ESP DACIA SOLENZA 2004 Repair Manual

ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 25
Lubricate the camshaft with engine oil.
Mount the camshaft and its clamp.
Check the camshaft axial clearance, which
must be between 0.06 mm and 0.15 mm , in
case this one i s not corresponding, check the
clamp and the camshaft.
Dismounting – Remounting
Mount : -camshaft sealing gasket by means of
the MOT 1127 – 01 device. - thermostat support;
Loctite 518 is to
be used for its sealing. The l ayer H must be 0.6 till 1 mm thick
and is to be applied as per the following dia-
gram.
-camsha ft gear.
Camshaft gear is to be blocked by means
of the MOT 799 – 01 device and tighten its
a ttachment screw, to the required moment of
4.5 daNm (lubricate the screw head and
thread with engine oil).
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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-26211
11 - 4
DISTRIBUTION SYSTEM
56
Cylinder head gasket
Dismount the hoses from the thermostat sup-
port.
Dismou nt :
- compressor (see chapter 62 “Air con-
ditioning”); -power steering pump (see chapter 36”
Power steering pump );
- alternator (see chapter 1 6 “Alterna-
tor” ); -
oil gauge guide;
- thermal screen;
- multi-purpose support;
- exhaust manifold.
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; - cylinder head.
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ENGINE E7J - 26214
14 - 3
ANTI-POLLUTION
Pet rol vapors re-aspiration
1
4
3
2
Petrol vapors re-aspiration
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 – When conditions for purging valve
controlling are accomplished and this one is
not opening, check its controlling electri c
circuit (between UCE injection pin 4 and
purging valve), from point of view continuity
or short-circuit. The RCO value of the signal received by
the purging value from the computer, may be
red by means of the CLIP tester in PR 023.
The minimal value is 0.7 % (corresponding
to the closing position of the purging valve).
LOCA TION – DISMOUNTING
The carbon can assembly ( 1) with
incorporated purging valve, is placed on the
front right wing lining. Disconnec t the piping ( 2) coming from the
tank and piping ( 3) to the engine.
Di sconnect the electric connector ( 4) of
the purging valve. Remove the can from the attachment
support. Perform the dismounting operations
in
the reverse order REMOUNTING
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IGNITION AND INJECTION
17
17 - 1
PRESENTATION
The system is composed of : -electronic control unit (UCE injection);
-a double ignition coil;
-f our spark plugs;
- spark plugs cables.
OPERATING PRINCIPLE
Subject to the information received from different sensors, but mainly subject to engine RPM
and charge, the electronic control unit will establish the advance at ignition, will identify the cylinders
being at upper dead point and consequently , will control the corresponding coil to them.
This is producing the spark at the level of the two cylinders being at upper de ad point,
interrupting the mass connection of the corresponding coil.
Ignition system
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IGNITION AND INJECTION
17
17 - 14
The e ngines equipped with UCE injection type SIRIUS 32 are provided with oxygen sensors, as
follows:
-one up stream oxygen sensor – for engines corresponding to EURO 96 de-pollution norms.
- one upstream oxygen sensor and one downstream oxygen sensor – for engine s corresponding
to EURO 2000 de-pollution norms.
OXYGEN SENSORS HEATING
Oxygen sensors heating control is given by UCE injection as follows: -for up stream oxygen sensor – starting with engine starting.
-f or downstream oxygen sensor – after a certain time from engine starting, imposed by the
UCE injection charts, being subject to engine RPM and water temperature, red only when the
accelera tion pedal is not released.
UPSTREAM OXYGEN SENSOR VOLTAGE
After connecting the CLIP tester select “ Injection Diagnostic” and refer to “PR009 parameter:
Upstream oxygen sensor voltage”. The displayed value, expressed in mV, is representing the voltage
supplied towards UCE injection by the oxygen sensor placed upstream as the catalyst. When the
engine is running in the “closed loop” phase, voltage must fluctuate quickly between the following
lim i ts :
-20 mV ± 50 for poor fuel mixture;
-840 mV ± 70 for rich fuel mixture.
Smaller is the difference between these two limits, less good the sensor information is
(g en erally this difference is of 500 mV).
DOWNSTREAM OXYGEN SENSOR VOLTAGE
After connecting the CLIP tester select “ Injection Diagnostic” and refer to “PR010 param-
eter: Downstream oxygen sensor voltage”. The displayed value, expressed in mV, is representing
the voltage supplied towards UCE injection by the oxygen sensor placed after the catalyst. This
sensor has the purpose to catalyst diagnostic and to perform a second checking, more exactly, of
the fuel mixture enriching. This function is becoming active only after a certain time of engine
running at warm and it is not active in the engine idling phase.
When the engine is running in “closed loop” phase and at stabilized speed, voltage must fluctuate
ha ving between the maximal and minimal limits a difference of 600-mV ± 100. At deceleration,
voltage mu st be under 200 mV.
Enriching adjustment
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IGNITION AND INJECTION
17
17 - 19
CONDITIONS OF OBD INDI CATOR L IGHTING
During driving it is possible that certain functions are not subject to diagnostic (for instance due
to crowded traffic driving).
Indicator lighting -it is occurring if the same OBD failure is detected during three consecutive driving or
fu rther to an electric failure.
Indicator blinking -it is occurring if combustion misfires are detected, that may cause the catalyst damage.
Indicator off
- it is occurring if the OBD failure is not happening during three consecutive driving, but the
fa ilure in cause will remain memorized by the UCE injection.
In orde r to cancel the failures memorized by the UCE injection, failures must not be detected
du ring 40 consecutive tests (or to perform the erasing of the memorized failures, by means of the
CLIP te st er).
O BSERVATION : if a previously detected failure has been not detected again, then the cause
may be: -driving type performed by the end-user, not driving exactly in the conditions imposed for
fa ilure detection;
-rando m character (non-permanent) of the respective failure.
“On Board Diagnostic” lighting conditions
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IGNITION AND INJECTION
17
17 - 23
RE PARATI ON CONFI RM ATI ON
Check by means of the CLIP tester, the bellow states, which must have the following configu-
ration:
- ET 103: Catalyst diagnostic taken into consideration ------------------------------ ACTIVE
- ET1 07: Catalyst diagnostic performed ---------------------------------------------- ACTIVE
-n o functional failure of the catalyst is detected by the CLIP tester.
Th e purpose of the oxygen sensor diagnostic is to detect a disturbance leading to exceeding the
OBD step, caused by the HC polluting emissions. Diagnostic is performed by measuring and
co mparing the oscillating periods of the values red by the oxygen sensors.
Th e po ssible degradations of the oxygen sensors, are of two types:
-m echanical degradation of the electric component (case, wire broke) which is to be de-
fined as electric failure.
-c hemical degradation f the component, leading to a retardation of the sensor responding
time, consequently an increase of the minimal/maximal oscillating period. When the test conditions are accomplished, perform the average of the periods pointed out by
the sensor, retrieving the parasite effects, which are compared with an OBD step average period.
TEST PE RFORM ING CONDITIONS
Diagnostic of the oxygen sensor can be not performed but after a certain engine running time
an d in some specific established operation conditions and if the preliminary conditions, achieved
when setting the contact n, are achieved and preserved: -no electr ic failure
-c orrect performing of the “learnings” by the UCE injection and of the cylinders recognition.
-n o detected combustion misfire.
-N on-performing of the oxygen sensor diagnostic after contact setting on.
-water temper ature to be over 75°C
Engine Speed Regime Manifold pressure Stabilization period Time before authorization (Km/h) (rot/min) (mbar) (s ec)(min)
Oxygen sensor diagnostic
E7J 63-130 1792-3712 299-799 5 14
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IGNITION AND INJECTION
17
17 - 25
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
elem ents:
-D iagnostic Technical Note
-F unctional electric diagram of the respective vehicle
-CLIP technic al tester, 90 ways terminal (ELE 1497).
DIAGNOSTIC PE RFORMING STEPS
- CLIP tester connection to the diagnostic socket for identification of the SIRIUS 32 computer
type, of the “E1” program and the diagnostic variant “10”.
- Informati on identification in the document “Diagnostic” corresponding to the injection system.
- Reading and observing of the working instructions presented in the diagnostic documentation.
- Reading of the failures memorized by the injection computer, by means of the CLIP tester and
caus es identification by means of chapter “ Failures interpretation”
DO NOT ERASE T HE MEMORIZED FAILURES BEFORE RE ADING THEM BY MEANS OF THE CLIP TESTER
Write the memorized failures, after having previously red by means of the CLIP tester, in order
to be taken into consideration and treated, if these are to be themselves erased.
1. Treat all existent failures.
2. Memorized failures:
Perform the operations mentioned in “Recommendations” corresponding to each failure, in order
to confirm the failure.
If the failure is becoming present, then it must be treated.
3. For vehicle provided with OBD.
If the failure is memorized and the OBD indicator is on, read the failure context remarks, the
co rres po nding state at” OBD indicator lighting requesting”, in order to establish if this is the cause
for i ndicator lighting.
In such case, treat the failure as being present.
REMARK : the state “ OBD indicator lighting requesting” may be YES or NO and may be
co nsulted by selecting menu “ FUNCTIONS”, then OBD INDICATOR LIGHTING”.
Perform the conformity checking (evidencing of eventually disturbances not yet declared by the
system self-diagnostic). Validate the reparation performing (failure cause elimination).
Take benefit of the information from the failure-locating tree, in case the problem is persisting.
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