DACIA SOLENZA 2004 Workshop Manual

ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 26
CYLIND
ERS BLOCK
Dismounting – Remounting
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 27
CYLINDER S BLOCK DISMOUNTING
Dismount :
- water inlet pipe and oil dipper rod
guide ( their sealing is performed by means of
rubber rings that must be replaced at each dis-
mounting); - clutch;
-engine flywheel, immobilized by means
of the MOT 582 ;
- lower crankcase;
-cr ankshaft gear;
- tightening roller;
-cr ankshaft closing casing;
Dismounting – Remounting
- water pump. Dismount
the oil pump attachment screws.
Dismo unt the oil pump and its driving chain.
Ma rk the connecting rod caps compared
with the connecting rod body.
AT T E N T I ON!
Do not use punches for marking in or-
der to avoid cracks occurring; a perma-
nent marker is to be used.
Dismo unt
- connecting rods caps and the bearings;
- jackets maintaining device MOT 484 or
clamps MOT 588 ;
- assembly jackets-pistons-connecting
rods; - bearings caps a nd their bearings;
- crankshaft and axial clearance bearings;
- bearings from the cylinders block.
PISTONS SHAFTS DI SMOUNTING
Place t he piston on the support lining up
the piston bolt (shaft) with the gap whole from
the support (two T lines for marking the whole
center are facilita ting the lining up).
Remove the bolts using a press by means
of the extraction mandrel E.
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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 - 30
The arrow marked on the piston head must
be oriented towards engine flywheel. The c onnecting rods ha ve no mounting
direction, but the ha lf-bearings spurs are to
be positioned on the same part. In order to assemble the piston and the
connecting rod, proceed as follows: -place the bushing B 13 on the support
and attach the piston (with the arrow oriented
upwards) on the bushing;
Dismounting – Remounting
- lubricate the centering guide and the
piston bolt with engine oil;
- check t he free gliding of the piston
bolt and the piston positioning.
When the connecting rod end is reaching
the necessary temperature (about 250 °C),
proceed to the ra pid of the piston bolt, as
follows: -introduce the centering guide in the
piston; - position the connecting rod i n the
piston;
-press till end the piston bold.
Check if the pi ston bolt is remaining re -
tired as against the piston outer diameter for
each of the connecting rod position in the pis-
ton.
Rings mounting
Mount the rings on the pi ston in the
following sequence: -
oiling ring ( 3);
-s ealing ri ng (2) w ith the mark “TOP”
upwards; -compression ri ng (1) with t he mark
“TOP” upward. The compression and sealing rings are to be
mounted with the slots disposed at 90° against
de bolt’s axle and displaced between them with
180°. The oiling ring is to be mounted with the
slot oriented at 45° against the bolt’s a xle.
The rings slots being adjusted, shall never be
reworked.
Lubricate the pistons with engine oil.
M ount the assemblies “connecting rod-
piston-rings” in the cylinder’s jackets, by means
of the mounting bushing. Mount the sealing gaskets on the cylinder
jackets.
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ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 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 - 32
The axial bearings may have the following
thickness: 2.80, 2.85, 2.90, 295 mm.
M ount the connecting rods caps and
tighten to the required moment of 4.2 daNm.
Check:
-connecting rods lateral clearance;
- assembly rotation.
Mount: -gear and driving chain of the oil pump;
- oil pump (check the existence of the
centering bushings) and tighten the screws to
the required moment of 2.5 daNm;
Dismounting – Remounting
MOT 550
- the crankshaft closing casing; the
sealing is performed using LOCTITE 518 (
the layer H must be 0.6 – 1 mm thick);
- sealing gasket from crankshaft clos-
ing casing (lubricated with oil) by means of
the MOT 550 device;
-crankshaft sealing gasket towards fly-
wheel (at no. 1 bearing) by means of the MOT
1129-01 device. Lubricate the sealing gasket external part
and lip with engine oil.
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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 - 35
DISTRIBUTION
Dismounting – Remounting
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