clutch 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
ENGINE - CLUTCH - GEARBOX
01 - 1
Vehicle
EnginClutch type Gearbox
type
typeCylinder
capacity (cm3)
Type
DACIA
SupeRNova E7J-260 1390 215 CPOE 3500 JH3 – 050
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ENGINE E7J-A-2/6010
10 - 4
ENGINE AND LOWER ENGINE UNITS
The following are uncoupled:-the end of acceleration cable 1 from
the command lever of t he clapper; it is then
extracted off m uff 2 in the stand;
-the mileage cable: the two clamps are
pressed, and the cable is extra cted; -t he ri ght -si de he a dlight adjust m ent
cable, which is then positioned by the car
bodywork;
-the l inking pipes c oming from t he c arbon
canister and the canister-draining valve; -the fue l supply pi pes (both t he going- and
the re turn one) from the i njection ra mp, by
using MOT.1311-06 ;
The scre w linking the gear- bar and t he
auxiliary connecting rod to the gearbox is
dismantled.
MOTOR-PROPELLING GROUP
-the hydra ulic command con duit of the
clutch; fastener 1 is taken out and supply pipe
2 is withdrawn in the dire ction shown by the
arrow.
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ENGINE E7J-A-2/6010
10 - 5
ENGINE AND LOWER ENGINE UNITS
MOTOR-PROPELLING GROUP
The screw- nut of t he hyd ro- e l a st ic
buffer is taken off (right);
The Motor-Propelling set is taken out and
then placed on a stand.
Re- Mounting
The steps are taken in the re verse order (see dismantling / taking apart).
To do:
-the filling-up a nd the drainage of the cooling circuit (see Chapter “ Filling-up and
Dr aining”).
CAUTION! USE ONLY TYPE D A NTIFREEZE.
- filling-up the engine and the gearbox with oil;
- filling-up and draining the clutch hydraulic command circuit (see Chapter “Draining
of the clutch hydraulic command circuit”); The liquid to use is brake fluid type SAE J 1703, DOT 3, DOT 4.
The screws and the screw-nuts of the couple are fastened back.
When mounting, line up markings from hoses and related parts.
The Motor-Propelling set is upheld by
the two handles, by means of a m oving
lifting device (a mobile crane);
The four screws fixing the Motor-Propel-
ling set ba ttery stand are taken off, as well
as the screw-nut of t he elastic buffer;
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ENGINE E7J-A-2/6010
10 - 8
ENGINE AND LOWER ENGINE UNITS
The following are taken off:-the alterna tor and its belt;
-the induction coil and the plugs of the
sparks; -the pipe of the oil-level indicator;
-the mechanism of the clutch disc.
The electri c connectors are taken off and
the engine cabling is dismantled. Then the following are taken off:-the clapper body;
-the injection ramp;
-the intake collector;
-the thermic scre en and t he exhaust c ol-
lector; -the water intake pipe;
-the thermostat stand;
P entru automobilele echipate cu instala
ie
de aer c onndiºionat se demomonteazã: - rola de întindere, prin desfacerea
ºu ruburilor F ºi G;
- cureaua compre sorului;
- conectorul electric al compre sorului;
- compresorul;
- suport ul c ompre sorul ui ºi suport ul
interm ediar. ENGINE DISMMOUNTING
SE
PARA TION - DISMANTLING
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ENGINE E7J-A-2/6010
10 - 9
ENGINE AND LOWER ENGINE UNITS
The dismantling (taking apart ) operations are done in the reverse order;
The screws and screw-nuts are tightened to the couple.ENGINE MOUNTING
IT IS
COMPULSORY TO CHANGE ALL THE DISMANTLED FITTINGS!
TIGHTENING COUPLES (daNm)
Fixing the alte rnator:
-M 10-125 screw
5
-M 10-35 screw2,1
Clutch mechanism2
Intake collector2,,5
Exhaust collector2,5
Fixing the compressor4
Compressor stand4
Int ermediate stand2
Stretching spool2
SE PARA TION - DISMANTLING
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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
RE CO VERY ENGINE
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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)
RECO VERY ENGINE
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 59
STATEAIR CONDITIONING AC COMPRESSOR REQUIREMENT
SUGGESTIONSNo defect should be present or memorized
The compressor
clutch do es n ot
couple Check the insulation and continuity along the circuit towards pin 10
injection calculator.
Remedy if necessary.
If
the incident persists, refer to the diagnosing of he air-conditioning.
AFTER REPAIRPerform again the conformity test
CALCULATOR POWER VOLTAGE
PA R AMETER
No defect should be present or memorized.
No consumer should be turned on.
SUGGESTIONS
The contac
t is set
If the voltage < the minimal voltage, then the battery may be flat.
Check the charging circuit, in order to detect the cause of the problem.
If the voltage > the maximal voltage, then it is possible that the
battery may be overcharged.
Check the charging voltage to be correct, with and without consumers.
In idle mode
If the vo ltage < the minimal voltage, then the charging voltage is too
small.
Check the charging circuit, in order to detect the cause of the problem.
If th e voltage > the maximal voltage, then the charge of the battery is
too high.
The vo ltage regulator is faulty.
Remedy this problem, and then check the level of the electrolyte in the
ba ttery.
DIAG NOSING-INTERPRETING THE STATES
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