ENGINE - POSITION ON STAND AND REMOVE

Operation 1004D40 · REMOVE ENGINE AND WASH

2.2

Removing

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

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

1. Remove the manual gearbox centering bushes from the engine block.

2. Fit the tool on the engine block.

3. Apply suitable chains to the engine and support it using a suitable hydraulic hoist.

4. Place the engine (4a) on the overhaul stand (4b) using the tool fitted previously.

Refitting

- Remove the engine from the overhaul stand.

- Remove the harness and the hydraulic hoist supporting the engine.

- Remove the tool from the engine block.

- Place the manual gearbox centering bushes on the engine block.

1. Place the flywheel (1a) in its housing and secure it tightening the new bolts (1b) to the recommended torque.

2.4 JTD 20v

Secure and support the engine using a hydraulic lift fitted with chains.

1. Adjust the moving tensioner (1a) for the single drive belt using the spanner (1b), then insert the tool (1c) in the opening in the tensioner.

2. Remove the protective plug for the auxiliar shaft drive belt cam tensioner.

3. Undo the bolt retaining the cam tensioner.

4. Remove the auxiliary shaft drive belt.

1. Undo the fixing nut (1a) and disconnect the electrical connection from the alternator (1b).

1. Undo the bolts (1a) and remove the alternator (1b).

1. Undo the fixing bolts (1a) and remove the alternator upper mounting bracket (1b).

1. Undo the bolts (1a) and remove the rear engine support (1b).

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

2. Fit the rear bracket for positioning the engine on the overhaul stand.

1. Disconnect the electrical connection for the air conditioning compressor.

2. Undo the bolts (2a) and remove the air conditioning compressor and front engine support assembly (2b).

1. Fit the front bracket for positioning the engine on the overhaul stand.

1. Undo the fixing nuts (1a) and remove the heat shield (1b) for the exhaust manifold.

1. Open the band (1a) and disconnect the fluid return pipe from the turbocharger (1b).

2. Undo the connector (2a) and disconnect the oil supply pipe (2b) to the turbocharger from the crankcase.

1. Undo the bolts (1a) fixing the rigid EGR pipe (1b) to the exhaust manifold and remove the gasket (1c).

2. Undo the nuts (2a) securing the exhaust manifold (2b) to the cylinder head.

1. Undo the bolt fixing the turbine mounting bracket to the crankcase.

2. Remove the exhaust manifold and turbocharger assembly (2a) and the metal gasket (2b).

1. Undo the fixing bolt (1a) and remove the power assisted pump protective shield (1b).

2. Using a hydraulic lift, place the engine (2a) on the overhaul stand (2b).

It is possible to use the following stand as an alternative to the overhaul stand mentioned above:

Fasten the mounting brackets to the overhaul stand.

Release the engine from the hydraulic lift.

Proceed as follows to remove the engine from the overhaul stand.

Secure and support the engine using a hydraulic lift fitted with chains.

Undo the fastenings and remove the engine complete with mounting brackets.

Remove the brackets for positioning the engine on the overhaul stand from the crankcase.

1. Place a new metal gasket (1a) in position and then fit the exhaust manifold and turbine assembly (1b).

2. Tighten the bolt fixing the turbine mounting bracket to the crankcase.

1. Tighten the nuts (1a) fixing the exhaust manifold (1b) to the cylinder head and check the torque.

2. Place the new gasket (2a) in position and tighten the bolts (2b) fixing the rigid EGR pipe (2c) to the exhaust manifold/turbine tightening to torque.

1. Connect the oil return pipe from the turbocharger (1a) and secure it using the band (1b).

2. Connect the turbocharger oil supply pipe (2a) to the crankcase and tighten the connector (2b) to the recommended torque.

1. Place the exhaust manifold heat shield (1a) in position and tighten the fixing nuts (1b) checking the torque.

1. Place the air conditioning compressor and front engine support assembly (1a) in position and tighten the fixing bolts (1b) to the recommended torque.

2. Connect the electrical connection for the air conditioning compressor.

1. Connect the electrical connection for the engine oil level sensor.

2. Fit the protective shield (2a) for the power assisted steering pump in place and tighten the fixing bolt (2b).

1. Fit the rear engine support (1a) in place and tighten the fixing bolts (1b) to the recommended torque.

1. Fit the upper alternator mounting bracket (1a) and tighten the fixing bolts (1b) to the recommended torque.

1. Fit the alternator (1a) in place and tighten the fixing bolts (1b) to the recommended torque.

1. Connect the electrical connection to the alternator.

Place the engine components single belt in position using a spanner on the moving tensioner.

Release the engine from the hydraulic lift.

1.9 JTD 16v

Removing

1. Fit the flywheel lock.

2. Undo the bolts (2a) and remove the engine flywheel (2b).

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

- Remove the flywheel lock.

3. Undo the bolts (3a) and remove the flywheel guard (3b).

1. Position the engine on the support tools (1a) and overhaul tools (1b).

Refitting

- Remove the engine from the tools used for supporting it.

- Place the rear flywheel guard in its housing and secure it using the bolts.

- Place the flywheel lock in its housing.

- Place the flywheel in its housing and secure it by tightening the new bolts to the recommended torque.

- Remove the flywheel lock.

1.9 JTD 8v

- Unscrew the bolts and remove the engine flywheel, then refer to

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 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.

- Fit the engine flywheel with reference to

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