2004 DACIA SUPERNOVA gearbox

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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16E7J-A-2/60 ENGINE
16 - 8
ST ARTING AND CHARGING
DIS M O UNT ING
The car is put on a two-column lifting stand;
The battery of storage cells is disconnected;
The screw-nuts fixing the degassing vessel are taken apart.
The degassing vessel is re moved (without disconnecting the link conduits) to the fore
part of the car i n order to facilitate access to the screws fixing the starter; The screws fixing the command bar on the connecting rod of the gearbox are taken off
(the jack is retrieved);
The screws no. 1 fixing the start er are taken;
STA RTER
The car is suspended;
The electric connectors of the starter are disconnected;
The start er is taken out through the bottom of the engine compartment. R
E-MOUNT ING
The taking-apart opera tions are done in the reverse order.
The screws are tightened at a 4.4 daNm couple.
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20
CLUTCH
The ge arbo x has a noise / rattle
The clutch pe dal pushed to the fullest:
-stopped car
-eng ine not running.
The comp lete return of the
clutch peda l is checked
The state of the
pedal is checked
The state of the hydraulic
ci rc uit, that of the emitting
cylinder and of the hydrau-
lic receiver, are checked
The state of the
clutch is checked
The fau lty parts
are replaced
The state of the hydraulic
circu it is checked and the
circu it is drained
The state of the
hydrau lic receiver is
checkedThe fa ulty parts
are replaced
The stroke of the
hydrau lic receiver
is checked
The state of the
clutch is checked
NON-CO NFORMING




CONFORMING

CONFORMING
CONFORMING

CONFORMING

NON-
CONFORMING
CONFORMING

NON-CONFORMING
D I A G N O STIC

CONFORMING
NON-CONFORMING
NON-
CONFORMING

The defect is looked
for at the level of the
gearbox
20 - 6
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20
CLUTCH
Trepidation
(t he car starts “by fits”)
The sta te of the props
of the gearbox is checked
Oiled clutch, or clutch hav-
ing a beat
The fau lty parts are replaced.
The o rigin of the beat is elimi-
nated.
The pr ops are replaced and the tight-
ening of the gearbox fixing spots on
the engine is checked, and also the
fixing of the engine
Clutch pedal has a “creak”
The axis of the clutch
pedal is oiled
Pedal axis worn-out
The fau lty parts are replaced
NON-CONFORMING



NON-
CONFORMING

CONFORMING



D I A G N O STIC
20 - 8
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20
CLUTCH
CLUTCH DISC MECHANISM
REPLACEMENT
This operation is done after taking apart the engine - gearbox ensemble and after
their separation.
The stopping sector MOT 582 is mounted.
The screws fixi ng th e mechan ism are taken off.
The mechan ism and the clutch disc are taken apart.
Visual inspection is done: - wear of engi ne flywheel;
- co ndition of the starter crown;
- watertightness at the level of the crankshaft fitting;
- co ndition of the flywheel surface (it must not have scratches).
The fau lty parts are replaced and the grooves of the clutch shaft are cleaned.
SPECIAL DEVICES
MOT 582 Flywheel immobilizing sector
AMB 1518 Clutch centering device
TIGHTENING COUPLES (daNm)
Clutch mechanism screws 2
20 - 9
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20
CLUTCH
The clutch disc is mounted with the A damping flange towards the gearbox
The clutch d isc is centered with the AMB 1518 centering device
The clutch mech anism is mounted;
Th e fixing screws are progressively put on the thread of the mechanism, then they are tight-
ened to the couple;
The MOT 582 fly wheel-stopping sector is taken off.
CLUTCH DISC MECHANISM
20 - 10
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CV JH3 - 05021
MANUAL GEARBOX
21 - 1
SECTIONS
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CV JH3 - 05021
MANUAL GEARBOX
21 - 2
IDENTIFICATION
A
- type of gearbox
B - i ndex of ge arbox
C - manufacturer’s number
D - manufacturing factory
000 000
0 0000 00
A B
D C
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