wheel DACIA SUPERNOVA 2004 Owner's Manual

ENGINE E7J-A-2/6011
UPPER AND FRONT ENGINE UNITS
SPECIAL TOOL- AND-CHECK SETS
MOT.1202-01 -”CLIC” collar-pincers
MOT.1505 -Device for measuring belt tension
MOT.484 -Device for jacket maintaining -Wrench for angular tightening
-Pincers for elastic collar
TIG H TENING CO UPL E S (daNm )
S crew-nut of stretching runner/pulley 5
Screw of crankshaft pulley 2+68
o+/-6o
Screws of pendular suspension stand 6.2
Screw-nut of hydro-elastic buffer 3.7
Wheel Screws 7.5
Co mbustion-head Screws 2+97
o+/-2o
To take apart :
-the connector of the induction coil;
-the fue l hoses (t he going- and re -
turn circ uit); -the connectors of the injectors;
-the plugs of the sparks;
-the induction coil.
11 - 3
CYLINDER HEA D FITTING
D
IS M O UNT ING
The car is placed on a two-column lift -
ing stand; The battery i s disconnected;
The cooling circuit is emptied at the
jack situated at the lower pa rt of the radia-
tor; The distribution belt is taken apart (see
Chapter Distri bution Belt);
The following are taken apart: -air-filter;
-the c onnector of the c lapper-posi-
tion potentiometer (1); -the acceleration cable;
-the connector of the atmosphe ric
pressure sensor (2);
-the co nnector of the step-by-step
engine (3); -the connector of t he air temperature
sensor (4) on the intake collector;
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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 ENGINE17
IGNITION AND INJECTION
17 - 29
DIAG
NOSING-INTERPRETING THE DEFECTS
DEF ECT
PRE SEN TOR
MEMORIZEDINFORMATION ROTATION SENSOR
1. Faulty cogs of the engine flywheel
2. Absence of flywheel signal.
In orde r to do this type of diagnosing, the sensor for atmospheric pressure
mu st not be faulty
Conditions of breakdown detection by the calculator:
-the contact is taken and the dialogue with the calculator is waited for to
be lo st, then the dialogue with the calculator is re-entered and the memo-
rized defec ts are erased
-opera te the starter for 10 seconds or start the engine and keep it in idle
m ode.
Condition of performing the diagnosing:
-defec t is present
-the defect has been memorized but is recorded in the “present” state.
Check the connection and the state of the rotation sensor
Change the connector if necessary.
Check the resistance of rotation sensor.
Remedy rotation sensor if necessary.
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 54 of calculator
♦ pin A of rotation sensor
pin 24 of calculator
♦ pin B of ro tation sensor.
Remedy if necessary.
Check the condition of the cogs of the engine flywheel.
Change the rotation sensor if the incident persists.
The proble m 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.
Er ase defects memorized by the computer.
Perform the steps under “Suggestions” to confirm the repair.
Remedy other possible defects.
AFTER
R EPAIR
12.
SUGGESTIONS
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 47
DIAG
NOSING-INTERPRETING THE DEFECTS
POLLUTING COMBUSTION MISFIRE
DESTRUCTIVE COMBUSTION MISFIRE
1. Combustion misfire during the last running done
2. Confirmed combustion misfire.DEFECT
PR ESENT
Combustion misfire at cylinder 1
Combustion misfire at cylinder 2
Combustion misfire at cylinder 3
Combustion misfire at cylinder 4.
Furnishe s informa tion c onc e rning the na ture and loc ation of bre a kdown.
SUGGESTIONS
31.
Connect the tester and select “Test of ignition”.
Watch the indications and replace the necessary parts.
Connect the tester and select “Test of compression”.
Watch the indications and replace the necessary parts.
Connect the tester and check the cogs of the flywheel.
Remedy if necessary.
If no defect is found ou
t, then there is a problem with the fuel-supply circuit. You must
check:
-p etro l filter
-f low and pressure of fuel
-condition of petrol pump
- if there are impurities inside the tank
-condition of injectors.
Remedy the elements of the fuel-supply circuit that are faulty.
Note down other functional defects.
Erase the defec ts memorized by the calculator.
Remedy other possible defects.
AFTER REPAIR
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 66
DIAG
NOSING-BREAKDOWN LOCALIZATION ALGORITHM
STARTING PROBLEMS
1.
Do not use this information before having done the complete check-up
with the tester!
SUGGESTIONS
♦♦
♦♦
Check if there is petrol in the fuel tank (do not rely on the
on-board in
dices). Check if it is the fuel recommended by
the manufacturer.
Disconnect the tube between the draining valve and the
intake collector and strangle it up. If the disturbances disap-
pear, the cause was the draining valve.
Connect the “CLIP TEHNIC” device to do this test in ac-
cordance with the usual manner of work.
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
unbloc k it.
Check the fuel
Check the canister
draining valve♦♦♦♦
Check the engine
co
mp ression
Check the
engine flywheel
Check the step-by-
step engine
♦♦ ♦♦
♦
♦
Check if there are no broken tubes.
Check the state of the sparking plugs and the ignition coil.
Check the tubes and
hoses
♦♦♦♦
Check the ignition♦♦♦♦
Check the flow and the pressure of the fuel: the condition
of
the petrol-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
♦♦♦♦
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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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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 70
DIAG
NOSING-BREAKDOWN LOCALIZATION ALGORITHM
Check if the clapper body is not clogged.
Check if there are cases of lack of watertightness (noise)
on the powe r-brakes.
Connect the tester “CLIP” and do the test corresponding
to the check-up of the rotation signal.
Check if the spurs, the brake cylinders and the wheel ball-
rings are no t seized-up.Check the body o f
the clapper♦
Ch eck t he power-br akes
Check the engine
flywheel
Check the running
train
Check the cooling
of the engine
♦
♦
♦
Check if there is enough engine cooling.♦
Check the canister
draining valve Disconnect the tube between the draining valve and the in-
take collector and strangle it up. If the disturbances disap-
pear, the caus
e was the draining valve.
Check the engine
comp ression Connect the “CLIP TEHNIC” device to do this test in accor-
dance w ith the usual manner of work.
AFTER REPAIR Erase the defec
ts memorized. If there are no other problems,
eras e the parameters memorized by the calculator.
♦
♦
A
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19 - 12
19
COOLING - EX HA U ST - FU EL TANK
DISMOUNTING
The car is set on a two-column lifting stand.
The ba ttery is disconnected.
Th e co oling circuit is emptied at the filling stopper placed at the lower part of the radiator.
The fo llowing are taken apart.
- the distribution belt (see Chapter “ Distribution belt”) ;
- the ex tending pulley / runner (1);
- the fixing screws of the water-pump.
The water-pump is taken out at the upper end of the engine compartment.
SPECIAL DEVICES
MOT. 1202-02 Pincers for elastic collars
MOT. 1505 Device for measuring the belt tension
TIGHTENING COUPLES (daNm)
Screw-nut for extending pulley / runner 5
Screw for the crankshaft pulley 2+68
o+/-6o
Screws for right-side pendular stand 6.2
Screw-nut for hydro-elastic buffer 4.4
Screws for water-pump 2.2
Screw-nuts for water-pump 1
Screws for wheels 7.5
WATER PUMP
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19 - 20
19
COOLING - EX HA U ST - FU EL TANK
DIS M OUNT ING
In order to take apart the petrol tank from the car the following opera tions are in order:
The battery i s disconnected;
The tank is emptied of fue l;
The carpet in the boot is taken out;
The cabling case of the fuel-level transmitter i s taken off;
The collar fi xing the airi ng conduit on the tank lid is taken off;
The junctures of t he fue l-supply c onduits (goi ng- and return-) are taken off t he tank lid;
The driving axis of the spare-wheel stand is taken off;
The car is suspended on an elevator;
The spare-wheel is taken out of i ts holder;
The scre ws fixing the protection screen of the tank, and then the tank itself, are taken
off; The collars fixing the anti-t ilt valve juncture are taken off.
R
EMOUNTING
It is done in the reverse orde r of the taking apart opera tions. T
ANK FUEL
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20
CLUTCH
CLUTCH DISC MECHANISM
REPLACEMENT
This operation is done after taking apart the engine - gearbox ensemble and after
their separation.
The stopping sector MOT 582 is mounted.
The screws fixi ng th e mechan ism are taken off.
The mechan ism and the clutch disc are taken apart.
Visual inspection is done: - wear of engi ne flywheel;
- co ndition of the starter crown;
- watertightness at the level of the crankshaft fitting;
- co ndition of the flywheel surface (it must not have scratches).
The fau lty parts are replaced and the grooves of the clutch shaft are cleaned.
SPECIAL DEVICES
MOT 582 Flywheel immobilizing sector
AMB 1518 Clutch centering device
TIGHTENING COUPLES (daNm)
Clutch mechanism screws 2
20 - 9
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