fuel cap 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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ENGINE E7J-26212
12 - 1
F UEL M IXTURE
Chara cteristics
ENGINE
VehicleGearbox Type Index Bo re StrokeCylinder
(mm) (mm)capacity
(cm3)
SOLENZA JH3-051 E7J 262 75,8 77 1390 9,5/1
T (0C) 250C500C800C1100C
Air T sensor 2058 - 20 45 816 - 804 315 - 303 141 - 129
R (Ohm)
Water T sensor 2300 - 2100 850 - 750 275 - 290 110 - 120
R (Ohm)
(1) The CO value at 2500 rpm must be maximum 0.3 %.
〈 For a water temperature of over 80 ° C and after a steady value of 2500 rpm during 30
sec; after this, return to idle running and perform measurement of polluting emissions level.
The water and air temperature sensors are of CTN type (negative coefficient of temperature)
and their resistance variation subject to the temperature, has the following evolution:
Verificãri efectuate la ralanti *
Engine Emisii poluan
i Fuel
Ty p e I ndex Revolution CO(%) CO
2(%) HC Lambda (minimum octane
(RPM) (1) (ppm) ( λλλλ
) number)
E7J262 750 ± 50 0,5 14,5 100 0,97.... Unleaded fuel
ma xm inmax ....1,03 (CO95)
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MOTEUR E7J-26213
FUEL SUPPLY
13 - 3
Pump capacity
1
PUMP CAPACITY CHECKING
SPECIAL TOOLS
Pliers for “CLICK” collars.
IMPORTANT
Duri ng this operation, it is obligatory :
- not - sm oki ng a nd not bri ngi ng
incandescent obj ects at the working pl ace; - protect against petrol splashing due
to residual pressure remained in piping
during their dismounting.
VEHICLES WITH FUEL RETURN
The checking of the fuel pump capacity is
recommended to be performed by t he fue l
return hose connected on the level transmitter -
pump assembly .
Disconnect the fuel return pipe ( 1).
Connect on the pipe a hose, one extremity
being introduced in a calibrated vessel, from 0
to 2000 ml. VE HIC
LES WITHOUT FUEL
RETURN
Disconnect the supply pipe from the fuel
electric pump assembly .
Connect on the pipe a hose, one extremity
being introduced in a calibrated vessel from 0
to 2000 ml.
Start the fuel electric pump by bridging the
3 and 5 terminals of the fuel pump H relay
(placed in the fuse and relays box from engine
compartment).
The pump output must be minimum 1.3 l /
min at 12 V.
If the output is not correct, check the pump
s upply voltage (capacity i s decreasing by
approximate 10% for a voltage drop of 1 V).
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IGNITION AND INJECTION
17
17 - 61
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
1V oltage ET001 : after contact computer In case of a
PR004 : computer supplying voltage ACTIV Eproblem
c onsult
th e PR004
dia gnostic
LC012 : O2 sensor option reading With one wire or three wires
LC017 : Engine fan driving with running engine With (if the option
is existing)
LC019 : upstream oxygen sensor With
LC020 : downstream oxygen sensor With (if the option is existing)
2 Comp uter LC036 : low flow fuel pump configuration With (if the option Nothing to
is existing) be noticed
LC042 : AC cold loop at injection With (if the option is existing)
LC048 : climate control configuration reading With (if the option is existing)
LC054 : Gearbox type Mechanical gearbox
LC096 : Compres sor with fix cy linder capaci ty With (if the option
is existing)
Diagnostic – Conformity checking
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19 - 16
COOLING - EXHAUST - TANK
FILLING CAP
Fuel tank
The fuel tank is having a filling cap, sealed-type, with key. The filling cap for unleaded fuel has
a filler whole incompatible with a c lassical filling gun (lead has a negative effect upon the de-
pollution system : oxygen sensor and catalyst).
In case of vehicle overturning, the anti-overturning valve is getting blocked, avoiding in this
wa y, the petrol leakage towards the carbon can.
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19 - 17
COOLING - EXHAUST - TANKFuel tank
DISMOUNTIN G
Drain the fuel tank ( 4)
Disconnect the battery.
Remove the trunk carpet.
Di smount the tank visiting cover from the
three attachment screws.
Di sconnect the e lectric connector f the fuel
pump assembly a nd detach from clips the
connection from the fuel supply pipe. Take out the spare wheel and release it
together with its support.
Remove the filling cap ( 2) and dismount the
two attachment screws of the upper filling cap.
Lift the vehicle on a two columns elevator.
Dismount the four-attachment screws (6) of
the fuel tank on the carriage body, then maintained
in tilted position, disconnect the rapid coupling
on the anti-overturning valve ( 7).
D etach from clips collar ( 3) of the aerating
pipe on the upper filling cap.
Release the fuel tank together with the aerating
connection. Dismount the thermal screen ( 5) off the three
maintaining clips. Dismount the attachment clip ( 1) of the filling
cap muff on the lower filling cap.
Dism ount t he fue l pum p a sse mbly by
dismounting the attachment nut by means of the
MOT 1397 device.
REMOUNTIN G
Perform the dismounting operatio ns in the
reverse order. The t ightening moment of t he fuel tank
attachment screws on the carriage body is of
2.1 daNm and the tightening moment for fuel
pump assembly attachment nut, is of minimal
7daNm .
REMARK :
Collar (1) is for single use only.
When remounting, use a new click collar
(1 ), for the attachmen t of the lower filling cap
connection on the fuel tank.
REMARK:
At remonting, for each 2 back screws
at t ac he ment fue l tank, ap l y 0.002 kg
FIXAMED M 28, for to realise security
moment.
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19 - 18
COOLING - EXHAUST - TANK
VEHICLES WI THOUT VISITING CAP
Fuel tank
TIGHTENING MOMENTS (daNm)
Fuel ta nk attachment screws 2.1
IMPORTANT :
Dur ing thi s operation it is
compulsory:
-not smoking and not approaching
with i ncandescent obj ects in t he working
area, -keep awa y from fue l spray i ng
when disc onn ectin g the fu el
connections, protect the sensitive area of
fuel leak.
Dismount :
- protection shield ( 3);
- filling cap attachment clip (5) on tank;
- fuel pump assembly (6).
REMOU NT I NG
Perform the di smounting opera tions in the
reverse order.
Tighten to the required moment the fuel tank
attachment screws (2.1 daNm); the thread of
the two rear attachmen t screws is to be lubricated
before mounting with Fixamed M28 (necessary
quantity – 2 grams).
Re p lace the single use clip ( 5) with a tightening
clip “CAILLAU” .
12
6
5 4
3
DISMOUNTIN G
Place the vehi c le on a t wo-c ol um n
elevator. Disconnect the battery (-) terminal.
Dismount the fuel tank cap.
Drain the fuel tank through the filling cap,
by means of a draining pneumatic or electric
pump. Dismount the a ttachments screws ( 1) of
the upper filling cap.
Lift the vehicle by means of the elevator.
Di smount the four attachment screws of
the fuel tank. Dismount the attachment clip ( 2) of the
aeration hose ( 4) on filling cap.
Carefully lower the tank and disconnect it:
- wiring connector;
- fuel supply pipe;
- petrol vapors re-aspiration pipe (for
petrol engines); - fuel return pipe (for Diesel engines);
Extract the aera tion hose on top of tank
crossbar and dismount the tank.
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COOLING - EXHAUST - TANK
TANK DIAGRAM
1. Aerating pip
2. Safety valve (over pressure, depression)
3. Anti-overturning valve
4. Pipe connection to carbon can
5. Restrictor
E. Air evacuation orifice during filling
F. Air volume enabling fuel dilatatio n.
R. Fuel cap.
V. Maximal admissible fuel volume.
5
4
E
Fuel tank
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19 - 22
COOLING - EXHAUST - TANK
Fuel pump
SPECIAL TOOLS
MOT 1397 Wrench for dismounting the fuel pump assembly nut
TIGHTENING MOMENTS (d aNm)
Fuel pump assembly nut 7
IMPORTANT
During the intervention on the fuel tank or on the
fuel supply circuit, it is absolutely necessary:
-n ot smoking and not bringing near any incan-
d escent parts in the working area;
-gu ard against possible petrol leakage, due to
residual pressure remained on piping, when
dis mounting.
DI SMO UNT I N G
In order to dismount the fuel pump assem bl y it is
not necess ary the tank dismounting, the access being
done t h rough the vehicle trunk.
In order to do that:
-d isconnect the battery;
-d ismount the attachment screws of the fuel
tan k v isiting cover;
-d isconnect the electric connector (B) of the
fuel pump assembly supply;
-d isconnect the rapid coupling (A) of t he fuel
supply pipe. Dismount the fuel pump assembly (2) attachment
nut (1), by means of the MOT 1397 device, after
1
2
p reviously marking on the fuel tank the position of
the arrow existing on the pump cap.
Release the fuel pump assem bl y.
REMOUNTI NG
Mount the fuel pump assem bl y on t he fuel tank
obs ervi ng the marking done when dismounting.
Mount the attachment nut of the fuel pump
assembly. Tighten the nut by means of the MOT 1397
device, so that the arrow from the nut meets the
arro w from the fuel pump assembly (this is ensuring
the minimal necessary tightening for sealing
achi ev ement.
REMARK :
After each dismounting, obligatory
replace the nut and its gasket.
The gasket will have the same color with the
dismounted one.
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19 - 23
COOLING - EXHAUST - TANKFuel pump
VEHICLES WI THOUT VISITING CAP
SPECIAL TOOLS
MOT 1397 Wrench for pump assembly dismounting- remounting
TIGHTENING MOMENTS (daNm)
Fuel tank attachment screws 2.1
Pump assembly attachment nut 7
In order to dismount the fuel p ump as-
sembly, it is n eces s ary th e fuel tank dis-
mounting.
IMPORTANT
Duri ng this operation it is compulsory:
-n ot smoking and not approaching
with inca ndescent objects in the working
area, - keep away from fuel spraying when
disconnecting the fuel connections, -protect the sensitive area of fuel leak.
DISMOUNTIN G
Dismount the fuel tank.
Dismount the attachme nt nut of the fuel pump
assembly by means of the wrench MOT 1397.
Dismount the fuel pump assembly
AT T E N T I O N !
When dismounting the nut, take c are that
fuel pump assembly i s not geared in rotation
with t he nut, which may lead to float rod
di st ortion and c onseque ntly t o fuel l evel
wrong indication.
Remark:
If until fuel pump mounting on t ank,
more than an hou r is taken in to
consideration, remount the nut on t he
tank, in order to avoid any distortion.
R EMOU NT I NG
Replace the sealing gasket of the fuel
pump assembly. The gasket shall have the
same color with the dismounted one. Mount the fuel pump assembly so that
arrow (1) from t he fuel pump assembly i s
corresponding to the arrow (20 from the
tank.
Position the nut and tighten it by hand to
maximum possible, pre venting t he pum p
assembly rotation.
Tighten the nut by m eans of the MOT
1397 wrench until arrow (3) from the nut is
aligned with the marks from fuel tank a nd
pump assembly .
2
3 1
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