DACIA SUPERNOVA 2004 Workshop Manual

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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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;
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ENGINE E7J-A-2/6010
10 - 32
ENGINE AND LOWER ENGINE UNITS
DISTRIBUTION
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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
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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
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ENGINE E7J-A-2/6010
10 - 35
ENGINE AND LOWER ENGINE UNITS
2. Cam-Shaft pinion with line-up marks:The engine is wound until it reaches the Upper center point (c ylinder no. 1 at
ignition), then furt her up to the first line-up mark.
-what is adjusted: exhaust 1
exhaust 3
-for the second mark:
-what is adjusted: intake 1
intake 3
-for the third mark:
-what is adjusted: exhaust 2
exhaust 4
-for the fourth mark:
-what is adjusted: intake 2
intake 4
ADJUSTMENT OF ROCKER-ARMS
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ENGINE E7J-A-2/6010
10 - 36
ENGINE AND LOWER ENGINE UNITS
After the tu ning of the distri bution and the adjustment of the rocker-arms, the
following are further re-m ounted: -the cylinder-head cap, fitted with a new fitting; the screws are tightened at 1 daNm;
-the water-intake conduit and t he oil-level gauge guide (with new watert ight-
sealing ri ngs); -the cap of the distribution;
-the pulley of the crankshaft; the screw is first tightened at 2 daNm, then at 68
o+/-6o.
C
AUTION!
If the screw is not duly tightened, it c an come undone, which c an result in t he oi l-
pump not being operated and the distribution being disrupted, thus causing serious
damage to the engine.
-the intake and exhaust collectors: the screws are tightened at 2.5 daNm;
-the belt(s) of accessories: the same method as that for the distribution belt is used.
The stretching values are :
* alternator belt 263+/-10Hz
* Air-Comditioning (A.C) compressor belt 222+/-10Hz.
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