power steering 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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05 - 3
DRAINING – FILLING
05Power steering
AT T E N T I ON !
For filling and addi tion, only oi l DACIA of class DEXTRON II D is t o be used.
Circuit capacity: 1 liter.
CIRCUIT FILLING
Fill the reservoir with oil.
In order to fill the circuit with oi l, easy rotate t he steeri ng wheel in bot h directions so that
steering rack is performing a complete stroke.
Check the oil level in the reservoir and addition if the case.
Start t he e ngine, easy rot ate the steeri ng wheel in both dire ctions so that steering rack is
performing a complete stroke. Restore the oil level in the reservoir till MAXI level.
LEVEL CHECKING
Each 10,000 km, check the oil level in the reservoir, that must be between the MINI-MAXI
marks.
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VA LUES AND ADJUSTMENTS
07
07 - 2
Optional e quipment weight disposal on shafts axles

Fr ont axle Rear axle
Air conditioning 230
Power steering 170
We i g h ts (kg)
Ve rsion
V ehicle type
Unloaded vehicle weight
Maximum authorized weight
on axle
Maximum technical
admissible weight of the
loaded vehicle
M aximum technical admissible towing
weight (trailer without braking system)
Maximum technical admissible towing
W eight (trailer with braking system)
Maximum admissible weight of the
assembly
Maximum load on towing hook
T owing hook weight 1,4
R5A715
1035592
443
1075 632
443 730
800
1450 718
732
450
800
2250 2260
40
20 R5A716
1045602
443
1085 642
443
1460 728
732
Minim
Front
Rear
Maxim
Front
Rear
Front
Rear
Total
Front
Rear
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VA LUES AND ADJUSTMENTS
07
07 - 4
Accessories belts tension
Belts tensioning values are:
- alternator belt 253 – 273 Hz
- compressor belt 150 – 155 Hz
- power steering pumps belt 151 – 161 Hz
- compressor belt / DA pump 222 ± 8 Hz
A ccessories belt tensioning method.
Belt tensioning is to be performed with cold engine.
Mount the new belt.
Tighten the belt till obtaining the prescribed mounting tensioning.
Block the tensioner.
Perform three engine crankshaft rotations. P lace t he reading head of the MOT 1505 device i n the m easurement area and check if the
belt tensioning is within the mounting prescribed values; restore is necessary.
REMARK :
Once a belt is dismounted, is not to be remounted, but replaced.
A – crankshaft C – Compressor T – Tensioner pulley.
B – alternator D – Power steeri ng pump – Tensioning checking point.
B
A
A D
TA C
T
T
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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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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 - 7
Power train group
Dismount the hydro-elastic buffer nut (on
the right side).
Remove the power train and place it on a
support.
Disco n nect th e pr e ssu re controller
connector for power steering.
Dismo unt :
- hoses from oil reservoi r for power
s teering by means of pliers MOT 1202-01;
- high pressure pipe from the power
steering pump.
Dismount the refrigerant fluid pipes from
compressor (vehicles with AC unit).
Sustain the power t rain by means of the
two liftin g supports u sing a mobile lifting device
(mobile crane). Dismount the four attachment screws of the
power train support-battery and the elastic bu ffer
nut (9).
9
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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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