2004 DACIA SOLENZA brake fluid

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
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VA LUES AND ADJUSTMENTS
07
07 - 6
Brakes
Veh icl e
Normal
20 Minim
19 Normal
228 Minim
229 Front
0.04 Rear
-
Brake disk width and drums diameter (mm) Front Rear Maxi
m disk
axia l run out
Veh icl e
Normal
14 Minim
7 Normal
5 Minim
0.5 mm
above the
rivets SAE J 1703
DOT 4
Gaskets thickness (mm)
Front Rear Bra ke fluid
SOLENZ A
SOLENZ A
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GENERAL
30 - 6
30Composition and dimensions of the main
braking system elements
Front brakes
- brake caliper bore diameter → 54 mm
- brake disk diameter → 235 mm
- disk axial runout measured at → 215 0. 04 mm
- brake disk maximal thickness 20 mm
- brake disk minimal thickness 19 mm
- braking pad thickness (support included) 14 mm
- brake pad minimal thickness (support included) 7 mm
Rear brakes
- wheel braking cylinder bore diameter → 22 mm
- new drum diameter → 228 mm
- drum diameter after grinding → 229 mm
- braking shoes lining width 40 mm
- braking shoes lining thickness 5 mm
- minimal accepted braking lining height above rivets 0.5 mm
Master cylinder
- diameter of bore 20.6 mm
Brake fluid reservoir without alarm sensor
Pressure limiter for circuit in parallel
S ervobrake master vac 7" 177.8 mm
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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
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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
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GENERAL
30 - 13
30Brake fluid
PERIODIC CHANGE OF THE BREAK FLUID
The m anufacturing conception of t he brakes equipping t he Dacia vehicles especially the
ventilated disk brake, enable the maximum diminishing of the fluid vaporization, even in case of
intensive using of brakes (mountain area), due to good disk cooling.
The brake fluids, suffer in all cases a slight degradations during the use, by a slight humidity
absorption, that makes necessary the complete replacement after a period of time or after some
driving (4 years or 60,000 driven km)
COMPLETION OF THE BRAKE FLUID LEVEL
The wear of brakes pads and shoes, leads to a gradually diminution of brake fluid level in its
reservoir. It is useless to compensate this diminution, because the level will be restored when changing
the brake pads and shoes.
Obviously , in the meantime, the level of brake fluid in reservoir must not go down bellow the
MINI mark.
HOMOLOGATED BRAKE FLUIDS
The mixture in t he braking circuit of two non different brake fluids may leads to important
risks mainly due to gasket damage, incompatible with new fluid.
In order t o a void such risks, it is obligatory to use only bra ke fl uid re commended by the
producer, i.e. : SAEJ 1703, DOT 4.
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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.
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GENERAL
30 - 15
30Braking system purging
OPERATING CONDITIONS
The vehicle is on ground, in rear axle half-loaded position.
CHECKING THE BRAKE SYSTEM SEALING
The vehicle will be idle running.
After purging the front and rear circuits, check if the level of brake fluid in reservoir is within
the MIN I and MAXI marks. Press the brake pedal and maintain it constant for 30 s, during this
time the pedal shall not change its place.
In case leaking is occurring, check by visual inspection all the elements of the braking system,
eliminate leaking and restart a.m. operations.
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