Dacia Solenza 2004 Repair Manual
  1. Manuals
  2. Brands
  3. Dacia Manuals
  4. Automobile
  5. Solenza 2004
  6. Repair manual

Dacia Solenza 2004 Repair Manual

Mr 525-1 mechanics, engine: e7j, gearbox: jh3, tapv: b41a, b41b, b41c
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
Table of Contents

Advertisement

Quick Links

Download this manual
The reparation methods prescribed by the manufacturer in the present document are established subject to
technical specifications in force at the document issuing date.
These are subject to modifications brought by the manufacturer at the fabrication of different assemblies,
subassemblies or accessories of its vehicles.
All rights reserved to SC Automobile Dacia SA.
Reproduction or translating even partially of this present document is forbidden without the written
authorisation of AUTOMOBILE DACIA S.A.
Ref: 6001999066
REPAIR MANUAL
DACIA
MR 525-1 MECHANICS
ENGINE: E7J
GEARBOX: JH3
TAPV: B41A, B41B, B41C
MARCH 2004
vnx.su
English version

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Solenza 2004 and is the answer not in the manual?

Questions and answers

Related Manuals for Dacia Solenza 2004

Summary of Contents for Dacia Solenza 2004

  • Page 1 These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA. Reproduction or translating even partially of this present document is forbidden without the written authorisation of AUTOMOBILE DACIA S.A.

  • Page 2: Table Of Contents

    General poinds vehicle FUEL MIXTURE Characteristics ............12-1 CHARACTERISTICS Body valve ..............12-4 Inlet manifold ............12-5 Engine – Clutch - Gearbox ........01-1 Exhaust manifold ............12-6 Vehicle identification .......... 01-2 Air filter ..............12-7 LIFTING MEANS FUEL SUPPLY Mobile jack –...
  • Page 3 with air conditioning ........... 19-9 FRONT AXLES ELEMENTS Diagnostic – failures interpretation at vehicles with air conditioning ....... 19-10 Characteristics ............. 31-1 Water pump ............... 19-11 Suspension arm ..........31-2 Exhaust Assembly............19-13 Elastic bushings of the suspension arm ... 31-5 Fuel tank ..............

  • Page 4: Characteristics

    CHARACTERISTICS Engine – Clutch - Gearbox ENGINE CLUTCH GEARBOX VEHICLE TYPE TYPE TYPE CYLINDER TYPE CAP ACIT Y JH3 - 051 DACIA SOLENZA E7J-262 1390 180 CPO 3300 01 - 1 vnx.su...

  • Page 5: Vehicle Identification

    CHARACTERISTICS Vehicle identification UNITL THE DATE OF 26.06.2003 Manufacturer plate VIN identification number MANUFACTURER PLATE ..Kg ..Kg ..Kg ..Kg The manufacturer plate is located on the radiator front crossbeam. 1. Homologation number 2. Model year code and carriage body manufacturer series. 3.
  • Page 6 5 A 7 1 5 3 * POSITION CHARACTERS EXPLANATION – manufacturer world identification, 1 - 3 UU1 – AUTOMOBILE DACIA SA. ROMANIA, – vehicle destination, R – vehicle for persons transportation, – power train unit location, 5 – transversal front engine and front drive, –carriage body type,...
  • Page 7 CHARACTERISTICS Vehicle identification STARTING WITH THE DATE OF 26.06.2003 MANUFACTURER’S PLATE DISPOSAL TYPE SELF-ADHESIVE Fig.2.1 01 - 4 vnx.su...
  • Page 8 CHARACTERISTICS Vehicle identification STARTING WITH THE DATE OF 26.06.2003 The MANUFACTURER PLA TE, self-adhesive type, has the bellow presented con- figuration, with two distinctive areas, presenting :manufacturer’s identification data and APV type identification data. APV IDENTIFICATION DATA MANUFACTURER’S IDENTIFICATION DATA 1.1Code type auto APV 1.2Manufacturing number A.

  • Page 9: Lifting Means

    LIFTING MEANS Mobile jack – Adjustable supports Safety sign (particularly cautions to be observed in case of an intervention) SPECIAL TOOLS Cha 280-02 Adequate support on mobile jack Cha 408-01 Adjusting support on mobile jack Cha 408-02 Adjusting support on mobile jack The use of a mobile jack implies the ADJUSTABLE SUPPORT S obligatory use of adjustable supports.

  • Page 10: Elevator Positioned Under Vehicle Body

    LIFTING MEANS Elevator positioned under vehicle body SAFETY SIGN Situations to be considered: 1. SITUATION OF VEHICLE COMPONENTS DISMOUNTING When there are not available four columns elevators, two columns elevators may be used, in this case, lifting slides shall be placed under the floor closing plate, at the supporting points level of the vehicle jack 2.

  • Page 11: Towing

    TOWING All types ATTENTION ! NEVER USE AS TOWING POINTS, THE TRANSMISSION AXLES (PLAN- ETARY SHAFTS). The towing points, front, or rear, are to be used only for vehicles towing on wheels. These points cannot be anyhow used for drawing out the damaged vehicle from a trench (hole), or for direct or indirect vehicle lifting on a transport platform.

  • Page 12: Lubricants - Ingredients

    LUBRICANTS – INGREDIENTS Condition PRODUCT PLACE WHERE IT IS USED OILING (GREASING) Grease OLISTA LONG TIME 3EP R100137188 Guiding tube, clutch release fork Grease Right transmission joint G.I ELF CARDREXA RNT2 Transmission joint G.E. Grease Gearbox control rod protection bellows MOLYKOTE 33M Attachment buffer on anti-roll bar Grease...
  • Page 13 LUBRICANTS – INGREDIENTS Condition PLACE WHERE IT IS USED PRODUCT ETANªARE Water pump Thermostat support LOCTITE 518 Crankshaft half crankcase Gearbox crankcases assembling Thread of the reverse driving contact Crankshaft no.1 bearing cap LOCTITE 5900 Engine lower crankcase (RHODORSEAL 5661) Exhaust Sealing paste Wurth SOLDERING...

  • Page 14: Draining - Filling

    DRAINING – FILLING Engine SPECIAL TOOLS - wrench MOT 1018 Draining : plug (2) Filling : plug (1) 05 - 1 vnx.su...

  • Page 15: Gearbox

    DRAINING – FILLING Gearbox Special tools - wrench MOT 1018 Drain : plug (2) Fill : plug(1) 05 - 2 vnx.su...

  • Page 16: Power Steering

    DRAINING – FILLING Power steering ATTENTION ! For filling and addition, only oil DACIA of class DEXTRON II D is to be used. Circuit capacity: 1 liter. CIRCUIT FILLING Fill the reservoir with oil. In order to fill the circuit with oil, easy rotate the steering wheel in both directions so that steering rack is performing a complete stroke.

  • Page 17: Values And Adjustments

    VALUES AND ADJUSTMENTS Dimensions Dimensions (mm) Total length: 4083 Total width: G = 1664 Total height: empty H = 1379 loaded (authorized maximum total weight) 1329 Wheel base empty A = 2476 loaded 2479 Front wheel track width, ground level measurement * empty E = 1429 * loaded...

  • Page 18: Weights (Kg)

    VALUES AND ADJUSTMENTS Weights (kg) Version Vehicle type R5A715 R5A716 Minim 1035 1045 Front Unloaded vehicle weight Rear Maxim 1075 1085 Front Rear Front Maximu m authorized weight on axle Rear 1460 1450 Total Maximum technical admissible weight of the Front Rear loaded vehicle...

  • Page 19: Capacity - Quality

    VALUES AND ADJUSTMENTS Capacity - Quality DENOMINATION QUALITY CAPACITY (l) (approximate )* Engine oil DACIA OIL EXTRA SAE 10 W 40; API SJ 2,9* Gearbox oil SAE 75 W 80 W; API GL 5 DACIA OIL EXTRAGEAR Breaking fluid 0,450...

  • Page 20: Accessories Belts Tension

    VALUES AND ADJUSTMENTS Accessories belts tension Belts tension ing values are: - alternator belt 253 – 273 Hz - compressor belt 150 – 155 Hz - power steering pumps belt 151 – 161 Hz - compressor belt / DA pump 222 ±...

  • Page 21: Wheels, Tires

    VALUES AND ADJUSTMENTS Wheels, Tires Inflating pressure (bars) (1) Vehicle Wheels Tires Front Rear Empty/Loaded Empty/Loaded 5.5J144 CH43 165 / 65R14 2.0/2.2 2.0/2.1 SOLENZA 5.5B134CH46 165 / 70R13 2.0/2.2 2.0/2.1 (1) Maximum loaded, wheels on the ground. - tightening moment of the wheels screws : 7.5 daNm; - wheel axial run out : maximum 1 mm;...

  • Page 22: Brakes

    VALUES AND ADJUSTMENTS Brakes Brake disk width and drums diameter (mm) Maxim disk axial run out Front Rear Vehicle Normal Minim Normal Minim Front Rear 0.04 SOLENZA Gaskets thickness (mm) Front Rear Brake fluid Vehicle Normal Minim Normal Minim SOLENZA 0.5 mm SAE J 1703 DOT 4 above the...

  • Page 23: Dimensions Under Carriage Body

    VALUES AND ADJUSTMENTS Dimensions under carriage 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 the power train support. H5 –...

  • Page 24: Checking Values Of The Front Axle Angles

    VALUES AND ADJUSTMENTS Checking values of the front axle angles ANGLES VEHICLE VALUES ADJU STMENTS POSITION H5 - H2 = 100 CAMBER H5 - H2 = 90 H5 - H2 = 80 ± 30' H5 - H2 = 70 Not adjustable H5 - H2 = 60 Right / left maxim difference = of...

  • Page 25: Checking Values Of The Rear Axle Angles

    VALUES AND ADJUSTMENTS Checking values of the rear axle angles ANGLES ADJUSTMENTS VEHIC LE V ALUES POSITI O N CAMBER Not adjustable Unloaded 30' ± 10' PARALLEL ISM (For two wheels) Closing Not adjustable Unloaded 30' ± 10' 2,9 mm ± 1 mm ELASTIC BUSHINGS TIGHTENING Unloaded...

  • Page 26: Engine Assembly

    ENGINE ASSEMBLY E7J-262 Ingredients ENGINE TYPE COMPONENTS Engine oil DACIA OIL Engine lubricatio n EXTRA 10 W40; API SJ Lower crankcase sealing RHODORSEAL 5661 Crankshaft pulley attachment screw Loctite FRENETANCH Water pump, thermostat support, crankshaft Loctite 518 closing casing, crankshaft no.1 bearing cover...

  • Page 27: Oil Consumption

    ENGINE ASSEMBLY Oil consumption ENGINE E7J-262 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, necessar y to the oil complete draining into the lower crankshaft. Check the oil at the oil-indicating rod.

  • Page 28: Oil Pressure

    ENGINE ASSEMBLY Oil pressure E7J-262 ENGINE 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). For the engine E7J, components C + E + F from the oil pressure measuring kit MOT 836-05 are to be used.

  • Page 29: Power Train Group

    ENGINE ASSEMBLY ENGINE E7J-262 Power train group TIGHTENING MOMENTS) (daNm) Right support attachment screw on engine Hydro-elastic buffer attachment nut Left elastic buffer attachment nut Wheels screws Power train-battery attachment screws Connecting rod attachment nut on steering cross member support Anti-roll connecting rod attachment screw on gearbox connecting rod 10.5 Control bar attachment screw on gearbox connecting rod Pipes attachment screws on compressor...
  • Page 30 ENGINE ASSEMBLY E7J-262 Power train group ENGINE - collar (2) between the descending Disconn ect: tube and expansion chamber, remove the - connector (5) from the UCE (pull flap descending tube; (6) and then disengage); - anti-roll connecting rod. - engine wiring from engine fuse box; Disconnect the reverse driving contact connector.
  • Page 31 ENGINE ASSEMBLY ENGINE E7J-262 Power train group - hoses from gases evacuation vessel; - petrol vapors recycling pipes from the carbon can and from can purging valve; - fuel supply pipes (supp ly and return) from injection ramp by means of the MOT.1311-06 device.
  • Page 32 ENGINE ASSEMBLY E7J-262 Power train group ENGINE Dismount the four attachment screws of the Disconnect the pressure controller power train support-battery and the elastic buffer connector for power steering. nut (9). Dismo unt: - hoses from oil reservoir for power steering by means of pliers MOT 1202-01;...
  • Page 33 ENGINE ASSEMBLY Power train group ENGINE E7J-262 REMOU NTIN G Perform the dismounting operations in the reverse order. Tighten the screws and nuts to the required moment. Perform: - filling and purging of the cooling circuit (see chapter 19”Filling and purging”); - filling with oil of the engine and gearbox ;...

  • Page 34: Separation - Gearbox

    ENGINE ASSEMBLY Separation - Gearbox E7J-262 ENGINE TIGHTENING MOMENTS (daNm) RPM sensor Starter attachment screws Gearbox attachment on engine: nuts M 10 screws M10 - 90 screws M10 - 35 DISMOUNTING Dismount the RPM sensor 2 attachment screws on clutch casing. Detach the starter electric connections.

  • Page 35: Separation - Unfitting

    ENGINE ASSEMBLY ENGINE E7J-262 Separation – Unfitting - clutch disc and mechanism; ENGINE UNFITTING - engine flywh eel; - intake manifold ; Dismo unt: - thermal screen and exhaust manifold; - alternator and its belt; - water inlet pipe; - oil dipper guide; - thermostat support.

  • Page 36: Tightening Moments

    ENGINE ASSEMBLY Tightening moments E7J-262 ENGINE TIGHTENING MOMENTS (daNm) Cylinder head cover attachment screws Distribution belt tightening cam nut Water pump attachment elements: - M6 - M8 Crankshaft pulley screw 2 plus an angle of 68°±6° Camshaft gear screw Rockers ramp screws Engine flywhee l screws 5 - 5.5 Oil pump screws...

  • Page 37: Special Tools

    ENGINE ASSEMBLY Special tools ENGINE E7J-262 DENOMINATION SERVICE DACIA CODE ITEM NO Oil plug wrench MOT 1018 1001101800 Device for mounting the camshaft sealing gasket MOT 1 127-01 1001112701 Device for mou nting crankshaft sealing gasket toward s flywheel MOT 1 129-01 1001112901...

  • Page 38: Characteristics

    ENGINE ASSEMBLY E7J-262 ENGINE Characteristics CYLINDER HEAD The cylinder head is not to be re-tightened. The rockers adjustment is to be performed only at cold, only in case of engine reparation influencing their clearance. The adjustment values are: - for admission: 0.10 mm; - for exhaust: 0.25 mm.
  • Page 39 ENGINE ASSEMBLY ENGINE E7J-262 Characteristics VALVES SEATS Sealin g face an gle (α) - intake - exhaust Sealing face width (x) - intake 1.7 ± 0.1mm - exhaust 1.7 ± 0.1mm External diameter (D) - intake 38.5 mm - exhaust 34.5 mm VALVES GUIDES The valves for both intake and exhaust are provided with oil-rings, that must be replaced at...
  • Page 40 ENGINE ASSEMBLY E7J-262 Characteristics ENGINE VALVES SPRINGS The valves springs are identical for both intake and exhaust. Length in free state (mm) 44.93 Length under load (mm) at: - 27 daNm - 65 daNm 27.6 Length of the stuck coils (mm) 26.01 Coil diameter (mm) Internal diameter (mm)
  • Page 41 ENGINE ASSEMBLY Characteristics ENGINE E7J-262 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 –...
  • Page 42 ENGINE ASSEMBLY Characteristics E7J-262 ENGINE BOLTS Length (mm) External diameter (mm) Internal diameter (mm) CYLINDER JACKETS Type: wet removable. The sealing gasket is J rubber ring type. + 0,03 Internal diameter (mm) 75.8 Jacket height (mm) H2 Centering diameter (mm) D 80.6 Jackets over-height X without gasket (mm)
  • Page 43 ENGINE ASSEMBLY ENGINE E7J-262 Characteristics RINGS Thickness (mm): - compression ring - sealing ring 1.75 - oiling ring CONNECTING RODS Connecting rod end side clearance: 0.310 to 0.572 mm. ATTENTION! It is forbidden the use of punches for marking due to the risk of primer cracks A permanent marker is to be used.
  • Page 44 ENGINE ASSEMBLY Characteristics E7J-262 ENGINE OIL PUMP - clearance B (mm): - minim 0.02 The oil pump is a gear wheels type. - maxim 0.86. 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.

  • Page 45: Dismounting - Remounting

    ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 CYLINDER HEAD 10 - 20 vnx.su...
  • Page 46 ENGINE ASSEMBLY E7J-262 Dismounting – Remounting ENGINE CYLIN DER HEA D DISMOU NTING Drain the oil from the engine. Dismo unt: - wiring from the engine; - compressor and/or power steering pump ( for vehicles equipped with air conditioning unit and/or power steering); - compressor support and/or power steering pump support;...
  • Page 47 ENGINE ASSEMBLY ENGINE E7J-262 Dismounting – Remounting Bring the engine at the setting on point, lining up the mark from the crankshaft gear L with the fix mark M (the mark L from the camshaft being in vertical position as shown in the bellow drawing).
  • Page 48 ENGINE ASSEMBLY Dismounting – Remounting E7J-262 ENGINE Dismount: - camshaft sealin g ring; - cylinder head cover; - camshaft gear (to be blocked by - intake manifold and exhaust manifold; means of MOT 799-01 device); - cylinder head screws, less the one with - camshaft;...
  • Page 49 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 ATTENTION! ATTENTION! New valves must have the same marking Avoid foreign materials introduction 8 with the old ones in order to avoid the into the oil grooves, otherwise the latter damaging of the seat/valve assembly. will clog, and consequently the rockers slides and cams rapid damaging.
  • Page 50 ENGINE ASSEMBLY Dismounting – Remounting E7J-262 ENGINE Lubricate the camshaft with engine oil. - thermostat support; Loctite 518 is to Mount the camshaft and its clamp. be used for its sealing. Check the camshaft axial clear ance, which The layer H must be 0.6 till 1 mm thick must be between 0.06 mm and 0.15 mm, in and is to be applied as per the following dia- case this one is not corresponding, check the...
  • Page 51 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 CYLINDERS BLOCK 10 - 26 vnx.su...
  • Page 52 ENGINE ASSEMBLY Dismounting – Remounting E7J-262 ENGINE CYLINDER S BLOCK DISMOUNTING Dismount the oil pump attachm ent screws. Dismo unt: Dismo unt the oil pump and its driving chain. - water inlet pipe and oil dipper rod Mark the connecting rod caps compared guide ( their sealing is performed by means of with the connecting rod body.
  • Page 53 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 CYLIND ERS BLOCK REMOUN TING Clean the cylinders block, especially the jackets seating and sealing surfaces. Preparation of assembly “ pistons-jackets” The parts contained in the kit are in pairs. Mark the parts assembly from A to D in order to keep the matching.
  • Page 54 ENGINE ASSEMBLY Dismounting – Remounting E7J-262 ENGINE The over-height 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;...
  • Page 55 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 The arrow marked on the piston head must - oiling ring (3); be oriented towards engine flywheel. - sealing ring (2) with the mark “TOP” The connecting rods have no mounting upwards; direction, but the half-bearings spurs are to - compression ring (1) with the mark be positioned on the same part.
  • Page 56 ENGINE ASSEMBLY E7J-262 Dismounting – Remounting ENGINE Mount the assembly in the block, as per Marking on bearing Marking on crankshaft previous established sequence and check and Blue ensure that a 0.1 mm gauge is passing be- tween jackets. Identidfication of matching classes on crankshaft is performed by marking on the balance-weight of bearing number 5.
  • Page 57 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 - 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;...
  • Page 58 ENGINE ASSEMBLY E7J-262 Dismounting – Remounting ENGINE Mount the water pump (sealin g is performed Mount the lower casing and tighten the using LOCTITE 518). screws to the required moment of 1 daNm. Apply a layer of sealant material H, 0.6 – 1 Sealing is performed using RHODORSEAL mm thick, according to the drawing.
  • Page 59 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 2. CYLINDER HEAD TIGHTENING CYLINDER HEAD REMOU NTING Dismount the blocking device of the cyl- Cylinder head tightening is to be performed inders jackets. successive for the screws groups 1-2, 3-4, Mount: 5-6, 7-8 and 9-10; - cylinder head centering bushing on - unscrew 1-2 screws until total release;...
  • Page 60 ENGINE ASSEMBLY E7J-262 Dismounting – Remounting ENGINE DISTRIBUTION 10 - 35 vnx.su...
  • Page 61 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 DISTRIBUTION ADJUSTMENT The belt tensioning is to be performed only with cold engine (environment ambient tem- perature). On the belt backside, there is an arrow indicatin g the rotation directio n and two marks for setting.
  • Page 62 ENGINE ASSEMBLY Dismounting – Remounting E7J-262 ENGINE ROCKERS ADJUSTMENT Adjustment to be performed only with cold engine. The adjustment values are: - admission 0.10 mm - exhaust 0.25 mm 1. Camshaft gear without marks. a) Method called “ in balance” Adjust cylinder rocker Cylinders valves in balance (exhaust end, admission beginning)
  • Page 63 ENGINE ASSEMBLY Dismounting – Remounting ENGINE E7J-262 2. Camshaft gear with marks Rotate the engine until is reaching the Upper Dead Point (cylinder 1 at ignition), and then con- tinue until first item: - adjust : exhaust 1 exhaust 3 - at second item : - adjust : admission 1 admission 3...

  • Page 64: Lower Casing

    ENGINE ASSEMBLY Lower casing E7J-262 ENGINE TIGHTENING MOMENTS (daNm) Lower casing screws Wheels screws Tie-rod attachment nut Tie rod attachment screw Anti-roll connecting rod attachment screw (on frame) Anti-roll connecting rod attachment screw (on gearbox) 10,5 DISMOU NTIN G Place the vehicle on a two-column eleva- tor.
  • Page 65 ENGINE ASSEMBLY Lower casing ENGINE E7J-262 REMOU NTIN G Clean the lower casing and the cylinders casing of old sealant material. Apply a layer (D) of RHODORSEAL 5661 of about 3 mm thick, according to the bellow drawing. Do not forget the replacement of the two half-moon gaskets from casing ends (A). Perform the dismounting operations in the reverse order.

  • Page 66: Oil Pump

    ENGINE ASSEMBLY E7J-262 Oil pump ENGINE TIGHTENING MOMENTS (daNm) Oil pump attachment screws Oil pump cap attachment screws DISMOU NTIN G Drain the oil from the engine. Dismo unt: - lower casing (see chapter 10”Lower casing on vehicle”). Dismount the oil pump attachmen t screws on casing. Dismount the drive chain from the oil pump gear.

  • Page 67: Multi-Purpose Support

    ENGINE ASSEMBLY Multi-purpose support ENGINE E7J-262 TIGHTENING MOMENTS (daNm) Support attachment screws Support upper attachment screws DISMOU NTIN G Place the vehicle on a two-column elevator. Disconnect the battery. Dismo unt: - compressor (see chapter 62”Air conditioning”) for vehicles equipped with air conditioning unit;...

  • Page 68: Distribution System

    DISTRIBUTION SYSTEM Distribution belt ENGINE E7J-262 (daNm) TIGH TENING MOMENTS Wheels screws Crankshaft pulley screw 2+68 ± 6 Tensioning roller nut Right support screws Hydro-elastic buffer nut DISMOU NTIN G Place the vehicle on a two-column eleva- tor. Mount between chassis and cylinder casing, the MOT.
  • Page 69 DISTRIBUTION SYSTEM Distribution belt ENGINE E7J-262 Set the engine at setting point (see method described in chapter 10 “ Engine assembly”, page 10 –19). Loosen the tensioning roller nut. Dismount the distribution belt. REMOU NTIN G Mount a new distribution belt. Tension the distribution belt to a value of 145 –...

  • Page 70: Cylinder Head Gasket

    DISTRIBUTION SYSTEM ENGINE E7J-262 Cylinder head gasket Necessary Special Tools MOT 1202-01 Pliers for elastic collars MOT 1505 Belt tensioning measurement device MOT 484 Jackets clamping device Wrench for angle tightening Wrench for “CLIC” collars TIGHTENING MOMENTS ( daNm ) Tensioning roller nut Crankshaft pulley screw 2 + 68°...
  • Page 71 DISTRIBUTION SYSTEM Cylinder head gasket ENGINE E7J-262 - oil gauge guide; - thermal screen; - multi-purpose support; - exhaust manifold. Dismount the hoses from the thermostat sup- port. Dismo unt: - cylinder head screws except the screw corresponding to A position, which is to be loosen, then rotate the cylinder head around the screw remained not-dismounted;...
  • Page 72 DISTRIBUTION SYSTEM ENGINE E7J-262 Cylinder head gasket Mount the MOT 484 device or MOT REMOU NTIN G 588 clamps for jackets maintenance. Clean the gasket-seating surface of the cyl- inder head. MOT 484 Mount the cylinder head with a new gasket. Perform the dismounting operation s in the re- verse order.

  • Page 73: Fuel Mixture

    FUEL MIXTURE Characteristics ENGINE E7J-262 ENGINE Vehicle Gearbox Type Index Bor e Stroke Cylinder (mm) (mm) capacity JH3-051 75,8 1390 9,5/1 SOLENZA Verificãri efectuate la ralanti * Engine Emisii poluan i Fuel Type Index Revolution CO(%) CO Lambda (mini m um octane (λ...
  • Page 74 FUEL MIXTURE ENGINE E7J-262 Characteristics DENOMINATION PARTICU LARITIES UCE injecti on SIEMENS - Connector wi th 90 ways Injection system Sequential multi-point Ignition Static with doub le coil PINI R (W) 0,52 Ω Ω Ω Ω ± Ignition control l ed by 0,52 Ω...
  • Page 75 FUEL MIXTURE Characteristics ENGINE E7J-262 DENOMINATION PARTICULARITIES At idling running At maximum acceleration Potentiometer with valve 1200 Ω Ω Ω Ω ± 1200 Ω Ω Ω Ω ± A - B 1400 Ω Ω Ω Ω ± 2000 Ω Ω Ω Ω ±...

  • Page 76: Body Valve

    FUEL MIXTURE ENGINE E7J-262 Body valve Disconnect the body control lever DISMOU NTIN G Disconnect the battery. Dismount the valve body. Dismount the air inlet duct from the battery protection screen. Dismount the air filter four attachment screws. Disconnect the hose (1) for oil vapors re- aspiration, between the cylinder head cover and the air filter.

  • Page 77: Inlet Manifold

    FUEL MIXTURE Inlet manifold ENGINE E7J-262 TIGHTENING MOMENT (daNm) Inlet manifold nuts and screws DISMOU NTIN G Place the vehicle on a two-columns elevator. Disconnect the battery. Dismo unt: - the air filter assembly; - the acceleration cable from the body control lever;...

  • Page 78: Exhaust Manifold

    FUEL MIXTURE ENGINE E7J-262 Exhaust manifold TIGH TENING MOMENT (da Nm) Exhaust manifold attachment nuts Downward pipe attachment nuts on Exhaust manifold DISMOU NTIN G Dismount the multi-purpose support ( see chapter 10 “ Multi-purpose support”) Dismount the thermal screen. Dismount the descending pipe attachmen t nuts on the exhaust manifold Dismount the exhaust manifold attach ment nuts.

  • Page 79: Air Filter

    FUEL MIXTURE Air filter ENGINE E7J-262 FILTER ELEMENT REPLACEMENT Dismount the attachment screws (1) of the air filter cover. Detach the attachment clamps (2). Remove the cover and replace the filter element (3). DISMOUNTING OF THE AIR FIL TER Dismount the air filter inlet hose Dismount the four-attachment screws (4) of the air filter on the cylinder head cover and inlet manifold .

  • Page 80: Fuel Supply

    FUEL SUPPLY MOTEUR E7J-262 Supply interruption REMARK: Only vehicle observing the de-pollution norm EURO 00 are equipped with shock sensor. PURPOSE To avoid the fire hazard due to the fuel losses, that may occur in case of an accident. OPERATION The hazard sensor (1) is placed in the engine compartment, being mounted on the left shock absorber column.

  • Page 81: Fuel Ramp

    FUEL SUPPLY MOTEUR E7J-262 Fuel ramp In order to dismount an injector, retrieve ATTENTION ! the clip 5, and then extract the injector. When opening the fuel circuit, protect by means of a gauze piece against petrol splashing due to residual pressure. DISMOU NTIN G Disconnect the battery.

  • Page 82: Pump Capacity

    FUEL SUPPLY MOTEUR E7J-262 Pump capacity PUMP CAPACITY CHECKING VEHIC LES WITHOUT FUEL RETURN SPECIAL TOOLS Disconnect the supply pipe from the fuel electric pump assembly . Pliers for “CLICK” collars. Connect on the pipe a hose, one extremity being introduced in a calibrated vessel from 0 to 2000 ml.

  • Page 83: Supply Pressure

    FUEL SUPPLY MOTEUR E7J-262 Supply pressure SUPPLY PRESSURE CHECKING MOT 1311 -01 SPECIAL TOOLS MOT 1311 – 01 Petrol pre ssure checking kit MOT 1311 – 04 J - connection MOT 1311 – 06 Device for connections dismounting. ATTENTION ! When opening the fuel circuit, protect by means of a gauze piece against petrol splashing due to residual pressure from...

  • Page 84: Anti-Pollution

    ANTI-POLLUTION ENGINE E7J - 262 Petrol vapors re-aspiration THE CIRCUIT OPERATING DIAGRAM 1 INTAKE MANIFOLD 2 CAN PURGING VALVE 3 CARBON CAN 4 FUEL TANK M COMMUNICATION CONNECTION WITH ATMOSPHERE ATTENTION ! For a normal operation of the circuit, the M connection must be clogged. 14 - 1 vnx.su...
  • Page 85 ANTI-POLLUTION ENGINE E7J - 262 Petrol vapors re-aspiration OPERATING PRINCIPLE OPERATION CHECKING OF THE CAN PURGING VALVE The communication of the tank with the A defective operation of the petrol vapors atmosphere is done through the carbon can. re-aspiration system, may lead to an unstable The petrol vapors are retained when they are idling or even to the engine stopping.
  • Page 86 ANTI-POLLUTION ENGINE E7J - 262 Petrol vapors re-aspiration REMOUNTING Petrol vapors re-aspiration Perform the dismounting operations in the reverse order If the pressure is varying more than 10 mbar, then the purging valve is defective and the carbon can assembly is to be replaced. NO –...

  • Page 87: Oil Vapors Re-Aspiration

    ANTI-POLLUTION ENGINE E7J - 262 Oil vapors re-aspiration CIRCUIT PRESENTATION 1 – Hose for oil vapors re-aspiration, connected upstream of valve body between cylinder head cover and air filter case (the circuit is used for middle and big charges). 2 – Hose for oil vapors re-aspiration, connected downstream of valve body between cylinder head cover and intake manifold.

  • Page 88: Alternator - Starter

    ALTERNATOR – STARTER ENGINE E7J-262 Alternator IDENTIFICATION ENGI NE ALTERN ATOR IN TEN SITY VALEO A11 VI 87 E7J - 262 VALEO A13 VI 212 CHECKING After 15 minutes of heating under a 13.5 V tension. ENGIN E RPM ALTERNATOR 75 A ALTERNATOR 8 0 A (rot/min) 1000...
  • Page 89 ALTERNATOR – STARTER ENGINE E7J-262 Alternator B. The indicator is lighting, engine being running. This shows a charging failure, which may be caused by: - alternator driving belt broken, charging wire connected to alternator is broken (+ per- manent); - alternator failure(rotor, stator, diodes or brushes); - voltage regulator failure;...
  • Page 90 ALTERNATOR – STARTER ENGINE E7J-262 Alternator DIAGNOSTIC Special tool: CLIP tester and accessories for physical measurements. CHARGING CIRCUIT CHECKING CLIP tester is enabling the alternator checking, by measuring the generated voltage and intensity with and without electric consumers. REMARK: The ammeter pliers is of inductive type 0 ÷ 1000 A. Its mounting is done without the battery disconnecting, enabling so the memorized data preserving and the adapting values from the injection computer.
  • Page 91 ALTERNATOR – STARTER ENGINE E7J-262 Alternator SPECIAL TOOLS MOT 1505 Belt tension measurement device REMOU NTIN G TIGHTENING MOMENTS (daNm) Upper attachment screw Perform the dismounting operations in the Lower attachment screw reverse order Tighten the alternator driving belt to 263 Vehicles without air conditioning.
  • Page 92 ALTERNATOR – STARTER ENGINE E7J-262 Alternator Vehicles equipped with air conditioning DISMOU NTIN G Place the vehicle on a two-column elevator Disconnect the battery Dismount the alternator upper attachment screw. Dismount the front right wheel. Lift the vehicle. Dismo unt: - protectio n fairing;...

  • Page 93: Starter

    ALTERNATOR – STARTER ENGINE E7J-262 Starter IDENTIFICATION ENGINE STARTER E7J - 262 D 907 - M00 2T 13581 DIAGNOSTIC Special tool : CLIP tester – TECHNIC for measuring the battery voltage and the absorbed intensity in the starting stage. OPERATION ABNORMALITIES THAT MIGHT BE NOTICED - Battery failure = large voltage drop on starter during engine starting stage.
  • Page 94 ALTERNATOR – STARTER ENGINE E7J-262 Starter TIGHTENING MOMENTS (daNm) Starter attachment screws Control bar attachment screw on gearbox connecting rod DISMOU NTIN G Place the vehicle on a two-column elevator. Disconnect the battery. Dismount the attachment nuts of the gazes exhaust vessel. Dismount the hoses support attachment nut on the engine lifting support.

  • Page 95: Ignition And Injection

    IGNITION AND INJECTION Ignition system PRESENTATION The system is composed of : - electronic control unit (UCE injection ); - a double ignition coil; - four spark plugs; - spark plugs cables. OPERA TING PRINCIPLE Subject to the information received from different sensors, but mainly subject to engine RPM and charge, the electronic control unit will estab lish the advance at ignition, will identify the cylinders being at upper dead point and consequently , will control the corresponding coil to them.
  • Page 96 IGNITION AND INJECTION Ignition system IGNIT ION COIL The system is including a double coil (X), controlled by the electronic control unit (UCE). The coil has and electric connect o r (Y) wi t h four ways , and is simultaneously producing sparks at cylinders 1 and 4, whe n it is controlled by the pin 32 of the UCE injection and at cylinders 2 and 3, whe n it is controlled by the pin 1 of the UCE injection.

  • Page 97: Spark Plags

    IGNITION AND INJECTION Spark plags ENGI NE BRAND TYPE E7J - 262 SAGEM RFC 52 LZ Distance between electrodes: 0.9 mm Tightening moment: 2.5 - 3 daNm Flat seat with gasket 17 - 3 vnx.su...

  • Page 98: Injection System

    IGNITION AND INJECTION Injection system CHARACTERISTICS • Electronic control unit (UCE injection) with 90 pins SIEMENS. • Sequential multi-poin t injectio n. • Controlling one injector each time. • Static ignition with a double ignition coil. • Canister purging valve controlled in opening duty cycle. •...
  • Page 99 IGNITION AND INJECTION Injection system ELEMENTS LOCATION 4 6 3 2 1 14 16 1. RPM sensor ( tightening moment : 0.8 daNm); 2. Water temperature sensor (tightening moment: 2.5 daNm); 3. Atmospheric pressure sensor; 4. Step-by-step engine for idling adjustment; 6.
  • Page 100 IGNITION AND INJECTION Injection system UCE injection; RPM sensor 8. Choke sensor; Water temperature sensor Atmospheric pressure sensor Step-by-step engin e for idli ng Ignition coil adjustment Valve position potentiometer Air temperature sensor; 17 - 6 vnx.su...
  • Page 101 IGNITION AND INJECTION Injection system Oxygen sensor Carbon canister with purging valve included Air conditioning pressure controller Power steering pressure controller In the fuse box located in the engine compartment, the following relays may be identified: A. Compressor relay B. Engine cooling fan relay, step I C.
  • Page 102 IGNITION AND INJECTION Injection system WATER TEMPERATURE SENSOR The water temperature sensor (1) is sending to UCE injection the information regarding water tempera- ture, and another information is sent to the indicator from the instrument panel, which will show the water temperature.
  • Page 103 IGNITION AND INJECTION Injection system ANTI-STARTING INDICATOR When setting the contact on, UCE injection is recei v ing from UCE DECODER a code, whi c h is compared with the one previously memorized; if the two codes are matching, then the engine starting is authorized. After contact setting on, anti-starting indicator which was previously blinking, will light for three seconds then it will go off, confirming in this way, the key recognizing.
  • Page 104 IGNITION AND INJECTION Characteristics MULTI-POINT INJECTION CHARACTERISTICS 〈 SIRIUS 32 with 90 pins computer is managing the ignition and the injection. 〈 For diagnostic, CLIP Sagem tester is to be used. 〈 The injection system in use is a sequential multi-point type, injection and ignition phases controlling being based on the SIRIUS 32 c omputer program logic, starting from the signal received from the RPM sensor.

  • Page 105: Injection / Air Conditioning Strategy

    IGNITION AND INJECTION Injection / air conditioning strategy AIR CONDITIONING UNIT IS USING A COMPRESSOR WITH VARIABLE DISPLACEMENT The connections injection/air conditioning, are the followings: - pin 46 of the injection computer is receiving the information “ air conditioning request” further to the air conditioning switch acting; - pin 10 of the injection computer will transmit the coupling control of the air conditioning compressor by means of the “A”...

  • Page 106: Idling Regime Correction

    IGNITION AND INJECTION Idling regime correction IDLING REGIME CORRECTION SUBJECT TO BATTERY VOLTAGE AND TO ELECTRIC BALANCE ON VEHICLE. This correction is de dicated to the compensation of the voltage drop due to the electric consu mers starting, when the battery is weaker charged. In this purpose, engine RPM is increased, allowing in this way the alternator rotation increase and consequently of the battery voltage.

  • Page 107: Idling Regime Adaptive Correction

    IGNITION AND INJECTION Idling regime adaptive correction PRINCIPLE In engine normal operation conditions at warm, the RCO value is varying between a high and a low limit, in order to obtain the nominal idling regime. Further to an operation dispersion (running in, engine clogging, etc), it may be possible that RCO idling value to be situated next to the lower and higher values.

  • Page 108: Enriching Adjustment

    IGNITION AND INJECTION Enriching adjustment The engines equipped with UCE injection type SIRIUS 32 a re provided with oxygen sensors, as follows: - one upstream oxygen sensor – for engines corresponding to EURO 96 de-pollution norms. - one upstream oxyg en sensor and one downstream oxyg en sensor – for engine s corresponding to EURO 2000 de-pollution norms.
  • Page 109 IGNITION AND INJECTION Enriching adjustment ENRICHING CORRECTION After connecting the CLIP tester, select “Injection diagnostic” and refer to “PR035 parameter: Enriching correction value”. The value displayed is representing the corrections average imposed by the UCE injection, subject to the fuel mixture enriching, red by the upstream oxygen sensor (the sensor is analyzing the oxygen concentration from the exhaust gases).

  • Page 110: Enriching Adaptive Correction

    IGNITION AND INJECTION Enriching adaptive correction PRINCIPLE When the engine is in “closed loop” phase, the enriching adjustment is c orrecting the injection time in order to be able to obtain a fuel mixture with the enriching as close as possible to 1. The correction value is fluctuating around the value 128, within the limits 0 and 255.
  • Page 111 IGNITION AND INJECTION Enriching adaptive correction ROAD TEST Test performing c onditions: - warm engine ( water temperature > 80°C); - engine RPM not exceeding 4000 rot/min. For this test, it is recommended starting from a sufficient low engine RPM, in gearbox third or fourth gear, accelerating th en progressively in order to obtain a pressure stability in th e inlet (PR001 = inlet manifold pressure) for 10 seconds in each area, as per next table: Area 1...

  • Page 112: On Board Diagnostic" System Characteristics

    IGNITION AND INJECTION “On Board Diagnostic” system characteristics At vehicles equipped with diagnostic system OBD (On Board Diagnostic), when detecting a cause leading to an excessive pollution, on the instrument panel the OBD indicator will be on, indicating to the driver that vehicle must be repaired to eliminate the pollution cause. The OBD system is taking into consideration during its operation of the performing the follow- ing dia gnostics: - electric diagnostics;...

  • Page 113: On Board Diagnostic" Lighting Conditions

    IGNITION AND INJECTION “On Board Diagnostic” lighting conditions CONDITIONS OF OBD INDICATOR LIGHTING During driving it is p ossible that certain functions are not subject to dia gnostic (for instance due to crowded traffic driving). Indicator lighting - it is occurring if the same OBD failure is detected during three consecutive driving or further to an electric failure.

  • Page 114: On Board Diagnostic" Diagnostic Conditions

    IGNITION AND INJECTION “On Board Diagnostic” diagnostic conditions DIAGNOSTIC CONDITIONS If when setting on the contact, with stopped engine, one of the following conditions is accom- plished: - air temperature, red by the air temperature sensor, is not situated between –6° and 119°C. - water temperature, red by the water temperature sensor, is not situated between –6°...

  • Page 115: Diagnostic Of Combustion Misfires Detection

    IGNITION AND INJECTION Diagnostic of combustion misfires detection This diagnostic may detect: - spark plug fouling or smoking, - fouling or modification from the normal value of the injectors flow, - fuel supply system abnormalities (pressure controller, fuel pump,..) - problems with the electric connections for controlling fuel supply circuits and the injection. The diagnostic is performed by variations measurement of the engine prompt rotation speed.

  • Page 116: Catalyst Diagnostic

    IGNITION AND INJECTION Catalyst diagnostic The purpose of the catalyst diagnostic is the detection of the disturbances leading to exceeding an OBD step due to HC pollution emissions. The catalyst storage capacity of the oxygen is the indicator of its condition. When the catalyst is beginning to ”age”, the storage capacity of the oxygen is diminishing, in the same time with the diminishing of the treatment capacity of the pollution gases.

  • Page 117: Oxygen Sensor Diagnostic

    IGNITION AND INJECTION Oxygen sensor diagnostic REPARATION CONFIRMATION Check by means of the CLIP tester, the bellow states, which must have the following configu- ration: - ET103: Catalyst diagnostic taken into consideration ------------------------------ ACTIVE - ET107: Catalyst diagnostic performed ---------------------------------------------- ACTIVE - no functional failure of the catalyst is detected by the CLIP tester.
  • Page 118 IGNITION AND INJECTION Oxygen sensor diagnostic FAILURES DETECTION This diagnostic is to be performed when driving in the fourth or fifth gear, at constant speed (about 70 Km/h) and for a period of minimum 60 seconds. Engine Gearbox ratio Speed Maximum p eriod (Km/h) (sec)

  • Page 119: Diagnostic - General

    IGNITION AND INJECTION Diagnostic – General This document is presenting the diagnostic for the injection computers SIRIUS 32, which have nr.program E1 and Diag.variant 10. In order to perform the diagnostic of this injection system, it is necessary to use the following elements: - Diagnostic Technical Note - Functional electric diagram of the respective vehicle...

  • Page 120: Diagnostic - Failures Interpretation

    IGNITION AND INJECTION Diagnostic – Failures interpretation V ALVE POTE NTIOMET ER CIRCUIT DF002 1. DEF : Open ci r cuit or short-circuit PRESENT MEMORIZED If failure “DF345 : Suppl y 5 v olts potenti o meters or trans ducers” is pres ent or memori z ed, this must be treated with pri o rity.
  • Page 121 IGNITION AND INJECTION Diagnostic – Failures interpretation DF003 AIR TEMPERA TURE SENSOR CIRCUIT PRESENT 1. DEF : Open ci r cuit or short-circuit MEMORIZED If failure “DF345 : Suppl y 5 vo lts potenti o meters or trans ducers ” is present or memori z ed, this must be treated with pri o rity.
  • Page 122 IGNITION AND INJECTION Diagnostic – Failures interpretation DF004 WATER TEMPERA TURE SEN SOR CIRC UIT PRESENT 1. DEF : Open ci r cuit or short-circuit MEMORIZED If failure “DF345 : Suppl y 5 vo lts potenti o meters or trans ducers ” is present or memori z ed, this must be treated with pri o rity.
  • Page 123 IGNITION AND INJECTION Diagnostic – Failures interpretation DF006 DETONATION SENSOR CIRCUIT PRESENT 1. DEF : Open ci r cuit or short-circuit MEM OR IZED Conditions for diagnostic application for memorized fai l ure: Perform a road test with warm and in charge engine. * If the failure is memorized with OBD indicator on, check i n the cont e xt part, RECOMMENDATIONS if state “ET289 : Detonation sensor circuit”...
  • Page 124 IGNITION AND INJECTION Diagnostic – Failures interpretation ACTUA TORS RELA Y CONTROL CIRCUIT DF009 1DEF : Open ci r cuit or short-circuit PRESENT CO : open circuit CC.O : shot circuit at mass MEM OR IZED CC.1 : short circuit at + 12 V. Conditions for di a gnostic appl i cation for memori z ed fai l ure: Set the contact on then enter in dialog with the injection computer by means of the CLIP tester.
  • Page 125 IGNITION AND INJECTION Diagnostic – Failures interpretation DF012 INJECTION > AC CONNECTI O N PRESENT No comments failure MEM OR IZED Conditions for di a gnostic appl i cation for memori z ed fai l ure: Failure is declared present further to a 10 seconds timing with engine running RECOMMENDATIONS and climate control under operation, state ET009: active (during test, battery voltage must be not under 11 V).
  • Page 126 IGNITION AND INJECTION Diagnostic – Failures interpretation CANISTE R PURGING V ALVE CIRCUIT DF014 1.DEF : Open ci r cuit or short-circuit PRESENT CO : Open circuit CC.O : Shot circuit at mass MEM OR IZED CC.1 : Short circuit at + 12 V. Conditions for di a gnostic appl i cation for memori z ed fai l ure: Set the contact on or launch commend “AC016: Canister Purging Valve”...
  • Page 127 IGNITION AND INJECTION Diagnostic – Failures interpretation RPM SIGNAL INFORM ATION DF017 1. DEF : Engine flywheel tooting damage PRESENT 2. DEF: tooth signal absence MEM OR IZED In order to perform this diagnostic, the pressure sensor must be not in failure.
  • Page 128 IGNITION AND INJECTION Diagnostic – Failures interpretation UPSTREAM OXYGE N SENSOR HEATING CIRCUIT DF018 1DEF : Open ci r cuit or short-circuit PRESENT CO : open circuit MEMO RIZED CC.O : shot circuit at mass CC.1 : short circuit at + 12 V. Conditions for di a gnostic appl i cation for memori z ed fai l ure: - Start the engine and ensure that state “AC261: Upstream O2 sensor heating”...
  • Page 129 IGNITION AND INJECTION Diagnostic – Failures interpretation INJECTION COMPUTER DF 022 1 . DEF : Replace the computer PRESENT Nothing to mention. RECOMM ENDATIONS Non-conform or damaged computer. Check if the computer the one s pecific for that type of vehi c le. Do not i m mediately replace the computer without i d entifying preci s ely its damaging cause.
  • Page 130 IGNITION AND INJECTION Diagnostic – Failures interpretation WATER TEMPERA TURE WARNING CIRCUIT DF 032 1DEF : Open ci r cuit or short-circuit PRESENT : open circuit CC.O : short-circuit at mass MEM OR IZED CC.1 : shot-circuit at + 12 volts Conditions for di a gnostic appl i cation for memori z ed fai l ure: Start the engine and maintain it at over 1500 rot/min until engine fun RECOM MENDATION S...
  • Page 131 IGNITION AND INJECTION Diagnostic – Failures interpretation DOWNSTREAM OXYG EN SE NSOR HEA TING CIRCUIT DF038 1DEF : Open ci r cuit or short-circuit PRESENT CO : open circuit CC.O : shot circuit at mass MEM OR IZED CC.1 : short circuit at + 12 V. Conditions for di a gnostic appl i cation for memori z ed fai l ure: - Start the engine and ensure that state “ET03: downstream O2 sensor heating”...
  • Page 132 IGNITION AND INJECTION Diagnostic – Failures interpretation ANTI-ST ARTIN G CIRCUIT DF 044 1 . DEF : Open ci r cuit or short-circuit PRESENT MEMO RIZED RECOMME NDA TIONS Nothing to mention. Check the connection and condition of the coded line, starting from injection computer pin 58 Replace the computer connector if necessary.
  • Page 133 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 045 ATMOSPHERIC PRESSURE SENSOR CIRCUIT PRESENT 1 . DEF : Open ci r cuit or short-circuit 2 DEF : Pressure evolution in manifold MEM OR IZED If failure “DF345”: Supply 5 volts potentiometers or sensors” is present or memorized, this must be treated as most important.
  • Page 134 IGNITION AND INJECTION Diagnostic – Failures interpretation CYLINDE R 1 INJECTOR CIRCUIT DF 052 1. DEF Open ci r cuit or short-circuit PRESENT CO : open circuit CC.O : shot circuit at mass MEM OR IZED CC.1 : short circuit at + 12 V. Conditions for di a gnostic appl i cation to memorized failure: Start the engine and especially stop it immedi a tely the failure is becomi n g present, so that catalyst-damaging risk is avoided.
  • Page 135 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 053 CYLINDE R 2 INJECTOR CIRCUIT PRESENT 1. DEF : Open ci r cuit or short-circuit CO : open circuit MEM OR IZED CC.O : shot circuit at mass CC.1 : short circuit at + 12 V. Conditions for di a gnostic appl i cation to memorized failure: Start the engine and es pecially stop it immediately the failure is becoming present, so that catalyst-damaging risk is avoided.
  • Page 136 IGNITION AND INJECTION Diagnostic – Failures interpretation CYLINDE R 3 INJECTOR CIRCUIT DF 054 1 DEF : Open ci r cuit or short-circuit PRESENT CO : open circuit CC.O : shot circuit at mass MEM OR IZED CC.1 : short circuit at + 12 V. Conditions for di a gnostic appl i cation to memorized failure: Start the engine and especially stop it immediately the failure is becoming present, so that catalyst-damaging risk is avoided.
  • Page 137 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 055 CYLINDE R 4 INJECTOR CIRCUIT PRESENT 1. DEF : Open ci r cuit or short-circuit CO : open circuit MEMO RIZED CC.O : shot circuit at mass CC.1 : short circuit at + 12 V. Conditions for di a gnostic appl i cation to memorized failure: Start the eng ine and especially stop it immediately the fai l ure i s becomi n g present, so that catalyst-damaging risk is avoided.
  • Page 138 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 057 UPSTREAM OXYGEN SENSOR CIRCUIT PRESENT 1.DEF : Open ci r cuit or short-circuit MEM OR IZED If failure “DF345” : Supply 5 volts potentiometers or sensors” is present or memorized, this must be treated as most important. Conditions for di a gnostic appl i cation to memorized failure: Set the contact on.
  • Page 139 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 058 DOWNSTREAM OXYGEN SENSOR CIRCUIT PRESENT 1.DEF : Open ci r cuit or short-circuit MEM OR IZED If fai l ure “DF345” : Supply 5 volts potentiometers or sensors” is present or memorized, this must be treated as most important.
  • Page 140 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 060 IDLING ADJUSTMENT CIRCUIT PRESENT 1.DEF : Open ci r cuit or short-circuit CO : Open circuit MEM OR IZED CC.O : Short-circuit at mass CC.1 : Short-circuit at +12 volts Conditions for di a gnostic appl i cation to memorized failure: Set the contact on.
  • Page 141 IGNITION AND INJECTION Diagnostic – Failures interpretation CYLINDE RS 1-4 IGNITI O N COIL CIRCUIT DF 061 1.DEF : Open ci r cuit or short-circuit PRESENT CO : Open ci r cuit CC.O : Short-circuit at mass MEM OR IZED CC.1 : Short-circuit at +12 volts Conditions for di a gnostic appl i cation to memorized failure: Start the engine and stop it immediately as the failure is occurring as being...
  • Page 142 IGNITION AND INJECTION Diagnostic – Failures interpretation CYLINDERS 2-3 IGNIT ION COIL CIRCUIT DF 062 1.DEF : Open ci r cuit or short-circuit PRESENT CO : Open ci r cuit CC.O : Short-circuit at mass MEM OR IZED CC.1 : Short-circuit at +12 volts Conditions for di a gnostic appl i cation to memorized failure: Start the engine and stop it immediately as the failure is occurring as being present (risk for catalyst) or rotate de engine with the starter, without starting...
  • Page 143 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 064 VEHICLE SPEED INFORMA TION PRESENT MEM OR IZED Conditions for di a gnostic appl i cation to memorized failure: Perform a drive test and notice the vehicle speed. Continue to perform the drive test uphill at constant speed. Continue to perform the drive test uphill, the acceleration pedal not being RECOMMENDATIONS pushed.
  • Page 144 IGNITION AND INJECTION Diagnostic – Failures interpretation DF102 OXYGE N SENSOR FUNCTIONAL FAILURE PRESENT It shows an incoherent information received b means of the upstream oxygen sensor. MEM OR IZED Apply this diagnostic if the failure is present or memorized. RECOMMENDATIONS Check for leakage on exhaust line.
  • Page 145 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 106 CATALYST FUNCTIONAL F AILURE PRESENT It shows an incoherent information received before and after catalyst by means of the two oxygen sensors. MEM OR IZED Apply this diagnostic if the failure is present or memorized. RECOMME N DATI O NS Check for leakage on exhaust line.
  • Page 146 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 109 POLLUT ED COMBUSTION MISFIRE DF 110 DESTRUCTIVE COMBUSTION MISFIRE PRESENT MEM OR IZED State ET014 : Recognition of the cylinder 1 must be active, in order to identify each cylinder. ET093 : combustion misfire on cyl i nder 1 ET094 : combustion misfire on cyl i nder 2 RECOMME N DATI O NS ET095 : combustion misfire on cyl i nder 3...
  • Page 147 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 109 DF 110 CONTINU ATION ET093 : combus t ion misfire on cylinder 1 ET094 : combustion misfire on cyl i nder 2 ET095 : combus t ion misfire on cylinder 3 RECOMMENDATIONS ET096 : combustion misfire on cyl i nder 4 These will provide information regarding failure cause and location.
  • Page 148 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 118 PRESENT MEM OR IZED On the vehicles equipped with refrigerant fluid pressure transducers, the injection computer is recalculating the value of the PR044 parameter: Compressor absorbed power, starting from the RECOMMENDATIONS values of the refrigerant fluid pressure.
  • Page 149 IGNITION AND INJECTION Diagnostic – Failures interpretation OBD INDICA TOR CIRCUIT DF 120 1. DEF : Open ci r cuit or short-circuit PRESENT CO : open circuit CC.O : shot circuit at mass MEM OR IZED CC.1 : short circuit at + 12 V. Apply the diagnostic in such way so that failure is present or memo rized.
  • Page 150 IGNITION AND INJECTION Diagnostic – Failures interpretation FUEL PUMP RELA Y CIRCUIT DF 261 1. DEF Supply failure + after rel a y PRESENT 2. DEF Open ci r cuit or short-circuit MEM OR IZED If failure “DF345 : Su pply 5 volts potentiometers and sensors” is present or memori z ed, it must be treate d as most important .
  • Page 151 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 261 CONTINU ATION RECOM MEND ATIONS It is a failure on the power circuit of the fuel 2. DEF pump relay. Check the connection and con dition of the fuel pump relay connector. Replace the connector if necessary.
  • Page 152 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 271 ACTUA TORS RELA Y EXIT VOLTAGE PRESENT 1. DEF Open ci r cuit or short-circuit MEM OR IZED Conditions for di a gnostic appl i cation at memorized failure: Set the contact off and wait until the communication with the computer is lost.
  • Page 153 IGNITION AND INJECTION Diagnostic – Failures interpretation DF 345 SUPPL Y + 5 VOLTS POTENTIO METERS AND SENSORS 1. DEF Open ci r cuit or short-circuit PRESENT RECOM MEND ATIONS Check with the contact set on, the parameter “PR004: computer supplying voltage”...

  • Page 154: Diagnostic - Help

    IGNITION AND INJECTION Diagnostic – Help Valve potentiometer resistance Track = 1200 Ω ± 20 % Slider = < 1050 Ω = 53 Ω ± 10% Idling regulator resistance at 25°C Ignition coil resistance Primary = 0.5 Ω ± 5 % Secondary = 7200 Ω...

  • Page 155: Diagnostic - Conformity Checking

    IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: Stopped engine, contact set on. Sequence Function Parameter / Control l ed state or acti o n Visualization Diagnostic and Observations...
  • Page 156 IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: Stopped engine, contact set on. Sequence Function Parameter / Control l ed state or acti o n Visualization Diagnostic and Observations...
  • Page 157 IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: Stopped engine, contact set on. Sequence Function Parameter / Control l ed state or acti o n Visualization Di a gnostic and Observations...
  • Page 158 IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: Warm engine at idling and no cons umers. Sequence Function Parameter/Controlled s tate or action Visualization Diagnostic and Observations Battery ET001 : +after contact computer...
  • Page 159 IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: Warm engine at idling and no cons umers. Sequence Function Parameter/Controlled s tate or action Visualization Diagnostic and Observations In case of a problem Anti-detonationPR013 : Det o nation average signal...
  • Page 160 IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: Warm engine at idling and no cons umers. Diagnostic Sequence Function Parameter/Cont rolled state or actio n Visualization and Observations Engine...
  • Page 161 IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: During a drive test Sequence Function Parameter /Contro lled sta te or action Visualization Diagnostic and Observations ET032 : Canister purging ACTIV E Canister purging...
  • Page 162 IGNITION AND INJECTION Diagnostic – Conformity checking RECOM MEND ATIONS The values shown on this conformity checking are only as indication. Performing conditions: During a drive test Seq uen ce Function Parameter/ C ontrolled state Visualization Diagnostic or action and Observations After memorizing the adaptation Enriching values...

  • Page 163: Diagnostic - States Interpretation

    IGNITION AND INJECTION Diagnostic – States interpretation CLIMATE CONTROL REQUEST ET009 RECOM MEND ATIONS No failure must be pres ent or memorized. The injection computer is not noticing the air conditioning starting control. Check the insulation and continuity on the line from pin 23 (climate control of type Info Power Absorbed by com pressor) or from pi n 46 (climate control of type Logical connection) of the injection computer.
  • Page 164 IGNITION AND INJECTION Diagnostic – States interpretation ET035 LOW SPEED ENGINE FAN RECOM MEND ATIONS No failure on the water temperature sensor circuit must be present in order to perform this diagnostic. Check: engine fan condition engine fan resistance condition condition f the engine fan mass connection low speed engine fan supply supply line between engine fan and engine fan relay...
  • Page 165 IGNITION AND INJECTION Diagnostic – States interpretation HIGH SPEED - ENGINE FAN ET036 RECOM MEND ATIONS No failure on the water temperature sensor circuit must be present in order to perform this diagnostic Check: engine fan condition engine fan resistance condition condition of the engine fan mass connection high speed engine fan supply supply line between engine fan and engine fan relay...
  • Page 166 IGNITION AND INJECTION Diagnostic – States interpretation ENRICHING ADJUSTMENT ET037 RECOM MEND ATIONS No failure must be pres ent or memorized. Check the connection and condition of the upstream oxygen sensor connector Mend if necessary Check the ignition Check the tightening of the canister purging valve (a leak is appreciably disturbing the mixture enriching achievement).
  • Page 167 IGNITION AND INJECTION Diagnostic – States interpretation IDLING ADJUSTM ENT ET039 RECOM MEND ATIONS No failure must be pres ent or memorized. Attention to the rec ommended value of idling RPM: PR041 Check the connection and condition of the idling regulator connector. Replace the connector if necessary.
  • Page 168 IGNITION AND INJECTION Diagnostic – States interpretation ET070 CLIMATE CONT ROL COMPRESSOR RECOM MEND ATIONS No failure must be pres ent or memorized. Check the insulation and continuity on the line starting from pin 10 of the injection computer. Mend if necessary. If the incident is persisting, consult the climate control diagnostic AFTER Restart the conformity checking from the beginning.

  • Page 169: Diagnostic - Parameters Interpretation

    IGNITION AND INJECTION Diagnostic – Parameters interpretation PR001 MANIFOLD PRESSURE RECOM MEND ATIONS No failure must be pres ent or memorized. Incoherent manifold Check the insulation, continuity and the absence of the parasite pressure, contact on resistance of the con nections between: Pin 15 injection computer >...
  • Page 170 IGNITION AND INJECTION Diagnostic – Parameters interpretation PR002 WATER TEMPERA TURE No failure must be pres ent or memorized. RECOM MEND ATIONS If the value red is incoherent, check t h at sensor is correctly following the standard curve “resistance subject to temperature”.
  • Page 171 IGNITION AND INJECTION Diagnostic – Parameters interpretation AIR TEMPERA TURE ET003 No failure must be pres ent or memorized. RECOM MEND ATIONS If the value red is incoherent, check that sensor is correctly following the standard curve “resistance subject to temperature”. Replace the sensor if this is presenting deviations (Observation: the presence of the deviations from normal values of a sensor are often due further to an electric shock).
  • Page 172 IGNITION AND INJECTION Diagnostic – Parameters interpretation COMPUTER SUPPL YING VOLT AGE PR004 RECOMMEN DATIONS No failure must be pres ent or memorized. No consumers If voltage > Min, the batte r y is discharged : Check that charging voltage is correct with and without consumers. Under contact If voltage >...
  • Page 173 IGNITION AND INJECTION Diagnostic – Parameters interpretation V ALVE POSIT ION PR017 RECOM MEND ATIONS No failure must be pres ent or memorized. Limit mem orizing of Check that potentiometer mechanical limitter has not been PR008 or non-detection Check the acceleration control (friction, pedal ET005 obstacle,…). of the released acceleration pedal ET003 or non-detecting...
  • Page 174 IGNITION AND INJECTION Diagnostic – Parameters interpretation PR030 ENRICHING ADAPTATION IN OPERA TION PR031 ENRICHING ADAPTATION AT IDLING RECOM MEND ATIONS No failure must be present or memorized. Perform the steps for memorizing the adaptation values by the injection computer. Erase the computer memory.
  • Page 175 IGNITION AND INJECTION Diagnostic – Parameters interpretation FUEL PUMP RELA Y AC010 RECOM MEND ATIONS No failure must be pres ent or memorized. Before perform this checking, check the lines correspondence on the electric diagram adequate to that vehicle. Check that choke sensor is in operating condition Mend the choke sensor if necessary.
  • Page 176 IGNITION AND INJECTION Diagnostic – Parameters interpretation WATER TEMPERATURE WARNING INDICATOR AC212 RECOM MEND ATIONS No failure must be pres ent or memorized. Check the mass presence on the indicator line, after control activating. Mend if necessary If a short-circuit has occurred at the supply circuit +12 volts on the indicator line, the instrument panel may be damaged.

  • Page 177: Failure Locating Algorithm

    IGNITION AND INJECTION Failure locating algorithm Do not use these information but before performing the complete RECOM MEND ATIONS checking by means of the CLIP tester IMPOSSIBI L ITY OF COMMUNICA TION UCE INJECTION - CLIP TESTER ALP 1 ST ARTING PROBLEMS (engine is not starting or is difficulty starting) ALP 2 IDLING PROBLEMS (unstable idl i ng)
  • Page 178 IGNITION AND INJECTION Failure locating algorithm ALP 1 IMPOSSI B ILITY OF COMMUNICA TION UCE INJECTION CLIP TESTER RECOM MEND ATIONS Nothing to be noticed Ensure that not the CLIP tester is the cause of the failure, by trying to communicate with the computer of another vehicle.
  • Page 179 IGNITION AND INJECTION Failure locating algorithm ALP 2 STARTING PROBLEMS engi n e is not starting or i s difficulty starting) Do not consult this diagnostic but before performing a complete RECOM MEND ATIONS checking by means of the CLIP tester. Check that starter is well operating Check there is petrol in the fuel tank (fuel indicator failure).
  • Page 180 IGNITION AND INJECTION Failure locating algorithm ALP 3 IDLING PROBLEM S (uns t able idl i ng) RECOM MEND ATIONS Do not consult this diagnostic but before performing a complete checking by means of the CLIP tester. Check if there is petrol in the fuel tank (fuel indicator failure) Check if the vehicle is supplied with adequate fuel Check that supply circuit hoses are not broken (especially further to a dismounting) Check the condition of the fuel filter...
  • Page 181 IGNITION AND INJECTION Failure locating algorithm ALP 4 INTEMP ERA TE ACCELERA TION OR DECELERA TION (engine unstable running) RECOM MEND ATIONS Do not consult this diagnostic but before a complete checking by means of the CLIP tester Check if air filter is not deformed. Check if there is petrol in the fuel tank (fuel indicator failure) Check if the vehicle is supplied with adequate fuel Check that supply circuit hoses are not broken (especially further to a dismounting)
  • Page 182 IGNITION AND INJECTION Failure locating algorithm ENGINE OPERATION BREAKDOWN ALP 5 Do not use these information but after performing complete RECOM MEND ATIONS checking by means of CLIP tester. Check the follo wings : - fuel conformity; - lack of air circuit clogging, supply circuit and fuel circuit; - lack of important air leak;...
  • Page 183 IGNITION AND INJECTION Failure locating algorithm ENGINE STOPPING ALP 6 Do not use these informations but after performing complete RECOM MEND ATIONS checking by means of CLIP tester. Check the follo wings : - lack of air circuit clogging, supply circuit and fuel circuit. - lack of fuel leak - injectors - injecton pump...
  • Page 184 IGNITION AND INJECTION Failure locating algorithm ENGINE NOISE ALP 7 Do not use these information but after performing complete RECOM MEND ATIONS checking by means of CLIP tester. Check the followings: - lack of air leak; - pre-heating spark plugs; - injection pump setting on;...
  • Page 185 IGNITION AND INJECTION Failure locating algorithm ALP 8 SMOKE Do not use these informations but after performing complete RECOM MEND ATIONS checking by means of CLIP tester. Check the followings: - injection pump setting on; - injectors; - injection pump; - lack of air leak;...
  • Page 186 IGNITION AND INJECTION Failure locating algorithm LACK OF PERFORMANCES ALP 9 Do not use these informations but after performing complete RECOM MEND ATIONS checking by means of CLIP tester. Check the follo wings : - fuel conformity; - lack of air circuit clogging, supply circuit and fuel circuit; - lack of fuel leak and air leak;...
  • Page 187 IGNITION AND INJECTION Failure locating algorithm FUEL CONSUMPTION ALP 10 Do not use these informations but after performing complete RECOM MEND ATIONS checking by means of CLIP tester. Check the follo wings : - air filter; - diesel filter; - vahicle exploitation conditions; - injectors.

  • Page 188: Cooling - Exhaust - Tank

    COOLING - EXHAUST - TANK Characteristics COOLING FLUID QUANTITY AND QUALITY ENGI NE QUANTI TY* (liter s ) QU ALITY CHARA CTERISTICS Antifreeze type D Protection until –40°C GLACEOL RX 〈 Mixture : 50% concentrated antifreeze + 50% distilled water. THERMOST AT ENGIN E TYPE OPENING STAR T (°C)

  • Page 189: Filling - Purging

    COOLING - EXHAUST - TANK Filling - Purging The heating radiator has no valve. The fluid circulation is permanently done in the heating radiator, this leading to the engine cooling. FILLING Open the purging screw located on the water pipe between engine and climate control radiator. Fill up the circuit by the expansion vessel hole Tighten the purging screws in the moment when the fluid is flowing in a continuos jet.

  • Page 190: Checking

    COOLING - EXHAUST - TANK Checking SPECIAL TOOLS MS 554-01 Adapter for M.S. 554-07 MS 554-06 Adapter for M.S. 554-07 MS 554-07 Kit for checking the cooling system sealing 1. CIRCUIT SEALING CHECKING 2. CHECKING ALVE CALIBRATION Mount the adapter M.S 554 –01 instead of Mount the expansion vessel valve on the expansion vessel valve.

  • Page 191: Cooling System Diagram

    COOLING - EXHAUST - TANK Cooling system diagram Thermostat Water pump Composition : 1. Engine 2. Cooling radiator 3. Expansion vessel 4. Heating radiator 5. Thermostat support 6. Nozzle Ø 3 7. Purging screw T. Thermostat The operation of the engine fan is controlled by the UCE injection, as follows: 1.

  • Page 192: Radiator

    COOLING - EXHAUST - TANK Radiator SPECIAL TOOLS Pliers for elastic clips MOT 1202 - 01 Hoses clamp MOT 453 DISMOU NTIN G Carefully remove the engine fan from the Drain the air conditioning unit – for the ve- sustaining points (7). hicles with air conditioning (see chapter 62”...
  • Page 193 COOLING - EXHAUST - TANK Radiator For the vehicles with air conditionin g : - Connect the two pipes to the condenser. - Connect the engine fan resistance connector (1) and the engine fan connector, then attach it by clips. Connect the battery.

  • Page 194: Cooling Engine Fan For Vehicles Without Air Conditioning

    COOLING - EXHAUST - TANK Cooling engine fan for vehicles without air conditioning DISMOU NTIN G Disconnect the battery (-) terminal. Remove the air inlet pipe from the attachment of the battery screen. Detach from clips the oil reservoir of the power steering from the battery screen. Disconnect the engine fan connector (1) and detach from clips wiring of point (2) Dismount the four attachment screws (3) of the engine fan on radiator.

  • Page 195: Diagnostic - Failures Interpretation At Vehicles Without Air Conditioning

    COOLING - EXHAUST - TANK Diagnostic – failures interpretation at vehicles without air conditioning COOLING ENGINE FAN NOT WORKING (for vehicles without air conditioning) Replace Check fuse F01 from engine fuse compartment. Is it good? Start the vehicle’s engine. Disconnect the water Replace water temperature sensor.
  • Page 196 COOLING - EXHAUST - TANK Cooling engine fan for vehicles with air conditioning DISMOU NTIN G Disconnect the battery (-) terminal. Remove the air inlet pipe from the attachment of the battery screen. Detach from clip the power steering oil reservoir from the battery screen. Disconnect the engine fan connector (1) Detach wiring from clips (2) and (3).

  • Page 197: At Vehicles With Air Conditioning

    COOLING - EXHAUST - TANK Diagnostic – failures interpretation at vehicles with air conditioning 19 - 10 vnx.su...
  • Page 198 COOLING - EXHAUST - TANK Water pump SPECIAL TOOLS MOT. 1202-01 Pliers for elastic clips MOT. 1505 Device for belts tension measurement MOT. 1135-01 Device for distribution belt tensioning MOT. 545 Engine sustaining device TIGHTENING MOMENTS (daNm) Tightening cam nut Crankshaft pulley hub screw ±...
  • Page 199 COOLING - EXHAUST - TANK Water pump CLEANING It is very important not to scratch the surfaces for gaskets of the aluminum parts. In order to dissolve the gasket particles stacked, product “Decapjoint” is to be used. Apply the product on the surfaces to be cleaned, leave it for about 10 minutes, then clean using a wood palette knife.

  • Page 200: Exhaust Assembly

    COOLING - EXHAUST - TANK Exhaust Assembly ATTENTION ! Descending pipe in operation, may reach high temperatures and consequently must not come in contact with flammable materials which may lead to their auto-ignition. Catalytic converter is to be mechanical shock protected. DISMOU NTIN G n order to dismount the noise absorber assembly (1), lift the vehicle on an elevator and perform the following operation s:...
  • Page 201 COOLING - EXHAUST - TANK Assembl exhaust 19 - 14 vnx.su...

  • Page 202: Fuel Tank

    COOLING - EXHAUST - TANK Fuel tank IMPORTANT: From the fuse box located inside the engine During the intervention on the fuel tank compartment, remove the H relay of the petrol and on the fuel supply circuit, at the working pump and bridge across plugs 3 and 5 of the place, do not smoke and do not bring near relay connector, ensuring the petrol pump...
  • Page 203 COOLING - EXHAUST - TANK Fuel tank FILLING CAP The fuel tank is having a filling cap, sealed -type, with key. The filling cap for unleaded fuel has a filler whole incompatible with a classical filling gun (lead has a negative effect upon the de- pollution system : oxygen sensor and catalyst) .
  • Page 204 COOLING - EXHAUST - TANK Fuel tank REMOU NTIN G Perform the dismounting operatio ns in the reverse order. DISMOU NTIN G The tightening moment of the fuel tank Drain the fuel tank (4) Disconnect the battery. attachment screws on the carriage body is of 2.1 daNm and the tightening moment for fuel Remove the trunk carpet.
  • Page 205 COOLING - EXHAUST - TANK Fuel tank VEHICLES WITHOUT VISITING CAP TIGHTENING MOMENTS (daNm) Fuel tank attachment screws IMPORTANT : Dur ing thi s operation compulsory: - not smoking and not approaching with incandescent objects in the working area, - keep away from fuel spraying when disc onnectin g fu el...
  • Page 206 COOLING - EXHAUST - TANK Fuel tank TANK DIAGRAM 1. Aerating pip 2. Safety valve (over pressure, depression) 3. Anti-overturning valve 4. Pipe connection to carbon can 5. Restrictor E. Air evacuation orifice during filling F. Air volume enabling fuel dilatatio n. R.
  • Page 207 COOLING - EXHAUST - TANK Fuel tank FUEL CIRCUIT DIAGRAM 1. Supply pipe 2. Carbon can 3. Piping attachmen t clip 4. Vapor re-aspiration pipe. 5. Fuel tank. 19 - 20 vnx.su...
  • Page 208 COOLING - EXHAUST - TANK Fuel tank Valves function Safety valve ( over pressure, depression) In case recyclin g circuit of the petrol vapors is clogged, this valve is avoiding the over-pressur e (inflated tank) or the depression (by fuel consumption - the tank is flattening). Restrictor Does not allow leaded fuel filling in the tank.

  • Page 209: Fuel Pump

    COOLING - EXHAUST - TANK Fuel pump SPECIAL TOOLS MOT 1397 Wrench for dismounting the fuel pump assembly nut TIGHTENING MOMENTS (daNm) Fuel pump assembly nut Dismount the fuel pump asse mbly (2) attachment IMPOR TANT During the interv ention on the fuel tank or on the nut (1), by means of the MOT 1397 device, after fuel supply circu it, it is absolutely neces sary : - not smoking and not bringing near any incan-...
  • Page 210 COOLING - EXHAUST - TANK Fuel pump VEHICLES WITHOUT VISITING CAP SPECIAL TOOLS MOT 1397 Wrench for pump assembly dismounting- remounting Remark: TIGHTENING MOMENTS (daNm) If until fuel pump mounting on tank, Fuel tank attac hment screws more than an hou r is taken in to Pump assembly attachment nut consideration, remount the nut on the tank, in order to avoid any distortion.

  • Page 211: Fuel Filter

    COOLING - EXHAUST - TANK Fuel filter For EURO 2 and EURO 3 The fuel filter is mounted on the fuel pump assembly placed in the fuel tank. Its replacement is implying the replacement of the entire fuel pump assembly (1). For de-pollution norm 1504 The fuel filter is attached on the front side of the fuel filter.

  • Page 212: Engine Suspension

    COOLING - EXHAUST - TANK Engine suspension TIGHTENING MOMENTS (daNm) 19 - 25 vnx.su...

  • Page 213: Clutch

    CLUTCH Identification Engine Vehicle Mechanism Disk type type 26 grooves V: Green D = 181.5 mm G: Grey E = 6.8 mm SOLENZA 180 CPO 3300 CHARACTERISTICS - Single disk dry clutch cable controlled. - Clutch mechanism with diaphragm spring. - Clutch disk with elastic hub.

  • Page 214: Diagnostic

    CLUTCH Diagnostic GEARS ENGAGING PROBLEMS Check the clutch disk release (see the checking method bellow described.) Check the clutch releasing fork stroke Is the release correct ? (see the method bellow described). Is the fork stroke correct? Check the adjustment of the gearbox extern control lever (adjust if necessary).
  • Page 215 CLUTCH Diagnostic EFFECT OF TREPIDATION Check for oil leaks at the clutch Fix the oil leak and replace the clutch casing level. disk if necessary. If there are no leaks. Check the tightening and the condition of the gearbox and engine supports (fix it if necessary).
  • Page 216 CLUTCH Diagnostic NOISE AT FREE CLUTCH (oppressive and regular noise subject to engine regime) Check for oil leaks at clutch casing Fix the oil leak and replace the level. clutch disk if necessary. If there are no leaks. Check the engine running at idling (unstable or incorrect).

  • Page 217: Clutch Disk - Mechanism

    CLUTCH Clutch disk – Mechanism REPLACEMENT This operation is to be performed after dismounting the gearbox –engine assembly and after their separation. S.D.V. -uri necesare MOT 582 Flywheel immobilizing sector AMB 1518 Clutch centering device - the wear of the pressure bearing guide TIGHTENING MOMENTS (daNm) and of the control fork;...
  • Page 218 CLUTCH Clutch disk – Mechanism Mount the clutch mechanism. Progressively screw “radial way”, the mechanism attachment screws, then tighten them to the required moment. Dismount the immobilizing sector MOT 582. Lubricate with grease OLISTA LONG TIME 3EP R100 137188. - bearing guiding tube; - clutch releasing fork sliders;...

  • Page 219: Pressure Bearing - Clutch Releasing Fork

    CLUTCH Pressure bearing – Clutch releasing fork REPLACEMENT This operation is to be performed after separation of the gearbox. from engine DISMOUNTING Dismount: - pressure bearing by swinging over the fork; - protection bellows and remove the clutch-releasing fork. REMOUNTING Lubricate the guiding tube, slides and fork joint with grease OLISTA LONG TIME 3EP R100 137188.

  • Page 220: Engine Flywheel

    CLUTCH Engine flywheel REPLACEMENT This operation is to be performed after dismounting the clutch mechanism and the gearbox. SPECIAL TOOLS MOT 582 Flywheel immobilizing sector TIGHTENING MOMENTS (daNm) Flywheel screws 5 ÷ 5,5 DISMOUNTING Mount the immobilizing sector MOT 582. Dismount the flywheel attachment screws.

  • Page 221: Mechanical Gearbox

    MECHANICAL GEARBOX CV JH3 - 051 Sectional view 21 - 1 vnx.su...

  • Page 222: Identification

    MECHANICAL GEARBOX Identification CV JH3 - 051 A - type of gearbox B – index of gearbox C – manufacturer’s series D – the code for the manufacturing 000000 21 - 2 vnx.su...

  • Page 223: Tightening Moments In Danm

    MECHANICAL GEARBOX CV JH3 - 051 Tightening moments in daNm TIGHTENING MOMENTS (daNm) Attachment screws of the mechanism crankcase on the clutch – differential case Secondary shaft screw Primary shaft nut Back cap fixing screws Oil draining plug Reverse driving contact Screws for fixing the bellows assembly –...

  • Page 224: Particurarities

    MECHANICAL GEARBOX Particurarities CV JH3 - 051 Grila de viteze este identicã cu cea de la cutiile de viteze montate pe automobilele Dacia SupeRNova. To engage the reverse driving, the gearbox lever is brought in neutral position, then it is en- gaged like in any other gear gear The synchronizers are BORG –...

  • Page 225: Ratios

    3.727 2.048 1.393 1.029 0.795 3.545 CAPACITY , LUBRICANTS Oil used : Dacia Extragear 75 W – 80 W; API GL5 The oil quantity needed for the gearbox operation is 3.5 liters. The oiling of the gearbox parts is done by splash lubrication Checking of the oil level is done through the filling plug A.
  • Page 226 MECHANICAL GEARBOX CV JH3 - 051 Ingredients TYPE LOCTITE 518 Crankcases assembling Thread of reverse driving contact LOCTITE FRENBLOC Secondary shaft screw 21 - 6 vnx.su...
  • Page 227 Capacity, lubricants CV JH3 - 051 Oil used : Dacia Extragear 75 W – 80 W; API GL5 The oil quantity needed for the gearbox operation is 3.5 liters. The oiling of the gearbox parts is done by splash lubrication Checking of the oil level is done through the filling plug A.

  • Page 228: Parts That Are Replaced After Each Dismonting

    MECHANICAL GEARBOX CV JH3 - 051 Parts that are replaced after each dismonting The following parts are to be replaced, if they have been dismounted: - oil seal rings; - fasten ing rings; - elastic pins; - primary shaft nut; - the bushing under the pinion of the 5 –...

  • Page 229: Necessary Special Tools

    MECHANICAL GEARBOX CV JH3 - 051 Necessary special tools SER VICE DENOMINA TION DACIA COD E ITEM NUMBER C.V. 22 - 01 Bearings extractor b ody 1002216401 C.V. 945 Chuck for mou nting the planetary pinion oil ring 1002094500 C.V. 946...

  • Page 230: Gearbox Dismounting

    MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 ATTENTION ! The dismounting and checking of the parts must be done on a surface coated with rub- ber or soft plastic. Before taking apart the gearbox from the vehicle, drain the oil from the gearbox. DISMOU NTIN G Dismo unt : - clutch release fork (1) ;...
  • Page 231 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting Dismount the elastic pin of the 5 th gear, by means of the C.V. 31 – 01 mandrel. Dismount the fixed pinion of the 5 th gear Dismount the fork and the sliding collar of by means of the C.V.
  • Page 232 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 Dismount the reverse driving contact (A). Remove the pin of the 3-4 fork by means In order to recover the balls and the lock- ing springs of the 1-2 and 3-4 shafts, two of the C.V.
  • Page 233 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting Dismount the secondary shaft assembly to- gether with the axle and 1-2 fork. Remove the primary shaft together with Place vertically the secondary shaft, with the the reverse driving shaft and pinion. pinion of the 1-st gear downwards, so that the other pinions will not fall down.
  • Page 234 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting SHAFTS THE PRIMARY SHAFT The primary shaft shall not be repaired and is not adjustable. The shaft has a groove (B) for oiling the 5-th gear free pinion. Clean the oiling – groove of the 5 th gear The oil seal ring in front of the shaft and the bearing cams are in direct contact with the shaft.
  • Page 235 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 BEARING DISMOUNTING OFF THE MECHANISMS CRANKC ASE The safety ring of the bearing (the holding ring) is enlarged by means of a pair of safety pincers, then the bearing is extracted from the crankcase by hammering towards the inside of the mecha- nisms crankcase, by means of the C.V.
  • Page 236 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 BEARING DISMOUNTING FROM THE CLUTCH – DIFFERENTIAL CRANKC ASE Dismount the clutch shaft bearing towards the clutch opposite direction, by means of the C.V. 553 device. Ensure that device is well fixed upon depressing the bearing. BEARING REMOUN TING FROM THE CLUTCH –...
  • Page 237 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 SECONDARY SHAFT SECONDARY SHAFT DISMOUNTING Dismounting of the secondary shaft is performed starting from the 4 th gear. Dismount the elements, in the following order: 1. – the support washer 2. – gear IV pinion 3.
  • Page 238 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 The stopping rings are to be replaced after each dismounting. For mounting and dismounting the stopping rings, a pair of safety pincers to keep the ends apart, and, on the opposite side, a pair of flat tipped pincers to prevent the stopping ring breaking, are to be used.
  • Page 239 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 REPLACEMENT OF THE SECONDARY SHAFT BEARINGS The secondary shaft bearing from the mechanisms crankcase is identical to the one from the primary shaft so that its dismounting and remounting are performed in the same way as for the primary shaft.
  • Page 240 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting DIFFERENTIAL The differential of the JH3-051 gearbo x 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 –...
  • Page 241 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting The stopping safety device (A) is extracted, by means of a pincers from the differential crankcase (press on clutch crankcase in order to release the safety ring). The differential assembly is dismounted using a press, by means of a bushing C.V. 554 (the bushing is pressing on the differential crankcase).
  • Page 242 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting DIFFERENTIAL BEARINGS REPLACEMENT DISMOU NTIN G In order to extract the big bearing (7), of the differential from the clutch-differential crankcase, a profiled metallic strap is used, which is pressed by means of an extension, at a press. In order to dismount the other bearing (10), first extract the safety (9), then press with a press on the bearing by means of a sleeve with the outer diameter of 50 mm, towards the inside of the clutch-dif ferential crankcase.
  • Page 243 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting MOUNTING OF THE DIFFERENTIAL ASSEMBL Y IN THE CLUTCH CRANKCA SE The differential assembly is pressed into the crankcase, then the stopping safety device (3) is mounted on the planetary shaft by means of the C.V. 946 device. Rotate the differential assembly and check the speedometer pinion rotation.
  • Page 244 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting INTERNAL CONTROLS The internal control axles must not show any deformations or wear on the milling for locking balls, and their sliding on bearings must be done freely, without excessive clearance. The contact surfaces of the forks with collar of the rocking must not show either deformations nor wear.
  • Page 245 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting CONTROL AXLE DISMOUNTING This operation is to be performed after crank- cases separation. The control axle is provided with a blocking element “LOCTOU” –(A) attached on the crankcase. The sealing is ensured by means of the tore gasket (B).
  • Page 246 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting CRANKCASES ASSEMBLING With the 1 – 2 axle in free position, the fol- The assemb ling surfaces must be flat (small lowing are mounted: imperfections can be eliminated by means of - synchronizing assembly 3 – 4 together a thin file).
  • Page 247 MECHANICAL GEARBOX CV JH3 - 051 Gearbox dismounting Mount the elastic pin for reverse driving axle Apply a continuos layer of LOCTITE attachment by means of the C.V. 560 mandrel. 518 on the gasket surface between the clutch crankcase and the mechanism crankcase. Engage the 3 -d gear.
  • Page 248 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 Mount the 5-th gear fix pinion on the sec- Engage the 1-st gear with the gear lever and ondary shaft by means of the C.V. 1175 de- the 5 th gear by sliding the 5-th gear fork on its vice.
  • Page 249 MECHANICAL GEARBOX Gearbox dismounting CV JH3 - 051 Observe the mounting direction, the pin slot must be oriented towards the back cap. Bring the gearbox in the neutral position Mount a new gasket to ensure the back cap sealing. Mount the back cap with the A groove in the primary shaft, and the oiling collector in the B oil collecting groove, and tighten the screws at the required moment of 2,5 daNm .

  • Page 250: Replacement Of The Planetary Sealing Gasket (On The Vehicle)

    MECHANICAL GEARBOX Replacement of the planetary CV JH3 - 051 sealing gasket (on the vehicle) SDV-uri SPECI ALE NECESARE C.V. 945 Mandrin montare garniturã etanºare planetarã Remove the “O” ring off the planetary shaft, TIGHTENING MOMENTS (daNm) then, by means of a pins mandrel and a hammer, Shock absorber attachment is gently hit in order to make it pivoting in its place.
  • Page 251 MECHANICAL GEARBOX Replacement of the planetary CV JH3 - 051 sealing gasket (on the vehicle) Position and mount the planetary transmission on the planetary pinion. Perform the dismounting operations in the reverse order Tighten at the required moment the screws and the nuts. Perform the oil filling of the gearbox.

  • Page 252: Replacement Of The 5-Th Gear Synchroniser And Pinion (On The Vehicle)

    MECHANICAL GEARBOX Replacement of the 5-th gear synchroniser CV JH3 - 051 and pinion (on the vehicle NECESSARY SPECIAL TOOLS C.V. 22 – 01 Bearings extractor body C.V. 31 - 01 Mandrels set for elastic pins C.V. 1000 Extractor for the 5-th gear fix pinion C.V. 1170 Extractor for the 5-th gear hub.
  • Page 253 MECHANICAL GEARBOX Replacement of the 5-th gear synchroniser CV JH3 - 051 and pinion (on the vehicle C.V. 31-01 C.V. 22-01 C.V. 1000 Bring the gearbox in the neutral position. Extract the synchroniser hub by means of the REMOU NTIN G extractor C.V.
  • Page 254 MECHANICAL GEARBOX Replacement of the 5-th gear synchroniser CV JH3 - 051 and pinion (on the vehicle Mount on the primary shaft, in the following sequence: - the support washer (with the larger side towards the pinion ) - the bushing under the pinion; - the free 5 th pinion equipped with its synchroni s er ring ;...

  • Page 255: Transmission

    TRANSMISSION Front transversal transmission SPECIAL TOOLS RO 604-01 Hub immobilizing device PF 476 Ball joint extractor TIGHTENING MOMENTS (daN/m) Transmission nut Screw for fixing the bellows lid on the gearbox Wheels attachment screw Scre ws, nuts for fixing the stee ring knuckl e on the shock absorber 10,5 Screw for fixing the caliper on the steering knuckle Nut for steering ball joint DISMOUNTING - THE SIDE TO W HEEL...
  • Page 256 TRANSMISSION Front transversal transmission DISMOUNTING – THE SIDE TO THE GEARBOX The right side Due to the solution assumed by the manufacturer, the transmission joint (the tulip of the transmission) with the transmission shaft of the gearbox shall be performed only by mea the grooves.
  • Page 257 TRANSMISSION 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 lid on the gearbox. The right side Grease the tulip frame grooves (the grooves area) and the transmission shaft of the gearbox with transmission oil.

  • Page 258: Bellows - Bearing Assembly To The Gearbox (Left)

    TRANSMISSION Left Bellows - Bearing assembly transmission to the gearbox THE JOINT TO THE GEARBOX - GI SPECIAL TOOLS Bearing mounting chuck on the shaft PF 1331 1. Tripod assembled 2. Bellows 3. bearin g 4. bellows attachmen t lid 5.
  • Page 259 TRANSMISSION Left Bellows - Bearing assembly transmi s sion to the 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.
  • Page 260 TRANSMISSION Left Bellows - Bearing assembly transmi s sion to the gearbox Maintaining the transmission on the press, on both sides, shall be ensured on the G groove made on shaft, by means of a device type FACOM U 53 G, ( the flat side towards bellows) in order to avoid the deflector damages on the wheel side.

  • Page 261: Bellows To Wheel (Left)

    TRANSMISSION Left transmi s sion Bellows to wheel JOINT TOWARDS WHEEL SPECIAL TOOLS GE 86 joint bellows replacement device PF 537-04 1. Steering knuckle casing ass. 2. Retainer star 3. Tripod to the wheel 4. Tulip shaft 5. Maintai n ing collars 6.
  • Page 262 TRANSMISSION Left transmi s sion Bellows to wheel REMOUNTING The mounting of the new bellows is to be performed by means of the PF 573 – 04 device. Catch the inclined transmission in a vice with soft jaws in order to avoid the shaft damaging. Engage the PF 537 –...
  • Page 263 TRANSMISSION Left transmi s sion Bellows to wheel Introduce the smaller diameter of the bellows on the PF 537 – 04 device. Cover a hand with clean gauze and place it on the bellows in such a way as to stretch the first fold.
  • Page 264 TRANSMISSION Left transmi s sion Bellows to wheel Catch the steering knuckle casing in a vice with soft jaws. Put the spring and head in the tripod groove. Brings the clogs to the center. Position the retaining star (S), and each of its arms, being at the bisecting lines of the angles formed by the tripod arms.
  • Page 265 TRANSMISSION Left transmi s sion Bellows to wheel Position the two bellows beads in the grooves of the steering knuckle casing, consequently on the transmission shaft tube. Place a non-cutting, round headed rod between the transmission shaft and the bellows in order to dose the amount of air inside.

  • Page 266: Bellows To Gearbox (Right)

    TRANSMISSION Right transmissi on Bellows to gearbox JOINT TOWARDS GEARBOX - GI 1. Tulip 2. Tripod 3. Blocking ring 4. Rubber bellows 5. Maintai n ing collars DISMOU NTIN G Cut the maintaining collar. Cut by means of a saw the existent collar, taking care not to scratch the tulip in the mounting area with the bellows.
  • Page 267 TRANSMISSION Right transmissi on Bellows to gearbox Cut the bellows. Remove maximum of grease. NOTE : The tulip not being equipped with a hood having retainin g wings, dismounting is to be performed without forcing. It is avoided the cams exit from the trunnions (tripod arms) because the roll- needles and the cams are paired and must be not reversed.
  • Page 268 TRANSMISSION Right transmissi on Bellows to gearbox Using a press, extract the assembled tripod, sustain it on an extractor type FACOM U 53 G, protecting the clogs of the tripod. REMOU NTIN G Grease the transmission shaft to help the protection bellows putting back (positioning of the smallest diameter of the bellows on the transmission shaft).

  • Page 269: Bellows To Wheel (Right)

    TRANSMISSION Bellows to wheel JOINT TOWARDS THE WHEEL – GE 1. Steering knuckle casing assembled 2. Retaining star. 3. Tripod to wheel 4. Tulip shaft 5. Maintainin g collars 6. Protection rubber bellows DISMOU NTIN G Dismount the two maintaining collars using two rod s locally produced (see the method previously described for dismounting the joint GE, left transmission) .

  • Page 270: General

    GENERAL General principle schedule of the brake circuit DACIA SOLENZA vehicles, are equipped with hydraulic braking system, brake pump with by-pass double circuit, braking booster, brake limiter in order to avoid the rear wheels blocking Front brakes are disc type and rear brakes are hub type.

  • Page 271: Tightening Moments (In Danm)

    GENERAL Front Tightening moments (in daNm) axle FRONT HALF-AXLE 10.5 7...7.5 10.5 30 - 2 vnx.su...
  • Page 272 GENERAL Front axle Tightening moments (in daNm) FRONT HALF-AXLE 10.5 30 - 3 vnx.su...
  • Page 273 GENERAL Rear axle Tightening moments (daNm) REAR AXLE 30 - 4 vnx.su...
  • Page 274 GENERAL Rear axle Tightening moments (daNm) REAR AXLE 1.45 30 - 5 vnx.su...

  • Page 275: Composition And Dimensions Of The Main Braking System Elements

    GENERAL Composition and dimensions of the main braking system elements Front brakes - brake caliper bore diameter → 54 mm - brake disk diameter → 235 mm - disk axial runout measured at → 215 0. 04 mm - brake disk maximal thickness 20 mm - brake disk minimal thickness 19 mm...

  • Page 276: Braking System Diagnostic

    GENERAL Braking system diagnostic Rigid ped al: when braking, an I. FAILURE : RIGID PEDAL increased effort for a small decel- eration is performed Is the connection Replace: shaft, pedal or shaft between the servobrake fork. servobrake fork and the pedal, grabed? Is the engine Replace the servobrake...
  • Page 277 GENERAL Braking system diagnostic I. FAILURE : RIGID PEDAL (ctd) One of the rigid Replace the corresponding rigid brake pipes is it pipe. smashed ? Dismount the brake caliper or the brake cylinder? Are the brake cali p er’s pistons or Replace the defective parts the cylinders ones (with Genuine Spare Parts)
  • Page 278 GENERAL Braking system diagnostic II. FAILURE : LONG PEDAL When braking, the brake pedal is slowly moving. Perform a test with the stopped engine, after previously performing five successive pushing on the brake pedal (in order to vacuum the servobrake). Is the bra ke fl u id level Locate and repair or replace the lower compared to...
  • Page 279 GENERAL Braking system diagnostic I. CONSTANT EFFECT TO THE PEDAL EFFECTS POSSIBLE CAUSES Tough pedal: - Assistance defect High effort for small decele ration. - Brake linings: - greasy - stacking to the disk ( non-conform ) - heating, prolonged braking with constant pedal press - Stuck piston - Rigid duct narrowed (flattening)
  • Page 280 GENERAL Braking system diagnostic CONSTANT EFFECT AT BEHAVIOUR EFFECTS POSSIBLE CAUSES - Non-uniform worn brake linings (backing Brakes not accomplishing the required braking distance off); - Brake linings slightly greased; - Springs with modified characteristics. Vibrating brakes - Brake disks with high wobbling; - Inconstancy brake disks width;...

  • Page 281: Brake Connections And Ducts

    GENERAL Brake connections and ducts The connection between the brake ducts and the brake pump, brake calipers, pressure limiter is performed by means of the connections threaded with metric pitch. PARTS IDENTIFICATION The cupping shape of the steel ducts (A) The shape of the threaded lengths on parts (B) Connections of ducts (C) 30 - 12...

  • Page 282: Brake Fluid

    Brake fluid PERIODIC CHANGE OF THE BREAK FLUID The manufacturing conception of the brakes equipping the 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.

  • Page 283: Braking System Purging

    GENERAL Braking system purging The air existence in the hydraulic circuit may be noticed by an elastic displacement of the brake pedal, sometimes even, close to the floor. This fact is more evident with the engine running. GENERAL RECOMMENDATIONS · Always use for completion or total changing the brake fluid SAE J 1703 , DOT 4. ·...
  • Page 284 GENERAL Braking system purging OPERATING CONDITIONS The vehicle is on ground, in rear axle half-loaded position. CHECKING THE BRAKE SYSTEM SEALING The vehicle will be idle running. After purging the front and rear circuits, check if the level of brake fluid in reservoir is within the MINI and MAXI marks.

  • Page 285: The Influence Of Angles

    GENERAL 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);...

  • Page 286: Angles Checking Principle

    GENERAL Angles checking principle PRELIMINARY CHECKING Before starting the steering angles checking, it will be necessar y to check the following points and exclude the possible non-conformities. 1. Tires and rims checking, regarding: - type and dimension; - inflating pressure; - wear degree.

  • Page 287: Front Axles Checking And Adjustment

    GENERAL Front axles checking and adjustment THE SEQUENCE OF THE OPERATIONS Due to the geometric conception of the front axle, the modification of one of one-side angles (camber, ball joint, parallelism) has no major impact on the value of other side angles (caster being the one with higher influence).
  • Page 288 GENERAL Front axles checking and adjustment Case 1. The symmetry dimension “X” is correct - the value “A” is equaled distributed on both sides. Case 2 . The symmetry dimension “X” is incorrect - read the value “A” on each side, adds it, and calculate the average value, establishing the value for each side.
  • Page 289 GENERAL Front axles checking and adjustment PARALLELISM ADJUSTMENT Loosen the lock nut (1) maintaining the tie rod of steering connecting rod (2) in a fixed positio n. Act upon the tie rod of steering connecting rod taking into account its rotation sense, in order to obtain the convergence or divergence and also the fact that one of its complete rotation leads to an axial displacement of 1.5 mm.
  • Page 290 GENERAL Front axles checking and adjustment THE DEVIATION TO THE LEFT OR TO RIGHT AT STABLE SPEED Perform the preliminary checking: Wheels (front, rear) : Joints clearance: - pressure - bushings - dimensions - types Checking points heights: - balancing - symmetry a.m.
  • Page 291 GENERAL Front axles checking and adjustment The axle adjustment is correct Replacement of damaged Checking finished elements Deviation persists Checking finished Commute the wheels until the deviation is balanced. CAPTION : To check Performed operations 30 - 22 vnx.su...

  • Page 292: Front Axles Elements

    FRONT AXLES ELEMENTS Characteristics The front axle is composed of two joint half axles with independents wheels, designed for the suspension type Mc.Pherson. The joints of front half axle arm are done by means of an elastic bearing (chassis side) and by means of a suspension ball joint (wheel side) The transmission of the motion to the wheels is done by means of two planetary axles, not equal, with homocinetic tripod joints.

  • Page 293: Suspension Arm

    FRONT AXLES ELEMENTS Suspension arm TIGHTENING MOMENTS (daNm) Wheels attachment screws Suspension arm shaft nuts 10.5 Attachment nut of the ball joint screw Anti – roll bar bearings screws Ball joint attachment screws nuts on the arm 7….7.5 Straps attachment screws REMARK : The dismounting-remounting operations are identical for both half axles (specifying that on the right side one strap is provided and on the left side two straps are provided).
  • Page 294 FRONT AXLES ELEMENTS Suspension arm REMOU NTIN G REMARK : Ensure the presence of the protection plate (A) on the suspension ball joint axle. Perform the operations in the following sequence: − Arm attachment on the power train support without tightening to the required moment the axles nuts (3) .
  • Page 295 FRONT AXLES ELEMENTS Suspension arm The mounting of the arm attach ment axles and of the straps on the frame, is different from left side to right side. RIGHT SIDE LEFT SIDE 31 - 4 vnx.su...

  • Page 296: Elastic Bushings Of The Suspension Arm

    FRONT AXLES ELEMENTS Elastic bushings of the suspension arm Necessary Special Tools P.F. 601 Bushings mounting device P.F. 602 Bushing extractor REPLACEMENT This operation implies bushings replacemen t one by one, in order to maintains their centering as to the arm shaft. The operation is to be performed using a press (mechanical/ manual driving) Dismount one of the bushings, by means of the PF 602 device, using a 31 mm outside diam- eter rod.

  • Page 297: Suspension Ball Joint

    FRONT AXLES ELEMENTS Suspension ball joint DISMOU NTIN G Perform the same operations as for dismounting the suspension arm. Unscrew the two attachment nuts (3) of the arm shafts, without their dismounting . Dismo unt : - the ball joint attachment screws (4) on the arm; - the ball joint.

  • Page 298: Brake Lining (Pads)

    FRONT AXLES ELEMENTS Brake lining (pads) SPECIAL TOOLS FR 500 Pushing piston device REMARK : REMARK : It is forbidden to push the brake In order to maintain the brake efficiency, pedal after the c alipers wer e the replacement of the brake lining (pads) dismounted from the fork.
  • Page 299 FRONT AXLES ELEMENTS Brake lining (pads) REMOU NTIN G Push the caliper piston by means of the FR 500 device. FR 500 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 Press several times the brake pedal, in order to place in contact the caliper piston with the...

  • Page 300: Checking The Brake Pads Wear

    FRONT AXLES ELEMENTS 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 is 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...

  • Page 301: Brake Caliper

    FRONT AXLES ELEMENTS Brake caliper TIGHTENING MOMENTS (daNm) REPAIR ING Wheel screws Dismount the protection gasket. Rigid duct on fr o nt flexible screw Purging screw Extract the piston using a wooden wedge and Flexible hose - cal i per a compressed air source.
  • Page 302 FRONT AXLES ELEMENTS Brake caliper REMOU NTIN G Perform the dismounting operations in the reverse order plus the following operations: - filling of the caliper with brake fluid in order to facilitate the brake system purging; - purging the brake system. BRAKE CALIPER SEALING CHECKING Connect to the caliper, a pressure gauge attached to a compressed air source.

  • Page 303: Brake Disk

    FRONT AXLES ELEMENTS 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 replacemen t. - 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 Disk attachment screw on the hub...

  • Page 304: Steering Knuckle

    FRONT AXLES ELEMENTS Steering knuckle SPECIAL TOOLS PF 600 Hub disk extractor PF 600 Ball joint extractor PF 476 TIGHTENING MOMENTS (daNm) Wheel attachment screw Steering ball joint nut Transmission nut 28.0 Attachment fork screw on steering knuckle 6.5 Continue by dismounting the steering Screw nut of the steering knuckle knuckle, observing the operations sequence: attachment wi t h the shock absorber leg...
  • Page 305 FRONT AXLES ELEMENTS Steering knuckle REMOU NTIN G REMARK : Before remounting check the wear of the bearing, that shall be replaced if the grease is flown. Position and press the steering knuckle together with the hub – disk assembly , performing the operations in the reverse order, after previously having greased the steering knuckle grooves.

  • Page 306: Steering Knuckle Bearing (35 X 65 X 35)

    FRONT AXLES ELEMENTS Steering knuckle bearing (35 x 65 x 35) DISMOU NTIN G The steering knuckle-bearing assembly is Dismount the steering knuckle (see method to be placed above the hub and after centering “Dismoun ting steering knuckle). the support washer, press the bearing on the Remove the safety ring ( bore ring) from the hub, using a bushing with the inner diameter interior of the steering knuckle.

  • Page 307: Front Suspension

    FRONT AXLES ELEMENTS Front suspension CROSS SECTION 6 daNm 2 daNm 10.5 daNm 7.5 daN m 2.7 daN m 4 daNm 28 daNm 7..7.5 daNm 10.5 daNm 31 - 16 vnx.su...

  • Page 308: Shock Absorber, Spring

    FRONT AXLES ELEMENTS Shock absorber, Spring SHOCK ABSORBER TIGHTENING MOMENTS (daNm) Shock absorber rod nut Shock absorber l o wer attachmen t nut 10.5 Shock absorber upper attachme nt screws The shock absorbers are stored in horizontal position. In these conditions, it is possible that shock absorbers working vertically, to get depressed.

  • Page 309: Spring - Shock Absorber Assembly

    FRONT AXLES ELEMENTS Spring – shock absorber assembly DISMOUNTING SPRING-SHO CK ABSORBER ASSEMBLY OFF THE VEHICLE SSPECI AL TOOLS Device SUS 600 Combined wrench SUS 601 Loosen the front wheel attachme nt screws. Lift the vehicle by means of a two-column elevator.
  • Page 310 FRONT AXLES ELEMENTS Spring – shock absorber assembly SPRING-SHOCK ABSORBER ASSEMBLY REMOUNTING ON THE VEHICLE Place the spring on the SUS 600 device shaft (2). Position on the spring the upper plate and the filtering block of the shock absorber. Put on the shaft the lock bushing (6) and the spacer (5).

  • Page 311: Anti Roll Bar

    FRONT AXLES ELEMENTS Anti roll bar TIGHTENING MOMENTS (daNm) BARÃ ANTIRULIU FA Ã Clamp screws for attach ing the elastic Diametrul (mm) bushings on longitudinal girder Φ Φ Φ Φ 24 Clamps screws for attachi n g bushings on arm DISMOU NTIN G Lift the vehicle by means of a two-column elevator.

  • Page 312: Power Train Support

    FRONT AXLES ELEMENTS Power train support TIGHTENING MOMENTS (daNm) Wheels attachment screws Shock absorber lower attachment screws to the steering knuckle arm 10.5 Connecting straps upper attachment screws 2.7 Anti-roll connection rod attachment screws to the steering crossbar support Connection screw of the steering column lower shaft-steering box gear ATTENTION ! Dismounting of the front axles screws...
  • Page 313 FRONT AXLES ELEMENTS Power train support - clamps attachment of the low pressure duct of the power-assisted steering (on the left side); Attach a parts support under the power train support and dismount: - connectio n screw anti-roll connecting rod- steering box crossbar support and tilt - attachment screws of the bellows-bearing over the anti-roll connecting rod downward.
  • Page 314 FRONT AXLES ELEMENTS Power train support REMOU NTIN G Perform the dismounting operations in the reverse order, observing the tightening moments. In case a new steering box is to be mounted, perform the parallelism adjustment, observing the parallelism adjustment procedure previously described. 31 - 23 vnx.su...

  • Page 315: Rear Axles Elements

    REAR AXLES ELEMENTS Characteristics The rear axle is composed of an axle having a “ U “ shaped torsion profile to which arms are welded For the transversal stability and the resistance fatigue improvement of the cross- bar, the axle is equipped with a Ö...

  • Page 316: Rear Axle

    REAR AXLES ELEMENTS Rear axle SPECIAL TOOLS Drum cover extr acting pliers R0 441 Hub extractor PF 600 Dismounting pliers for shoes return spring FR03 Shoes protectors FR09 Pliers for mai n taining brake cylinders pistons FR05A Dynamometer wrench MOT30 Comparing dial gauge R0541A TIGHTENING MOMENTS (daNm)
  • Page 317 REAR AXLES ELEMENTS Rear axle REMOU NTIN G Before remounting, lubricate with grease the attachment screws of the rear axle shock ab- sorber bottom and the chassis, consequently , the connecting screws rear axle-chassis. Line up the arms bearings right to the chassis supports, mounting the nuts with the screws assembling the axle to the chassis, without tightening them to the moment, Remount the springs.

  • Page 318: Rear Suspension

    REAR AXLES ELEMENTS Rear suspension LONGITUDINAL SECTION 33 - 4 vnx.su...

  • Page 319: Shock Absorber

    REAR AXLES ELEMENTS Shock absorber TIGHTENING MOMENTS (daNm) Shock absorber l o wer attachmen t nut Shock absorber upp er attachmen t nut 1.35 REMARK : The shock absorbers are stored in horizontal position. In these conditions, it is possible that shock absorbers working vertically , to get depressed.

  • Page 320: Spring

    REAR AXLES ELEMENTS Spring SPECIAL TOOLS Device SUS 600 TIGHTENINBG MOMENTS (daNm) Wheel attachment screw Shock absorber lower attachment nut +0,08 Rear axle spring coil diameter is of φ 16 DISMOU NTIN G REMOU NTIN G Place the locking clamp of the SUS 600 de- Perform the dismounting operations in the vice, in order to maintain the spring compressed.

  • Page 321: Brake Drum

    REAR AXLES ELEMENTS Brake drum The two brake drums having the same diameter; the rectifying of one of them, obligatory implies the same operation for the other one. SPECIAL TOOLS Plug extracting pliers RO441 Drum extractor PF600 TIGHTENING MOMENTS (daNm) Wheel attachment screw Steering knuckle nut DISMOU NTIN G...

  • Page 322: Brake Cylinder

    REAR AXLES ELEMENTS Brake cylinder SPECIAL TOOLS Dismounting pliers for shoes return spring FR 03 Plug extractor pliers RO 441 TIGHTENING MOMENTS (daNm) Wheel attachment screw Rear wheel steering knuckle nut Purging screw Brake rigid piping connection screw Cylinder attachment screw on plate. DISMOU NTIN G Loosen the rear wheel attachment screws.
  • Page 323 REAR AXLES ELEMENTS Brake cylinder Adjust: - the shoes, by applying a repeated pressure to the brake pedal; - the rear axle bearing clearanc; - the handbrake ( see chapter 37). Mount the wheel. Lower the vehicle on the ground. Tighten the wheels screws to the required moment.

  • Page 324: Brake Shoes

    REAR AXLES ELEMENTS Brake shoes SPECIAL TOOLS Plug extracting pliers RO441 Dismounting pliers for shoes return spring FR03 Pliers for maintaining brake cylinders pistons FR05A By means of the pliers FR05A the brake cyl- TIGHTENING MOMENTS (daNm) inder pistons are immobilized. Wheel screws Remove the return upper spring of the shoes Rear wheel steering knuckle nut 1 6...
  • Page 325 REAR AXLES ELEMENTS Brake shoes Dismount the auxiliary connecting rod (B) REMOU NTIN G connection from the adjustment lever (C). Perform in reverse order the dismount- ing operations. REMARK: The adjustment of the device for the automatic clearance taking over, is de- pending of the spring tensioning (E), that is caught between the rear shoe and the auxiliary connecting rod.
  • Page 326 REAR AXLES ELEMENTS Brake shoes Checking of the brake shoes wear may be performed also without dismounting the brake drums. In this purpose: - lift the vehicle by means of a two-column elevator; - dismount the rubber protector of the visiting window from the brake plate; - check by visual inspection the condition of the brake shoes wear.

  • Page 327: Bearing

    REAR AXLES ELEMENTS Bearing SPECIAL TOOLS Plug extracting pliers RO 441 Drum extractor PF 600 TIGHTENING MOMENTS (da Nm) Rear wheel steering knuckle nut Wheel attachment screws CHECKING Check by means of a comparing device attached on the drum, the axial clearance: 0 – 0.15 mm max after mounting and tightenin g to the moment of 22 daNm.
  • Page 328 REAR AXLES ELEMENTS Bearing REMOU NTIN G By means of a tube with the outer diameter Ö51mm and a press, mount the bearing up to the contact with the drum support surface (carefully not to damage the sealing ring and to ensure a constant pushing force during this operation).
  • Page 329 REAR AXLES ELEMENTS Bearing ELASTIC BUSHING REPLACEMENT Dismount by means of a press, the worn bushing, using a sleeve with the outer diameter D=39mm. Press the new bushing. When pressing, observe the value : A=30mm. 3 3 3 3 0 0 0 0 Remark: For the elastic bushing mounting, use the PS701 device, and for dismounting the extractor PS700.

  • Page 330: Wheels And Tires

    WHEELS AND TIRES Characteristics WHEELS The wheels identification marking is represented in two ways: - engraved marking for steel rims - cast marking for aluminum rims The marking enables acknowledgment of the main wheels dimensions criteria. This marking may be: - Complete Example : 5.5 J 14 4 CH 43 , or - Simplified...
  • Page 331 WHEELS AND TIRES Characteristics TIRES Identification marking examples: 165 / 65 R 14 79 T - 165 - Tire width in mm (1) - 65 - h / l height / width ratio, percentage; - R - Radial structure - 14 - Inner diameter in inches (→); this is corresponding with the rim diameter –...
  • Page 332 WHEELS AND TIRES Characteristics Some speed symbols: Max speed ZR more than Structure types : Radial WHEELS -TIRES Vehicle type Wheel Wheel Wheel screws Tires Inflating pressure axial/radial tightening at cold (bars) runout moment Front Rear (mm) (daNm) Unloaded/ Unloaded/ Loaded Loaded 5.5J14*...

  • Page 333: Wheels Balancing

    WHEELS AND TIRES Wheels balancing BALANCING WEIGHTS Use exclusively the weights delivered as spare parts, with attachment by means of mass incorporated clamps. A = balancing weights for steel rims B = balancing weights for aluminum alloy rims. 35 - 4 vnx.su...

  • Page 334: Steering Assembly

    STEERING ASSEMBLY Steering connecting rods SPECIAL TOOLS DIR. 1306 Device for steering rack locking up in regard to steering box casing. P.F. 476 Device for ball joints depressing DIR. 505 Wrench for dismounting/remounting joint body on rack TIGHTENING MOMENTS (daNm) Wheels screws Steering ball joint nut Joint body in rack...
  • Page 335 STEERING ASSEMBLY Steering connecting rods REMOU NTIN G At each dismounting, it is OBLIGATORY the replacement of the limiter washer(1) as well as of the safety washer (2). Mount in the rack : joint body (3), not before positioning the safety washer (2), the limiter washer (1) and oiling the threaded part (4) of the joint body with FIXAMED R 58-C.S.1/82 (not excessively).

  • Page 336: Manual Steering Box

    STEERING ASSEMBLY Manual steering box SPECIAL TOOLS P.F. 476 Device for ball joints depressing TIGHTENING MOMENTS (daNm) Wheels screws Steering ball joint nut Steering box attachment screws on crossbeam 5 Cardan joint connection screws with column lower shaft Disconnect the battery. Loosen the front wheels scr e ws.

  • Page 337: Steering Box Pusher

    STEERING ASSEMBLY Steering box pusher ADJUSTMENT screwing ˘ rotations, then secure it by bead- ing (caulking) in “S” area. When a noise is found in the area of the When mounting, put 23 ± 5 cm grease steering box pusher, it is obligatory to per- UM 185 Li2M for : rack, gear, sealing ring form its correct adjustment.

  • Page 338: Noise Absorbant Bushing

    STEERING ASSEMBLY Noise absorbant bushing DISMOU NTIN G Loosen the screws of the right front wheel. Lift the vehicle by means of a two-column elevator. Dismount the right front wheel. Dismo unt : -steering box casing protection bellows-left steering rod end; -the right steering connected rod.

  • Page 339: Bellows

    STEERING ASSEMBLY Bellows REMARK : A damaged bellows is to be obligatory replaced with a new one. BELLOWS MOUNTING Bellows mounting is performed by means of a con-shaped device that is positioned on the connecting rod joint body (axial ball joint) for bellows easy sliding and avoid damaging. Put some UM 185 Li2M grease on the bellows part in contact with the joint body (axial ball joint), to easy the bellows sliding.

  • Page 340: General

    STEERING ASSEMBLY General CONSTANT POWER STEERING (CPS) 1. Power steering pump 2. Power steering box 3. High pressur e piping 4. Low pressure piping 5. Oil reservoir 6. Rotary valve 7. Pressure controller 8. Accessories belt 36054 9. Rigid ducts 10.

  • Page 341: Power Steering Box

    STEERING ASSEMBLY Power steering box SPECIAL TOOLS MOT 453 Flexible piping pliers P.F. 476 Device for ball joint depressing TIGHTENING MOMENTS (daNm) DA-CA supply pipe attachment screw on power train Attachment screw of steering box high pressure pipe-pump Wheels screws Steering ball joint nut Steering box attachment screws on cross-member Screws for pipes clamps attachment on power train...
  • Page 342 STEERING ASSEMBLY Power steering box Clamp the two flexible pipes ( supply and low pressure) by means of the MOT 453 device. - low pressure piping (maintaining clip being previously dismounted); Disconnect the oxygen sensor, in case of vehicles equipped according to EURO III Dismo unt : norms.
  • Page 343 STEERING ASSEMBLY Power steering box REMARK : Refill the circuit with oil ( full reservoir). It is forbidden to dismount from the power With stopped engine, easy act upon the steering box the pipes between the rotary steering wheel in both directions, so that rack valve and the steering box.

  • Page 344: Power Steering Box Pusher

    STEERING ASSEMBLY Power steering box pusher When an excessive rack clearance, Check if the rack is freely moving all the followed by clattering in the steering box is length. occurring, before replacing the steering box, Bend the adjustment nut bead in the two the pusher with rack is to be adjusted.

  • Page 345: Power Steering Pump

    STEERING ASSEMBLY Power steering pump - four screws in case of the DA/CA pump. SPECIAL TOOLS MOT 453 Flexible piping pliers DIR 1083-01 Device for PDA pul ley remoun ting PS 1094 Bearing extract or TIGHTENING MOMENTS (da Nm) Screws for D.A. pump attachme nt Screws for D.A.
  • Page 346 STEERING ASSEMBLY Power steering pump REMARK : Dir. 1083-01 The replacement of the PDA hub is to be performed at working bench, by means of the Special tools previously described. PULLEY HUB REPLACEMENT Catch the pump in the working bench vice. Attach the arms of the PS 1094 device on the hub.

  • Page 347: Steering Column

    STEERING ASSEMBLY Steering column TIGHTENING MOMENTS (daNm) Steering wheel attachment screw Steering column attachment screw on dri v ing post Connection screw steering column lower shaft- steering box gear s haft DISMOU NTIN G Disconnect the battery. Dismo unt: - steering wheel cover, clips attached; Dismount the side attachment screws (7) - steering wheel attachme nt screw on the of the upper part dashboard, by means of a...
  • Page 348 STEERING ASSEMBLY Steering column For vehicles equipped with central the steering box gear shaft and the cardan end locking: of the steering column lower shaft. - disconnect the central locking Dismo unt the connection screw , mark ing the connector. joint position .
  • Page 349 STEERING ASSEMBLY Steering column In the passengers compartment : REMOU NTIN G Fix and tighten to the required moment the 1. Manual steering column six screws attaching the steering column to the Pass the cardan joint of the lower shaft driving post.
  • Page 350 STEERING ASSEMBLY Steering connecting rods ......................36 - 1 Manual steering box ....................... 36 - 3 Steering box pusher ........................ 36 - 4 Noise absorbant bushing ......................36 - 5 Bellows ............................ 36 - 6 General............................ 36 - 7 Power steering box ......................... 36 - 8 Power steering box pusher ....................

  • Page 351: The Mechanical Elements Controls

    THE MECHANICAL ELEMENTS CONTROLS Brake pump TIGHTENING MOMENTS (daNm) Rigid pipe connection Brake pump attachment nut on servobrake I.C.P. transducer ( pressure drop indicator ) Purging screw DISMOU NTIN G Disconnect the battery. Drain the brake fluid reservoir. Dismount the brake fluid reservoir off the brake pump (avoiding fluid leakage). Dismo unt : - the rigid pipe screws from the brake pump and mark their position;...
  • Page 352 THE MECHANICAL ELEMENTS CONTROLS Brake pump REMOU NTIN G Perform the dismountin g operations in reverse order. Check the length of servobrake the pushing rod , value X=9 mm and correct it if necessar y. -0,2 After assembling the brake pump with the fluid reservo ir and fillin g with brake fluid , no leakage must occur in the surface of separation between the two elements.

  • Page 353: Servobrake

    THE MECHANICAL ELEMENTS CONTROLS Servobrake TIGHTENING MOMENTS (daNm) Brake pump attachment nut on servobrake Servobrake attachment nut on cowl panel MASTER VAC 7 " SERVO MECHANISM The ” Master-Vac 7" servobrake is a brake booster destined to reduce the driver’s effort on the brake pedal.
  • Page 354 THE MECHANICAL ELEMENTS CONTROLS Servobrake Detach the connection screws of the rigid REMOU NTIN G brake ducts from the main brake pump. Before remounting, check: and if necessar y, Disconnect the electrical contact from ICP perform the follo wing adjustmen ts: transducer.
  • Page 355 THE MECHANICAL ELEMENTS CONTROLS Servobrake SPECIAL TOOLS MOT 453 Obturator TIGHTNESS CHECKING ATTENTION ! The tightness of the servobrake is checked on the vehicle, with the hydraulic cir- cuit under operation Connect the vacuum meter between the servobrake and the inlet manifold by means of a “ T ”...

  • Page 356: Air Filter - Servobrake Retainer Valve

    THE MECHANICAL ELEMENTS CONTROLS Air filter – servobrake retainer valve DISK FILTER REPLACEMENT RETAINER VALVE REPLACEMENT The operation is performed without DISMOU NTIN G dismountin g the servobrake off the vehicle. Dismount the servobrake off the vehicle. Loosen the lock nut (E) and dismount : DISMOU NTIN G - the coupling fork - the lock nut.

  • Page 357: Handbrake - Adjustment

    THE MECHANICAL ELEMENTS CONTROLS Handbrake - adjustment The adjustment of the handbrake shall be performed with the vehicle lift on a two-column elevator. Note : The adjustment is obligatory performed anytime the brake shoes or secondary cables have been replaced. Release the control lever of the hand brake (release position) Tighten the nut (1) until the shoes lining come lightly into contact with the brake drum.

  • Page 358: Handbrake Control Lever

    THE MECHANICAL ELEMENTS CONTROLS Handbrake control lever TIGHTENING MOMENTS (daNm) Attachment screws of the handbrake lever on central floor DISMOUNTIN G Disconnect the battery. Release the hand brake control lever ( released position). Lift the vehicle by means of a two columns elevator; Detach the rudder bar fork (5) from the end rod (3) by unscrewing the lock nut (1) and remove the ball-ended washer (2).
  • Page 359 THE MECHANICAL ELEMENTS CONTROLS Handbrake control lever Disconnect handbrake contact (9). Take off the assembly handbrake. Move the seats ahead and dismount: RE MOU NTIN G - safety belts lower attachment screws; - attachment screws of the front safety Grease the shafts with UM 185 Li 2M belts locks and remove them.

  • Page 360: Handbrake Secondary Cables

    THE MECHANICAL ELEMENTS CONTROLS Handbrake secondary cables SECONDARY CABLE - REPLACEMENT Remove the secondary cables stops from SPECIAL TOOLS the central floor. Ro 441 Wheel drum cover tongs Dismount the sheathe stops from the brake Fr.600 Hub extractor plates. Remove the secondary cables. TIGHTENING MOMENTS (daNm) Wheel attachment screw Steering knuckle nut...

  • Page 361: Brake Flexible Hoses

    THE MECHANICAL ELEMENTS CONTROLS Brake flexible hoses TIGHTENING MOMENTS (daNm) X (flexible on caliper) Y (attachment screw of the rigid pipe on the flexible 135 ± 2 IMPOSED PRECAUTIONS TO BE RESPECTED WHEN DISMOUNTIN G – REMOUNTING A RECEIVER OR A BRAKE FLEXIB LE HOSE Due to security reasons, in order to avoid brake flexible hose twisting and the risk to get in contact with the suspen sion elements, it is necessar y to observe the following operations sequence, as well as the flexible attachment on the wing lining by means of a stopper, positioned at 135 ±...
  • Page 362 THE MECHANICAL ELEMENTS CONTROLS Brake flexible hoses Unscrew the flexible from the caliper and after that from the connection with the rigid pipe. REMOU NTIN G Assemble the caliper with the caliper fork. Mount the caliper wedges and then tighten to the required moment the flexible on the caliper. The flexible hoses must be tighten to the required moment with the rigid pipes, when the front axle is in the position : - symmetric wheels (mounted suspension );...

  • Page 363: Brake Pressure Controller

    THE MECHANICAL ELEMENTS CONTROLS Brake pressure controller REMARK : Brake pressure controller is not to be repaired. TIGHTENING MOMENTS (daNm) Attachment nut of the pressure controller assembly on the carriage body Connection screws of the rigid pipe on the pressure controller DISMOU NTIN G Drain of fluid, the braking circuit.
  • Page 364 THE MECHANICAL ELEMENTS CONTROLS Brake pressure controller ADJUSTMENT OF THE BRAKE PRESSURE CONTROLLER FOR THE PARALLEL BRAKING SYSTEM TIGHTENING MOMENTS (daNm) SPECIAL TOOLS FR 501 Purging device Adjustment nut 0.15 Imposed conditions : - the vehicle on wheels - empty trunk - one person on board ADJUSTMENT METHOD Mount the flexible connection of the FR 501 device at the purging screw of one rear wheel...

  • Page 365: Gears Control

    THE MECHANICAL ELEMENTS CONTROLS Gears control DISMOUNTIN G The dismounting of the gears changing lever shall be performed after dismounting the central console (see chapter 58 – “ Inside accessories”). Dismount under the vehicle the control lever (1). Dismount inside the vehicle the four attachment nuts (2) of the control case. Dismount the assembly composed of control case (3) and gears control lever.
  • Page 366 THE MECHANICAL ELEMENTS CONTROLS Gears control SPECIAL TOOLS CV 550 Linkage adjusting device GEARS CONTROL ADJUSTMENT This is to be performed after mounting the engine-gearbox assembly and the assembly lever- control case every time when : - dismounting of the engine-gearbo x assembly , the control bar or the assembly lever-control case;...

  • Page 367: Clutch And Brake Pedals

    THE MECHANICAL ELEMENTS CONTROLS Clutch and brake pedals CLUTCH PEDAL DISMOU NTIN G Release the clutch cable from the pedal cam (6) ( after releasing it from clutch control fork). Dismount the safety lock (1) together with the washers (2) and (3). Push the pedals shaft (10) in the arrow direction.

  • Page 368: Clutch Cable

    THE MECHANICAL ELEMENTS CONTROLS Clutch cable REMOU NTIN G TIGHTENING MOMENTS (Nm) Perform the dismounting operations in the Clutch cable counter nut reverse order. DISMOU NTIN G Adjust the clutch control In the engine compartment : - release the clutch cable (1) from the CLUTCH CONTROL ADJUSTMENT clutch control fork.
  • Page 369 THE MECHANICAL ELEMENTS CONTROLS Clutch cable REPLACEMENT OF CLUTCH CABLE BUFFER DISMOU NTIN G Dismount the nut and the lock nut from the clutch cable end. Mount the buffer (1). REMOU NTIN G Remounting is done by performing the dismounting operations in the reverse order. Adjust the clutch control ( see chapter 37 –...

  • Page 370: Pedals Support

    THE MECHANICAL ELEMENTS CONTROLS Pedals support - attachment screw (2) of the pedals DISMOU NTIN G support to the welded support of the driving Disconnect : post cross-beam; - battery; - clutch pedal (4); - stop contact connectors. - brake pedal (5); Dismo unt: - stop contact (6).

  • Page 371: Acceleration Control

    THE MECHANICAL ELEMENTS CONTROLS Acceleration control ACCELERATION CABLE ACCELERATION PEDAL Detach from clips the cable from the TIGHTENING MOMENTS (daNm) acceleration pedal (3) by harpoon (5) compressing. Pedal bearing attachment nut Release the acceleration cable (1) from the valve lever (A). DISMOU NTIN G Detach from clips the cable from the acceleration pedal (3) by harpoon (5)
  • Page 372 These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA. Reproduction or translating even partially of this present document is forbidden without the written authorisation of AUTOMOBILE DACIA S.A.
  • Page 373 Body LATERAL OPENINGS GENERAL Rear door / Front door........47-1 Lower structure composing elements... 40-1 Upper structure composing elements... 40-2 NON – LATERAL OPPENINGS Carriage body removable elements....40-3 Openings clearance ........40-4 Front bonnet..........48-1 Repairing general conditions ...... 40-9 Hatchback ............
  • Page 374 Front grill............55-4 Aileron............55-5 Side ornaments..........55-6 OUTSIDE ACCESSORIES External rear view mirror ......56-1 Spare wheel support ........56-2 Front wheels fairing ........56-3 Rear wheels fairing ........56-4 Air extractor ..........56-5 vnx.su...

  • Page 375: General

    GENERAL Lower structure composing elements 1. Front anti-shock cross member 2. Front cross beam 3. Longitudinal girder closing plate 4. Upper front longitudinal girder 5. Front longitudinal girder 6. Central cross member 7. Front floor 8. Threshold closing plate 9. Seat attachment structure 10.

  • Page 376: Upper Structure Composing Elements

    GENERAL Upper structure composing elements 1. Headlam p support 2. Upper radiator cross bar 3. Fro nt grill 4. Fro nt wing lining 5. Fro nt pillar lining 6. Fro nt pillar 7. Roof belt 8. Middle pillar 9. Inner wheel passage 10.

  • Page 377: Carriage Body Removable Elements

    GENERAL Carriage body removable elements 1. Side support 2. Front wing 3. Front door 4. Rear door 5. Hatchback 6. Front bonnet 40 - 3 vnx.su...

  • Page 378: Openings Clearance

    GENERAL Openings clearance 40 - 4 vnx.su...
  • Page 379 GENERAL Openings clearance 40 - 5 vnx.su...
  • Page 380 GENERAL Openings clearance 40 - 6 vnx.su...
  • Page 381 GENERAL Openings clearance 40 - 7 vnx.su...
  • Page 382 GENERAL Openings clearance 40 - 8 vnx.su...

  • Page 383: Repairing General Conditions

    GENERAL Repairing general conditions The replacement (reparation) operations of the weldable elements described in this chapter are specified subject to: cutting out of the parts to be replaced, access to the welded elements, tools and checking devices accessibility , etc. In case the vehicle body has suffered important deformations it is recommended the straight- ening of the damaged body elements, by means of some hydraulic presses.

  • Page 384: Welding Types And Parameters

    GENERAL Welding types and parameters At the reparation of the welded body elements, three welding categories may be used: protection gas welding (CO2), electric spot-weldin g and filling materials (built-up) welding (oxyacetylene). At the built-u p welding, it is reco mmended that flam e must be slightly inclined so that arch can be seen and the flame extremity to be maintained at aprox.
  • Page 385 GENERAL Welding types and parameters REMARK : In case of using the Ar + CO2 mixture, the welding voltage will decrease with 2 Vertical welding position (obligatory from top to bottom)- pict. 2 Plate thickness Electrode diameter (mm) 0,8 1,0 Welding wire speed (m/min) 3,3 3,2 Welding current (A)

  • Page 386: Collision Diagnosis

    GENERAL Collision diagnosis During the vehicle exploitation, the carriage body may suffer different distortions, that lead many times to the wheels setting angles modificatio n, body elements breakage, vibrations or even mechanical parts wear. In these conditions, before performing the vehicle body reparation, some checking is necessar y: Visual checking - consisting in the examinatio n of the mechanical elements attachments and of the distortions occurring in the vehicle damaged areas.
  • Page 387 GENERAL Collision diagnosis CENTRAL PART CHECKING The central part checking is performed in the purpose to establish if one of the distortions is not affecting this part of the floor, from where the checking starts. Compare the followings lengths : EI = FJ ; EJ = FI . FRONT LONGITUDINAL GIRDERS CHECKING Compare the followings lengths: CG = DH;...
  • Page 388 GENERAL Collision diagnosis REAR LONGITUDINAL GIRDERS CHECKING Compare the following lengths: EK = FL ; EL = FK . REAR ARM CHECKING Compare the following lengths: FM = EN. If a difference is noticed when measuring the lengths (FM – EN ), the rear arms are to be replaced.
  • Page 389 GENERAL Collision diagnosis FLOOR FRAME CHECKING POWER-TRAIN SUPPORT ASSEMBLY CHECKING 40 - 15 vnx.su...

  • Page 390: Carriage Body Checking

    - CAR 503 – set of 22 towers MZ; - CAR 504 - set accessories for traction ; - CAR 505 - set of specific supports for DACIA Berline, Break. - CAR 506 - set of specific supports for DACIA 1304, 1307 - CAR 507 - set of specific supports for DACIA Nova/SupeRNova /SOLENZA.
  • Page 391 GENERAL Carriage body checking To straighten the vehicle body, CELETTE bench is provided with a traction arm of 10 tons, Caiman type, 250-mm stroke of the hydraulic cylinder, with rapid anchorage on any side of the mobile bench (pict. 2). pict.
  • Page 392 GENERAL Carriage body checking 3. TRACTION ACCESSORIES SET ( CAR 504) CELETTE bench is equipped with a traction accessories set CAR 504, which allows the op- erator to achieve different anchoring when a body strengthening is performed (pict. 5). pict. 5 4.
  • Page 393 GENERAL Carriage body checking Each specific support is identified by a number (2) marked at the lower part and has one or two attachments holes (3) in the MZ tower (in this case you should take into consideration the specific diagram from the assembly drawing supplied together with the kit.
  • Page 394 GENERAL Carriage body checking Power train frame attachment on the lower cross member The specific supports (1) and (2) are used in front straightening, front mechanic elements being dismounted, enabling the positioning of the lower cross member, consequently the front attachment of the power train frame (pict.
  • Page 395 GENERAL Carriage body checking replacing the front wing lining. Power train frame rear attachment on front longitudinal girder. The specific supports (7) and (8) are used in the front straightening, enabling the positio n- ing of the front longitudinal girder and conse- fig.
  • Page 396 GENERAL Carriage body checking Rear axle arm attachment The specific supports (11), (12), (13), (14), 1 3 1 4 1 5 1 6 (15) and (16) are enabling the position ing, cen- tering and rear alignment of the vehicle on the bench in case of a straightening.

  • Page 397: Lower Structure

    LOWER STRUCTURE Front longitudinal girder REPLACEMEN T This operation shall be performed only on the checking/repair bench. For the specific sup- ports mounting on the bench, please see the 40 sub-chapter. DISMOU NTIN G Dismount the damaged elements, which are in contact with the front longitudinal girder.
  • Page 398 LOWER STRUCTURE Front longitudinal girder Mount the connection elements by performin g the dismounting operatio ns in the reverse order. 41 - 2 vnx.su...

  • Page 399: Front Anti-Shock Cross Member

    LOWER STRUCTURE Front anti-shock cross member DISMOU NTIN G Dismount the elements in contact with the front anti-shock cross member. Detach the welding point of the front anti- shock cross member (1) in contact with the front cross member in the area (2)- upper bor- der and area (3) –...

  • Page 400: Rear Longitudinal Girder

    LOWER STRUCTURE Rear longitudinal girder REPLACEMEN T This operation shall be performed only on the repair/checking bench.. For the specific sup- ports mounting on the bench, please see the 40 chapter. DISMOUNTIN G Dismoun t the damaged elements, which are in contact with the rear longitudinal girder.

  • Page 401: Front Upper Structure

    FRONT UPPER STRUCTURE Front wing DISMO UNT ING Dismount the two attachment screws of the bonnet lower half-hinge on the front pillar lining. Dismount partially the front bumper. Dismount the attachment screws (1) of the wheel passage fairing. Dismount the side-signaling lamp from the front wing. Dismount the attach ment screws (2), (3), (4) and (5) of the wing on the front wing lining, front pillar lining, front bumper attachment side support, front pillars support and side frame lining (front lower area).

  • Page 402: Front Wing Lining

    FRONT UPPER STRUCTURE Front wing lining REPLACEMEN T This operation shall be performed only on the checking/repair bench. For the specific sup- ports mounting on the bench, please see the 40 sub-chapter. DISMOUNTING Dismount the damaged element s , which are in contact with the front wing lining.

  • Page 403: Radiator Upper Cross Member

    FRONT UPPER STRUCTURE Radiator upper cross member DISMOU NTIN G Dismount the elements, which are in con- tact with the radiator upper cross member. Detach the welding points of the radiator upper cross member (1), which are in connection with: - front wing lining in the area (3);...

  • Page 404: Headlamp Support

    FRONT UPPER STRUCTURE Headlamp support DISMOU NTIN G Dismount the elements, which are in contact with the headlamp support. Detach the welding points of the headlamp support (2), which are in connection with : - front wing lining in the area (6) - radiator upper cross member in the area (7);...

  • Page 405: Windscreen Lower Cross Member

    FRONT UPPER STRUCTURE Windscreen lower cross member DISMOU NTIN G Dismount the elements, which are in con- tact with the windscreen lower cross member (front bonnet, windscreen, dashboard, driving post cross member). Detach the weldin g points of the windscreen lower cross member (1), which are in contact with : - windscreen frame in the area (2);...

  • Page 406: Driving Post Cross Member

    FRONT UPPER STRUCTURE Driving post cross member DISMOU NTIN G The dismounting operatio n of the driving post cross member is usually an additional operation in case of replacin g such carriage body element s - windscreen lower cross member ; - cow panel;...

  • Page 407: Side Upper Structure

    SIDE UPPER STRUCTURE Front pillar DISMOU NTIN G Dismount the elements that are in contact with the front pillar (front door, front bonnet, front wing). Detach the weldin g points of the front pillar (1), which are in connection with : - side frame lining in the area (3) ;...

  • Page 408: Middle Pillar

    SIDE UPPER STRUCTURE Middle pillar DISMOU NTIN G Dismount the elements, which are in contact with the middle pillar. Detach the weldin g points of the middle pillar (1) which are in connection with : - side frame lining in the areas (3) and (4); - middle pillar rein forcement in the area (4);...

  • Page 409: Rear Upper Structure

    REAR UPPER STRUCTURE Rear lower panel DISMOU NTIN G Dismount the elements that are in contact with the rear lower panel. Detach the welding points of the rear lower panel (1) which are in connection with : - lamp support (left/rig h t) in the area (2); - side panel (left/right) in the area (3);...

  • Page 410: Rear Lamp Support

    REAR UPPER STRUCTURE Rear lamp support DISMOU NTIN G Dismount the elements in connection with the rear lamp support (rear bumper, rear lamp, equipping elements). Detach from welding points of the rear lamp support in connection with: - side panel in the area (2); - rear lower panel in the area (3);...

  • Page 411: Inner Wheel Passage

    REAR UPPER STRUCTURE Inner wheel passage DISMOU NTIN G Dismount the elements, which are in con- tact with the inner wheel passage (1). Detach the SE CO welding points between the rear wheel passage and : - backrest lock support in the area (2); - connection bracket knee in the area (3);...

  • Page 412: Side Panel

    REAR UPPER STRUCTURE Side panel DISMOU NTIN G Dismount the elements, which are in con- tact with the side panel (1). Detach the welding points of the side panel, which are in connectio n with : - side frame lining in the area (2); - roof in the area (3);...

  • Page 413: Top Of Body

    TOP OF BODY Roof DISMOU NTIN G Dismount the elements, which are in con- tact with the roof (front/rear doors, windscreen, hatchback, roof and rear quar- ter panel lining).). Detach the welding points of roof (1), which are in connectio n with : - roof belt in the area (2) ( left/right);...

  • Page 414: Windscreen Frame

    TOP OF BODY Windscreen frame DISMOU NTIN G Dismount the elements in connection with the windscreen frame (front bonnet, windscreen, left/ right front wing, left/right front door). Detach the welding points of the windscreen frame (1), which are in contact with : - side frame lining and roof belt in the area (2) left/right;...

  • Page 415: Body Protection

    BODY PROTECTION Engine shield DISMOU NTIN G Dismount four M 6x1 – 20 Embase screws attached in four (3) M6x1 safety nuts on the power train support. Release the engine shield (1). REMOU NTIN G Perform the dismounting operations in the reverse order. 46 -1 vnx.su...

  • Page 416: Lateral Openings

    LATERAL OPENINGS Rear door Front door DISMOU NTIN G Dismount the elements, which are in connection with the front/rear door. Dismount the door panel. Dismount the door wiring protected by sleeve (1) and remove it through the existent door caisson hole. Dismount the attachment screw (2) of the limiting mechanism of the front/rear door.

  • Page 417: Non - Lateral Oppenings

    NON – LATERAL OPPENINGS Front bonnet DISMOU NTIN G Dismo unt : - attachment screws (1) and (2) of the upper half-hinges on the front bonnet lining; - front bonnet. REMOU NTIN G Pre-attach the screw (1) from the windscreen frame on the front bonnet lining (left/rig h t).

  • Page 418: Hatchback

    NON – LATERAL OPPENINGS Hatchback DISMOU NTIN G Dismount the hatchback wiring (1) and remove it through the existent hole in the hatchback lining. Dismo unt : - safety locks (2) of the balancing shock absorbers on the hatchback - attachment screws (3) of the balancin g shock-absorbers on the hatchback;...

  • Page 419: Mechanisms Of Lateral Openings

    MECHANISMS OF LATERAL OPENINGS Front door-opening mechanism with electric control Dismount the lock fork (13) from the electric control latch. Disconnect the actuator connector (7). Remove the opening control rod of the front door (3). Dismount the attachment screws (5) of the assembled box (4) from the front door caisson.

  • Page 420: Front Door-Opening Mechanism Withmanual Control

    MECHANISMS OF LATERAL OPENINGS Front door-opening mechanism with manual control - front door panel (see chapter 72); - front door deflective panel. Detach: - lock fork (12) from the latch. - opening control rod of the door (4); Detach from clips the blocking rod. Dismount the attachment screws (6) of the assembled box (5) from the front door caisson.

  • Page 421: Rear Door-Opening Mechanism With Electric Control

    MECHANISMS OF LATERAL OPENINGS Rear door-opening mechanism with electric control Disconnect the actuator connector. (8) Remove the opening control rod of the door (3); Dismount the attachment screws (5) of the assembled box (4) from the rear door caisson. Remove the electric control latch (6) through the technological opening from the rear door caisson.

  • Page 422: Rear Door-Opening Mechanism With Manual Control

    MECHANISMS OF LATERAL OPENINGS Rear door-opening mechanism with manual control opening mechanism from the rear door latch. Dismo unt: - rear door blocking control rod from the latch; - ear door inside opening rod (4) from the latch; - attachmen t screws (6) of the assembled box (5) from the door .

  • Page 423: Front Door Electric Window Regulator

    MECHANISMS OF LATERAL OPENINGS Front door electric window regulator TIGHTENING MOMENTS(daNm) Crank attachment screws and nuts 0.7 DISMOU NTIN G Disconnect the battery. Bring the glass at the position P = 85 mm. Dismo unt: - front door panel (see chapter 72); - front door deflective panel.

  • Page 424: Front Door Manual Window Regulator

    MECHANISMS OF LATERAL OPENINGS Front door manual window regulator TIGHTENING MOMENTS(daNm) Crank attachmen t nuts REMOU NTIN G Perform the dismounting operations in the reverse order, taking into account the follo wing recommendations: - crank is to be introduced in the caisson DISMOU NTIN G through the technological opening and is to be Bring the glass at the position P = 85 mm.

  • Page 425: Rear Door Window Regulator

    MECHANISMS OF LATERAL OPENINGS Rear door window regulator REMOU NTIN G TIGHTENING MOMENTS(daNm) Perform the dismounting operations in the reverse order, taking into account the following Crank attac hment screws and nuts and nuts 0.7 recommendations: DISMOU NTIN G - crank is to be introduced in the caisson Dismo unt: through the technological opening.

  • Page 426: Lock

    MECHANISMS OF LATERAL OPENINGS Locks 1 . metallic insert locks kit 2. fork 3. cylinder lock FRONT DOOR LOCK DISMOU NTIN G Dismo unt: - crank handle by clips-detaching from the crank axle; - inside opening mechanism; - closin g handle; - front door panel;...

  • Page 427: Mechanisms Of Non Lateral Openings

    MECHANISMS OF NON LATERAL OPENINGS Front bonnet lock TIGHTENING MOMENTS(daNm) Attachment screws of the bonnet lock hock and lock Dismount the attachment screws (7) of the handle (8) on the side frame lining. DISMOU NTIN G Dismo unt : - attachment screws (2) of the bonnet lock (1) to the front bonnet lining;...

  • Page 428: Hatchback Lock

    MECHANISMS OF NON LATERAL OPENINGS Hatchback lock lock on the hatchback lining; - guiding element (8) and adjustment washer (7) of the guiding element; - attachment screws (10) of the guiding support (9) on the hatchback frame. - special screw attaching hatchback latch TIGHTENING MOMENTS (daNm) Hatchback latch attachment screw Guiding support attachment screw...

  • Page 429: Pneumatic Balancing Device

    MECHANISMS OF NON LATERAL OPENINGS Pneumatic balancing device DISMOU NTIN G Dismount is performed by successive act- ing upon the safety locks (1) from the pneu- matic balancing device end (2). REMOU NTIN G Perform the dismounting operations in the reverse order.

  • Page 430: Glasses

    GLASSES Windscreen glass DISMOUNTING OF A BROKEN GLASS If the glass or part of it did not fall, the dis- mounting and the cleaning of the window gas- kets by the pieces of the broken glass will be easier to be made by sticking a sheet of paper on each surface.
  • Page 431 GLASSES Windscreen glass Each time a windscreen is mounted, ensure the uniform setting of the whole assembly on the carriage body by tapping several times with a rubber hammer, on the edge of the glass frame. REMARK: Do not tap the glass on corners and on the two vertical sides. Take care that both spacers are correctly positioned.

  • Page 432: Hatchback Glass

    GLASSES Hatchback glass The mounting of the hatchback glass – gas- WINDSCREEN AND HATCHBACK ket assembly , is performed in the same way with GLASS REPLACEMENT the windscreen mounting. The replacement of these glasses is per- formed in case they are broken, when they are not according to the required overall di- mensions or when they have manufacturing defects (image distortions, cracks, etc).

  • Page 433: Front Door Glasses

    GLASSES Front door glasses DISMOU NTIN G Dismo unt: - front door panel (see chapter 72); - front door deflector panel; - inner and outside wiper; Bring the glass up to the P=85 mm position. Dismount the attachment screws of the glass support on the regulator glider and then remove the glass (1) together with the glass support.

  • Page 434: Rear Door Glasses

    GLASSES Rear door glasses DISMOU NTIN G Dismo unt: - rear door panel (see chapter 72); - rear door deflector panel; - glass outside wiper by means of a screwdriver. Lower the glass in the minimal position , so that through the technological opening, the screws attaching the glass support on the regulator glider, to be dismounted.

  • Page 435: Outside Protections

    OUTSIDE PROTECTIONS Front bumper DISMOU NTIN G Dismount the front grill. Lift the vehicle by means of a two-column elevator. Disconnect the projector lamps connectors. Dismo unt: - bumper attachment screws (1) on power train frame; - bumper attachment screws (2) on the front anti-shock cross member; - bumper attachment screws (3) on the front wing attachment side supports.

  • Page 436: Rear Bumper

    OUTSIDE PROTECTIONS Rear bumper DISMOU NTIN G Disconnect the rear lamps connectors. Dismo unt: - rear lamps; - attachment screws (2) of the rear bumper(1) on the rear lower plate; - attachment screws (5) of the rear bumper on the rear wheels passage; - attachment screws (3) of the rear bumper (lower part) on the rear extreme cross member;...

  • Page 437: Hatchback Handle Ornament

    OUTSIDE PROTECTIONS Hatchback handle ornament DISMOUNTING Dismoun t the attachment nuts (2) of the hatchback handle orname nt (1) on the outside hatchback panel. Release the hatchback handle ornament. REMOU NTIN G Perform the dismounting operations in the reverse order. 55 - 3 vnx.su...

  • Page 438: Front Grill

    OUTSIDE PROTECTIONS Front grill DISMOU NTIN G Dismo unt : - front grill (2) attachment screws (1) on the radiator upper cross beam; - Front grill attachment screw (3) on the radiator upper cross beam. REMOU NTIN G Perform the dismounting operations in the reverse order. 55 - 4 vnx.su...

  • Page 439: Aileron

    OUTSIDE PROTECTIONS Aileron DISMOU NTIN G Dismount the attachment screws (2) of the aileron (1) on the hatchback outside panel. Release the aileron. REMOU NTIN G Perform the dismounting operations in the reverse order. Check the integrity of the gaskets (3) and (4), if damaged, replace them. The attachment screws (2) are to be tighten to the required moment of 5 Nm.

  • Page 440: Side Ornaments

    OUTSIDE PROTECTIONS Side ornaments DISMOU NTIN G Side ornaments of the front panels, doors and wings, are to dismounted by unstuck. Carefully clean the place from where ornaments have been detached, with an adequate sol- vent and wipe with soft and dry cloth. REMOU NTIN G Position the centering spurs (1) of the side ornaments in the wholes provided in the doors panels and attach them by sticking.

  • Page 441: Outside Accessories

    OUTSIDE ACCESSORIES External rear view mirror DISMOU NTIN G Extract the interior ornamen t (3) by gliding the two pins in the existing bushings (2) in the front door caisson. For the external rear view mirror, controlled by cables, loosen the attachment screw of the external rear view mirror control on the inside ornament, releasing so, the rear view control (5).

  • Page 442: Spare Wheel Support

    OUTSIDE ACCESSORIES Spare wheel support DISMOU NTIN G Remove the safety (3) from the threaded driving axle (5). Dismount the driving axle from the nut welded on the support (4) attached by means of the screws (2) to the rear extreme cross member. Release the spare wheel support (6) from the welded supports (1).

  • Page 443: Front Wheels Fairing

    OUTSIDE ACCESSORIES Front wheels fairing DISMOU NTIN G Lift the vehicle by means of a two-column elevator. Dismo unt: - front wheels; - right front wheel fairing (2), (5) and left front wheel fairing (7), from attach ment clips (6) and (8), consequently from screws (4) and (9) of the front wheels passages;...

  • Page 444: Rear Wheels Fairing

    OUTSIDE ACCESSORIES Rear wheels fairing DISMOU NTIN G Dismount the attachmen t screw (1) of the rear wheel fairing (2) on rear bumper, consequently the attachment screw (3) of the rear wheel fairing on the rear bumper side support. REMOU NTIN G Perform the dismounting operations in the reverse order.

  • Page 445: Air Extractor

    OUTSIDE ACCESSORIES Air extractor DISMOU NTIN G For the air extractor dismounting it is not necessary to dismount the rear bumper. Detach from clips the air extractor (2) from the left rear side panel (1) through the opening of the rear panel lining and push it from inside to outside. REMOU NTIN G Perform the dismounting operations in the reverse order (with the rubber part towards exterior 56 - 5...
  • Page 446 These are subject to modifications brought by the manufacturer at the fabrication of different assemblies, subassemblies or accessories of its vehicles. All rights reserved to SC Automobile Dacia SA. Reproduction or translating even partially of this present document is forbidden without the written authorisation of AUTOMOBILE DACIA S.A.
  • Page 447 Mechanisms and accesoires OPENINGS SEALING INSIDE ACCESSORIES Opennings sealing ..........65 - 1 Dashboard ............57-1 GLASSES SEALING Inside rear view mirror ........57-8 Sun visors ............57-9 Glasses gaskets ..........66 - 1 Central console ..........57-10 Inside wipers ............. 66 - 2 Handbrake case ..........
  • Page 448 INSIDE AND REAR LIGHTING CD Player ............86-7 Connectors ............86-8 Inside and rear lighting ........81-1 Roof antenna ............ 86-9 Ceiling lamp ............81-4 Bulbs ..............81-5 ELECTRICAL ASSISANCE EQUIPEMENT Lamps failures diagnostic ......... 81-6 Cockpit fuse box ..........81-8 Windscreen washing .........

  • Page 449: Inside Accessories

    INSIDE ACCESSORIES Dashboard upper part dashboard lower part dashboard TIGHTENING MOMENTS(daNm) Disconnect the battery. Dismount the two attachment screws of the steering wheel airbag on the steering wheel by Steering wheel attachment screw Attachment screw steering wheel airbag 0.65 means of a T20 (TORX) head screwdriver. IMPORTANT ! All interventions at the airbag system must be performed only by qualified...
  • Page 450 INSIDE ACCESSORIES Dashboard In order to dismount the under steering wheel DISMOU NTIN G Dismo unt : control from the upper shaft of the steering - steering attachment screw (1) on the wheel, loosen the screw (6) and extract the steering column, by means of a screwdriver pro- under steering wheel control (7).
  • Page 451 INSIDE ACCESSORIES Dashboard Disconn ect the anti-star t ing bushing connec- tor. Dismo unt: Detach from clips the anti-starting bushing - two side attachment screws (8) of the (12). upper part dashboard by means of a wrench T 20(“L” shape); - screws (9) attaching the upper part dashboard with the lower part on the driving post cross member, by means of a screwdriver...
  • Page 452 INSIDE ACCESSORIES Dashboard Remove the access cover of the fuse box. Dismount the three attachment screws (14) of the fuse box. - hazard; - rear window defrosting. Disconnect the connectors: - cigarette lighter; - rear window defrosting. Dismount the attachment nut (21) of the headlamps adjustment control.
  • Page 453 INSIDE ACCESSORIES Dashboard REMOU NTIN G Perform the dismounting operations in the reverse order, taking into consideration the follow- ing recommendations: - ensure that steering is at middle point (wheels are in a direct line); - mounting of the lower part dashboard is to be performed by guiding it on a centering part placed on the driving post cross beam;...
  • Page 454 INSIDE ACCESSORIES Dashboard Airbag Important! Before reconnecting the driver’s airbag connector, it is necessary to apply a checking procedure of the system: - Check if airbag indicator from the instrument panel is on, when the contact is set - Connect the igniter to the airbag connector (to the wiring) and check if the airbag indicator is off.
  • Page 455 INSIDE ACCESSORIES Documents compartment door DISMOU NTIN G Upper attachment: By means of a screwdriver, detach from clips the limiting wire for documents compartment door’s opening from lower part dashboard. Lower attachment: Push the plastic pin to the right side of driving post (in the arrow direction) and release the documents compartment door from the lower part dashboard.

  • Page 456: Inside Rear View Mirror

    INSIDE ACCESSORIES Inside rear view mirror DISMOU NTIN G Dismounting of the interior rear view mirror (1) is to be performed by its depressing from the support (2) in the direction of the arrow shown in the drawing. The rear view mirror support (2) is stacked on windshield (3). REMOU NTIN G Perform the dismounting operations in the reverse order.

  • Page 457: Sun Visors

    INSIDE ACCESSORIES Sun visors DISMOU NTIN G Dismount the sun visor (2) attachment screw (1). Extract the sun visor from the hook (3). REMOU NTIN G Perform the dismounting operations in the reverse order. 57 - 9 vnx.su...

  • Page 458: Central Console

    INSIDE ACCESSORIES Central console Detach the central console from the climate DISMOU NTIN G Disconnect the battery. maintenance- ventilating distributor clips Extract the ashtray (1) from its place. (RACV) from points (5). Swing over the diagnostic socket cap and push inside the console. Disconnect the window lifting switch connector (for vehicle s equipped with electric windows).

  • Page 459: Handbrake Case

    INSIDE ACCESSORIES Handbrake case - attachmen t screws of the front safety belts DISMOU NTIN G Through the cutting out existent in the cock- at lower part; pit carpet in the handbrake lever, dismount the - attachment screws of the locks on the tun- attachment screw (1) of the handbrake case in nel;...

  • Page 460: Turning Handle

    INSIDE ACCESSORIES Turning handle DISMOU NTIN G Dismount the screws from points A attaching the turning handle on the body roof. Release the turning handle. REMOU NTIN G Perform the dismounting operations in the reverse order. 57 - 12 vnx.su...

  • Page 461: Security Elements

    SECURITY ELEMENTS Front safety belts - middle pillar covering (see chapter TIGHTENING MOMENTS(da Nm) 71); Front safety belt attachment screw 2.7 - attachment screw (3) of the safety belt retriever on the middle pillar lining. Dismount the attachment screw (4) of the safety belt lock on the tunnel.

  • Page 462: Rear Safety Belts

    SECURITY ELEMENTS Rear safety belts Place back the bench backrest in normal TIGHTENING MOMENTS(daNm) position. Rear safety belt attachment screw Swing over its supports the bench seat. Dismount the rear belt attachment screws (4) on the central floor. DISMOUNTING Dismount the two attachment screws of the bench backrest.

  • Page 463: Heating

    HEATING General 1 – heating radiator 2 – cold/warm air flaps control 3 – air repartition flaps control 4 – air repartition control cable 5 – air-mixing control cable a – air inlet b – windscreen defogging exit c – dashboard air vents exit 61 - 1 vnx.su...

  • Page 464: Operating Principle

    HEATING Operating principle AIR TEMPERATURE CONTROL The knob (A) is controlling the flaps for cold/warm air. By rotating to the right the (A) knob, the air temperature is increasing. Cold air Warm air The heating radiator is not having any valve and is permanently supplied. The flap controlled by the cable (1) is ensuring the operation of the cold air re-heating system.
  • Page 465 HEATING Operating principle AIR REPARTITION CONTROL Position The knob (B) is controllin g air repartitio n flap s Airflow is distributed between all air vents, (1). defogging air vents of front side windows, windscreen defogging air vent and passengers legs. Position For a better efficiency, the dashboard air vents are to be closed.

  • Page 466: Climate Control Unit

    HEATING Climate control unit DISMOU NTIN G Connector Disconnect the battery. Dismo unt : - climate control box protector; - climate control box gasket - gas purge vessel; - engine air filter. Detach from clips the front wiring from the central part of the climate control box.

  • Page 467: Ventilation-Climate Control Air Distributor (Racv)

    HEATING Ventilation-climate control air distributor (RACV) DISMOU NTIN G Disconnect the battery. Dismo unt : - dashboard (see chapter 57 “dash- board”); - central console; - electric windows control connectors; - front pillars coverings; - driving post cross beam; - climate control box protector; - gas purge vessel;...

  • Page 468: Heating Radiator

    HEATING Heating radiator Disconnect the battery. REMOU NTIN G Dismoun t the distributor of ventilat i on air con- Perform the dismounting operations in the ditioning (RACV) position (2) by recovering the reverse order cooling fluid (see R.A.C.V. Dismounting- Re- Fill up the recovered fluid and restore the mounting).

  • Page 469: Control Panel

    HEATING Control panel Dismount the two control cables (distribu- DISMOU NTIN G tion and mixing). Disconnect the battery. Dismo unt : Connectors - ashtray (B); - front doors electric windows switches Connector (6) (C). - gearbox lever cover (D); Denomination Control + blower speed 4 Control + blower speed 4 Supply + after contact...
  • Page 470 HEATING Control panel Connector (3) Pin Denomination 1 Free 2 Free 3 Free 4 Free 5 Free 6 Free 7 + parking lights 8 Free 9 Mass 10 Free 11 Free 12 Free 13 Free 14 Free 15 Free Disconnect the connector (3), carefully push the lever (4) and rotate the lever (5) in the direction of (E) arrow.

  • Page 471: Control Cables

    HEATING Control cables DISMOU NTIN G Dismounting of the control cables (1) may be performed without dashboard dismounting . Dismo unt: - ashtray; - switches of the front doors electric windows; - control panel as well as cables (1) attached to this one by screws. Dismount the maintaining clips (2) in the cockpit lower part.

  • Page 472: Motor Fan Control Resistance

    HEATING Motor fan control resistance DISMOUNTING (Cl i mate control uni t being already di s mounted) Dismount the resistance attachment screw (1). Extract the resistance (2). Disconnect the connector (3). REMOU NTIN G Perform the dismounting operations in the reverse order. 61 - 10 vnx.su...

  • Page 473: Diagnose

    HEATING Diagnose CLIMATE CONTROL BLOWER NOT WORKING Check the fuse F 17 from cockpit. Is it ok? Replace fuse F 17. Check the continuity of the speeds switch of the climate control panel for: Replace ventila- Step 1 – between pins A4 or A5 pin B5;...
  • Page 474 HEATING Diagnose CLIMATE CONTROL PANEL LIGHTING NOT WORKING Replace fuse F14. Check in cockpit fuse 14. Is it OK ? Check the continuity and resistance against vehicle between: - cockpit fuse F 14 exit pin 7 climate control panel Replace front - pin 9 climate control panel vehicl e mass.

  • Page 475: Air Conditioning

    AIR CONDITIONING General The purpose of the air conditioning unit is to produce a decrease of the temperature in the passengers compartment and to obtain a lower value temperature compared to the external environment one, reducing in the same time the air moisture. MAINTENANCE For a vehicle equipped with air conditioning, during the year it is recommend ed: - the checking of the refrigerant fluid filling;...
  • Page 476 AIR CONDITIONING General AIR CONDITIONING UNIT GENERAL METHOD OF ONE ELEMENT REPLACEMENT OF THE AIR CONDITONING UNIT DISMOU NTIN G Make the unit functioning for at least 10 minutes (if the unit permits) . Drain the circuit in the charging equipment. Measure the quantity of recovered refrigerated fluid.

  • Page 477: Draining - Filling The Refrigerant Circuit

    AIR CONDITIONING Draining – filling the refrigerant circuit DRAININ G Connect the charging equipment piping to the filling-draining valves. Perform the vacuuming of the air condition unit with the recovering of the oil and the refriger- ant fluid. Close the hoses valves. Disconnect the charging equipment piping and stop the equipment.

  • Page 478: Air Conditioning Unit Operating Diagram

    AIR CONDITIONING Air conditioning unit operating diagram 62- 4 vnx.su...

  • Page 479: Operating Principle

    AIR CONDITIONING Operating principle The climate control assembly is enabling outside air penetration in the vehicle climate control unit. Climate controls: A – air temperature adjustment B – air distribution in the cockpit C – air quantity adjustment in cockpit Air temperature adjustment Control knob (A) is enabling the obtaining of the desired temperature in the cockpit.
  • Page 480 AIR CONDITIONING Operating principle Air quantity adjustment in cockpit The flow of circulating air in cockpit is adjusted by rotating the (C) knob in the correspondin g positions for the four speed steps of the blower. The more speed step is bigger the more airflow is bigger.

  • Page 481: Particles Filter

    AIR CONDITIONING Particles filter REMOU NTIN G DISMOU NTIN G Remount in its place the particles filter per- Dismount the protector of the climate con- forming the same dismounting operations. trol box. Remove from clips the wiring towards blower casing from the D.S.A.F. Dismount then the particles filter protec- REMARK : tion cap from the attachment screw by slid-...

  • Page 482: Cold Air Blowing Device (Dsaf)

    AIR CONDITIONING Cold air blowing device (DSAF) TIGHTENING MOMENTS (daNm) Attachments screws of the expansion vale on the evaporator 0,6 Pipes attachment nut on evaporator 0,57 Tightening screw of the pipe attachment clamp on compressor 1,2 Pipes attachment nut on filter reservoir 1,4 –...
  • Page 483 AIR CONDITIONING Cold air blowing device (DSAF) Disconnect the central locking switch connector (if the vehicle is provided with central locking). Dismount the right air vent. Dismount the DSAF attachment screws on cowl panel and attachment screws on climate maintenance box and release it. Dismount the attachment screws (9) of the connection pipe (10) on the distributor of RACV AC-ventilation air and release it.

  • Page 484: Evaporator

    AIR CONDITIONING Evaporator DISMOUNTING Disconnect the battery. Drain the air condiotioning unit to the station by recovering the refrigerant fluid Dismount it from screws (6) and release the cold air-blowing device (2) from the climate con- trol box (see D.S.A.F . dismounting-remounting) Disconnect and release the two attachment screws (3) of the air blower.

  • Page 485: Control Panel

    AIR CONDITIONING Control panel The dismounting – remounting operation has been described in chapter 61 “ Climate control”. Connector (3) Denomination Free Free Free Free Free Free + parking lights Mass Mass 10 Supply + after contact 11 Supply + after contact 12 Air conditioning control 13 Climate control blower speed signal 14 Control + air recycling...

  • Page 486: Compressor

    AIR CONDITIONING Compressor FUNCTION REMOU NTIN G The compressor is suction the vapors com- In case compressor is replaced, this one is delivered filled with oil. ing from evaporator at low temperature and Position the compressor with the filling cap pressure, compress them and transmit the gas upwards.

  • Page 487: Condenser

    AIR CONDITIONING Condenser SPECIAL TOOLS Hoses clamp MOT 453 Elastic clips pliers MOT 1202-01 The condenser is placed on the cooling radiator, ensuring the exhaust of the refrigerant heat accumulated at compression. DISMOU NTIN G Disconnect the battery. Drain the AC unit and recover the oil and the refrigerant fluid at the charging station.

  • Page 488: Pressure Controller

    AIR CONDITIONING Pressure controller Disconnect the pressure controller LOCA TION connector. Pressure controller (1) is located on the high- Replace the pressure controller. pressure pipe, near the dryer reservoir. When mounting, lubricate the pressure controller sealing gasket with oil PAG SP 10. T ighten the pressure controller to the required moment of 0,9 +/- 0,1 daNm.

  • Page 489: Filter Reservoir

    AIR CONDITIONING Filter reservoir Filter reservoir (1) is attached by means of a REMOU NTIN G support collar on the right longitudinal girder. Perform the dismounting operations in the reverse order. Its function in the AC unit operation is : Fill the AC unit wit h refrigerant fluid HFC - filtering the refrigeran t fluid;...

  • Page 490: Unit Piping

    AIR CONDITIONING Unit piping TIGHTENING MOMENTS(daNm) 10 9 Pipe attachment nut 3/4’’on condenser 1,8-2 Pipe attachment nut 5/8’’on condenser 1-1,4 Pipes attachment screw on compressor 1,2 Pipes attachment nut on evaporator 0,57 The AC unit piping is ensuring the refrigeran t fluid circulatio n between the unit components.
  • Page 491 AIR CONDITIONING Unit piping Release the pipe and mount protection caps at its extremities, at compressor and condenser. REMOU NTIN G Perform the dismounting operations in the reverse order. Replace the gaskets and lubricate them with oil PAG SP 10. When a pipe is replaced, add 10 ml of oil PAG SP 10 and in case of its breaking , 100 ml.
  • Page 492 AIR CONDITIONING Unit piping REMOU NTIN G Perform the dismounting operations in the reverse order. The “0” rings from the pipe’s extremities are to be replaced with new ones. Before mounting, these are to be lubricated with oil PAG SP 10. When replacing a pipe, add 10 ml of oil PAG SP 10 and in case of its breaking –...

  • Page 493: Thermostatic Expansion Valve

    AIR CONDITIONING Thermostatic expansion valve Its function is to reduce the refrigerant fluid pressure at the evaporator entrance, to a default value. In this way, the fluid passing through the evaporator may be suction by the compressor in a complete gaseous condition. DISMOU NTIN G Drain the refrigerant circuit by means of the charging station .

  • Page 494: Climate Control Blower

    AIR CONDITIONING Climate control blower DISMOUNTI NG ( D.S.A.F . being already dis mounted) Disconnect the connector (1). Dismount the two attachment screws (2) of the climate control blower. Swing over and extract carefully the blower from its seat (3). REMOU NTIN G Perform the dismounting operations in the reverse order.

  • Page 495: Blower Control Resistance

    AIR CONDITIONING Blower control resistance DISMOUNTI NG ( D.S.A.F . bein g already dismounted) Disconnect the connectors (1) and (4). Dismount the resistance attachment screw (5). Extract the resistance (6). REMOU NTIN G Perform the dismounting operations in the reverse order. 62 - 21 vnx.su...

  • Page 496: Recycling Flap Motor Fan

    AIR CONDITIONING Recycling flap motor fan DISMOUNTI NG (D.S.A.F . bein g already dis m ounted) The access to the recyclin g flap gear motor is it possible only after dismountin g the air blowing device (D.S.A.F.) Disconnect the connector (4) Dismount the gear motor attachment screw (7).

  • Page 497: Diagnose

    AIR CONDITIONING Diagnose CLIMATE BLOWER FAN OR RECYCLING FLAP NOT WORKING Check fuses F03, F04, F17 and F26 from Replace fuses F03, cockpit.. Are they ok? F04, F17 or F26. Is any n12 V voltage between: - vehicle’s mass pin 10 climate control panel ? - vehicle’s mass pin 11 climate control panel ? Replace front wiring.
  • Page 498 AIR CONDITIONING Diagnose CLIMATE CONTROL PANEL LIGHTING NOT WORKING Replace fuse F14. Check in cockpit fuse F14. Is it OK? Check the continuity and resistance against vehicle mass between: - cockpit fuse F 14 exit pin 7 climate panel; Replace front - pin 9 climate panel vehicl e mass.

  • Page 499: Carriage Body Sealing

    CARRIAGE BODY SEALING Carriage body sealing 1 - climate control protector 2 - climate control box gasket 3 - water evacuation hose 4 - bonnet support 5 - obturators WATER EVACUATION HOSE CLIMATE CONTROL PROTECTOR DISMOUNTING DISMOUNTING Dismount the climate control box gasket. Dismount Swing over windscreen the climate control - climate control box gasket;...

  • Page 500: Openings Sealing

    OPENINGS SEALING Opennings sealing 1 – doors sealing gaskets 2 – trunk sealing gasket 3 – rear quarter panel ornament 4 – gutter sealing gasket DOOR FRAMES GASKETS Attention! Ensure a good positioning of the seal- DISMOUNTING ing gasket at the openings level. Dismount the front/rear doors frames gas- kets following the their outliners, by draw- GUTTER SEALING GASKETS...

  • Page 501: Glasses Sealing

    GLASSES SEALING Glasses gaskets 1. Windscreen gasket 2. Hatchback gasket 3. Fix window gasket 4. Doors glasses gaskets kit. DISMOU NTIN G Dismount the windscreen and hatchback glass, together with the gasket by pushing from the inside of the vehicle. If reused, the glass gasket shall be cleaned or replaced with a new one.

  • Page 502: Inside Wipers

    GLASSES SEALING Inside wipers INSIDE WIPERS DISMOU NTIN G Dismo unt: - opening handle; - window regulator crank; - inside door opening mechanism; - panel attachment screws. Remove the inside wiper. REMOU NTIN G Perform the dismounting operations in the reverse order. 66 - 2 vnx.su...

  • Page 503: Outside Wipers

    GLASSES SEALING Outside wipers DISMOU NTIN G Lower the window in the minimum position. Dismount the outside wiper (1), by detaching it from the clips (2). REMOU NTIN G Perform in the reverse order the dismounting operation. 66 - 3 vnx.su...

  • Page 504: Front Door Glass Channel

    GLASSES SEALING Front door glass channel DISMOU NTIN G - front door panel (see chapter 72); - front door deflective panel; - inner and outside wiper; - front glass (see chapter 54); - front door glass run channel; - exterior mirror (see chapter 56). REMOU NTIN G Perform the dismounting operation in the reverse order.

  • Page 505: Rear Door Glass Run Channel

    GLASSES SEALING Rear door glass run channel DISMOU NTIN G Dismo unt : - rear door panel (see chapter 72); - read door deflective panel; - rear glass( see chapter 54); - guide run channel (1); - rear door glass run channel (2); - glass guide (3);...

  • Page 506: Carriage Body Inside Trims

    CARRIAGE BODY INSIDE TRIMS Carriage body inside trims 1 - Upper front pillar trim 2 - Middle pillar trim 3 - Rear quarter panel trim 71 - 1 vnx.su...

  • Page 507: Upper Front Pillar Trim

    CARRIAGE BODY INSIDE TRIMS Upper front pillar trim DISMOUNTING Dismount : - dashboard upper part (see chapter 57); - front door sealing gasket in the contact area with the front pillar trim; - trim attachment screw (2) on the side frame lining. Detach from clips the upper front pillar trim (1) and release it.

  • Page 508: Middle Pillar Trim

    CARRIAGE BODY INSIDE TRIMS Middle pillar trim DISMOUNTING REMOUNTING Perform the dismounting operations in Move the front seat to enable operator the reverse order. access to the front pillar. Dismount: The tightening moment of the belt attach- ment screws is of 2,7 daNm, and the one of - partially the front/rear door gaskets (in the contact areas with middle pillar trim);...

  • Page 509: Rear Quarter Panel Trim

    CARRIAGE BODY INSIDE TRIMS Rear quarter panel trim DISMOUNTING Dismount: - rear quarter panel ornament; - partially the rear door sealing gasket in the contact area with the rear quarter panel trim; - rear table; - table support (see chapter 74); - attachment screw(2) of the rear belt on the upper part;...

  • Page 510: Roof Lining

    CARRIAGE BODY INSIDE TRIMS Roof lining 1 – roof lining 2 - clips DISMOUNTING Detach from clips the ceiling lamp and disconnect it (see chapter 81); Dismount: - turn handles (see chapter 58); - sun visors (see chapter 58); - upper front pillar trims; - volumetric sensors (for vehicles provided with alarm);...

  • Page 511: Trunk Carpet

    CARRIAGE BODY INSIDE TRIMS Trunk carpet DISMOUNTING Unstuck the trunk carpet from the self-adhesive tapes placed on the rear floor. REMOUNTING Perform the dismounting operations in the reverse order. 71 - 6 vnx.su...

  • Page 512: Cowl Panel Noise Absorbent

    CARRIAGE BODY INSIDE TRIMS Cowl panel noise absorbent DISMOUNTING Dismount : - dashboard (see chapter 57); - driving post cross beam (see chapter 42); - central console (see chapter 58); - distributor of the air ventilation climate maintenance RACV (see chapter 61); - attaching screw of the steering column support on the driving post cross-beam;...

  • Page 513: Cockpit Carpet

    CARRIAGE BODY INSIDE TRIMS Cockpit carpet 1 – cockpit carpet 2 – clip DISMOUNTING REMOUNTING Dismount : Perform the dismounting operations in the - front seats (see chapter 78); reverse order. - rear bench seat (see chapter 78); The clips attaching is to be performed with - front seat belts lockers (see chap- a maximum force of 3 daN.

  • Page 514: Lateral Openings Trims

    LATERAL OPENINGS TRIMS Front door panel DISMOU NTIN G Detach from clips the door panel in points Disconnect the battery. (2) . Dismo unt: - window regulator crank (A) for glass REMOU NTIN G lifting, that is mounted by clips attachment on Perform in the reverse order the dismounting the window regulator axle ( in case of the operations taking into account the following...

  • Page 515: Rear Door Panel

    LATERAL OPENINGS TRIMS Rear door panel Detach from clips the rear door panel from points (2). REMOU NTIN G Perform the dismounting operations in the reverse order, taking into consideration the followings recom mendations: - check the integrity of the deflectiv e panel and of the continuos sealant material layer Romtix 1502 P on the door caisson outliner;...

  • Page 516: Rear Table

    REAR TABLE Lateral table DISMOUNTING Release the table cord from button (3) that is attached on the hatchback by means of the screw (2) and the nut (4). Extract the panel (1). Release the rear table (1) from the lateral supports channel.
  • Page 517 REAR TABLE Lateral table PIVOT DISMOUNTING REMOUNTING Dismount the rear plate. Perform the dismounting operations in Dismount by measn of a screwdriver, in the reverse order. the arrow direction, the table pivot. In case head of the pivot, its remaining is inserted inside the metallic rod of the table by means of a screwdriver and a hammer, as per bellow presented drawing.
  • Page 518 REAR TABLE Lateral table REAR PLATE BUFFER REAR PLATE CORD DSIMOUNTING DISMOUNTING Push the rear plate buffer by means of a screwdriver according to the bellow Dismount presented drawing - rear table, - the agraffe of the rear plate cord together with its cord as per bellow presented drawing.

  • Page 519: Front Seat

    FRONT SEATS SLIDES GUIDES Front seat REMOU NTIN G TIGHTENING MOMENTS(daNm) Perform the dismounting operations in the reverse order. Front seat attachment screws The front seat attachment screws are to be DISMOU NTIN G tighten to the required moment of 2,1 daNm. Dismount the attachment screws (1) of the front seat on the side and central cross mem- ber in the front part.
  • Page 520 FRONT SEATS SLIDES GUIDES Front seats slides guides DISMOU NTIN G Dismount the front seat (see chapter 78 “ Seats”). In order to dismount the attachment screws (1) of the slides guides (2) and (3) on the front seat, it is necessary the backward and forward slides guides moving, by acting upon the lever (4).

  • Page 521: Seats / Rear Bench

    SEATS / REAR BENCH Rear bench - dismount the backrest attachment TIGHTENING MOMENTS (daNm) screws (6) to the lower part ( fixing plate) on rear floor; Lower part back rest attachment screws Back rest attachment screws on support 0.15 DISMOU NTIN G Dismount the seat (1) , by swinging and by removing them from the welded supports (4) on the carriage body.

  • Page 522: Battery - Front Headlights

    BATTERY - FRONT HEADLIGHTS Battery CHECKING It is recommended to check the following: - cracks or breaches of the battery box (case) - battery upper part cleanness - plugs condition It is required to strictly check the following: - lack of plugs sulfate composite - proceed, is necessar y to their cleaning and then greasing with neutral grease;...
  • Page 523 BATTERY - FRONT HEADLIGHTS Battery ATTENTION ! In case of acid splashes on body, abundantly wash with water all affected parts. If eyes have been touched, urgently call for a doctor. 1. DANGER = EXPLOSION RISK During battery charging, connected to a charger- rectifier, oxygen and hydrogen emissions are occurring.
  • Page 524 BATTERY - FRONT HEADLIGHTS Battery DISMOU NTIN G After identification and elimination of the real cause of the battery discharging, proceed as follows: Remove the plastic protector from the plus plug of the battery. Dismount the attachment nut of the mass wiring from the minus plug of the battery. Dismount the attachment nut of the wiring from the plus plug of the battery.

  • Page 525: Headlamp Assembly

    BATTERY - FRONT HEADLIGHTS Headlamp assembly NOTE : After headlamps dismounting, their adjustment must be performed. DISMOU NTIN G Disconnect the battery (-) plug. Pull backwards the gasket of the headlamp adjustment cor r ection control (1). Dismount the headlamp adjustment correction control from the headlamp adjustment device (see replacement of the headlamps mechanic adjustment control).

  • Page 526: Fog Projectors

    BATTERY - FRONT HEADLIGHTS Fog projectors DISMOU NTIN G Lift the vehicle by means of an elevator. Disconnect the fog projector connector from the vehicle wiring (pull the two clips of the connector). Detach carefully from the 3 clips of points (B), the fog projector support (A) from the bumper, using a straight screwdriver.

  • Page 527: Bulbs

    BATTERY - FRONT HEADLIGHTS Bulbs FOG PROJECTOR BULB REPLACEMENT DISMOU NTIN G Suspend the vehicle on an elevator. Disconnect the fog projector connector Rotate the bulb holder (F) and extract it from its place. REMOU NTIN G Perform the dismounting operations in the reverse order, correctly positio ning the bulb holder in its place.
  • Page 528 BATTERY - FRONT HEADLIGHTS Bulbs FRONT TURNING BULB REPLACEMENT DISMOU NTIN G Disconnect the connector (3). Rotate the holder (4) and remove it. Remove the worn bulb from the holder REMOU NTIN G Perform the dismounting operations in the reverse order, with the checking of the correct holder (4) positioning to avoid dust and humidity penetration in the headlamp assembly .
  • Page 529 BATTERY - FRONT HEADLIGHTS Bulbs HEADLAMP-FRONT LAMP ASSEMBLY SEALING (getting fogged, it has condensation water or water penetration) Check the front part of the assembly: direct Y es Replace the headlamp. a water jet towards the headlamp glass. Is the water penetrating inside the headlamp? Is water penetrating inside the parking-turning Y es Replace the parking-turning lamp.

  • Page 530: Headlamps Adjustment

    BATTERY - FRONT HEADLIGHTS Headlamps adjustment MEETING LIGHTS ADJUSTMENT (LOW BEAM) This is performed by acting upon the V screw (vertically plane adjustment) or H (horizontally plane adjustmen t). By screwing, the lighting beam is ”lowering” and by unscrewing is “ascen ding”. Check if the lighted area is centered on the vertical axis and if the optical separation at 15°...
  • Page 531 BATTERY - FRONT HEADLIGHTS Headlamps adjustment FOG PROJECTORS ADJUSTMENT The fog projectors adjustment is to be performed in the following conditions: the vehicle to be placed on a horizontal surface; the vehicle has not passengers inside the cockpit or weights in the trunk; the tires are pressurized at the manufacturer prescribed pressure.

  • Page 532: Replacement Of The Headlamps Mechanic Adjustment Control

    BATTERY - FRONT HEADLIGHTS Replacement of the headlamps mechanic adjustment control DISMOU NTIN G 5 6 3 4 Disconnect the (-) plug of the battery; Dismount the headlamp adjusting control from the turning lamp-headlamp assembly: - pull backward the gasket of the headlamp adjustment corrector (1); - detach from clips the protector (2) of the headlamp adjustment mechanism;...
  • Page 533 BATTERY - FRONT HEADLIGHTS Replacement of the headlamps mechanic adjustment control Attach on the cowl panel, by means of clips, the cables passing bushing, ensuring the cockpit compartment sealing against possible water drain along the cables passing bushing. Mount the bonnet opening control cable in the opening handle (see chapter 52). Position the headlamps adjustment control on the dashboard.

  • Page 534: Inside And Rear Lighting

    INSIDE AND REAR LIGHTING Inside and rear lighting REAR LAMPS REAR LAMP REPLACEMENT DISMOU NTIN G Disconnect the battery (-) plug. Disconnect the rear lamp connector . Inside trunk, dismount the screw with triangle head (A). Extract the rear lamp towards outside. REMOU NTIN G Perform the dismounting operations in the reverse order, positionin g correctly the rear lamp in its seat.
  • Page 535 INSIDE AND REAR LIGHTING Inside and rear lighting Disconnect the additional stop lamp REPLACEMENT OF REAR TURNING, connector. PARKING, FOG, REVERSE DRIVING, Detach the two side clips and extract the STOP BULB reflector-glass assembly from the lamp body. Detach carefully from clips the lamp glass, DISMOU NTIN G Disconnect the battery (-) terminal.
  • Page 536 INSIDE AND REAR LIGHTING Inside and rear lighting REPLACEMENT OF THE SIDE REAR LAMP DISMOU NTIN G Dismount the attachment screws of the wing protector. Dismount the wing protector Disconnect the connector Detach from clips the side rear lamp. REMOU NTIN G Perform the dismounting operations in the reverse order.

  • Page 537: Ceiling Lamp

    INSIDE AND REAR LIGHTING Ceiling lamp The ceiling lamp is central located, between the two sun visors. The ceiling lamp has 3 operating positions subject to ceiling lamp glass position (4): - position 1 : ceilin g lamp off - position 2 delayed ceiling lighting; this will light for 15 seconds after driver’s front door closing or after the command of unlocking the doors with the RF remote control.
  • Page 538 INSIDE AND REAR LIGHTING Bulbs BULBS Headlamps High/l o w beam lights Bulb H4, 12V-60/55W Parking lights Bulb W5W, 12 V-5W Front turning lamp Bulb PY21W, 12V-21W (colored) Fog projectors Halogen bulb H11, 12V-55W Rear Parking, stop lights Bulb AB1, 12V-21/5W lamps Turning lights Bulb PY21W, 12V-21W...

  • Page 539: Lamps Failures Diagnostic

    INSIDE AND REAR LIGHTING Lamps failures diagnostic REAR DRIVING LAMP NOT WORKING Check fuse F06 from cockpit fuse box. Replace fuse F06 Is it worn? Check the continuity and resistance against vehicle mass between: - exit fuse F06 pin2 reverse driving contact connector - pin1 reverse driving contact connector pin 6 right rear lam connector...
  • Page 540 INSIDE AND REAR LIGHTING Lamps failures diagnostic STOP LAMPS NOT WORKING Check fuse F04 from cockpit fuse box. Replace fuse F04 Is it good? Bridge the Stop contact terminals. Replace the Stop contact Are the lamps working? The stop contact wire supply is Is the Stop contact supplied ? broken or disconnected.

  • Page 541: Cockpit Fuse Box

    INSIDE AND REAR LIGHTING Cockpit fuse box DISMOU NTIN G Disconnect the (-) plug of the battery. Pull the seat (1) of the access flap (2) to the fuse box located in the cockpit, at the left end of the dashboard. Carefully remove flap (2). Dismount the attaching screws (3) of the fuse box on the driving post crossbeam and detach it from clips (4) REMOU NTIN G...
  • Page 542 INSIDE AND REAR LIGHTING Cockpit fuse box The fuses are protecting the following electric circuits: Fuse Symbol Fuse Protected circuit number type Free PLAF 15 A Instrument panel, cockpit UCE(ceiling lamp operation, radio 20 A Cockpit UCE, air conditioning climate control panel * 15 A Cockpit UCE, diagnostic socket, airbag UCE, anti-starting bushing...

  • Page 543: Uce Decoder Protection

    INSIDE AND REAR LIGHTING UCE decoder protection DESCRIPTION OF THE OPERATION Dismount the battery (-) terminal; Dismount the access flap to the cockpit fuse box; Dismount the attachment screw of the UCE decoder and relays assembly. Lift from its attachment place and remove UCE decoder and relays assembly . Carefully insert UCE decoder-relays assembly in the protector (1) so that protector is not damaged.

  • Page 544: Accoustic Warning - Anti Starting

    ACCOUSTIC WARNING - ANTI STARTING General This type of anti startin g system is based on the key recog nition, which has a specia l constructio n. It may be separated in two elements which can be identified in the following way: the key head (position A.) made of plastic, which can be dismounted and the metal insertion (position B), which is fixed and ensured by clipping in the key head.
  • Page 545 ACCOUSTIC WARNING - ANTI STARTING General THE KEY HEADS The key head has marked inside, a number of identification, formed by 8 alphanumeric characters (letters and figures) and this one is mentioned on the vehicle’s purchasing invoice. In case the reading of the code marked in the key head is necessar y, this can be opened in the following way : - keep the key in horizontal position, the half with the metal insertion being downwards ;...
  • Page 546 (4 characters) can be red from the vehicle-purchasing invoice. If also the invoice was lost, the two mentioned codes can be found out based on the chassis series of that vehicle, accessing the database of the DACIA manufacturer, calling the “Client Voice” department (phone 0248 500 000).
  • Page 547 ACCOUSTIC WARNING - ANTI STARTING General The ceiling delayed lighting is a ctivated subject to the position of the light glass (1): - position A the ceiling is lighting permanently; - position B de layed ceiling lighting; this w ill light f or 15 se conds after driver’s front do or closing or after the command of unlocking the doors with the RF remote control.

  • Page 548: One Key Head Replacement

    ACCOUSTIC WARNING - ANTI STARTING One key head replacement After ordering a new key head based on the alphanumeric code mentioned on the invoice, dismount the old key head and remove the metal insertion (mechanical part), then introduce the old metal insertion in the new key head according to the previously mentioned procedure.

  • Page 549: Dismounting - Remounting E.c.u. Decoder

    ACCOUSTIC WARNING - ANTI STARTING Dismounting - remounting E.C.U. decoder All new decoders, are not c oded. After mounting on the vehicle, it is ne cessary the memorisation of the key head code by the decoder in order to be operational. If only the decoder is replaced, no intervention is necessary to the injection computer, which will keep the old a nti starting code.

  • Page 550: Anti Starting Bushing Replacement

    ACCOUSTIC WARNING - ANTI STARTING Anti starting bushing replacement If, further to the diagnostic by means of the CLIP tester, it is established the necessity of the replacement of the anti starting bushing, proceed as follows: - disconnect the (-) terminal of the battery; - dismount the attachment screws of the steering wheel half-casings ;...

  • Page 551: R.f. Remote Control For Blocking/Unlocking The Doors

    ACCOUSTIC WARNING - ANTI STARTING R.F. remote control for blocking/unlocking the doors The RF remote control has only the function of blocking/ unlocking the doors. The RF remote control with evolutionary code can use only two keys as the decoder may manage only two different evolutionary codes.

  • Page 552: Electric Control Unit Injection Replacement

    “ Procedure for repairing code introduction” may be used, which allows the moving of the vehicle to the nearest DACIA service centre for complete repairing. In order to perform this procedure it is necessary the CLIP tester and the specific repairing code of that vehicle.

  • Page 553: Acoustic Warning

    ACCOUSTIC WARNING - ANTI STARTING Acoustic warning (For auto made before 03.07.2003) The acoustic warning is a ttached on the closing plate of the upper longitudinal girder. DISMOU NTIN G Lift the vehicle by means of an elevator. Disconnect the acoustic warning connector (1). Dismount the attachment screw (2) of the acoustic warning on the closing plate of the left upper longitudinal girder.
  • Page 554 ACCOUSTIC WARNING - ANTI STARTING Acoustic warning REPLACEMENT OF THE ACCOUSTIC WARNING (for auto made after 03.07.2003) The new acoustic warning is attached in the engine compartment, on the left upper front longitudinal girde r. DISMOU NTIN G Disconnect the battery (-) terminal. Remove by hand the battery screen from the acoustic warnin g attach ing area so that dismounting of the screw (1) is permitted.

  • Page 555: Procedures

    ACCOUSTIC WARNING - ANTI STARTING Procedures A. E.C.U. DECODER REPLACEMENT PROCEDURE AND ANTI STARTING CODE MEMORISING The new E.C.U. decoder is always not coded. After its mounting on the vehicle it is necessar y that this one is memorising the anti starting code in order to be operational. REMARK: If only the E.C.U.
  • Page 556 ACCOUSTIC WARNING - ANTI STARTING Procedures 1. Return to “COMPUTER TEST” 2. Set the contact on for 2 seconds in “M” position, without starting the engine. The anti starting indicator will begin to blink rapidly . 3. Access the menu “ STATE LIST”, where the following states must exist: 9D RECEIVED KEY CODE ………………………………..……...
  • Page 557 ACCOUSTIC WARNING - ANTI STARTING Procedures REMARK: For the RF remote control synchronisation, after the replacement of an E.C.U. decoder, the synchronisation procedure must be per formed taking into account the following situations: - fo r one RF r emote c ontr ol, pe r for m the “ SIMPLE SYNCHRONISED PROCEDURE”;...
  • Page 558 ACCOUSTIC WARNING - ANTI STARTING Procedures 7. Set the contact in “M” position with one of the keys (without starting the engine), for about 2 seconds and then check the following states, which must be: 9D RECEIVED KEY CODE ………………………………..…..ACTIVE 19G NOT PERFORMED KEY PROGRAMMING …………..…...
  • Page 559 10G ANTI STARTING ……………………………………………….ACTIVE After getting from DACIA database the repairing code (based on the vehicle chassis series and on the code from the vehicle’s key head), perform the following operations. 1. Connect the CLIP tester to the diagnostic socket and to the battery (or to the lighter socket) of the vehicle.
  • Page 560 ACCOUSTIC WARNING - ANTI STARTING Procedures D. SIMPLE SYNCHRONISED PROCEDURE This procedure allows the synchronisation of a RF remote control with E.C.U. decoder and is to be applied in the following situations: - the RF remote control code is no longer in the range of the E.C.U. decoder reception, because of blind consecutive pushing over a 1000 time on the RF remote control button.;...

  • Page 561: Diagnostic

    ACCOUSTIC WARNING - ANTI STARTING Diagnostic FAILURES AND STATES INTERPRETATION 1. FAILURE OF COMMUNICATION CLIP TESTER/ E.C.U. DECODER RECOMMENDATION Check if the lines K and L are not disturbed by another computer of the vehicle. Check the condition of fuse F 03 from the cockpit fuse box. Replace the fuse if necessary.
  • Page 562 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 2. 4D STATE: + 12 V (+DC) SUPPLY, EXISTENT RECOMMENDATION Observation : - 4D state = ACTIVE when the contact is on “M” position; - 4D state = PASSIVE when the contact is not on “M ”position. Check the F03 fuse condition.
  • Page 563 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 3. FAILURE : DOORS BLOCKING SWITCH RECOMMENDATION Check if the switch does not remain permanently pressed due to a mechanical blocking. Check the isolation related to the mass of the wiring between the E.C.U. decoder doors’ Repair the electric wiring.
  • Page 564 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 4.FAILURE: MISSING SIGNAL ON THE CODED LINE E.C.U. DECODER- COMPUTER INJECTION RECOMMENDATION Check the continuity and the isolation related to the mass and + 12 V of the wiring between the E.C.U. decoder PinA6 pin58 injection computer.
  • Page 565 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 5. FAILURE : DEFECTIVE COMMUNICATION ANTI STARTING SYSTEM - E.C.U. DECODER RECOMMENDATION Check the continuity and the isolation related to the mass and + 12 V voltage of the wiring between the anti starting system pin 4 pin A2 E.C.U.
  • Page 566 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 6. STATE 11G: ACTIVATE THE RF REMOTE CONTROL/ RECEIVED RF SIGNAL INDICATION If the 17D state is PASSIVE, do not apply the next diagnostic because the E.C.U. decoder is unused (new). RECOMMENDATION Perform first the remote control synchronisation. Do not access the next diagnostic if the state 11G remains PASSIVE when activating the RF remote control at the blocking and unlocking of the doors.
  • Page 567 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 7. 11D STATE: OPERATE THE RF REMOTE CONTROL / GOOD RF SIGNAL INDICATION Do not access the following diagnostic unless the state 11D RECOMMENDATION becomes ACTIVE when operating the RF remote control. Check if the keys belong to the vehicle in question. There is a desynchronising between the code of the RF remote control and the E.C.U.
  • Page 568 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 8. 14G STATE : DOORS BLOCKING/ UNLOCKING RECOMMENDATION The state 10G (anti starting) must be ACTIVE. Check the continuity and the isolation related to the +12 V and to the mass of the electric wiring on the line E.C.U.
  • Page 569 ACCOUSTIC WARNING - ANTI STARTING Diagnostic FAILURES LOCATING BASED ON CLIENT CLAIM (algorithm for damage locating) ALP1. MISSING COMMUNICATION CLIP TESTER / E.C.U DECODER RECOMMENDATION Check if the lines K and L are not perturbed by another computer of the vehicle. Check the condition of the F03, F04 fuses from cockpit fuse box.
  • Page 570 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP2. CONTACT SET ON THE ANTI STARTING INDICATOR BLINKS (THE ENGINE IS NOT STARTING) RECOMMENDATION Set the contact on. Connect the CLIP tester. See ALP1 Is there any communication with the E.C.U. decoder ? Check the fuse F03 for anti starting bushing Replace the fuse.
  • Page 571 ACCOUSTIC WARNING - ANTI STARTING Diagnostic Is the anti starting bushing correctly fixed on Position the bushing and fix its the stee ring column and is it correctly connected connection. Check the continuity and the isolation related to the mass and the +12 V wiring. Fix the electric wiring.
  • Page 572 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP3. THE ANTI STARTING INDICATOR REMAINS PERMANENTLY LIGHTED ( even when the contact is taken off) OR IT REMAINS PERMANENTLY SWITCHED RECOMMENDATION Check if the “Procedure E.C.U. decoder replacement” w as correctly performed Check the fuse F03 condition from the cockpit Replace the fuse.
  • Page 573 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP4. CONTACT ON THE ANTI STARTING INDICATOR BLINKS QUICKLY (engine is not starting) RECOMMENDATION Set the contact on. Connect the CLIP tester. See ALP1. Is there any communication between the tester and E.C.U. decoder ? Check the correct memorisation of the anti starting code by the Is the state 19D, ACTIVE?
  • Page 574 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP5. THE VEHICLE IS NOT STARTING RECOMMENDATION Is there the failure “SIGNAL MISSING ON There is an engine problem. THE CODED LINE E.C.U. DECODER – COMPUTER INJECTION?” There is a problem at the shock sensor. Perform a conformity checking.
  • Page 575 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP6. BLOCKING/UNLOCKING DOORS NOT OPERATING RECOMMENDATION Check with the CLIP tester the absence of the failures. If there are memorised failures, these must be removed. Are the doors blocking mechanisms correctly Repair the damaged mechanisms. operating ? Y es Check the continuity and the isolation related to the...
  • Page 576 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP7. UNLOCKING DOORS NOT OPERATING BY RF REMOTE CONTROL RECOMMENDATION Check the absence of failures with the CLIP tester. If there are memorised failures, these must be repaired. Are the states 11G and 11D becoming See the treatment of the states 11G ACTIVE when the RF remote control is and 11D cf.
  • Page 577 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP 8. TURNING LIGHTS DO NOT SWITCH ON AT THE BLOCKING / UNLOCKING OF THE DOORS RECOMMENDATION Check the absence of the failures with the CLIP tester. If there are failures, fix them first. Check if the synchronisation of the RF remote control and the E.C.U.
  • Page 578 ACCOUSTIC WARNING - ANTI STARTING Diagnostic ALP9. THE CEILING LAMP DOES NOT SWITCH ON AT THE BLOCKING / UNLOCKING OF THE DOORS OR IT REMAINS PERMANENTLY TURNED ON RECOMMENDATION Check the absence of failures with the CLIP tester. If there are memorised failures, fix them first. The ceilin g lamp was in Check if the doors are locked? Normal...
  • Page 579 ACCOUSTIC WARNING - ANTI STARTING Diagnostic THE CONFORMITY CHECKING Next, the checking of different states and configurations of the anti starting system is to be performed. RECOMMENDATION In case of finding some failures at the diagnostic by means of the CLIP tester, analyse them based on the diagnostic (ALP) corresponding to the respective failure.
  • Page 580 ACCOUSTIC WARNING - ANTI STARTING Diagnostic 11. Remote control signal reception. 11G = activate the RF remote ACTIVE for 3 seconds control. if the decoder Received signal indication receives the remote control signal. 12. Remote control signal validation 11D = activate the RF remote ACTIVE for 3 sec. control.

  • Page 581: Diagnostic - General

    ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General DISMOUNTING ONE KEY-HEAD DISMOUNTING ONE KEY-HEAD (WITHOUT REMOTE CONTROL). (WITH REMOTE CONTROL) Place the key-head on a table, the half with By means of a little screwdriver, that is the metal insertion being downwards. inserted in the slot (E), act by carefully detaching from clips the two parts of the key- head.
  • Page 582 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General DESCRIPTION OF THE SYSTEM By means of this system, the anti-starting is activated few seconds after the contact has been taken off (signalized by the blinking of the anti- starting red indicator). Its components are : 〈...
  • Page 583 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General Cockpit Central Unit For anti-star t ing function , the Cockpit Central Unit is ensuring the following functions: - key signal decoding - dialoguing with the injecti o n computer. - Conducting the anti-starting indicator placed on instrument panel. - Dialoguin g with the diagnostic tester.
  • Page 584 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General DISMOUNTING ONE KEY-HEAD DISMOUNTING ONE KEY-HEAD (WITH REMOTE CONTROL) (WITHOUT REMOTE CONTROL). Place the key-head on a table, the half with By means of a little screwdriver, that is inserted in the slot (E), act by carefully the metal insertion being downwards.
  • Page 585 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General This document is presenting the diagnostic generally valid for all computers, for anti-starting function. In order to perform the diagnostic of this system, it is then all-important to dispose of the following elemen ts: - workshop manual of the corresponding vehicle - electric diagram of the function, for the correspondin g vehicle - special tools specified in the column “Necessar y Special tools”.
  • Page 586 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General OPERATION When anti-starting system is on, the red LED is blinking (rare signal: one blink/sec). After setting the contact on, the key code is transmitted to the Cockpit Central Unit. If the code is recognized by the Cockpit Central Unit, this one is sending coded signals to the injection computer and the anti-starting LED is off.
  • Page 587 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General If doors are unlocked and none of them is GENERAL not opened in the next 30 seconds, the system is automatically re-locking the vehicle doors Cockpit Central Unit (UCH) is replacing the UCE decoder. (without hazard lights blinking).
  • Page 588 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General REPLACEMENT AND SETTING New parts are not coded. Once mounted on vehicle, in order to become under operation, the memorization of a code it is necessary. In order to perform this procedure, it is absolutely necessary that some vehicle parts are already coded (with the vehicle code).
  • Page 589 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General Cockpit central Unit is not coded. Once mounted on vehicle, in order to become under operation, the memorization of a code it is necessary. In order to perform this procedure, it is obligatory to have at least one of the vehicle old keys, to know the reparation code and the injection computer must be correctly coded (please refer to the assignation table).
  • Page 590 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General THE PROCEDURE OF COCKPIT CENTRAL UNIT PROGRAMMING Enter in dialogue with system “Anti-starting” Select menu “Control menu” and “Specific control”. Select control “SC027 Cockpit Central Unit Programming”. Tester is displayin g: “Take off the key from anti-theft contact” The code can be entered only when contact is et off Tester is displa ying:...
  • Page 591 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General If tester is displayin g: “The after-sale code does not correspond to the pre- sented key. Check if the code was correctly en- tered and if a vehicle key was presented ”. The entered code does not correspond to the vehicle’s key, the key does not belong to that...
  • Page 592 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General This message will be displayed for few THE PROCEDURE OF seconds, then you may come out from the re- KEYS ASSIGNATION assignation procedure ATTENTION: the maximum admissible IMPORTANT : if not all keys are available it interval between each operation is of 5 min- will be necessary to subsequently perform the assignation procedure with all the keys.
  • Page 593 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General THE PROCEDURE OF KEYS’ ASSIGNATION Enter in dialogue with the system “Ant i -starting” Select menu “ Control module” and “Specific control”. Validate line “SC 028: Key programming”. Tester is displaying: “ take off the key from anti-theft contact”...
  • Page 594 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General Tester is displaying: “At tention. The non present e d keys shall be not active. Re- l aunch the p roced ure in order t o re- a ssign them”. This procedure is enabling the decommissionin g of one key in case of its loss, for instance Tester is displaying: “...
  • Page 595 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – General THE CODING OF THE INJECTION COMPUTER. The injection computer is delivered not coded. Therefore, the anti-starting system code memorizing will be necessar y, when its mounting, in order to authorize the vehicle starting. It is sufficient to set the contact on for few seconds, without starting the engine.

  • Page 596: Diagnostic - Failures Interpretation

    ACCOUSTIC WARNING - ANTI STARTING Diagnostic – Failures interpretation DF055 CODED LINE CIRCUIT PRESENT MEM OR IZED Applying conditions of the diagnostic to the memorized failure: RECOMMENDA T ION S - failure declared present when setting the contact on (+After contact). Check the connection and condition of the connector with 40 pins EH1 of the Cockpit Central Unit.
  • Page 597 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – Failures interpretation DF069 UCH CONNECTION ANTI-STARTING BUSHING PRESENT CC.O: short-circuit at mass CC.1: short-circuit at 12 V MEMORIZED RECOMMENDATIONS Applying conditions of the diagnostic to the memorized failure: - failure declared present when setting the contact on (+After contact). Check the condition and connection f the anti-starting bushing CC.0 If necessary, repair the connector.

  • Page 598: Diagnostic - Conformity Checking

    ACCOUSTIC WARNING - ANTI STARTING Diagnostic – Conformity checking Do not perform this checking but only after a complete check-up by means of the diagnostic tester. The values showed in this conformity RECOMMENDA T IONS checking are mentioned only for your information. Execution condition: stopped engine, contact set on.
  • Page 599 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – Conformity checking STATES TEST ET154: Presence + 12V after contact ET002: Received key code ET003: Valid key code. ET017: active anti-starting. It is possible that when checking some states, a failure to be identified, due to different infor- mation supplied.

  • Page 600: Diagnostic - States Interpretation

    ACCOUSTIC WARNING - ANTI STARTING Diagnostic – States interpretation ACTIVE ANTI-STARTING ET017 The active anti-starting state must become inactive at + After RECOMMENDATIONS contact. The anti-star t ing must be active when the key is not in contact ET017 ACTIVE although there is a key in the ignition contact and + After contact Check if there is not a failure before handling this state.
  • Page 601 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – States interpretation PRESENCE + 12 V AFTER CONTACT ET154 RECOMMENDATIONS Nothing to notice ET154 INACTIVE with contact on. Perform the checking of F13 fuse 925A) n the cockpit fuse box. Check by means of a multiple meter presence of +12 V with the contact on, at the level of fuse socket.
  • Page 602 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – States interpretation RECEIVED KEY CODE ET002 Check that no failure is present or memorized. RECOMMENDATIONS The state will be declared “YES” when contact set on (+After contact) with a valid key. If state remains at “NO”, before any other intervention, try with another key belonging to the vehicle ET002 is NO : when the contact is set on with a key belonging to the vehicle.
  • Page 603 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – States interpretation VALID KEY CODE ET003 RECOMMENDATIONS The state will be declared “YES” when contact set on (+After contact) with a key belonging to the vehicle. If state remains at “NO”, before any other intervention, try with another key belonging to the vehicle ET003 is NO although the contact is set on with a key belonging to the vehicle and although the key code is received.
  • Page 604 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – States interpretation ANTI – STARTING INDICATOR ET167 RECOMMENDATIONS The state <<active anti-star t ing>> must pass at NO after setting the contact on. The state << active anti-starting>> must become “YES” after 10 seconds from contact setting off. Check the connection and condition of the instrument panel connector.

  • Page 605: Diagnostic - Damage Location Algorithm

    ACCOUSTIC WARNING - ANTI STARTING Diagnostic - Damage location algorithm RECOMMENDATIONS Do not consult these information but after a complete checking by means of the CLIP tester. THERE IS NO COMMUNICATION WITH THE COMPUTER ___________ALP1 82 - 62 vnx.su...
  • Page 606 ACCOUSTIC WARNING - ANTI STARTING Diagnostic – Damage location algorithm There is no communication with the computer ALP1 RECOMMENDATIONS Nothing to notice Check the communication of CLIP tester with a computer from another vehicle. Check: connection between CLIP tester and the diagnostic socket (check the cable condition). Cockpit and engine compartment fuses.

  • Page 607: Instrument Panel

    INSTRUMENT PANEL Instrument panel without RPM meter 83 - 1 vnx.su...

  • Page 608: Instrument Panel With Rpm Meter

    INSTRUMENT PANEL Instrument panel with RPM meter 83 - 2 vnx.su...

  • Page 609: Connectors Disposal

    INSTRUMENT PANEL Connectors disposal Connector B (brown) Connector A (white) Denomination Denomination Left turning indicator Vehicle speed signal Meeting lights indicator Engine RPM signal Free Road lights indicator Rear windscreen defrosting indicator Free + After contact Free Free Driver safety belt indicator Free OBD indicator Free...

  • Page 610: Perform Functional Instrument Panel

    INSTRUMENT PANEL Perform functional instrument panel DISMOU NTIN G Disconnect the battery (-) terminal. Dismount the 3 attach ment screws of the steering wheel half-casing, by means of a TORX 20 screwdriver. Detach from clips the steering wheel half-casings and remove them. By means of a TORX 20 wrench (“L”...

  • Page 611: Speed Transducer

    INSTRUMENT PANEL Speed transducer The instrument panel (speedometer, mileage) and the speed limit alert are receiving the information regarding vehicle speed from an electronic transducer. This information is also used by the UCE injection. Connect or Denomination Supply after contact (+DC) Vehicle speed signal Mass * For vehicles with speed limit alert.

  • Page 612: Fuel Level Transmitter

    INSTRUMENT PANEL Fuel level transmitter SPECIAL TOOL MOT 1397 Dismounting wrench of the fuel level transmitter assembly The fuel level transmitter assembly is mounted on the fuel tank. Its dismounting is not im- plying dismounting of the fuel tank. IMPORT ANT: During all interventions at the fuel level transmitter, observe the following precautions: - do not smoke;...

  • Page 613: Water Temperature Sensor

    INSTRUMENT PANEL Water temperature sensor OPERA TION The water temperature sensor (1) is sending to the injection computer the water temperature information, and another information is sent to the indicator device from the instrument panel, that will show the water temperature. Electric tests –...

  • Page 614: Diagnostic - Damages Interpretation

    INSTRUMENT PANEL Diagnostic – damages interpretation OIL PRESSURE INDICATOR STILL ON AFTER ENGINE STARTING Check the oil pressure. Pressure is correct? Replace the oil pressure There is a failure in the oil circuit. transmitter. Fix it. OIL PRESSURE INDICATOR IS NOT ON WHEN CONTACT SET ON Place the wire from the oil pressure transmitter to the mass...
  • Page 615 INSTRUMENT PANEL Diagnostic – damages interpretation FUEL LEVEL INDICATOR NOT SHOWING CORRECTLY Disconnect the connector of the fuel level transmitter. Is the fuel indicator returning to zero? Put at vehicle mass pin B1 Replace the fuel of the fuel level transmitter level transmitter.

  • Page 616: Steering - Connector

    STEERING - CONNECTOR Anti-theft mechanism ANTI-THEFT MECHANISM (IGNITION-STARTING SWITCH) The anti theft mechanism is placed on the right part of the steering column and has the purpose to starter control, electric system connecting and disconnecting, being provided in the same time also with a steering locking device, with anti theft lock.

  • Page 617: Under Steering Wheel Control

    STEERING - CONNECTOR Under steering wheel control The under steering wheel control assembly and the rotating contact included in this one, can not be separated. DISMOUNTING Disconnect the battery (-) terminal. Place the steering at the middle point (straight line driving position of the vehicle). Detach from clips the steering wheel central ornament (cover).
  • Page 618 STEERING - CONNECTOR Under steering wheel control The under steering control assembly and the rotating contact included in this one are not to be separated. The rotating contact is ensuring the electric connection between the steering column and the steering wheel. This contact is connected with the from wiring by means of wires stacked as tape-shaped having the necessar y length provided to ensure 5 steering wheel rotations (limited by the wheels camber plus one more for safety).
  • Page 619 STEERING - CONNECTOR Under steering wheel control REMOU NTIN G Ensure that steering is on middle point (wheels are in the straight-on driving position of the vehicle). Position the under-steer ing wheel control assembly so that after remounting the two steering wheel half-cases, the assembly handles are lined up with the instrument panel and the dashboard.
  • Page 620 STEERING - CONNECTOR Under steering wheel control TURNING AND LIGHTING WINDSCREEN WIPER SWITCH CONNECTOR CONTROL CONNECTOR Denomination Denomination Windscreen wiper Front fog projectors High speed control Free Low speed control Rear fog lamp Windscreen washer pump control Acoustic warnin g Free Right turning Timer low speed control...

  • Page 621: Rear Windows Defrosting Switch

    STEERING - CONNECTOR Rear windows defrosting switch Connector Denomination Rear window defrosting indicator Defrosting control Supply + after contact Mass Supply + parking 84 - 6 vnx.su...

  • Page 622: Central Locking Switch

    STEERING - CONNECTOR Central locking switch Connector Denomination Doors blocking control Supply + parking Mass Mass Doors unlocking control 84 - 7 vnx.su...

  • Page 623: Passenger Electric Window Switch

    STEERING - CONNECTOR Passenger electric window switch Connector Denomination Passenger window lowering Mass Supply + after contact Supply + parking Passenger window lifting 84 - 8 vnx.su...

  • Page 624: Driver Electric Window Switch

    STEERING - CONNECTOR Driver electric window switch Connector Denomination Driver window lowering Mass Supply + after contact Supply + parking Driv er window liftin g 84 - 9 vnx.su...

  • Page 625: Hazard Switch

    STEERING - CONNECTOR Hazard switch Connector Denomination Supply + parking Control + signaling relay Left turning lights control Right turning lights control Mass + Battery + Accessories Control + signalin g 84 - 10 vnx.su...

  • Page 626: Electric Lighter

    STEERING - CONNECTOR Electric lighter DISMOU NTIN G Disconnect the battery (-) terminal. Dismount the upper part dashboard. Disconnect connectors (1), (2) and (3). Mark identification of their mounting position. Holding with one hand the fix part (4) dismount the lighter attach ment clamp (5) on the lower part dashboard.

  • Page 627: Windscreen Wiper

    WINDSCREEN WIPER Drive mechanism Dismount the shafts attachment nuts (6) on The drive mechanism is mounted in the cli- the windscreen lower frame; recover the washers mate control box. and gaskets. Detach from clips the washing hose. DISMOU NTIN G Ensure that assembly is stopped in the Dismount the mechanism attachment screw (7) on the windscreen lower crossbeam.
  • Page 628 WINDSCREEN WIPER Drive mechanism Connector Denomination Mass Stopping at fix point + Battery Low speed control High speed control 85 - 2 vnx.su...

  • Page 629: Diagnostic

    WINDSCREEN WIPER Diagnostic Check fuse F07 from cockpit. Replace Is it good? fuse F 07 Check the windscreen wiper Replace the under steering wheel control assembly . switch. Is it good? Check the windscreen wiper Replace the windscreen wiper timer. timer.
  • Page 630 WINDSCREEN WIPER Diagnostic Set the contact off. Check the continuity and the resistance against vehicle mass between: - exit fuse F02 pin 3 electric motor connector of the windscreen wiper Electromo torul - pin 2 electric motor connector of the windscreen wiper pin 4 ºtergãtor parbriz timer connector of the windscreen wiper;...

  • Page 631: Auto Radio

    AUTO RADIO General The auto radio may be fitted in the versions: radio-tapes player and radio with CD player. RADIO-TAPES PLAYER PRESENTATION 1. On/off key 2. Key for tape fast-forwards up to next song 3. Tape eject key 4. Tape inserting door 5.
  • Page 632 AUTO RADIO General MAIN FUNCTIONS Function “ON / OFF Logic” The radio may operate also when engine is stopped, when contact key is on “S” position. In this situation, after 20 minutes of operation, an acoustic signal will be heard and the radio will automatically stop.
  • Page 633 AUTO RADIO General Radio tuning on a transmitter The radio receiver is using three selection modes that may be seen on the screen and ap- proached on the radio front side: - manually ( TUNER MANU ) - by pre-selection (TUNER PRESEL) - in alphabetical order (LIST) Program memorizing After the desired waves range has been selected (UL, UM or FM) and the transmitter...
  • Page 634 AUTO RADIO General - select the adequate area - America - Japan - Asia - Arabia - Others ( Europe, Africa, others) - Select the sound tonality curves: - 0 : inactive adjustment - 1 : Twingo - 2 : Clio - 3 : Megane - 4 : Laguna - 5 : Top range...
  • Page 635 AUTO RADIO General OBSERV ATION : the auto radio is provided with a sound tonality modification subject to vehicle type. To modify that, see chapter “ configuration”. Self-diagnostic This mode is allowing some main functions controlling: -speakers testing by simultaneously pushing of 2 and 4 keys, the speakers are supplied one by one. The display is enabling their locati o n.

  • Page 636: Tapes Player

    AUTO RADIO Tapes player TAPES PLAYER This function is completely automatic, immediately after the tape is being inserted in the device through the door provided for this purpose, the tape being oriented with the opening towards right. Tape fast forwards For this purpose, the “sau”...

  • Page 637: Cd Player

    AUTO RADIO CD Player CD PLAYER CD (compact disc) playing. Insert the CD, with the recorded face downward, in the door located on the device front part. The CD lecture is beginning with track number 1. If the CD has been previously inserted, then you switch on listening to a radio station, in case you wish to listen again to the CD, push key SRC and select CD.

  • Page 638: Connectors

    AUTO RADIO Connectors Connectors White connector (C) Black connector (A) Denomination Denomination + Right rear speaker Free - Right rear speaker Free + Right front speaker Free – Right front speaker Battery supply + Left front speaker Free – Left front speaker Supply + parking + Left rear speaker Supply + after contact...

  • Page 639: Roof Antenna

    AUTO RADIO Roof antenna ROOF ANTENNA HOLDER DISMOU NTIN G Disconnect the battery (-) terminal. Detach from clips the ceiling lamp using a straight head screwdriver (see chapter 80). Disconnect the ceiling lamp connector Dismount the attachment screw of the antenna holder on the roof. Remove the antenna holder.
  • Page 640 AUTO RADIO Roof antenna REMOU NTIN G Mount the antenna cable (insert the antenna connector (3) through the space between the roof and the ceiling attachment support, observing the mounting position existent prior to the dismounting. Mount the antenna holder on the roof. Unstuck the Aplix pills protection and these are to stacked on the roof, attaching the antenna cable.

  • Page 641: Electrical Assisance Equipement

    ELECTRICAL ASSISANCE EQUIPEMENT Windscreen washing Disconnect the washing hose connected to It is located on the left side of the climate the electric pump. control box, being attached by means of a Carefully remov e the washing reservoir from screw. It has the windscreen washing electric the climate control compartmen t and tilt it in such pump attached on the washer reservoir.

  • Page 642: Relays And Uce Decoder Assembly From Cockpit

    ELECTRICAL ASSISANCE EQUIPEMENT Relays and UCE decoder assembly from cockpit DISMOU NTIN G Disconnect the battery (-) terminal. Pull the seat (1) of the access flap (2) to the fuse box located in the cockpit, at the left end of the dashboard.
  • Page 643 ELECTRICAL ASSISANCE EQUIPEMENT Relays and UCE decoder assembly from cockpit REPLACEMENT OF COCKPIT INTERMEDIARY RELAY DISMOU NTIN G Disconnect the battery (-) terminal. Dismount the relays assembly and UCE decoder. Remove the relay: flash (6), timer (7), signaling (8) or speed limit warning (9) from their connectors.

  • Page 644: Cockpit Central Unit

    ELECTRICAL ASSISANCE EQUIPEMENT Cockpit Central Unit OBSERVATION : DESCRIPTION Cockpit Central Unit type “high range” may Cockpit central Unit is placed under the be mounted instead of Cockpit Central Unit dashboard, on the left side (in a protecti o n box “basic range”...
  • Page 645 ELECTRICAL ASSISANCE EQUIPEMENT Cockpit Central Unit DISMOUNTING REMARK: - No handling or intervention at the protection box is allowed; in case of damage, replace the Cockpit Central Unit. - Before dismounting, it is necessary the reading of the Cockpit central Unit configuration. Different UCH configurations may be performed by means of the diagnostic tester.

  • Page 646: Diagnostic - General

    ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – general This document is presenting the diagnostic generally valid for all computers, for Cockpit Central Unit function, at SOLENZA vehicles all types of engine In order to perform the diagnostic of this system, it is then all-important to dispose of the following elemen ts: - workshop manual of the corresponding vehicle - electric diagram of the function, for the correspondin g vehicle...
  • Page 647 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic - General Subject to equipment level, two types of Cockpit Central Unit may be mounted: Basic range High range Cockpit Central Unit Diagnostic connection Coded anti-starting (V2) Turning lights and indicator management Acoustic warning (turning lights on forgetfulness) Windscreen wiper: fix point stopping management Cockpit lighting management Cockpit timing lighting...
  • Page 648 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic - General CONNECTION (the most complete) Black connector EH1 ( 40 pins) White connector P1 (15 pins) DENOMINATION Not used DENOMINATION Not used Mass Not used Ceiling lamp outlet Not used + Before contact Not used Windscreen wiper control Not used Windscreen wiper supply (+ after...
  • Page 649 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic - General DISMOUNTING – REMOUNTING Cockpit central Unit is attached by clips in its support. IMPORTANT: the support of Cockpit Central Unit must be not dismounted because there is the risk of damage it. Dismounting implies therefore its replacement. 87 - 9 vnx.su...
  • Page 650 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – general GENERAL CONFIGURATIONS OF THE COCKPIT CENTRAL UNIT There are the following possible configurations of the cockpit Central Unit: Denomination and symbol on CLIP tester Type of Cockpit Con figurati o n Central Unit Only at N4 Ceiling lamp timing (LC021) automatic Only at N4...

  • Page 651: Diagnostic - Failures Interpretation

    ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Failures interpretation WINDSCREEN WIPER FIX POINT STOPPING DF119 MEMORIZED Diagnostic application conditions to the memorized failure: RECOMMENDATIONS - failure declared present further to wiper control REMARK: wipers random operation in timing position (timing non-respected) Check that fix point stopping state ET 005 is active each time when wipers blades reach the pause position and then pass to inactive.
  • Page 652 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Failures interpretation UCH INTERN ELECTRONIC ABNORMALITY DF121 PRESENT Failure declared present when setting contact off RECOMMENDATIONS Particularity: in case of a memorized failure, check not to be other present failures and perform the failures erasing. Replace the Cockpit Central Unit AFTER REPAIRING Fix all others failures...
  • Page 653 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Failures interpretation DOORS BLOCKING SWITCH CIRCUIT (CPE) DF131 CC.0: short circuit at mass PRESENT RECOMMENDATIONS Failu re declared presen t when activating the doors blocking switc h Check connection and condition of connector with 40 pins EH1 of UCH Replace connector if necessar y Check insulation and continuity on communication lines: Pin 8A of UCH connector EH1 with 40 pins...

  • Page 654: Diagnostic - Conformity Checking

    ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic - Conformity checking RECOMMENDATIONS Do not perform this conformity checking but after a compete checking by means of diagnostic tester. The values displayed in this conformity checking are only informative. The execution condition: stopped engine, contact set on. Parameter or state Visualization and Diagnostic...
  • Page 655 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic - Conformity checking RECOMMENDATIONS Do not perform this conformity checking but after a compete checking by means of diagnostic tester. The values displayed in this conformity checking are only informative. The execution condition: stopped engine, contact set on. Parameter or state Visualization and Diagnostic...
  • Page 656 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic - Conformity checking Do not perform this conformity checking but after a compete checking by means of diagnostic tester. The values displayed RECOMMENDA TIONS in this conformity checking are only informative. The execution condition: stopped engine, contact set on. Visualization and Function Diagnostic...
  • Page 657 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Conformity checking At “N4” Cockpit Central Unit, some states and parameters are only displayed on the screen “Function test”. There are two function tests: “Radio-Frequency” “ET002: +12 volts after contact” “ET193: RF received information” “ET010: RF valid key” “Doors management”...

  • Page 658: Diagnostic - States Interpretation

    ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – States interpretation +12 VOLTS AFTER CONTACT ET002 ET002 INACTIVE with contact set on. Perform a checking of fuse from cockpit Check using a multiple-meter presence of +12 volts with contact set on, at the level of fuse support.
  • Page 659 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – States interpretation RF VALID KEY ET010 RECOMMENDATIONS ONLY for “N4” Cockpit Central Unit Check that no failure is present. State is declared YES when pushing the remote control button. If state is declared NO, set on then set off + After contact Try again then with another key of the vehicle.
  • Page 660 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic –States interpretation HAZARD LIGHTS INFORMATION ET291 RECOMMENDATIONS No failure must be present or memorized. Act upon the hazard lights switch. State must be ACTIVE Check supply fuse for turning / Cockpit Central Unit. ET291 INACTIVE F13 (25A) Replace it if necessary.
  • Page 661 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – States interpretation RIGHT TURNING INFORMATION ET309 LEFT TURNING INFORMATION ET310 No failure must be present or memorized. RECOMMENDATIONS Set on the contact Act upon the left or right turning control State must be ACTIVE ET309 Check the supply fuse F13 (25A) for turning lights/Cockpit Central Unit.
  • Page 662 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – States interpretation WINDSCREEN WIPER TIMER ET213 RECOMMENDATIONS No failure must be present or memorized. Set on the contact Act upon the left or right turning control State must be ACTIVE ET213 Check the windscreen wiper fuse F07 (20A). INACTIVE Replace it if necessary.
  • Page 663 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – States interpretation FRONT DOORS ET192 RECOMMENDATIONS Check that no failure is be present or memorized. Open the drivers’ door Check that for open door the corresponding state is active or for closed door, the corresponding state is inactive Check continuity and insulation of the wiring between: Driver’s doors contact and pin 40B of UCH connector EH1 Fix if necessary (see electric diagram of that vehicle)
  • Page 664 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – States interpretation RECEIVED INFORMA TION ET193 RECOMMENDATIONS Only for “N4” Cockpit Central Unit. Check that no failure is present State is declared YES when pushing the remote control If state is declared NO, set on then set off the contact. Try again with another key of the vehicle.
  • Page 665 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – States interpretation PARKING LIGHTS INFORMATION ET257 RECOMMENDATIONS Check that no failure is present or memorized. Act upon the parking lights control. State must be ACTIVE, and the parking lights on Check the bulbs. Check parking lights fuse F14 (7.5 A) ET257 Replace it if necessar y INACTIV...

  • Page 666: Diagnostic - Damage Location Algorithm

    ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Damage location algorithm RECOMMENDATIONS Do not consult these information but after a complete checking by means of CLIP tester THERE IS NO COMMUNICATION WITH THE COMPUTER ALP1 LIGHTING ALP2 TURNING LIGHTS ARE NOT WORKING PARKING LIGHTS ARE NOT WORKING ALP3 WINDSCREEN WIPING WINDSCREEN WIPER LOW SPEED NOT WORKING...
  • Page 667 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Damage location algorithm There is no communication with the computer ALP 1 RECOMMENDATIONS Nothing to notice Check the tester operation on another vehicle Check: - Connection between CLIP tester and the diagnostic socket (cable in good condition). - Cockpit and engine compartment fuses.
  • Page 668 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Damage location algorithm Turning lights not working ALP 2 RECOMMENDATIONS Do not consult these information but before a complete checking by means of the CLIP tester. Check the bulbs Check the condition of fuse F13 (25A) and replace it if necessary. Push the hazard switch and check that state <<ET291 hazard lights information>>...
  • Page 669 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Damage location algorithm ALP 3 Parking lights not working RECOMMENDATIONS Do not consult these information but before a complete checking by means of the CLIP tester. Check the bulbs Check the condition of parking lights fuse F14 (7.5A) Replace it if necessary.
  • Page 670 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Damage location algorithm Windscreen wiper low speed not working ALP 4 RECOMMENDATIONS No failure must present or memorized Check the condition of windscreen wiper fuse F07 (20A) Replace the fuse if necessary. Check supply +12 volts after contact at pin A7 windscreen wiper switch Fix if necessar y Ensure the continuity and insulation of the connections: pin 4 windscreen wiper motor...
  • Page 671 ELECTRICAL ASSISANCE EQUIPEMENT Diagnostic – Damage location algorithm Windscreen wiper high speed not working ALP 5 RECOMMENDATION No failure must present or memorized Check the condition of windscreen wiper fuse F07 (20A) Replace the fuse if necessary. Check supply +12 volts after contact at pin A7 windscreen wiper switch Fix if necessar y Ensure the continuity and insulation of the connections: Wiper switch pin A2...

  • Page 672: Wiring

    The Dacia SOLENZA vehicles are By experience, the speedometer is not equipped with a passive security system showing correctly the impact speed, this being,...

  • Page 673: Airbag - Electronic Control Unit

    WIRING Airbag – Electronic control unit releasin g line, memorizing the releasin g. That is why, after an impact generating the AIRBAG OPERATION airbag releasing, it is necessary the UCE When setting the contact on, the airbag system airb ag unblocking, then the computer blocking control indicator from the instrument panel is in order to block all releasing.
  • Page 674 WIRING Airbag – Electronic control unit - select mode “Control”. -select function “Actuators”, then validate “Computer blocking” - select menu “State list” and ensure that UCE airbag has been blocked. The state “Blocked computer” is becoming ACTIVE. When this function is acti v ated, all relea sing lines are inhibited, the airbag indicator from instrument panel is lighted (new UCE airbag are delivered with blocked releasing lines).
  • Page 675 WIRING Airbag – Electronic control unit it is not correct, see chapter “Diagnostic”. after each airbag releasing. AIRBAG SYSTEM CONFIGURATION UCE AIRBAG UNBLOCKING After replacing UCE airbag it is necessary the releasing lines unblocking. The same method as for the UCE airbag blocking is to Because the vehicle is equipped only the be used, by validation control “Computer driver’s airbag, it is necessary the UCE airbag...
  • Page 676 WIRING Airbag – Electronic control unit airbag. - An internal failure of UCE airbag. REMARK : By means of the CLIP UCE AIRBAG CONNECTOR tester it is possible the visualization of the releasing of the driver’s airbag. Denomination Free If the airbag has been tripped: Free - replace the releasing elemen ts and the Free...
  • Page 677 WIRING Airbag – Electronic control unit CHECKING OF THE AIRBAG SYSTEM CIRCUITS. The transmitting wiring of the airbag-r e leasing signal is integrated in the front wiring. In case of an abnormality noticed on the transmitting wiring of the airbag-star ting signal, this is to be replaced and not repaired.

  • Page 678: Driver's Airbag

    WIRING Driver’s airbag tester. OBSERVATION The driver’s airbag is located in the steering Before dismounting the airbag pillow, bloc the UCE airbag by means of the CLIP tester (see “Blocking UCE airbag”. When this function is active, all transmitting lines of the releasing signal are inhibited.
  • Page 679 WIRING Driver’s airbag Mount the two attachment screws (required tightening moment: 0.65 daNm) located under the steering wheel, attachin g the airbag pillow. IMPORTANT After remounting, check the system operation, by means of the CLIP tester. If everything is correct, unblock UCE airbag (see “Unblocking UCE airbag”). If it is not correct, see chapter “Diagnostic.

  • Page 680: Airbag - Special Devices

    WIRING Airbag – Special devices “Diagnost ic”). ATTENTION ! It is forbidd en the airb ag system measurement by means of an ohmmeter or any other electric measurement devices because there is the risk of releasing due to some device working current. (see chapter “Diagnostic”).
  • Page 681 WIRING Airbag – Special devices THE DESTROYING DEVICE In order to avoid all accident risks the airbag pyrotechnic gas generator must be started before changing the airbag or before definitely call in the vehicle. In this purpose, the device Ele.1287 is to be used. For details, please see chapter “...

  • Page 682: The Airbag Destroying Procedure

    WIRING The airbag destroying procedure n order to avoid all accident risks the airbag pyrotechnic gas generator must be started before changing the airbag or before definitely call in the vehicle. For this purpose, damaging with the ground. Cover the assembly with 4 tires placed one the device Ele 1287 is to be used.

  • Page 683: Airbag Diagnostic - General

    WIRING Airbag diagnostic – General wrapper. APPLICATION CONDITIONS OF THE CHECKING DEFINED AT DIAGNOSTIC Each failure is interpreted for a specific memorizing type (present failure, memorized failure, memorized or present failure). The defined checking for each failure tracing is not to be applied unless the failure is interpreted for the failure type declared by the CLIP tester.
  • Page 684 WIRING Airbag diagnostic – General SYSTEM CONFIGURATION A UCE airbag B Driver’s airbag igniter CT Rotating contact A1 Supply +12 V A3 Mass A2 Airbag indicator B1,B2 Diagnostic lines The measured resistance value in measurement points C0, C2 and C4 is between 2.1 ¿ and 7 ¿.

  • Page 685: Diagnostic - Failure Interpretation

    WIRING Diagnostic – Failure interpretation DF001 UCE AIRBAG PRESENT MEMORIZED Characteristics: nothing to notice. RECOMMENDATIONS Replace UCE airbag (see chapter <<help>> for this intervention). AFTER INTERVENTION Nothing to notice 88 - 14 vnx.su...
  • Page 686 WIRING Diagnostic – Failure interpretation DF002 UCE AIRBAG SUPPLY VOLTAGE 1. DEF : micro- disconnection PRESENT 2. DEF : Supply voltage too small. 3. DEF : Supply voltage too high. Use 30 pins adapter B40 for the intervention at the level of UCE RECOMMENDATIONS airbag connector 1.
  • Page 687 WIRING Diagnostic – Failure interpretation DF003 DRIVER’S AIRBAG CIRCUIT PRESENT : shortcircuit : open circuit CC.1 : shortcircuit at + 12 volts CC.0 : shortcircuit at mass Characteristics: the measurement of the airbag releasing line is to be RECOMMENDATIONS performed only by means of the CLIP tester. Use 30 pins adapter B40 for the intervention at the level of the computer connector Nothing to notice...
  • Page 688 WIRING Diagnostic – Failure interpretation DF003 PRESENT CONTINUATION Nothing to notice CC.1 – CC.0 RECOMMENDATIONS Block the computer by means of the CLIP tester (see “Blocking UCE airbag”) Set the contact off and dismount the two attachment screws of the airbag on the steering wheel. Check the condition of the airbag releasing lines.
  • Page 689 WIRING Diagnostic – Failure interpretation DF010 AIRBAG DEFECTIVE INDICATOR CIRCUIT PRESENT CC.1 : short-circuit at + 12 volts : open circuit or short-circuit at mass CC.0 Characteristics: the measurement of the airbag releasing lines is to RECOMMENDATIONS be performed only by means of the CLIP tester. Use 30 pins adapter B40 for the intervention at the level of the computer connector (the gray connector of the 30 pins adapter).
  • Page 690 WIRING Diagnostic – Failure interpretation absence, unblock the computer. DF016 COMPUTER CONFIGURATION PRESENT Characteristics: nothing to notice. RECOMMENDATIONS The presence of this failu re is correspo nding to an incoherence between the computer configuratio n and the vehicle equipping, detected by the CLIP tester. Modify the UCE airbag configuration by means of the CLIP tester, using the control “System elemen ts configuratio n”.
  • Page 691 WIRING Diagnostic – Failure interpretation failure absence, unblock the computer. BLOCKED COMPUTER DF034 PRESENT 1. DEF : blocked further to a shock 2. DEF : blocked by means of CLIP tester. RECOMMENDATIONS Characteristics: nothing to notice This failure is allowing visualization of the blocking state of the airbag computer. When present, all releasing lines are inhibited, driver’s airbag releasing being not possible.

  • Page 692: Diagnostic - Conformity Checking

    WIRING Diagnostic – Conformity checking Perform the conformity checking only after complete checking by RECOMMENDATIONS means of CLIP tester. Parameter or state Visualization and Diagnostic Sequence Function Checking or action observations Computer Parameter PR002: Solenza : 50 Without conformity <<Vehicle type>> Computer Use of the control Ensure if the computer...

  • Page 693: Diagnostic - Help

    WIRING Diagnostic – Help UCE AIRBAG REPLACEMENT New airbag computer are delivered in blocked condition in order to avoid all risks of undesirable releasing (all releasing lines are inhibited). This “blocked” mode is noticed by the airbag indicator lighting from the instrument panel when setting the contact on.

  • Page 694: Diagnostic - Failure Locating Tree

    WIRING Diagnostic – Failure locating tree Missing dialog with the airbag computer. ALP1 RECOMMENDATIONS Characteristics: nothing to notice Ensure that not CLIP tester is the failure cause – try its communication with some other vehicle UCE airbag. If CLIP tester is not the failure cause and the dialogue is not established with no other computer of the same vehicle, it is possible that another damaged computer is perturbing the diagnostic lines L and K.

  • Page 695: Front Door Wiring Protector

    Dismount the front door deflective panel. Disconnect and detach from clips actuator’s connector (2) Disconnect window electric regulator connector (3) (for Solenza Dacia vehicles) Cut attachmen t clip (4) of the front door wiring. Mark the mounting position of the attach ment clip.

  • Page 696: Rear Door Wiring Protector

    WIRING Rear door wiring protector DISMOU NTIN G Disconnect the battery (-) terminal. Detach from clips the crane handle. Dsimount the rear door panel (see chapter 72 “ Rear door panel”). Dismount the rear door deflective panel. Dismount the attachment clip (1) of the rear wiring. Disconnect and detach from clips actuator’s connector (2).

  • Page 697: Electric Diagrams

    ELECTRIC DIAGRAMS General GENERAL PRESENTATION From electric point of view, the vehicle electric diagrams have been structured as Applied Principle Schemes (APS), presented according to each system function. These APS diagrams also contain details concerning the internal function of some simple electric components (contacts, relays), thus contributi n g to a better understanding of the system functioning and of the incident good diagnosis.
  • Page 698 ELECTRIC DIAGRAMS General The fuse box from the engine compartment is presente d in Chapter 9, that contains information about its location on the vehicle and the functional purpose of the relays and fuse placed on it. The functional codes of the wires are detailed explained in Chapter 12. FUNCTIONAL DIAGRAMS INTERPRETATION The functional diagram information included in Chapter 7 are to be interpreted taking into consideration the explanation referring to the following example:...
  • Page 699 ELECTRIC DIAGRAMS General MA = motorization in agreement with the EURO 96 (EURO II) de-pollution norm MB = motorization according to the EURO 2000 (EURO III) de-pollution norm PROJAB = fog projectors RAD01 = Front loud speaker radio-cassette player RAD02 = Rear loud speaker radio-cassette player RAD03 = Front and rear loud speaker radio-CD player TLAIF1 = Countries group definition (SASO norms) 2.
  • Page 700 ELECTRIC DIAGRAMS General INTERPRETATION OF CONNECTORS WIRES FUNCTION INDEX The information concerning the function of the wires in connectors and connections included in chapter 11, are to be interpreted taking into account the explanations based upon the following example: 1 = symbol (sign) of the page containing connectors and electric connections 2 = connector destination 3 = name of the wiring on which the respective connector is placed 4 = general criteria of page separation...
  • Page 701 ELECTRIC DIAGRAMS General X412 ENGINE WIRING E7J262 DETONATION SENSOR 1 1 1 1 4 4 4 4 CY2AE Position Section Destin ation 0.50 SIGNAL + DETONATION SENSOR 0.50 MASS DETONATION SENSOR 0.60 DETONATION SENSOR SCREENING ATMOSPHERIC PRESSURE SENSOR 89 - 07 89 - 5 vnx.su...

  • Page 702: Functional Diagrams List

    ELECTRIC DIAGRAMS Functional diagrams list ELECTRIC DIAGRAMS DENOMINATION DIAGRAM NUMBER DOORS CENTRAL LOCKING ANTI-STARTING SPEED LIMIT INDICATOR ELECTRIC LIGHTER CLIMATE CONTROL CLIMATE CONTROL AND AIR CONDITION CEILING LAMP FRONT WINDOWS ELECTRIC CONTROL RADIO 9-10 STARTING CIRCUIT ENGINE COOLING FAN 12-13 ELECTRONIC INJECTION 14-15-16-17-18-19-20-21 CHARGING CIRCUIT...
  • Page 703 ELECTRIC DIAGRAMS Functional diagrams list ELECTRIC DIAGRAMS DENOMINATION DIAGRAM NUMBER WINDSCREEN WIPER-WASHING FOG PROJECTORS REAR FOG LAMPS MEETING LIGHTS REVERSE DRIVING LIGHTS PARKING LIGHTS ROAD LIGHTS STOP LIGHTS TURNING AND HAZARD LIGHTS 91-92 89 - 7 vnx.su...

  • Page 704: Functional Diagrams List Index

    ELECTRIC DIAGRAMS Functional diagrams list index Code Component den o mination Code Component denomin a tion Electric lighter Lights, turning lights and horn switch Alternator Motor windscreen wiper Anti-theft system Ceiling lamp Acoustic warning Windscreen washing pump Battery Valve potentiometer Windscreen wiper timer Power steering pressure controller Injection computer (ECE)

  • Page 705: Connections Lists - Mass List

    ELECTRIC DIAGRAMS Connections lists - Mass list CONNECTIONS LIST R157 = REAR/HATCHBACK WIRING CONNECTIONS (A) R212 = FRONT WIRING CONNECTIONS – DASHBOARD/ENGINE (B) R265 = FRONT WIRING CONNECTIONS – DASHBOARD/REAR(C) R316 = FRONT WIR IN G CON NECTIO NS – FOG PR OJECTORS/ DASHBOARD (D) MASS LIST M20 = REAR WINDOW DEFROSTING MASS...

  • Page 706: Electric Components Location On Vehicle

    ELECTRIC DIAGRAMS Electric components location on vehicle Mass attachments on vehicle ELECTRIC COMPONENTS LOCATION ON VEHICLE MASS ATTACHMENT ON THE VEHICLE M Y H ME MB MC MH 89 - 10 vnx.su...
  • Page 707 ELECTRIC DIAGRAMS Electric components location on the vehicle Denomination Denomination Injector 1 Turning lights r e lay Injector 2 Front door contact Injector 3 Windscreen wiper timer Injector 4 Left front door actuator Atmospheric pressure sensor Left electric window actuator Detonation sensor Left front door loud speaker Starter...
  • Page 708 ELECTRIC DIAGRAMS Electric components location on the vehicle 89 - 12 vnx.su...
  • Page 709 ELECTRIC DIAGRAMS Functional electric diagrams FUNCTIONAL ELECTRIC DIAGRAMS 89 - 13 vnx.su...

  • Page 710: Cockpit Fuse Box

    ELECTRIC DIAGRAMS Cockpit fuse box The cockpit fuse box is placed in driving post left side, being attached on the dashboard lateral side. The fuses are protecting the following electric components and circuits: FUSE FUSE PROTECTED CIRCU IT TYPE NUMBER Diagnostic socket, ceiling light, windscreen wiper motor (fix point stopping), FLASH relay (+C) UCE decoder, anti-starting...
  • Page 711 ELECTRIC DIAGRAMS Cockpit fuse box Left road lights, instrument panel (indicator) Right road lights Acoustic warning Signaling direction lights and hazard 7.5A Front/rear parking lights, lighting: switches, climate control, instrument panel, lighter, radio. Front/rear parking lights Lighter, radio Cooling motor fan Fog lamps, instrument panel (indicator) Rear window defrosting U.C.E.

  • Page 712: Fuse Box From Engine Compartment

    ELECTRIC DIAGRAMS Fuse box from engine compartment A. Vehicles without AC equipment The fuse box placed in the engine compartment is attached in front of the left shock absorber column and contains relays and fusible protecting the following electric circuits: FUSE PROTECTED CIRCU IT FUSE...
  • Page 713 ELECTRIC DIAGRAMS Fuse box from engine compartment B. For vehicles with air conditioning The fuse box placed in the engine compartment is attached in front of the left shock absorber column and contains relays and fusible protecting the following electric circuits: FUSE FUSE PROTECTED CIRCU IT...
  • Page 714 ELECTRIC DIAGRAMS Index in connectors and couplings No.con. Denomination Page ELECTRIC LIGHTER 89-139 ALTERNATOR 103 HA 89-113 ALTERNATOR EXCITATION 103 HB 89-113 ANTI-THEFT MECHANISM 89-139 ACOUSTIC WARNING 89-140 (+)BATTERY (engine wiring) 89-114 (+)BATTERY (front wiring-dashboard) 107AA 89-140 WINDSCREEN WIPER TIMER 89-141 UCE INJECTION( for vehicles without AC) 89-115...
  • Page 715 ELECTRIC DIAGRAMS Index in connectors and couplings INJECTOR 4 89-125 FUEL LEVEL TRANSMITTER AND ELECTRIC PUMP 89-175 89-179 REAR WINDOW DEFROSTING ELECTRIC RIGHT WINDOW ACTUATOR 89-150 ELECTRIC LEFT WINDOW ACTUATOR 89-150 OIL PRESSURE CONTACT 89-126 LIGHTS, TURNING LIGHTS, HORN SWITCH 89-151 89-152 WINDSCREEN WIPER MOTOR...
  • Page 716 ELECTRIC DIAGRAMS Index in connectors and couplings 1091 ICP BRAKING SYSTEM 89-169 1140 VEHICLE SPEED TRANSDUCER 89-137 1156 CLIMATE CONTROL BLOWER (without AC) 89-169 1202 AC PRESSURE SENSOR (PRESSURE CONTROLLER) 89-137 CLIMATE BLOWER ELECTRIC MASS 89-138 FRONT LEFT BODY ELECTRIC MASS 89-170 REAR LEFT PLATE ELECTRIC MASS 89-176...

  • Page 717: Wires Functions In Connectors And Couplings

    ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 ALTERNATOR (for vehicles without AC ) Destination Position Section +BA TTERY > INLE T FUSE F01 16.0 + BA TTERY > ST ARTER 103 HA ALTERNATOR (for vehicles with AC ) Position Section Destination...
  • Page 718 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 ENGINE WIRING E7J262 BATTERY PLUS TERMINAL Position Section Destination 16.0 + BA TTERY > + ST ARTER + BA TTERY > INLE T FUSE F04 1 0 7 89 - 22 vnx.su...
  • Page 719 ELECTRIC DIAGRAMS Wires functions in connectors and couplings 89 - 23 vnx.su...
  • Page 720 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination CONTROL - IGNITI O N COIL CYLINDE RS 2-3 MASS CANISTE R PURGE V ALVE CONT ROL CONTROL - COOLING FAN RELA Y CONTROL - WATER TEMPERA TURE INDICA TOR 0.35 CONTROL 2 IDLING REGU LATOR SIGNAL + W ATER TEMPERA TURE SENSOR...
  • Page 721 ELECTRIC DIAGRAMS Wires functions in connectors and couplings 89 - 25 vnx.su...
  • Page 722 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination CONTROL - IGNITI O N COIL CYLINDE R 2-3 MASS CANISTE R PURGE V ALVE CONT ROL CONTROL – ENGINE COOLING FAN 1 SPEED CONTROL - WATER TEMPERA TURE INDICA TOR 0.35 AIR CONDITION STOPPING CONTROL>COMPRESSOR RELA CONTROL 2 IDLING REGU LATOR...
  • Page 723 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination 0.35 AIR PRESSURE SENSOR > SUPPL - DET ONATION SENSOR UPSTREAM OXYGEN SENSOR MASS - FREON PRESSURE SENSOR + FREON PRESSURE SENSOR SIGNAL - PRESSURE CONTROLL ER POWER STEERING CONTROL - INJECTOR 4 CONTROL - INJECTOR 2 89 - 27...
  • Page 724 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 DETONATION SENSOR Position Section Destination 0.50 SIGNAL + DETON ATION SENSOR 0.50 DETONA TION SENSOR M ASS 0.60 DETONATION SENSOR SCREENING CY2AE ATMOSPHERIC PRESSURE SENSOR Position Section Destination MASS AIR PRESSURE SENSOR SIGNAL AIR PRESSURE SENSOR AIR PRESSURE SENSOR>...
  • Page 725 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 RPM SENSOR Position Section Destination 0.60 SIGNAL - RPM ENGINE > UCE INJECTION 0.60 SIGNAL - RPM ENGINE > UCE INJECTION CA 13E 1 4 9 REVERSE DRIVING CONTACT Position Section Destination 0.60...
  • Page 726 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 STARTER Destination Position Section 16 .0 + BATTERY 16 .0 + BA TTERY > + ALTERNA TOR SL8C 163 GA STARTER EXCITATION Destination Position Section + ST ARTE R CONTROL CS6PI 6,3 MM 163 AB...
  • Page 727 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 AIR CONDITIONING COMPRESSOR CLUTCH Position Section Destination 38 R CONTROL +AIR CONDITIONING COMPRESSOR CLUTCH 1 7 1 ENGINE COOLING FAN (for vehicles without air condition) Position Section Destination MASS CONTROL + ENGINE COOLING FAN 89 - 31...
  • Page 728 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 INJECTOR 1 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 1 CY2AE INJECTOR 2 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 2 CY2AE 89 - 32...
  • Page 729 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 INJECTOR 3 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 3 CY2AE 1 9 5 INJECTOR 4 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 4 CY2AE 89 - 33...
  • Page 730 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 OIL PRESSURE TRANSMITTER Position Section Destination 0.60 CONTROL -OIL PRESSURE INDICA T OR POTENTIOMETER VALVE Position Section Destination 0.60 MASS POTENTIOMETE R VALVE 0.60 SIGNAL + POTENTIOMETER VAL VE 0.60 SIGNAL + POTENTIOMETE R POSITION VALVE CM1PE...
  • Page 731 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 POWER STEERING PRESSURE CONTROLLER (for vehicles with power steering) Destination Position Section SIGNAL - PRESSURE CONTROLL ER POWER STEERING MASS DOWNSTREAM OXYGEN SENSOR Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL -HEATING DOWNSTREAM OXYGEN SENSO 0.60 SIGNAL DOWNST REAM OXYGEN SENSOR...
  • Page 732 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 WATER TEMPERATURE INJECTION SENSOR Position Section Destination 0.35 SIGNAL + W ATER TEMPERA TURE 0.60 - WATER TEMPERA TURE 0.60 SIGNAL + W ATER TEMPERA TURE SENSOR COOLING MOTOR FAN AND AIR CONDITION (for vehicle with air conditioning) Position Section Destination...
  • Page 733 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 AIR TEMPERA TURE INJECTION SENSOR Position Section Destination 0.60 SIGNAL + AIR TEMPERA TURE SENSOR 0.60 MASS AIR TEMPERA TURE SENSOR ENGINE COOLING FAN RESISTANCE (for vehicles with air conditioning) Destination Position Section 4 9L...
  • Page 734 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING E7J262 CANISTER PURGING VALVE Position Section Destination 0.60 + INJECTORS > OUTLE T ACTUA TORS RELA Y 0.60 CONTROL CANISTE R PURGE V ALVE CY13C 89 - 38 vnx.su...
  • Page 735 ELECTRIC DIAGRAMS Wires functions in connectors and couplings AP2 9 BP1 7 BP1 7 3 GT BP1 7 E 0 4 BP1 7 E 0 1 89 - 39 vnx.su...
  • Page 736 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination + INJ ECTORS > ACTUA TORS OUTLET RELA Y CONTROL - MOTOR FAN 1ST SPEED RELA Y + PROTECTE D BATTERY >OUTLE T FUSE F01 ENGIN E CONTROL + ENGINE COOLING FAN BP1 7 + PROTECTE D BATTERY >OUTLE T FUSE F04 ENGIN E...
  • Page 737 ELECTRIC DIAGRAMS Wires functions in connectors and couplings AP2 9 BP1 7 BP1 7 3 GT E 0 4 BP1 7 BP1 7 E 0 3 3 8 K E 0 2 Ve-A 3 J P 89 - 41 vnx.su...
  • Page 738 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL AIR CONDITIONING STOPPING>U.C.E INJECTION + PROTECTED BATTER Y> OUTL ET FUSE F03 CONTROL - AIR CONDIT ION COMPRESSOR CLUTCH + INJECTORS >...
  • Page 739 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 STEP BY STEP ENGINE Position Section Destination 0.60 CONTROL 1 IDLING REGU LATOR 0.60 CONTROL 2 IDLING REGU LATOR 0.60 CONTROL 3 IDLING REGU LATOR 0.60 CONTROL 4 IDLING REGU LATOR CM1PE IGNITION COIL Position Section...
  • Page 740 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 UPSTREAM OXYGEN SENSOR Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - HEA TING UPSTREAM OXYGEN SENSOR 0.60 SIGNAL UPSTREAM OXYGE N SENSOR 0.60 UPSTREAM OXYGEN SENSOR MASS CM1PE...
  • Page 741 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 VEHICLE SPEED TRANSDUCER Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y 0.35 SIGNA L VEHICLE SPEED 0.35 MASS AIR CONDITION PRESSURE SENSOR (pressure controller) Position Section Destination 0.60...
  • Page 742 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 ENGINE ELECTRIC MASS Destination Position Section MASS > U.C.E. INJECTION (PINS 3,28 and 33, TRANSDUCER VEHICLE SPEED, POWER STEERING PRESSURE CONTROLLER SR 8L ENGINE COOLING FAN ELECTRIC MASS Position Section Destination MASS...
  • Page 743 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD ELECTRIC LIGHTER Destination PARKING LIGHT S > OUT LET FUSE F1 4 0.35 LPG MASS + AFTER PROTECTED CONT ACT AP40 AP4 0 > OUTLE T FUSE F06 ANTI-THEFT MECHANISM Position Section...
  • Page 744 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD ACOUSTIC WARNING Destination CONTROL + ACOUSTIC WARNING > OUTLET FUSE F12 BATTERY PLUS TERMINAL Position Section Destination + BATTERY + BATTERY 107AA 89 - 48 vnx.su...
  • Page 745 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD WINDSCREEN WIPER TIMER Destination Position Section MASS 0.35 CONTROL + WINDSCREEN WIPER PUM P WINDSCREEN WIPER T IMER L OW SPEED CONTROL CONTROL + WIPER FIX POINT STOPPING + AFTER PROTECTED CONT ACT WINDSCR EEN WIPER 0.35 CONTROL + WIN DSCREEN WIPER TIMER...
  • Page 746 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD CONTROL AIR CONDITIONING BOARD (for vehicles with air conditioning) Destination Position Section 38AL CONTROL + COOLING FAN SPEED 4 38AL CONTROL + COOLING FAN SPEED 4 AP41 + AFTER PROTECTED CONT ACT >...
  • Page 747 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD HAZARD SWITCH Position Section Destination 0.35 + P ARKING LIGHT S > OUTL ET FUSE F14 + P ARKING LIGHTS > RADIO CONTROL + TURNING LIGHTS RELA Y CONTROL LEFT TURNING LIGHTS CONTROL RIGHT TURNING LIGHTS 0.35...
  • Page 748 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT ELECTRIC WINDOW SWITCH Position Section Destination DRIVER’S WINDOW LOWERING CONTROL MASS MASS ABP4 + AFTER PROTECTED CONT ACT > OUTLET FUSE F23 ABP4 + AFTER PR OTECTED CONT ACT > RIGHT WINDOW SWITCH 0.35 + P ARKING LIGHT S >...
  • Page 749 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD TURNING LIGHTS RELAY Position Section Destination MASS + PROTECTED TURNING LIGHTS > OU TLET FUSE F13 CONTROL + TURNING LIGHTS CONTROL + TURNING LIGHTS 89 - 53 vnx.su...
  • Page 750 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RIGHT FRONT DOOR ACTUATOR Destination Position Section CONTROL + ELECTRIC LOCKING DOORS > U.C.E. DECODER CONTROL + ELECTRIC UNLOCKING DOORS > U.C.E. DECODER 1 DBD1 LEFT FRONT DOOR ACTUATOR Position Section Destination...
  • Page 751 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD WINDSCREEN WIPER-WASHING SWITCH Destination Position Section 0.35 CONTROL + WIN DSCREEN WIPER TIMER CONTROL + HIGH SPEED WINDSCREEN WIPER CONTROL + LOW SPEED WINDSCREEN WIPER 0.35 CONTROL + WINDSCR EEN WASHING PUM P CONTROL + WINDSCR EEN WASHING PUM P CONTROL + L OW SPEED WINDSCREEN WIPER TIMER + AFTER PROTECTED CONT ACT WINDSCR EEN WIPER...
  • Page 752 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT FRONT DOOR CONTACT Destination 1 3 A CONTROL - CEILING LIGHTNING > DOORS CONT ACTS FRONT RIGHT PARKING LIGHT Destination + P ARKING LIGHT S > OUTL ET FUSE F15 0.35 MASS FRONT LEFT PARKING LIGHT...
  • Page 753 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RIGHT FRONT DOOR SPEAKER Destination Position Section 0.35 SIGNAL + RIGHT FRONT D OOR SPEAKER (RADIO) 0.35 SIGNAL - RIGHT FRONT DOOR SPEAKER (RADIO) 3 4 E LEFT FRONT DOOR SPEAKER Position Section...
  • Page 754 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT WINDOW ELECTRIC REGULATOR ACTUATOR Position Section Destination DRIVER’S WINDOW LIFTING CONTROL DRIVER’S WINDOW LOWERING CONTROL 2 1 A RIGHT WINDOW ELECTRIC REGULATOR ACTUATOR Position Section Destination PASSENGER WINDOW L IFTING CONT ROL PASSENGER WINDOW LOWERING CONTROL 2 2 A...
  • Page 755 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LIGHTS, TURNING LIGHTS AND HORN SWITCH Position Section Destination 0.35 CONTROL FOG PROJECTORS RELAY 0.35 CONTROL FOG PROJ E CTORS RELA Y > DA SHBOARD CONTROL + REAR FOG L AMP > INL ET FUSE F19 CONTROL + ACOUSTIC W ARNING >...
  • Page 756 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD WINDSCREEN WIPER MOTOR Destination Position Section MASS CONTROL + FIX POINT STOPPING BP1 1 + PROTECTED BA T TERY > OUT LET FUSE F02 CONTROL + LOW SPEED WINDSCREEN WIPER CONTROL + HIGH SPEED WINDSCREEN WIPER CEILING LIGHT Destination...
  • Page 757 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD WINDSCREEN WASHING PUMP Destination MASS CONTROL + WINDSCR EEN WASHING PUM P DIAGNOSIS SOCKET Destination Position Section AP43 + AFTER PROTECTED CONT ACT > OUTLET FUSE F04 MASS MASS 0.35...
  • Page 758 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RIGHT HEADLAMP CD8F Destination MASS RIGHT MEETI N G HEADLIGH TS PROTECTED > OUTL ET FUSE F09 RIGHT ROAD LIGHTS PROTECTED > OUTL ET FUSE F11 LEFT HEADLAMP CD8F Destination MASS...
  • Page 759 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD INSTRUMENT PANEL Destination Position Section 0.35 CONTROL LEFT TURNING LIGHTS 0.35 CP G PROTECTE D LEFT MEETING HEADLIGHTS > INDICA TOR 0.35 RP G PROTECTED LE FT ROAD LIGHTS > INDICA TOR 0.35 CONTROL –...
  • Page 760 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD Destination Position Section 0.35 CONTROL - HANDBRAKE INDICA T OR, I.C.P . 0.35 CONTROL - HANDBRAKE INDICA T OR, I.C.P . . 0.35 CONTROL - ANTI-ST ARTING INDICA TOR 0.35 - FUEL LEVEL 0.35...
  • Page 761 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD FRONT RIGHT TURNING LAMP Destination RIGHT TURNI N G LIGHTS CONTROL MASS FRONT LEFT TURNING LAMP Destination LEFT TURNING LIGHTS CONTROL MASS 89 - 65 vnx.su...
  • Page 762 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RADIO Position Section Destination BP1 2 + PROTECTED BA T TERY > OUT LET FUSE F03 + P ARKING LIGHT S > OUTL ET FUSE F14 AP40 + AFTER PROTECTED CONT ACT >...
  • Page 763 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RIGHT SIDE SIGNALING LAMP Destination CONTROL RIGHT SIGNAL ING LIGHTS MASS LEFT SIDE SIGNALING LAMP Destination CONTROL LEFT SIGNAL ING LIGHTS MASS 89 - 67 vnx.su...
  • Page 764 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD CLIMATE CONTROL PANEL (for vehicles with air conditioning) Destination Position Section 38AL CONTROL + CLIM ATE F AN SPEED 4 AP41 + AFTER PROTECTED CONT ACT > OUTLET FUSE F17 AP41 +PROTECTED AFTER CONT ACT >...
  • Page 765 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD CLIMATE CONTROL FAN (for vehicles with air conditioning) Destination Position Section 38EV CONTROL +AIR CONDITIO NING RECYCL ING 38AN CONTROL - AIR CONDIT IONING RECYCLING 38AH CONTROL + CLIM ATE F AN SPEED 1 38AJ CONTROL + CLIM ATE F AN SPEED 2 38AK...
  • Page 766 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD SPEED LIMIT INDICATOR Destination Position Section SIGNA L VEHICLE SPEED AP43 +AFTER PROTECTED CONT ACT > OU TLET FUSE F04 MASS AP4 3 4 7 F 89 - 70 vnx.su...
  • Page 767 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD UU.C.E. DECODER Destination Position Section CEILI N G LIGHT CONTROL 0.3 5 SIGNAL WAY ANTI-ST ARTER RECEIVER (TR) 0.3 5 SIGNAL D IAGNOSIS - LINE K 0.3 5 SIGNAL DIAGNOSIS - LINE L 0.3 5 CONTROL - ANTI-ST ARTING INDICA TOR...
  • Page 768 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD ANTI-STARTING BUSHING Position Section Destination 0.35 SIGNAL RADIO RECEIV ER - FREQUENCY 0.35 MASS 0.35 BP1 2 PROTECTED BA TTERY > OU TLET FUSE F03 0.35 SIGNAL WAY ANTI-ST ARTING RECEIVER (TR) BP12 U.C.E.
  • Page 769 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD FLASH RELAY Destination Position Section BP1 1 + PROTECTED BA T TERY > SHUNT 80BD FLASH RELA Y CONTROL BP1 1 + PROTECTED BA T TERY > OUT LET FUSE F02 BP1 1 + PROTECTED BA T TERY >...
  • Page 770 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD COCKPIT FUSE BOX Destination + BATTERY A02 0.6 BP1 1 + PROTECTE D BATTERY A03 1.0 BP1 2 + PROTECTE D BATTERY + AFTER CONT ACT A04 0.6 AP43 + AFTER PROTECTED CONT ACT A05 1.0...
  • Page 771 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD A17 1.4 AP41 + AFTER PR OTECTED CONT ACT > CLIM ATE CONTROL FAN CONTROL + REAR FOG LIGH TS > L IGHTS SWITCH + PROTECTE D REAR FOG LIGHTS 0.35 + PROTECTED REAR FOG LIGH TS >...
  • Page 772 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD 1016 BP44 AP11 AP29 AP43 BP12 BP11 89 - 76 vnx.su...
  • Page 773 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD I.C.P. BRAKING SYSTEM Destination 1091 CONTROL - HANDBRAKE INDICA T OR, I.C.P . 0.35 MOTOR FAN AIR CONDITIONING (for vehicles without air conditioning) Destination Position Section 38AH CONTROL + CLIM ATE CONTROL F AN SPEED 1 38AJ CONTROL + CLIM ATE CONTROL F AN SPEED 2...
  • Page 774 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT FRONT BODY ELECTRIC MASS Position Section Destination MASS > FRONT SIDE SIGNALIZING L LEFT/RIGHT , WINDSCR EEN WIPER PUM P, WINDSCREEN WIPER MOTOR , CLIM ATE CONTROL F A N (PINS 14 and 1 5 ) LEFT FRONT BODY ELECTRIC MASS Destination Position Section...
  • Page 775 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD FRONT LEFT COCKPIT ELECTRIC MASS Position Section Destination MASS > CEILING LIGHT , RADIO, DASHBOARD, REAR WINDOW DEFROSTING SWITCH, TURNING LIGHTS RELA Y , WINDSCREEN WIPER T IMER MASS >...
  • Page 776 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING REAR RIGHT DOOR ACTUATOR Position Section Destination CONTROL + ELECTRIC DOO R S LOCKING> ACTUA TORS CONTROL + ELECTRIC DOORS UNLOCKING > ACTUA TORS 1 DBD1 REAR LEFT DOOR ACTUATOR Position Section Destination CONTROL + ELECTRIC DOO R S LOCKING >...
  • Page 777 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING HANDBRAKE CONTACT Destination CONTROL - HANDBRAKE INDICA T OR, I.C.P . 0.35 H1 REAR RIGHT LAMP Destination Position Section CONTROL + STOP LIG HTS + P ARKING LIGHT S > OUTL ET FUSE F15 MASS CONTROL RIGHT TURNING LIGHTS H66P...
  • Page 778 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING REAR LEFT LAMP Position Section Destination + PROTECTED REAR FOG L IGHTS > OUTLET FUSE F19 CONTROL LEFT TURNING LIGHTS MASS CONTROL + STOP LIG HTS + P ARKING LIGHT S > OUTL ET F14 REAR RIGHT SPEAKER Position Section...
  • Page 779 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING REAR LEFT SPEAKER Position Section Destination 0.35 SIGNAL + REAR LEFT SPEAKE R (RADIO) 0.35 SIGNAL - REAR LEFT SPEAKER (RADIO) FUEL LEVEL TRANSMITTER AND ELECTRIC PUMP Position Section Destination 0.35 - FUEL LEVEL...
  • Page 780 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING DRIVER’S SAFETY BELT CONTACT Destination Position Section 0.3 5 MASS 0.35 60DV DRIVER’S SAFETY BEL T INDICA TOR MASS 60DV REAR LEFT TABLE ELECTRIC MASS Position Section Destination MASS > L EFT/RIGHT REAR L A MP FUE L LEVEL TRANSMITTER AND ELECTRIC PUM P, DRIVER SAFETY BEL T CONT ACT SR 8L...
  • Page 781 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FOG PROJECTORS WIRING RIGHT FOG PROJECTOR Destination + FOG PROJ E CTOR > RELA Y MASS LEFT FOG PROJECTOR Destination + FOG PROJ E CTORS > RELA Y MASS 89 - 85 vnx.su...
  • Page 782 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FOG PROJECTORS WIRING FOG PROJECTORS RELAY Position Section Destination 0.35 CONTROL + FOG PROJECTORS RELA Y 0.35 MASS BPR1 + BA TTERY > OUTL ET FUSE F28 + FOG PROJ ECTORS > LEFT FOG PROJECTOR + FOG PROJ ECTORS >...
  • Page 783 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 HATCHBACK WIRING REAR WINDOW DEFROSTING Destination CONTROL + REAR WINDOW DE FROSTING LICENSE PLA TE LAMP Destination M YH + P ARKING LIGHT S > OUTL ET FUSE F14 MASS 0.35 STOP LAMP - S3 Destination 6 5 A...
  • Page 784 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 HATCHBACK WIRING HATCHBACK WIRING ELECTRIC MASS Destination Position Section MASS > LEFT HA TCHBACK ELECTRIC M ASS SR 8L LEFT HATCHBACK ELECTRIC MASS Position Section Destination M YH MASS > HA TCHBACK WIRING ELECTRIC MASS 0.35 MY H MASS >...
  • Page 785 ELECTRIC DIAGRAMS Wires functions in connectors and couplings COUPLINGS REAR WIRING COUPLINGS / HATCHBACK REAR WIRING COUPLING Destination Position Section CONTROL + STOP LIG HTS 0.35 + P ARKING LIGHT S > OUTL ET FUSE F14 CONTROL + REAR WINDOW DE FROSTING 6 5 A LPG 15B R 157 HATCHBACK WIRING COUPLING...
  • Page 786 ELECTRIC DIAGRAMS Wires functions in connectors and couplings COUPLINGS FRONT WIRING COUPLING - DASHBOARD / ENGINE FRONT WIRING COUPLING Destination Position Section + ST ARTE R CONTROL + FUEL PUMP 3NA1 + EXCIT ATION ALTERNA TOR SIGNAL AIR CONDITIO NING COUPLING + PROTECTED BA T TERY >...
  • Page 787 ELECTRIC DIAGRAMS Wires functions in connectors and couplings COUPLINGS ENGINE WIRING COUPLING Destination Position Section + CONTROL ST ARTER + FUEL PUMP > CHOCK SENSOR 3NA1 + FUEL PUMP 3NA1 + ALTERNA TOR EXCIT ATION SIGNAL AIR CONDITIO NING COUPLING + PROTECTED BATTERY >...
  • Page 788 ELECTRIC DIAGRAMS Wires functions in connectors and couplings COUPLINGS FRONT WIRING COUPLING - DASHBOARD / REAR FRONT WIRING COUPLING Position Section Destination CONTROL + ELECTRIC UNLOCKING DOORS > UCE DECODER CONTROL + ELECTRIC LOCKING DOORS > U.C.E. DECODER 3NA1 +FUEL PUMP > FUEL PUMP RELAY 0.35 - FUEL LEVER >...
  • Page 789 ELECTRIC DIAGRAMS Wires functions in connectors and couplings COUPLINGS REAR WIRING COUPLING Section Position Destination CONTROL + ELECTRIC UNLOCKING DOORS > ACTUATORS CONTROL + ELECTRIC UNLOCKING DOORS > ACTUATORS CONTROL + ELECTRIC LOCKING DOORS > ACTUATORS CONTROL + ELECTRIC LOCKING DOORS > ACTUATORS 3NA1 + FUEL PUMP 0.35...
  • Page 790 ELECTRIC DIAGRAMS Wires functions in connectors and couplings COUPLINGS FRONT WIRING COUPLING - DASHBOARD / FOG PROJECTORS FRONT WIRING COUPLING Position Section Destination 0.35 CONTROL + FOG PROJECTORS RELAY > LIGHTS SWITCH BPR1 + PROTECTED BATTERY > OUTLET FUSE F28 BPR1 R316 FOG PROJECTORS WIRING COUPLING...
  • Page 791 ELECTRIC DIAGRAMS Wires functions explanation LIN K WIRES FONCTION COD E SUPPLY + AFTER CONTACT ABP4 + AFTER PROTECTED CONTACT > COCKPIT OUTLET FUSE F23 AP11 + AF TER PROTEC TED CONT AC T R EVER SE DR IVI N G LI GHTS >COC KPIT OUTL ET F USE F06 AP12 + AFTER PROTECTED CONTACT >...

  • Page 792: Wires Functions Explanation

    ELECTRIC DIAGRAMS Wires functions explanation SIGNAL + AIR TEMPERATURE SENSOR SIGNAL - PRESSURE CONTROLLER POWER STEERING CONTROL CANISTER PURGING VALVE RPM ENGINE SIGNAL > RPM SENSOR SIGNAL - RPM ENGINE > RPM SENSOR CONTROL 1 IDLING REGULATOR CONTROL 2 IDLING REGULATOR CONTROL 3 IDLING REGULATOR CONTROL 4 IDLING REGULATOR SIGNAL + WATER TEMPERATURE SENSOR...
  • Page 793 ELECTRIC DIAGRAMS Wires functions explanation PASSENGER ELECTRIC WINDOW LIFTING CONTROL PASSENGER ELECTRIC WINDOW LOWERING CONTROL CONTROL - OIL PRESSURE INDICATOR CONTROL - WATER TEMPERATURE INDICATOR SIGNAL + REAR LEFT SPEAKER SIGNAL - REAR LEFT SPEAKER SIGNAL - REAR RIGHT SPEAKER SIGNAL - REAR RIGHT SPEAKER SIGNAL - FRONT RIGHT SPEAKER SIGNAL - FRONT RIGHT SPEAKER...
  • Page 794 ELECTRIC DIAGRAMS General GENERAL PRESENTATION The vehicle electric diagrams have been structured as Applied Principle Schemes (APS), presented according to each system function of the vehicle, from electric point of view. These diagrams also contain details concerning the internal function of some simple electric components (contacts, relays), thus contributing to a better understanding of the system functioning and of the incident good diagnosis.
  • Page 795 ELECTRIC DIAGRAMS General The fuse box from the engine compartment is presented in chapter 9, that contains information about its location on the vehicle and the functional purpose of the relays and fuse placed on it. The functional codes of the wires are detailed explained in chapter 12. FUNCTIONAL DIAGRAMS INTERPRETATION The functional diagram information included in chapter 7 is to be interpreted taking into consideration the explanation referring to the following example:...
  • Page 796 ELECTRIC DIAGRAMS General MA = motorization observing the de-pollution norm EURO 96 (EURO II) MB = motorization observing the de-pollution norm EURO 2000 (EURO III) PROJAB = fog projectors RAD01 = Front speaker radio-cassette player RAD02 = Rear and front speaker radio-cassette player RAD03 = Front and rear speaker radio-CD player 2.
  • Page 797 ELECTRIC DIAGRAMS General INTERPRETATION OF CONNECTORS WIRES FUNCTION INDEX The information concerning the function of the wires in connectors and connections presented in chapter 11, are to be interpreted taking into account the explanations based upon the following example: 1 = symbol (sign) of the page containing connectors and electric connections 2 = connector destination 3 = name of the wiring on which the respective connector is placed 4 = general criteria of page separation...
  • Page 798 ELECTRIC DIAGRAMS General X412 ENGINE WIRING E7J262 DETONATION SENSOR 1 1 1 1 4 4 4 4 CY2AE Position Section Destination 0,50 SSIGNAL + DETONATION SENSOR 0,50 MASS DETONATION SENSOR DETONATION SENSOR SCREENING 0,60 ATMOSPHERIC PRESSURE SENSOR 89 - 07 89 - 5 vnx.su...
  • Page 799 ELECTRIC DIAGRAMS Functional diagrams list ELECTRIC DIAGRAMS DENOMINATION DIAGRAM NUMBER DOORS CENTRAL LOCKING ANTI-STARTING ELECTRIC LIGHTER CLIMATE CONTROL CLIMATE CONTROL AND AIR CONDITIONING CEILING LAMP FRONT WINDOWS ELECTRIC CONTROL RADIO 9-10 STARTING CIRCUIT ENGINE COOLING FAN 12-13 ELECTRONIC INJECTION 14-15-16-17-18-19-20-21 CHARGING CIRCUIT REAR WIRING MASS FRONT WIRING/ DASHBOARD MASS...
  • Page 800 ELECTRIC DIAGRAMS Functional diagrams list ELECTRIC DIAGRAM DENOMINATION DIAGRAM NUMBER REAR FOG LAMPS MEETING LIGHTS REVERSE DRIVING LIGHTS PARKING LIGHTS ROAD LIGHTS STOP LIGHTS TURNING AND HAZARD LIGHTS 89 - 7 vnx.su...
  • Page 801 ELECTRIC DIAGRAMS Electric components index CODE COMP ONENT DENOMINA TION CODE COMP ONENT DENOMINA TION Electric lighter Lights, turning lights and horn switch Alternator Windscreen wiper motor Anti-theft system Ceiling lamp Acoustic warning Windscreen washing pump Battery Valve potentiometer Injection computer (ECE) Power steering pressure controller Doors closing switch Diagnostic socket...
  • Page 802 ELECTRIC DIAGRAMS Connections lists - Mass list CONNECTIONS LIST R157 = REAR/HATCHBACK WIRING CONNECTIONS (A) R212 = FRONT WIRING CONNECTIONS – DASHBOARD/ENGINE (B) R265 = FRONT WIRING CONNECTIONS – DASHBOARD/REAR(C) R316 = = FRONT WIRING CONNECTIONS – FOG PROJECTORS/ DASHBOARD (D) MASS LIST = REAR WINDOW DEFROSTING MASS = LEFT FRONT BODY ELECTRIC MASS...
  • Page 803 ELECTRIC DIAGRAMS Electric components location on vehicle Mass attachments on vehicle ELECTRIC COMPONENTS LOCATION ON VEHICLE MASS ATTACHMENT ON THE VEHICLE M Y H MC MH 89 - 10 vnx.su...
  • Page 804 ELECTRIC DIAGRAMS Electric components location on the vehicle DENOMINATION DENOMINATION Windscreen washing pump Injector 1 Left front door contact Injector 2 Left front door actuator Injector 3 Left electric window actuator Injector 4 Left front door speaker Atmospheric pressure sensor Cockpit fuse box Detonation sensor UCE cockpit...
  • Page 805 ELECTRIC DIAGRAMS Electric components location on the vehicle 89 - 12 vnx.su...
  • Page 806 ELECTRIC DIAGRAMS Functional electric diagrams FUNCTIONAL ELECTRIC DIAGRAMS 89 - 13 vnx.su...
  • Page 807 ELECTRIC DIAGRAMS Cockpit fuse box The cockpit fuse box is placed in driving post left side, being attached on the dashboard lateral side. The fuses are protecting the following electric components and circuits: FUSE FUSE TYPE PROTECTED CIRCU IT NUMBER Instrument panel, UCE cockpit (ceiling lamp), radio (I.C.) UCE cockpit, climate control panel AC (I.C.) 20 A...
  • Page 808 ELECTRIC DIAGRAMS Cockpit fuse box Left road lights, instrument panel (indicator) 7,5 A Right road lights 7,5 A Acoustic warning 15 A UCE cockpit(turning lights and hazard), diagnostic 25 A socket (IIC) Front/rear parking ligh ts, lighting: switches, climate 7,5 A control panel, instrument panel, lighter, radio.
  • Page 809 ELECTRIC DIAGRAMS Fuse box from engine compartment A. Vehicles without air conditioning The fuse box placed in the engine compartment is attached in front of the left shock absorber column and contains relays and fusible protecting the following electric circuits: FUSE FUSE PROTECTED CIRCUIT...
  • Page 810 ELECTRIC DIAGRAMS Fuse box from engine compartment B. Vehicles with air conditioning The fuse box placed in the engine compartment is attached in front of the left shock absorber column and contains relays and fusible protecting the following electric circuits: FUSE FUSE PROTECTED CIRCUIT...
  • Page 811 ELECTRIC DIAGRAMS Wires functions index in connectors and couplings No.con. Page Denomination ELECTRIC LIGHTER 89 - 127 ALTERNATOR 103 HA 89 - 101 ALTERNATOR EXCITATION 103 HB 89 - 101 ANTI-THEFT MECHANISM 89 - 127 ACOUSTIC WARNING 89 - 128 (+)BATTERY PLUG(engine wiring) 89 - 102 (+)BATTERY PLUG (front wiring-dashboard)
  • Page 812 ELECTRIC DIAGRAMS Wires functions index in connectors and couplings INJECTOR 4 89 - 113 REAR WINDOW DEFROSTING 89 - 168 ELECTRIC RIGHT WINDOW ACTUATOR 89 - 137 89 - 137 ELECTRIC LEFT WINDOW ACTUATOR OIL PRESSURE CONTACT 89 - 114 LIGHTS, TURNING LIGHTS, HORN SWITCH 89 - 138 WINDSCREEN WIPER MOTOR...
  • Page 813 ELECTRIC DIAGRAMS Wires functions index in connectors and couplings ICP BRAKING SYSTEM 89 - 158 1091 VEHICLE SPEED TRANSDUCER 1140 89 - 125 1156 CLIMATE CONTROL BLOWER (without AC) 89 - 158 1202 AC PRESSURE SENSOR (PRESSURE CONTROLLER) 89 - 125 CLIMATE BLOWER ELECTRIC MASS 89 - 126 FRONT LEFT BODY ELECTRIC MASS...
  • Page 814 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 ALTERNA TOR (for vehicles without air conditioning ) Position Section Destination + BATTERY > INLET FUSE F01 16,0 + BATTERY > STARTER 103 HA ALTERNA TOR (for vehicles with air conditioning ) Position Section Destination + BATTERY >...
  • Page 815 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 ENGINE WIRING E7J262 BATTERY PLUS TERMINAL Position Section Destination 16,0 + BATTERY > + STARTER + BATTERY > INLET FUSE F04 1 0 7 89 - 22 vnx.su...
  • Page 816 ELECTRIC DIAGRAMS Wires functions in connectors and couplings 89 - 23 vnx.su...
  • Page 817 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination CONTROL - IGNITI O N COIL CYLINDE RS 2-3 MASS CANISTE R PURGE V ALVE CONT ROL CONTROL - COOLING FAN RELA Y CONTROL - WATER TEMPERA TURE INDICA TOR 0,35 CONTROL 2 IDLING REGU LATOR SIGNAL + W ATER TEMPERA TURE SENSOR...
  • Page 818 ELECTRIC DIAGRAMS Wires functions in connectors and couplings 89 - 25 vnx.su...
  • Page 819 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination CONTROL - IGNITI O N COIL CYLINDE R 2-3 MASS CANISTE R PURGE V ALVE CONT ROL CONTROL – ENGINE COOLING FAN 1 SPEED CONTROL - WATER TEMPERA TURE INDICA TOR 0,35 AIR CONDITION STOPPING CONTROL>COMPRESSOR RELA CONTROL 2 IDLING REGU LATOR...
  • Page 820 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination 0,35 AIR PRESSURE SENSOR > SUPPL - DET ONATION SENSOR UPSTREAM OXYGEN SENSOR MASS - FREON PRESSURE SENSOR + FREON PRESSURE SENSOR SIGNAL - PRESSURE CONTROLL ER POWER STEERING CONTROL - INJECTOR 4 CONTROL - INJECTOR 2 89 - 27...
  • Page 821 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 DETONATION SENSOR Position Section Destination 0,50 SIGNAL + DETON ATION SENSOR 0,50 DETONA TION SENSOR M ASS DETONATION SENSOR SCREENING 0,60 CY2AE ATMOSPHERIC PRESSURE SENSOR Position Section Destination MASS AIR PRESSURE SENSOR SIGNAL AIR PRESSURE SENSOR AIR PRESSURE SENSOR>...
  • Page 822 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 RPM SENSOR Position Section Destination 0,60 SIGNAL - RPM ENGINE > UCE INJECTION 0,60 SIGNAL - RPM ENGINE > UCE INJECTION CA 13E 1 4 9 REVERSE DRIVING CONTACT Position Section Destination 0,60...
  • Page 823 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 STARTER Destination Position Section 16 ,0 + BATTERY 16 ,0 + BATTERY > + ALTERNAT SL8C 163 GA STARTER EXCITATION Position Section Destination + ST ARTE R CONTROL CS6PI 6,3 MM 163 AB...
  • Page 824 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 AIR CONDITIONING COMPRESSOR CLUTCH Position Section Destination 38 R CONTROL +AIR C ONDITIONING COM PRESSOR CLUTCH 1 7 1 ENGINE COOLING FAN (for vehicles without air conditioning) Position Section Destination MASS CONTROL + ENGINE COOLING FAN...
  • Page 825 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 INJECTOR 1 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 1 CY2AE INJECTOR 2 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 2 CY2AE 89 - 32...
  • Page 826 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 INJECTOR 3 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 3 CY2AE 1 9 5 INJECTOR 4 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - INJECTOR 4 CY2AE 89 - 33...
  • Page 827 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 OIL PRESSURE TRANSMITTER Position Section Destination 0,60 CONTROL -OIL PRESSURE INDICA T OR POTENTIOMETER VALVE Position Section Destination 0,60 MASS POTENTIOMETE R VALVE 0,60 SIGNAL + POTENTIOMETER VAL VE 0,60 SIGNAL + V ALVE POSITION POTENTIOMETER CM1PE...
  • Page 828 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 POWER STEERING PRESSURE CONTROLLER (for vehicles with power steering) Position Section Destination SIGNAL - PRESSURE CONTROLL ER POWER STEERING MASS DOWNSTREAM OXYGEN SENSOR Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONT ROL -HEA TING DOWNSTREAM OXYGEN SENSOR 0,60 SIGNAL DOWNST REAM OXYGEN SENSOR...
  • Page 829 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 INJECTION WATER TEMPERATURE SENSOR Position Section Destination 0,35 SIGNAL + W ATER TEMPERA TURE 0,60 - WATER TEMPERA TURE 0,60 SIGNAL + W ATER TEMPERA TURE SENSOR COOLING MOTOR FAN AND AIR CONDITIONING (for vehicle with air conditioning) Destination Position Section...
  • Page 830 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 INJECTION AIR TEMPERA TURE SENSOR Position Section Destination SIGNAL + AIR TEMPERA TURE SENSOR 0,60 MASS AIR TEMPERA TURE SENSOR 0,60 ENGINE COOLING FAN RESISTANCE (for vehicles with air conditioning) Destination Position Section CONTROL + LOW SPEED COOL ING F AN RESIST ANCE...
  • Page 831 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 CANISTER PURGING VALVE Position Section Destination 0,60 + INJECTORS > OUTLE T ACTUA TORS RELA Y 0,60 3 BB CONTROL CANISTE R PURGE V ALVE CY13C 89 - 38 vnx.su...
  • Page 832 ELECTRIC DIAGRAMS Wires functions in connectors and couplings AP2 9 BP1 7 BP1 7 3 GT BP1 7 E 0 4 BP1 7 E 0 1 89 - 39 vnx.su...
  • Page 833 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination + INJ ECTORS > ACTUA TORS OUTLET RELA Y CONTROL - MOTOR FAN 1ST SPEED RELA Y + PROTECTE D BATTERY >OUTLE T FUSE F01 ENGIN E CONTROL + ENGINE COOLING FAN + PROTECTE D BATTERY >OUTLE T FUSE F04 ENGIN E BP1 7...
  • Page 834 ELECTRIC DIAGRAMS Wires functions in connectors and couplings AP2 9 BP1 7 BP1 7 3 GT E 0 4 BP1 7 BP1 7 E 0 3 3 8 K E 0 2 Ve-A 3 J P 89 - 41 vnx.su...
  • Page 835 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL AIR CONDITIONING STOPPING>U.C.E INJECTION + PROTECTED BATTER Y> OUTL ET FUSE F03 CONTROL - AIR CONDIT ION COMPRESSOR CLUTCH + INJECTORS >...
  • Page 836 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 STEP BY STEP ENGINE Position Section Destination 0,60 CONTROL 1 IDLING REGU LATOR 0,60 CONTROL 2 IDLING REGU LATOR 0,60 CONTROL 3 IDLING REGU LATOR 0,60 CONTROL 4 IDLING REGU LATOR CM1PE IGNITION COIL Position Section...
  • Page 837 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 UPSTREAM OXYGEN SENSOR Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y CONTROL - HEA TING UPSTREAM OXYGEN SENSOR 0,60 3 GK SIGNAL UPSTREAM OXYGE N SENSOR 0,60 3 GH UPSTREAM OXYGEN SENSOR MASS...
  • Page 838 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 VEHICLE SPEED TRANSDUCER Position Section Destination + INJECTORS > OUTLE T ACTUA TORS RELA Y SIGNA L VEHICLE SPEED 0,35 0,35 MASS AIR CONDITION PRESSURE SENSOR (pressure controller) Position Section Destination 0,60...
  • Page 839 ELECTRIC DIAGRAMS Wires functions in connectors and couplings ENGINE WIRING X412 E7J262 ENGINE ELECTRIC MASS Destination Position Section MASS > U.C.E. INJECTION (PINS 3,28 and 33, TRANSDUCER VEHICLE SPEED , POWER STEERIN G PRESSURE CONT ROL LER SR 8L ENGINE COOLING FAN ELECTRIC MASS Destination Position Section MASS...
  • Page 840 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD ELECTRIC LIGHTER Destination PARKING LIGHT S > OUT LET FUSE F1 4 0,35 LPG MASS + AFTER PROTECTED CONT ACT > OUTLET FUSE F06 ANTI-THEFT MECHANISM Destination Position Section SUPPL Y + AFTER CONTACT >...
  • Page 841 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD ACOUSTIC WARNING Destination CONTROL + ACOUSTIC W ARNING> OUTLET FUSE F12 BORNA PLUS BATERIE Position Section Destination + BATTERY + BATTERY 107AA 89 - 48 vnx.su...
  • Page 842 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD DOORS LOCKING SWITCH Destination Position Section 0,35 CONTROL – DOORS ELECTRIC LOCKING TIMING 0,35 + P ARKING L IGHTS>OUTL ET FUSE F14 0,35 COCKPIT LEFT FRONT EL ECTRIC M ASS 0,35 COCKPIT LEFT FRONT EL ECTRIC M ASS 0,35...
  • Page 843 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD CLIMATE CONTROL PANEL (for vehicles without air conditioning) Destination Position Section 38AL CONTROL + CLIM ATE CONTROL BLOWER SPEED 4 38AL CONTROL + CLIM ATE CONTROL BLOWER SPEED 4 AP41 + AFTER PROTECTED CONT ACT >...
  • Page 844 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD HAZARD SWITCH Position Section Destination 0,35 + P ARKING LIGHT S > OUTL ET FUSE F14 0,35 + P ARKING LIGHT S > OUTL ET FUSE F14 0,35 CONTROL LEFT TURNING LIGHTS 0,35...
  • Page 845 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT ELECTRIC WINDOW SWITCH Destination Position Section DRIVER’S WINDOW LOWERING CONTROL COCKPIT LEFT FRONT EL ECTRIC M ASS COCKPIT LEFT FRONT EL ECTRIC M ASS AP39 + AFTER PROTECTED CONT ACT > OUTLET FUSE F23 AP39 + AFTER PR OTECTED CONT ACT >...
  • Page 846 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT FRONT DOOR ACTUATOR Position Section Destination CONTROL + DOORS ELECTRIC LOCKING .> U.C.E. DECODER CONTROL + DOORS ELECTRIC UNLOCKING >U.C.E. DECODER 1 DBD1 RIGHT FRONT DOOR ACTUATOR Position Section Destination CONTROL + DOORS ELECTRIC LOCKING >...
  • Page 847 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD WINDSCREEN WIPER-WASHING SWITCH Destination Position Section CONTROL + WIN DSCREEN WIPER TIMER 0,35 CONTROL + HIGH SPEED WINDSCREEN WIPER CONTROL + LOW SPEED WINDSCREEN WIPER CONTROL + WINDSCR EEN WASHING PUM P CONTROL + L OW SPEED WINDSCREEN WIPER TIMER + AFTER PROTECTED CONT ACT WINDSCR EEN WIPER + AFTER PROTECTED CONT ACT WINDSCR EEN WIPER...
  • Page 848 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT FRONT DOOR CONTACT Destination 1 3 A 0,35 13A CONTROL - CEILIN G LIGHTNING 13A CONTROL - CEILIN G LIGHTNING * - for vehicles without central locking FRONT RIGHT PARKING LIGHT Destination LPD + P ARKING LIGHT S >...
  • Page 849 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RIGHT FRONT DOOR SPEAKER Destination Position Section SIGNAL + RIGHT FRONT SPEAKE R (RADIO) SIGNAL - RIGHT FRONT SPEAKER (RADIO) 3 4 E LEFT FRONT DOOR SPEAKER Position Section Destination 0,60...
  • Page 850 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT WINDOW ELECTRIC REGULATOR ACTUATOR Destination Position Section DRIVER’S WINDOW LIFTING CONTROL DRIVER’S WINDOW LOWERING CONTROL 2 1 A RIGHT WINDOW ELECTRIC REGULATOR ACTUATOR Destination Position Section PASSENGER WINDOW L IFTING CONT ROL PASSENGER WINDOW LOWERING CONTROL 2 2 A...
  • Page 851 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LIGHTS, TURNING LIGHTS AND HORN SWITCH Destination Position Section 0,35 CONTROL FOG PROJECTORS RELAY CONTROL FOG PROJ E CTORS RELA Y > INSTRUMENT PANEL 0,35 CONTROL + REAR FOG L AMP > INL ET FUSE F19 CONTROL + ACOUSTIC W ARNING >...
  • Page 852 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD WINDSCREEN WIPER MOTOR Position Section Destination CARRIAGE BODY LEFT FRONT ELECTRIC MASS CONTROL + FIX POINT STOPPING + PROTECTED BA T TERY > OUT LET FUSE F07 CONTROL + LOW SPEED WINDSCREEN WIPER CONTROL + HIGH SPEED WINDSCREEN WIPER CEILING LIGHT...
  • Page 853 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD WINDSCREEN WASHING PUMP Destination CARRIA GE BODY FRON T LEFT ELECTRIC MASS CONTROL + WINDSCR EEN WASHING PUM P DIAGNOSIS SOCKET Destination Position Section 0,35 AP10 + AFTER PROTECTED CONT ACT > OUTLET FUSE F04 0,35 COCKPIT FRONT LE F T EL ECTRIC M ASS 0,35...
  • Page 854 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RIGHT HEADLAMP CD8F Destination CARRIAGE BODY FRONT LEFT ELECTRIC MASS CPD RIGHT MEET ING LIGHTS PROTECTED > OUTL E T FUSE F09 RPD RIGHT ROAD LIGHTS PROTECTED > OUTLET FUSE F11 LEFT HEADLAMP CD8F...
  • Page 855 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD INSTRUMENT PANEL Destination Position Section 0.35 CONTROL LEFT TURNING LIGHTS 0,35 CP G PROTECTE D LEFT MEETING HEADLIGHTS > INDICA TOR 0,35 RP G PROTECTED LE FT ROAD LIGHTS > INDICA TOR 0,35 CONTROL –...
  • Page 856 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD Position Section Destination 0,35 CONTROL - HANDBRAKE INDICA T OR, I.C.P . 0,35 CONTROL - HANDBRAKE INDICA T OR, I.C.P . 0,35 CONTROL - ANTI-ST ARTING INDICA TOR 0,35 - FUEL LEVEL 0,35...
  • Page 857 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD FRONT RIGHT TURNING LAMP Destination RIGHT TURNI N G LIGHTS CONTROL CARRIAGE BODY FRONT LEFT ELECTRIC MASS FRONT LEFT TURNING LAMP Destination LEFT TURNING LIGHTS CONTROL CARRIAGE BODY FRONT LEFT ELECTRIC MASS 89 - 64 vnx.su...
  • Page 858 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RADIO Position Section Destination + PROTECTED BA T TERY > OUT LET FUSE F02 PARKING LIGHT S > OUT LET FUSE F1 4 0,35 PARKING LIGHT S > OUT LET FUSE F16 COCKPIT FRONT LE F T EL ECTRIC M ASS Position Section...
  • Page 859 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD RIGHT SIDE SIGNALING LAMP Destination CONTROL RIGHT SIGNAL ING LIGHTS CARRIAGE BODY FRONT LEFT ELECTRIC MASS LEFT SIDE SIGNALING LAMP Destination CONTROL LEFT SIGNAL ING LIGHTS CARRIAG E BODY FRONT LEFT ELECTRI C MASS 89 - 66 vnx.su...
  • Page 860 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD CLIMATE CONTROL PANEL (for vehicles with air conditioning Destination Position Section 38AL CONTROL + CLIM ATE BLOWER SPEED AP41 + AFTER PROTECTED CONT ACT > OUTLET FUSE F17 AP41 + AFTER PROTECTED CONT ACT >...
  • Page 861 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD CLIMATE CONTROL BLOWER (for vehicles with air conditioning) Destination Position Section CONTROL +AIR CONDITIO NING RECYCL ING 38EV CONTROL - AIR CONDIT IONING RECYCLING 38AN 38AH CONTROL + CLIM ATE BLOWER SPEED 1 38AJ CONTROL + CLIM ATE BLOWER SPEED 2 38AK...
  • Page 862 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD UCE COCKPIT Destination Position Section CONTROL + DOORS ELECTRIC LOCKING + PROTECTED BA T TERY > OUT LET FUSE F03 COCKPIT CONTROL + DOORS ELECTRIC UNLOCKIN G 13AD CONTROL + CEILING LIGHTING + PROTECTED BA T TERY >...
  • Page 863 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD U.C.E. COCKPIT Destination Position Section COCKPIT FRONT LE F T EL ECTRIC M ASS CONTROL – CEILIN G LIGHTING + PROTECTED BA T TERY > OUT LET FUSE F13 COCKPIT BP5 6 CONTROL WINDSCREEN WIPER LOW SPEED +AFTER PROTECTED CONT ACT ?>...
  • Page 864 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD U.C.E. COCKPIT Destination Position Section CONTROL + DOORS ELECTRIC UNLOCKIN G TIMING 0,35 + PROTECTED L E FT PARKING LIGHT S > OUT LET FUSE f1 4 COCKPIT 0,3 5 ANTI-ST ARTING RECEIVE R SIGNAL WAY 0,35...
  • Page 865 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD U.C.E. COCKPIT Destination Position Section 0,3 5 AP10 AFTER PROTECTED CONT ACT > OUTLE T FUSE F04 COCKPIT CONTROL + WIN DSCREEN WIPER TIMER CONTROL LEFT TURNING TIMING 0,3 5 CONTROL RIGHT TURNI N G TIMING 0,3 5...
  • Page 866 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD U.C.E. AIRBAG Position Section Destination 0,35 AP10 AFTER PROTECTED CONT ACT > OUTLET FUSE F04 TUNNEL ELECTRON IC MASS 0,35 129A CONTROL – AIRBAG FAILURE INDICA TOR 0,35 DIAGNOSTI C SIGNAL LINE K 129F...
  • Page 867 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD DRIVER AIRBAG Destination Position Section 129F SIGNAL + DRIVER AIRBAG 129G SIGNAL - DRIVER AIRBAG 129G 129F ANTI-STARTING BUSHING Position Section Destination 0,60 COCKPIT FRONT LE F T EL ECTRIC M ASS PROTECTED BA TTERY >...
  • Page 868 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD COCKPIT FUSE BOX Destination + BATTERY A02 2,0 + PROTECTE D BATTERY A03 1,4 + PROTECTE D BATTERY A03 0,35 PROTECTED BATTER Y + AFTER CONT ACT A04 1,0 AP10 + AFTER PROTECTED CONT ACT...
  • Page 869 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD CONTROL + REAR FOG LIGH TS > L IGHTS SWITCH + PROTECTE D REAR FOG LIGHTS 0,35 + PROTECTED REAR FOG LIGH TS > INDICA TOR + ACCESSORIES AP12 + AFTER PR OTECTED CONT ACT >...
  • Page 870 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD 1016 67CP AP29 AP10 89 - 77 vnx.su...
  • Page 871 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD I.C.P. BRAKING SYSTEM Destination 1091 CONTROL - HANDBRAKE INDICA T OR, I.C.P . 0,35 CLIMATE CONTROL BLOWER (for vehicles without air conditioning) Destination Position Section 38AH CONTROL + CLIM A TE CONTROL BLOWER SPEED 1 38AJ CONTROL + CLIM A TE CONTROL BLOWER SPEED 2 38AK...
  • Page 872 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD LEFT FRONT BODY ELECTRIC MASS Position Section Destination MASS > FRONT SIDE SIGNALIZING L LEFT/RIGHT , WINDSCR EEN WIPER PUM P, WINDSCREEN WIPER M OTOR , CLIM ATE CONTROL BLOWER (PINS 14 an d 15) LEFT FRONT BODY ELECTRIC MASS Destination Position Section...
  • Page 873 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FRONT WIRING – DASHBOARD FRONT LEFT COCKPIT ELECTRIC MASS Position Section Destination MASS > CEILING LIGHT , RADIO, DASHBOARD, REAR WINDOW DEFROSTING SWITCH, MASS > LE FT/RIGHT ELECTRIC WINDOW SWITCH, LIG HTER, LOCKING D OORS SWITCH, CLIM A TE CONTROL, DIAGN OSIS SOCKET , HAZARD SWITCH...
  • Page 874 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING REAR RIGHT DOOR ACTUATOR Position Section Destination CONTROL + ELECTRIC DOO R S LOCKING> ACTUA TORS CONTROL + ELE CTRIC DOORS UNL O CKING> ACTUA TORS 1 DBD1 REAR LEFT DOOR ACTUATOR Destination Position Section CONTROL + ELECTRIC DOO R S LOCKING >...
  • Page 875 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING HANDBRAKE CONTACT Destination CONTROL - HANDBRAKE INDICA T OR, I.C.P . 0,35 H1 REAR RIGHT LAMP Destination Position Section CONTROL + STOP LIG HTS + P ARKING LIGHT S > OUTL ET FUSE F15 REAR LEFT TABLE ELECTRIC MASS CONTROL RIGHT TURNING LIGHTS H66P...
  • Page 876 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING REAR LEFT LAMP Position Section Destination + PROTECTED REAR FOG L IGHTS > OUTLET FUSE F19 CONTROL LEFT TURNIN G LIGHT REAR LEFT TABLE ELECTRIC MASS CONTROL + STOP LIG HTS + P ARKING LIGHT S >...
  • Page 877 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING REAR LEFT SPEAKER Position Section Destination 0,35 SIGNAL + REAR LEFT SPEAKE R (RADIO) 0,35 SIGNAL - REAR LEFT SPEAKER (RADIO) FUEL LEVEL TRANSMITTER AND ELECTRIC PUMP Position Section Destination 0,35 - FUEL LEVEL...
  • Page 878 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 REAR WIRING REAR LEFT TABLE ELECTRIC MASS Position Section Destination MASS > LEFT/ R IGHT REAR LAMP FUEL LEVEL TRANSMITTER AND ELECTRIC PUMP SR 8L 89 - 85 vnx.su...
  • Page 879 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FOG PROJECTORS WIRING RIGHT FOG PROJECTOR Destination + FOG PROJ E CTOR > RELA Y FOG PROJ ECTORS WIRING ELECTRIC M ASS LEFT FOG PROJECTOR Destination + FOG PROJ E CTORS > RELA Y FOG PROJECTORS WIRING ELECTRIC MASS 89 - 86 vnx.su...
  • Page 880 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 FOG PROJECTORS WIRING FOG PROJECTORS RELAY Position Section Destination 0,35 CONTROL + FOG PROJECTORS RELA Y 0,35 FOG PROJ E CTO RS WIRING EL E CTRIC M ASS BPR1 + BA TTERY > OUTL ET FUSE F28 + FOG PROJ ECTORS >...
  • Page 881 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 HATCHBACK WIRING REAR WINDOW DEFROSTING Destination CONTROL + REAR WINDOW DE FROSTING LICENSE PLA TE LAMP Destination M YH + P ARKING LIGHT S > OUTLE T FUSE F14 0,35 MYH MASS STOP LAMP - S3 Destination 6 5 A...
  • Page 882 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 HATCHBACK WIRING HATCHBACK WIRING ELECTRIC MASS Destination Position Section MASS > LEFT HA TCHBACK ELECTRIC M ASS SR 8L LEFT HATCHBACK ELECTRIC MASS Position Section Destination M YH MASS > HA TCHBACK WIRING ELECTRIC MASS 0,35 MY H MASS >...
  • Page 883 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 COUPLINGS REAR WIRING COUPLINGS / HATCHBACK REAR WIRING COUPLING Destination Position Section CONTROL + STOP LIG HTS 0,35 + P ARKING LIGHTS > OUTLET FUSE F1 4 CONTROL + REAR WINDOW DE FROSTING 6 5 A LPG 15B R 157 HATCHBACK WIRING COUPLING...
  • Page 884 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 COUPLINGS FRONT WIRING COUPLING - DASHBOARD / ENGINE FRONT WIRING COUPLING Destination Position Section + ST ARTE R CONTROL + FUEL PUMP 3NA1 + CONTROL – ALTERNA TOR CHARGING INDICA T OR 0,35 SIGNAL AIR CONDITIO NING COUPLING BP3 7...
  • Page 885 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 COUPLINGS ENGINE WIRING COUPLING Destination Position Section + CONTROL ST ARTER 3NA1 + POMPÃ BENZ INÃ > SENZO R ªOC+ FUEL PUMP > CHOCK SENSOR 3NA1 + FUEL PUMP + CONTROL – ALTERNA TOR CHARGING INDICA T OR SIGNAL AIR CONDITIO NING COUPLING BP3 7 + PROTECTED BATTERY >...
  • Page 886 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 COUPLINGS FRONT WIRING COUPLING - DASHBOARD / REAR FRONT WIRING COUPLING Position Section Destination CONTROL + ELECT RIC UNLOCKING DOORS > UCE DECODER CONTROL + ELECTRIC LOCKING DOORS > U.C.E. DECODER +FUEL PUMP >...
  • Page 887 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 COUPLINGS REAR WIRING COUPLING Section Position Destination CONTROL + ELE CTRIC UNLOCKING DOORS > ACTUA TORS CONTROL + ELE CTRIC UNLOCKING DOORS > ACTUA TORS CONTROL + ELECTRIC LO C KING DOO RS > ACTUA TORS CONTROL + ELECTRIC LO C KING DOO RS >...
  • Page 888 ELECTRIC DIAGRAMS Wires functions in connectors and couplings X412 COUPLINGS FRONT WIRING COUPLING - DASHBOARD / FOG PROJECTORS FRONT WIRING COUPLING Position Section Destination CONTROL + FOG PROJ E CTORS RELA Y > LIGH TS SWITCH 0,35 + PROTECTED BA T TERY > OUT LET FUSE F28 BPR1 BPR1 R316...
  • Page 889 ELECTRIC DIAGRAMS Wires functions explanation LIN K WIRES FONCTION COD E SUPPLY + AFTER CONTACT + AFTER PROTECTED CONTACT > COCKPIT OUTLET FUSE F06 AP10 + AFTER PROTECTED CONTACT > COCKPIT OUTLET FUSE F04 AP12 + AFTER PROTECTED CONTACT > COCKPIT OUTLET FUSE F20 + AFTER PROTECTED CONTACT >...
  • Page 890 ELECTRIC DIAGRAMS Wires functions explanation SIGNAL + AIR TEMPERATURE SENSOR SIGNAL - PRESSURE CONTROLLER POWER STEERING CONTROL CANISTER PURGING VALVE RPM ENGINE SIGNAL > RPM SENSOR SIGNAL - RPM ENGINE > RPM SENSOR CONTROL 1 IDLING REGULATOR CONTROL 2 IDLING REGULATOR CONTROL 3 IDLING REGULATOR CONTROL 4 IDLING REGULATOR SIGNAL + WATER TEMPERATURE SENSOR...
  • Page 891 ELECTRIC DIAGRAMS Wires functions explanation CONTROL + DOORS ELECTRIC LOCKING CONTROL DRIVER ELECTRIC WINDOW LIFTING CONTROL DRIVER ELECTRIC WINDOW LOWERING PASSENGER ELECTRIC WINDOW LIFTING CONTROL PASSENGER ELECTRIC WINDOW LOWERING CONTROL CONTROL - OIL PRESSURE INDICATOR CONTROL - WATER TEMPERATURE INDICATOR SIGNAL + REAR LEFT SPEAKER SIGNAL - REAR LEFT SPEAKER SIGNAL - REAR RIGHT SPEAKER...

Table of Contents

Save PDF