tow 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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TOWING
03
Front (right) Rear (left)
03 - 1
NE VE R U SE AS T OW IN G POIN
TS, THE TRANSMISSION AXLES
(PLANETARY SHAFTS)
The towing points, front, or rear, are to be used only for vehicles towing on wheels.
These poi nts cannot be a nyhow used for drawing out the damaged vehicle from a trench
(hole), or for direct or indirect vehicle lifting on a transport platform. ALL TYPES
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ENGINE E7J-A-2/6010
10 - 13
ENGINE AND LOWER ENGINE UNITS
PISTONS
The bol t i s steady i n the connecting rod
and loose in the piston.
Dir ection of mounting: with the arrow to-
wa rds the flywheel.
There are three classes of association with
the jacket.
Markings on the pistons:
1 - arrow towards the flywheel
2 - class of piston (A-B-C)
3 - line-up marks used by the supplier.
Piston
line-up Piston diameter (m m) Jacket diameter (m m)
marks
A 75,765 - 75,775
* 75,8 - 75,75,81*
B 75,775 - 75,785* 75,81 - 75,82*
C 75,785 - 75,795 75,82 - 75,83
The piston di ameter i s measured for t he
mark:
A = 46 mm. * - the respective values are not included in the classes
CH
ARASTERISTICS
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ENGINE E7J-A-2/6010
10 - 26
ENGINE AND LOWER ENGINE UNITS
RE-MOUNT ING
The jackets are positioned such a way as:
-the difference be tween two succes-
sive jackets should be max. 0.05 mm; -the extra-height should be placed i n
ascending order between cylinder s 1 and 4.
-the extra-height X must be within
0.02 mm and 0.09 mm;
-in case there is an erroneous extra -
height, it is c hecked a gain by means of a
new set of jackets in orde r to see whether
the cause is the block or the jacket; if not,
check the theore tical values of both the
block and the jackets. The A, B, C, D set is done over with
the correct extra -height obtained, then the
jackets, the bolts and the pistons are num-
bered from 1 to 4 (no. 1 towards the fly-
w heel), so that t he concorda nce with t he
corresponding connecting rods is found.
The axes of the pistons a re m ounted by
means of the MOT 574-22 device.
The axes of the pistons are fixed in the
rod, and loose in the pistons.
Check i f the axes of t he pistons slide
freely in the new corre sponding pistons.
The axis of piston E is mounted on the
mounting axis A.
The C centring device is screwed up to
the end and then unscrewed a quart er of a
rotation.
THE CYLINDER CRANKCASE
In order to heat the connecting rods an
electric range of 1 500 W is used.
RECO VERY ENGINE
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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.
RE CO VERY ENGINE
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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;
RE CO VERY ENGINE
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E7J-A-2/60 ENGINE16
16 - 3
ST ARTING AND CHARGING
DIAGNOSING
Special device: Tester CLIP - SAGEM and accessories for physical measurements.
I
NSPE CT ION OF CHARG ING CIRCUIT
The CLI P - SAGEM tester allows the inspection of the alternator, by measuring the volt-
age and the curre nt supplied with, and without electri c consumers.
NOTE: The Ampere pincers are of the inductive type (0-1000 A). Its mounting
wi ll be done without disconnecting the battery, thus allowing for the memorized
da ta and the adapting values in the injection calculator to be preserved.
M ount the ammeter clamps directly to t he alternator exit, having the arrow oriented
towards this one
.
The measurements are effected in thre e steps: - measuring the battery voltage without contact on;
- measuring the regulated voltage and the current supplied without consumers;
-
measuring the regulated voltage and the current supplied with a maximum of consumers.
The values obtained as a result of t he measurements lead to the following interpretations: -the voltage of t he ‘empty’ battery < 12.3 V: so, the battery is flat;
With no consumers: -regulated voltage > 14.8 V: so, the regulator is faulty;
-regulated voltage (‘empty’) < 13.2 V or charging current < 2 A: so, there is a defect
of charging. With consumers: -regulated voltage > 14.8 V: so, the regulator is faulty;
-regulated voltage (‘empty’) < 12.7 V:the alternator charging current in regard to its
characteri stics must be checked.
IN TENSITY (A) EN GINEE7J
Rated intensity 75 80
Minimal intensity, which has to be supplied by the
altern ator to all working consumers 51 60
If the measured output is too little, the following will be checks:
-wear of alternator (collector brushes, etc.);
-battery connections;
-the mass braid of the engine;
-conformity of alternator;
-tension of carryi ng belt.
If the measured output is correct and the regulated voltage is too little, the cause may be:
-the car has too many electric consumers;
-the battery is flat. AL
TERNATOR
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 12
ENRICHING ADAPTIVE CORRECTION
PRINCIPLE
In the “ closed loop” stage, t he enri ching correction va lue (PR 035) is adjusting the
injection times in order to obtain a ratio as close as possible to the enriching value = 1.
The correction value is close to 128, having as limits 0 and 255; nevert heless, dispersions
of the injection system components may occur, that a re giving the correction a displacement
towards 0 or 255, in order to obtain the enriching value 1.
The a daptive c orrection i s allowing the injection c hart displacement i n order to re -
focus the enri chment adjustment (PR 035) on the 128 value.
The values of the adjustment correction may be read by means of the CLIP tester, as follows :
- connect the tester to the vehicle diagnosis socket and to the battery (or to the lighter socket).
- select
“COMPUTERS TEST” , then “PETROL INJECTION”
- in the menu “FU NCTIONS TEST”, access “ENRICHING ADJUSTMENT”, where
you can find para meters PR 030= enriching a dapting in opera tion (the adaptive corre ction
for the partial and large charge s area) and PR 031= enriching adapting at idling (adapting
correction at idling and in small charges area).
PARAMETER FIELD
Enriching adapting in operation (PR 030) 80% £ X £ 176 %
Enriching adapting at idling (PR 031) 80% £ X £ 176 % ENRICHING ADAPTIVE CORRECTION
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 21
DIAG
NOSING-INTERPRETING THE DEFECTS
CIRCUIT OF COMMAND ACTUATOR RELAY
1. Circuit of command or short-circuit to the mass of the circuit to-
wards pin 39 of the calculator
2.
Short-circ uit a t 12V a long the c irc uit tow a rds p in 39 of the c a lc ula tor
4.
SUGGESTIONSConditions of breakdown detection by the calculator:
-tak e the contact and wait till dialogue with the tester is lost
-put th e contact and enter dialogue.
Condition of performing the diagnosing:
-defec t is present.
REMARK : This defect has priority and should be dealt with be-
fore the following ones.
Check the state of the battery and the connections to the mass.
Remedy if necessary.
Check the connecting and the state of the connector of 238 relay.
Change the connector if necessary.
Check the presence of +12V at the pole 1 of 238 relay.
Remedy the circuit to fuse S
1 in the engine compartment.
Check the coil of the 238 actuator relay.
Change relay if necessary.
Connect the 90-way terminal-tester instead of the calculator and check the insulation and
the continuity along the circuit:
pin 39 of calculator
♦ pole 2 of actu ato r r elay 2 38.
Remedy if necessary.
The proble m is not yet solved! Consequently, the injection calculator must be changed.
CAUTION! The destruction of the calculator has probably been caused by an electric shock.
The cause of the destruction must be found before mounting a new
calcul ator.
AFTER REPAIR Er
ase defects memorized by the computer.
Perform the steps under “Suggestions” to confirm the repair.
Remedy other possible defects.
DEFECT
PR ESENT
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E7J-A-2/60 ENGINE17
IGNITION AND INJECTION
17 - 22
DIAG
NOSING-INTERPRETING THE DEFECTS
CIRCUIT OF COMMAND PETROL PUMP
1. Open circuit or short-circuit to the mass of the circuit towards pin 68 of the c alculator
2. Short-circuit at 12V along the circuit towards pin 68 of the calculatorDEFECT
PRESENT
SUGGESTIONS
Conditions of breakdown detection by the calculator:
-tak e the contact and wait till dialogue with the tester is lost
-put the contact and enter dialogue.
Condition of performing the diagnosing:
-defec t is present.
REMARK : This defect has priority and should be dealt with before
the following ones.
Check the connection and the state of the 236 petrol pump connector.
Change connector if necessary.
Check, after setting the contact, the presence of +12V at the pole 1 of 236 petrol pump.
Remedy if necessary.
Connect the 90-way terminal-tester instead of the calculator and check the insulation
and the co ntinuity along the circuit:
pin 68 of calculator
♦ pole 2 of the 236 petrol pump.
Remedy if necessary.
Check the coil of the 236 petrol pump.
Remedy if necessary.
The prob lem is not yet solved! Consequently, the injection calculator must be changed.
CAUTION! The destruction of the calculator has probably been caused by an
electric shock.
The cause of the destruction must be found before mounting a new
calculator.
AFTER
R EPAIREr ase defects memorized by the computer.
Perform the steps under “Suggestions” to confirm the repair.
Remedy other possible defects.
5.
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