lock DACIA SUPERNOVA 2004 User Guide

ENGINE E7J-A-2/6010
10 - 31
ENGINE AND LOWER ENGINE UNITS
CYLINDER HEAD RE-MOUNTING
.The following are to be mounted:
-the jack for c ylinder-head centri ng
on the block; -the new cylinder-head fitting;
-the cylinder-head (aft er the stand
has been taken apart ); the joining surface
cylinder c rankcase- cylinder-he ad is care-
fully cleaned; -the cylinder-he ad scre ws (whose
threads and scre w-ends are oiled).
THE METHOD OF TIGHTENINGT THE CYLINDER-HEAD
1. Pre-compressing the fitting -a l l the scre ws a re tight ened at 2
da Nm, then at 97o+/- 2o, in th e or d er below:
-wait for 3 minut es - the
stabilization delay.
2. Combustion-head tightening-screws 1 - 2 are loosened till they
are totally free;
-sc rews 1 -2 a re ti ghte ne d at 2
daNm, t hen at 97
o+/-2o;
Screws no. 2 are tightened at
2.3 daNm , but nor before oiling the
threads. -the cylinder-head cap, without tight-
ening it (in orde r to be a ble then to set/
tune the distri bution); -the pinion of the crankshaft.
-t he op e ra t i on of l o ose n i ng a n d
tightening is repeated for the scre w groups
3-4-5-6-, then for 7-8-9-10.
The cylinder head is not restricted.To be mounted subsequently:
-the rocker-arm ra mp, by position-
ing marki ng no. 1 on the axis towards the
distribution;
RE CO VERY ENGINE
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ENGINE E7J-A-2/6010
10 - 33
ENGINE AND LOWER ENGINE UNITS
On the back of the be lt there i s an arrow
indicating the direction of rotation, and two
tuning marks; -the L line-up marks on the crank-
shaf t pi nion are aligned with the fixed mark M;
(the mark on the
pinion of t he cam-shaft in
down)
CAU T ION!
The pinion of the cam-shaft
ca n have five line-up marks: it is only
th e rectangular-shaped mark on the
face of a cog that represents the Up-
per Ce ntre Point, all the others serv-
ing to adju st the rocker arms.
-the marks on the belt are aligned
w ith those on the pi nions, observing t he
direction of mounting and be ginning from
the pinion of the crankshaft;
-the captor of the MOT 1505 appa-
ratus is placed (held in the position indi-
cated in the schema) at 5-10 mm to t he
belt. Any of the two captors can be used on
condition the t wo of them should not be
placed simultaneously in front of the belt.
The distribution belt is set in vibration (the
m easurement is validated by a beep of the apparatus).
-the belt is stretched by opera ting t he
str etching runner/pulley, until a value within
210 and 275 Hz is obtained;
-the stretching device is blocked, and its
screw-nut is tightened at 3 daNm;
-the crankshaft is wound 5 1/2 rotations
(no. 2 cylinder in the position of rocker-arm
adjustment); -the screw-nut of t he runner/ pulley is
stretched until a value between 145 and 185
Hz is obtained.
CAU T ION!
If the value of 275 Hz is ex-
ceeded, the belt can no longer be used,
and it ha s to be changed.
-the 0 screw-nut of the runner/pulley is tight-
ened at 5 daNm.
If not, this may get dismounted, ri sking the
engine damaging.
G
ENERAL DIREC TIONS
The stretching of the belt should only be done
for th e co ld engine mode (i.e. ambient temperature);
-a belt which has been taken off must not be re-
mounted - it will have to be replaced by a new one.
DISTRIBUTION
RECO VERY ENGINE
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ENGINE E7J-A-2/6010
10 - 34
ENGINE AND LOWER ENGINE UNITS
It is done only for the cold engine mode.
The adjustment values are:-intake 0.10 mm
-exhaust 0.25 mm
1. Cam-Shaft pinion without line-up marks
a) The method called “in balance”
Th e cylinder valves in balance (end of
exhaust; start of intake)
1
3
4
2
The cylinder rocker-arms are adjusted
4
2
1
3
b) The method called “exhaust valve opened to the maximum”
The engine is wound (c lockwise, as seen from the distribution) t ill t he e xhaust va lve
of cylinder no. 1 reaches maximum opening, and t he play is adjusted for the intake
valve of c ylinder no. 3, and also for the exhaust valve of cylinder no. 4.
The same is done for the other cylinders, as in the chart :
Exh aust valve open to the
maximum
1
3
4
2
Intake valve to be adjusted
3
4
2
1
Exhaust valve to be adjusted
4
2
1
3
ADJUSTMENT OF ROCKER-ARMS
RECO VERY ENGINE
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E7J-A-2/60 ENGINE16
16 - 5
ST ARTING AND CHARGING
The position of the alternator i s blocked.
The engine is revolved thre e and a half cra nkshaft turns;
The reading end of t he MOT. 1505 measuring device is placed in the measuring area;
The tension in the belt is measured;
It is checked whether t his fits i nto the mounting tension tolerance; if not, the belt will
be stretched again until the recommended tension ( 263 Hz +/- 10%) is reached.
The inspection a nd t he a djustment of the belt a re done with t he e ngine at ambient
temperature . Tighten at the require d moment, the alternator a ttachment screws :
- screw M10(lower attachment)-5 daNm
-screwM10 (upper attachment)-2.2 daNm.
Remark: Once dismounted, a belt is not to be remounted, but replaced.
MOT. 1505
MOT. 1505
AL
TERNATOR
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16E7J-A-2/60 ENGINE
16 - 6
ST ARTING AND CHARGING
DIS M O UNT ING
(in the air -conditioning variant)
The car is placed on a two-column lifting stand;
The electric connections are uncoupled from the battery;
The following are taken apart: -the top scre w of the alternator;
-the belt of the alternator;
The right-side front wheel of the car is taken apart;
The car is suspended;
The two screws fixing the shock-absorber on the steeri ng swivel stand are taken off;
The steeri ng swivel stand is lowered and the right-side planetary tra nsmission is taken
off the planetary pi nion of the gearbox; The electric conductors of the alternator a re disconnected;
The screw of the alternator is taken off;
The alterna tor is taken apart laterally past the right-side planetary tra nsmission.
R
E-MOUNT ING
The taking-apart opera tions are done in the reverse order;
The carrying belt of the alternator is stretched to obtain the mounting tension recom-
mended (263 Hz +/- 10% );
The position of the alternator i s blocked;
The engine is revolved thre e and a half cra nkshaft turns;
The reading end of the MOT. 1505 measuring device is placed in the measuring area;
The tension in the belt is measured;
It is checked whether t his fits into the mounting tension tolera nce; if not , the belt will be
str etched again until the re commended tension ( 263 Hz +/- 10%) is reached.
The i nspection and the adjustment of the belt are done with the engine at ambient
temperature .
Tighten at the require d moment, the alternator a ttachment screws :- screw M10 (lower attachment)-5 daNm
-screw M10 (upper attachment)-2.2 daNm.
Remark: Once dismounted, a belt is not to be remounted, but replaced.
AL TERNATOR
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E7J-A-2/60 ENGINE16
16 - 7
ST ARTING AND CHARGING
IDENTIFICATION
ENGINE STARTER
E7J - A-2/60 D 907 - M00 2T 13581
DIAGNOS TICATION
S pecial device: CLIP - SAGEM-TECHNIC TESTER which measures the battery
voltage and the intensity absorbed by the starter.
ANOMALOUS FUNCTIONING THAT CAN BE SETTLED
-Battery failure –contact drop on the starter when starting the engine.
-Blocked starter (t he absorbed curre nt is very high);
Coupling relay defect (the current absorbed is very weak).
In order to do the measurements one must carry t he engine in starter mode, thus pre -
venting the engine to run.
To do t hat, the revolution sensor (located in the c lutch cra nkcase) should be t aken apart .
Remark: After doing these tests, erase the possible defects memorized
by the calculator with the tester.
STA RTER
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 39
DIAG
NOSING-INTERPRETING THE DEFECTS
DETONATION SENSOR CIRCUIT
Breakdown of detonation signalDEFECT
PR ESENT OR
MEMORI ZED23.
Condition of breakdown detection by the calculator:
-do a route-test, with the engine heated and under high rotation
ra tio.
Condition of performing the diagnosing:
-the defe ct is present
-the defect has been memorized but is re corded in the “present” state.
SUGGESTIONS
Check the connection and the condition of the detonation sensor
Change the connector if necessary.
Check the mounting of the detonation sensor on the engine block.
Tighten to the couple the detonation sensor.
Connect the 90-way terminal-tester instead of the calculator and check the insulation,
the continuity and the absence of contact resistance along the circuits:
pin 20 of calculator -> pin 1 of detonation sensor
pin 79 of calculator -> pin 2 of detonation sensor
pin 79 of calculator -> detonation sensor screening.
Remedy if necessary.
If the incident persists, change the detonation sensor.
Th e pr ob lem is not yet solved! Consequently, the injection calculator must be changed.
CAUTION! The destruction of the calculator has probably been caused by an electric shock.
The cause of the destruction must be found before mounting a new
calcul ator.
Erase defects memorized by the computer.
Perform the steps under “Suggestions” to confirm the repair.
Remedy other possible defects.AFTER
REPAIR
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 67
DIAG
NOSING-BREAKDOWN LOCALIZATION ALGORITHM
IDLE MODE PROBLEMS
Do not use this information before having done the complete check-
up w ith the tester!2.
SUGGESTIONS
Check if there is petrol in the fuel tank (do not rely on the
on-board indi ces). Check if it is the fuel recommended by
the manufa cturer.
Check the fuel

Check if there are no broken tubes.
Check the tubes and hose
s.
♦
♦
Check the state of the sparking plugs and the ignition coil.
Check, on the o il ga uge , if the le ve l of the oil is not too h igh.
Connect the tester “CLIP” and do the test corresponding
to the check-up of the rotation signal.
Gently touch the step-by-step engine in order to possibly
unblock it.
Check the condition of the fittings.
Check, after taking them apart, whether the injectors leak.
Check if the clapper body is not clogged.
Check the ignition
Check the engine oil level
Ch eck the step-by-step engine
Check the intake collector
Check the injectors
Ch eck the body of the clapper
♦
♦
Check the engine flywheel♦
♦
♦
♦
♦
Check the flow and the pressure of the fuel: the condition
of the pe trol-pump, of the pressure regulator. Check the
injectors (flow, shape of jet)
Check if the exhaust circuit is not strangled-up and the
cata lyst is not stopped-up.
Check the fuel-supply
circuit
Check the exhaust system
♦
♦
A
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19 - 6
19
COOLING - EX HA U ST - FU EL TANK
COOLING FAN REPLACEMENT
for vehicles with air conditioning
1 6 5
3 2 4
7
8
DISMOUNTING
Di
sconnect the (-) plug of the battery.
Di sconnect the cooling fan connector (5).
Di sconnect the cooling fa n resistance connector (1). Mark t he mounting position iden-
tification of the two connectors.
Detach the wiring from clip (6).
Cut the clip attaching the wiring on the cooling fan assembly in point (7).
Dismount the four-attachement screws (3) of the cooling fan on the radiator, recovering the
washers (2) and (4). Remove the cooling fan assembly.
REMOUNTING
Check the condition of the fan propeller, cooling fan electri c motor, washers.
Tighten the attachement screw (3) of the assembly.
Replace the clip from point (7).
Mount the wiring of t he cooling fan assembly taking i nto the considera tion the mount-
ing position m arked before dismounting. This is to be fi xed by means of a clip in point (7)
and will pass trough the clip (6). Connect the cooling fan re sistance connector (1).
Connect the cooling fan c onnector (5). Observe t he m ounting position i dentification of
the two connectors. Connect the battery plug (-). In case the vehicle is equipped with progammable radio-
cassettes, electronic clock, e tc, these a re to be reset before returning the vehicle to t he client. Check t he c ooling fan opera tion: start the vehicle engine and disconnect the water
temperature sensor. The cooling fa n must start. Reconnect the water t emperature sensor,
then by means of the CLIP tester, erase the memorized failure related to the water t em-
perature sensor.
FAILURES
ERASING
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19 - 9
19
COOLING - EXHA U ST - FUEL TANK
RESISTANCE COOLING FAN REPLACEMENT
for vehicles with air conditioning
De scription of t he opera tion :
Di sconnect the battery (-) term inal.
Di sconnect the resistance connector.
Di smount the two attachment screws of the re sistance.
Position the new resistance assembly.
Mount the two attachment screws of the resistance (tightening moment 4.5 Nm).
Connect the resistance connector.
Connect t he battery (-) terminal. In case the vehicle is equipped with programmable
radio-cassettes player, electronic clock, etc, those are to be re-programmed before return-
ing the vehicle to the client. Check the engine motor fa n operation.
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