Dacia F8Q (2004) Repair Manual

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REPAIR MANUAL

DACIA COMMERCIAL

RM 503-1 MECHANICS

ENGINE: F8Q

GERBOX: NG1; NG7

TAPV: U75D; U75E; U75G

The reparation methods prescribed by the manufacturer in the present document are established subject to

technical 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.

authorisation of AUTOMOBILE DACIA S.A.

Ref: 6001 999 462 NOVEMBER 2004 English version

General poinds vehicle

01 SPECIFICATIONS

Engine - Clutch - Gearbox ........................... 01-1

Vehicle identification ................................. 01-2

02 LIFTING

Mobile jack Protection routes ....................... 02-1

Elevator to be attached under the carriage

body .............................................................. 02-2

03 TOWING

All types ........................................................ 03-1

04 LUBRICANTS CONSUMABLES

Conditions ..................................................... 04-1

05 DRAINING AND FILLING

Engine ............................................................ 05-1

Gearbox ......................................................... 05-2

Rear axle differential ..................................... 05-3

07 VALUES AND SETTINGS

Dimensions .................................................... 07-1

Capacity - Qualities .......................................07-10

Wheels and tires............................................ 07-11

Brakes ........................................................... 07-12

Heights under carriage body ......................... 07-13

Control values of the front axle angles ..........07-14

Control values of the rear axle angles ...........07-18

Engine and peripherics

10 ENGINE AND LOWER ENGINE UNITS

Ingredients .................................................... 10-1

Idetification ................................................... 10-2

Oil consumption ............................................. 10-3

Oil pressure .................................................... 10-4

Dismounting - Remounting engine ............... 10-5

Engine fitting - unfitting ............................... 10-9

Tightening moments......................................10-10

Characteristics .............................................. 10-11

Necesary special tools .................................. 10-16

Dismounting - Remounting............................ 10-17

Lower crankcase............................................ 10-37

Oil pump........................................................ 10-38

Crankshaft sealing gasket towards

distribution ................................................... 10-39

Crankshaft sealing towards flyweel............... 10-40

Engine set replacing ......................................10-41

11 UPPER AND FRONT ENGINE UNITS

Distribution belt ............................................ 11-1

Cylinder head gasket..................................... 11-4

12 FUEL MIXTURE

Intake manifold............................................. 12-1

Exhaust manifold .......................................... 12-2

13 PUMP SUPPLY

Fuel stop in case of collision....................... 13-1

Characteristics .............................................. 13-2

Particularities................................................ 13-4

Cleanliness rules ......................................... 13-6

Elements location.......................................... 13-8

Operation ................................................... 13-10

Injection indicator operation ........................ 13-12

Anti-starting function.................................... 13-13

Idle running rotation correction.................... 13-14

Pre / Post –heating control........................... 13-15

Injectors ....................................................... 13-17

Decreased flow electric valve and stop

electric valve................................................. 13-18

Increased flow electric valve and advance

electric valve................................................. 13-20

Injection pump connector.............................. 13-22

Injection pump.............................................. 13-24

Injection pump pressing on........................... 13-27

Diesel oil filter.............................................. 13-29

Water temperature centralised control

(G.C.T.A.)..................................................... 13-30

Acceleration potentiometer........................... 13-31

Diagnosis - Generalities................................ 13-32

Diagnosis - damages interpretation .............. 13-34

Diagnosis – Help........................................... 13-66

Diagnosis - Conformity checking................. 13-67

Breakdown localizing algorithm ................. 13-70

14 ANTIPOLLUTION

Oil vapors re-aspiration................................ 14-1

Exhaust gases recycling (E.G.R.) ................. 14-2

16 STARTING AND CHARGING

Alternator ..................................................... 16-1

Starter ........................................................... 16-6

19 COOLING - EXHAUST - FUEL TANK

Characteristics .............................................. 19-1

Draining – Filling – Purging ........................ 19-2

Checking....................................................... 19-3

Cooling system diagram................................ 19-4

Water pump................................................... 19-5

Radiator......................................................... 19-6

Exhaust assembly.......................................... 19-7

Tank draining................................................. 19-9

Dismounting – Remounting tank................... 19-10

Fuel level transmitter..................................... 19-11

Tightening moments (da Nm)........................ 19-12

Transmission

20 CLUTCH

Identification................................................. 20-1

Diagnostic .................................................... 20-2

Mechanism - Disk ........................................ 20-5

Engine flywheel............................................ 20-6

Clutch shaft bearing...................................... 20-7

21 MANUAL GEARBOX

Characteristics.............................................. 21-1

Tightening moments in daNm...................... .21-2

Ingredients ................................................... 21-3

Manual gearbox : Dismounting -

Remounting................................................... 21-4

Repair............................................................ 21-8

Backcap......................................................... 21-37

Control shaftannular oil seal replacement.... 21-38

Speedometer endless screw pinion

replacement .................................................. 21-39

Ve l ocity step synchrontzer replacement ..... 21-40

Clutch shaft annular oil seal replacement... 21-41

Propeller shaft annular oil replacement........ 21-42

main elements ............................................... 31-30

Suspension - Tightening moments ............... 31-31

Front shock absorber .................................. 31-32

Front suspension spring .............................. 31-36

Front stabilizer rod ...................................... 31-37

33 REAR BEARING ELEMEN TS

Plate drive rear axle ..................................... 33-1

Brake drum................................................... 33-4

Brake cylinder.............................................. 33-6

Brake shoes.................................................. 33-8

Bearing (39 x 68 x 37)................................ 33-10

Plate drive rear axle differential .................. 33-11

Non drive plate rear axle ............................. 33-20

Non drive pipe rear axle ............................. 33-22

Shock absorber ............................................ 33-24

Spring .......................................................... 33-25

Rear antiroll rod .......................................... 33-26

35 WHEELS AND TYRES

Characteristics ............................................. 35-1

Wheels balancing ........................................ 35-4

29 DRIVE SHAFTS

Front cross transmission ............................... 29-1

Bellows towards to the gearbox ................... 29-5

Bellows towards the wheel .......................... 29-7

Longitudinal transmission (cardanic) .......... 29-8

30 GENERAL

31 FRONT BEARING ELEMENTS

Chassis

General principle schedule of a brake circuit in parallel with

by-pass circuit .............................................. 30-1

Tightening moments (daN) .......................... 30-2

The dimensions of the main

braking elements .......................................... 30-7

Brake connections and sewerage ................. 30-8

Brake fluid ................................................... 30-9

Braking circuit purging ................................ 30-10

Diagnostic .................................................... 30-11

Front axle checking-adjustment ................... 31-1

Diagnostic .................................................... 31-4

Upper arm ..................................................... 31-5

Elastic bushings, upper arm ball joint .......... 31-8

Lower arm .................................................... 31-10

Elastic bushings, lower arm ball joint .......... 31-13

Brake gaskets................................................ 31-15

Brake caliper................................................. 31-17

Brake disk..................................................... 31-21

Brake caliper support ................................... 31-24

Steering knuckle............................................ 31-25

Steering knuckle bearing............................... 31-28

Characteristics of front suspension

36 STEERING ASSEMBLY

Characteristics, tightening couplers ............ 36-1

Setting the steering gear central point ......... 36-3

Noise absorber bearing ................................ 36-5

Pusher adjustment ........................................ 36-7

Adjustable steering auxiliary

connecting rod ............................................ 36-12

Steering wheel shaft bushing ........................ 36-14

Steering gear shaft ....................................... 36-16

37 MECHANICAL ELEMENTS CONTROLS

Brake pump.................................................. 37-1

Servobrake................................................... 37-5

Vacuum pump ............................................... 37-8

Air filter – servobrake retainer valve........... 37-9

Handbrake ................................................... 37-10

Handbrake control level .............................. 37-11

Handbrake primary and secondary cable .... 37-12

Brake limiter ............................................... 37-14

Brake pedal and clutch ................................ 37-16

Clutch cable - Clutch stroke adjustment ..... 37-17

The steering column support assy

and fire wall ................................................. 37-18

Throttle pedal .............................................. 37-19

Gear box control mechanism ....................... 37-20

38 VACUUM-ELECTRIC CONTROL

SYSTEM 4 X 4 COUPLING

Presentation.................................................. 38-1

Electric-vacuumating control adjustment .... 38-2

Vacuum capsule............................................ 38-3

Electric valve................................................ 38-4

SPECIFICATIONS

Engine – Clutch – Gearbox

TYPE

Pick Up P

Pick Up 4x4

Drop Side P

Drop Side 4x4

Pick Up T

Drop Side T

VEHICLE ENGINE

CODE

VIN

D 2611*

D 4616*

D 2711*

D 4716*

D 1611*

D 1711*

DRIVE

rear

4x4

rear

4x4

front

TYPE

F8Q-636

CAPAC I T Y

1870

(cm3)

CLUTCH

200CPOV

3700

200CPOV

3700

200CPOV

3700

200 CPOV

3700

GEARBOX

NG1-103

(50C-31)

NG7-101

(51C-02)

NG1-103

(50C-31)

NG7-101

(51C-02)

(NG1-104)

365-18

(NG1-104)

365-18

Double Cab P

Double Cab T

Double Cab 4x4

D 2F71*

D 1F11*

D 4F76*

rear

front

4x4

F8Q-636

1870

200 CPOV

3700

(NG1-103)

50C-31

(NG1-104)

365-18

(NG7-101)

51C-02

* (x or 7 or T) – this sign is showing : engine type, engine pollution norm and driving

post location

01 - 1

SPECIFICATIONS

Vehicle identification

UNITL THE DATE OF 26.06.2003

Manufacturer plate

VIN identification number

MANUFACTURER PLATE

a. 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 with-

out braking system;

g. Homologation number for the importer

country

code + 7 characters for the chassis manufacturing number;

the loaded car

with braking system

on front axle;

rear axle.

;

h. VIS sign; one character for year model

i. Maximum technical admissible weight of

;

j. Maximum admissible weight with trailer

;

k. Maximum technical admissible weight

l. Maximum technical admissible weight on

01 - 2

SPECIFICATIONS

Vehicle identification

UNITL THE DATE OF 26.06.2003

VEHICLE IDENTIFICATION

VIN IDENTIFICATION NUMBER

Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

CODE U U 1 D CODE U U 1 D CODE U U 1 D CODE U U 1 D

CODE U U 1 D CODE U U 1 D CODE U U 1 D CODE U U 1 D CODE U U 1 D

POSITION CHARACTERS EXPLANATION

1 - 3 - manufacturer identification

4 - vehicle type

5 - engine-gearbox unit location

6 - carriage body type

7 - payload location

8 - gearbox type

9 - engine code and vehicle driving location

10 - year model code - 2 - 2002

11 - 17 - chassis manufacturing number

1 6 1 1 * * * * * * * * * 1 7 1 1 * * * * * * * * * 2 6 1 1 * * * * * * * * * 2 7 1 1 * * * * * * * * * 4 6 1 6 * * * * * * * * * 4 7 1 6 * * * * * * * * * 1 F 7 1 * * * * * * * * * 2 F 7 1 * * * * * * * * * 4 F 7 6 * * * * * * * * *

UU1 - AUTOMOBILE DACIA S.A. ROMÂNIA

D - vehicle for goods transportation

1 - longitudinal front engine and front drive 2 - longitudinal front engine and rear drive 4 - longitudinal front engine and four wheel drive (front drive coupling

optional

6 - PICK UP 7 - DROP SIDE F - PICK UP, DOUBLE CAB

1 - two front seats + bed body 7 - five places : 2 front places + 3 places rear bench + bed body

1 - gearbox with 5 + 1 steps 6 - gearbox with 5 + 1 steps and 4x4 coupling

X - motor 1870 cm type EURO 2, left hand drive 7 - engine 1870 cm type EURO 3, left hand drive T - engine 1870 cm type 1504, left hand drive

with ignition by compression, combustibil (Diesel oil),

01 - 3

SPECIFICATIONS

STARTING WITH THE DATE OF 26.06.2003

MANUFACTURER’S PLATE DISPOSAL TYPE SELF-ADHESIVE

Vehicle identification

Fig.2.1

01 - 4

SPECIFICATIONS

Vehicle identification

STARTING WITH THE DATE OF 26.06.2003

The MANUFACTURER PLATE, self-adhesive type, has the bellow presented con- figuration, with two distinctive areas, presenting :manufacturer’s identification data and APV type identification data.

B C D

F G H

MANUFACTURER’S IDENTIFICA-

TION DATA

A. Manufacturer’s name B. Community reception number or

homologation number.

C. Identification number. D. Total authorized weight of the

loaded vehicle.

E. Total authorized running weight F. Total weight on front axle. G. Total weight on rear axle. H. Additional inscription. I. Manufacturing date inscription J. Consignment number.

APV IDENTIFICATION DATA

1.1Code type auto APV

1.2Manufacturing number

2.1 Equipping level code

2.2 Additional code for limited serial

definition

2.3 Additional code for special serial

definition

3.1 Carriage body color code

3.2 Seats upholstery code

3.3 Interior matching code.

4.1 Technical definition code

4.2 Optional equipping code.

01 - 5

LIFTING

Mobile jack – Protection routes

The use of a mobile jack implies the using of protection intermediary routes.

It absolutely forbidden the vehicle lifting using the front or rear suspension arms as

supporting points.

The mobile jack is not to be used for vehicle lifting in order to perform works under the

carriage body (the two columns elevator is to be used).

LIFTING THE FRONT PART

OF THE VEHICLE

In order to lift the front of the vehicle, use the mobile jack and the protection intermediary route Cha 280 ( for protection of the body and mechanical elements) which are placed on the front longitudinal girders in the suspension arms axle.

LATERAL LIFTING

OF THE VEHICLE

For lateral lifting of the vehicle use the mobile jack and the protection intermediary route CHA 280; place it under the threshold at the front door level.

The threshold edge shall be correctly positioned in the channel of the protection intermediary route.

02 - 1

LIFTING

Elevator to be attached under the carriage body

For lifting, place the intermediary routes of the elevator arms in the supporting point of the vehicle inbuilt used by jack. The threshold edges shall be correctly positioned in the routes channels.

FRONT

REAR

02 - 2

TOWING

Alltypes

NEVER USE AS TOWING POINTS, THE TRANSMISSION AXLES (PLAN-

ETARY SHAFTS)

The towing points, front (1) or rear (2) are to be used only for vehicles hauling on wheels, by towing. These points cannot be anyhow used for drawing out the damaged vehicle from a trench (hole), or for direct or indirect vehicle lifting on a transport platform.

FRONT (right)

REAR (left)

03 - 1

LUBRICANTS CONSUMABLES

Condition

PRODUCT PLACE WHERE IT IS USED

LUBRICATION (GREASING )

Front transmission pinion grooves

Grease

UM 170 Li Ca Pb 2M

Gear box control shaft Cardan flange annular oil seal

ELF CARDREXA RNT2 or

UM 185 Li 2M

Grease

UM 185 Li 2M

Grease U 95 Ca 2

Grease

Li Ca Pb tip II cu MoS2

(or 20 UM Li III)

Grease 22

Planetary transmissions

Front wheel steering knuckle grooves Cardan transmission Planetary transmission Front wheel bearing Suspension ball joints Rear axle differential

Wheels bolts

Pressure bearing guide Steering box (gear-rack, bearings) Clutch shaft grooves Pressure bearing Clutch mechanism diaphragm

Steering box rubber gaskets

Grease U100 Ca 4-5

Auxiliary steering connecting rod

04 - 1

LUBRICANTS CONSUMABLES

PRODUCT

RHODORSEAL

5661

LOCTITE 518

KIT DURCISSEUR

LOCTITE 577

Condition

PLACE WHERE IT IS USED

SEALING

Camshaft bearing cap no.1 and 5 Crankshaft no.1 bearing cap Planetary transmission pins

Gearbox half crankcase Clutch casing Rear axle

Crankshaft no.1 bearing cap

Rear driving contact thread Plug M 16- gearbox Rear axle

Sealant material 503 ( mastic)

LOCTITE FRENETANCH

DECAPJOINT

Rear axle differential

SOLDERING

Flywheel attachment screws

CLEANING

Cylinder head gasket surface

04 - 2

DRAINING AND FILLING

Engine

ENGINE

Necessary special tools - wrench for draining plug : MOT 1018

Draining : plug (2) Filling : plug (1)

05 - 1

DRAINING AND FILLING

Gearbox

GEARBOX

Drain : plug (2)

Fill : plug (1)

05 - 2

DRAINING AND FILLING

Rear axle differential

REAR AXLE DIFFERENTIAL

Draining: plug (2) Filling: plug (1)

05 - 3

VALUES AND SETTINGS

Dimensions

DIMENSIONS

DACIA Pick Up P, 4x4 and T

1334

DACIA Pick Up P, 4x4 end T

DIMENSIONS (mm)

Total length Total width Total height:

- Empty

- Loaded

Axle base Front wheel track width Rear wheel track width

Ground clearance(k):

- Loaded

Turn radius:

- Between footways

- Between walls

4674 1636

1550

2675 1334 1320

>140

5600 5800

07 - 1

VALUES AND SETTINGS

Dimensions

WEIGHTS

DACIA Pick Up P, 4x4 and T

VEHICLE

VEHICLES

WEIGHTS

1. Unloaded vehicle weight ( with 75 Kg. driver)

- on the front axle,

- on the rear axle,

- total.

2. Deadweight (unloaded vehicle weight):

- on the front axle,

- on the rear axle,

- total.

3. Technical admissible maximal weight of the loaded vehicle:

- on the front axle,

- on the rear axle,

- total.

DENOMINATION

DRIVE

VIN CODE

DACIA

Pick Up P

REAR

D 2611*

635 520

1155

590 490

1080

720 1510 2230

DACIA

Pick Up 4x4

INTEGRAL

D4616*

645 530

1175

600 500

1100

740 1510 2250

DACIA

Pick Up T

FRONT

D 1611*

645 480

1125

600 450

1050

640 1260 1900

4. Technical admissible maximal weight on each axle:

- on the front axle,

- on the rear axle.

5. Payload:

- on seats,

- on bed body,

- total.

07 - 2

760

1550

150

1000

1150

760

1550

150 1000 1150

760

1300

150 700 850

VALUES AND SETTINGS

Dimensions

TOWING WEIGHTS

DACIA Pick Up P, 4x4 and T

VEHICLE

TOWING

WEIGHTS

1. Te c hnical admissible maximal weight for towing (trailer with braking system)

2. Admissible maximal weight of the assembly

3. The vehicle is capable / is not capable for

trailer towing

4. To w ing maximal weight without braking system.

DENOMINATION

DRIVE

VIN CODE

DACIA

Pick Up P

REAR

D 2611*

1095

3225**

capable

450*

DACIA

Pick Up 4x4

INTEGRAL

D 4616*

1075

3225**

capable

450*

DACIA

Pick Up T

FRONT

D 1611*

not applicable

not capable

5. Te c hnical admissible maximal weight on

towing coupling point

** By reducing the bed payload with 100 Kg.

07 - 3

VALUES AND SETTINGS

Dimensions

DIMENSIONS

DACIA Drop Side P, 4x4 and T

1334

4599

DACIA Drop Side P, T ºi 4x4

DIMENSIONS (mm)

Total length Total width

Total height:

- Empty

- Loaded

Axle base Front wheel track width

Rear wheel track width Ground clearance (k):

- Loaded

Turn radius:

- Between footways

- Between walls

4599 1636

1550

2675 1334 1320

> 140

5600 5800

07 - 4

VALUES AND SETTINGS

VEHICLE

VEHICLES

WEIGHTS

1. Unloaded vehicle weight (with 75 Kg. driver)

- on the front axle,

- on the rear axle,

- total.

DENOMINATION

DRIVE

VIN CODE

Dimensions

WEIGHTS

DACIA Drop Side P, 4x4 and T

DACIA

Drop Side P

REAR

D 2711*

635 555

1190

DACIA

Drop Side 4x4

INTEGRAL

D 4716*

1210

645 565

DACIA

Drop Side T

FRONT

D 1711*

645 510

1155

2. Deadweight (unloaded vehicle weight):

- on the front axle,

- on the rear axle,

- total.

3. Technical admissible maximal weight of the loaded vehicle:

- on the front axle,

- on the rear axle,

- total.

4. Technical admissible maximal weight on each axle:

- on the front axle,

- on the rear axle.

5. Payload:

- on seats,

- on bed body,

- total.

590 525

1115

690 1540 2230

760 1550

150

965

1115

600 535

1135

690 1540 2230

760 1550

150

945 1095

600 480

1080

690 1240 1930

760 1300

150

700

07 - 5

VALUES AND SETTINGS

DACIA Drop Side P, 4x4 and T

TOWING

WEIGHTS

1. Te c hnical admissible maximal weight for towing (trailer with braking system)

2. Admissible maximal weight of the assembly

3. The vehicle is capable / is not capable for

trailer towing

DENOMINATION

VIN CODE

Dimensions

TOWING WEIGHTS

VEHICLE

DRIVE

DACIA

Drop Side P

REAR

D 2711*

1060

3225**

capable

DACIA

Drop Side 4x4

INTEGRAL

D 4716*

1040

3225**

capable

DACIA

Drop SideT

FRONT

D 1711*

not

applicable

not capable

4. To w ing maximal weight without braking system

5. Te c hnical admissible maximal weight on towing coupling point

** By reducing the bed payload with 100 Kg.

450*

07 - 6

VALUES AND SETTINGS

Dimensions

DIMENSIONS

DACIA Double Cab P, 4x4 and T

1334

DACIA Double Cab P, 4x4 ºi T

DIMENSIONS (mm)

Total length Total width Total height:

- Empty

- Loaded

Axle base Front wheel track width Rear wheel track width Ground clearance (k):

- Loaded

Turn radius:

- Between footways

- Between walls

4794 1636

1525

2795

1334/1312

1320

>140

5600 5800

07 - 7

VALUES AND SETTINGS

DACIA Double Cab P, 4x4 and T

VEHICLE

VEHICLES

WEIGHTS

1. Unloaded vehicle weight (with 75 Kg. driver)

- on the front axle,

- on the rear axle,

- total.

2. Deadweight (unloaded vehicle weight):

- on the front axle,

- on the rear axle,

- total.

DENOMINATION

VIN CODE

DRIVE

Dimensions

WEIGHTS

DACIA

Double Cab P

REAR

D 2F71*

680 570

1250

635 540

1175

DACIA

Double Cab 4x4

INTEGRAL

D 4F76*

690 580

1270

645 550

1195

DACIA

Double Cab T

FRONT

D 1F71*

690 530

1120

645 500

1145

3. Technical admissible maximal weight of the loaded vehicle:

- on the front axle,

- on the rear axle,

- total.

4. Technical admissible maximal weight on each axle:

- on the front axle,

- on the rear axle.

5. Payload:

- on seats,

- on bed body,

- total.

710 1520 2230

820 1550

375

680 1055

730 1520 2250

820 1550

375

680 1055

710 1260 1970

820 1300

375

450

825

07 - 8

VALUES AND SETTINGS

Dimensions

TOWING WEIGHTS

DACIA Double Cab P, 4x4 and T

VEHICLE

TOWING

WEIGHTS

1. Te c hnical admissible maximal weight for towing (trailer with braking system)

2. Admissible maximal weight of the assembly

3. The vehicle is capable / is not capable for trailer towing

DENOMINATION

DRIVE

VIN CODE

DACIA

Double Cab P

REAR

D 2F71*

1095

3225**

capable

DACIA

Double Cab 4x4

INTEGRAL

D 4F76*

1075

3225**

capable

DACIA

Double Cab T

FRONT

D 1F71*

not

applicable

not

applicable

4. To w ing maximal weight without braking system

5. Te c hnical admissible maximal weight on towing coupling point

** By reducing the bed payload with 100 Kg.

450**

07 - 9

VALUES AND SETTINGS

Capacity - Qualities

DENOMINATION

Engine oil Dacia Oil Diesel

Gearbox oil DACIA OIL

SUPERGEAR

The rear axle group oil DACIA

OIL SUPERGEAR

Brake fluid

Cooling fluid

* To be ajusted at dipstick ** Mixture : 50% concentrated anti-freeze + 50% distilled water.

SAE API 10W40 ACEA B3 CF

SAE 80 W 90/GL5

SAE 80 W 90 / GL5

SAE J 1703 DOT 4

Typ e D - GLACEOL RX

QUALITY

CAPACITY

(liters)

4,6*

2,3

0,450

07 - 10

VALUES AND SETTINGS

Wheels and tires

VEHICLE

TYPE

DACIA Pic k Up T, P ºi 4x4 DACIA Drop Si de T, P ºi 4x4 DACIA Doub le Cab T, P ºi 4x4

(1) Using maximum loading, wheels on ground.

• Tightening moment of the wheels screws: 9 daNm.

• Rim axial run out: maxim 1,2 mm.

• Rim radial run out: maxim 1,2 mm.

RIMS TIRES

5 J 14

175 R 14

PR 8

ROLLING

CIRCUMFERENCE

1920 ± 25

PRESSURE

(bari) (1)

(mm)

FRONT REAR

2,0 4,5

ATT EN TI ON! The increase of tire temperature during running implies a growth of the tire pres-

sure with 0.2 – 0.3 bars compared with the prescribed values.

In case of checking the tires pressure immediately after vehicle driving, consider

this growth of pressure.

07 - 11

VALUES AND SETTINGS

Brakes

FRONT BRAKES

Brake caliper bore diameter (for aerated brake disk)

Disk thickness aerated

Minimal disk thickness aerated

Brake pad thickness ( the support included)

Minimal brake pad thickness (the support included)

Disk axial run out, measured at → 215 mm

REAR BRAKES

Wheel braking cylinder diameter

New drum diamete

Maximum drum diameter after grinding

Braking lining width

Braking lining thickness

Φ 54 mm

20 mm

19 mm

14 mm

7 mm

0,1 mm

Φ 25,4 mm

Φ 254 mm

Φ 255 mm

50 mm

5 mm

Minimal accepted braking lining height above rivets

MAIN BRAKE CYLINDER

Tandem master cylinder with ICP by

Type of main brake cylinder

nner diameter

Stroke - primary piston

- secondary piston

• Brake fluid reservoir - double without level warning.

• Pressure reducing valve - for parallel circuit.

• Brake fluid - norm SAE J 1703 DOT4.

• Servobrake - master vac 8" 224 mm

07 - 12

pass included

Φ 22,2 mm

min. 19 mm min. 13 mm

0,5 mm

VALUES AND SETTINGS

Heights under carriage body

VA LUES UNDER CARRIAGE BODY CONDITIONING THE ADJUSTMENT

OPERATIONS OF THE STEERING ANGLES.

H1 – the distance measured from the wheels center to the ground H2 – the distance measured from the longitudinal girder lower part to the ground H5 – the distance measured from the joint axis of the front leaf spring to the ground,

measured in the area of the lower arm attachment.

C – this value is showing the position where the rack must reach in order to obtain

the middle point for the steering rack.

07 - 13

VALUES AND SETTINGS

Control values of front the axle angles

COMMERCIAL U 75 DRIVE (1304, 1307)

ANGLES

CASTER

CAMBER

BALL JOINT

TOTAL PARALLELISM

VA L U ES

11'

28'

45' ± 30'

02'

19'

36' 52'

2 2

Maximum Left /

Right difference = 1

10 22'

21'

20'

18' ± 30'

17'

15'

14'

Maximum Left /

Right difference = 1

80 01'

02'

03'

04' ±30'

05'

07'

08'

Maximum Left /

Right difference = 1

POSITION OF THE VEHICLE

1304

H5 - H2 = 260 H5 - H2 = 250 H5 - H2 = 240

H5 - H2 = 230

H5 - H2 = 220 H5 - H2 = 210 H5 - H2 = 200

H1 - H2 = 66

H1 - H2 = 62

H1 - H2 = 58

H1 - H2 = 54

H1 - H2 = 51

H1 - H2 = 47

H1 - H2 = 43

H1 - H2 = 66

H1 - H2 = 62

H1 - H2 = 58

H1 - H2 = 54

H1 - H2 = 51

H1 - H2 = 47

H1 - H2 = 43

H5 - H2 = 265 H5 - H2 = 255

H5 - H2 = 245 H5 - H2 = 235 H5 - H2 = 225

H5 - H2 = 215 H5 - H2 = 205

H1 - H2 = 66

H1 - H2 = 62 H1 - H2 = 58 H1 - H2 = 54 H1 - H2 = 51 H1 - H2 = 47

H1 - H2 = 43

H1 - H2 = 66

H1 - H2 = 62 H1 - H2 = 58

H1 - H2 = 54 H1 - H2 = 51 H1 - H2 = 47

H1 - H2 = 43

ADJUSTMENTS

1307

Adjustable by

modification of

the tie-rod

length from

mounting

Not adjustable

ELASTIC JOINTS BLOCKING

Opening (toe-in)

10’ ± 10’

(for one wheel

05’ ± 05”)

Empty

07 - 11

Empty

Adjustable by

means of the tie rods rota-

tion

Empty

VALUES AND SETTINGS

Control values of the front axle angles

OTHER STEERING SYSTEM VALUES TO BE RESPECTED

ANGLES

Steering box positioning 6 – 7,75 on the scale By means of

Steering rack central C=65mm By means of the

point steering wheel

VA L U ES

T.F.246 eccentrics

POSITION OF THE VEHICLE

1304

1307

ADJUSTMENTS

rotation

07 - 12

VALUES AND SETTINGS

Control values of the front axle angles

COMMERCIAL U 75 / 4X4 DRIVE (1304, 1307)

ANGLES

CASTER

CAMBER

PIVOT

BALL JOINT

TOTAL PARALLELISM

VA L U ES

11'

29'

46' ± 30'

02'

19'

36' 53'

2 2

Maximum Left / Right

difference = 1

10 21'

20'

19'

18' ± 30'

16'

15'

13'

Maximum Left / Right

difference = 1

01'

02'

03'

04' ±30'

05'

07'

08'

Maximum Left / Right

difference = 1

Opening (toe-in)

0 160

-0

(for one wheel

08’± 05’)

-0

± 10

POSITION OF THE VEHICLE

1304

H5 - H2 = 260 H5 - H2 = 250 H5 - H2 = 240

H5 - H2 = 230

H5 - H2 = 220 H5 - H2 = 210 H5 - H2 = 200

H1 - H2 = 66

H1 - H2 = 62

H1 - H2 = 58

H1 - H2 = 54

H1 - H2 = 51

H1 - H2 = 47

H1 - H2 = 43

H1 - H2 = 66

H1 - H2 = 62

H1 - H2 = 58

H1 - H2 = 54

H1 - H2 = 51

H1 - H2 = 47

H1 - H2 = 43

Empty

1307

H5 - H2 = 265 H5 - H2 = 255

H5 - H2 = 245 H5 - H2 = 235 H5 - H2 = 22

H5 - H2 = 215

H5 - H2 = 205

H1 - H2 = 66

H1 - H2 = 62 H1 - H2 = 58

H1 - H2 = 54 H1 - H2 = 51 H1 - H2 = 47 H1 - H2 = 43

H1 - H2 = 66

H1 - H2 = 62 H1 - H2 = 58

H1 - H2 = 54 H1 - H2 = 51 H1 - H2 = 47 H1 - H2 = 43

Empty

ADJUSTMENTS

Adjustable by modification of the tie-rod

length from previous

mounting

Not adjustable

Adjustable by

means of the tie

rods rotation

ELASTIC JOINTS BLOCKING

Empty

VALUES AND SETTINGS

Control values of the front axle angles

OTHER STEERING SYSTEM VALUES TO BE RESPECTED

ANGLES

Steering box positioning 6 – 7,75 on the scale By means of

Steering rack central C=65mm By means of the

point steering wheel

VA L U ES

T.F.246 eccentrics

POSITION OF THE VEHICLE

1304

1307

ADJUSTMENTS

rotation

07 - 14

VALUES AND SETTINGS

Control values of the rear axle angles

COMMERCIAL U 75 DRIVE (1304, 1307)

ANGLES

CAMBER

PARALLELISM

ELASTIC JOINTS

BLOCKING

VA L U ES

00± 34'30''

(For two wheels)

To e out

00 ± 34'30''

VEHICLE

POSITION

Empty

ADJUSTMENTS

Not adjustable

07 - 15

VALUES AND SETTINGS

Control values of the rear axle angles

COMMERCIAL U 75 / 4 X 4 DRIVE (1304, 1307)

ANGLES

CAMBER

PARALLELISM

VA L U ES

± 19'59''

(For two wheels)

Toe out

± 19'59''

VEHICLE

POSITION

Empty

ADJUSTMENTS

Not adjustable

ELASTIC JOINTS BLOCKING

Empty

* In order to check and adjust the front axle angles values, respectively the rear axle

ones, the following must be done:

- perform the tires checking concerning:

- dimensions

- inflating pressure

- degree of wear

- perform the joints checking:

- elastic joints condition

- ball joint clearance

-wheel bearing clearance

The vehicle must be obligatory:

- positioned with the wheels on bench rotating plates being in horizontal direction

- braked ensured

- suspension tested, for vehicle setting at its free height

- steering brought at central point and steering rack blocked in this position.

These operations are to be followed by optical device attachment on vehicle, observing

the prescriptions of the steering measurement bench manufacturer.

07 - 16

ENGINE AND LOWER ENGINE UNITS

Ingredients

TYPE UTILIZATION

RHODORSEAL 5661 Front transmission pins, bearing covers (1)

and camshaft (5), bearing cover No. (1) and crankshaft

OIL 10W40 ACEA B3 API CF Parts lubrication during mounting

LOCTITE FRENETANCH Engine flywheel placing area on crankshaft

DÉCAPJOINT Cleaning of the cylinder head gasket plane

KIT DURCISSEUR Sealing of the bearing cover No.(1) crankshaft

Engine oil capacity: 4.6 liter (with filter) Used engine oil quality: Dacia Oil Diesel 10W40 API CF, ACEA B3

10 - 1

ENGINE AND LOWER ENGINE UNITS

Ve h i c l e Type

Pick Up P Drop Side P

Pick Up 4x4 Drop Side 4x4

Pick Up T Drop Side T

Double Cab P

Double Cab 4x4

Cod VINType

D 2611X(7;T)* D 2711X(7;T)

D 4616X(7;T) D 4716X(7;T)

D 1611X(7;T) D 1711X(7;T)

D 2F71X(7;T)

D 4F76X(7;T)

Identification

Engine

F8Q-636

Gearbox

NG 1-103

(50C-31)

NG7-101 (51C-02)

NG 1-104

(365-18)

NG 1-103

(50C-31)

NG 7-101

(51C-02)

Cylinder

capacity

(cm3)

Bore

(mm)

Stroke

(mm)

Vo l ume

ratio

1870 80 93 21,5

Double Cab T

D 1F71X(7;T)

NG 1-104

(365-18)

* X (7;T) - According to the pollution norm “X” - Euro 96; “7” - Euro 2000; “T” - 1504.

The engine identification is performed by means of a metallic plate, which is stuck on

the engine block.

ABDE

000 0 0 00

0 000000

A – engine type B – engine homologation letter D – “RENAULT” identity code E – engine index F – engine fabrication series G – code for assembling factory

10 - 2

ENGINE AND LOWER ENGINE UNITS

Oil consumption

OIL CONSUMPTION MEASURING

a) Oil filling at maximal level

This operation is to be performed when the engine is warm (an engine fan rotation) and after a stabilization of 15 minutes, necessary to the oil complete draining into the lower crankshaft.

Check the oil at the oil-indicating rod.

Fill to the maximal level.

Seal the draining and filling taps (mark them with paint, for further checking if these have not been dismounted

b) Customer driving time

Ask the customer to drive for about 2000 km or until the oil reaches the minimal level.

c) Refilling to the maximal level

This operation is to be performed when the engine is warm (an engine fan rotation) and after a stabilization of 15 minutes.

Check the oil at the oil-indicating rod.

Fill to the maximal level.

Write down the oil quantity and the driven mileage after filling to the maximal level.

d) Oil consumption measuring

Oil filled quantity (liter)

OIL CONSUMPTION =

kilometers (thousand)

10 - 3

ENGINE AND LOWER ENGINE UNITS

Oil pressure

Necessary Special Tools

MOT 836 - 05 Oil pressure measuring kit

CHECKING

The oil pressure is to be checked when the engine is warm (about 80°C).

The pressure value should be:

1.2 bars at 1000 rpm

3.5 bars at 3000 rpm

10 - 4

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting engine

Necessary Special Tools

MOT 1202 - 01 Pliers for elastic clips MOT 1311 - 06 Connections dismounting device

Pliers for clips type “CLIC”

TIGHTENING MOMENTS (daNm)

Engine supports attachment screws 3.6 Engine elastic supports nuts 2.7 Gearbox attachment on engine:

- upper attachment screws 4.4

- nuts 4.4

- lower attachment screws 2.1 RPM sensor 0.8 Starter attachment 4.4

The vehicle engine is to be dismounted through the engine compartment upper part by means of a mobile lifting device.

DISMOUNTING

The vehicle is to be placed on a 2– columns elevator.

The battery is to be dismounted.

The followings are to be drained:

- the cooling circuit, through water

pump inlet pipe and radiator lower hose:

- the engine oil.

The followings are to be dismounted:

- the air filter inlet sleeve;

- the radiator.

Disconnect:

- the mass wire from the engine lifting

clamp;

- the injection pump connector (1); lift

the flap (a) by means of a screw driver and take out the connector in the direction of arrow (b);

- the oil pressur e transmitter connector (2);

- the pre-heating spark plugs cables (3);

- the alternator electric connections ( 4);

- the diesel filter connector;

- the water temperature sensor connector

(5); pull the connector in the direction of the arrow (n) in the same time with clips pushing (m).

10 - 5

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting engine

- the temperature sensor connector (6);

- the EGR connector (7) : push the valve

in the direction of the arrow (x) and pull the connector in the direction of the arrow (y);

Dismount the supply connections (A)

and fuel return (B).

- The RPM senso r con nec tor. The wi ri n g attachment clip on the clutch

crankase is to be dismounted.

Remove from clips the fuel ducts from the air filter casing and from the distribution crankcase.

Dismount the air filter casing.

10 - 6

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting engine

Disconnect :

- the hoses ( 1) from the expansion

vessel;

- the se rv obrake connection (2);

- the connection (3) of the vacuum tank

(4 X 4 vehicles);

the climate co nt ro l hoses from the

the rmo stat box by means of the pli ers MOT 1202-01.

Dismount the RPM sensor from the clutch

crankcase of the gearbox

Dismount the upper attachment screws of

the gearbox on the engine.

Dismount the side attachment nuts of the

gearbox on the engine.

Lift the vehicle by means of the elevator

Dismount the engine shield. Dismount the lower attachment screws of

the gearbox on the engine.

Dismount the starter (see chapter 16

“ Starter “).

Dismount the attachment nuts of the

descent tube on the exhaust manifold.

Dismount the attachment clamp of the

descent tube on the engine.

Dismount the elastic supports nuts of the

engine.

10 - 7

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting engine

REMOUNTING

Perform the dismounting operations in

the reverse order.

Perform the cooling circuit filling and purging (see chapter 19 “ Filling and purging “).

Perform the engine oil filling

Sustain the gearbox by means of a jack. Fix the lifting device on the engine lifting

supports.

Move forward the engine and lift it. Place the engine on a support.

10 - 8

ENGINE AND LOWER ENGINE UNITS

Engine fitting - unfitting

For the replacement of the standar d engine, the following operations are to be performed:

DISMOUNTING

The followings are to be dismounted:

- the air filter;

- the alternator, the belt and its tightening device;

- the alternator support;

- the oil rod and its guide;

- the clutch disk and mechanism;

- the engine flywheel;

- the high pressure pipes;

- the injection pump gear;

- the injection pump, the injectors and the port-injectors;

- the vacuum pump;

- the water pump pipe;

- the water pump;

- the pre-heating sparking plugs;

- the E.G.R. assembly;

- the intake and exhaust collectors;

- the distribution crankshafts;

- the oil filter;

- the thermostat box;

- the camshaft gear;

- the crankshaft gear and pulley;

- the distribution belt tightening roller;

- the oil mono-contact.

REMOUNTING

The worn or damaged parts are to be replaced. Perform the dismounting operations in the reverse order. The attachment screws and nuts are to be tightened according to the required moment.

10 - 9

ENGINE AND LOWER ENGINE UNITS

Tightening moments

TIGHTENING MOMENTS (daNm)

Alternator attachment screws

- M 10 ……………………………………………………………...……… 3.8

- M 8 ………………………………………………………………………. 1.9

Injectors supply pipes (high pressure) ……………………………….......… 2.5

Injection pipe attachment…………………………………………………… 2.5

Injection pump pulley nut ………………………………………….......…… 5.5

Intake – exhaust manifold fixing ………………………………………..…. 2.7

Air filter attachment ……………………………………………………....… 0.8

Port – injectors ………………………………………………………….....… 7

Incandescent sparking plugs ………………………………………………1.5 ÷ 2

E.G.R. attachment ……………………………………………….......……… 0.8

Gases tube attachment on exhaust manifold …………………….............…1.9

Water pump pipe attachment ………………………………………….....… 3.8

Camshaft gear screw …………………………………………………...…… 5

Cylinder head cover nuts……………………………………………….....… 1.2

Camshaft bearing covers screws……………………………………….…… 2 Engine flywheel screws……………………………………………………. 5 ÷ 5.5 Lower crankcase screws……………………………………………….… 1.2 ÷ 1.5 Connection rods covers screws…………………………………………… 4.5 ÷ 5

Bearing covers screws……………………………………………………...... 6.5

Crankshaft pulley screw…………………………………………..... 2 + 115° ± 15°

Water pump attachment screws………………………………….................. 1.6

Water pump pulley screws…………………………………………………... 2

Oil pump attachment screws……………………………………….............. 2 ÷ 2.5

Distribution belt tensioning nut…………………………………………….. 5

Starter attachment screws …………………………………………….......... 4.4

Clutch mechanisme attachment screws …………………………………… 5

10 - 10

ENGINE AND LOWER ENGINE UNITS

Characteristics

CYLINDER HEAD

The cylinder head is aluminum made and

it is provided with turbulence chambers.

Cylinder head height = 159.5 ± 0.2 mm. The cylinder head is not to be rectified. The maximal deformation of the gasket

plane is 0.05 mm.

Cylinder head moments will by respected

the discribed method (see chapter 10 “Dis-

mounting - Remounting”).

TURBULENCE CHAMBERS

- over-height compared with the cylinder head: y = 0.01 ÷ 0.04 mm;

- cylinder head slot diameter (d): d = 37.5 mm

- channel angle compared with the cylinder head (á):

á = 35°

E = 1.4 mm.

B. A one-hole gasket is to be used for

an over-height within 0.613 mm (inclusive) and 0.767 mm (exclusive).

E = 1.5 mm.

C. A three-holes gasket is to be used

for an over-height higher than 0.767 mm

E = 1.6 mm.

NOTICE:

The necessary holes for the gasket thickness identification are placed in a 25-mm˝ area as against its edge. Any other hole is not to be taken into consideration, in case it is placed out of the above-mentioned area.

The gasket thickness identification mark (R) may be seen even with the cylin- der head mounted.

CYLINDER HEAD GASKET

The cylinder head gasket (E) thickness var- ies according to the pistons maximal overheight, as follows:

A. A two-holes gasket is to be used for an over-height lower than 0.613 mm

10 - 11

ENGINE AND LOWER ENGINE UNITS

The cylinder head gasket thickness is to be obligatory recalculated according to the pistons over-height in case one of the following elements is replaced:

- crankshaft,

- cylinders crankcase,

- connecting rods

- pistons.

Otherwise the cylinder head gasket is to be replaced with a same thickness one.

VA L V E S

Valve rod diameter 8 mm

Characteristics

VA LV ES SEATS

Sealing face angle (á):

- intake 120°

- exhaust 90°

Sealing face width (X): 1.8 mm

External diameter (D):

- intake 36.8 mm

- exhaust 32.6 mm

Sealing face angle:

- intake 120°

- exhaust 90°

Tray diameter:

- intake 35.2 ± 0.1 mm

- exhaust 31.5 ± 0.1 mm

10 - 12

ENGINE AND LOWER ENGINE UNITS

Characteristics

VA L V E S GUIDES

The valves guides are identical for both intake and exhaust. They are provided with oil-rings for sealing the valves rods.

Internal diameter 8 mm

External diameter

- nominal 13 mm

- repair (marked with 2 channels) 13.30 mm

Guides position as against the gasket plane (A) 43.25 mm

Cylinder head bore for guide

- nominal 12.9 mm

- repair 13.20 mm

VA L V E S SPRINGS

The valves springs are identical for both

intake and exhaust.

Length in free state 47.2 mm

Length under a load of:

- 23 ± 2 daNm 37.9 mm

- 70.5 ± 3.5 daNm 27.4 mm

Length of the stuck coils 25.77 mm

Coil diameter 4 mm

Internal diameter 21.5 mm

CAMSHAFT

The engine is provided with a camshaft having the cams on its head, mounted in the cylinder head and driven by the distribution belt .

The camshaft cams operate the valves by tappets

Replacing the tappets, only with cold engine, regulates the thermal clearance.

Thermal clearance values:

- intake: 0.20 ± 0.05 mm,

- exhaust: 0.40 ± 0.05 mm.

10 - 13

Axial clearance (mm)

Number of bearings

Distribution diagram

0,05 ÷ 0,13

ADA

ÎÎA

ADE

ÎÎE

- 2° 45° 45° - 4°

ENGINE AND LOWER ENGINE UNITS

TA PPETS

The tappet with conform thickness (y) is to be chosen for getting the thermal clearance.

As spare parts, there are 24 classes of tappets, with thickness (y) within 7.550 and 8.150 mm.

The thickness increases every

0.025 mm.

Tappets external diameter:

-0,01

35 mm.

-0,04

PISTONS

As spare part , there i s only on e class (M).

The piston is to be mounted: with the turbulence chamber towards the oil filter.

The pistons diameter (D) is to be measured at a distance A = 60 mm from the piston head.

D = 80 mm.

Characteristics

BOLTS

The bolts are freely mounted in the connecting rod and piston. They are axially kept by means of a security device.

Length (mm) 63

Internal diameter (mm) 13.3

External diameter (mm) 24

RINGS

Thickness (mm)

- Compression ring 2

- Sealing ring 2

- Oiling ring 3

The rings are to be mounted with the mark “TOP” towards the piston head and the grooves separated at 120°.

To p

10 - 14

ENGINE AND LOWER ENGINE UNITS

Characteristics

CONNECTING RODS

Connecting rod s ide c learance: 0.22 ÷ 0.40

mm.

The connecting rod end is bushed. The bushes are not to be replaced.

NOTICE: The connecting rods and their covers are not to be marked by means of punches, but by permanent markers.

CRANKSHAFT

Number of bearings 5 Bearings nominal diameter (mm) 54.795 ± 0.01

Pressure gauges nominal diameter (mm) 48 ÷ 0.02 / ÷ 0

OIL PUMP

The oil pump is with gear wheels type, driven by means of a chain by the crankshaft.

Oil minimal pressure at 80°C (bars):

- at 1000 rpm……………………1.2

- at 3000 rpm……………………3.5

Pistons coolers valves opening pressure: 2.2 ± 0.2 bars. The followings are to be checked:

- Clearance A (mm): - minimum 0.100

- maximum 0.240

Axial clearance (mm) 0.07 ÷ 0.23

Axial half-bearings 2.30; 2.35; thickness (mm) 2.40; 2.45

- Clearance B (mm): - minimum 0.020

- maximum 0.085

10 - 15

ENGINE AND LOWER ENGINE UNITS

SERVICE

CODE

MOT 251-01

MOT 252-01

MOT 582

MOT 799-01

MOT 988-02

MOT 990-03

MOT 991-01

MOT 997-01

Necesary special tools

DENOMINATION

Comparing support

Plate for over-height pistons measurement

Flywheel immobilizing sector

Camshaft gear immobilizing device

Camshaft sealing mounting device

Crankshaft sealing mounting device towards distribution

Crankshaft sealing mounting device towards flywheel

Port – injectors mounting – dismounting device

MOT 1054

MOT 1200-01

MOT 1520

MOT 1522

MOT 1525

MOT 1485-01

MOT 1516-01

MOT 1492

MOT 1493

MOT 1505

MOT 1202-01

MOT 1516

MOT 1566

Rod for engine pressing-on.

Injection pump pulley maintaining device

Injection pump blocking rod E.P.I.C.

Injection pump blocking pulley E.P.I.C.

Injection pump pulley extractor

Pistons coolers dismounting device

Pistons coolers mounting device (used with MOT 1516)

Connecting rods bearings device

Bearings mounting device

Belts tension measurement device

Pliers for elast ic clips Mounting device for pistons coolers Wre nch for mo unt ing /dismo un tin g hi gh- pr ess ure duc ts

10 - 16

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

CYLINDER HEAD

10 - 17

ENGINE AND LOWER ENGINE UNITS

DISMOUNTING

- drain the oil from the engine.

- drain the cooling fluid. The followings are to be dismounted:

- the air filter,

- the oil vapors recycling system hoses,

- the alternator belt and its tensioning de-

vice,

Dismounting - Remounting

- the distribution belt (see Chapter 11

“Distribution Belt”).

The followings are to be dismounted:

- the injectors supplying pipes,

- the incandescent sparking plugs sup-

plying wires,

- the injection pump (see Chapter 13

“Injection Pump”),

- the depression hose off the vacuum

pump,

- the alternator,

- the distribution crankcases,

- the intake and exhaust manifold,

- the camshaft gear,

- the cylinder head cover. The cylinder head attachment screws

are to be unscrewed.

The cylinder head is to be dismounted without rotate it (the cylinder head is centered by means of two bushes (C)).

10 - 18

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

The camshaft bearing covers are to be dismounted (the covers order and direction are to be marked prior their dismounting).

12345

- the incandescent sparking plugs,

- the turbulence chambers,

- the thermostat support.

The followings are to be dismounted:

- the camshaft,

- the tappets (they are to be marked as

against the cylinder head),

- the injectors, by means of the

MOT 997-01 device,

The following are to be dismounted:

- the valves springs,

- the valves,

- the valves oil sealing rings.

In order to get a right tightening of the cylinder head screws, the oil that may be in the cylinder head fixing holes is to be extracted by means of a syringe.

WARNING!

Avoid foreign materials introduction into the oil grooves, otherwise the latter will clog, and the camshaft will quickly breakdown.

It is very important not to scratch the gasket seating face.

The DECAPJOINT is to be used for cleaning the gasket possible stuck bits.

Spread out the substance on the area to be cleaned, wait for about 10 minutes, and clean with a wooden spatula.

MOT 997-01

During this operation, wear protection gloves.

10 - 19

ENGINE AND LOWER ENGINE UNITS

The cylinder head flatness is checked by

means of a ruler and a kit of gauges.

Maximal permitted deformation: 0.05 mm.

The cylinder head is not to be rectified.

Dismounting - Remounting

The valves are to be run-in on their

seats.

The valves are to be marked as against

the cylinder head.

The parts are to be oiled with engine

oil.

The followings are to be mounted in or-

der:

- the valves oil-sealing rings (1), by

means of a 12 mm tubular wrench,

- the valves (2),

- the lower hoods (3),

- the va lve springs (4), (are identical for

both intake and exhaust),

- the upper hoods (5),

the half-cones (6).

REMOUNTING

The new valves are to be placed on posi- tion; the valves return as against the gasket plane is to be checked by means of the MOT

251-01 and MOT 252-01 devices, as follows:

- intake: 0.85 ± 0.09 mm

- exhaust: 0.97 ± 0.09 mm

MOT 251-01

MOT 252-01

10 - 20

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

The turbulence chambers (7) are to be

mounted.

MOT 252-01

MOT 251-01

Their over-height is to be checked by

means of the devices MOT 251-01 and

MOT 252-01: x = 0.01 ÷ 0.04 mm

The incandescent sparking plugs are to be mounted and tightened at a moment of

1.5 ÷ 2 daNm

The anti-flame washers (9) are to be mounted observing their orientation. The anti-flame washers (9) and the gaskets are to be replaced every time the port-injectors are to be dismounted.

The port-injectors are to be mounted and

tightened at a moment of (6.5 ÷ 7.5 daNm)

The thermostat support is to be mounted.

10 - 21

ENGINE AND LOWER ENGINE UNITS

THERMAL CLEARANCE ADJUSTMENT

This operation is to be performed only when the engine is cold. The method “In balance” is used when checking the valves clearance (the cylinder valves at the end of the exhaust and the beginning of the intake).

Dismounting - Remounting

The comparing gauge is to be set on

“zero”.

MOT 252-01

Cylinder valves

in balance

1 3 4 2

The measured values are to be compared with the reference ones:

- intake: 0.20 mm

- exhaust: 0.40 mm

In case the clearance (x) is not accord- ing to the requirements, the respective tap- pet is to be replaced with one having the adequate thickness (y).

The value (y) squares with the tappet class (there are 24 classes).

The va lue (y) is to be measured by a MOT 252-01 plate, a magnetic plate support, and a

comparing gauge with a precision of

0.001 mm.

Cylinder valves to be checked

4 2 1 3

The comparing fee ler i s to be lifted (not

to modify the assembly position).

The tappet is to be introduced and the

value (y) is to be measured.

The value (y) varies every 0.025 mm,

from 7.550 to 8.150.

10 - 22

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

The following are to be mounted:

- the camshaft,

- the camshaft bearings covers, ob- serving the marking performed during the dismounting.

A thin layer of RHODORSEAL 5661 is to be applied on the bearings covers (1) and (5), according to the drawing indications.

The pistons are to be positioned so

that neither of them is on its upper dead point, in order to avoid the contact with the valves, during the camshaft covers tightening (the blocking mark on the

crankshaft is to be horizontally positioned).

The camshaft bearings covers screws are to be progressively tightened at a required moment of (2 daNm).

The camshaft axial clearance is to be checked; the clearance should be within

0.05 and 0.13 mm

The followings are to be mounted:

- the vacuum pump (2) and its gasket

(3),

- the c amshaft-sealing gasket, by means of

the MOT 988-02 device.

MOT 1505

MOT 988-02

10 - 23

ENGINE AND LOWER ENGINE UNITS

- the camshaft gear – its screw (4) is to be

tightened at a required moment of 5 daNm.

- the injection pump support – its screws

are to be tightened at a required moment of (2.5 daNm),

Dismounting - Remounting

- the injection pump – the screws are to be progressively screwed by hand and then tightened at 2.5 da Nm (see Chapter 13

“Injection Pump”),

- the cylinder head cover,

- the injectors pipes, the injection pump gear – it is to be immobilized by means of the MOT 1200-01 device and its nut is to be tightened at 5.5 daNm.

MOT 1200-01

10 - 24

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

CYLINDERS CRANKCASE

10 - 25

ENGINE AND LOWER ENGINE UNITS

DISMOUNTING

The following are to be dismounted:

- the clutch,

- the engine flywheel (it is immobilized

by means of the MOT 582),

- the lower crankcase,

- the crankshaft gear,

- the distribution belt lower protection

plate,

- the distribution with oil-sealing ring

crankcase,

Dismounting - Remounting

CYLINDERS CRANKCASE

- the water pump,

- the crankshaft sealing gasket support,

- the oil pump (the two attachment

screws are to be unscrewed and the pump is to be turned over).

Mark the connecting rod covers

compared with the connecting rod body.

10 - 26

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

The following are to be dismounted:

- the connecting rod covers and bear-

ings,

- the pistons – connecting rod assembly (the pistons are to be marked as against the cylinders

- No.1 towards the flywheel),

- the bearings covers and bearings,

- the bearing No.1 oil-sealing ring,

- the crankshaft and the bearing for axial clearance adjustment

- the bearings on the cylinders crank- case.

The piston axle-maintaining locks are to be extracted and the connecting rods are to be dismounted (the axle is freely mounted in the piston and c onnecting rod).

PISTONS COOLERS REPLACEMENT

COOLERS DISMOUNTING

- the cooler (1) is to be drilled with a Ö 7

mm drill,

- extract the stopper (2) and spring (3).

The rings are to be dismounted.

NOTICE:

The ball (4) is not to be extracted in order to avoid the splinter entering the oil circuit.

The remained splinter is to be removed by

means of a brush.

10 - 27

ENGINE AND LOWER ENGINE UNITS

The MOT 1485–01 is to be screwed in the

cooler and the latter is to be extracted.

MOT 1485-01

Dismounting - Remounting

The cooler is introduced in the device

rod.

PISTONS COOLERS MOUNTING

The cooler mounting is performed by

means of the MOT 1516-01 device.

MOT 1516-01

The MOT 1516-01 device plate (3) is to be mounted on the cylinders crankcase and centered by mans of the centering device (2).

The screws (1) are to be tightened then the centering device is to be removed.

NOTICE:

Pay attention when mounting the cooler; the end (4) is to be directed towards the cylinder center.

The cooler is to be positioned again

and again, until the pressing rod shoulder (5) contacts the plate (3).

10 - 28

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

REMOUNTING

The cylinders crankcase gasket areas and the crankshaft oiling grooves are to be cleaned.

The connecting rod bearings are identical

and they are not provided with groin.

They are to be mounted by means of the MOT 1492 device.

Pay attention to the coolers direction.

A: coolers direction for cylinders 2 and 4.

coolers direction for cylinders 1 and 3.

The bearing support (1) is to be chosen according to the engine shown in position (2).

The bearing support is to be mounted in the device slot (3).

The connecting rod is to be mounted on the device so that the lower part of the connecting rod leg (4) contacts the centering part.

10 - 29

ENGINE AND LOWER ENGINE UNITS

The bearing (5) is to be placed on the

bearing support (see the following drawing).

Dismounting - Remounting

The connecting rod cover is to be placed on the support so that the latter hits the two studs (6) then the bearing (7) is to be mounted on its support.

The bearing support is moved according to the arrow so that the bearing hits the connecting rod.

The same operations are to be per-

formed for all the other connecting rods.

The followings are to be performed when mounting the connecting rods covers bearings:

The bearing support is moved according to the arrow so that the bearing hits the cover.

The pistons are to be mounted with the bolts and connecting rods.

10 - 30

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

The axle / piston keeping locks are to

be mounted.

The rings are to be mounted on the

piston as follows:

- the oiling ring (3),

- the sealing ring (2) with the “TOP”

mark upward,

- the compression ring (1) with the

“TOP” mark upward.

The rings are to be positioned at 120° from one another, with the oiling ring slot in front of one of its channel full.

The ring slot is not to be adjusted.

The rings – piston – connecting rod assembly is to be oiled and mounted in the cylinders crankcase so that the turbulence chamber is directed towards the oil filter

The bearings are not provided with groins

The bearings to be mounted in the cylinder crankcase are provided with oiling holes.

The MOT 1493 device is to be used for the bearings mounting.

MOT 1493

The MOT 1493 device is placed on the cylinders crankcase.

10 - 31

MOT 1493

ENGINE AND LOWER ENGINE UNITS

The bearing is to be mounted in the MOT

1493 device. Then the bearing is to be pushed

on the point (A) until it hits the point (B) of the device.

Dismounting - Remounting

The bearing-covers (3), (4) and (5) are

to mounted and tightened at 6.5 daNm.

The crankshaft axial clearance (j) is

to be checked:

j = 0.07 ÷ 0.23 mm

The axial bearings may have: 2.30, 2.35,

2.40 and 2.45 mm.

The MOT 1493 device is to be placed on

the bearing cover.

The bearing is to be m ounted in the device. Then the bearing is to be pushed on the point (A) until it hits the point (B) of the MOT 1493 device

The oiled crankshaft and t he axial bearings are to be mounted (at bearing No.2).

The followings are to be mounted:

- the bearing cover (2); then it is to

be tightened at a required moment of (6.5 daNm),

- the connecting rod covers; then they

to be tightened at 4.5 ÷ 5 daNm.

The bearing (1) is to be sealed by silicon

injection.

a) Mounting of the gaskets

- If the channel thickness is lower to 5

mm, a 5.1 - mm thickness gasket is to be used.

- If the channel thickness is greater than

5 mm, a 6 - mm thickness gasket is to be used.

The gaskets are to be mounted with

channel towards exterior.

b) Silicon injection

The necessary kit for this operation

includes a 50 ml syringe and a 5 ml tube of DURCISSEUR.

10 - 32

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

IMPORTANT:

The injection is to last at least 5 minutes, in order to avoid the syringe mixture polymerization.

The cylinders crankcase and the bearing cover areas (A) are to be cleaned and degreased with thinner.

Thirty milliliters (30 ml) of RHODORSEAL 5661 are to be mixed with one third (1/3) of the tube of DURCISSEUR until obtaining a homogeneous mixture.

The mixture is to be introduced into the syringe and then slowly injected into the bearing cover grooves so that the sealing between the bearing cover and the cylinders crankcase is perfect.

Wait for the mixture polymerization and remove the excess.

A thin layer of RHODORSEAL 5661 is to be applied on the cylinders crankcase areas (B).

The bearing cover (1) is to be mounted and tightened at 6.5 daNm.

10 - 33

ENGINE AND LOWER ENGINE UNITS

The assembly rotation is to be checked.

The bearing (1) oil-sealing ring is to be mounted by means of the device MOT 991-01.

MOT 991-01

Dismounting - Remounting

The crankshaft oil-sealing ring on the

distribution side is to be oiled.

The oil-sealing ring is to be mounted

by means of the device MOT 990-03.

MOT 990-03

The crankshaft cover centering bushes are to be checked on the distribution side.

The support is to be mounted with a new gasket.

The oil pump ce ntering bushes presence

is to be checked.

The oil pump is to be mounted and the attachment screws are to be tightened at a required moment of 2 ÷ 2.5 daNm.

10 - 34

ENGINE AND LOWER ENGINE UNITS

Dismounting - Remounting

The engine flywheel supporting area on the crankshaft is to be lubricated with LOCTITE AUTOFORM.

The geared sector MOT 582 is to be dismounted.

MOT 582

The screws are to be tightened at a required moment of (5 ÷ 5.5 daNm).

The geared sector MOT 582 is to be dismounted.

The clutch is to be mounted (see the Chapter 20 “The Clutch”) and its attachment screws are to be tightened at 2 daNm.

The lower crankcase is to be provided with a new gasket; its screws are to be tightened at a required moment of (1.2 ÷

1.5 daNm).

CYLINDER HEAD REMOUNTING

- The followings are to be mounted:

- The cylinder head centering bushes;

- The cylinder head gasket.

NOTICE:

In case of replacing one of the following

elements

- the crankshaft,

- the cylinders crankcase,

- the connecting rods,

- the piston,

it is obligatory to recalculate the cylinder head gasket thickness according to the pistons area. Otherwise the cylinder head gasket is to be replaced with an identical one.

In order to establish the gasket thickness the pistons over-height is to be measured by means of the devices MOT 251-01 and MOT

252-01.

The calamine is to be removed fr om the pistons head.

The crankshaft is to be rotated towards the running direction and the piston (1) and its upper dead point.

The piston over-height is to be measured.

The operation is to be repeated for all the other pistons.

10 - 35

ENGINE AND LOWER ENGINE UNITS

NOTICE

The measurements are to be performed on the engine longitudinal axe, in order to avoid the errors caused by the piston turning over.

IMPORTANT!

ONLY THE MAXIMAL OVER-HEIGHT IS

TO BE TAKEN INTO CONSIDERATION.

The followings are to be used to get a

maximal over-height of the piston:

- less than 0.613 mm a two-holes gasket

is to be used (thickness 1.4 mm),

- within 0.613 mm (inclusive) and 0.767

mm (inclusive): a one-hole gasket is to be used (thickness 1.5 mm),

- higher than 0.767 mm: a three-holes gas-

ket is to be used (thickness 1.6 mm).

The pistons are to be brought at halfstroke, in order to avoid the contact with their valves.

The cylinder head is to be centered on the two centering bushes.

The cylinder head screws are to be tightened at the required moment and oiled, observing the following method:

CYLINDER HEAD TIGHTENING

METHOD

1. GASKET PRE-SETTING

Dismounting - Remounting

The cylinder head screws are to be

tightened at 3 daNm, then at an angle of 80° ± 4°, observing the order indicated in the drawing. Wait for 3 minutes.

2. CYLINDER HEAD TIGHTENING

The screws 1 and 2 are to be totally unscrewed and tightened at 2.5 daNm, then at an angle of 213° ± 7°.

The same i s to be done for the screws

3-4, 5-6, 7-8 and 9-10.

The cylinder head is not to be re-tightened.

The distribution belt is to be mounted and tensioned at 61 ± 5 Hz (see Chapter

11 “The Distribution Belt”).

The nut of the tightening roller is to be obligatory tightened at 5 daNm.

Perform the pressing-on of the injection pump. (see Chapter 13 “Injection Pump Pressing-on”).

Then, the followings are to be mounted:

- the distribution covers,

- the crankshaft pulley – its screw is

to be tightened at 2 daNm then at an angle of 115° ± 15°,

- the intake-exhaust manifold - its

screws are to be tightened at 2.7 daNm

- the alternator and its belt – the al-

ternator belt is to be tensioned at 127 ± 5 Hz (see Chapter 16 “Alternator”).

10 - 36

ENGINE AND LOWER ENGINE UNITS

Lower crankcase

TIGHTENING MOMENTS (daNm)

Lower crankcase attachment screws ............................................................... 1.5

Cross-tie attachment screws............................................................................... 5.7

Attachment screws of the anti-rolling bar on longitudinal girders................. 2

DISMOUNTING The vehicle is to be placed on a two-columns elevator. The battery is to be dismounted. The oil is to be drained from the motor. The following are to be dismounted:

- the engine shield,

- the engine shield cross-tie,

- the attachment screws of the anti-rolling bar on longitudinal girders.

The lower crankcase attachment screws are to be dismounted.

REMOUNTING

The lower crankcase is to be cleaned. The lower crankcase is to be mounted with a new gasket.

Perform the dismounting operations in the reverse order. The engine is to be filled with oil

(Dacia Oil Diesel 10W40 API CF).

10 - 37

ENGINE AND LOWER ENGINE UNITS

TIGHTENING MOMENTS (daNm)

Oil pump attachment screws .......................................... 2 ÷ 2,5

DISMOUNTING

The followings are to be dismounted:

- the lower crankcase (see Chapter 10 “Lower Crankcase”),

- the two attachment screws of the oil pump on the cylinders crankcase.

Oil pump

The oil pump is turned over, the driving chain is to be extracted from the gear, and the

pump is to be dismounted.

The oil pump cover is to be dismounted. The oil pump gear clearance is to be checked (see Chapter 10 “Characteristics”).

REMOUNTING

Perform the dismounting operations in the reverse order. The engine is to be filled with oil. The oil pressure at 80° is to be checked.

- at 1000 rpm…………………1.2 bars

- at 3000 rpm ………………...3.5 bars

10 - 38

ENGINE AND LOWER ENGINE UNITS

Crankshaft sealing gasket towards distribution

Necessary Special Tools

MOT 1054 Engine pressing-on rod MOT 990-03 Crankshaft sealing gasket mounting device

towards distribution

MOT 1505 Belts tension measurement device

TIGHTENING MOMENTS (daNm)

Crankcase pulley screw 2+115°±15° Distribution belt tensioning roller nut 5 Alternator attachment screw 1,9

MOT 990-03

GASKET REPLACEMENT

DISMOUNTING

The distribution belt is to be dis-

mounted (see Chapter “Distribution Belt”)

The gear is to be dismounted from

the crankshaft.

The crankshaft-sealing gasket is to be

extracted.

REMOUNTING

The new sealing gasket is to be mounted

by means of the device MOT 990-03.

The distribution belt is to be mounted (see

the method described in the Chapter “Distribution Belt”).

10 - 39

ENGINE AND LOWER ENGINE UNITS

MOT 991-01 Crankshaft sealing mounting device towards flywheel MOT 582 Flywheel immobilization sector

TIGHTENING MOMENTS (daNm)

Engine flywheel attachment screws ……5 ÷ 5.5

Clutch attachment screws…..........……… 2

Gearbox attachment screws on engine

- upper attachment ……….......……… 4.4

- lower attachment ………........………2.1

GASKET REPLACEMENT

Crankshaft sealing towards flyweel

Necessary Special Tools

REMOUNTING

The new s ealing gasket is to be mounted by means of the device MOT 991-01.

MOT 991-01

This operation is to be performed after dismounting the gearbox, the clutch, and the engine flywheel.

DISMOUNTING

The gearbox is to be dismounted from the vehicle (see Chapter 21 “Dismounting-

Remounting Of The Gearbox”).

The clutch is to be dismounted (see

Chapter 20 “Clutch Dismounting-Remounting”).

The engine flywheel attachment screws are to be dismounted (immobilized by means of the device MOT 582).

The crankcase-sealing gasket is to be extracted.

The gasket housing is to be cleaned.

The holes thread of the flywheel attach- ment screws is to be cleaned with a dry gaze.

The flyw heel seating area on the c rankshaft is to be degreased.

The engine flywheel is to be mounted and to be immobilized with MOT 582.

The flywheel seating area is to be applied with LOCTITE AUTOFORM.

The stopping sector MOT 582 is to be dismounted.

The holes thread of the flywheel attachment screws is to be cleaned with a dry gaze.

10 - 40

ENGINE AND LOWER ENGINE UNITS

Engine set replacing

Necessary Special Tools

MOT 251-01 Comparing support MOT 252-01 Comparing support plate MOT 1054 Engine pressing-on rod

MOT 1505 Belts tension measurement device

TIGHTENING MOMENTS (daNm)

Connecting rods attachment

screws ............................................. 4.5 ÷ 5

Injectors supplying pipes ……………2.5 Crankcase pulley screw …...… 2 + 115 ± 15° Distribution belt tensioning

roller nut.............................................…5

Oil pump attachment screws……… 2 ÷ 2.5

DISMOUNTING

The vehicle is to be placed on a two-

columns elevator.

The battery is to be dismounted. The oil is to be drained from the mo-

tor.

The cooling fluid is to be drained. The lower crankcase is to be dis-

mounted (see Chapter 10 “Lower Crank- shaft”).

The oil pump attachment screw is to be dismounted and the pump is to be extracted by turning it over.

The cylinder head is to be dismounted (see Chapter 10 “Cylinder Head

Dismounting-Remounting”).

The connecting rods covers are to be dismounted.

The connecting rods covers are to be marked as against the connecting rods

bodies.

The pistons-connecting rods assembly is to be dismounted.

The axe piston-maintaining locks are to be extracted and the connecting rods are

to be dismounted.

10 - 41

REMONTARE

The bearings are to be mounted on the

connecting rods bodies and covers (see the method described in Chapter 10 “Cylinders Crankcase Dismounting –Remounting”)

The pistons and the bolts – pistons are to

be mounted.

The a xe gear-maintaining locks s ecurities

are to be mounted.

The pistons rings are to be mounted

observing the order:

- the oiling ring,

- the sealing ring with the mark “TOP”

upward,

- the compression ring with the mark

“TOP” upward.

The rings are to be positioned at 120

from

one another.

ENGINE AND LOWER ENGINE UNITS

The rings – piston – connecting rod assembly is to be lubricated with engine oil and mounted in the cylinders crankcase, with the turbulence chamber towards the oil filter.

The connecting rods cover are to be mounted, observing the dismounting marks and the screws are to be tightened at the required moment (4.5 ÷ 5 daNm)

The piston over-height is to be measured by means of the devices MOT 521-01 and MOT 252 – 01 , in order to calculate the thickness of the cylinder head.

NOTICE:

The measurements are to be performed on the engine longitudinal axle in order to eliminate the errors caused by the piston turning over.

Engine set replacing

For a piston maximal over-height:

- less than 0.613 mm : a two – holes

gasket is to be used for identification (thickness 1.4 mm),

- within 0.613 mm (inclusive) and

0.767 mm (inclusive): a one-hole gasket is to be used for identification (thickness

1.5 mm),

- higher than 0.767 mm: a three-holes gasket is to be used for identification (thickness 1.6 mm)

The cylinder head is to be mounted

(see the Chapter 10 “Dismounting- Re-

mounting”).

The oil pump is to be mounted and the attachment screws are to be tightened at the required moment.

The lower crankcase is to be mounted (see the Chapter 10 “Lower Carter”).

The distribution belt is to be mounted (see Chapter 11 “Distribution Belt”).

The alternator belt is to be mounted (see Chapter 16 “Alternator”).

The engine is to be filled with oil

Dacia Oil Diesel 10W40 API CF.

The cooling circuit is to be purged and filled with cooling fluid GLECEOL Rx

type D (see Chapter 19 “Filling - Purging”).

IMPORTANT:

ONLY THE MAXIMAL OVERHEIGHT IS TO BE TAKEN INTO CONSIDERATION.

10 - 42

UPPER AND FRONT ENGINE UNITS

Distribution belt

Necessary Special Tools

MOT 1054 Engine pressing-on rod MOT 1505 Belt tensioning measurement device

TIGHTENING MOMENTS (daNm)

Crankshaft pulley screw 2 + 115° Tensioning roller nut 5

DISMOUNTING

Place the vehicle on a two-columns el-

evator.

Disconnect the battery. Drain the cooling circuit by the radia-

tor lower hose.

Dismount the radiator. Dismount the accessories belt (see

chapter 16 “Alternator”.

Rotate de crankshaft in order to line up the mark from the camshaft gear with the pressing-on window ( C).

Mount the engine pressing-on rod MOT

1054.

MOT 1054

Dismount :

- the crankshaft pulley,

- the support of the fuel return pipe,

- the distribution crankcases.

11 - 1

UPPER AND FRONT ENGINE UNITS

Dismount the tensioning roller and remove

the distribution belt.

NOTICE :

An unscrewing more than one rotation of the tensioning roller may lead to its falling from the pivoting screw.

REMOUNTING

Check if the rod MOT 1054 is correctly mounted. Mount a new distribution belt, observing the rotation direction shown by the arrows back of the belt. The belt has marked on the external part three marks and one mark on the internal side for pressing-on; the internal mark is off one external mark.

Line up the internal m ark from the belt with the mark from the crankshaft gear.

Then, line up the marks from the crankshaft gear and the injection pump gear with the corresponding marks from the belt.

Distribution belt

Tighten the distribution belt by screwing a screw (A) in the lower distribution crankcase.

Place one of the two captors (a) or (b) of the MOT 1505 device reading head at a distance x = 5 – 10 mm of belt in the position shown in the drawing.

The measurement may be performed on any of the belt face (1) or (2), subject that both captors are not to be in the same time in front of the belt during measurement.

11 - 2

UPPER AND FRONT ENGINE UNITS

Distribution belt

Make vibrating the belt by means of a finger.

The measurement is validated by a device

“bip”

Tighten the belt until obtaining the value

= 68 ± 3 Hz.

Block the tensioning roller.

Rotate then, four turns the crankshaft and position again the di stribution at the upper dead point.

Unblock the tensioning roller.

Tighten again the distribution belt

(acting upon the A screw) until obtaining the value T

The tensioning ro ller nut is to be obligatory tightened at 5 daNm. If not, this may unlo ose risking the engine damage.

Remount the crankshaft pulley and obligatory tighten its screw at a moment of 2 daNm plus an angle of 115° ± 15°.

Check the injection pump pre ssing-on (see chapter 13 “ Injection Pump Pressing-on”)

Remount the other elements performing the dismounting operations in the reverse order.

Mount and tension the accessories belt (see chapter 16 “ Alternator”)

Perform the filling and purging of the cooling circuit (see chap ter 19 “ Cooling circuit filling – purging”).

NOTE:

Once a belt is dismounted it can not be remounted.

= 61 ± 5 Hz.

MOT

MOT 1505

11 - 3

UPPER AND FRONT ENGINE UNITS

Cylinder head gasket

Necessary Special Tools

MOT 251-01 Comparing support MOT 252-02 Measurement plate for pistons over-height MOT 1054 Engine pressing-on rod MOT 1505 Belt tensioning measurement device MOT 1202-01 Pliers for elastic collars

Wrench for angle tightening

TIGHTENING MOMENTS ( daNm )

Tensioning roller nut 5 Crankshaft pulley screw 2+115°±15°

DISMOUNTING

- disconnect the connector ( 2) of the electric valve E.G.R. and the connector (3) of the air temperature sensor,

- the hoses and the connector of the water temperature sensor from the thermostat box,

Place the vehicle on a two-columns elevator. Disconnect the battery. Dismount the distribution belt ( see chap - ter 11 “ Distribution belt “) Drain the cooling circuit by the water pump inlet pipe Dismount :

- the exhaust descent pipe,

- the vacuum pump connection(1),

- the air intake connection,

- the connection for oil vapor recycling ,

- detach from clips the fuel pipes from the air filter case,

- dismount the air filter assembly,

Disconnect :

- the supply wires of the pre-heating spark plugs,

- the injectors connectors and the injection pump connector (5),

- the fuel supply and return connections in (A) and (B),

- the resistance connector for diesel heating from the diesel filter.

11 - 4

UPPER AND FRONT ENGINE UNITS

Cylinder head gasket

Dismount the fuel return pipe support (6).

Loosen the attachment screws of the distribution lower crankcase in order to facilitate the cylinder head dismounting.

The following are to be dismounted:

- the alternator driving belt tightener,

- the cylinder head screws.

Remove by lifting, the cylinder head but without ro tating it, because it is centered by means of two bushings (C).

11 - 5

UPPER AND FRONT ENGINE UNITS

Protect the oil grooves to avoid impurity penetration (addition); penetration of addition in the oil grooves may govern their clogging and consequently induce a fast failure of the crankshaft.

It is very important not to scratch the gasket seating face.

The DECAPJOINT is to be used for cleaning the gasket possible stuck bits.

Spread out the substance on the area to be cleaned, wait for about 10 minutes, and clean with a wooden spatula.

Cylinder head gasket

Place the MOT 252-01 device on the

piston.

Place the MOT 251-01 device provided with a comparing device on the support plate of the MOT 252-01.

Place the comparing gauge feeler in contact with the cylinders crankcase and look for the piston upper dead point.

Measure the pistons over-height.

During cleaning operation, pr otection

gloves are to be worn.

The cylinder head flatness is checked by

means of a ruler and a kit of gauges.

Maximal permitted deformation: 0.05 mm.

The cylinder head is not to be rectified.

Measurement of the pistons over-height.

The calamine is to be removed from the

pistons head.

The crankshaft is to be rotated towards the running direction for bringing the piston (1) at its upper dead point.

NOTICE:

The measurements are to be performed on the engine longitudinal axe, in order to avoid the errors caused by the piston turning over.

ONLY THE PISTON MAXIMAL OVER-HEIGHT IS TO BE TAKEN INTO CONSIDERATION.

The followings are to be used to get a maximal over-height of the piston:

- less than 0.613 mm: a cylinder head gasket provided with two identification holes.

- between 0.613 mm and 0.767 mm, a cylinder head gasket with one identification hole is to be used

- higher than 0.767 mm: a cylinder head gasket provided with three identification holes.

11 - 6

UPPER AND FRONT ENGINE UNITS

Cylinder head gasket

REMOUNTING

Mount the corresponding new c ylinder head gasket (according to the maximal over-height).

This is centered by means of two centering bushings (C).

Wa it for 3 minutes, as stabilizing time.

CYLINDER HEAD TIGHTENING

The cylinder head tightening is to be performed consecutively for the screws group 1-2, 3-4, 5-6, 7-8 and 9-10

- The screws 1- 2 are to be totally un-

screwed.

- Tighten the 1-2 screws at 2.5 d aNm, then

at an angle of 213° ± 7°.

- Repeat the dismounting and tightening operation for the screws group 3-4, 5-6, 7-8 and 9-10.

The cylinder head is not to be re-

tightened.

The pistons are obligatory positioned so

that neither one is at the upper dead point, in order to avoid the contact w ith the valves during cylinder head tightening.

The cylinder head is to be centered on

the two centering bushings.

The cylinder head gasket is to be

tightened as follows:

1. GASKET PRE-SETTING

The cylinder head screws are to be tightened at 3 daNm, then at an angle of 80° ± 4°, observing the order indicated in

the drawing.

NOTICE:

In order to get a right tightening of the cylinder head screws, the oil that may be in the cylinder head fixing holes is to be extracted by means of a syringe.

Before mounting, the screws thread and head are to be lubricated with engine oil.

Mount the distribution belt ( see chapter 11 “ Distribution belt “)

For remounting perform the dismounting operations in the reverse order.

Fill and purge the cooling circuit (see chapter 19 “ Filling – Purging “).

11 - 7

FUEL MIXTURE

Intake manifold

TIGHTENING MOMENTS (daNm)

Collectors attachment nuts 2.7 Air filter case attachment 0.8 Exhaust gases pipe flange screws 1.9

DISMOUNTING

Place the vehicle on a two-columns elevator. Disconnect the battery. Dismount under the vehicle, the two attachment nuts of the downward pipe on the

exhaust manifold.

Dismount the downlead pipe attachment clamp on the engine. Detach from clips the fuel pipes from the air filter case (1). Dismount the three nuts and the attachment screw of the air filter case (2) on the intake

manifold.

Disconnect the oil vapors recycling connection. Dismount the air filter case attachment screw on the engine lifting support. Disconnect:

- sensor of air temperature connector

- E.G.R. connector

- sensor of water temperature connector

Remove the air filter assembly.

12 - 1

FUEL MIXTURE

Dismount the exhaust gases recycling pipe. Dismount the diesel return hose support attached on the distribution casing. Dismount by means of a ratchet wrench and an extension, the following:

- the upper attachment nuts (A) of the intake manifold and exhaust manifold

- the lower attachment nuts (B) of the manifolds

- the attachment nuts (C) of the exhaust manifold. Recover the washers. Dismount the two manifolds (intake and exhaust).

Exhaust manifold

REMOUNTING

Tighten the attachment nuts of the two manifolds at the required moment ( 2.7 daNm). Replace and correctly place the gaskets (3) and (4). Perform the dismounting operations in the reverse order.

12 - 2

PUMP SUPPLY

Fuel stop in case of collision

PURPOSE

The hazard sensor interrupts the fuel supply in case of an accident, thus avoiding the

fire hazard due to the fuel losses.

OPERATION

The hazard sensor (1) is placed in the engine compartment, mounted on the left shock

absorber column.

In case of hazard, the sensor ball leaves its lodgement, thus stopping the injection relay supply (+); the latter supplies the injection computer, the injection pump and the E.G.R. electric valve (exhaust gases recycling). Therefore the pump will neither intake the fuel nor will generate high pressure.

The hazard of fire generated by diesel oil projection is thus excluded.

HAZARD SENSOR RE-STARTING

The upper part of the hazard sensor is to be pushed to re-position the ball into its lodgement and thus to re-start the sensor.

13 - 1

PUMP SUPPLY

Characteristics

Engine

Vehicle Gearbox

Type Index

Bore

(mm)

Stroke

(mm)

Cylinder-

capacity

)

(cm

Compression

ratio

Pick Up

Drop Side

Double Cab

Idle

running

NG 1 NG 7

Rotation (rpm) Smoke opacity

F8Q 636 80 93 1870 EURO’9621.5/1

825 ± 50 5175 ± 50 4600 ± 100 1.0 m-1 (33%) 2.5 m-1 (64%)

Denomination Particularities

Injection pump

LUCAS DIESEL E.P.I.C. Electronic rotary pump, provided with:

- increased flow electric valve,

- decreased flow electric valve,

- advance electric valve,

- STOP electric valve,

- flow rotor axial position captor (solid),

- advance cam position captor (solid).

De-pollution

standards

Legal maximumHomologation valueMaximal (loaded)Maximal (unloaded)

Pump pressing on Increased flow electric valve Decreased flow electric valve Advance electric valve STOP electric valve Advance cam position captor Flow slide position captor Diesel oil temperature captor

Injection computer Injectors

Port-injectors

Pressing on by means of the rod MOT 1520 Resistance: 31 ± 2 Ohms Resistance: 31 ± 2 Ohms Resistance: 31 ± 2 Ohms Resistance: 1.39 ± 0.1 Ohms Resistance: 52 ± 4 Ohms Resistance: 41 ± 4 Ohms Integrated in pump Resistance: 2716 ± 60 Ohms at 20°C Electronic checking unit (U.C.E.) – 90 ways LUCAS RDNOSDC 6751 II Ta re: 125 ÷ 140 bars LUCAS LCR 67354 Port-injector tightening: 7daNm Port-injector tightening on cylinder head: 7daNm

13 - 2

PUMP SUPPLY

Denomination

Discharge lines

Pre-heating relay

Pre-heating plugs

Acceleration potentiometer

Engine rotation (RPM) sensor

Absolute pressure sensor

E.G.R. valve

Characteristics

Particularities

φ External: 6 mm φ Internal: 2.5 mm

Length: 300 mm NAGARES BRE /6-12

Controlled by computer

BERU

Resistance: 0.6 Ω Tightening moment: 2 daNm

CTS

Double track potentiometer

MGI

Resistance ∪ 760 Ω at 20 °C Inserted in computer

PIERBURG

Electric valve with inserted wheel and position captor Valve resistance: 8 ± 0.5 Ω at 20 °C Resistance: 4 KΩ at 20 °C

Temperature (°C) ±±±± 1°

Air temperature sensor

(resistance in Ohms) Water temperature sensor (resistance in Ohms)

-10

10454  8623 2175  1928 857  763 325  292

25 50 80

290  275850  7732364  214013588 11332

13 - 3

PUMP SUPPLY

Particularities

The pump E.P.I.C. (Electronic Programmed Injection Checking) is an electronic

distributive injection pump. The following elements are placed on the pump:

- advance electric valve (A),

- increased flow electric valve (B),

- decreased flow electric valve (C),

-STOP electric valve (D),

-flow rotor axial position captor (solid) (E),

- advance cam angular position captor (solid) (F),

- diesel oil temperature probe (solid, placed in the pump body).

The increased flow electric valve and the advance one constitute a common body and

one cannot separate them. They are placed on the pump upper part.

The decreased flow electric valve and the STOP one constitute a common body and one

cannot separate them. They are placed on the pump lower part (at its back).

One cannot dismount the two captors (the flow and advance ones) since the injection computer is to memorise their position. This operation is to be performed only on an injection bench.

The injection pump E.P.I.C. is connected to an U.C.E. injection calculator (Electronic Checking Unit). The latter calculates the flow and the advance and controls the electric valves accordingly. The U.C.E. calculator also controls the exhaust gases recycling (E.G.R.).

The cleanliness rules are to be observed both prior and during any intervention on the E.P.I.C. system.

13 - 4

PUMP SUPPLY

Particularities

The engine is to be started and idle run after each intervention on the injection system. The possible diesel oil losses are to be checked. When cutting the contact the engine may run 1 – 2 seconds longer before stopping.

When repairing or dismounting the injection pump, the supply connections, the return and the high-pressure ones are to be covered with new adequate obturators, in order to avoid impurities entering into the injection circuit.

13 - 5

PUMP SUPPLY

COMPULSORY CLEANLINESS RULES TO BE OBSERVED

WHEN INTERVENING ON E.P.I.C. INJECTION SYSTEM

The E.P.I.C. system (Electronic Programmed Injection Checking) is very sensitive to polluting agents. The polluting agents entering into the injection system may cause the followings:

- the E.P.I.C. system damages or definitive breakdown,

- the elements gripping or unsealing.

Any post-selling intervention on the injection system is to be performed in perfect cleanliness conditions. It means that no impurities - small as they may be - are allowed to enter the system or the circuits, during the dismounting or through the fuel connections.

The followings may constitute polluting agents:

- metallic or plastic chips,

- paint,

- hard paper, brushes, paper, clothes, gauze fibres,

- foreign bodies (hair for instance),

- ambient dust particles.

Cleanliness rules

ATT EN TI ON!

It is definitely forbidden to clean the engine with a high-pressure water jet, due to the connectors damaging haza rd. Moreover, the wet connectors may cause electric connections troubles.

COMPULSORY RULES TO BE OBSERVED WHEN

INTERVENING ON E.P.I.C. INJECTION SYSTEM

• Make sure there are enough available obturator caps. The caps are all single use.

• Make sure there are enough available plastic bags. They are to be hermetically closed every time the dismounted parts are to be stocked, in order to protect the latter from any impurities. The bags are all single use.

• Make sure there are enough available cleaning un-shred cloths. Gauze or common shredding cloths using is definitely forbidden, since they may ca use polluting agents entering into the fuel circuit.

COMPULSORY CLEANLINESS RULES TO BE

OBSERVED WHEN OPENING THE FUEL CIRCUIT

• A brand new diluter is to be used for any intervention (impurities-free).

• A brand new and clean brush is to be used for any intervention.

• The parts to be dismounted, the Special Tools to be used and the working-bench are to be thinner-cleaned by means of a brush.

13 - 6

PUMP SUPPLY

Cleanliness rules

• The cleaned parts are to be compressed air blown.

• The hands are to be washed prior and during any intervention, if necessary.

• Only LATEX protection gloves are to be used.

RULES TO BE OBSERVED DURING THE INTERVENTIONS

• As soon as the supplying circuit is opened, its connections are to be obstructed with adequate caps, in order to avoid impurities (dirt) entering into the circuit. The caps are all single use.

• The parts stocking bags are to be hermetically closed, even when they are to be soon re-opened as the ambient air is a polluting factor.

• After having obstructed all their orifices with obturator caps, all the injection system dismounted elements are to be stocked in hermetic bags.

• After having opened the fuel circuit, the use of brushes, diluter and common gauze is definitely forbidden.

• In case of replacing a worn element with a new one, the latter is to be unpacked only when mounting it.

13 - 7

PUMP SUPPLY

Elements location

9547 6101112

1.Air filter

2.Intake air temperature sensor

3. E.G.R. Electric valve (exhaust gases recycling)

4.Acceleration pedal position potentiometer

5.U.C.E. Injection computer

6.Injection relay

7.Pre-heating relay

8.Fuel filter

9. Engine rotation (RPM) sensor

10.STOP and decreased flow electric valves

11.Advance and increased flow electric valves

12. E.P.I.C. Injection pump

13. Cooling fluid temperature sensor

1823

13 - 8

PUMP SUPPLY

Elements location

2. Intake air temperature sensor

3. E.G.R. Electric valve (exhaust gases

recycling)

4. Acceleration pedal position potentiometer

7. Pre-heating relay

10. STOP and decreased flow electric

valves

11. Advance and increased flow electric

valves

13. Cooling fluid temperature sensor

14. Injection pump pressing on rod orifice

13 - 9

PUMP SUPPLY

The U.C.E. injection computer permanently checks the system sensor transmitted parameters. The U.C.E. computer controls the electric valves according to these parameters and to the memorised reference values. It also permanently checks the obtained results and performs all their necessary corrections.

The E .P.I.C. injection pump i s a rotary distributor t ype one. T he supplying pum p intakes the diesel oil. The latter is brought to the so-called “transfer pressure” in the pump body. The transfer pressure is obtained by means of the plunger little pistons. Rollers in contact with a cams ring drive these pistons.

The precisely processed cams ring determines the injection beginning moment and its duration.

The injection computer determines the cams ring position by means of the advance electric valve, thus modifying the plunge pistons movement beginning moment.

The cam position captor permanently informs the computer about the injection beginning moment.

The plunger pistons stroke defines the injected diesel oil quantity towards each cylinder.

The two electric valves (increased and decreased flow) allow the modification of this stroke, therefore of the injected diesel oil quantity.

The flow rotor axial positioning captor permanently informs the computer about the injected diesel oil quantity.

The diesel oil is then sent to the distributive pump area, which determines the cylinder to be supplied. A rotary piston assures this function.

The engine operation steps are as follows:

Operation

Pre-starting (prior the start-up)

The system performs the following checking between the contact putting ON moment and the engine start-up one:

-rotor maximal stop position,

- advance piston minimal stop position,

- increased and decreased flow electric valves operation,

- advance electric valve operation.

Starting (engine start-up)

The computer controls a certain position of the pump rotor and the STOP electric valve supplying during the engine start-up, namely starter driving.

Normal operation

The computer modifies the diesel oil flow accordingly, by means of the increased and decreased flow electric valves. The flow is adjusted or cut in case of sudden acceleration or deceleration, according to the memorised reference parameters.

13 - 10

PUMP SUPPLY

Operation

Engine stop

The computer controls the STOP electric valve closure, then the engine rotation evolution when cutting the contact. The computer drives the decreased flow electric valve until the engine STOP, in case the rotation does not suddenly decrease.

13 - 11

PUMP SUPPLY

INJECTION INDICATOR OPERATION (PRE-HEATING)

The instrument panel injection indicator (luminous), lights under the following situations:

- when putting the contact ON, the injection indicator lights and remains lit during the

pre-heating step, then turns off.

- the indicator lights in case of injection system failure. The indicator flashes for few seconds during the pre-heating step, signalising a break

down presence from the contact putting ON.

Injection indicator lighting possible causes

- computer or injection pump supplying trouble,

- damaged rotation sensor,

- pump internal memory device damage,

- damage:

- acceleration pedal position potentiometer,

- increased flow electric valve damage,

- decreased flow electric valve damage,

- STOP electric valve damage,

- cam position captor damage,

- computer damage.

Injection indicator operation

13 - 12

PUMP SUPPLY

Anti-starting function

The anti-starting code is to be permanently memorised by the injection computer, otherwise the latter does not operate.

INJECTION COMPUTER REPLACEMENT

When delivered, the new injection computers are un-coded.In case of computer replacement, the new one is to memorise the anti-starting code. Then the anti-starting function viability is to be checked, by putting the contact ON for few seconds (See Chapter

82 “Anti-starting” for details).

ANTI-STARTING OPERATION CHECKING

The key is to be taken out the contact and, 10 seconds after; the indicator is to flash once per second. See Chapter 82 “ Anti-starting” in case of checking the engine starting-up impossibility.

13 - 13

PUMP SUPPLY

IDLE RUNNING ROTATION CORRECTION ACCORDING TO WATER

The idle running rotation is to be increased and sustained at 900 rpm for a cooling fluid

temperature of - 23°C.

CORRECTION ACCORDING TO THE ELECTRIC BALANCE

This correction purpose is to compensate the voltage drop, caused by other consumers

operation when the battery is low-loaded.

To perform the voltage drop compensation, the idle running rotation is to be increased,

thus allowing the alternator higher rotation and the battery voltage consequent increasing.

Lower the voltage, higher the correction is. The correction is thus viable and starts when the battery voltage drops under 12 Volts.

The idle running rotation is to be stabilized at maximum 900 rpm.

Idle running rotation correction

TEMPERATURE

IDLE RUNNING ROTATION CORRECTION

IN CASE OF POTENTIOMETER DAMAGE

In case one of the acceleration pedal potentiometer tracks is damaged, the idle running

rotation is to be maintained at 1000 rpm.

In case both acceleration pedal potentiometer tracks are damaged, the idle running

rotation is to be maintained at 1300 rpm.

13 - 14

Dacia F8Q (2004) Repair Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Vehicle identification

Elevator to be attached under the carriage body

Alltypes

Engine

Gearbox

Rear axle differential

Dimensions

Capacity - Qualities

Wheels and tires

Brakes

Heights under carriage body

Control values of the rear axle angles

Ingredients

Identification

Oil consumption

Oil pressure

Dismounting - Remounting engine

Engine fitting - unfitting

Tightening moments

Characteristics

Necesary special tools

Dismounting - Remounting

Lower crankcase

Oil pump

Crankshaft sealing gasket towards distribution

Crankshaft sealing towards flyweel

Engine set replacing

Distribution belt

Cylinder head gasket

Intake manifold

Exhaust manifold

Fuel stop in case of collision

Characteristics

Particularities

Cleanliness rules

Elements location

Operation

Injection indicator operation

Anti-starting function

Idle running rotation correction