (checking surface) – it must be a s horizontal as possible.
2. Wheels, tires – check (from e quipping point of vi ew) to have same type of wheels and
tires on bot h axles (dimensions, inflating pressure, wear de gree). A pronounced wear i s not
allowing the correct horizontal positioning.
3. Suspension – check the shock absorbers, springs condition and height symmetry under
carriage body.
4. Joints – check the e lastic joints condition, steering and suspension ball joints clearance,
bearings clearances of the front and rear axles 5. Radial and axial run out of the wheels – must not be over 1 mm. This will be compensated
with the reading instruments. 6. Manufacturer’s method – each vehicle manufacturer is providing the checking conditions,
axles weights repartition, and presentation of under carriage body heights, not loaded.
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GENERAL
30 - 6
30Composition and dimensions of the main
braking system elements
Front brakes
- brake caliper bore diameter → 54 mm
- brake disk diameter → 235 mm
- disk axial runout measured at → 215 0. 04 mm
- brake disk maximal thickness 20 mm
- brake disk minimal thickness 19 mm
- braking pad thickness (support included) 14 mm
- brake pad minimal thickness (support included) 7 mm
Rear brakes
- wheel braking cylinder bore diameter → 22 mm
- new drum diameter → 228 mm
- drum diameter after grinding → 229 mm
- braking shoes lining width 40 mm
- braking shoes lining thickness 5 mm
- minimal accepted braking lining height above rivets 0.5 mm
Master cylinder
- diameter of bore 20.6 mm
Brake fluid reservoir without alarm sensor
Pressure limiter for circuit in parallel
S ervobrake master vac 7" 177.8 mm
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GENERAL
30 - 16
30
The influence of angles
The influence of different angles over the road behavior, stability and abnormal wear preventing
of the vehicles tires.
CAMBER
The exit from the tolerance field of the left or right wheel camber, may have as result:
- tires external or internal edge wear (excessive positive or negative camber);
- steerin g is deviating towards the camber angle is more pronounced (asymmetry ), a deviation
from the trajectory is taking place, which must be corrected by means of the steering wheel (the
pronounced wear on the tire in question is occurring);
CASTER
A larger difference of 1° between the right side caster and left side, may have as result:
- a deviation from the trajectory, which must be corrected by means of the steering wheel, the
abnormal tires wear (the pronounced wear on the tire in question is occurring), tough steering,
instability when turning.
PA R ALLELISM
This adjustment has little importance over the vehicle road behavior.
Anyhow, note the followings:
-a prominent closing may lead to tires external edges wear.
-a prominent opening may lead to tires interior edges wear.
DIMENSIONS UNDER CARRIAGE BODY
These are especially influencing the different angles of the steering geometry.
A vehicle, which has run a large amount of km, it will have under the carriage body, dimension s
smaller than a new vehicle. This is the reason why some vehicle manufacturers, are prescribing, when the checking is
done with empty vehicle, different under carriage body dimensions and their respective places
where these values must be taken. Other vehicle manufacturers are recommending the suspension
compression by means of special (specific) tools or loading repartition in different places.
These different procedures (as performing ways) have as final purpose, the cancellation of the
vehicle suspension lowering, which has driven an important number of Km, compared with its
initial condition.
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GENERAL
30 - 17
30Angles checking principle
PRELIMINARY CHECKING
Before starting the steering angles checking, it will be necessary to check the following points
and exclude the possible non-conformities.
1. Tires and rims checking, regarding: - type and dimension;
- inflating pressure;
- wear de gree.
2. Joints : - elastic bearings and bushings condition;
- ball joints clearance;
- bearing clearance;
- steering wheel column clearance.
3. Tires runout and axial runout (compensation is to be performed by means of the reading
instruments);
4. Dimensions symmetry under carriage body (suspension condition).
5. Manufacturer’s method : each vehicle manufactu rer is prescribing the checking conditions,
loading repartition on axles, under carriage body dimensions presentation.
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GENERAL
30 - 21
30Front axles checking and adjustment
THE DEVIATION TO THE LEFT OR TO RIGHT
AT STABLE SPEED
Perform the preliminary checking:
Wheels (front, rear ) : Joints clearance:
- pressure - bushings
- dimensions
- types Checking points heights:
- balancing - symmetry
a.m. conditions
are respected
Correct the faults
The deviation persists
Checking finished
Check the fr ont axle st eering ge ometry
The deviation persists
NO
YES
NO
YES
YES
Check the rear axle
p arallelism and the alignmentA
Checking finished
NO
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35
WHEELS AND TIRES
35 - 1
Characteristics
WHEELS
The wheels identification marking is repre sented in two ways: -engraved marking for steel rims
- cast marking for aluminum rims
The marking enables acknowledgment of the main wheels dimensions criteria.
This marki ng may be:
- Complete Example : 5.5 J 14 4 CH 43 , or
- Simplified
Example: 5.5 J 14
The wheel attachment holes are situated on a diameter of 100 mm.
Maximum axial runout : to be measured in points P1 and P2.
Maximum radial runout : to be measured in points G1 and G2.
AB C D E F
Rim width Rim Rim nominal Number of Tire Offset
Rim type ( in inches) edge diameter attachment staffing ( in mm) profile (in inches) points profile
5.5 J 14 4CH 43 5.5 J 14 4 CH 43
5.5 B 13 4CH 46 5.5 B 13 4 CH 46
G1
P1P2
G2
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