engine DACIA SUPERNOVA 2004 Owner's Guide

ENGINE E7J-A-2/6010
10 - 21
ENGINE AND LOWER ENGINE UNITS
CAU T ION!
Avoid introducing foreign bodies
into the oil grooves and tubes; you may
risk blocking up the holes of the rocker
arms and rapidly deteriorating the
cams an d the gliding parts of the
rocker-arms.
The checking of the planeness of the
cylinder he ad i s to be done with a rul er
and a set of t hickness gauges
Maximum distortion allowed: 0.05 mm.
No rectification of t he combustion he ad
is authori zed.
R
E-MOUNTING
Oil all the parts.
Mount the valve oil-seal rings no. 2 by
means of a tubular-wrench of 11 size onto
the valve guides no. 3;
Mount in the fol lowing order:
-the washers no. 1 at the base of the
valve springs;
-the new valves no. 4.
-the springs no. 5 are identical for
both intake and exhaust; -caps no. 6;
Compress springs no. 5, then m ount the
s emi-cones no. 7, which are identical for
both intake and exhaust.
CYLI NDER HEAD
CAU T ION!
They must have the same line-up
marking (8) as the old ones in order
to avoid the destruction of the valve -
stool set.
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ENGINE E7J-A-2/6010
10 - 22
ENGINE AND LOWER ENGINE UNITS
To mount: -camshaft annular oil seal by
means of t he MOT 1127-01 device;
-the thermostat stand.
Fo r watertight sealing, use Loctite 518.
Gir dle H must be 0.6mm up t o 1 mm
thick; it is applied in keeping with the fol-
lowing schema:
-the pinion of the cam-shaft is fixed
w ith the MOT 799-01 device, then the
thread and the end of t he scre w are oiled
and the scre w is tightened at 4.5 daNm.
CYLINDER HEAD
R
E-MO UNT ING
Oil the cam-shaft .
Mount the cam-shaft and its flange.
Check the axial play, which has to be
within 0.06 mm and 0.15 mm; in case it
does not fi t, check the flange or the cam-
shaft.
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ENGINE E7J-A-2/6010
10 - 23
ENGINE AND LOWER ENGINE UNITS
THE CYLINDER CRANKCASE
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ENGINE E7J-A-2/6010
10 - 24
ENGINE AND LOWER ENGINE UNITS
DIS M O UNT ING
The following are dismounting:-the water conduit and the oil-l evel-
gauge guide; their watert ight sealing is
done with rubbe r rings which must be re-
placed for every dismantlement; -the clutch;
-t he engine flywhe e l, bl oc ked by
means of MOT 582;
-the lower c rankcase;
-the pinion of the crankshaft;
-the stretching runner/ pulley;
-the water-pump;
-the oil-pump
Per f o r m co nn e cting rods caps
identification in regards t o connecting rod
body. To
be taken off:
-the caps of t he connecting rod a nd
the bushes;
-the jacket-maintaining device;
the jacket-piston-rod set; -the bearing caps and their bushing;
-the shaft and the axial play bushes;
-the bushes on the block.
The axes of the pistons are taken apart .
The piston is placed on i ts stand, after
positioning the piston bolt (a xis) with the
release hole (t wo lines T for position-find-
ing the centre of the hole will make align-
ment easier). The bol ts are taken off in a pressing-
machine by means of the E extraction
CAUTION!
Do not use punchers for line-
up m arking in order to avoid fis-
sures; use an indelible pen.
THE CYLINDER CRANKCASE
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ENGINE E7J-A-2/6010
10 - 25
ENGINE AND LOWER ENGINE UNITS
Re-Mounting
Cl e a n t he c ra nkc a se, e spe c ial ly t he
jacket-sealing part .
Preparation of the pi st o n- and-jacket set
The parts supplied in the collection are
matched. Do the line-up marking of the set, from
A to D, in orde r to keep the pa rts matched.
Remove completely the anti-rust fi lm;
never era se the parts.
These engines are equipped with rub-
ber rings for jacket watertight-sealing;
these rings ensure only watertight-seal-
ing condition. The jackets lean directly
against the cylinder cra nkcase; extra
height X is achieved by the manufac-
turer.
The checking-up of the jacket extra -
height is done in the fol lowing way: -the jackets a re pl ace din the block
without their sealing-ring;
-extra-h eight X is checked by
means of the MOT.251 and MOT.252-01
devices.
THE CYLINDER CRANKCASE
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ENGINE E7J-A-2/6010
10 - 26
ENGINE AND LOWER ENGINE UNITS
RE-MOUNT ING
The jackets are positioned such a way as:
-the difference be tween two succes-
sive jackets should be max. 0.05 mm; -the extra-height should be placed i n
ascending order between cylinder s 1 and 4.
-the extra-height X must be within
0.02 mm and 0.09 mm;
-in case there is an erroneous extra -
height, it is c hecked a gain by means of a
new set of jackets in orde r to see whether
the cause is the block or the jacket; if not,
check the theore tical values of both the
block and the jackets. The A, B, C, D set is done over with
the correct extra -height obtained, then the
jackets, the bolts and the pistons are num-
bered from 1 to 4 (no. 1 towards the fly-
w heel), so that t he concorda nce with t he
corresponding connecting rods is found.
The axes of the pistons a re m ounted by
means of the MOT 574-22 device.
The axes of the pistons are fixed in the
rod, and loose in the pistons.
Check i f the axes of t he pistons slide
freely in the new corre sponding pistons.
The axis of piston E is mounted on the
mounting axis A.
The C centring device is screwed up to
the end and then unscrewed a quart er of a
rotation.
THE CYLINDER CRANKCASE
In order to heat the connecting rods an
electric range of 1 500 W is used.
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ENGINE E7J-A-2/6010
10 - 27
ENGINE AND LOWER ENGINE UNITS
The arrow marke d by the end of the
piston must be directed towards the
flywheel. The conne c ting rods d o not ha ve a
mounting dire ction, but the spurs of t he
s emi-bushes will be positioned on the same
side. For the assembly of t he piston and the
connecting rod, the following directions
will be observe d:
-jack B13 is set onto the stand and t he pis-
ton (with the arrow pointing upwards) is
fixed on the jack;
-the centri ng device and the axis of
the piston are oiled with motor oil; -the free sliding of the piston axis is
checked, as well as the positioning of t he
piston. When the base of the connecting rod
reaches the needed tempera ture (ca. 250
o),
the speedy mounting of the pisto n axis
should be done in the following manner: -the centring guide is introduc ed in
the piston; -the rod i s positioned in the piston;
-the piston axis is pressed up to the
end. It should be checked if the piston axis
remains retracted as to the outer diameter
of the piston for any position of the con-
necting rod in the piston. The “ rod-piston-ring” sets a re mounted
in the cylinder jackets by using the
mounting jack. The waterti ght - se a l i ng f i t t i ngs a re
mounted onto the cylinder j ackets.
THE CYLINDER CRANKCASE
The rings are mounted: -the oiling ring;
-the watertight-sealing ring (with the
“TOP” mark pointing upwards); -the compression ring (with the “TOP”
mark pointing upwards). The slits of the ri ngs being adjusted, they
shall never be altered; they are oiled and the
rings are positioned; the slit of t he oi ling ring
will be placed opposite a full part of its channel.
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ENGINE E7J-A-2/6010
10 - 28
ENGINE AND LOWER ENGINE UNITS
The set i s mounted i n t he c rankcase in the
previously established order, and it is made
su r e that a 0.1 mm-long we d g e p a sse s
between the jackets
The jac kets are bl oc ked by m e a ns of
MOT.484 stand.
Mount connecting-rod bearings
(connecting rod bearings are identical). The cra nkpi ns a nd t he be ari ngs a re
oiled. The bearing caps are mounted. On no.
1 cap ( in the K area ) a t hi n l ayer of
R HODORSEAL 5661 is applied.
The screws are tightened at 2.5 daNm,
and then at an angle of 43o+/-6o.
The axial play of the cranksha ft i s
checked; it must be within: * 0.045 and 0.852 with wear ;
* 0.045 and 0.252 without wear.
MOT. 484
THE CYLINDER CRANKCASE
Take up the bearings of bearing on the housing
cylinders . Half-be aring l iners t hat are to be
m ounted on crankshaft bearing are provided with
o iling holes.
Beari ng liners a re ma tchning with the
crankshaft in two classes, as follows :
Marking on be aring linersMarking on crankshaft
Red
A
Blue B
Identification of matching classes on
cranksha ft i s done by m a rki ng on t he
counter-balance from number 5 bearing
liner. Crankshaft marking example :
AAB AB
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ENGINE E7J-A-2/6010
10 - 29
ENGINE AND LOWER ENGINE UNITS
The axial bushes can have: 2.80 mm,
2.85 mm, 2.90 mm, 2.95 mm. The rod caps are m ounted and tightened
at 4.2 daNm.
To check:
-the horizontal play of the rods;
-the rotation of t he whole set.
To mount:
-the oi l-pump (c heck t he existence
of the c entri ng jacks); the screws are tight-
ened at 2.5 daNm;
-the pi nion and the c arrying c hain of
the oil-pump;
-the oil-seal ring on the front cap
(which is oi led), by means of t he MOT
550 device;
-the front cap of the crankshaft; the
w atertight-sealing is done with LOCTITE
518 (the girdl e must be 0.6 - 1mm thick);
-the oil-seal ri ng on no. 1 be aring -
by means of MOT 1129 - 01.
The bri m and the outer part of t he oil-
seal ring are oiled.
550
THE CYLINDER CRANKCASE
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ENGINE E7J-A-2/6010
10 - 30
ENGINE AND LOWER ENGINE UNITS
Mount the lower c asing and tighten the scre ws at a moment of 1daNm.
The watertight-sealing is done with RHODORSEAL 5661; girdle D must be 3 mm thick.
Do not forget to replace the two crescent-shaped fittings (in the A are a) with new
ones.
-the fl ywheel: beforehand oil t he face for t he pl acing of the flywheel on the crank-
s haft, using LOCTITE AUTOFORM; apply on the screws one drop of LOCTITE
FRENETANCH and tighten them at 5 - 5.5 daNm, after having blocked the flywheel
by means of the cogged sector MOT 582.
-the clutch (be cautious about the centring): scre ws are tightened at 2 daNm;
-the water-pump (the watertight-sealing is done with LOCTITE 518, the H girdle
must be of 0.6 - 1 mm). The screws are tightened at a couple of 1 - 2 daNm.
LOWER CASE
RE-MOUNTING
THIS OPERATION IS ALSO VALID IN CASE THE CRANKCASE IS RE- MOUNTED ON THE CAR (SEE PAGE 10-36)
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