air filter DACIA SUPERNOVA 2004 Repair Manual

01 SPECIFICATIONSEngine – Clutch - Gearbox............................. 01-1
Vehicle identification.. ................................. 01-2
02 LIFTING Mobile jack - Protection route;....................... 02-1
Elevator positioned under the carriage body... 02-3
03 TOWING All types.......................................................... 03-1
04 LUBRICANTS CONSUMABLES Condition....................................................... 04-1
05 DRAINING – FILLING Engine............................................................ 05-1
Gearbox.......................................................... 05-2
07 VALUES AND SETTINGS Dimensions..................................................... 07-1
Capaci ty - Qualities........................................ 07-2
Driving belts tightening and accesorie s.......... 07-3
Distribution belt tension................................. 07-4
Cy linder head tightening................................ 07-5
Wheeles and tyres........................................... 07-6
Br akes............................................................. 07-7
Dimensions under carriage body.................... 07-8
C hecking values of the fr ont axle angles........ 07-9
C hecking values of the rear axle angle s......... 07-10
10 ENGINE AND LOWER ENGINE UNITS Ingredients...................................................... 10-1
Motor-propelling group.................................. 10-2
Separation - Dismantling................................ 10-7
Characteristics................................................ 10-10
Rec overy engine.............................................10-17
Lowervcrankase..............................................10-37
Oil pump........................................................ 10-38
Tightening moments....................................... 10-39
11 UPPER AND FRONT ENGINE UNITS Distribution belt............................................. 11-1
Cylinder head fi tting....................................... 11-3
12 FUEL MIXTURE Characteristics................................................ 12-1
Cl apper body .................................................. 12-4
Intake cole ctor................................................ 12-5
Exhaust collector............................................ 12-6
13 PUMP SUPPLY
Br eaking fuel supply ..................................... 13-1
Injection pump............................................... 13-2
Petrol filter.................................................... 13-3
P upm flow...................................................... 13-4
Supply pressure.............................................. 13-5
14 ANTI-POLLUTION Petrol vapours-aspiration ............................. 14-1
16 STARTING AND CHARGING Alternator....................................................... 16-1
Starter............................................................. 16–7
17 IGNITION AND INJECTION Ignition system.............................................. 17-1
Sparking plugs.............................................. 17-2
Peculi arities.................................. ................ 17-3
Placi ng of elements........................................ 17-4
Idling regime adjustment............................... 17-9
Adjustment of the fuel mixture enriching...... 17-11
Enriching adaptive correction....................... 17-12
Diagnosing-Introduction... ............................ 17-15 Diagnosing-Interpreting the defects.............. 17-17
Diagnosing-Conformity test........................... 17-49
Diagnosing-Interpreting the states................. 17-55
Diagnosing-breakdown localization
algorithm....................................................... 17–66
19 COOLING - EXHAUST - FUEL TANK Characteristics............................................... 19-1
Filli ng and draining ...................................... 19-2
C ontrol.......................................................... 19-3
The schema.................................................... 19-4
Ra diator dismounting and remounting.......... 19-5
C ooling fan replacement
for vehicles with air conditioning................. 19-6
C ooling fan diagnostic
for vehicles with air conditioning................. 19-7
Re sist ance cooling fan replacement
for vehicles with air conditioning................. 19-9
C ooling fan replacement
for vehicles without air conditioning............ 19-10
C ooling fan diagnostic
for vehicles with air conditioning.................. 19-11
Water pump .................................................. 19-12
Dismounting - remounting exhaust................ 19-14
Emptyng of tank............................................ 19-16
Tank fuel description..................................... 19-17
Tank fuel....................................................... 19-20
Electric petr ol pump...................................... 19-21
20 CLUTCH Identification................................................. 20-1
Diagnostic.. ................................................... 20-3
Clut ch disc mechanism.................................. 20-9
Moteur et peripherics
General poinds vehicle0
1
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21 MANUAL GEARBOXSecti ons.......................................................... 21-1
Identification ................................................. 21-2
Tightening moments...................................... 21-3
Ratios ............................................................ 21-4
Capacity, lubricants....................................... 21-5
Particul arities................................................. 21-6
Ingredie nts..................................................... 21-7
Parts of systema tic replacement.................... 21-8
S pecial tools.................................................. 21-9
Gearbox dismounting ................................... 21-10
29 DRIVE SHAFTS Front transversa l transmission........................ 29-1
Bell ows - Be aring assembly to
t he gearbox.................................................... 29-4
Bell ows to wheel........................................... 29-7
Be llows to gearbox....................................... 29-12
Bell ows to wheel........................................... 29-15
30 GENERAL General principle sc hedule
of the brake circuit........................................ 30-1
Tightening moments...................................... 30-2
Com position and dimensions
of the ma in braking system elements............ 30-6
Br aking system diagnostic............................ 30-7
Br ake connections and se werage.................. 30-12
Br ake fluid.................................................... 30-13
Br aking circuit purging................................. 30-14
The inf luence of the front axle angle s on
t he road behaivior (vehicle comportment)
and on tyres wear........................................... 30-16
Prelimi nary checking..................................... 30-17
C hecking of the front axles adjustment......... 30-19
31 FRONT BEARING ELEMENTS Characteristics... .......................................... 31-1
Sus pension arm... .......................................... 31-2
Elastic bushings of suspension arm............... 31-4
Sus pension ball joint..................................... 31-5
Br ake gaskets................................................ 31-6
Br ake caliper................................................. 31-7
Br ake disk..................................................... 31-9
St eering knuckle............................................ 31-10
St eering knuckle bearing. .............................. 31-12
Fr ont suspension............................................ 31-13
Shock absor ber, Sprint. ................................. 31-14
Sp ring assembly shock absorber................... 31-15
Anti-roll bar................................................... 31-17
33 REAR BEARING ELEMENTS Characteristics............................................... 33-1
Rear axle....................................................... 33-2 Re
ar suspension............................................ 33-4
Shock absorber............................................. 33-5
Spring ........................................................... 33-6
Br ake drum................................................... 33-7
Br ake cylinder.............................................. 33-8
Br ake shoes.................................................. 33-10
Be aring (25 x 52 x 37)................................ 33-12
35 WHEELS AND TYRES Characteristics.............................................. 35-1
Wheels balancing......................................... 35–4
36 STEERING ASSEMBLY Axial ball joint............................................. 36-1
Steering box................................................. 36-3
Pus her........................................................... 36-4
Noise absorber bearing................................. 36-5
Bell ows......................................................... 36-6
Deformable lower shaft................................ 36-7
Ste ering weel position adjustment................ 36-9
37 MECHANICAL ELEMENTS CONTROLS Brake pump.................................................. 37-1
Servobrake................................................... 37-6
Air filter – se rvobrake reta iner valve........... 37-9
Handbrake adjustment.................................. 37-10
Handbrake control lever............................... 37-11
Handbrake secondary cable.......................... 37-12
Br ake flexible hoses..................................... 37-14
Br ake pressure controller.............................. 37-16
clutch hydraulic control................................ 37-19
The gear control........................................... 37-23
Pe dals support.............................................. 37-25
Acceleration pedal....................................... 37-26
Acceleration contr ol cable........................... 37-27
Transmission2
Chasis3
SION
LL
NT
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SPECIFICATIONS
01
VEHICLE IDENTIFICATION
a.. Manufactu rer identification code;
b. Code of the vehicle;
c. Gearbox ty pe code;
d. Engine type code and driving location ( according to VIN code structure);
e. Vehicl e code;
f. Trailer ma ximum authorized weight without braking system;
g. Homologation number for the importer country;
h. VIS sign-one character for year model code + 7 characters for the chassis manufacturing number;
i. Maximum technical admissible weight of the loaded car;
j. Maximum admissible weight with trailer with braking system;
k. Maximum technical admissible weight on front axle;
l. Maximum technical admissible weight on rear axle.
LABEL T YPE OVAL PLATE
The se lf- adhesive label type oval plate is stuck on the right lateral side surface of the
dashboard. This enables the identification of the vehicle type and of its equipment, being exclusively
used fo r after-sale activity.
01 - 3
1,1
2,1 2,2
4,1 4,2
The reading of the codes marked on the oval plate type label
Caption:
Line 1
1.1 Cod type auto APV (after-sale):
B41A(E U 9 6 ) B41B(EU00) B41D(1 5 .04)
Line 2
2.1 Le vel of equipping: E0, E1, E2, E3
2.2 Options eq uipping code:
Line 4
4. 1 Technical definition code, driving place.
S2 : Left hand drive
4.2 Options equipment code: A: Normal suspension K: Without pre-filter
C : Temperate climate M: Steering mechanical system
E: Warm climate R: Without variable shock absorber
F : Normal heating T: Without plate corrector
G : Air conditioning V: Without wheels anti blocking (ABS)
B = represents body type
A ,B,D = represents engine type E7J, 1397 cmc, front wheel
drive type, mechanical gearbox.
Attention
Do not unstuck or damage the label from the lateral side surface of the dashboard. This
label represents the only way of vehicle identification needed to the after sale services, for a
period of 8 (eigh t) years from the purchasing date.
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ENGINE E7J-A-2/6010
10 - 2
ENGINE AND LOWER ENGINE UNITS
MOTOR-PROPELLING GROUP
Di smounting and re -mounting the motor-propelling group i s done at the upper pa rt of the
engine compart ment by means of a moving lift ing device. C
OUPLES FO R S
CRE W-FIXING (daNm)
Screws for fixing right-side stand on engine 6,2
Hydro- elastic buffer attachment nut 3,7
Screw-nut for left-side elastic buffer 6,2
Wheel sc rews 7,5
Screws for fixing motor-propelling group-battery stand 2,1
Screw-nut for fixing small connecting rod on steering traverse 6,2
Screw for fixing anti-swing connecting rod on gearbox case 10,5
Control bars attachment screw on gearbox connecting rods 2,7
Car is placed on a lift-stand with two columns;
The fol lowing are taken down: battery, air-
filter case, engine bonnet, front wheels; Oxygen probe connector is taken off;
Dismantle: therm ic protection screen, cata-
lytic convert er on the exhaust collector;
DIS M O UNT ING
The fol lowing are eva cuated:
-the cooling circuit at the bottom par t
of the radiator ;
-the oil in the gearbox ;
-the oil in the engine, if necessary.
The fol lowi ng are ta ken dow n: -engine shield;
-the screws that fasten the catalyti c
converter on the stand;
-the pipe-collar between the catalyti c
converter and the trigger ;
-the catalytic converter;
-the anti-swing auxiliary connectin g
rod.
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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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ENGINE E7J-A-2/6012
FUEL MIXTURE
DIS M O UNT ING
The battery is disconnected.
The air tube is taken off the battery-prot ecting screen.
The four screws (1) for air-filter fixing are taken off.
The hose connecting the combustion-he ad cap and the air-filter i s disconnected.
The air-filter is taken apart
To disconnect:
-the accelera tion cable (the end of the cable is uncoupled from the command lever
of the clapper, and then it is taken off t he sleeve on the stand);
-the connectors:
I . of the step-by-step engine; II. of the clapper pot entiometer.
RE-MO UNT ING
The fitting of t he clapper body is replaced;
The same steps are taken as in the case of the dismantling, only in the reverse order.
12 - 4
1
I II
CLAPPER BODY
(no. 2 clamp is pulled upwards and the connector is taken off)
The command lever i s uncoupled off the body of t he clapper;
The clapper body is taken apart.
22
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ENGINE E7J-A-2/6012
FUEL MIXTURE
The following are taken apart:
- air-filter;
- accelera tion cable;
- injection ramp ( see Chapter Injec-
tion ramp );
The electric connectors are uncoupled: - atmospheri c pressure sensor;
- air tempera ture sensor;
- step-by-step engine;
- clapper potentiometer.
The fuel supply conduits are taken apart (bot h going- and return);
The clapper c ommand lever is uncoupled and the body of the clapper is taken off;
The screws and screw-nuts fixing the intake collector a re taken apart .
RE-MOUNT ING
The fittings of the intake collector are re placed;
The same steps are taken as in the case of the dismantling, only in the reverse order.
Tighten the inlet manifol d screws and nuts at the require d moment of 2.5 daNm. T
IG H TENING CO UPL E (daNm)
Screws and screw-nuts for intake collector 2.5 INTA
KE COLLECTOR
12 - 5
DISMOUNTING
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E7J-A-2/60 ENGINE13
PUMP SUPPLY
CAU T ION!
When th e fuel circuit is opened, any
pe trol jet due to residue pressure must
be averted by mea ns of a gauze.
DIS M O UNT ING
The battery is disconnected.
The air-filter is taken out.
To disconnect:
-no. 1 fuel supply tube;
-no. 3 return fuel tube;
-no. 4 pressure-regulator tube.
Injection ramp Screws no. 2 are taken off.
The ramp is taken apart .
In orde r to t a ke a p ar t a n i n j ect o r,
w ithdraw c lamp no. 5 and then pull t he
injector.
RE-MO UNT ING
Replace t he t orric fittings at the base of
the i njectors (if t he i njector has been taken
apart as well a s the fitting at the end of t he
injector). For the supply junctions and the return
petrol tubes to be c orrectly coupled a click
must be heard the moment the coupling is
done.
The rest of the ope rations are done in
the reverse order a s that of the taking a part.
INJECTION RAMP
13 - 2
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E7J-A-2/60 ENGINE13
PUMP SUPPLY
SU PPLY PRESSURE CONTROL
SPECIAL DE V I C E S
MOT 1311-01 Control Kit for
petrol pressure
MOT 1311-04 J Junction
MOT 1311-06 Junction-disconnect
ing device
CAUTION!
When the fuel circuit is opened, any
petrol jet due to residue pressure must be
averted by means of a gauze.
The air-filter is taken apart .
The fuel supply hose is disconnected.
The MOT 1311-04 deri vation junction
is connected onto the ramp, then the fue l-
s upply channelling is re-connected onto the
junction.
Te rm inals no. 3 and 5 of the H fuel-pump
relay (l ocated in the engine fuse -box) a re
shunted.
Pressure must be 3+/-0.2 bar.
By applying a 500 mbar depression on
the pressure-regulator, the pre ssure of the
fuel must be 2.5+/-0.2 bar.
13 - 5
MOT. 1 311 -0 4 MOT. 1 311 -0 1
The manometer 0-10 bar, as well a s the
flexible hose MOT 1311-01 are mounted.
SU PPLY PRESSURE
MOT. 1 311 -0 6
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16E7J-A-2/60 ENGINE
16 - 4
ST ARTING AND CHARGING
SPECIAL DEVICES
MOT 1505BELT TENSION MEASURIN G DEVICE
DIS M O UNT ING
The car is set on a two-column lifting stand;
Disconnect the electric connections from the battery.
The fuel supply conduit is uncoupled;
The following are taken off: - air filter;
- the oil-gauge tube;
- the top scre w of the alternator;
- the alterna tor belt;
- the stretching fl ange of the alternator.
The car is suspended.
The electric connectors of the alternator are uncoupled;
Di smount the alternator l ower attachment screw.
Lower the vehicle.
The alterna tor is taken out at the top.
AL TERNATOR
R
E-MOUNTING
The mounting opera tions are done in the reverse orde r;
The carrying belt of t he alternator is stretched to get the re commended ( 263
Hz+/- 10% ) mounting voltage;
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