2004 DACIA SUPERNOVA clutch

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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21 MANUAL GEARBOXSecti ons.......................................................... 21-1
Identification ................................................. 21-2
Tightening moments...................................... 21-3
Ratios ............................................................ 21-4
Capacity, lubricants....................................... 21-5
Particul arities................................................. 21-6
Ingredie nts..................................................... 21-7
Parts of systema tic replacement.................... 21-8
S pecial tools.................................................. 21-9
Gearbox dismounting ................................... 21-10
29 DRIVE SHAFTS Front transversa l transmission........................ 29-1
Bell ows - Be aring assembly to
t he gearbox.................................................... 29-4
Bell ows to wheel........................................... 29-7
Be llows to gearbox....................................... 29-12
Bell ows to wheel........................................... 29-15
30 GENERAL General principle sc hedule
of the brake circuit........................................ 30-1
Tightening moments...................................... 30-2
Com position and dimensions
of the ma in braking system elements............ 30-6
Br aking system diagnostic............................ 30-7
Br ake connections and se werage.................. 30-12
Br ake fluid.................................................... 30-13
Br aking circuit purging................................. 30-14
The inf luence of the front axle angle s on
t he road behaivior (vehicle comportment)
and on tyres wear........................................... 30-16
Prelimi nary checking..................................... 30-17
C hecking of the front axles adjustment......... 30-19
31 FRONT BEARING ELEMENTS Characteristics... .......................................... 31-1
Sus pension arm... .......................................... 31-2
Elastic bushings of suspension arm............... 31-4
Sus pension ball joint..................................... 31-5
Br ake gaskets................................................ 31-6
Br ake caliper................................................. 31-7
Br ake disk..................................................... 31-9
St eering knuckle............................................ 31-10
St eering knuckle bearing. .............................. 31-12
Fr ont suspension............................................ 31-13
Shock absor ber, Sprint. ................................. 31-14
Sp ring assembly shock absorber................... 31-15
Anti-roll bar................................................... 31-17
33 REAR BEARING ELEMENTS Characteristics............................................... 33-1
Rear axle....................................................... 33-2 Re
ar suspension............................................ 33-4
Shock absorber............................................. 33-5
Spring ........................................................... 33-6
Br ake drum................................................... 33-7
Br ake cylinder.............................................. 33-8
Br ake shoes.................................................. 33-10
Be aring (25 x 52 x 37)................................ 33-12
35 WHEELS AND TYRES Characteristics.............................................. 35-1
Wheels balancing......................................... 35–4
36 STEERING ASSEMBLY Axial ball joint............................................. 36-1
Steering box................................................. 36-3
Pus her........................................................... 36-4
Noise absorber bearing................................. 36-5
Bell ows......................................................... 36-6
Deformable lower shaft................................ 36-7
Ste ering weel position adjustment................ 36-9
37 MECHANICAL ELEMENTS CONTROLS Brake pump.................................................. 37-1
Servobrake................................................... 37-6
Air filter – se rvobrake reta iner valve........... 37-9
Handbrake adjustment.................................. 37-10
Handbrake control lever............................... 37-11
Handbrake secondary cable.......................... 37-12
Br ake flexible hoses..................................... 37-14
Br ake pressure controller.............................. 37-16
clutch hydraulic control................................ 37-19
The gear control........................................... 37-23
Pe dals support.............................................. 37-25
Acceleration pedal....................................... 37-26
Acceleration contr ol cable........................... 37-27
Transmission2
Chasis3
SION
LL
NT
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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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ENGINE E7J-A-2/6010
10 - 4
ENGINE AND LOWER ENGINE UNITS
The following are uncoupled:-the end of acceleration cable 1 from
the command lever of t he clapper; it is then
extracted off m uff 2 in the stand;
-the mileage cable: the two clamps are
pressed, and the cable is extra cted; -t he ri ght -si de he a dlight adjust m ent
cable, which is then positioned by the car
bodywork;
-the l inking pipes c oming from t he c arbon
canister and the canister-draining valve; -the fue l supply pi pes (both t he going- and
the re turn one) from the i njection ra mp, by
using MOT.1311-06 ;
The scre w linking the gear- bar and t he
auxiliary connecting rod to the gearbox is
dismantled.
MOTOR-PROPELLING GROUP
-the hydra ulic command con duit of the
clutch; fastener 1 is taken out and supply pipe
2 is withdrawn in the dire ction shown by the
arrow.
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ENGINE E7J-A-2/6010
10 - 5
ENGINE AND LOWER ENGINE UNITS
MOTOR-PROPELLING GROUP
The screw- nut of t he hyd ro- e l a st ic
buffer is taken off (right);
The Motor-Propelling set is taken out and
then placed on a stand.
Re- Mounting
The steps are taken in the re verse order (see dismantling / taking apart).
To do:
-the filling-up a nd the drainage of the cooling circuit (see Chapter “ Filling-up and
Dr aining”).
CAUTION! USE ONLY TYPE D A NTIFREEZE.
- filling-up the engine and the gearbox with oil;
- filling-up and draining the clutch hydraulic command circuit (see Chapter “Draining
of the clutch hydraulic command circuit”); The liquid to use is brake fluid type SAE J 1703, DOT 3, DOT 4.
The screws and the screw-nuts of the couple are fastened back.
When mounting, line up markings from hoses and related parts.
The Motor-Propelling set is upheld by
the two handles, by means of a m oving
lifting device (a mobile crane);
The four screws fixing the Motor-Propel-
ling set ba ttery stand are taken off, as well
as the screw-nut of t he elastic buffer;
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ENGINE E7J-A-2/6010
10 - 8
ENGINE AND LOWER ENGINE UNITS
The following are taken off:-the alterna tor and its belt;
-the induction coil and the plugs of the
sparks; -the pipe of the oil-level indicator;
-the mechanism of the clutch disc.
The electri c connectors are taken off and
the engine cabling is dismantled. Then the following are taken off:-the clapper body;
-the injection ramp;
-the intake collector;
-the thermic scre en and t he exhaust c ol-
lector; -the water intake pipe;
-the thermostat stand;
P entru automobilele echipate cu instala
ie
de aer c onndiºionat se demomonteazã: - rola de întindere, prin desfacerea
ºu ruburilor F ºi G;
- cureaua compre sorului;
- conectorul electric al compre sorului;
- compresorul;
- suport ul c ompre sorul ui ºi suport ul
interm ediar. ENGINE DISMMOUNTING
SE
PARA TION - DISMANTLING
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ENGINE E7J-A-2/6010
10 - 9
ENGINE AND LOWER ENGINE UNITS
The dismantling (taking apart ) operations are done in the reverse order;
The screws and screw-nuts are tightened to the couple.ENGINE MOUNTING
IT IS
COMPULSORY TO CHANGE ALL THE DISMANTLED FITTINGS!
TIGHTENING COUPLES (daNm)
Fixing the alte rnator:
-M 10-125 screw
5
-M 10-35 screw2,1
Clutch mechanism2
Intake collector2,,5
Exhaust collector2,5
Fixing the compressor4
Compressor stand4
Int ermediate stand2
Stretching spool2
SE PARA TION - DISMANTLING
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ENGINE E7J-A-2/6010
10 - 24
ENGINE AND LOWER ENGINE UNITS
DIS M O UNT ING
The following are dismounting:-the water conduit and the oil-l evel-
gauge guide; their watert ight sealing is
done with rubbe r rings which must be re-
placed for every dismantlement; -the clutch;
-t he engine flywhe e l, bl oc ked by
means of MOT 582;
-the lower c rankcase;
-the pinion of the crankshaft;
-the stretching runner/ pulley;
-the water-pump;
-the oil-pump
Per f o r m co nn e cting rods caps
identification in regards t o connecting rod
body. To
be taken off:
-the caps of t he connecting rod a nd
the bushes;
-the jacket-maintaining device;
the jacket-piston-rod set; -the bearing caps and their bushing;
-the shaft and the axial play bushes;
-the bushes on the block.
The axes of the pistons are taken apart .
The piston is placed on i ts stand, after
positioning the piston bolt (a xis) with the
release hole (t wo lines T for position-find-
ing the centre of the hole will make align-
ment easier). The bol ts are taken off in a pressing-
machine by means of the E extraction
CAUTION!
Do not use punchers for line-
up m arking in order to avoid fis-
sures; use an indelible pen.
THE CYLINDER CRANKCASE
RE CO VERY ENGINE
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