2004 DACIA SOLENZA Repair Manual

19
19 - 22
COOLING - EXHAUST - TANK
Fuel pump
SPECIAL TOOLS
MOT 1397 Wrench for dismounting the fuel pump assembly nut
TIGHTENING MOMENTS (d aNm)
Fuel pump assembly nut 7
IMPORTANT
During the intervention on the fuel tank or on the
fuel supply circuit, it is absolutely necessary:
-n ot smoking and not bringing near any incan-
d escent parts in the working area;
-gu ard against possible petrol leakage, due to
residual pressure remained on piping, when
dis mounting.
DI SMO UNT I N G
In order to dismount the fuel pump assem bl y it is
not necess ary the tank dismounting, the access being
done t h rough the vehicle trunk.
In order to do that:
-d isconnect the battery;
-d ismount the attachment screws of the fuel
tan k v isiting cover;
-d isconnect the electric connector (B) of the
fuel pump assembly supply;
-d isconnect the rapid coupling (A) of t he fuel
supply pipe. Dismount the fuel pump assembly (2) attachment
nut (1), by means of the MOT 1397 device, after
1
2
p reviously marking on the fuel tank the position of
the arrow existing on the pump cap.
Release the fuel pump assem bl y.
REMOUNTI NG
Mount the fuel pump assem bl y on t he fuel tank
obs ervi ng the marking done when dismounting.
Mount the attachment nut of the fuel pump
assembly. Tighten the nut by means of the MOT 1397
device, so that the arrow from the nut meets the
arro w from the fuel pump assembly (this is ensuring
the minimal necessary tightening for sealing
achi ev ement.
REMARK :
After each dismounting, obligatory
replace the nut and its gasket.
The gasket will have the same color with the
dismounted one.
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19
19 - 23
COOLING - EXHAUST - TANKFuel pump
VEHICLES WI THOUT VISITING CAP
SPECIAL TOOLS
MOT 1397 Wrench for pump assembly dismounting- remounting
TIGHTENING MOMENTS (daNm)
Fuel tank attachment screws 2.1
Pump assembly attachment nut 7
In order to dismount the fuel p ump as-
sembly, it is n eces s ary th e fuel tank dis-
mounting.
IMPORTANT
Duri ng this operation it is compulsory:
-n ot smoking and not approaching
with inca ndescent objects in the working
area, - keep away from fuel spraying when
disconnecting the fuel connections, -protect the sensitive area of fuel leak.
DISMOUNTIN G
Dismount the fuel tank.
Dismount the attachme nt nut of the fuel pump
assembly by means of the wrench MOT 1397.
Dismount the fuel pump assembly
AT T E N T I O N !
When dismounting the nut, take c are that
fuel pump assembly i s not geared in rotation
with t he nut, which may lead to float rod
di st ortion and c onseque ntly t o fuel l evel
wrong indication.
Remark:
If until fuel pump mounting on t ank,
more than an hou r is taken in to
consideration, remount the nut on t he
tank, in order to avoid any distortion.
R EMOU NT I NG
Replace the sealing gasket of the fuel
pump assembly. The gasket shall have the
same color with the dismounted one. Mount the fuel pump assembly so that
arrow (1) from t he fuel pump assembly i s
corresponding to the arrow (20 from the
tank.
Position the nut and tighten it by hand to
maximum possible, pre venting t he pum p
assembly rotation.
Tighten the nut by m eans of the MOT
1397 wrench until arrow (3) from the nut is
aligned with the marks from fuel tank a nd
pump assembly .
2
3 1
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19
19 - 24
COOLING - EXHAUST - TANKFuel filter
For de-pollution norm 1504
The fuel filter is attached on the front side of the fuel filter.
It is recommended, the fuel filter replacement, every 20 000 Km.
For EURO 2 and EURO 3
The fuel filter is mounted on the fuel pump assembly placed in the fuel tank.
Its replacement is implying the replacement of the entire fuel pump assembly (1).
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19
19 - 25
COOLING - EXHAUST - TANKEngine suspension
TIGHTENING MOMENTS (daNm)
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20
CLUTCH
20 - 1
Identification
CHARACTERISTICS
- Single disk dry clutch cable controlled.
- Clutch mechanism with diaphragm spring.
- Clutch disk with elastic hub.
- Pressure bearing with balls permanently in contact with the diaphragm (constant pressing
force).
Vehicle type Engine
type Mechanism Disk
E7J
S OLENZA
180 CPO 330026 grooves V: Green
D
= 181.5 mm G: Grey
E = 6.8 mm
D
V
G
V
V G V
E
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CLUTCH
20
20 - 2
Diagnostic
GEARS ENGAGING PROBLEMS
Check t he c lutch disk re lease (see the
checking method bellow described.)
Is the release corre ct ?
Check the adjustment of the gearbox
extern c ontrol lever (adjust if ne cessary).
If the problem is persisting.
Check the clutch releasing fork stroke
(see the method bellow descri bed). Is the fork stroke correct?
Int e rna l probl e m i n the ge arbox
(repair t he gearbox) .
Replace the clutch .
Pr
oblems at clutch
control pedal.
Check:
- pedal re turn,
- control cable.
(Fix if necessary).
No
No
Ye s
Ye s
C HECKING METHOD
“ DISK RELEASE “
The checking is to be performed at idling, with warm engine. - release the clutch,
- wait for thre e seconds,
- engage the reverse dri ving (engagement must be performed without noise).
CHECKING METHOD
“ CLUTCH RELEASING FORK STROKE “
By means of a lineal perform the following operations:
- measure the distance between the fork upper part and the clutch cable support, in the
clutched position;
- measure the distance be tween t he fork upper part and c lutch cable support, in t he
clutch releasing position;
- calculate the differe nce between the t wo values (the fork active stroke) and compare i t
with the re ference value ( 29 mm).
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20
CLUTCH
20 - 3
Diagnostic
EFFECT OF TREPIDATION
Check for oil leaks at the clutch
casing level.
If there are no leaks.
Check the tightening and the
c ondi t i on of t he ge arbox a nd e ngi ne
supports (fix it if necessary).
If the incident is persisting.
Che c k t he c l utch c ont rol (fi x it if
necessary).
If the incident is persisting.
Check the idle regime (unstable or
incorrect).
Fix it if necessary.
If the incident is persisting.
Replace the clutch. F
ix the oil leak and replace the c lutch
disk if necessary.
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CLUTCH
20
20 - 4
Diagnostic
NOISE AT FREE CLUTCH
(oppressive and regular noise subject to engine regime)
Check for oil leaks at clutch casing
level.
If there are no leaks.
Check the tightening and condition
of the gearbox and engine supports
( fix it if ne cessary).
If the incident is persisting.
Check the engine running at idling
(unstable or i ncorrect).
Fix it if necessary. If the incident is persisting
Fi x t he oi l lea k and re pl a c e t he
clutch disk if necessary.
Replace the clutch.
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