CAMSHAFT IDLER GEARS - REPLACE

Operation 1036L20 · CAMSHAFTS (2) IN CAMSHAFT HOUSING (1)

1.4 16v

Removing

- Disconnect the negative battery terminal.

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

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

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

Op. 1036L40 CAMSHAFT SEAL SUPPORT IN CAMSHAFT HOUSING - R.R.

1. Remove the protective plugs for the camshafts in the camshaft housing.

2. Rotate the crankshaft in its normal direction of rotation and fit the camshaft timing tool.

1. Fit the driven pulley locking tool.

1. Undo the bolts (1a) and remove the camshaft gears (1b).

Refitting

- Place the camshaft gears in their housings and secure them tightening the bolts to the recommended torque.

Firstly, fit the exhaust side gear; then fit the inlet side gear aligning the (inner and outer) teeth until they are matched with the teeth on the exhaust side gear.

- Remove the tools used for timing the camshafts and tighten the sealing plugs to the recommended torque.

- Undo the bolt and remove the driven pulley locking tool.

Op. 1036L40 CAMSHAFT SEAL SUPPORT IN CAMSHAFT HOUSING - R.R.

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

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

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

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.

- Connect the negative battery terminal.

1.9 JTD 16v

1.4 16v TJet

Removing

- Position the vehicle on a lift.

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 1056B65 SOUND INSULATING COVER FOR INJECTOR ASSEMBLY - R.R.

Op. 1064A31 HEAT SHIELD FOR TURBOCHARGER - R.R.

Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R.R

Op. 1080B62 CATALYTIC CONVERTER - R + R

Op. 1084C22 HEAT SHIELD ON ENGINE OIL HEAT EXCHANGER - R.R.

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

Op. 1084B40 ENGINE OIL DELIVERY PIPE TO TURBOCHARGER - R + R

Op. 1084B42 ENGINE OIL RETURN PIPE FROM TURBO - R + R

Op. 1088D50 ENGINE COOLANT OUTLET PIPE FROM TURBOCHARGER - R.R.

Op. 1088D48 PIPE FROM ENGINE COOLANT RESERVOIR TO TURBOCHARGER - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.

Op. 1072B53 AIR CHAMBER REINFORCEMENT BRACKET - R.R.

Op. 1080D34 ENGINE OIL VAPOUR SEPARATOR - R + R

Op. 1048B58 TURBOCHARGER AIR BY-PASS VALVE - R.R.

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

1. Remove the camshaft protective plug, inlet side.

2. Rotate the crankshaft in its normal direction of rotation and fit the camshaft timing tool.

- Proceed in the same way for fitting the exhaust side camshaft timing tool.

1. Fit the driven pulley locking tool.

1. Undo the fastenings (1a) and remove the bracket (1b).

1. Undo the nuts (1a) and remove the camshaft seal rear cover (1b) with gasket.

1. Undo the bolts (1a) and remove the camshaft gears (1b).

Refitting

- Place the camshaft gears in their housings and secure them tightening the bolts to the recommended torque.

Firstly, fit the exhaust side gear; then fit the inlet side gear aligning the (inner and outer) teeth until they are matched with the teeth on the exhaust side gear.

- Place the camshaft rear cover in its housing complete with new gasket and tighten the nuts.

- Place the wiring mounting bracket in its housing and tighten the fastenings.

- Remove the tools used for timing the camshafts and tighten the sealing plugs to the recommended torque.

- Undo the bolt and remove the driven pulley locking tool.

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

Op. 1048B58 TURBOCHARGER AIR BY-PASS VALVE - R.R.

Op. 1080D34 ENGINE OIL VAPOUR SEPARATOR - R + R

Op. 1072B53 AIR CHAMBER REINFORCEMENT BRACKET - R.R.

Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1088D48 PIPE FROM ENGINE COOLANT RESERVOIR TO TURBOCHARGER - R.R.

Op. 1088D50 ENGINE COOLANT OUTLET PIPE FROM TURBOCHARGER - R.R.

Op. 1084B42 ENGINE OIL RETURN PIPE FROM TURBO - R + R

Op. 1084B40 ENGINE OIL DELIVERY PIPE TO TURBOCHARGER - R + R

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

Op. 1084C22 HEAT SHIELD ON ENGINE OIL HEAT EXCHANGER - R.R.

Op. 1080B62 CATALYTIC CONVERTER - R + R

Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R.R

Op. 1064A31 HEAT SHIELD FOR TURBOCHARGER - R.R.

Op. 1056B65 SOUND INSULATING COVER FOR INJECTOR ASSEMBLY - R.R.

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

- Remove the vehicle from the lift.