ENGINE - POSITION ON STAND AND REMOVE

Operation 1004D40 · REMOVE ENGINE AND WASH

1.4 16v

1. Undo the bolts (1a) and remove the engine flywheel (1b) complete with safety plate (1c).

2. Undo the bolt and remove the flywheel lock.

3. Undo the bolt (3a) and remove the guards (3b).

1. Using the tool and a hydraulic lift, place the engine on the overhaul stand.

- Support the engine using the tools and a hydraulic lift.

- Undo the bolts fixing the engine block to the overhaul stand support.

- Place the engine on a suitable board.

- Place the engine flywheel guards in position and tighten the lower guard fixing bolt.

- Place the flywheel in position complete with safety plate taking care over the centering bush and screw in the new bolts without tightening to torque.

- Fit the flywheel lock.

- Tighten the new bolts securing the engine flywheel to the recommended torque.

1.9 JTD 8v, 1.9 JTD 16v

Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED

Op. 1024B22 ENGINE FLYWHEEL - R.R WITH CLUTCH REMOVED FOR VERSIONS WITH MANUAL GEARBOX

1. Undo the bolts (1a) and remove the flywheel guard (1b).

1. Fit the support (1a) on the engine block (1b).

1. Using the tool and a hydraulic lift, place the engine on the overhaul stand.

- Support the engine using the mounting tools and a hydraulic lift.

- Undo the bolts fixing the engine block to the overhaul stand support.

- Fit the flywheel guard and secure it using the bolts.

Op. 1024B22 ENGINE FLYWHEEL - R.R WITH CLUTCH REMOVED FOR VERSIONS WITH MANUAL GEARBOX

Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED

1.4 16v TJet

Rest the engine on the stand

1. Fit the flywheel lock.

2. Unscrew the three bolts securing the clutch mechanism at 120 degrees.

3. Fit tool (3a) and tool (3b) tightening bolts (3c) in the seats of the bolts removed previously.

4. Turn the tool handwheel until pins (4a) are in contact with disc (4b).

5. Undo the remaining bolts securing the clutch mechanism.

6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.

- Remove the tools fitted previously.

7. Remove the clutch mechanism.

- Remove the clutch plate.

1. With flywheel lock (1a) fitted, undo bolts (1b) and remove engine flywheel (1c).

The bolts fixing the flywheel are pre-treated with sealant, therefore they should be replaced each time they are removed.

1. Undo bolt (1a) and remove flywheel guard (1b).

1. Disconnect the electrical connection for the upper Lambda sensor.

2. Undo the fastenings and remove the turbocharger heat shield.

1. Undo the fastenings and remove the catalytic converter heat shield.

1. Undo the bolts securing the catalytic converter to the bracket on the crankcase.

2. Undo nuts (2a) and remove catalytic converter (2b) complete with Lambda sensor.

1. Fit the support to the engine block and place the engine on the overhaul stand using the hydraulic lift.

Removal of engine from the stand

- Support the engine using the mounting tools and a hydraulic lift.

- Undo the fastenings securing the engine block to the overhaul stand support.

- Place the engine on a suitable board.

- Place the catalytic converter in position complete with lambda sensor and tighten the nuts.

- Tighten the bolts securing the catalytic converter to the bracket on the crankcase.

- Place the catalytic converter heat shield back in its housing and tighten it using the fastenings.

- Place the turbocharger heat shield back in its housing and tighten it using the fastenings.

- Connect the electrical connection for the upper Lambda sensor.

- Place the two engine flywheel guards in position and tighten the bolt securing them to the engine oil sump.

- Place the flywheel in its housing, fit the flywheel lock and tighten the new bolts inserted previously to the recommended torque.

1. Fit the tool on the crankshaft.

- Refit the clutch plate in position.

2. Refit the clutch mechanism in position.

Clean any anti-corrosion protection or detergents from the friction surface of the clutch mechanism.

3. Fit tool (3a) using bolts (3b).

4. Turn the tool handwheel until pins (4a) are in contact with disc (4b).

5. Tighten the remaining free clutch fixing bolts by hand.

6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.

- Remove the tools fitted previously.

- Tighten the remaining clutch retaining bolts by hand.

- Gradually tighten the bolts securing the clutch diagonally until the recommended torque is reached.

7. Remove the flywheel lock.