2004 DACIA SOLENZA Repair Manual

FRONT AX LES ELEMENTS
31
31 - 6
Suspension ball joint
DISMOUNTIN G
Perform the same operations as for dismounting the suspension arm.
Unscrew the two attachment nuts (3) of the arm shafts, without their dismounting .
Dismou nt :
- the ball joint a ttachment screws ( 4) on the arm;
- the ball joint.
REMARK :
When dismounting the suspension ball joint off t he arm, check by visual inspection
if the corresponding holes from the suspension arm, are out of round.
If they are out of round, obligatory replace the suspension arm.
REMOU NT I NG
REMARK :
Ensure the presence of t he protection pl ate (A) on the suspension ball joint axle.
Mount the suspension ball joint on the arm, by means of the two attachment screws (4) and
tighten their nuts to the required moment.
Perform then, the same operations as for suspension arm remounting, observing the tightening
moments.
PROTECTION BELLOW S REPLACEMENT
Dismount the damaged bellows.
Clean the ball joint in the area covered by
the bellows (ball joint body and pin).
Fill the new bellows with approximate 3g
MOS
2 s pecial grease.
Mount the new bellows on the ball joint.
Place on the bellows by means of a resis-
tant thread, the fixing clip (B), then the fixing
clip A (Ø= 19).
4
3A
A
B
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FRONT AX LES ELEMENTS
31
31 - 7
Brake lining (pads)
REMARK :
In order to maintain the brake efficiency,
the replacement of the brake l ining (pads)
shall be made only in complete kit. Brake pads brand TEXTAR are to be used
as spare parts.
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of a two-column
elevator.
Dismount the front wheel.
Disconnect the wear sensor wire.
Remove: - the safeties of the wedges ( 1);
- the wedges, by sliding them.
D etach the caliper assembly from the fork
together with the flexible hose.
Remove:
- the brake pads from fork seats
(maintaining springs are attached with them);
- the maintaining springs from the brake
pads. REMARK :
It is forbi
dde n t o push the brake
pedal after the c alipers were
dismounted from the fork. If the brake pads are not fully used
but on their friction surface, especially
in the middle pad channel, there are
material traces, it is recommended the
cleaning of these surfaces in order to
avoid the noise when braking. Irregularly we ar of one brake pad or
wear diffe rences between t he inner pad
the outside pad, greater than 10% of the
minimum remaining l ining, impose the
kit replacement.
SPECIAL TOOLS
FR 500 P ushing piston device
1
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FRONT AX LES ELEMENTS
31
31 - 8
Remount :
- the maintaining springs on the brake pads;
- the brake pads their places in the fork, assembled with the maintaining springs;
- the caliper
- the wedges and their locks
Pr ess several t imes the brake pedal, in order to place in c ontact the c aliper piston with the
brake pads. Mount the wheels
Get down the vehicle from the elevator.
Tighten to the required moment, the front wheels attachment screws.
FR 500
REMOU NT I NG
Push the caliper pi ston by means of the FR 500 device.
Brake lining (pads)
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FRONT AX LES ELEMENTS
31
31 - 9
Checking the brake pads wear
Point of view construction, the front brake is a ventilated disc type with floating caliper and
fork (1) attached by means of the screws to the steering knuckle.
Brake linings ( 3) ( brake pads) are “TEXTAR“ type, without wear sensor.
The wear checking i s performed by comparing the mark ( P) from the caliper, with the ( C)
mark from the fork
Maximum wear of the brake lining (brake pads) is token into consideration and their obligatory
replacement is imposed, when the protuberance ( P) from the caliper ( 2) is as seen in “D” close-
up, against the middle of the channel “ C” from the fork (1).
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FRONT AX LES ELEMENTS
31
31 - 10
Brake caliper
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of a two-column
elevator Dismount the wheel.
Drain the brake fluid from the reservoir
Remove the locks and the caliper wedges.
Un screw the rigid duct screw from the
brake flexible hose and detach the caliper
assembly.
REMARK :
If it is necessary to dismount the
cali per fork, di sm ount the at tachm ent
sc rews on the caliper fork.
When remounting the fork, replace the
Grower washers, tighten the screws to the
r equired moment of 6.5 daNm then seal
them with FIXAMED R 58.
RE PAI R ING
Dismount the protection gasket.
Extract the piston using a wooden wedge and
a compressed air source.
Remove the sealing gasket from its seat in the
caliper groove by means of a blade. Clean with alcohol the parts, replace t he
damaged ones, mounting being performed in the
dismounting reverse order, after previously all
parts have been oiled with brake fluid.
REMARK :
Before remounting on the fork, check the
sealing of t he assembled caliper.
TIGHTENING MOMENTS (d aNm)
Wheel screws 7.5
Rigid duct on fr ont flexible screw 1.5
Purging screw 1
Flexible hose - caliper 1.7
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FRONT AX LES ELEMENTS
31
31 - 11
Brake caliper
REMOU NT I NG
Perform the dismounting operations in the reverse order plus the following operations:
- filling of the caliper with brake fluid in order to facilitate the brake system purging;
- purging the brake system.
BRAKE CALIPER SEALING CHECKING
Connect to the caliper, a pressure gauge attached to a compressed air source.
Place a wooden wedge in order to block the piston
Create a 0.3 bars pressure in the caliper
Dip the caliper into a vessel with alcohol.
Move the piston several times to remove the air from the sealing gasket seat.
Check the sealing at various pressures, without exceeding the pressure of 2 bars.
If the brake shows air leaks by the piston, perform its dismounting.
Replace the piston, the ga sket, or the caliper body, as the c ase stands.
Perform again the sealing test.
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FRONT AX LES ELEMENTS
31
31 - 12
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of a two col-
umns elevator Dismou nt :
- the wheel;
- the two attachment screws (A) of
the brake disk assembly on the steering
knuckle ; -the two sunk screws (B) attaching the
disk on the hub.
Brake disk
REMARK :
The brake disks can be not rectified.
A bigger wear or an important mark on the brake disk braking surfaces impose obligatory its
replacement.
- The minimal accepted thickness: 19 mm;
- The maximum accepted axial deviation 0.04 mm on a diameter of Ø 215.
TIGHTENING MOMENTS (daNm)
Brake caliper fork attachment screw on steering knuckle 6.5
Di sk attachment screw on the hub 1.4
Front wheel steering knuckle nut 28
Wheel screws 7.5
R EMOU NT I NG
Remount :
- the disk on the hub by means of the two
sunk screws (B) and tighten them to the required
moment; - the brake disk assembled on the steering
knuckle, tightening the ( A) screws to the required
moment. Press the brake pedal several times, in order
to bring the piston in contact with the brake pads.
REMARK :
In case of replacing the brake disk it is
absolutely necessary to replace the brake
pads ( TEXTAR brand).
A
B
Di sm ount the brake disk. Before
remounting, check :
- the wear of the brake flexible hoses;
- t he we ar of t he bra ke pa ds and
replace them if necessary.
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FRONT AX LES ELEMENTS
31
31 - 13
SPECIAL TOOLS
Hub disk extractor PF 600
Ball joint extractor PF 476
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of an elevator with
two columns
Dismou nt :
- the wheel
- the bra ke disk a ssembly together with
the flexible connection;.
- the transmission gear nut;
- the bra ke disk assembly by means of
the PF 600 extractor.
Continue by dismounting t he steering
knuckle, observing the operations sequence: - dismount the steering ball joint nut;
- depress the steeri ng ball joint by
means of the PF 476 extractor;
- dismount the two screws that attach
the steering knuckle on the shock absorber
leg;
- dismount the attachmen t screw of the
steering ball joint – steering knuckle;
- detach the steering knuckle.
TIGHTENING MOMENTS (d aNm)
Wheel attachment screw 7.5
Steering ball joint nut 4.0
Transmission nut 28.0
Attachment fork screw on steering knuckle 6.5
Screw nut of the steering knuckle
attachment with the shock absorber leg 10.5
Attachment screw nut of the b all
joint with the steering knuckle 6.2
Steering knuckle
PF 476
PF 600
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