2004 DACIA SOLENZA engine

20
CLUTCH
20 - 7
Pressure bearing – Clutch releasing fork
R EPLACEMENT
This operation is to be performed after separation of the gearbox. from engine
DISMOUNTING
Di smount:
- pressure bearing by swinging over the fork;
- protection bellows and remove the clutch-re leasing fork.
REMOUNTING
Lubricate the guiding tube, slides and fork joint with grease OLISTA LONG TIME
3EP R100 137188. Mount the fork and the protection bellows.
Mount the pressure bearing on the guiding tube with groins ( A) clips-attached on fork
Check the pressure beari ng sliding on guiding tube.
REMARK:
In case of an intervention not implying the gearbox dismounting, or after gearbox
mounting, the control fork is not to be lifted because the pressure bearing groins (A)
may come out from the clutch-releasing fork.
vnx.su

CLUTCH
20
20 - 8
S
PECIAL TOOLS
MOT 582 Flywheel immobilizing sector
.
Engine flywheel
TI GHTENING MOMENTS (daNm)
Flywheel screws 5 ÷ 5,5
REPLACEMENT
This operation is to be performed after dismounting the clutch mechanism and the ge arbox.
DISMOUNTING
Mount the immobilizing sector MOT 582.
Di smount the fl ywheel attachment screws.
The screws are not to be re used.
Di smount the engine flywheel.
REMOUNTING
Clean the holes thread from the cra nkshaft by means of a dry gauze.
Degrease the flywheel seating surfaces on the crankshaft .
Mount the flywhe el with new scre ws (the scre ws thread shall be lubr icated with
LOCTITE FRENETANCH).
Tighten the screws to the required moment.
Dismount the immobilizing sector MOT 582
REMARK
The flywheel attachment screws are to be replaced aft er each dismounting.
vnx.su

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 3
Tightening moments in daNm
TIGHTENING MOMENTS (daNm)
A ttachment screws of the mechanism crankcase on the
clutch – differential case 2.5
S econdary shaft screw 7
Primary shaft nut 19
Back cap fixing screws 2.5
Oil draining plug 2.5
R everse driving contact 2.5
S crews for fixing the bellows assembly – left transmission cap assembly 2.5
Screws for fixing gearbox on engine case (M10 – 90) 4.4
Screws for fixing gearbox on engine case (M10 – 35) 2.1
Nuts for fixing gearbox on engine 4.4
LOCTOU blocking element fixing screw 0.5
S crews for fixing RPM sensor on the clutch case 0.8
S crews for fixing the control axle assembly 2
S crews for fixing clutch cable support 4.8
vnx.su

GENERAL
30 - 7
30Braking system diagnostic
Rigid pedal: when braking, an
increased effort for a small decel-
eration is performed
Ye s Replace: shaft, pedal or
servobrake fork.
Ye s
Ye s
Ye s No
No
No
No
Replace the servobrake
(broken membrane)
Replace the servobrake
(broken membrane)
Check:
- the integrity of the depression
pipe, consequently of the retain-
ing valve;
- the sealing of the depression pipe
at the servobrake, consequently at
the vacuum pump (inlet manifold).

Is the engine
regime changing
when braking ?
The engine pedal
is rigid from time
to time ?
1
Is the connection
shaft between the
ser vobra ke fork
and the pedal,
grabed?
At the servobrake
entrance i s the
depre ssion the
imposed one ? I. FAILUR
E : RIGID PEDAL
vnx.su

GENERAL
30 - 9
30
II. FAIL URE : LONG PEDAL
When braking, the brake pedal is slowly moving.
Perform a test with the stopped engine, after previously
performing five successive pushing on the brake pedal
(in order to vacuum the servobrake).
Locate and repair or replace the
item where a brake fluid leak is
established.
Ye s
No
Is the br ak e f luid level
lower compared to
the r e quired o ne?
Replace the brake pump, because the pressure gas-
ket (sealing) between the primary circuit and the sec-
ondary circuit is defective.
STOP
Braking system diagnostic
vnx.su

GENERAL
30 - 10
30Braking system diagnostic
I. CO NSTANT EFFECT TO THE PEDAL
EFFECTS
T ough pedal:
High effort for small deceleration.
Elastic pedal
In order to di agnose, an i ncident where
the use was normal is to be analyzed and two
tests are to be pe rformed:
1. While driving the vehicle :
Interpretation test: pedal stroke/ deceleration
rate.
2. While vehicle i s stopped, engine c ut.
A dditional test of brake pedal press:
Pe rform five c onsecutive pressings on the
brake pedal in order to vacuum the
servobrake, before taking into consideration
the test result.
Long pedal
The test i s to be performed with stopped
vehicle and cut engine.
REMARK:
It is neces sary to perform five
consecutive pressings on the brake pedal,
in order to vacuum the servobrake before
taking into consideration the test result.
Floor pedal
The test i s to be performed with stopped
vehicle and cut engine.
REMARK :
Perform five consecutive pressings on
the brake pedal, i n order to vacuum the
s ervobrake before takin g into
consideration the test result. POSSIBLE CAUSES
- Assi stance defect
- Brake linings:
- greasy
- stacking to t he disk ( non-c onform )
- heating, prolonged bra king with c onstant
pedal press
- Stuck piston
- R igid duct narrowed (flattening)
- Air presence in the circuit: defective purging
- Internal leak in the braking circuit.
- Leak of fluid from reservoir (external fluid
leak from braking circuit).
Automatic adjustment : ha nd brake c able too
tighten. - Important and asymmetric wear of the
b rake linings
- St roke too ample between the servobrake
pushing rod and the brake pump
- Brake fluid having high temperature.
- Hydraulic l eak (check the sealing of the
b raking system components)
- Sealing gaskets defects of the two brake
pump circuits.
- Brake fluid having high temperature
vnx.su

GENERAL
30 - 14
30Braking system purging
The air existence in the hydraulic circuit may be noticed by an elastic displacement of the brake
pedal, sometimes even, close to the floor. This fact is more evident with the engine running.
GENERAL RE COM M E NDATIONS
· Always use for completion or total changing the brake fluid SAE J 1703 , DOT 4.
· In case of changing the brake fluid it is necessary to wash the system with industrial alcohol.
· During the purging, the brake fluid from the reservoir must not go down bellow the MINIM
level marked on the reservoir.
To perform the purging, one person will stay on the driver place, to press the brake pedal and
the other one will perform t he purging at purging points, using a 500 ml vessel, a tra nsparent
plastic tube and brake fluid for completion.
REMARK:
The brake fluid obtaine4d during performing the purging operation IS NOT TO BE
REUSED, but after 48 hours, to avoid air bubbles introduction in the hydraulic circuit.
PR OCED UR E
Place on the purging screw, a transparent tube with its end in a vessel with brake fluid a nd
proceed as follows : - press the brake pedal slowly;
- dismount the bleeding screw, maintaining the full stroke of the pedal;
- tighten the bleeding screw;
- slowly release the brake pedal.
Repeat the same procedure until complete cease of bubbles.
Pr oceed in the same way also for the other purging places.
T ake into consideration the existence all the time of the brake fluid in the reservoir.
OBSERVATION : Before beginning the purging procedure, dismount the I.C.P. contact
from the brake pump that it will be remounted at the end of the operation, brake pedal released.
It is important to observe the following sequence of the purging points:
1.Main brake cylinder;
2. Left rear wheel brake cylinder;
3. Right rear wheel brake cylinder ;
4. Caliper of front right wheel ;
5. Caliper of front left wheel;
6. By-pass circuit through main cylinder purge.
vnx.su

FRONT AX LES ELEMENTS
31
31 - 21
Power train support
TIGHTENING MOMENTS (daNm)
Wheels attachment screws 7.5
Shock absorber lower attachment screws
to the steering knuckle arm 10.5
C onnecting straps upper attachment screws 2.7
Anti-roll connection rod attachment screws
to the steering crossbar support 6.2
Con nection screw of the steering column
lower shaft-steering box gear 2.1
AT T E N T I O N !
Di smounting of the front axles screws
and nuts implies their obligatory
r eplacement and tightening to the required
moments.
DISMOUNTIN G
Disconnect the battery.
Dismount :
- connection screw of the steering column
lower shaft-steering box gear;
-therm al sc reen att achment nut s on
exhaust manifold and remove the thermal screen;
- attachment studs descending pipe –
exhaust manifold. Loosen the front wheels scr ews.
Lift the vehicle by means of a two-column
elevator. Dismount
the engine shield.
Dr ain oil from power-assisted steeri ng
circuit ( see chapter 05). Drain oil from gearbox ( see chapter 05).
Dismo unt :
- front bumper 9 see chapter 55);
- left/right front wheels fairi ng ( see
chapter 56); -connecting straps upper attachments
power train support – carriage body; -uppe r a t t achm ents of the shoc k
absorption connecting straps (connecting
str aps of suspension arms shaft s-carriage
body); -brake calipers off t he for k a nd
suspend the calipers; -connection clip of descending pipe-
e xpansion chamber and remove the
descending pipe.
vnx.su