handbrake 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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33
REAR A XLES ELEMENTS
33 - 9
Brake cylinder
Adjust:-the shoes, by applying a repeated pressure to the brake pedal;
- the rear axle bearing clearanc;
- the handbrake ( see c hapter 37).
Mount the wheel.
Lower the vehicle on the ground.
Tighten the wheels screws to the required moment.
Pu rge the braking system (see chapter 38).
REPAIRING
DISMOUNTIN G
Dismount the brake cylinder off the vehicle;
Dismo unt :
- the purging screw;
- the protection bellows;
-the Ö22 pistons assembled with the pressure gaskets.
Check the condition of the cylinder boring, any trace of wear, oxidation or scratches implies
the replacement of the assembled brake cylinder.
If the cylinder components are in a good condition, lubricate them with brake fluid and mount
them in the reverse order of dismounting .
Check the easy moving of the assembled pistons in the cylinder boring.
Mount the brake cylinder on the plate;
Mount the wheel brake drum.
Check the adjustment of the hand brake.
Purge the braking system.
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THE M ECHANICAL ELEMENTS CONTROLS
37
37 - 7
Handbrake - adjustment
The adjustment of the handbrake shall be performed with the vehicle lift on a two-column
elevator. Note :
The adjustment i s obligatory performed anytime t he brake shoes or secondary cables
have been replaced.
Release the control lever of the hand brake (release position)
Tighten the nut ( 1) until the shoes lining come lightly into contact with the brake drum.
The adjustment shall be performed so that is insuring a hand brake lever stroke of min.12
teeth until the blocking of the wheels. Lower the vehicle from the elevator.
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THE M ECHANICAL ELEMENTS CONTROLS
37
37 - 8
Handbrake control lever
TIGHTENING MOMENTS (daNm)
Attachment screws of the handbrake lever on c entral floor 1.2
DISMOUNTIN G
Disconnect the battery.
Release the hand brake control lever ( released position).
Lift the vehicle by means of a two columns elevator;
Detach the rudder bar fork ( 5) from the end rod (3) by unscrewing the lock nut (1) and
remove the ball-ended washer ( 2).
Remove the secondary cables ends from rudder bar seats.
D etach from clips the rod ( 3) from rudder bar (4)
Lower the vehicle from the elevator and inside the vehicle dismount: - seat;
- carpet attachment clips in the rear side area
- inner attachment of the left/right middle pillars coverings.
M ove the front seats backwards and dismount the a ttachment screw (6) of the handbrake
control on the central floor.
3 4521
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THE M ECHANICAL ELEMENTS CONTROLS
37
37 - 9
Move the seats a head and dismount:
- safety belts lower attachment screws;
- attachment screws of the front safety
belts locks and remove them.
Clear the cockpit carpet towards front seats.
Dismount the handbrake control attachment
screw ( 7) on the central floor.
Remove the upper casing of the handbrake
(8).
Han dbrake control lever
Disconnect handbrake contact (9).
Take off the assembly handbrake.
RE MOUNTIN G
Grease the shaft s with UM 185 Li 2M
grease.
Perform the dismounting operations in the
reverse order, taking care to apply a sealant
material layer on the outline of lower casing of
the handbrake lever assembly .
Readjust the handbrake.
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THE M ECHANICAL ELEMENTS CONTROLS
37
37 - 10
Handbrake secondary cables
SECONDARY CABLE - REPLACEMENT
DISMOUNTING
Disconnect the battery.
Loosen the rear wheels attachment screws.
Release the ha nd brake control l ever (re-
lease position).
Lift the vehicle by means of a two-column
elevator.
Detach the rudder ba r fork from the end
rod by unscrewing the lock nut (M12 x 1.25)
and remove the ball-ended washer.
Remove the secondary cables ends from
rudder bar seats.
Dismount the two rear wheels.
Dismount the brake drums ( see chapter 33
– Rear axles e leme nts ). Remove the secondary cables stops from
the central floor. Dismount the sheathe stops from the brake
plates. Remove the secondary cables.
REMOU NT I NG
Grease the cable with UM 185 Li 2M
grease
Perform the dismounting operations in the
reverse order.
Adjust the drum clearance ( see chapter 33-
Rear axles elements ”).
Adjust the handbrake control lever stroke.
SPECIAL TOOLS
Ro 441 Wheel drum cover tongs
Fr.600 Hub extractor
TIGHTENING MOMENTS (d aNm)
Wheel attachment screw 7.5
Steering knuckle nut 16.5
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INSIDE ACCESSORIES
Dashboa rd .......................................................... 57-1
Inside rear view mirror ..................................... 57-8
S un visors ........................................................... 57-9
Central console ................................................. 57-10
Handbrake case ................................................ 57-11
Turning handle .................................................. 57-12
SECU RITY ELEMENTS
Fr ont safety belts ............................................... 59 - 1
Re ar safety belts ............................................... 59 - 2
HEATING
General .............................................................. 61-1
Operating principle ........................................... 61-2
C limate c ontrol unit .......................................... 61-4
Ve n t ilation- climate control air
distributor (RACV) .......................................... 61-5
Heating radiator ................................................ 61-6
C ontrol panel ..................................................... 61-7
C ontrol cable s ................................................... 61-9
Motor fan control resistance............................ 61-10
Diagnose ............................................................. 61-11
AIR CONDITIONING
General ............................................................... 62-1
Draining – filling the refrigerant circuit ......... 62-3
Air conditioning unit operating diagram ........ 62-4
Operating principle ........................................... 62-5
Part icles filter .................................................... 62-7
Cold ai r blowing device (DSAF) ...................... 62-8
Evaporator ........................................................ 62-10
Control panel ..................................................... 62-11
Comp ressor ........................................................ 62-12
C ondenser .......................................................... 62-13
Pressu re controller ............................................ 62-14
F ilter reser voir ................................................... 62-15
Unit piping ......................................................... 62-16
Thermostatic expansion valve ......................... 62-19
C limate c ontrol blower ..................................... 62-20
Blow er control resistance .................................. 62-21
Rec ycling flap motor fan ................................. 62-22
Diagnose ............................................................. 62-23
CARRIAGE BODY SEALING
Ca rriage body se aling ....................................... 64 - 1 OPENINGS SEALING
Opennings sealing ............................................. 65 - 1 GLASSES SEALING
Glasses gaskets .................................................. 66 - 1
Inside wipers ..................................................... 66 - 2
Outside wipers ................................................... 66 - 3
Fr ont door glass channel ................................. 66 - 4
Rear door gla ss run channel ............................ 66 - 5
CARRIAGE BODY INSIDE TRIMS
C arriage body inside trims ............................. 71-1
Upper front pillar trim ..................................... 71-2
Mi ddle pillar trim ............................................. 71-3
Rear quarter panel tr im ................................... 71-4
R oof lining ......................................................... 71-5
Trunk carpet ...................................................... 71-6
Cowl panel noise absor bent ............................. 71-7
Cockpit carpet ................................................... 71-8
LATERAL OPENINGS TRIMS
Fr ont door panel ................................................ 72-1
R ear door panel ................................................. 72-2
REAR TABLE
Lateral table ....................................................... 74-1 FRONT SEATS SLIDES GUIDES
Fr ont seat ........................................................... 75-1
Fr ont seats slides guide s ................................... 75-2
SEATS / R EAR BENCH
R ear bench ......................................................... 76-1
BATTERY - FRONT HEADLIGHTS
Battery ... ............................................................ 80-1
Headlamp assembly .......................................... 80-4
F og projectors ................................................... 80-5
Bulbs ... ................................................................ 80-6
Headlamps adjustment .................................... 80-9
Repl acement of the headlamps mechanic
adjustment control ........................................... 80-1157
Mechanisms and accesoires5
59
61
62
Climatisation6
64
65
66
71
72
74
75
76
80
Echuipment electr ique8
Garnishing and tack room7
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57
57 - 11
INSIDE ACCESSORIES
Handb rake case
DISMOUNTIN G
Through the cutting out existent in the cock-
pit carpet in the handbrake lever, dismount the
attachment screw (1) of the handbrake case in
front part, on the tunnel.
Move towards front the seats.
Dismo unt :
- bench seat ( see c hapter 75); - attachmen
t screws of the front safety belts
at lower part; - attachment screws of the locks on the tun-
nel;
Detach from clips the carpet and roll it towards
front part.
Dismount the attachment screw ( 2) of the
handbrake case on the tunnel, in the rear part. Release the handbrake c ase.
REMOU NT I NG
Perform the dismounting operations in the re-
verse order. The safety belts screws are to be tighten to the
required moment of 2,7 daNm.
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83
INSTRUMENT PANEL
83 - 3 Con
nector D (gray)
Pin Denomination 1. Mass
2. Free
3. Free
4. Free
5. Water temperature alert
6. Oil pressure alert
7. Battery charging indicator
8. Fog lamp indicator
9. Fog projectors indicator
10. Right turning indicator
C
onnector C (black)
Pin Denomination 1. Free
2. Free
3. Free
4. Handbrake indicator / ICP braking
system
5. Free
6. Anti-starting indicator
7. – Fuel level transmitter
8. Fuel level signal
9. Free
10. + Battery
Connector A (white)
Pin Denomination 1. Left turning indicator
2. Meeting lights indicator
3. Road lights indicator
4. Rear windscreen defrosting indicator
5. Free
6. Free
7. Free
8. + Parking lights
9. Water temperature indicator
10. Free
Connectors disposal
Connector B (brown)
Pin Denomination 1. Vehicle speed signal
2. Engine RPM signal
3. Free
4. Free
5. + After contact
6. Driver safety belt indicator
7. OBD indicator
8. Free
9. Free
10. + After contact
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89
ELECTRIC DIAGRAMS
89 - 6
Functional diagrams list
DOORS CENTRAL LOCKING
ANTI-STARTING
SPEED LIMIT INDICATOR
ELECTRIC LIGHTER
CLIMATE CONTROL
CLIMATE CONTROL AND AIR CONDITION
CEILING LAMP
FRO NT WINDOWS ELECTRIC CONTROL
RADIO
STARTING CIRCUIT
E NGINE COOLING FAN
ELECTRONIC INJECTION
CHARGING CIRCUIT
REAR WIRING MASS
FRONT WIRING/ DASHBOARD MASS
BATTERY/CARRIAGE BODY MASS
FOG PROJECTORS WIRING MASS
HATCHB ACK WIRI NG MASS
E NGINE WIRING MASS
COCKPIT FUSE BOX
E NGINE FUSE BOX AND RELAY
HANDBRAKE INDICATOR / BRAKING SYSTEM FAILURE
FUEL LEVER INDICATOR
OIL PRESS URE INDICATOR
DIAGNOSTIC SOCKET
DASHB OAR D
ALER T TEMPERATU RE INDICATOR FOR COOLING FLUID
WA TER TEMPERATURE COOLING FLUID INDICATOR
SPEED INDICATOR
DRIVER’S AIRBAG
DRIVER SAFETY BELTS INDICATOR
ACOUSTIC WAR NING
REAR WINDOW DEFROSTING
ELECT RIC D IAGRAM S DE NOM INATION DI AGRAM NUM B E R
1
2
3
4
5
6
7
8
9-10
11
12-13
14-15-16-17-18-19-20-21
22
23-24
25-26-27-28-29-30-31-32-
33-34-35-36
37
38
39
40-41-42-43
44-45-46-47-48-49-50-51-
52-53-54-55-56-57-58-59
60-61-62-63
64
65-66
67
68-69
70-71-72-73-74
75
76
77-78
79
80
81
82
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