2004 DACIA SOLENZA gas type

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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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 17BOLTS
Length (mm)
60
External diameter (mm) 19
Internal diameter (mm) 11
CYLINDER JACKETS
T ype: wet removable.
The sealing gasket is J rubber ring type.
Internal diameter (mm) 75.8
Jacket height (mm) H2 130
Centering diameter (mm) D80.6
Jackets over-height X without
gasket (mm) 0.02-0.09
Jacket height (mm) H1 91.5
Deep in cylinder block K1 (mm)
91.5+ 0 ,03
Chara cteristics
+ 0 ,035
+ 0 ,005
- 0 ,015
- 0 , 055
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IGNITION AND INJECTION
17
17 - 3
ENGI NE BRAND TYPE
E7J - 262 SAGEM RFC 52 LZ
Di stance between electrodes: 0.9 mm
Tightening moment: 2.5 - 3 daNm
Flat seat with gasket
Spark plags
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 20
DIFFERENTIAL
The differential of the
JH3-051 gearbox is the simple type (with two satellites and two planetary
wheels, one of which making a common body with the tulip of the planetary transmission).
This differential is supported in the clutch – differential crankcase by means of two cylindrical
bearings equipped with balls of various sizes.
The two bearings are pressed in the clutch – differential crankcase.
The crown of the main transmission is assembled by hooping, on the differential crankcase.
DIFFERENTIAL DISMOUNTING
This operation is to be performed after separating the crankcases.
The zero ring (1) is removed from the right planetary shaft, then by means of a pins extractor
and a hammer, the sealing gasket (2) is gently hit in order to make it pivoting.
The oil seal ring is carefully pulled along the grooved part of the planetary pinion in order not
to deteriorate t he grooves.
G earbox dismounting
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TRANSM ISSION
29
29 - 5
Bellows - Bearing assembly
to th e gearbox
Using a press, extract the assembled tripod,
sustained it on an extractor, FACOM U 53 G
type, protecting the tripod clogs.
Before extracting, mark the position of the
tripod compared to the transmission shaft end.
Dismount the bellows - deflector bearing in
the same manner like tripod dismounting .
REMOU NT I NG
In order to be corre ctly positioned on the
s haft, the bearing must be pressed to achieve
the value L = 118 ± 0.2 mm between the
backside of the bearing and the shaft extremity.
This value is obtained by means of the PF 1331
device, when mounting, its extremity is at the
level of the shaft.
IMP ORTANT:
In order to avoid the deformation of the bearing, which includes a sealing gasket
(annular oil seal), the pressing effort must be constant (do not hammer).
Left
transmi ssion
GPF
1331
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40
GENERAL
40 - 10
Plate thickness( mm) Welding current(KA) Welding time(per) Tightening force(daNm)
0,5 6,55130
0,8 8,08200
1,0 9,510 250
1,25 10,510295
1,5 10,0 14310
2,0 12,0 16350
Plate thickness (mm) 0,6 1,0 1,5 2,0
Electrode di ameter (mm) 0,6 0,8 0,8 1,0 0,8 1,0 0,8 1,0
We l d ing wire speed (m/min) 2,5 1,9 3,2 2,4 4,4 3,8 5,7 4,4
Welding wire speed (A) 35 35 55 80 80 120 100 130
We l d ing speed (m/min) 0,25 0,25 0,35 0,33 0,33 0,50 0,45 0,45
We l d ing voltage (V) 17 17 18 18 19 19 20 20
Protection gas flow (1/min) 12 - 17
Elec trode free length (mm) 6 - 12
joint plates
welding butt welding fillet
welding
0- 1, 5m m 0- 1, 5m m
We
ldin g types and parameters
At the reparation of the welded body elements, three welding categories may be used: protection
gas welding (CO2), electric spot-welding and filling materials (built-up) welding (oxyacetylene).
At the built-u p welding, it is recommended that flame must be slightly inclined so that arch can be seen
and the flame extremity to be maintained at aprox. 5 mm from the part to be welded.
1. Spot welding resistive parameters for steel plates with carbon content C < 0,15 %.
R EMARK :
1 peri od = 1/50 part of a second.
2. We lding parame ters for the welding in protection gas for carbon steel plates or low-allo ye d steel.
Horizontal welding position (pict.1)
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40
GENERAL
40 - 11
Plate thickness 0,612 2,0
Electrode diameter (mm) 0,6 0,8 0,8 1,0 0,8 1,0
Welding wire speed (m/min) 2,5 1,9 3,3 3,2 5,7 4,4
W elding current (A) 35 35 70 100 100 130
We l ding speed (m/min) 0,25 0,25 0,38 0,48 0,50 0,50
W elding voltage (V) 17 17 18 18 20 20
Protection gas flow (1/min) 12 - 17
Electrode free length (mm) 6 - 12
REMARK :
In case of using the Ar + CO2 mixture, the welding voltage will decrease with 2
V.
Vertical welding position (obligatory from top to bottom)- pict. 2
We ldin g types and parameters
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88
WIRING
88 - 2
AIRBAG OPERATION
When setting the contact on, the airbag system
control indicator from the instrument pa nel is
lighted for 3 seconds then it is off.
UCE airbag is entering in a lookout state and
is considering the vehicle decelerations due to a
s ignal m easured by an integrated e lectronic
decelerometer.
In case of a stronger frontal impact, the
security electromechanical captor is tripping the
igniter of the pyrotechnic gas generator, which is
inflating the driver’s airbag. The airbag system is not releasing in case of a
s ide impact or a re ar impact.
When started, the pyrotechnic gas generator
is generating a detonation and some smoke.
IMPORTANT!
This system must be checked by means of the
CLIP tester, immediately when:
-a n accident did not caused the
movement, -the ve h icle was stolen or a stilling tentative
has been produced. -before selling a second hand vehicle.
AIRBAG INDICATOR FROM INSTRUMENT PANEL
This indicator is showing the operation state of
the driver’s airbag.
It is lighted for 3 seconds from contact setting
on, and then it is getting off and it staying like this.
If it is not on when setting the contact on or it is
on during vehicle driving, this is indicating a failure
in the system (see chapter “Diagnostic”) .
After driver’s airbag releasing, the airba g
indicator from the instrument panel is on and UCE
airbag is automatically bl oc king the driver’s airbag releasin
g line, memorizing the releasin g.
That is why, after an impact generating the
airbag re leasing, i t is necessary the UCE
airbag unblocking, then the computer blocking
in order to block all releasing.
The erasing of the memorized failures it is
possible only aft er data reading from “Im-
p act context” , then the shock sensor con-
tact is restored and the c ontrol “Computer
unblocking” may be performed.
UCE AIRBAG
DISMOUNTING – REMOUNTING
UCE airbag is mounted on the tunnel in
front of the gearbox lever. UCE air bag is provided with: -a security electromechanical captor,
-a decelerometer for airbag
- an ignition circuit of the pyrotechnic
system -an electric energy reserve,
-a diagnostic and memorizing circuit
of the detected failures, -a control circuit of the alert indicator
from instrumen t panel.
-A K-L communication interface with
the diagnostic socket.
UCE AIRBAG BLOCKING
Connect the CLIP tester to the vehicle,
the contact being set off. Set the contact on.
Block the UCE airbag: -select the menu “ Diagnostic”
- select and validate the vehicle type.
-s elect and validate the diagnostic
system “Airbag / Pre-tensioning systems”.
Airbag – Electronic control unit
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