DACIA SUPERNOVA 2004 Repair Manual

REPAIR MANUAL
DACIA
RM 524-1 MECHANICSENGINE: E7J
G ERBOX: JH3
TA P V: B 41A, B41B, B41D
Ref: 6001999441 APRIL 2004 English version
The reparation methods prescribed by the manufacturer in the present document are established subject to
t echnical specifications in force at the document issuing date.
These a re subject to modifications brought by the manufacturer at the fabrication of different assemblies,
s ubassemblies or accessor ies of its vehicles.
All rights rese rved to SC Automobile Dacia SA.
Re production or transla ting even partia lly of this prese nt doc ume nt is forbidde n without the writte n
authorisation of AUTOMOBILE DACIA S.A.
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01 SPECIFICATIONSEngine – Clutch - Gearbox............................. 01-1
Vehicle identification.. ................................. 01-2
02 LIFTING Mobile jack - Protection route;....................... 02-1
Elevator positioned under the carriage body... 02-3
03 TOWING All types.......................................................... 03-1
04 LUBRICANTS CONSUMABLES Condition....................................................... 04-1
05 DRAINING – FILLING Engine............................................................ 05-1
Gearbox.......................................................... 05-2
07 VALUES AND SETTINGS Dimensions..................................................... 07-1
Capaci ty - Qualities........................................ 07-2
Driving belts tightening and accesorie s.......... 07-3
Distribution belt tension................................. 07-4
Cy linder head tightening................................ 07-5
Wheeles and tyres........................................... 07-6
Br akes............................................................. 07-7
Dimensions under carriage body.................... 07-8
C hecking values of the fr ont axle angles........ 07-9
C hecking values of the rear axle angle s......... 07-10
10 ENGINE AND LOWER ENGINE UNITS Ingredients...................................................... 10-1
Motor-propelling group.................................. 10-2
Separation - Dismantling................................ 10-7
Characteristics................................................ 10-10
Rec overy engine.............................................10-17
Lowervcrankase..............................................10-37
Oil pump........................................................ 10-38
Tightening moments....................................... 10-39
11 UPPER AND FRONT ENGINE UNITS Distribution belt............................................. 11-1
Cylinder head fi tting....................................... 11-3
12 FUEL MIXTURE Characteristics................................................ 12-1
Cl apper body .................................................. 12-4
Intake cole ctor................................................ 12-5
Exhaust collector............................................ 12-6
13 PUMP SUPPLY
Br eaking fuel supply ..................................... 13-1
Injection pump............................................... 13-2
Petrol filter.................................................... 13-3
P upm flow...................................................... 13-4
Supply pressure.............................................. 13-5
14 ANTI-POLLUTION Petrol vapours-aspiration ............................. 14-1
16 STARTING AND CHARGING Alternator....................................................... 16-1
Starter............................................................. 16–7
17 IGNITION AND INJECTION Ignition system.............................................. 17-1
Sparking plugs.............................................. 17-2
Peculi arities.................................. ................ 17-3
Placi ng of elements........................................ 17-4
Idling regime adjustment............................... 17-9
Adjustment of the fuel mixture enriching...... 17-11
Enriching adaptive correction....................... 17-12
Diagnosing-Introduction... ............................ 17-15 Diagnosing-Interpreting the defects.............. 17-17
Diagnosing-Conformity test........................... 17-49
Diagnosing-Interpreting the states................. 17-55
Diagnosing-breakdown localization
algorithm....................................................... 17–66
19 COOLING - EXHAUST - FUEL TANK Characteristics............................................... 19-1
Filli ng and draining ...................................... 19-2
C ontrol.......................................................... 19-3
The schema.................................................... 19-4
Ra diator dismounting and remounting.......... 19-5
C ooling fan replacement
for vehicles with air conditioning................. 19-6
C ooling fan diagnostic
for vehicles with air conditioning................. 19-7
Re sist ance cooling fan replacement
for vehicles with air conditioning................. 19-9
C ooling fan replacement
for vehicles without air conditioning............ 19-10
C ooling fan diagnostic
for vehicles with air conditioning.................. 19-11
Water pump .................................................. 19-12
Dismounting - remounting exhaust................ 19-14
Emptyng of tank............................................ 19-16
Tank fuel description..................................... 19-17
Tank fuel....................................................... 19-20
Electric petr ol pump...................................... 19-21
20 CLUTCH Identification................................................. 20-1
Diagnostic.. ................................................... 20-3
Clut ch disc mechanism.................................. 20-9
Moteur et peripherics
General poinds vehicle0
1
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21 MANUAL GEARBOXSecti ons.......................................................... 21-1
Identification ................................................. 21-2
Tightening moments...................................... 21-3
Ratios ............................................................ 21-4
Capacity, lubricants....................................... 21-5
Particul arities................................................. 21-6
Ingredie nts..................................................... 21-7
Parts of systema tic replacement.................... 21-8
S pecial tools.................................................. 21-9
Gearbox dismounting ................................... 21-10
29 DRIVE SHAFTS Front transversa l transmission........................ 29-1
Bell ows - Be aring assembly to
t he gearbox.................................................... 29-4
Bell ows to wheel........................................... 29-7
Be llows to gearbox....................................... 29-12
Bell ows to wheel........................................... 29-15
30 GENERAL General principle sc hedule
of the brake circuit........................................ 30-1
Tightening moments...................................... 30-2
Com position and dimensions
of the ma in braking system elements............ 30-6
Br aking system diagnostic............................ 30-7
Br ake connections and se werage.................. 30-12
Br ake fluid.................................................... 30-13
Br aking circuit purging................................. 30-14
The inf luence of the front axle angle s on
t he road behaivior (vehicle comportment)
and on tyres wear........................................... 30-16
Prelimi nary checking..................................... 30-17
C hecking of the front axles adjustment......... 30-19
31 FRONT BEARING ELEMENTS Characteristics... .......................................... 31-1
Sus pension arm... .......................................... 31-2
Elastic bushings of suspension arm............... 31-4
Sus pension ball joint..................................... 31-5
Br ake gaskets................................................ 31-6
Br ake caliper................................................. 31-7
Br ake disk..................................................... 31-9
St eering knuckle............................................ 31-10
St eering knuckle bearing. .............................. 31-12
Fr ont suspension............................................ 31-13
Shock absor ber, Sprint. ................................. 31-14
Sp ring assembly shock absorber................... 31-15
Anti-roll bar................................................... 31-17
33 REAR BEARING ELEMENTS Characteristics............................................... 33-1
Rear axle....................................................... 33-2 Re
ar suspension............................................ 33-4
Shock absorber............................................. 33-5
Spring ........................................................... 33-6
Br ake drum................................................... 33-7
Br ake cylinder.............................................. 33-8
Br ake shoes.................................................. 33-10
Be aring (25 x 52 x 37)................................ 33-12
35 WHEELS AND TYRES Characteristics.............................................. 35-1
Wheels balancing......................................... 35–4
36 STEERING ASSEMBLY Axial ball joint............................................. 36-1
Steering box................................................. 36-3
Pus her........................................................... 36-4
Noise absorber bearing................................. 36-5
Bell ows......................................................... 36-6
Deformable lower shaft................................ 36-7
Ste ering weel position adjustment................ 36-9
37 MECHANICAL ELEMENTS CONTROLS Brake pump.................................................. 37-1
Servobrake................................................... 37-6
Air filter – se rvobrake reta iner valve........... 37-9
Handbrake adjustment.................................. 37-10
Handbrake control lever............................... 37-11
Handbrake secondary cable.......................... 37-12
Br ake flexible hoses..................................... 37-14
Br ake pressure controller.............................. 37-16
clutch hydraulic control................................ 37-19
The gear control........................................... 37-23
Pe dals support.............................................. 37-25
Acceleration pedal....................................... 37-26
Acceleration contr ol cable........................... 37-27
Transmission2
Chasis3
SION
LL
NT
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SPECIFICATIONS
01
ENGINE - CLUTCH - GEARBOX
01 - 1
Vehicle
EnginClutch type Gearbox
type
typeCylinder
capacity (cm3)
Type
DACIA
SupeRNova E7J-260 1390 215 CPOE 3500 JH3 – 050
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SPECIFICATIONS
01
VEHICLE IDENTIFICATION
THE PLACE OF THE MANUFACTURER PLATE, IDENTIFICATION NUM- BER (VIN), LABEL WITH HOMOLOGATION MARKS
MANUFACTURER PLATE
01 - 2
Identification number VIN
M anufacturer plate
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SPECIFICATIONS
01
VEHICLE IDENTIFICATION
a.. Manufactu rer identification code;
b. Code of the vehicle;
c. Gearbox ty pe code;
d. Engine type code and driving location ( according to VIN code structure);
e. Vehicl e code;
f. Trailer ma ximum authorized weight without braking system;
g. Homologation number for the importer country;
h. VIS sign-one character for year model code + 7 characters for the chassis manufacturing number;
i. Maximum technical admissible weight of the loaded car;
j. Maximum admissible weight with trailer with braking system;
k. Maximum technical admissible weight on front axle;
l. Maximum technical admissible weight on rear axle.
LABEL T YPE OVAL PLATE
The se lf- adhesive label type oval plate is stuck on the right lateral side surface of the
dashboard. This enables the identification of the vehicle type and of its equipment, being exclusively
used fo r after-sale activity.
01 - 3
1,1
2,1 2,2
4,1 4,2
The reading of the codes marked on the oval plate type label
Caption:
Line 1
1.1 Cod type auto APV (after-sale):
B41A(E U 9 6 ) B41B(EU00) B41D(1 5 .04)
Line 2
2.1 Le vel of equipping: E0, E1, E2, E3
2.2 Options eq uipping code:
Line 4
4. 1 Technical definition code, driving place.
S2 : Left hand drive
4.2 Options equipment code: A: Normal suspension K: Without pre-filter
C : Temperate climate M: Steering mechanical system
E: Warm climate R: Without variable shock absorber
F : Normal heating T: Without plate corrector
G : Air conditioning V: Without wheels anti blocking (ABS)
B = represents body type
A ,B,D = represents engine type E7J, 1397 cmc, front wheel
drive type, mechanical gearbox.
Attention
Do not unstuck or damage the label from the lateral side surface of the dashboard. This
label represents the only way of vehicle identification needed to the after sale services, for a
period of 8 (eigh t) years from the purchasing date.
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SPECIFICATIONS
01
VEHICLE IDENTIFICATION
Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
CODE U U 1 R 5 2 3 1 5* *******
01 - 4
Position Characters explanation
1 – 3 - manufacturer i dentifi cation
UU1 - AUTOMOBILE DACIA SA, ROMÂNIA
4- Vehicle type
R - vehicle for persons transportation
5- engine-ge arbox unit location
5 - transversal front engine and front drive
6- chassis type
2 - hatch – bach
7- payload location
3 - five places : 2 front places + 3 rear bench places
8- gearbox type
1 - gearbox with 5 + 1 steps (JH3 050)
9- engine code and vehicle driving location
- left hand drive
5 - RENAULT engine, 1400 cm3 engine, spark ignition (E7J - 260)
10 - year model code y – 2000
1 – 2001
2 – 2002
11 - 17 - chassis manufacturing number
VIN IDENTIFICATION NUMBER
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LIFTING
02MOBILE JACK - PROTECTION ROUTESSafety sign
(particularly cautions to be observed in case of an intervention)
SPECIAL TOOLS
DENOMINATION CODE
Protection route Cha 280-02
Adjusting socket on mobile jack Cha 408-01 or Cha 408-02
The use of a mobile jack implies the necessity of using protection routes.
It absolutely forbidden the vehicle lifting using the front suspension arms or the rear axle as
supporting points. The following type of m obile jack is using the sockets, the support Cha 408 – 01 or Cha
408 – 02 in orde r to place the route Cha 280 – 02. In order to lift the front or rear part of the vehicle, take as support the lifting points used also
for the vehicle jack.
LATERAL MOBILE JACK
Use the CHA 280 hold.
P lace it on under the threshold at the front door level.
The floor closing plate shall be positioned in the channel of the hold.
02 - 1
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LIFTING
02MOBILE JACK - PROTECTION ROUTESPROTECTION ROUTES
In order to place the vehicle on the protection routes, these are to be obligatory placed either
under the reinforcemen ts provided for the lifting vehicle with the vehicle jack, or under the supports
placed in behind the reinforcement. The positionin g of the protection routes in the vehicle rear areas is performs by lateral lifting of
the vehicle .
02 - 2
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LIFTING
02ELEVATOR POSITIONED UNDER THE CARRIAGE BODY
Safety sign :
1. THE DISMOUNTING OF VEHICLE COMPONENTS CASE .
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. THE PARTICULARLY CASE OF DISMOUNTING – REMOUNTING OF THE
ENGINE-GEARBOX ASSEMBLY.
In this specific case, the vehicle carriage body shall be consolidated with t he two columns
elevator arms using special slides.
These must be obligatory placed at the right of the supporting points of the vehicle jack and
must be locked in the holes/windows made in the floor closing plate.
02 - 3
Front
Rear
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