2004 DACIA SOLENZA check engine

CHARACTERISTICS
Engine – Clutch - Gearbox .................................. 01-1
Ve hicle identification .......................................... 01-2
LIFTING MEANS
M obile jack – Adjustable supports ..................... 02-1
Elevator positioned under vehic le body .............. 02-2
TOWING
All types .............................................................. 03-1
LUBRICANTS – INGREDIENTS
C ondition ............................................................ 04-1
DRAINING – FILLING
Engine.................................................................. 05-1
Gearbox .............................................................. 05-2
P ower steering ..................................................... 05-3
VALUES AND ADJUSTMENTS
Dimensions .......................................................... 07-1
Weights (kg) ........................................................ 07-2
C apacity - Quality ................................................ 07-3
Accessories belts tension ..................................... 07-4
Wheels, Tires ....................................................... 07-5
Br akes.................................................................. 07-6
Dimensions under carriage body ......................... 07-7
Checking values of the front axle angles .............. 07-8
Checking values of the rear axle angle s .............. 07-9
ENGINE ASSEMBLY
Ingredie nts............................................................ 10-1
Oil consumption ................................................. 10-2
Oil pressur e ......................................................... 10-3
Power tr ain group................................................. 10-4
Sepa ration - Gearbox .......................................... 10-9
Se para tion – Unfitting ......................................... 10-10
Tightening moments ........................................... 10-11
S pecial tools ......................................................... 10-12
C haracteristics ..................................................... 10-13
Dismounting – Remounting ................................. 10-20
Lower casing ...................................................... 10-39
Oil pump .............................................................. 10-41
Mul ti-purpose support ......................................... 10-42
DISTR IBUTIO N SYSTEM
Dis t rib ution belt ........................................................ 11-1
Cy l inder head gasket ............................................... 11-3 FUEL MIX TURE
Characteri stics .......................................................... 1 2 -1
Bo d y valve ................................................................. 1 2 -4
In let man ifo ld ........................................................... 1 2 -5
Exh aust man i fold ...................................................... 1 2 -6
Air fi l ter .................................................................... 1 2 -7 FUEL SUPPLY
Su p ply interruptio n .................................................. 1 3 -1
Fu el ramp .................................................................. 1 3 -2
Pu mp capaci ty ........................................................... 1 3 -3
Su p ply pressure ......................................................... 1 3 -4 ANTI-POLLUTIO N
Pet rol vapors re-as p irat ion ...................................... 1 4 -1
Oil vapors re-as p irat ion ............................................ 1 4 -4 ALTERNATOR – STARTER
Alternat or ................................................................. 1 6 -1
Starter ........................................................................ 1 6 -6 IGNIT ION AND INJECTION
Ig nition system ......................................................... 1 7 -1
Sp ark pl ags ............................................................... 1 7 -3
In ject ion system ....................................................... 1 7 -4
Characteri stics .......................................................... 1 7 -10
In ject ion / ai r co nditioning strat egy ......................... 1 7 -11
Id ling reg ime co rrection ........................................... 1 7 -12
Id ling reg ime ad aptive co rrection ............................ 1 7 -13
Enri ching ad justment ............................................... 1 7 -14
Enri ching ad aptive co rrection .................................. 1 7 -16
“On Board Diagnostic” system ch aracterist ics ....... 1 7 -18
“On Board Diag nostic” li ghting conditions ............. 1 7 -19
“On Board Diag nostic” di agnostic conditions ......... 1 7 -20
Diag nostic of co mbustion mis fires det ection ............ 1 7 -21
Cat alyst diag nostic .................................................... 1 7 -22
Oxy gen sensor diag nostic ......................................... 1 7 -23
Diag nostic – Gen eral ................................................. 1 7 -25
Diag nostic – Fai l ures interp retat ion ......................... 1 7 -26
Diag nostic – Hel p ...................................................... 1 7 -60
Diag nostic – Confo rmity ch ecking ............................ 1 7 -61
Diag nostic – Stat es interpret ation ............................ 1 7 -69
Diag nostic – Paramet ers interp retat ion .................. 1 7 -75
Fai l ure locat ing al gorithm ........................................ 1 7 -83 COOLING - EXHAUST - TANK
Characteri stics .......................................................... 1 9 -1
Fi l ling - Purging ........................................................ 1 9 -2
Checking ................................................................... 1 9 -3
Co o ling system diagram ........................................... 1 9 -4
Rad i ato r ..................................................................... 1 9 -5
Co o ling engine fan fo r vehicles
wit h out ai r co nditioning ............................................ 1 9 -7
Diag nostic – fai lures in terp retat ion at vehicles
wit hout ai r co nditioning ............................................. 1 9 -8
Co o ling engine fan fo r vehicles
General poinds vehicle0
01
02
03
04
05
07
Engine and péripheriques1
10
11
12
13
14
16
17
19
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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 - 4
Accessories belts tension
Belts tensioning values are:
- alternator belt 253 – 273 Hz
- compressor belt 150 – 155 Hz
- power steering pumps belt 151 – 161 Hz
- compressor belt / DA pump 222 ± 8 Hz
A ccessories belt tensioning method.
Belt tensioning is to be performed with cold engine.
Mount the new belt.
Tighten the belt till obtaining the prescribed mounting tensioning.
Block the tensioner.
Perform three engine crankshaft rotations. P lace t he reading head of the MOT 1505 device i n the m easurement area and check if the
belt tensioning is within the mounting prescribed values; restore is necessary.
REMARK :
Once a belt is dismounted, is not to be remounted, but replaced.
A – crankshaft C – Compressor T – Tensioner pulley.
B – alternator D – Power steeri ng pump – Tensioning checking point.
B
A
A D
TA C
T
T
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 2
OIL CONSUMPTION MEASURING
a) Oil filling to maximal level
This operation is to be performed when the engine is warm (one engine fan rotation) and after
a stabilization of 15 minutes, necessary to the oil complete draining into the lower crankshaft.
Check the oil at the oil-indicating rod.
Fill to the maximal level.
Seal the draining and filling taps (mark them with paint), for further checking if these have not
been dismounted
b) Customer driving time
Ask the customer to drive for about 2000 km or until the oil reaches the minimal level.
c) Refilling to the maximal l evel
This operation is to be performed when the engine is warm (one engine fan rotation) and after
a stabilization of 15 minutes.
Check the oil at the oil-indicating rod.
Fill to the maximal level.
Write down the oil quantity and the driven mileage after filling to the maximal level.
d) Oil consumption measuring
Oil filled quantity (liter)
OIL CONSUMPTION =
kilometers (thousand)
Oil con sumption
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 3
SPECIAL TOOLS
MOT 836 - 05 Oil pressure measuring kit
CHECKING
The oil pressure is to be checked when the engine is warm (about 80°C).
Oil p ressure
For the engine E7J, components C + E + F from the oi l pressure measuri ng kit
MOT 836-05 are to be used.
The minimal pressure value should be:
1 bar at idling;
3 bar at 4000 rpm.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 12
NO.DE NOM I NAT ION SERVICE DACI A
CODE ITEM NO
1O il plug wrench MOT 1018 1001101 800
2D evice for mounting the camshaft sealing gasket MOT 1127-01 1001112701
3Devic e for mounting crankshaft sealing gasket towards flywheel MOT 1129-01 1001112901
4Devic e for distribution belt tensioning MOT 1135-01 1001113501
5P liers for elastic clips MOT 1202-01 1001120 201
6Su itcase for petrol pressure checking MOT 1311-01 1001131101
7 Connection “J” MOT 1311-04 1001131104
8 Connection “K” MOT 1311-05 1001131105
9D evice for conne ction dismounting MOT 1311-06 1001131106
10 Pliers for valves oil seal ring dismounting MOT 1335 1001133 500
11 Device for checking the belt tensioning MOT 1505 1001150 500
12 Device for pi ston shaft mounting MOT 574-22 1001 0574 22
13 Sector for flywheel fixing MOT 582 1001 0582 00
14 Device for distribution gear blocking MOT 799-01 1001 0799 01
15 Device for mounting the crankshaft sealing gasket towards distribution MOT 550 1001 0550 00
16 Wrench for rockers adjustment MOT 567-01 1001 0567 01
17 Wrench for oil filter MOT 555 1001 0555 00
18 Device for power train sustaining MOT 545 1001 0545 00
19 Device for jackets maintaining MOT 484 1001 0484 00
or
Jackets maintaining clamps MOT 588 1001 0588 00
20 Comparing support MOT 251-01 1001 0251 01
21 Plate for measurement of cylinder jackets over-height MOT 252-01 1001 0252 01
Special tools
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 19
- clearance B (mm):
- minim 0.02
- maxim 0.86.
AT T E N T I O N !
Protect the distribution belt and the accessories belt in order to avoid the water and
cleaning materials splashing on them.
Chara cteristics
OIL PUMP
The oil pump is a gear wheels type.
Oil minimal pressure at 80°C is :
- at idling 1 bar
- at 4000 rpm 3 bar
Dismount the oil pump and check the
gearing clearances.
Check:
- cleara nce A ( mm)
- minim 0.110
- maxim 0.249
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 24
AT T E N T I O N !
Avoid foreign materials introduction
into the oil grooves, otherwise the latter
will clog, and consequently the rockers
s lides and cams rapid damaging.
The cylinder head flatness is checked by
means of a ruler and a kit of gauges.
Ma ximal permitted deformation: 0.05 mm.
REMARK:
The cylinder head is not to be rectifi ed.
CYLINDER HEAD ASSEMBLINGAll parts are to be lubricated with oil.
Mount the valve oil sealing rings 2 on the
valve guides 3, by means of an 11-mm
s ocket wrench.
The followings are to be mounted in order:
- washers 1 from valves springs bottom;
- new valves 4. -s
prings 5 ( identical for intake and
exhaust); - hoods 6
Compress the springs 5 then mount t he
half-cones 7 which are identical for intake and
exhaust. A
TTENTION!
N ew valves must have the same marking
8 with the old ones in order to avoid the
damaging of the seat/valve assembly.
Dismounting – Remounting
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