lock DACIA SOLENZA 2004 User Guide

ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 28
CYLINDERS BLOCK REMOUNTING
Clean the cylinders block, especially t he
jackets s eating and sealing surfaces.
Preparation of assembly
“ pistons-jackets”
The parts contained in the kit are in pairs.
Ma rk the part s assembly from A to D in
order to keep the matching.
Dismounting – Remounting
Remove completely the anti-rust foil.
REMARK:
Never scrape the parts. Jackets over-height
These engines are equipped with rubber
rings for jackets sealing, ensuring only the seal-
ing, jackets being seated directly on the cylin-
ders block and over-height being done from
manufacturing. The checking of the jackets over-height is
to be performed as follows: - place the jackets in the cylinders block
without the sealing ring;
- check t he X over-he ight by means of
the devices MOT 251-01 and MOT 252-01.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 29
Dismounting – Remounting
The over-he ight X must be between 0.02
mm and 0.09 mm.
Place the jackets in such way that :
-the difference between two joint jackets
to be maximum 0.05 mm;
- the over-height to be in ascending order
between cylinders 1 and 4;
- in case of an incorrect over-height, check
the over-height by m eans of a new kit of jack-
ets, i n order to see i f t he c ause i s the block or
the cylinders jacket or check the theoretical size
values of the block and of the jackets. When over-height is correctly obtained, per-
form the A, B, C, D assembly then mark with
numbers jackets, pistons and the bol ts from 1
to 4 (no.1 towards flywheel) so that the corre-
s pondence with the corresponding connecting
rods may be achieved.
Pistons bolts mounting
The pistons bolts are fixed in connecting rods
and free in pistons. Mount the pistons bolts by means of the
MOT 574-22 that is containing:
- a support for piston ( S);
- an extracting mandrel ( M);
- the piston supporting bushings (B);
- the bolts for mounting ( A) provided with
their centering guides (C ). Use an electric plate of
1500 W (electric
oven) for connecting rods heating. Place the connecting rods on the electric
plate so that connecting rod end surfaces are
in contact with the heating plate.
Check if the pistons bolts are freely gliding
in the new corresponding pistons. Mount the piston bolt E on the mounting
bolt A.
Sc rew the centering guide C till end and
then unscrew it for a quarter of turn.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 31
Mount the assembly i n the bl ock, as per
previous established sequence and check and
ensure that a 0.1 mm gauge is passing be-
tween jackets.
Dismounting – Remounting
MOT 484
Block the jackets by means of the device
MOT 484 or the clamps MOT 588.
M ount the base bearing on the cylinders
block. Hal-bearing lining that are mounted on
casing are provided with oiling holes.
The beari ngs lining are matching with the
crankshaft in two classes, as follows: Mount connecting rod bearings (connecting
rod bearings are the same) Lubricate the cranckpin and the bearings.
Mount the crankshaft and the axial bearings.
Mount the bearings caps. On the no.1 cap
(area K) apply a layer of LOCTITE 518, be-
tween 0.6 and 1 mm thick.
Tighten the bearings caps to a required mo-
ment of 2.5 daNm then to an a ngle of 43° ± 6°.
Check the axial clearance of the crankshaft,
which must be between:
*0.045 and 0.852 with wear;
* 0.045 and 0.252 without wear.
Marking on bearing
Red
Bl ue
Marking on crankshaft
A
B
Ide nt i dfi cation of m atching c lasses on
crankshaft i s performed by m arking on t he
balance-weight of bearing number 5. Marking example on crankshaft:
A AB AB
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 33
Mount the lower casing and tighten the
sc rews to the required moment of 1 daNm.
Sealing is performed using RHODORSEAL
5661; the l ayer D must be 3 mm thick.
Do not forget to replace the two half-moon
gasket (in area A ) with new ones.
Dismounting – Remounting
Mount the engine flywheel; the flywheel
attaching screws thread must be lubricate us-
ing LOCTITE FRENETANCH .
Block the engine flywheel by means of the
geared sector MOT 582 and tighten t he a t-
tachment screws to the required moment of 5
– 5.5 daNm.
Center the clutch disk and mount the clutch
mechanism (see chapter 20”Clutch”). Mount
the water pump (sealing is performed
using LOCTITE 518 ).
Apply a layer of sealant material H, 0.6 – 1
mm thick , according to the drawing.
Tight e n t he att achm e nt sc re ws to t he
required moment of 1 -2 daNm.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 34
CYLINDER HEAD REMOU NT I N G
Dismount the blocking device of the cyl-
inders jackets.
Mount: - cylinder head centering bushing on
the block; - cylinder head new gasket with the
marking “ TOP” upwards;
- cylinder head (lubricate the screws
ends and threads with engine oil).
REMARK:
In order to obtain a correct tighten-
ing of the cylinder head screws, remove
the oil that may be in the cylinder head
attachm ent whol es, by means of a sy-
rin ge.
CYL INDER HEAD TIGHTENING
METHOD
1. GASKET PRE-SETTING Tighten all screws to the required moment
of 2 daNm, then to an angle of 97° ± 2°,
observing the order indicated in the bellow
drawing.
Dismounting – Remounting
W ait for 3 minutes, stabilization time.2. CYLINDER HEAD TIGHTENING
Cylinder head tightening is to be performed
successive for the screws groups 1-2, 3-4,
5-6, 7-8 and 9-10; - unscrew 1-2 screws until total release;
- tighten the 1-2 screws to the required
moment of 2 daNm, then to 97°±2°
- repeat the releasin g and tightening op-
eration for the screws groups 3-4, 5-6, 7-8
and 9-10.
The cylinder head is not to be re-tight-
ened.
Continue by mounting: -rockers ramp, positioning item 1 from
the shaft towards distribution.
Tighten the ramp attachment screws 2 to the
required moment of 2.3 daNm, not be fore l u-
bricating with oil their heads and threads.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 36
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
indicating the rotation directio n and two marks
for setting. Line up the L item from the crankshaft gear
with the M fix item (item from camshaft gear
upward). AT T E N T I ON!
The camshaft gear may have five
marks; only the rectangular shaped mark
of one tooth is representing UDP (Upper
D ead Point), the ot hers are used for rock-
ers adjustment .
Dismounting – Remounting
Line up the i tems from the belt with t he
ones from the gears, observing the mounting
direction and starting from the crankshaft
gear. Place the MOT 1505 device captor (in
the position shown in the drawing) at a dis-
tance of 5-10 mm against the belt.
Any of the two captors may be used with
the condition that both captors are not in the
same time in front of the belt. Make vibrating the belt by means of a finger
(the measurement is validated by a device “bip”)
Tighten the belt, by acting upon the tightening
roller by means of the MOT 1135-01 device,
until obtaining of a value between 210 and
275 Hz. Block the tensioning roller and tighten its nut
to the required moment of 3 daNm.
Rotate then, five and a half turns the crankshaft
(cylinder no2 in the rockers adjustment position).
Dismount the tensioning roller nut.
Tighten again the distribution be lt unt il
obtaining of a value between 145 and 185 Hz.
AT T E N T I ON!
If the v alue of 275 Hz is exceeded, the
belt can not be used and its replacement is
necessary.
Obligatory tighten the rollers nut 0 to the re-
quired moment of 5 daNm.
If not, this may unloose ri sking t he e ngine
damage.
REMARK:
Once a belt is dismounted, t his is not to
be remounted, but replaced.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 37
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”
Cylinders valves in balance
(exhaust end, admission beginning)
1
3
4
2 Adjust cylinder rocker
4
2
1
3
b) Method called “ exhaust valve maximum opened”
Rotate the engine (clockwise, as seen from distribution) until the exhaust valve of the cylinder
1 is reaching to the maximum opening and then adjust the clearance at the admission valve of the
cylinder 3 and the valve clearance of the cylinder 4. Proceed in the same way also for the others cylinders as per next table:
Exhaust valve
Maximum opened
1
3
4
2Admission valve to be
adjusted
3
4
2
1 Exhaust valve to be
adjusted
4
2
1
3
Dismounting – Remounting
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ENGINE E7J-26216
16 - 6
ALTERNATOR – STARTER
ENGINE STARTER
E7 J - 262 D 907 - M00 2T 13581
IDENTIFICATION
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.
- Blocked starter = the absorbed current is very high.
- Solenoid failure = the absorbed current is very low.
In order to perform the measurements, it is necessary the engine drive by means of the starter,
but stopping the engine starting.
To do that, disconnect the RPM sensor (located on clutch casing).
REMARK:
After performing this checking, erase by means of the CLIP tester, the possible failures
memorized by the computer.
St arter
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IGNITION AND INJECTION
17
17 - 20
DIAGNOSTIC CONDI T IONS
If wh en 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.
-w ater temperature, red by the water temperature sensor, is not situated between –6° and
119°C.
-atmosphe ric pressure is under 775mbar,
then the OBD diagnostics are not authorized until the next contact setting on. In order to have a correct operation of the OBD diagnostic system, no electric failure of the
injection system must exist, even if the lighting of the OBD indicator is not established. The catalyst and oxygen sensor diagnostics can not be performed in the same time, but one
after other.
When the catalyst or oxygen sensor diagnostics are under operation, the canister purging valve
is closed, and the adaptive values are “blocked” at the last existent value prior to a.m. diagnostics
starting. TESTS PERFORMING LOGIC
-Solve fa ilures of electric nature.
-Erase a ll failures by means of the CLIP tester
-Perform the “teaching” stage of all adaptive values by the injection system (if necessary).
OB D COMPLETE ACTIVATION BY MEANS OF CLIP TESTER
-Erase all memorized failures.
-Erase the “learned” values from UCE injection if further to an intervention on an injection
system component, a disturbance of the “learned” values took place (step-by-step engine, flywheel
or RPM sensor, etc).
RETENTIONS (“LEARNINGS”) NECESSARY FOR UCEINJECT ION FOR OBD DI AGNOSTIC
〈 COUPLING/SUPPLY RATE LEARNING (state “ET014 = cylinder recognition 1” is PER-
FORMED with running engine). This is to be performed as following:
-a deceleration with “cutting” of the petrol injection in the third gear of the gearbox, be-
tween 3000-3500 rot/min for at least 2 seconds,
-a second deceleration with ”cutting” of the petrol injection in the third gear of the gearbox,
between 2400-2000 rot/min, for at least 2 seconds.
〈 MIXTURE ENRI CHING ADAPTIVE LEARNING
In order to do that, it is necessary that vehicle is running observing in the same time the pressure
ranges men tioned in the chapter “ Enriching adaptive correction”.
〈 State “ET202 = OBD diagnostic of combustion misfires taken into consideration” must be
AC TIVE.
“On Board Diagnostic” diagnostic conditions
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IGNITION AND INJECTION
17
17 - 29
AFTER
REPARATION P
erform the operations from “recommendations” for reparation confirmation.
Fix a ny other possible failures.
Erase the failures memoriz ed by the injection computer.
Perform a conformity checking by means of the CLIP tester.
C heck the c onnection and the state of the de tonation sensor connector.
R eplace the sensor ’s connector if necessary.
C heck the tightening of the RPM sensor on the engine block
Fi x if necessary.
C onnect the 90 w ays terminal box instead of the injection c omputer then c heck the insulation,
continuity and absence of the parasite resistance on lines:
Pin 20 injection computer > p in 1 detonation sensor
Pin 79 injection computer > p in 2 detonation sensor
Pin 19 injection computer > RPM sensor sc reening
Fix if necessary
If the problem is persisting after these checking, fix the other failures the n perform the conformity
checking.
RE CO MMENDATIONS
Conditions for diagnostic application for memorized failure:
Perform a road test with warm and in charge engine.
* If the failure is memorized with OBD indicator on, check in the context part,
if state “ET289 : Detonation sensor cir cuit” corresponding to the OBD
i ndicator lighting request is affirmative. In this case , proceed as per bellow
m entioned method.
Diagnostic – Failures interpretation
DF006
P RESENT
OR
ME MO RIZEDDETONATION SENSOR CIRCUIT
1. DEF : Open circuit or short-circuit
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