2004 DACIA SOLENZA engine

THE M ECHANICAL ELEMENTS CONTROLS
37
37 - 18
DISMOUNTING
In the engine compartment :
- release the clutch cable ( 1) from the
clutch control fork.
- detach from carri age body clips the
clutch cable.
Clutch cable
TIGHTENING MOMENTS (Nm)
Clutch cable counter nut 8
In the cockpit:
-r elease the c lutch cable ( 1) from the clutch
pedal cam and depress it from the pedals
support.
R EMOU NT I NG
Perform the dismounting operations in the
reverse order. Adjust the clutch control
C LUTCH CONTROL ADJUSTMENT
In order t o adjust the clutch pe dal stroke,
proceed as follows:
- place a gauge to ensure the 15 mm
clearance between the pedal and the pedals
s upport (4);
- tighten t he nut ( 3) on the clutch cable
end, until obtaining a stroke of 29 ± 1 mm at
the clutch disengaging fork by acting upon the
clutch pedal;
- tighten the co unter nut ( 2) to the
required moment of 8 Nm.15
4 1
1
23
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REPAIR MANUAL
DACIA
RM 525-2 BODYENGINE: E7J
G ERBOX: JH3
TA P V: B 41A, B41B, B41C
Ref: 6001999067 MARCH 2004 English version
The reparation methods prescribed by the manufacturer in the present document are established subject to
t echnical specifications in force at the document issuing date.
These a re subject to modifications brought by the manufacturer at the fabrication of different assemblies,
s ubassemblies or accessor ies of its vehicles.
All rights rese rved to SC Automobile Dacia SA.
Re production or transla ting even partia lly of this prese nt doc ume nt is forbidde n without the writte n
authorisation of AUTOMOBILE DACIA S.A.
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GENERAL
Lower structure composing elements........... 40-1
Upper structure composing elements........... 40-2
Ca rriage bo dy remo vable elem ents.............. 40-3
Op enings clea rance ...................................... 40-4
Repairing general conditions ...................... 40-9
We ldin g ty pe s an d pa rame ters ..................... 40-10
Collision diagnosis....................................... 40-12
Ca rriage bo dy checking. ............................... 40-16
LOWE R STRUCTURE
Fr on t lo ngitu dina l gird er.............................. 41-1
Fr on t an ti-sh ock cr o ss memb er.................... 41-3
Re ar longitudinal girder............................... 41-4
FRONT UPPER STRUCTURE
Fr on t wi ng .................................................... 42-1
Front wing lining................. ......................... 42-2
Ra diator upper cro ss me mber...................... 42-3
H ead lamp su pport ........................................ 42-4
Wind scre en lowe r cro ss memb er................. 42-5
Dr iving post cro ss memb er.......................... 42-6
SIDE UPPER STRUCTURE
Front pillar ................................................... 43-1
Mi ddle pillar ............................................... 43-2
REAR UPPER STRUCTURE
Rear lower panel ..... .................................... 44-1
Re ar lamp support ....................................... 44-2
In ner wh eel pa ssage..................................... 44-3
Side panel .................................................... 44-4
TOP OF BODY
Ro of ............................................................ 45-1
Wind screen fram e ....................................... 45-2
BODY PROTECTION
Engine shield ............................................... 46-1 LATERAL OPENINGS
Rear door / Front door........ . ......................... 47-1
NON – LATERAL OPPENINGS
Fr on t bo nnet ................................................. 48-1
Ha tchba ck.................................................... 48-2
MECHANISMS OF LATERAL OPENINGS
Front door-opening mechanism withelectric
control .......................................................... 51-1
Front door-opening mechanism withmanual
control .......................................................... 51-2
Rear door-opening mechanism with electric
co ntro l .......................................................... 51-3
Rear door-opening mechanism with manual
co ntro l ........................................................ 51-4
Front door electric window regulator .......... 51-5
Front door manual window regulator .......... 51-6
Re ar door window regulator ........................ 51-7
Lock ............................................................ 51-8
MECHANISMS OF NON LATERAL
OPENINGS
Front bonnet lock..... ..................................... 52-1
Ha tchb ack lock ............................................ 52-2
Pneumatic balancing device .. ..................... 52-3
GLASSES
Wind scre en glass ......................................... 54-1
Ha tchb ack glass ........................................... 54-3
Front door glasses..... .................................... 54-4
Rear door glasses ......................................... 54-5
OUTSIDE PROTECTIONS
Front bumper.......... ....................................... 55-1
Rear bumper.......... ........................................ 55-2
Hatchback handle ornament. ........................ 55-3
Body4
40
41
42
43
44
45
46
47
48
Mechanisms and accesoires5
51
52
55
54
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46
BODY PROTECTION
46 -1
Engine shield
DISMOUNTIN G
Dismount four M 6x1 – 20 Embase scre ws attached in four (3) M6x1 safety nuts on the
power train support. Release the engine shield (1).
REMOU NT I NG
Perform the dismounting operations in the reverse order.
1
2
3
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REPAIR MANUAL
DACIA
RM 525-3 SEALING, ELECTRICITY
ENGINE: E7J
G EARBOX: JH3
TA P V: B 41A, B41B, B41C
Ref: 6001999067 MARCH 2004 English version
The reparation methods prescribed by the manufacturer in the present document are established subject to
t echnical specifications in force at the document issuing date.
These a re subject to modifications brought by the manufacturer at the fabrication of different assemblies,
s ubassemblies or accessor ies of its vehicles.
All rights rese rved to SC Automobile Dacia SA.
Re production or transla ting even partia lly of this prese nt doc ume nt is forbidde n without the writte n
authorisation of AUTOMOBILE DACIA S.A.
vnx.su

INSIDE AND REAR LIGHTING
Inside and rear lighting .................................... 81-1
Ceili ng lamp ...................................................... 81-4
Bulbs ... ............................................................... 81-5
Lamps failures diagnostic ................................. 81-6
Cockpit fuse box ............................................... 81-8
UCE de co de r protection .................................. 81-10
ACCOUSTIC WARNING - ANTI STARTING
General .............................................................. 82-1
One key head replacement ............................... 82-5
Dismounting - remounting E.C.U. decoder ..... 82-6
Anti starting bushing replacement .................. 82-7
R. F. remote control for blocking/unlocking the
doors ................................................................... 82-8
Electric control unit injection replacement ..... 82-9
Acoustic warning ............................................... 82-10
Pr ocedures ......................................................... 82-12
Diagnostic .......................................................... 82-18
Diagnostic – General ........................................ 82-39
Diagnostic – Failures interpretation ............... 82-53
Diagnostic – Conformity checking ................... 82-55
Diagnostic – States interpretation ................... 82-57
Diagnostic - Damage location algorithm ........ 82-63
INSTRUMENT PANEL
Instrument panel without RPM meter ............ 83 -1
Instrument panel with RPM meter ................. 83 -2
connectors disposal ........................................... 83 -3
Pe rform functional instrument panel ............ 83 -4
Speed transducer .............................................. 83 -5
F uel level transmitter ........................................ 83 -6
Water te mperature sensor ................................ 83 -7
Diagnostic – damages interpretation .............. 83 -8
STEERING - CONNECTOR
Anti-theft mechanism ...................................... 84-1
Under steering wheel control .......................... 84-2
Re ar windows defrosting switch ..................... 84-6
Central locking switch ...................................... 84-7
Pa ssenger electric window sw itch ................... 84-8
Driver electric window switch ......................... 84-9
Hazard sw itch .................................................... 84-10
Electric lighter..........................................................84-11
WINDSCREEN WIPER
Drive mechanism ............................................. 85-1
Diagnostic ........................................................... 85-3 AUTO RADIO
General .............................................................. 86-1
T apes player ...................................................... 86-6 CD Pl
ayer .......................................................... 86-7
C onnectors ........................................................ 86-8
Roof antenna .................................................... 86-9
ELECTRICAL ASSISANCE EQUIPEMENT
Windscreen washing ......................................... 87-1
Re lays and UCE decoder asse mbly from
cockpit ............................................................... 87-2
Cockpit Central Unit ....................................... 87-4
Diagnostic – general ......................................... 87-6
Diagnostic – Failures interpretation ................ 87-11
Diagnostic - Conformity checking ................... 87-14
Diagnostic – States interpretation ................... 87-18
Diagnostic – Damage location algorithm ........ 87-26
WIRING
Airbag - general ................................................ 88-1
Airbag – Electronic control unit ..................... 88-2
Driver’s airbag .................................................. 88-6
Airbag – Special devic es ................................... 88-9
The airbag destroying procedure .................... 88-10
Airbag diagnostic – General ............................ 88-12
Diagnostic – Failure interpretation ................. 88-14
Diagnostic – Conformity checking .................. 88-20
Diagnostic – Help .............................................. 88-22
Diagnostic – Failure locating tree .................... 88-23
Fr ont door wiring protector ............................ 88-24
Re ar door wiring prote ctor .............................. 88-25
ELECTRIC DIAGRAMS
General .............................................................. 89 - 1
Functional diagrams list .................................. 89 - 6
F unctional diagrams list index ............................ 89 - 8
Connections lists - Mass list ............................. 89 - 9
Electric compone nts location on vehicle ......... 89 - 10
Ma ss attachments on vehic le ............................ 89 - 10
Electric compone nts location on the vehic le .... 89 - 11
Cockpit fuse box ................................................ 89 - 14
Fu se box from engine compartment ................ 89 - 16
Wires functions index in connectors and
couplings ........................................................... 89 - 18
Wires functions in connectors and
couplings ........................................................... 89 - 21
Wires functions explanation ............................ 89 - 9581
82
83
84
85
86
87
88
89
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61
HEATING
61 - 4
Climate control unit
DISMOUNTING
Disconnect the battery.
Dismount :
- climate control box protector;
- climate control box gasket
- gas purge vessel;
- engine air filter.
Detach from clips the front wiring from the
central part of the climate control box.
Dismoun t, then:
- attachment screws of the climate con-
trol unit on the climate control box. - attachment screws of the central part
of the climate control box.
Disconnect and release the climate control
unit from the climate control box.
REMOU NT I NG
Perform the dismounting operations in the
reverse order. Tighten t he attachment screws of the c li-
mate control unit on the climate control box, in
the sequence shown in drawing (1,2,3 ).
The required tightening moment of the at-
tachment screws of climate control unit on the
climate control box is of 0,6 daNm. Connector
2
3 1
Pin Denomination 3 Blower control speed 1
4 Blower control speed 2
5 Blower control speed 3
12 Blower control speed 4
13 Blower control speed 4
14 Mass
15 Mass
15 12
5
3
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61
HEATING
61 - 5
123
Ve
ntilation-climate control air distributor (RACV)
DISMOUNTIN G
Disconnect the battery.
Dismount :
- dashboard (see chapter 57 “dash-
board”);
- central console;
- electric windows control connectors;
- front pillars coverings;
- driving post cross beam;
- climate control box protector;
- gas purge vessel;
- climate control box gasket;
- engine air filter;
- climate control box central part from
the eight attachment screws;
- attachment screws of the climate c on-
trol unit and release the climate control blower
after disconnecting it.
- RACV attachment screws (1) on the
climate control box.
Clamp t he two hoses from the heating ra-
diator by means of the MOT 453 device.
Disconnect then the fast couplings from the
RACV heating radiator, recovering the c ool-
ing fluid. Dismou nt then:
- acoustic plate ( 2);
- mixing a nd distribution fl aps control
cables attached on RACV. Release RACV (3).
REMOU NT I NG
Perform the dismounting operations in the
reverse order. Fill up the cooling fluid and perform the cool-
ing circuit purging (see chapter 19 “ Filling –
Purging cooling circuit”).
Check :
- good operation of the flaps cables;
- good attachment of t he air ducts.
The require d tightening moment of t he
RACV attachment screws (1) on the climate
control box is of 0,6 daNm.
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