SINGLE CAMSHAFT HOUSING - REPLACE GASKET

Operation 1016B10 · CAMSHAFT HOUSING(S)

1.4 16v

Removing

- Disconnect the negative battery terminal.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

Op. 1056B60 SINGLE FUEL MANIFOLD PIPE, WITH INJECTORS - R.R.

Op. 1072B50 AIR CHAMBER - R.R.

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

Op. 1072B10 INLET MANIFOLD - R + R AND REPLACE SEAL

Op. 5510C14 IGNITION COIL/S - R.R.

Op. 5510C30 ENGINE TIMING SENSOR - R+R

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

Op. 1092G11 ENGINE COMPONENTS SINGLE DRIVE BELT - R.R. FOR VERSIONS WITH AIR CONDITIONING

Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R.

Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R.

Op. 1032B14 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT VERSIONS WITH AIR CONDITIONER

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1092A12 CRANKSHAFT PULLEY - R+R FOR VERSIONS WITH AIR CONDITIONING

Op. 1084A16 OIL DIPSTICK PIPE - R.R

1. Unscrew protective caps (1a) and, using the specific tool, unscrew bolts underneath (1b).

2. Gently raise the cylinder head extension and insert the tool to secure the tappets.

3. Remove the cylinder head extension from its housing and retrieve the seal underneath.

Refitting

- Fit a new cylinder head extension gasket.

1. Use specific tool for securing tappets (1a), position cylinder head extension (1b) in its housing.

2. Use the tool to tighten the cylinder head extension bolts to the specified torque.

3. Tighten the protective caps to the recommended torque.

Op. 1084A16 OIL DIPSTICK PIPE - R.R

Op. 1092A12 CRANKSHAFT PULLEY - R+R FOR VERSIONS WITH AIR CONDITIONING

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 1032B14 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT VERSIONS WITH AIR CONDITIONER

Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R.

Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R.

Op. 1092G11 ENGINE COMPONENTS SINGLE DRIVE BELT - R.R. FOR VERSIONS WITH AIR CONDITIONING

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 5510C30 ENGINE TIMING SENSOR - R+R

Op. 5510C14 IGNITION COIL/S - R.R.

Op. 1072B10 INLET MANIFOLD - R + R AND REPLACE SEAL

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

Op. 1072B50

Op. 1056B60 SINGLE FUEL MANIFOLD PIPE, WITH INJECTORS - R.R.

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 0010T20 ENGINE COOLANT - CHANGE

- Connect the negative battery terminal.

1.3 Multijet

Removing

- Position the vehicle on the lift.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE

Op. 1076B20 REAR EXHAUST SILENCER - R + R

Op. 1076B40 CENTRE EXHAUST PIPE - R.R.

1. Disconnect the rapid connector for the fuel supply pipe from the filter to the pressure pump, pressure pump side.

2. Undo the fixing bolts (2a) and remove the support (2b) for the degassing pipes and the fuel filter.

3. Remove the air filter mountings.

- Follow the instructions in the procedure below for all the pipes from the fuel manifold to the injector:

Op. 1060F34 PIPE FROM FUEL MANIFOLD TO INJECTOR - R.R.

Op. 1060G22 CAM ANGLE SENSOR - R.R

- Follow the instructions below for all the injectors:

Op. 1060F11 INJECTOR ONE R R

Op. 1060F52 FUEL RETURN PIPE FROM INJECTORS - R.R.

- Position a hydraulic jack for supporting the power unit.

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

1. Open the retaining band for the injector wiring

2. Undo the retaining bolts (2a) and move the injector wiring (2b) aside.

1. Remove the plug and insert the template in its place on the exhaust side camshaft.

Fit the tool and position with its millings horizontal. Ensure it fits into the seat on the camshaft.

1. Fit a suitable diameter drift in the opening in the gearbox.

1. Undo the plug in the timing cover (1a) and undo the driven pulley fixing bolt (1b) underneath.

2. Undo the fixing bolts (2a) and remove the tensioner inspection cover (2b).

1. Press the piston using the lever to disarm the tensioner.

After this operation the timing moving tensioner piston will be fully extracted.

- Release the exhaust side camshaft toothed pulley working via the opening in the timing cover resting it on the timing cover inner ribs.

1. Undo the bolts fixing the timing cover to the single camshaft housing.

2. Keep the brackets

3. Undo the bolts (3a) and (3b), then remove the single camshaft housing assembly (3c).

4. Remove the single camshaft housing gasket.

1. Working at the bench, undo the retaining bolts (1a) and remove the mounting bracket (1b).

Refitting

- Working at the bench, fit the mounting bracket and tighten the single camshaft housing fixing bolts.

1. Apply silicon sealant to the contact area between the cylinder head and the timing chain cover.

2. Position the camshaft housing centering bushes on the cylinder head as illustrated in the diagram.

The centering bushes between the cylinder head and the camshaft housing are longer (13.0 mm) than those between the engine block and the cylinder head; take care therefore not to mix them up because this could adversely affect the operation of the engine.

3. Position the gasket on the cylinder head by fitting it on the locating bushes.

4. Apply silicon sealant to the gasket between the lower cylinder head and the camshaft housing by the contact area with the timing cover.

5. Also apply a bead of sealant to the surface of the timing cover gasket following the black line of silicon on the actual gasket.

Apply a thin layer of sealant to the timing cover gasket so that it is not too thick and avoid excess sealant inside the timing cover.

- Working with the camshaft timing tools fitted, position the single camshaft housing taking care not to move the rocker arms out of position.

- Screw in the bolts securing the single camshaft housing to the cylinder head without tightening them.

1. Tighten the bolts fixing the timing cover to the single camshaft housing to the recommended torque.

During this stage do not tighten the remaining bolts fixing the timing cover.

1. Screw in the six rear bolts fixing the single camshaft housing following the order illustrated without tightening them.

2. Loosen the bolts (2a) and (2b) fixing the timing cover tightened previously.

3. Screw in the remaining bolts securing the camshaft housing, without tightening them, following the order illustrated in order to gradually work towards the timing cover.

1. Tighten the bolts fixing the single cylinder head to the recommended torque following the order illustrated.

2. Tighten the bolts (2a) and (2b) securing the single camshaft housing to the specified torque.

Follow the order shown in the figure for each tightening sequence.

1. Press the piston using the lever to arm the tensioner.

- Fit the remaining bolts fixing the timing cover to the single camshaft housing, then tighten all the bolts fixing the timing cover to the camshaft housing to the recommended torque.

- The non alignment between the single camshaft housing and the cylinder head should not exceed the recommended value.

It is only possible for the camshaft housing to project.

1. Press the piston using the lever to disarm the tensioner.

1. Tighten the driven pulley bolt to the specified torque.

2. Tighten the plug in the timing cover.

3. Fit the inspection cover for the tensioner (3a) and tighten the fixing bolts (3b).

- Remove the template and fit the plug in its place on the exhaust side camshaft.

- Remove the drift from the opening in the gearbox.

- Secure the wiring for the injectors to the retaining bands and tighten the fixing bolts

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

- Remove the hydraulic lift.

- Follow the instructions in the procedure below for all the pipes from the fuel manifold to the injector:

Op. 1060F34 PIPE FROM FUEL MANIFOLD TO INJECTOR - R.R.

Op. 1060G22 CAM ANGLE SENSOR - R.R

- Follow the instructions below for all the injectors:

Op. 1060F11 INJECTOR ONE R R

Op. 1060F52 FUEL RETURN PIPE FROM INJECTORS - R.R.

- Fit the air filter mountings.

- Fit the support for the degassing pipes and the fuel filter in place and tighten the fixing bolts.

- Connect the rapid connector for the fuel supply pipe from the filter to the pressure pump, pressure pump side.

Op. 1076B40 CENTRE EXHAUST PIPE - R.R.

Op. 1076B20 REAR EXHAUST SILENCER - R + R

Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 0010T20 ENGINE COOLANT - CHANGE

- Remove the vehicle from the lift.