2004 DACIA SUPERNOVA lock

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 - 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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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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ENGINE E7J-A-2/6010
10 - 33
ENGINE AND LOWER ENGINE UNITS
On the back of the be lt there i s an arrow
indicating the direction of rotation, and two
tuning marks; -the L line-up marks on the crank-
shaf t pi nion are aligned with the fixed mark M;
(the mark on the
pinion of t he cam-shaft in
down)
CAU T ION!
The pinion of the cam-shaft
ca n have five line-up marks: it is only
th e rectangular-shaped mark on the
face of a cog that represents the Up-
per Ce ntre Point, all the others serv-
ing to adju st the rocker arms.
-the marks on the belt are aligned
w ith those on the pi nions, observing t he
direction of mounting and be ginning from
the pinion of the crankshaft;
-the captor of the MOT 1505 appa-
ratus is placed (held in the position indi-
cated in the schema) at 5-10 mm to t he
belt. Any of the two captors can be used on
condition the t wo of them should not be
placed simultaneously in front of the belt.
The distribution belt is set in vibration (the
m easurement is validated by a beep of the apparatus).
-the belt is stretched by opera ting t he
str etching runner/pulley, until a value within
210 and 275 Hz is obtained;
-the stretching device is blocked, and its
screw-nut is tightened at 3 daNm;
-the crankshaft is wound 5 1/2 rotations
(no. 2 cylinder in the position of rocker-arm
adjustment); -the screw-nut of t he runner/ pulley is
stretched until a value between 145 and 185
Hz is obtained.
CAU T ION!
If the value of 275 Hz is ex-
ceeded, the belt can no longer be used,
and it ha s to be changed.
-the 0 screw-nut of the runner/pulley is tight-
ened at 5 daNm.
If not, this may get dismounted, ri sking the
engine damaging.
G
ENERAL DIREC TIONS
The stretching of the belt should only be done
for th e co ld engine mode (i.e. ambient temperature);
-a belt which has been taken off must not be re-
mounted - it will have to be replaced by a new one.
DISTRIBUTION
RECO VERY ENGINE
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ENGINE E7J-A-2/6010
10 - 34
ENGINE AND LOWER ENGINE UNITS
It is done only for the cold engine mode.
The adjustment values are:-intake 0.10 mm
-exhaust 0.25 mm
1. Cam-Shaft pinion without line-up marks
a) The method called “in balance”
Th e cylinder valves in balance (end of
exhaust; start of intake)
1
3
4
2
The cylinder rocker-arms are adjusted
4
2
1
3
b) The method called “exhaust valve opened to the maximum”
The engine is wound (c lockwise, as seen from the distribution) t ill t he e xhaust va lve
of cylinder no. 1 reaches maximum opening, and t he play is adjusted for the intake
valve of c ylinder no. 3, and also for the exhaust valve of cylinder no. 4.
The same is done for the other cylinders, as in the chart :
Exh aust valve open to the
maximum
1
3
4
2
Intake valve to be adjusted
3
4
2
1
Exhaust valve to be adjusted
4
2
1
3
ADJUSTMENT OF ROCKER-ARMS
RECO VERY ENGINE
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E7J-A-2/60 ENGINE16
16 - 5
ST ARTING AND CHARGING
The position of the alternator i s blocked.
The engine is revolved thre e and a half cra nkshaft turns;
The reading end of t he MOT. 1505 measuring device is placed in the measuring area;
The tension in the belt is measured;
It is checked whether t his fits i nto the mounting tension tolerance; if not, the belt will
be stretched again until the recommended tension ( 263 Hz +/- 10%) is reached.
The inspection a nd t he a djustment of the belt a re done with t he e ngine at ambient
temperature . Tighten at the require d moment, the alternator a ttachment screws :
- screw M10(lower attachment)-5 daNm
-screwM10 (upper attachment)-2.2 daNm.
Remark: Once dismounted, a belt is not to be remounted, but replaced.
MOT. 1505
MOT. 1505
AL
TERNATOR
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16E7J-A-2/60 ENGINE
16 - 6
ST ARTING AND CHARGING
DIS M O UNT ING
(in the air -conditioning variant)
The car is placed on a two-column lifting stand;
The electric connections are uncoupled from the battery;
The following are taken apart: -the top scre w of the alternator;
-the belt of the alternator;
The right-side front wheel of the car is taken apart;
The car is suspended;
The two screws fixing the shock-absorber on the steeri ng swivel stand are taken off;
The steeri ng swivel stand is lowered and the right-side planetary tra nsmission is taken
off the planetary pi nion of the gearbox; The electric conductors of the alternator a re disconnected;
The screw of the alternator is taken off;
The alterna tor is taken apart laterally past the right-side planetary tra nsmission.
R
E-MOUNT ING
The taking-apart opera tions are done in the reverse order;
The carrying belt of the alternator is stretched to obtain the mounting tension recom-
mended (263 Hz +/- 10% );
The position of the alternator i s blocked;
The engine is revolved thre e and a half cra nkshaft turns;
The reading end of the MOT. 1505 measuring device is placed in the measuring area;
The tension in the belt is measured;
It is checked whether t his fits into the mounting tension tolera nce; if not , the belt will be
str etched again until the re commended tension ( 263 Hz +/- 10%) is reached.
The i nspection and the adjustment of the belt are done with the engine at ambient
temperature .
Tighten at the require d moment, the alternator a ttachment screws :- screw M10 (lower attachment)-5 daNm
-screw M10 (upper attachment)-2.2 daNm.
Remark: Once dismounted, a belt is not to be remounted, but replaced.
AL TERNATOR
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E7J-A-2/60 ENGINE16
16 - 7
ST ARTING AND CHARGING
IDENTIFICATION
ENGINE STARTER
E7J - A-2/60 D 907 - M00 2T 13581
DIAGNOS TICATION
S pecial device: CLIP - SAGEM-TECHNIC TESTER which measures the battery
voltage and the intensity absorbed by the starter.
ANOMALOUS FUNCTIONING THAT CAN BE SETTLED
-Battery failure –contact drop on the starter when starting the engine.
-Blocked starter (t he absorbed curre nt is very high);
Coupling relay defect (the current absorbed is very weak).
In order to do the measurements one must carry t he engine in starter mode, thus pre -
venting the engine to run.
To do t hat, the revolution sensor (located in the c lutch cra nkcase) should be t aken apart .
Remark: After doing these tests, erase the possible defects memorized
by the calculator with the tester.
STA RTER
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