2004 DACIA SOLENZA tow

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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03 - 1
03
TOWING
AT T E N T I O N !
NEVER USE AS T OWING P OINTS, THE TRANSMISSION AXL ES (P L AN-
ETARY SHAFTS).
The towing points, front, or rear, are to be used only for vehicles towing on wheels.
These poi nts cannot be a nyhow used for drawing out the damaged vehicle from a trench
(hole), or for direct or indirect vehicle lifting on a transport platform.
FRONT (right) REAR (left)
All types
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VA LUES AND ADJUSTMENTS
07
07 - 2
Optional e quipment weight disposal on shafts axles

Fr ont axle Rear axle
Air conditioning 230
Power steering 170
We i g h ts (kg)
Ve rsion
V ehicle type
Unloaded vehicle weight
Maximum authorized weight
on axle
Maximum technical
admissible weight of the
loaded vehicle
M aximum technical admissible towing
weight (trailer without braking system)
Maximum technical admissible towing
W eight (trailer with braking system)
Maximum admissible weight of the
assembly
Maximum load on towing hook
T owing hook weight 1,4
R5A715
1035592
443
1075 632
443 730
800
1450 718
732
450
800
2250 2260
40
20 R5A716
1045602
443
1085 642
443
1460 728
732
Minim
Front
Rear
Maxim
Front
Rear
Front
Rear
Total
Front
Rear
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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 - 16
PISTONS
The bolt is fix mounted in the connecting rod
and free in piston.
Mounting direction: with the arrow towards
flying wheel. There are three matching classes with the
jacket.
Markings on pistons:1 – arrow towards flywheel
2 – piston class (A-B-C)
3 – items used by the supplier
Pistonclass Piston diameter (mm) Jacket diameter (mm)
A 75.765 - 75.775
*75.8 - 75.81*
B75.775 - 75.785*75.81 - 75.82*
C 75.785 - 75.795 75.82 - 75.83
The piston diameter is measured at the value
A = 46 mm.
Chara cteristics
* - these values are not included in classes.
Jacket marking
GreenBl ue
Red
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 29
Dismounting – Remounting
The over-he ight X must be between 0.02
mm and 0.09 mm.
Place the jackets in such way that :
-the difference between two joint jackets
to be maximum 0.05 mm;
- the over-height to be in ascending order
between cylinders 1 and 4;
- in case of an incorrect over-height, check
the over-height by m eans of a new kit of jack-
ets, i n order to see i f t he c ause i s the block or
the cylinders jacket or check the theoretical size
values of the block and of the jackets. When over-height is correctly obtained, per-
form the A, B, C, D assembly then mark with
numbers jackets, pistons and the bol ts from 1
to 4 (no.1 towards flywheel) so that the corre-
s pondence with the corresponding connecting
rods may be achieved.
Pistons bolts mounting
The pistons bolts are fixed in connecting rods
and free in pistons. Mount the pistons bolts by means of the
MOT 574-22 that is containing:
- a support for piston ( S);
- an extracting mandrel ( M);
- the piston supporting bushings (B);
- the bolts for mounting ( A) provided with
their centering guides (C ). Use an electric plate of
1500 W (electric
oven) for connecting rods heating. Place the connecting rods on the electric
plate so that connecting rod end surfaces are
in contact with the heating plate.
Check if the pistons bolts are freely gliding
in the new corresponding pistons. Mount the piston bolt E on the mounting
bolt A.
Sc rew the centering guide C till end and
then unscrew it for a quarter of turn.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 30
The arrow marked on the piston head must
be oriented towards engine flywheel. The c onnecting rods ha ve no mounting
direction, but the ha lf-bearings spurs are to
be positioned on the same part. In order to assemble the piston and the
connecting rod, proceed as follows: -place the bushing B 13 on the support
and attach the piston (with the arrow oriented
upwards) on the bushing;
Dismounting – Remounting
- lubricate the centering guide and the
piston bolt with engine oil;
- check t he free gliding of the piston
bolt and the piston positioning.
When the connecting rod end is reaching
the necessary temperature (about 250 °C),
proceed to the ra pid of the piston bolt, as
follows: -introduce the centering guide in the
piston; - position the connecting rod i n the
piston;
-press till end the piston bold.
Check if the pi ston bolt is remaining re -
tired as against the piston outer diameter for
each of the connecting rod position in the pis-
ton.
Rings mounting
Mount the rings on the pi ston in the
following sequence: -
oiling ring ( 3);
-s ealing ri ng (2) w ith the mark “TOP”
upwards; -compression ri ng (1) with t he mark
“TOP” upward. The compression and sealing rings are to be
mounted with the slots disposed at 90° against
de bolt’s axle and displaced between them with
180°. The oiling ring is to be mounted with the
slot oriented at 45° against the bolt’s a xle.
The rings slots being adjusted, shall never be
reworked.
Lubricate the pistons with engine oil.
M ount the assemblies “connecting rod-
piston-rings” in the cylinder’s jackets, by means
of the mounting bushing. Mount the sealing gaskets on the cylinder
jackets.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 32
The axial bearings may have the following
thickness: 2.80, 2.85, 2.90, 295 mm.
M ount the connecting rods caps and
tighten to the required moment of 4.2 daNm.
Check:
-connecting rods lateral clearance;
- assembly rotation.
Mount: -gear and driving chain of the oil pump;
- oil pump (check the existence of the
centering bushings) and tighten the screws to
the required moment of 2.5 daNm;
Dismounting – Remounting
MOT 550
- the crankshaft closing casing; the
sealing is performed using LOCTITE 518 (
the layer H must be 0.6 – 1 mm thick);
- sealing gasket from crankshaft clos-
ing casing (lubricated with oil) by means of
the MOT 550 device;
-crankshaft sealing gasket towards fly-
wheel (at no. 1 bearing) by means of the MOT
1129-01 device. Lubricate the sealing gasket external part
and lip with engine oil.
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