wheel 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
vnx.su

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
vnx.su

03 - 1
03
TOWING
AT T E N T I O N !
NEVER USE AS T OWING P OINTS, THE TRANSMISSION AXL ES (P L AN-
ETARY SHAFTS).
The towing points, front, or rear, are to be used only for vehicles towing on wheels.
These poi nts cannot be a nyhow used for drawing out the damaged vehicle from a trench
(hole), or for direct or indirect vehicle lifting on a transport platform.
FRONT (right) REAR (left)
All types
vnx.su

04 - 2
LUBRICANTS – INGREDIENTS
PRODUCTPLACE WHERE IT IS USED
ETANª ARE
LOCTITE 518
LOCTITE 5900
(RHODORSEAL 5661)
Sealing paste Wurth W
ater pump
Thermostat support
Crankshaft half crankcase
Gearbox crankcases assembling
Thread of the reverse driving contact
Crankshaft no. 1 bearing cap
Engine lower crankcase
Exhaust
S OLDERING
LOCTITE 270
(FRENBLOC)
LOCTITE 243
(FRENETANCH) Scr
ew of secondary shaft
Crankshaft flywheel screw
Engine balance wheel screw
CLEANING
LOCTITE
METALLREINIGER (DECAPJOINT) Aluminum parts
surfaces
04Condition
vnx.su

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.
vnx.su

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
vnx.su

VA LUES AND ADJUSTMENTS
07
07 - 5
Wheels, Tires
Vehicle
SOLENZA Wheels
5.5J144 CH43
5.5B134CH46 Tires
165 / 65R14
165 / 70R13
Inflating pressure (bars) (1) Front Rear
Empty/Loaded Empty/Loaded 2.0/2.2 2.0/2.1
2.0/2.2 2.0/2.1
(1) Maximum loaded, wheels on the ground.
- tightening moment of the wheels screws : 7.5 daNm ;
- wheel axial run out : maximum 1 mm;
- wheel radial rubout : maximum 1 mm.
The increase of t ire t emperature during driving implies a growth of the tire pressure with
0.2 – 0.3 bars compared with t he prescribed values.
In case of tires pressure checking immediately after vehicle driving, consider this growth of
pressure.
vnx.su

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.
vnx.su

VA LUES AND ADJUSTMENTS
07
07 - 8

Checking values of the front axle angles
ADJUSTMENTS
N
ot adjustable
N ot adjustable
N ot adjustable
Adjustable by
rotating the tie rod of the
steering rod
-
VE HICL E
POSITION
H5 - H2 = 100
H5 - H2 = 90
H5 - H2 = 80
H5 - H2 = 70
H5 - H2 = 60
H1 - H2 = 105
H1 - H2 = 98
H1 - H2 = 91
H1 - H2 = 85
H1 - H2 = 78
H1 - H2 = 71
H1 - H2 = 64
H1 - H2 = 105
H1 - H2 = 98
H1 - H2 = 91
H1 - H2 = 85
H1 - H2 = 78
H1 - H2 = 71
H1 - H2 = 64
N ot loaded
N ot loaded
VALUES
0
0 0 3'
0020'
0036' ± 30'
005 3'
101 0'
Right / left maxim
difference = of
10
-00 16'
-0010'
-0002'
0006' ± 30'
0015'
0024'
0035'
Right / left maxim
difference = of
10
130 36'
13025'
13014'
13003' ±30'
12050'
12038'
12024'
Right / left maxim
difference = of
10
Toe in:
0010' ± 10'
(for one wheel 0
005' ± 05')
-
ANGLES
CAMBER
CASTER
BALL JOINT
TOTAL PARALLELISM
ELASTIC BUSHINGS TIGHTENING
vnx.su

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.
vnx.su