gas type DACIA SUPERNOVA 2004 Repair Manual

ENGINE E7J-A-2/6010
10 - 1
ENGINE AND LOWER ENGINE UNITS
INGREDIENTS
TYPE
RHODORSEAL 5661
Loc tite FRENETANCH
Exhaust Pipe Paste
ORGANS
Lower ca sing, crankshaft bearing cap
Crankshaft pulley screws, flywheel
screws
Exhau st pipe sealing
IDENTIFICATION
Type / Mark Engine Gearbox
Cylinder
capa city
(cm
3) Cylinder
Bore
( mm) Stroke
( mm) Volumetric
Ratio
SupeRNova E7J
-A-2/60
JH3 - 050 1390 75,8 77 9,5/1
Id en tification is done by means of a plate located on the cylinder casing.
It includes:
A: type of engine
B: engine approval letter
D: identity RENAULT
E: index of engine
G: engine moun ting plant
F: engine ma nufacturing serial number
Loctite 518 Water-pump, thermostat stand, crank-
shaft closing end casing
Loc
tite AUTOFORM Flywheel face for mounting on crank-
shaft
INGR
EDIENTS
000 0 0 / 00
0 000000
A B D E
G F
E7J-260-MB
EURO 2
EURO 3
Engine o il DACIA OIL EXTRA
10 W40; AP I SJ/CF Engine o
iled
Decapjoint Cylinder head gasket surface cleaning
Depollution Norm
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CV JH3 - 05021
MANUAL GEARBOX
21 - 20
The differential of the
JH3050 gearbox is the simple type (with two satellite s and two planetary
wheels, one of which making a common body with the tulip of the planetary transmission).
This differential is supported in the clutch – differential crankcase by means of two cylindrical
bearings equipped with balls of various sizes.
The two bearings are pressed in the clutch – differential crankcase.
The crown of the main transmission is assembled by hooping, on the differential crankcase.
DIFFERENTIAL DISMOUNTING
This operation is performed after separating the crankcases. The zero ring (1) is removed from the right planetary shaft, then by means of a pins extractor
and a hammer, the sealing gasket (2 ) is gently hit with a hammer in order to make it pivoting.
The oil seal ring is carefully pulled along the grooved part of the planetary pinion in order
not to deteriorate the grooves.
GEARBOX DISMOUNTING
DIFFE RENTIAL
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DRIVE SHAFTS
29BELLOWS-BEARING ASSEMBLYTO THE GEARBOX
Usi ng a pre ss, e xt ract t he assembl ed
tripod, sustained it on an e xtractor, FACOM
U 53 G type, protecting the tripod clogs.
Before extra cting, mark the position of
the trip od compar ed to the t ransm issio n
shaft end.
Dismount the bellows - deflector beari ng
in the same manner l ike t ripod dismounting.
REMOUNTING
In order to be corre ctly positioned on the
s haft, the bearing must be pressed to achieve
the value L = 118 +/- 0.2 mm between the
b ackside of the bearing and the shaft
extremity. This value is obtained by means
of the PF 1331 device, when mounting, its
extremity is at the level of the shaft .
IMPORTANT
In order to avoid the deformation of the bearing, which includes a sealing gasket (annular
oil seal), the pre ssing effort must be constant (do not hammer).
29 - 05Left
transmi ssion
GPF 13
31
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30
GENERAL
30 - 13
BRAKE FLUID
PERIODICITY OF THE BREAK FLUID CHANGE
The manufacturing conception of the brakes equipping the Dacia vehicles, especially
the di sks brake type (F 54 inner empty pistons, low qua ntity of fluid in t he c ylinders,
sliding calipers avoiding existence of a fl uid reserve in the less cooled area of t he wheel)
enable t he m aximum re jection of fluid vapori zation ri sk, even in c ase of intensive using of
brakes (mountain are a). The current bra ke fluids are subject in all cases to a slight degradation during the fi rst
months of use by a slight humidity absorpt ion seri es (see the Vehicle Warra nty and
Maintenance Booklet, for brake fluid change)
LEVEL COMPLETION
The wear of brakes pads and shoes generate a gradually diminution of brake fluid level
in its reservoi r. It is useless t o compensate t his diminution, because the level will be re -
stored in the moment of next changing the brake pads and shoes. Obviously, in the mean-
time, the level of brake fl uid in re servoir must not go down bellow the minimal mark.
HOMOLOGATED BRAKE FLUIDS
The mixture i n t he bra king circuit of two non compatible brake fluids may leads to loss
important risks mainly due to gasket damage
In order t o avoid such risks, it is obligatory t o use bra ke fluids checked and approved by
our laboratories and which are accordi ng to Norm SAEJ 1703, DOT 4.
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40
GENERAL
40 - 6
WELDING TYPES AND P
ARAMETERS
At the reparation of the welded body elements, thre e welding categories may be used:
prot e c t ion ga s weldi ng (CO2), e l e ctri c spot weldi ng and fi l l ing m a teri als wel ding
(autogenous). At the autogenous welding, it is recommended that flame must be slightly inclined so
that arch can be seen and the flame extremity to be maintained at aprox. 5 m m from the
part to be welded.
1. Spot welding resistive para meters for steel plates with carbon c ontent C < 0,15 %.
Plate thic kness (mm) Welding current (KA) Welding time (per) Tightening force ( daN m. )
0,5 6,5 5 130
0,8 8,0 8 200
1,0 9,5 10 250
1,25 10,5 10 295
1,5 10,0 14 310
2,0 12,0 16 350
NOTE
1 period = 1/50 part of a second
2. Welding parameters for the welding in protector gas for carbon steel plates or low-
alloyed steel.
Horizontal welding position ( pict.1)
Plate thickness (mm) 0,61,0 1,5 2,0
Electrode diamet er (mm) 0,6 0, 80,8 1,00 ,8 1,0 0,8 1,0
Welding wire speed (m/min) 2,5 1,9 3,2 2,4 4,4 3,8 5,7 4,4
Welding current (A) 35 35 55 80 80 120 100 130
Welding speed (m/min) 0,25 0,25 0,35 0,33 0,33 0,50 0,45 0,45
Welding voltage (V) 17 17 18 18 19 19 20 20
Protection gas flow (1/min) 12 - 17
Electrode fr ee length (mm) 6 - 12
plates welding
in tiers end to end
welding corner
welding
0-1,5mm 0-1,5mm
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40
GENERAL
40 - 7
WELDING TYPES AND P
ARAMETERS
NOTE
In case of using the Ar + CO2 mixture, the welding voltage will decrease with 2 V.
Ve rtical welding position ( obligatory from top to bottom) pict. 2
Plate thickness 0,6 12 2,0
Electrode diameter (m m) 0,6 0,8 0,8 1,0 0,8 1,0
We l ding wire speed (m /min) 2,5 1,9 3,3 3,2 5,7 4,4
We l ding current (A) 35 35 70 100 100 130
We l ding speed (m/min) 0,25 0,25 0,38 0,48 0,50 0,50
We l ding voltage (V) 17 17 18 18 20 20
Pr otection gas flow (1/min) 12 - 17
Electrode fre e length (mm) 6 - 12
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LOWER STRUCTURE
FRONT LONGITUDINAL GIRDER ASSEMBLY41- 1
41
REPLACEMENT
This operation shall be performed only on the repair bench. For the specific supports mount-
ing on the bench, please see the 40 sub-chapter.
DISMOUNTING
In order to reduce the distortion risk of
the front longitudinal girder, for the welding
points detaching it is recommended the use
of steel cutter. Dismount the damaged elements, which
are in contact with the front longitudinal girder.
Pr oceed to a straightening on the body
checking/straightening Celette type, until
bringing it, as closed as possible to the initial
shape.
Detach the welding points of the front longitudinal girder which are in connection with : - the front cross bar in t he a rea (1);
- the front wing lining in the area (2);
- the central floor in the area (3);
- the c entral cross bar in the a rea (4);
- the upper longitudinal girder closing plate in the area (5).
Detach the welding points of the cross bar with the floor closing plate and the central floor in
the are a (6). Remove the damaged element.
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOUNTING
Position and center the new element.
Perform an electric welding (by spots and under gas protection) as follows: - in the area (1) connecting the front longitudinal girder with the front cross bar;
- in the area (2) connecting the front longitudinal girder with the front wing lining;
- in the area (3) connecting the front longitudinal girder with the central floor;
- in the area (4) connecting the front longitudinal girder with the front cross bar;
- in the area (5) connecting the front longitudinal girder with the upper girder closing plate;
- in the area (6) connecting the front longitudinal girder with the cowl panel.
Protect the new element with a corrosion preventing and noise absorbent product.
1
5 3
6
4
2
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LOWER STRUCTURE41
REAR LONGITUDINAL GIRDER
REPLACEMENT
This operation shall be performed only on the repair bench. For the specific supports mounting
on the bench, please see t he 40 chapter.
41 - 2
DISMOUNTING
Dismount
the damaged elements, which are
in contact with the rear longitudinal girder. Proceed to a straightening on the body
checking/straig htening Celette type, until bringing
the ve hicle a s closed as possible to t he i nitial
shape.
Detach the welding points of the rear longitudinal girder (1) which are in contact with:- the central floor in the area (1);
- the rear floor in the area (2);
- the rear end floor in t he area (3);
- the re ar side cross bar in t he are a (4);
- the t ank front cross bar in t he area (5);
- the tank re ar cross bar i n the area (6);
- the inner wheel passage in the area (7);
Straighten the areas resulted after dismounting.
Grind the areas resulted after dismounting.
REMOUNTING
Position and center the new element
W eld the rear longitudinal girder following the assembling outlines 1,2,3,4,5,6 and 7 (spots
and under gas protection welding) Protect the new element with a corrosion preventing and noise absorbent product.
1 5
47
2
3
6
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AIR CONDITIONING
62
62 - 7
The compressor is absorbing the vapors coming from the evaporator at low pressure and
temperature, is compressing them and convey the gas at high temperature and pressure. The refrigerant fluid in high pressure and temperature vapor condition is entering in the second
he at exchanger, which by condensation is transmitting the heat to the external environmental.
At the exit from the condenser, the refrigerant fl uid is in liquid condition, at a high pressure and temperature.
Type of compressor: SD 7Y15
Compressor oil : PAG SP 10 or SP20, volume –135 cmc.
Refrigerant: HFC 134 a, quantity of refrigerant : 0.590 kg
C OMPRESSOR REPLACEMENT
DISMOUNTING
Disconnect the battery.
Drain the refrigerant circuit.
Disconnect the compressor’s connection.
Disconnect the pipes from the compressor.
Dismount the belt tensioning screw and release the belt.
Dismount the compressor attachment screws.
Dismount the compressor.
Replace the compressor.
REMOUNTING
Perform in the reverse order the dismounting operations.
T ension the belt and tighten at the required moment the tightening attachment screw.
Fill the refrigerant circuit and check the good operation of the climate control system.
COMPRESSOR
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85
WINDSCR EEN WIPERS
DISMOUNTING
Dismount the electric motor off the windscreen wiper mechanism.
Dismount : the reductor and the rotor.
Unstuck the brushes A, B and E.
Remove the brushed.
REMOUNTING
Check the collector condition and its grooves.
Introduce the new brushes and check their free sliding in the supports. Stick then the brushes.
M ount : the rotor and the reductor
Adjust t he rotor axial clearance, by means of the adjustment screw.
Mount the electric motor on the mechanism.
REPA R ATION OF THE WIPER ARM DRIVE AXLE
The operation is to be performed after dismounting the mechanism off the vehicle.
DISMOUNTING
Detach the connecting rods ( A) and (B) from axles.
Dismount the axles ( 1) off the mechanism support (2).
Depress the splinted bushing
Dismount the axle; recover the bushing and the rubber gasket.
REMOUNTING
Check the rubber gaskets condition.
Clean the parts, to be free of oxides.
Gr ease the parts with LiCaPb type II grease.
Remount : the rubber gasket on the axle, axle, rubber gasket, and the bushing.
Press the splinted bushing.
Mount the axles on the mechanism support.
Grease the joints with LiCaPb t ype II grease and couple the connecting rods ( A) and (B) on axles.
85-4
WINDSCREEN WIPER MECHANISM
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