Inlet manifold - r + r and replace seal

Operation 1072B10 · Inlet manifolds

1.6 TS

Removing

Ensure that the ignition key is in the OFF postition, then disconnect the battery negative terminal.

Proceed with the removal - 1016A40 ignition coil cover on cylinder head- r+r.

Proceed with the removal - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with the removal - 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r.

1. Undo the bolts (1a) and release the mounting bracket (1b) for the power assisted steering fluid reservoir from the intake manifold.

1. Undo the nuts (1a) and remove the inlet manifold (1b).

Remove the gasket.

Refitting

Place the inlet manifold, complete with a new gasket, back in its housing and fix it tightening the nuts to the recommended torque.

Place the power assisted steering fluid reservoir mounting bracket back in its housing and secure it using the bolts.

Proceed with the refitting - 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r.

Proceed with the refitting - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with the refitting - 1016A40 ignition coil cover on cylinder head- r+r.

Connect the battery terminal (-).

2.0 TS

Removing

Position the vehicle on the ramp.

Ensure that the ignition key is in the OFF postition, then disconnect the battery negative terminal.

Proceed with the removal - 7055B54 under-engine guard - r r.

Proceed with the removal - 1016A40 ignition coil cover on cylinder head- r+r.

Proceed with the removal - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with the removal - 1072D10 modular inlet manifold - r+r.

1. Undo the bolts (1a) and remove the bracket (1b) connecting the intake manifold to the bracket on the engine for the reaction rod.

1. Undo the nuts (1a) and remove the inlet manifold (1b).

Remove the gasket.

Refitting

Place the inlet manifold, complete with a new gasket, back in its housing and fix it tightening the nuts to the recommended torque.

Place the bracket connecting the intake manifold to the bracket on the engine for the reaction rod back in its housing and secure it using the bolts.

Proceed with the refitting - 1072D10 modular inlet manifold - r+r.

Proceed with the refitting - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with the refitting - 1016A40 ignition coil cover on cylinder head- r+r.

Proceed with the refitting - 7055B54 under-engine guard - r r.

Connect the battery terminal (-).

Remove the car from the ramp.

1.9 JTD 8V

Removing

Place the car on a ramp.

Open the bonnet lid and disconnect the negative battery terminal.

- 1016A10 sound-proofing cover - r + r

- 5530B10 battery - r+r

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

- 1008C10 power unit upper reaction link r r

- 1008C14 engine link bracket - r r

- 1060G80 ds electric injection control unit - r r

- 4450B04 right front wheel r r

- 7055B54 under-engine guard - r r

- 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R.

- 1092G10 single engine belt r r

- 1092A10 Crankshaft services PULLEY - R.R.

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1060E30 pressure pump pulley - r r

- 1060F20 pressure pump/manifold pipe - r r

- 1060F36 lines to injectors - r r

- 1060E10 pressure pump - r r

1. Undo the bolt and the nut securing the vacuum tank bracket.

2. Move the vacuum tank\mounting bracket assembly outside the working area.

1. Disconnect the electrical connection from the fuel pressure sensor.

2. Undo the retaining nuts.

3. Remove the single fuel manifold pipe

1. Disconnect electrical connections (1a), (1b), (1c).

2. Undo the retaining bolts (2a) and remove the injection wiring (2b).

1. Undo bolts (1a) securing the pipe carrying exhaust gas to the EGR (1b) to the exhaust pipe.

1. Undo the bolts securing the exhaust gas delivery pipe to the solenoid.

2. Unscrew the bolts securing the exhaust gas delivery pipe bracket to the cylinder head.

1. Undo nut (1a) securing the exhaust gas delivery pipe to thermostat stud (1b).

2. Move the exhaust gas delivery pipe from its seat so that it can be removed from the intake manifold.

1. Unscrew nuts (1a) and bolts (1b) securing the intake manifold to the cylinder head and pressure pump mount.

2. Remove the stud securing the pressure pump to the mount.

3. Remove the intake manifold from the cylinder head.

Remove the inlet manifold gasket.

Refitting

Fit the new exhaust manifold gasket to the cylinder head studs.

Fit the intake manifold to its seat on the cylinder head.

Tighten the nuts securing the intake manifold to the cylinder head to the recommended torque.

Fit the pipe carrying exhaust gas to the EGR.

Tighten the bolts securing the front section of the pipe carrying exhaust gas to the exhaust manifold.

Tighten the bolts securing the rear section of the pipe carrying exhaust gas to the EGR valve.

Tighten the bolts securing the bracket securing the pipe carrying exhaust gas to the cylinder head.

Fit the bracket joining the intake manifold - pressure pump mount.

Fit the injection wiring and connect the electrical connections disconnected previously.

Connect the turbocharger vacuum pipe hose to the rigid pipe.

Position the single fuel manifold in its seat on the intake manifold.

Tighten the nuts securing the fuel manifold to torque.

Connect the electrical connection to the fuel pressure senor.

Fit the bracket complete with vacuum tank.

- 1060E10 pressure pump - r r

- 1060F36 lines to injectors - r r

- 1060F20 pressure pump/manifold pipe - r r

- 1060E30 pressure pump pulley - r r

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1092A10 Crankshaft services PULLEY - R.R.

- 1092G10 single engine belt r r

- 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R.

- 7055B54 under-engine guard - r r

- 4450B04 right front wheel r r

- 1060G80 ds electric injection control unit - r r

- 1008C14 engine link bracket - r r

- 1008C10 power unit upper reaction link r r

- 1016A10 sound-proofing cover - r + r

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

- 5530B10 battery - r+r

1.9 JTD 16V

Removing

Position the vehicle on the ramp

Proceed with removal - 1016A10 sound-proofing cover - r + r.

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

Proceed with removal - 1008C10 power unit upper reaction link r r.

Proceed with removal - 1060G80 ds electric injection control unit - r r.

Proceed with removal - 4450B04 right front wheel r r.

Proceed with removal - 7055B54 under-engine guard - r r.

Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R..

Proceed with removal - 1092G10 single engine belt r r.

Proceed with removal - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with removal - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with removal - 1032D12 timing system protective cover(s) - r + r.

Proceed with removal - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

Proceed with removal - 5530B10 battery - r+r.

1. Disconnect the electrical connection from the engine coolant temperature sensor.

1. Disconnect the electrical connections from the heater plugs.

1. Disconnect the electrical connection from the turbocharger vane actuator solenoid.

1. Disconnect the electrical connection from the air flow meter.

1. Disconnect the electrical connection from the E.G.R. valve.

2. Disconnect the electrical connection from the excess pressure sensor.

Release the wiring from the bands near the thermostat.

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side.

2. Loosen the band and disconnect the coolant outlet pipe from the cylinder head, engine coolant return pipe to the coolant reservoir side.

3. Loosen the band and disconnect the flexible coolant return pipe from the rigid coolant return pipe to the engine coolant reservoir.

4. Undo the bolts (4a) and remove hose (4b) carrying coolant to the coolant supply reservoir.

1. Loosen the band and disconnect the air intake hose from the connector on the throttle casing.

1. Undo the bolts (1a) and remove the connector on the throttle body (1b) complete with gasket (1c).

1. Disconnect the vacuum pipe from the pneumatic valve on the throttle body.

2. Undo the bolts (2a) and remove the electropneumatically controlled throttle body (2b) complete with gasket (2c).

Disconnect the vacuum pipe from the three-way connector on the brake servo vacuum intake pipe.

Disconnect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve.

1. Undo the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side.

1. Undo the nuts (1a) and move the oil vapour recovery pipe mounting bracket (1b) aside.

2. Undo the bolts (2a) and remove the E.G.R. system solenoid valve (2b).

3. Remove the gasket.

1. Disconnect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side.

2. Disconnect the rapid attachment for the fuel return pipe to the tank, return manifold pipe side.

3. Loosen the band and disconnect the fuel return pipe from the pressure pump, fuel return manifold pipe side.

1. Undo the bolts (1a) and remove the fuel return manifold pipe (1b) complete with the pipe from the injectors to the fuel recovery manifold (1c).

1. Undo the bolt fixing the guide pipe for the engine oil dipstick to the pressure pump mounting.

2. Disconnect the electrical connection from the fuel pressure regulator.

Release the electrical wiring from the band and move it to the side.

1. Loosen the band and disconnect the condensation oil recovery pipe from the crankcase sump.

1. Loosen the band and disconnect the oil vapour recovery pipe from the separator.

2. Loosen the band and disconnect the oil vapour recirculation pipe from separator.

Disconnect the electrical connection from the solenoid on the vacuum tank.

1. Undo the bolts (1a) and remove the mounting bracket (1b) complete with oil vapour separator (1c) and vacuum reservoir (1d).

1. Stop the pressure pump pulley from rotating using two bolts.

2. Undo the pressure pump pulley nut.

Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley.

1. Remove the pressure pump pulley (1a) using the tool (1b).

1. Undo nuts (1a) and remove pressure pump (1b) from its mount.

1. Disconnect the electrical connection from the engine oil pressure warning light switch.

2. Disconnect the electrical connection for the engine oil level sensor.

3. Disconnect the electrical connection for the rpm sensor.

1. Disconnect the earth lead from the alternator.

2. Disconnect the earth lead from the starter motor.

1. Disconnect the electrical connection from the pre-heating control unit.

1. Undo the bolts (1a) and remove the power steering pump drive pulley (1b).

1. Undo the bolts securing the power steering pump to its mounting.

Remove the guide tube complete with engine oil dipstick.

1. Undo the bolts (1a) and remove the pressure pump mounting (1b).

1. Undo the nuts (1a) and remove the air chamber assembly (1b) complete with gasket (1c).

Refitting

1. Refit air chamber (1a) complete with gasket (1b) and secure it by tightening nuts (1c) to the recommended torque.

1. Place the pressure pump support (1a) back in its housing and secure it tightening the bolts (1b).

Refit the guide tube and engine oil dipstick.

1. Place the power assisted steering pump back in its housing and fix it tightening the bolts to the recommended torque.

1. Place the power assisted steering pump pulley (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

Connect the electrical connection to the pre-heating control unit.

Connect the earth lead to the starter motor.

Connect the earth lead to the alternator.

Connect the electrical connection for the rpm sensor.

Connect the electrical connection for the engine oil level sensor.

Connect the electrical connection to the engine oil pressure warning light switch.

1. Fit the clutch pump (1a) back in its housing and tighten the nuts (1b) to the specified torque.

1. Replace the pressure pump pulley in its housing.

2. Stop the pressure pump pulley from rotating using two bolts.

3. Tighten the pressure pump pulley nut to torque.

Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley.

Place the mounting bracket complete with oil vapour separator and vacuum reservoir back in its housing and secure it using the bolts.

Connect the electrical connection to the solenoid on the vacuum tank.

Connect the oil vapour recirculation pipe to the separator and tighten the band.

Connect the oil vapour recovery pipe to the separator and tighten the band.

Connect the condensation oil recovery pipe to the crankcase sump and tighten the band.

Place the electrical wiring back in its housing and fix it to the band.

Connect the electrical connection to the fuel pressure regulator.

Tighten the bolt fixing the engine oil dipstick guide pipe to the pressure pump mounting.

Place the fuel return manifold pipe complete with the pipe from the injectors to the fuel recovery manifold back in its housing and secure it using the bolts.

Connect the fuel return pipe to the pressure pump, fuel return manifold pipe side and tighten the band.

Connect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side.

Connect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side.

1. Place the E.G.R. system solenoid valve (1a) complete with gasket (1b) back in its housing and fasten it tightening the bolts (1c) to the recommended torque.

2. Place the oil vapour recovery pipe mounting bracket (2a) back in its housing and secure it using the nuts (2b).

1. Tighten the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side to the recommended torque.

Connect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve.

Connect the vacuum pipe to the three-way connector on the brake servo vacuum intake pipe.

1. Replace the pneumatically-controlled throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

2. Connect the vacuum pipe to the pneumatic valve on the throttle body.

1. Replace the connector on the throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

Connect the air inlet hose to the connector on the throttle casing and tighten the band.

Place the coolant return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts.

Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band.

Connect the coolant oulet pipe from the cylinder head, engine coolant return pipe to the supply reservoir side and tighten the band.

Connect the engine coolant return pipe to the supply reservoir, thermostat side and tighten the band.

Fasten the electrical wiring to the bands near the thermostat.

Connect the electrical connection to the excess pressure sensor.

Connect the electrical connection to the EGR solenoid.

Connect the electrical connection to the air flow meter.

Connect the electrical connection to the turbocharger vane actuator solenoid.

Connect the electrical connections to the heater plugs.

Connect the electrical connection to the engine coolant temperature sensor.

Proceed with refitting - 5530B10 battery - r+r.

Proceed with refitting - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

Proceed with refitting - 1032D12 timing system protective cover(s) - r + r.

Proceed with refitting - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with refitting - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with refitting - 1092G10 single engine belt r r.

Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R..

Proceed with refitting - 7055B54 under-engine guard - r r.

Proceed with refitting - 4450B04 right front wheel r r.

Proceed with refitting - 1060G80 ds electric injection control unit - r r.

Proceed with refitting - 1008C10 power unit upper reaction link r r.

Connect the negative (-) battery terminal

Proceed with refitting - 1016A10 sound-proofing cover - r + r.

Remove the car from the ramps.