2004 DACIA SOLENZA brake pads

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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TRANSM ISSION
29
29 - 3
Front transversal transmission
REMOUNTING – THE SIDE TO THE GEARBOX
The left side
Engage the transmission GI joint in the gearbox (the transmission position as horizontally as
possible).
Mount the three attachment screws of the bellows l id on the gearbox.
The right side
Grease the tulip frame grooves (the grooves area) and the transmission shaft of the gearbox
with transmission oil.
Engage t he tra nsmission GI joint (t he tulip) on the transmission shaft of the ge arbox (the
transmission position must be as horizontally as possible).
REMOUNTING – THE SIDE TO THE WHEEL
For both sides
Engage the transmission in the steering knuckle, this one being necessary to freely enter, so that
threaded area of the steering knuckle is allowin g to remounting the transmission nut.
Perform then the dismounting operations in the reverse order.
Observe the tightening moments.
Remount the brake disk assembly.
Refill the gearbox with oil.
Press several times the brake pedal to enable caliper piston coming in contact with the brake
pads.
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GENERAL
30 - 8
30
1

I. FAILURE : RIGID PEDAL (ctd)
One of the rigid
brake pipes is it
smashed ?
Dismount the brake caliper or
the brake cylinder?
Replace the corresponding rigid
pipe.
Ar e the br a ke
caliper’s pistons or
the cylinders ones
correctly gliding ?
STOP
Replace the defective parts
(with Genuine Spare Parts)
Replace t he brake pads, conse-
quently the brake shoes (see
bellow situations).Are the brake pads,
consequently the shoes
gas ket in good condit ion?
The brake linings are to be replaced when
they are: -greasy -shiny
-not in accordance with the
manufacturer ’s prescriptions (genuine Spare
Pa rts have not been used).
Ye s Ye s
No
No
No
Braking system diagnostic
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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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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 - 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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