2004 DACIA SOLENZA steering wheel adjustment

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 - 7
Dimensions under c arriage body
DIMENSIONS UNDER CARRIAGE BODY CONDITIONING
ADJUSTMENT OPERATIONS OF THE STEERING ANGLES
H1, H4 - to be measured in front wheel axle, consequently rear wheel axle.
H2 - to be measured between the lower side of t he power train support.
H5 – to be measured between the elastic joint axle of the rear a xle arm and the ground.
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VA LUES AND ADJUSTMENTS
07
07 - 8

Checking values of the front axle angles
ADJUSTMENTS
N
ot adjustable
N ot adjustable
N ot adjustable
Adjustable by
rotating the tie rod of the
steering rod
-
VE HICL E
POSITION
H5 - H2 = 100
H5 - H2 = 90
H5 - H2 = 80
H5 - H2 = 70
H5 - H2 = 60
H1 - H2 = 105
H1 - H2 = 98
H1 - H2 = 91
H1 - H2 = 85
H1 - H2 = 78
H1 - H2 = 71
H1 - H2 = 64
H1 - H2 = 105
H1 - H2 = 98
H1 - H2 = 91
H1 - H2 = 85
H1 - H2 = 78
H1 - H2 = 71
H1 - H2 = 64
N ot loaded
N ot loaded
VALUES
0
0 0 3'
0020'
0036' ± 30'
005 3'
101 0'
Right / left maxim
difference = of
10
-00 16'
-0010'
-0002'
0006' ± 30'
0015'
0024'
0035'
Right / left maxim
difference = of
10
130 36'
13025'
13014'
13003' ±30'
12050'
12038'
12024'
Right / left maxim
difference = of
10
Toe in:
0010' ± 10'
(for one wheel 0
005' ± 05')
-
ANGLES
CAMBER
CASTER
BALL JOINT
TOTAL PARALLELISM
ELASTIC BUSHINGS TIGHTENING
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VA LUES AND ADJUSTMENTS
07
07 - 9
Checking values of the rear axle angles
ADJUSTMENTS
Not adjustable
N ot adjustable
VEHICLE
POSITION
Unloaded
Unloaded
Unloaded
VA L U ES
0030' ± 10'
(For two wheels) Cl osing
0
030' ± 10'
2,9 mm ± 1 mm
ANG L E S
CAMBER
PARALLELISM
ELASTIC BUSHINGS TIGHTENING
PRELIMINARY OPERATIONS TO BE OBSERVED BEFORE
CHECKING THE STEERING ANGLES
1. Area (checking surface) – it must be a s horizontal as possible.
2. Wheels, tires – check (from e quipping point of vi ew) to have same type of wheels and
tires on bot h axles (dimensions, inflating pressure, wear de gree). A pronounced wear i s not
allowing the correct horizontal positioning.
3. Suspension – check the shock absorbers, springs condition and height symmetry under
carriage body.
4. Joints – check the e lastic joints condition, steering and suspension ball joints clearance,
bearings clearances of the front and rear axles 5. Radial and axial run out of the wheels – must not be over 1 mm. This will be compensated
with the reading instruments. 6. Manufacturer’s method – each vehicle manufacturer is providing the checking conditions,
axles weights repartition, and presentation of under carriage body heights, not loaded.
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GENERAL
30 - 16
30
The influence of angles
The influence of different angles over the road behavior, stability and abnormal wear preventing
of the vehicles tires.
CAMBER
The exit from the tolerance field of the left or right wheel camber, may have as result:
- tires external or internal edge wear (excessive positive or negative camber);
- steerin g is deviating towards the camber angle is more pronounced (asymmetry ), a deviation
from the trajectory is taking place, which must be corrected by means of the steering wheel (the
pronounced wear on the tire in question is occurring);
CASTER
A larger difference of 1° between the right side caster and left side, may have as result:
- a deviation from the trajectory, which must be corrected by means of the steering wheel, the
abnormal tires wear (the pronounced wear on the tire in question is occurring), tough steering,
instability when turning.
PA R ALLELISM
This adjustment has little importance over the vehicle road behavior.
Anyhow, note the followings:
-a prominent closing may lead to tires external edges wear.
-a prominent opening may lead to tires interior edges wear.
DIMENSIONS UNDER CARRIAGE BODY
These are especially influencing the different angles of the steering geometry.
A vehicle, which has run a large amount of km, it will have under the carriage body, dimension s
smaller than a new vehicle. This is the reason why some vehicle manufacturers, are prescribing, when the checking is
done with empty vehicle, different under carriage body dimensions and their respective places
where these values must be taken. Other vehicle manufacturers are recommending the suspension
compression by means of special (specific) tools or loading repartition in different places.
These different procedures (as performing ways) have as final purpose, the cancellation of the
vehicle suspension lowering, which has driven an important number of Km, compared with its
initial condition.
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36
STEERING ASSEMBLY
36 - 4
Steering box pusher
ADJUSTMENT
When a noise is found in the area of the
st eering box pusher, it is obligatory to per-
form its correct adjustment.
1. Noise identification (clattering).
Hold by ha nd the rack in pusher’s side and
check the tra nsversal c leara nce (up-down). A
noise in the pusher’s area might occur while driv-
ing, caused by a clearance followed by a noi se
(clattering). If the clearance at the pusher is bigger than
0.31 mm, adjust the cleara nce and/or dismount
the steering box and eliminate the cause.
2. Checking and adjustment of the
push er’s clearance.
The pusher adjustmen t is to be performed tak-
ing into consideration both the rack wear and the
pusher’s wear:
- bring t he ra ck i n the minimum radial
runout position; - position the fe eler of a comparative
gauge on the cylindrical part of the rack ( oppo-
site to the threaded part) in the area of rack exit
from casing ( gear side); - rotate the gear on the whole rack length
and establish the minimal runout point, where the
value read on the gauge is minimal; - adjust the comparing gauge to zero;
- by means of a 17 mm fi xed wrench,
rotate the rack from the opposite end unt il the
pusher is in contact with the thre aded plug( a
higher wrench effort may be noticed for a re-
duced movement red on the comparing gauge);
- read the value shown by the comparing
gauge which must be smaller than 0.31 mm.
The pusher clearance adjustment is performed in
the minimal runout point by rotating the threaded
plug ( 4) to a moment of 1± 0.2 daNm and un-screwing ˘ rotations, then secure it by bead-
ing (caulking) in “S” area.
When mounting, put 23 ± 5 cm
3 grease
UM 185 Li2M for : rack, gear, sealing ring
and pusher’s spring, inner surface of t he
threaded plug. Check the operation and check also during
driving if the steering wheel is returning at the
straight line driving position (steering central
point).
1. Pusher
2. “O” ring
3. Spring
4. Threaded plug
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36
STEERING ASSEMBLY
36 - 11
Power steering box pusher
When an excessive rack clearance,
followed by clattering in the steering box is
occurring, before replacing the steering box,
the pusher with rack is to be adjusted. 1. Noise (clattering) identification.
Lift the vehicle by means of a two-column
elevator; On the pusher side:
- dismount the bellows attachment clip
on the steering box casing;
- push the bellow towards the steering
rod; - hold by hand the rack rod and check
the transversal clearance (up- down). A clearance followed by a noise (clatt ering)
is leading to a pusher noise, during driving. 2. Adjustment
Straigh ten th e caulking (A) of t he
adjustment nut bead (1).
By means of a 10 mm hexagonal wrench,
tighten the adjustment nut until there is no more
clearance.
AT T E N T I O N !
Do not tighten the nut more than 3
teeth.Check if the rack is freely moving all the
length. Bend the adjustment nut bead in the two
opposite slots of the steering box casing, ensuring
in this way its unscrewing.
Positio n the bellows on the steering box casing
and mount a new attachment clip.
Lower the vehicle from the elevator with
wheels on the ground.
Check, during driving if the steering wheel is
coming back to the steering center point.
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