REPAIR MANUAL DACIA
REPAIR MANUALDACIARM 524-1 MECHANICSENGINE: E7JGERBOX: JH3TAPV: B41A, B41B, B41DThe reparation methods prescribed by the manufacturer in the present document are established subject totechnical specifications in force at the document issuing date.These are subject to modifications brought by the manufacturer at the fabrication of different assemblies,subassemblies or accessories of its vehicles.All rights reserved to SC Automobile Dacia SA.Reproduction or translating even partially of this present document is forbidden without the writtenauthorisation of AUTOMOBILE DACIA S.A.Ref: 6001999441APRIL 2004vnx.suEnglish version
0General poinds vehicle01 SPECIFICATIONSEngine – Clutch - Gearbox. 01-1Vehicle identification. . 01-202 LIFTINGMobile jack - Protection route;. 02-1Elevator positioned under the carriage body. 02-303 TOWINGAll types. 03-104 LUBRICANTS CONSUMABLESCondition. 04-105 DRAINING – FILLINGEngine. 05-1Gearbox. 05-207 VALUES AND SETTINGSDimensions. 07-1Capacity - Qualities. 07-2Driving belts tightening and accesories. 07-3Distribution belt tension. 07-4Cylinder head tightening. 07-5Wheeles and tyres. 07-6Brakes. 07-7Dimensions under carriage body. 07-8Checking values of the front axle angles. 07-9Checking values of the rear axle angles. 07-101Moteur et peripherics10 ENGINE AND LOWER ENGINE UNITSIngredients. 10-1Motor-propelling group. 10-2Separation - Dismantling. 10-7Characteristics. 10-10Recovery engine.10-17Lowervcrankase.10-37Oil pump. 10-38Tightening moments. 10-3911 UPPER AND FRONT ENGINE UNITSDistribution belt. 11-1Cylinder head fitting. 11-312 FUEL MIXTURECharacteristics.Clapper body.Intake colector.Exhaust collector.12-112-412-512-613 PUMP SUPPLYBreaking fuel supply .Injection pump.Petrol filter.Pupm flow.Supply pressure.13-113-213-313-413-514 ANTI-POLLUTIONPetrol vapours-aspiration . 14-116 STARTING AND CHARGINGAlternator. 16-1Starter. 16–717 IGNITION AND INJECTIONIgnition system. 17-1Sparking plugs. 17-2Peculiarities. . 17-3Placing of elements. 17-4Idling regime adjustment. 17-9Adjustment of the fuel mixture enriching. 17-11Enriching adaptive correction. 17-12Diagnosing-Introduction. . 17-15Diagnosing-Interpreting the defects. 17-17Diagnosing-Conformity test. 17-49Diagnosing-Interpreting the states. 17-55Diagnosing-breakdown localizationalgorithm. 17–6619 COOLING - EXHAUST - FUEL TANKCharacteristics. 19-1Filling and draining . 19-2Control. 19-3The schema. 19-4Radiator dismounting and remounting. 19-5Cooling fan replacementfor vehicles with air conditioning. 19-6Cooling fan diagnosticfor vehicles with air conditioning. 19-7Resistance cooling fan replacementfor vehicles with air conditioning. 19-9Cooling fan replacementfor vehicles without air conditioning. 19-10Cooling fan diagnosticfor vehicles with air conditioning. 19-11Water pump. 19-12Dismounting - remounting exhaust. 19-14Emptyng of tank. 19-16Tank fuel description. 19-17Tank fuel. 19-20Electric petrol pump. 19-2120 CLUTCHIdentification. 20-1Diagnostic. 20-3Clutch disc mechanism. 20-9vnx.su
SIONLLNT2Transmission21 MANUAL GEARBOXSections. 21-1Identification. 21-2Tightening moments. 21-3Ratios. 21-4Capacity, lubricants. 21-5Particularities. 21-6Ingredients. 21-7Parts of systematic replacement. 21-8Special tools. 21-9Gearbox dismounting . 21-1029 DRIVE SHAFTSFront transversal transmission. 29-1Bellows - Bearing assembly tothe gearbox. 29-4Bellows to wheel. 29-7Bellows to gearbox. 29-12Bellows to wheel. 29-1530 GENERALGeneral principle scheduleof the brake circuit. 30-1Tightening moments. 30-2Composition and dimensionsof the main braking system elements. 30-6Braking system diagnostic. 30-7Brake connections and sewerage. 30-12Brake fluid. 30-13Braking circuit purging. 30-14The influence of the front axle angles onthe road behaivior (vehicle comportment)and on tyres wear. 30-16Preliminary checking. 30-17Checking of the front axles adjustment. 30-193Rear suspension.Shock absorber.Spring.Brake drum.Brake cylinder.Brake shoes.Bearing (25 x 52 x 37).33-433-533-633-733-833-1033-1235 WHEELS AND TYRESCharacteristics. 35-1Wheels balancing. 35–436 STEERING ASSEMBLYAxial ball joint.Steering box.Pusher.Noise absorber bearing.Bellows.Deformable lower shaft.Steering weel position adjustment.36-136-336-436-536-636-736-937 MECHANICAL ELEMENTS CONTROLSBrake pump.Servobrake.Air filter – servobrake retainer valve.Handbrake adjustment.Handbrake control lever.Handbrake secondary cable.Brake flexible hoses.Brake pressure controller.clutch hydraulic control.The gear control.Pedals support.Acceleration pedal.Acceleration control -2337-2537-2637-27Chasis31 FRONT BEARING ELEMENTSCharacteristics. . 31-1Suspension arm. . 31-2Elastic bushings of suspension arm. 31-4Suspension ball joint. 31-5Brake gaskets. 31-6Brake caliper. 31-7Brake disk. 31-9Steering knuckle. 31-10Steering knuckle bearing. . 31-12Front suspension. 31-13Shock absorber, Sprint. . 31-14Spring assembly shock absorber. 31-15Anti-roll bar. 31-1733 REAR BEARING ELEMENTSCharacteristics. 33-1Rear axle. 33-2vnx.su
SPECIFICATIONS01ENGINE - CLUTCH - lindercapacity (cm3 )139001 - 1vnx.suClutch typeGearboxtype215 CPOE 3500JH3 – 050
SPECIFICATIONS01VEHICLE IDENTIFICATIONTHE PLACE OF THE MANUFACTURER PLATE, IDENTIFICATION NUMBER (VIN), LABEL WITH HOMOLOGATION MARKSIdentification number VINManufacturer plateMANUFACTURER PLATE01 - 2vnx.su
SPECIFICATIONSVEHICLE IDENTIFICATION01a. Manufacturer identification code;b. Code of the vehicle;c. Gearbox type code;d. Engine type code and driving location ( according to VIN code structure);e. Vehicle code;f. Trailer maximum authorized weight without braking system;g. Homologation number for the importer country;h. VIS sign-one character for year model code 7 characters for the chassis manufacturing number;i. Maximum technical admissible weight of the loaded car;j. Maximum admissible weight with trailer with braking system;k. Maximum technical admissible weight on front axle;l. Maximum technical admissible weight on rear axle.LABEL TYPE OVAL PLATEThe self- adhesive label type oval plate is stuck on the right lateral side surface of thedashboard. This enables the identification of the vehicle type and of its equipment, being exclusivelyused for after-sale activity.The reading of the codes marked on theoval platetype labelCaption:Line 11.1 Cod type auto APV 1D(15.04)B represents body typeA,B,D represents engine type E7J, 1397 cmc, front wheeldrive type, mechanical gearbox.Line 22.1 Level of equipping: E0, E1, E2, E32.2 Options equipping code:Line 44.1 Technical definition code, driving place.S2 : Left hand drive4.2 Options equipment code:A: Normal suspensionC: Temperate climateE: Warm climateF: Normal heatingG: Air conditioningK: Without pre-filterM: Steering mechanical systemR: Without variable shock absorberT: Without plate correctorV: Without wheels anti blocking (ABS)AttentionDo not unstuck or damage the label from the lateral side surface of the dashboard. Thislabel represents the only way of vehicle identification needed to the after sale services, for aperiod of 8 (eight) years from the purchasing date.01 - 3vnx.su
SPECIFICATIONS01VEHICLE IDENTIFICATIONVIN IDENTIFICATION NUMBERPosition 1234567891011 121314 151617CODE UU1R52315*******PositionCharacters explanation1–3- manufacturer identificationUU1 - AUTOMOBILE DACIA SA, ROMÂNIA*4- Vehicle typeR - vehicle for persons transportation5- engine-gearbox unit location5 - transversal front engine and front drive6- chassis type2 - hatch – bach7- payload location3 - five places : 2 front places 3 rear bench places8- gearbox type1 - gearbox with 5 1 steps (JH3 050)9- engine code and vehicle driving location- left hand drive5 - RENAULT engine, 1400 cm3 engine, spark ignition (E7J - 260)10- year model codey – 20001 – 20012 – 200211 - 17- chassis manufacturing number01 - 4vnx.su
LIFTINGMOBILE JACK - PROTECTION ROUTES02Safetysign(particularly cautionsto be observed in caseof an intervention)SPECIAL TOOLSDENOMINATIONCODEProtectionrouteCha 280-02Adjustingsocketon mobile jackCha 408-01 orCha 408-02The use of a mobile jack impliesthe necessity of using protectionroutes.It absolutelyforbiddenthe vehiclelifting using the front suspensionarms or the rear axle assupportingpoints.The following type of mobile jack isusing the sockets, the support Cha 408 – 01 or Cha408 – 02 in order to place the route Cha 280 – 02.In order to lift the front or rearpart of the vehicle,take as support the liftingpoints used alsofor the vehicle jack.LATERAL MOBILE JACKUse the CHA 280 hold.Place it on under the threshold at the front door level.The floor closingplate shallbe positionedin the channel of the hold.02 - 1vnx.su
02LIFTINGMOBILE JACK - PROTECTION ROUTESPROTECTION ROUTESIn order to place the vehicleon the protectionroutes, theseare to be obligatory placed eitherunder the reinforcements provided for the liftingvehiclewith the vehiclejack,or under the supportsplaced in behind the reinforcement.The positioning of the protection routesin the vehicle rearareas is performsby laterallifting ofthe vehicle.02 - 2vnx.su
LIFTINGELEVATORPOSITIONED UNDER THE CARRIAGE BODY02Safety sign:1. THE DISMOUNTING OF VEHICLE COMPONENTS CASE .When there are not availablefour columns elevators, two columnselevators may be used, inthis case,lifting slidesshall be placed under the floor closingplate, at the supporting points levelof the vehiclejack.2. THE PARTICULARLY CASE OF DISMOUNTING – REMOUNTING OF THEENGINE-GEARBOX ASSEMBLY.In this specific case, the vehicle carriage body shall be consolidatedwith the two columnselevatorarms usingspecialslides.FrontRearThesemust be obligatory placed at the right of the supporting points of the vehiclejack andmust be locked in the holes/windowsmade in the floor closingplate.02 - 3vnx.su
TOWINGALL TYPES03NEVER U SE AS TOWIN G POIN TS, THE TRANSMI SS ION AXLES(PLANETARYSHAFTS)The towing points, front, or rear,are to be used only for vehiclestowing on wheels.These points cannot be anyhow used for drawing out the damaged vehicle from a trench(hole), or for direct or indirect vehiclelifting on a transport platform.Front (right)Rear (left)03 - 1vnx.su
LUBRICANTS CONSUMABLESCONDITIONSProduct04Place where it is usedOILING (GREASING)MOLYKOTE ”BR2”(LOCTITE 8103)Front transmissionpinion groovesGreaseELF CARDREXA RNT2Right transmission joint G.ITransmissionjoint G.E.GreaseMOLYKOTE 33MGearbox control protectionbellowsGreaseLi Ca Pb tip II cu MoS2Steering rack, pinion,oil sealring( steering box)SEALINGLOCTITE 518LOCTITE 5900(RHODORSEAL 5661)Water pumpSupport thermostatCrankshaft half crankcaseGearbox halfcrankcaseassemblingThread of the reverse driving contact.Crankshaft no.1 bearing capEngine lower crankcaseSOLDERINGLOCTITE 270(FRENBLOC)LOCTITE 549(AUTOFORM)Nut of primary shaftScrew of secondary shaftSpeed V fix pinion groovesSpeed V hub groovesFly wheelseating surface on the crankshaftCLEANINGLOCTITE METALLREINIGER(DECAPJOINT)Cylinder head gasketsurface cleaning04 - 1vnx.su
DRAINING--FILLINGFILLINGDRAININGENGINESpecial tools – wrench MOT 1018DRAINING: plug (1)FILLING: plug (2)05 - 1vnx.su05
05DRAINING - FILLINGGEAR BOXSpecial tools – wrench MOT 1018DRAINING: plug (1)FILLING: plug (2)05 - 2vnx.su
VALUES AND SETTINGSDIMENSIONS , WEIGHTSDIMENSIONS (mm)WEIGHTS (kg)Total length (B)4030Total width (G)1640Total height (H)* empty* with lifted hatchback (H1)13951940Wheel base (A)2475Front wheel track width (E)1410Rear wheel track width (F)1345Ground clearance (K)* loaded134Hatchback free height (Q)925Turning radius* Between footways* Between walls074950500007 - 1vnx.suUnloaded vehicle weight:* on the front axle* on the rear axle* total545405950Maximum authorized load* on the front axle* on the rear axle* total7156701385Authorized payload425Load with trailer with own brake815Load with trailer without own brake450
07VALUES AND SETTINGSDENOMINATIONCAPACITY - QUALITIESCHARACTERISTICSCAPACITY (liters)(approximate )*Engine oil DACIA OIL EXTRA SAE 10 W 40; API SJ/CF2,9*Gearbox oilDACIA OIL EXTRAGEARSAE 75 W 80 W; API GL 53,5Breaking fluidSAE J 1703; DOT 40,650Cooling fluid50% cooling fluid GLACEOL RX tip D50% distilled water6Refrigerant (AC)HFC – 134 a0,590 kgCompressor oilPAG SP 10 sau SP 20135 cm3* To be adjusted at dipstick07 - 2vnx.su
VALUES AND SETTINGS07DRIVING BELTS TIGHTENING AND ACCESSORIESSPECIAL TOOLSMOT 1505 - TENSION CHECKING DEVICECompressor beltAlternator beltBDAAA - crankshaftB - alternatorC - compressorD - tightenerControl point of tensionAlternator belt tension: 263 Hz /- 10 %Compressor belt tension: 222 Hz /- 10 %07 - 3vnx.suC
07VALUES AND SETTINGSDISTRIBUTION BELT TENSIONNECESSARYSPECIAL TOOLSMOT 1505 - belt tension checking deviceMOT 1135 - 01 distribution belt tensioningdeviceDISTRIBUTION BELT TENSIONINGCold engine (ambient temperature).Mount the new belt, the distribution being at settingpoint (P.M.S.).Place the tensioning cam and tighten the distribution belt by means of the MOT 1135-01device.Block the tensioning cam.Place the reading head of the MOT 1505 device in the measuring area ( at a distance of 5 10 mm from the belt); Any of the two captors may be used on the understandingthat not both ofthem are simultaneously in front of the belt.Make the distribution belt vibrating ( the measurement is validatedby a ”bip” of the device).Tighten the belt, by acting upon the tensioningcam, until obtaining a value within the range210 275 Hz.Block the tightenerand tighten its nut at the required moment of 3 daNm.Rotate 5 and a half turns the crankshaft.Unscrew the cam nut.Tighten again the belt until obtaining a value between145 and 185 Hz.Obligatory tightenthe tensioningcam nut at 5 daNm.NOTEIf the value is higher than 275 Hz, the distribution belt isto be replaced with a new one.07 - 4vnx.su
VALUES AND SETTINGSCYLIDER HEAD TIGHTENING07CYLINDER HEAD TIGHTENING METHOD1.Cylinder head pre-settlingTighten all screws at the required moment of 2 daNm, than at 97 grd /- 2 grd as persequenceshown in the drawing.Wait 3 minutes, stabilization time.2. Cylinder head tighteningUnscrew the screws 1 – 2 until total releasing.Tighten the screws 1 – 1 at the required moment 2 daNm, than at 97 grd /- 2 grd.Repeat thetightening/unscrewing operationfor the groups of screws 3-4-5-6than 7 – 8 – 9 10.The cylinder head cannot be re tightened.07 - 5vnx.su
07VALUES AND SETTINGSWHEELS ANDTYRESVEHICLERIMSTIRESDACIASUPERNOVA5,5B x135,5 Jx13H2165 / 70 R 13PRESSURE(daN/cm2)FRONT1,9Tightening moments of the wheels nuts 7.5 daNm.Axial run out : max 1 mmRadial run ou
Cha 408-02 The use of a mobile jack implies the necessity of using protection routes. It absolutely forbidden the vehicle lifting using the front suspension arms or the rear axle as supporting points. The following type of mobile jack is using the sockets, the support Cha 408 – 01 or Cha 408 – 02 in order to place the route Cha 280 – 02.
NEW AUTOMATIC GEARBOX* Because adventure begins at the corner of your street, All-New Duster is just as at home in the city. . Top speed (km/h)/0-100km/h (s) 166/13.1 168/13.8 193/10.6 199/9.7 183/10.2 175/10.2 GEARBOX AND TRANSMISSIONˆˆ Transmission 4x2 4x2 4x2 4x2 4x2 4x4 CO .
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