engine DACIA SUPERNOVA 2004 Repair Manual

REPAIR MANUAL
DACIA
RM 524-1 MECHANICSENGINE: E7J
G ERBOX: JH3
TA P V: B 41A, B41B, B41D
Ref: 6001999441 APRIL 2004 English version
The reparation methods prescribed by the manufacturer in the present document are established subject to
t echnical specifications in force at the document issuing date.
These a re subject to modifications brought by the manufacturer at the fabrication of different assemblies,
s ubassemblies or accessor ies of its vehicles.
All rights rese rved to SC Automobile Dacia SA.
Re production or transla ting even partia lly of this prese nt doc ume nt is forbidde n without the writte n
authorisation of AUTOMOBILE DACIA S.A.
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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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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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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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SPECIFICATIONS
01
VEHICLE IDENTIFICATION
Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
CODE U U 1 R 5 2 3 1 5* *******
01 - 4
Position Characters explanation
1 – 3 - manufacturer i dentifi cation
UU1 - AUTOMOBILE DACIA SA, ROMÂNIA
4- Vehicle type
R - vehicle for persons transportation
5- engine-ge arbox unit location
5 - transversal front engine and front drive
6- chassis type
2 - hatch – bach
7- payload location
3 - five places : 2 front places + 3 rear bench places
8- gearbox type
1 - gearbox with 5 + 1 steps (JH3 050)
9- engine code and vehicle driving location
- left hand drive
5 - RENAULT engine, 1400 cm3 engine, spark ignition (E7J - 260)
10 - year model code y – 2000
1 – 2001
2 – 2002
11 - 17 - chassis manufacturing number
VIN IDENTIFICATION NUMBER
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LIFTING
02ELEVATOR POSITIONED UNDER THE CARRIAGE BODY
Safety sign :
1. THE DISMOUNTING OF VEHICLE COMPONENTS CASE .
When there are not available four columns elevators, two columns elevators may be used, in
this case, lifting slides shall be placed under the floor closing plate, at the supporting points level
of the vehicle jack.
2. THE PARTICULARLY CASE OF DISMOUNTING – REMOUNTING OF THE
ENGINE-GEARBOX ASSEMBLY.
In this specific case, the vehicle carriage body shall be consolidated with t he two columns
elevator arms using special slides.
These must be obligatory placed at the right of the supporting points of the vehicle jack and
must be locked in the holes/windows made in the floor closing plate.
02 - 3
Front
Rear
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LUBRICANTS CONSU MABLES
04
ProductPlace where it is used
OILING (GREASING)
MOLYKOTE ”BR2”
(LOCTITE 8103) Front transmission pinion grooves
Grease Right transmission joint G.I
ELF CARDREXA RNT2 Transmission joint G.E.
Grease
MO LY K OTE 33M Gearbox control protection bellows
Grease
Li C a Pb t ip II c u MoS
2Steering rack, pinion, oil seal ring( steering box)
SEALING
LOCTITE 518 Water pump Support thermostat
Crankshaft half crankcase
Gearbox half crankcase assembling
Thread of the reverse driving contact.
Crankshaft no.1 bearing cap
LOCTITE 5900
(RHODORSEAL 5661) Engine lower crankcase
SOLDERING
LOCTITE 270 Nut of primary shaft
(FRENBLOC) Screw of secondary shaft Speed V fix pinion grooves
Speed V hub grooves
LOCTITE 549
(AUTOFORM) Fly wheel seating surface on the crankshaft CLEANING
LOCTITE METALLREINIGER
(DECAPJOINT) Cylinder head gasket surface cleaning
04 - 1
CONDITI
ONS
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DRAINING - FILLING
05
DRAINING - FILLING
DRAINING: plug (1)FILLING: plug (2)
Special tool s
– wrench MOT 1018
05 - 1
ENGINE
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VALUES AND SETTINGS
07CAPACITY - QUALITIES
07 - 2
DENOMINATION CHAR ACTERISTICS CAPACITY (liters)
(a pproximate )*
Engine o il DACIA OIL EXTRA SAE 10 W 40; API SJ/CF 2,9*
Gearbox oil SAE 75 W 80 W; API GL 5 3,5
DACIA OIL EXTRAGEAR
Breaking fluid SAE J 1703; DOT 4 0,650
Cooling fluid 50% cooling fluid GLACEOL RX tip D
50% distilled water 6
Refrigerant (AC) HFC – 134 a 0,590 kg
Compressor oil PAG SP 10 sau SP 20 135 cm
3
* To be adjusted at di pstick
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VALUES AND SETTINGS
07DISTRIBUTION BELT TENSION
DISTRIBUTION BELT TENSIONING
Cold engine (ambient temperature).
Mount the new belt, the distribution being at setting point (P.M.S.).
Place the tensioning cam and tighten t he distri bution belt by means of t he MOT 1135-01
device.
Block the tensionin g cam.
P lace the reading head of the MOT 1505 device in the measuring area ( at a distance of 5…
10 mm from the belt); Any of the two captors may be used on the understanding that not both of
them are simultaneou sly in front of the belt.
Make the distribution belt vibrating ( the measurement is validated by a ”bip” of the device).
Tighten the belt, by acting upon the tensioning cam, until obtaining a value within the range
210…275 Hz.
Block the tightener and tighten its nut at the required moment of 3 daNm.
Rotate 5 and a half turns the crankshaft.
Unscrew the cam nut.
Tighten again the belt until obtaining a value between 145 and 185 Hz.
Obligatory tighten the tensioning cam nut at 5 daNm.
NOTE
If the value is higher than 275 Hz, the distribution belt is to be replaced with a new one.
07 - 4
NECESSARY SPECIAL TOOLS
MO T 1505 - belt tension checking device
MOT 1135 - 01 distribution belt tensioning device
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