length DACIA SOLENZA 2004 Repair Manual

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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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 15
VA LVES SPRINGS
The valves springs are identical for both intake and exhaust.
Length in free state (mm) 44.93
Length under load (mm) at: - 27 daNm 37
- 65 daNm 27.6
Length of the stuck coils (mm) 26.01
Coil diameter (mm) 4
Internal d iameter (mm) 21.5
CAMSHAFT
Axial clearance (mm) 0.06 - 0.15
Number of bearings 5
Distribution diagram : - intake opening advance -5
0
- intake closing delay350
- exhaust opening advance410
- exhaust closing delay-50
Chara cteristics
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 17BOLTS
Length (mm)
60
External diameter (mm) 19
Internal diameter (mm) 11
CYLINDER JACKETS
T ype: wet removable.
The sealing gasket is J rubber ring type.
Internal diameter (mm) 75.8
Jacket height (mm) H2 130
Centering diameter (mm) D80.6
Jackets over-height X without
gasket (mm) 0.02-0.09
Jacket height (mm) H1 91.5
Deep in cylinder block K1 (mm)
91.5+ 0 ,03
Chara cteristics
+ 0 ,035
+ 0 ,005
- 0 ,015
- 0 , 055
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19
19 - 13
COOLING - EXHAUST - TANKExhaust Assembly
ATTENTION !
Descending pipe in operation, may reach high temperatures and consequently must not
co me in contact with flammable materials which may lead to their auto-ignition.
Catalytic converter is to be mechanical shock protected.
DISMOUNTIN G
In order to di smount the noise a bsorber assembly ( 1), lift t he ve hicle on an elevator and
perform the following operation s:
Loosen the nuts ( 2) of the attachment collar between the expansion chamber ( 3) and the
noise silencer ( 1).
Di smount the thre e a ttachment e lastic supports of the noise a bsorber, on the carri age
body, rear pa rt. Release the noise silencer.
In order to dismount the assembled expansion chamber (3), perform the following operations:
Di smount the c ollar ( 4) and disengage the e xpansion chamber assembled with the de -
scending pipe.
Dismount the three elastic supports of the assembled expansion chamber.
Loosen the attachment collar nuts ( 2) and remove the assembled expansion chamber by
easy rotation and onward pulling.
In order to dismount the descending pipe assembly (6), perform the following operations:
Dismount the engine shield.
Dismoun t the catalytic converter attachment nuts ( 7) on the two studs of the exhaust manifold
flange. Dismount the attachment screws of the converter support ( 5).
For EURO 96, dismount the oxygen sensor located in upstream of the catalytic converter.
For EURO 00, dismount the oxygen sensors located in upstream, consequently, in
downstream of the catalytic converter.
Dismount the collar (4) and disengage the assembled catalytic converter from the assembled
expansion chamber.
Remove the descending pipe.
REMOU NT I NG
Perform the dismounting operations in the reverse order.
Ensure a perfect sealing between the exhaust assembly elements, using sealing paste Wurth,
on the joining area length (inside) between the noise absorber – expansion chamber (0.013 Kg);
The oxygen sensor gasket is to be replaced at each dismounting.
The tightening moment between noise absorber and expansion chamber is: 3.6 daNm.
The tightening moment of descending pipe attachment nuts on the exhaust manifold flange is:
2 daNm. Tightening moment between the catalytic converter and expansion chamber: 2.5 daNm.
All elements are to be assembled having the ambient temperature.
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TRANSM ISSION
29
29 - 14
Bellows to gearbox
Using a press, extract the assembled tripod, sustain it on an extractor type FACOM U 53 G,
protecting the clogs of the tripod.
R EMOU NT I NG
Grease the transmission shaft to help the protection bellows putting back (positioning of the
smallest diameter of the bellows on the transmission shaft).
The tripod is fixed and mounted in the position marked on dismounting.
Three poi nts of crimping are made at 120 ° C by metal he ading of t he t ransmission shaft
grooves.
Distribute the grease prescribed quantity in the bellows and in the tulip casing.
Correctly position the bellows in the tulip-casing place.
A non-cutting, round-headed rod is introduced between the bellows and the tulip casing to
dose the air amount contained inside the bellows. Lengthen or compress the bellows until value A = 190 mm is obtained (the value between
the extremity of the bellows and the extremity of the tulip casing) then from this position extract
the rod and remount the collars.
Right
transmissi on
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GENERAL
30 - 12
30Brake connections and ducts
The connection between the brake ducts and the brake pump, brake calipers, pressure limiter
is performed by means of the connections threaded with metric pitch.
P ARTS IDENTIFICATION
The cupping shape of the steel ducts (A )
The shape of the threaded lengths on parts ( B)
Connections of ducts (C)
A
B
C
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36
STEERING ASSEMBLY
36 - 4
Steering box pusher
ADJUSTMENT
When a noise is found in the area of the
st eering box pusher, it is obligatory to per-
form its correct adjustment.
1. Noise identification (clattering).
Hold by ha nd the rack in pusher’s side and
check the tra nsversal c leara nce (up-down). A
noise in the pusher’s area might occur while driv-
ing, caused by a clearance followed by a noi se
(clattering). If the clearance at the pusher is bigger than
0.31 mm, adjust the cleara nce and/or dismount
the steering box and eliminate the cause.
2. Checking and adjustment of the
push er’s clearance.
The pusher adjustmen t is to be performed tak-
ing into consideration both the rack wear and the
pusher’s wear:
- bring t he ra ck i n the minimum radial
runout position; - position the fe eler of a comparative
gauge on the cylindrical part of the rack ( oppo-
site to the threaded part) in the area of rack exit
from casing ( gear side); - rotate the gear on the whole rack length
and establish the minimal runout point, where the
value read on the gauge is minimal; - adjust the comparing gauge to zero;
- by means of a 17 mm fi xed wrench,
rotate the rack from the opposite end unt il the
pusher is in contact with the thre aded plug( a
higher wrench effort may be noticed for a re-
duced movement red on the comparing gauge);
- read the value shown by the comparing
gauge which must be smaller than 0.31 mm.
The pusher clearance adjustment is performed in
the minimal runout point by rotating the threaded
plug ( 4) to a moment of 1± 0.2 daNm and un-screwing ˘ rotations, then secure it by bead-
ing (caulking) in “S” area.
When mounting, put 23 ± 5 cm
3 grease
UM 185 Li2M for : rack, gear, sealing ring
and pusher’s spring, inner surface of t he
threaded plug. Check the operation and check also during
driving if the steering wheel is returning at the
straight line driving position (steering central
point).
1. Pusher
2. “O” ring
3. Spring
4. Threaded plug
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36
STEERING ASSEMBLY
36 - 11
Power steering box pusher
When an excessive rack clearance,
followed by clattering in the steering box is
occurring, before replacing the steering box,
the pusher with rack is to be adjusted. 1. Noise (clattering) identification.
Lift the vehicle by means of a two-column
elevator; On the pusher side:
- dismount the bellows attachment clip
on the steering box casing;
- push the bellow towards the steering
rod; - hold by hand the rack rod and check
the transversal clearance (up- down). A clearance followed by a noise (clatt ering)
is leading to a pusher noise, during driving. 2. Adjustment
Straigh ten th e caulking (A) of t he
adjustment nut bead (1).
By means of a 10 mm hexagonal wrench,
tighten the adjustment nut until there is no more
clearance.
AT T E N T I O N !
Do not tighten the nut more than 3
teeth.Check if the rack is freely moving all the
length. Bend the adjustment nut bead in the two
opposite slots of the steering box casing, ensuring
in this way its unscrewing.
Positio n the bellows on the steering box casing
and mount a new attachment clip.
Lower the vehicle from the elevator with
wheels on the ground.
Check, during driving if the steering wheel is
coming back to the steering center point.
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36
STEERING ASSEMBLY
36 - 13
Power steering pump
REMARK :
The replacement of the PDA hub is to
be performed at working bench, by means
of the Special tools previously described.
PULLEY HUB REPLACEMENT
Catch the pump in the working bench vice.
Attach the arms of the PS 1094 device on
the hub.
Depress the hub.
REMARK :
Inse rt a screw (1) between the pump
sha f t and the pushing rod of the
depressing device.
Place the new hub on the pump shaft and
press it by means of the DIR 1083-01 device.
Gr ease previously the shaft with a thin layer
of UM 185 Li2 M type grease to facilitate
the remounting.
REMARK :
Insert between DIR 1083-01 device and
the hub, one spacer (2) of about 25 mm.
length.
Di r. 1083-01
PS 1094
1 2
A – Hub
B – Power steering pump
Press the hub on the pump shaft, observing
the va lue X = 49.67 ± 0.2 mm.
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THE M ECHANICAL ELEMENTS CONTROLS
37
37 - 2
Brake pump
REMOUNTIN G
Perform the dismountin g operations in reverse order.
Check the length of servobrake the pushing rod , value X=9
-0,2 mm and correct it if necessary.
After assembling the brake pump with the fluid reservoir and filling with brake fluid, no leakage
must occur in the surface of separation between the two elements.
IMPORTANT :
The I.C.P. transducer is mounted after t he braking system purging.
ICP sub-assembly is not reparable
REMARK :
In case of failure of one of the braking system elements, proceed as follows:
- dismount ICP transducer;
- repair the failure;
- purge the braking c ircuit;
- mount the ICP transducer.
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