Croma Factory Service Manual (2005-2010): Engine
General
Maintenance
Diagnostics
Engine
Transmission
Brakes
Steering & suspension
Heating & A/C
Electrical
Body & interior
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
General2 pages
Engine and power unit9 pages
- Power unit with manual gearbox - r.r
- Power unit with automatic transmission r + r
- Power unit (manual gearbox), removed, dismantle and reassemble
- Power unit (automatic transmission) removed, remove and re-build
- Engine - position on stand and remove
- Engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal
- Engine - dismantle and reassemble following operation 1004e10 - wash and check dismantled parts - refit cylinder head an
- Engine removed general overhaul
- Engine removed, general overhaul excluding where present injection pump or pressure pump and turbocharger
Power unit supports8 pages
- Introduction - power unit supports
- Power unit rigid support - gearbox side - r.r.
- Power unit rigid support - timing side - r.r.
- Power unit front support flexible mounting (timing side) - replace
- Gearbox side support flexible mounting(s) - replace
- Power unit rear l/h flexible block - r+r
- Gearbox lower reaction rod -r.r.
- Bracket on gearbox for lower reaction rod - r.r.
Engine crankcase2 pages
Cylinder head/s14 pages
- Description of components
- General remarks - cylinder head(s)
- Tappet covers
- Cylinder head/s - various operations
- Introduction - cylinder head(s)
- Sound-proofing cover - r.r
- Single tappet cover -r.r and replace gasket
- Ignition coil cover on cylinder head - r+r
- Single camshaft housing - replace gasket
- Single cylinder head - r.r. and replace gasket
- Single cylinder head, removed - overhaul
- Valve guides in single cylinder head - replace during op. 1016e10
- Single cylinder head, removed - r .r parts for grinding
- Single cylinder head or (one) l or r, removed - grinding
Crankcase sump and covers15 pages
- General remarks - crankcase sump and covers
- Crankcase oil sump
- Oil seals on crankshaft
- Introduction - crankcase sump and covers
- Crankcase oil sump - r.r clean surfaces for sealant application
- Crankcase oil sump - r.r clean surfaces for sealant application with engine or interfering components removed
- Engine oil drain plug - replace
- Crankcase oil sump partition - r.r. with crankcase sump removed
- Front crankshaft oil seal cover - r + r and replace seals with timing belt removed
- Front crankshaft oil seal cover - r.r and replace seals for versions with oil pump on crankshaft, timing side
- Front crankshaft cover oil seal - r.r.
- Flywheel side oil seal cover - r.r and replace gaskets
- Flywheel side oil seal cover - r.r. and replace gaskets with flywheel removed
- Flywheel side oil seal - replace
- Flywheel side oil seal - replace the versions with automatic transmission.
Crankshaft and flywheel8 pages
- Introduction - crankshaft and flywheel
- Crankshaft
- Engine flywheel
- Crankshaft - r.r with engine removed - check and, if necessary, replace main journals and crankpins
- Crankshaft phonic wheel for RPM and timing sensor - replace with crankshaft removed
- Engine flywheel - r + r for versions with manual gearbox
- Engine flywheel - r + r for versions with automatic transmission
- Engine flywheel - r.r with clutch removed for versions with manual gearbox
Pistons and connecting rods9 pages
- General remarks - pistons and connecting rods
- Pistons and connecting rods
- Introduction - pistons and connecting rods
- Connecting rod and piston set - r.r
- Piston connecting rod set - r.r. with engine and cylinder head(s) removed
- Piston with connecting rod - r.r
- Piston with connecting rod - dismantling at the bench
- Connecting rod small end bush (one) - replace
- Set of pistons, gudgeon pins and seals - replace pistons and connecting rods at the bench - includes alignment and balan
Timing system45 pages
- Belt timing system
- Timing system tensioners
- Introduction - timing system
- Chain gears and timing system components r r
- Timing system drive chain - r.r
- Toothed timing belt - r + r for timing adjustment or replacement
- Toothed driven pulley (one) - r + r with timing belt removed
- Toothed drive pulley - r + r with timing belt removed
- Toothed drive pulley - r + r
- Driven belt pulley(s) - r.r.
- Timing system moving tensioner - r.r with timing belt/chain removed
- Timing belt moving tensioner - r.r.
- Timing system fixed tensioner - r.r. with timing belt removed
- Fixed timing system tensioner (one) r + r
- Timing system fixed hydraulic tensioner - r r
- Timing system chain tensioner pad - r.r.
- Timing system fixed chain tensioner pad r r
- Timing belt tensioner support - r.r
- Timing system protective cover(s) - r + r
- Timing system front protective cover (upper part) - r.r.
- Timing system front protective cover (lower part) - r.r.
- Front (intermediate) timing protective cover - r.r.
- Protective timing inner cover - r.r. with timing belt removed
- Introduction - timing system
- Camshaft (1) in camshaft housings (2)
- Overhead camshaft (1) in cylinder head (1)
- Introduction - tappets and rocker shafts
- Overhead camshaft in cylinder head - r.r on vehicle
- Camshaft in cylinder head - r.r. with head removed
- Camshafts in camshaft housing - r.r - includes camshaft housing replacement, if necessary
- Inlet camshaft in cylinder head - r.r.
- Exhaust camshaft in cylinder head - r.r.
- Camshaft front oil seal in cylinder head - replacement with timing belt removed
- Phase transformer on overhead camshaft (one) intake exhaust on cylinder head - r.r.
- Variable valve timing system on intake exhaust camshaft in cylinder head r r
- Valve tappets - check and adjust clearance, if necessary
- Valve tappets - check clearance
- Valve tappets - adjustment following clearance check
- Hydraulic tappet (one) - replace with camshaft removed
- Hydraulic tappet (one) and valve control rocker (one) - r r with camshaft removed
- Hydraulic tappets (all) r.r
- Camshafts in camshaft housing - r.r. - includes camshaft housing replacement if necessary
- Camshaft in camshaft housing - r.r with camshaft housing removed - includes camshaft housing replacement, if necessary
- Camshafts in camshaft housing - r.r. with camshaft housing removed - includes possible replacement. of camshaft housing
- Front oil seal for camshaft in camshaft housing - replace
Fuel tank and pipes22 pages
- Introduction - fuel tank and pipes
- Specifications
- Introduction - fuel tank and components
- Check on supply voltage and current uptake
- Submerged fuel pump check
- Fuel level gauge check
- Fuel supply circuit check
- Fuel tank - r + r and decant fuel
- Fuel tank - r + r for replacement
- Fuel filler pipe assembly- r + r
- Plug for fuel filler pipe - r + r
- Fuel level gauge for submerged pump assembly - replace.
- Submerged pump assembly complete with level gauge control - r + r
- Inertia switch for electric pump supply circuit r + r
- Front fuel delivery line - r.r.
- Intermediate fuel delivery hose - r.r.
- Rear fuel delivery line - r.r
- Supply pipe from fuel filter to supply management device - r.r.
- Front fuel return pipe - r.r
- Intermediate fuel return pipe - r.r.
- Rear fuel return pipe - r.r.
- Lower fuel tank protection - r r
Fuel circuit pump/s and devices5 pages
Engine air supply circuit18 pages
- Introduction - engine air supply circuit
- Air intake/vacuum circuit check
- Air filter assembly - r.r.
- Air cleaner filter element - replace.
- Filter air intake hose - r.r.
- Cold air intake for air filter - r.r
- Sleeve(s) from flow meter to air supply capacity case - r + r
- Sleeve from flow meter to turbo charger air inlet pipe - r + r
- Turbocharger air intake pipe - r.r.
- Rigid supply pipe (one) between turbocharger and heat exchanger -r.r.
- Air delivery hose between turbocharger and heat exchanger - replace
- Heat exchanger air inlet hose - r.r.
- Turbocharger air outlet hose -r.r.
- Air supply hose from heat exchanger to rigid pipe - replace
- Intermediate rigid pipe between heat exchanger and throttle body - r r
- Hose from intermediate pipe to pipe on throttle casing - r.r.
- Rigid pipe for air inlet to throttle body - r r
- Turbocharger intercooler - r + r
Petrol injection system15 pages
- Introduction - petrol fuel injection system
- Air flow meter - r + r
- Throttle body intergral with dvl - r r
- Inlet or exhaust timing phase transformer solenoid - r.r.
- Inlet or exhaust injection timing sensor - r.r.
- Air pressure sensor - r + r
- Coolant temperature sensor - r + r
- Single fuel manifold pipe, with injectors - r.r.
- Coolant temperature sensor on radiator - r.r.
- Set of injectors - r + r with fuel manifold pipe removed - includes seal replacement
- Set of injectors - r.r. - comp. gasket replacement
- Injector (one) - r + r with fuel manifold pipe removed - includes seal replacemnt
- Switch on clutch pedal - r.r (petrol engines)
- Injection/ignition system e.c.u. (one) - r + r
- System cable loom - r.r.
Diesel injection system54 pages
- Introduction - diesel fuel injection system
- Introduction - diesel pressure pump and control
- Injectors and pipes
- Diesel injection pressure pump electronic control
- Diesel temperature check
- Flow modulator solenoid operation check
- Injector operation check
- Injector circuit operation check
- Atmospheric pressure check
- Supercharging pressure check
- Check measured air mass
- Diesel pressure check
- Engine speed check
- Check engine control unit software release
- Check control unit software and hardware
- Check operation of main engine control unit relay
- Check engine control unit connections
- Check engine control unit connections
- Integrated throttle body operation check
- Check engine control unit connections
- Check operation of sensor detecting presence of water in diesel filter
- Check operation of fuel pressure sensor on rail
- Flow meter operation check
- Low fuel return pressure circuit check
- Low fuel delivery pressure circuit check
- Injector seal test
- High pressure fuel circuit check
- Engine coolant temperature sensor operation check
- Diesel injection pressure pump - r.r.
- Pressure pump drive pulley - r.r.
- Pressure pump support - r.r.
- Pressure pump support - dismantling and reassembly at the bench
- Pressure regulator on pressure pump - r.r.
- Fuel injectors - r.r.
- Pipe from pressure pump to fuel manifold - r.r.
- Single fuel manifold pipe - r.r.
- Pipes (all) from fuel manifold to injector - r.r.
- Fuel return manifold - r.r.
- Fuel hose from single manifold injector to return manifold - r.r.
- Fuel return pipe from injectors - r.r.
- Air flow meter - r.r.
- Engine coolant temperature sensor - r.r.
- Pressure relief sensor - r.r.
- Engine RPM sensor - r.r.
- Cam angle sensor - r.r
- Fuel pressure sensor on fuel manifold to injectors - r.r
- Water presence sensor in fuel filter - r.r.
- Fuel pressure regulator on single manifold to injectors - r r
- Brake pedal switch - r.r
- Switch on clutch pedal - r.r. (JTD engines)
- Throttle body - r.r
- Vacuum resevoir - r.r
- Diesel electronic injection control unit - .r
- System cable loom - r.r.
Engine supercharging system10 pages
- Turbocharger assembly
- Description of components
- Supercharging pressure check
- Supercharging pressure solenoid (pierburg) valve operation check
- Variable geometry turbocharger actuator leakage test
- Supercharging temperature check
- Check turbo valve protection fuse
- Variable geometry turbocharger r r
- Pipe between vacuum reservoir and actuator control solenoid valve - r.r.
- Solenoid controlling turbocharger vane position actuator - r.r
Inlet and exhaust manifolds10 pages
- General remarks - intake and exhaust manifolds
- Introduction - intake and exhaust manifolds
- Air chamber - r.r.
- Inlet manifold - r + r and replace seal
- Throttle shaft control valve for inlet ports r r
- Exhaust manifold - r + r and replace seal
- Exhaust manifold gasket - replace
- Exhaust manifold with catalytic converter - r.r.
- Exhaust manifold heat shield - r+r
- Modular inlet manifold - r.r.
Exhaust pipes and silencers9 pages
- Introduction - exhaust pipes and silencers
- Front exhaust silencer front heat shiled r r
- Exhaust pipe rear heat shield(s) - r.r
- Exhaust pipe assembly - r + r
- Exhaust pipe assembly r r
- Rigid section of exhaust pipe between catalytic converter and silencer - r + r
- Rear exhaust silencer - r + r
- Front exhaust silencer - r + r
- Intermediate exhaust pipe with hose section - r+r
Emission control system35 pages
- Introduction - emission control system
- INTRODUCTION - EXHAUST EMISSION CONTROL SYSTEM - Versions with DPF
- Introduction - exhaust emission control system
- INTRODUCTION - EXHAUST EMISSION CONTROL SYSTEM - Versions without DPF
- Exhaust gas recirculation system (e.g.r.)
- Crankcase vapour/gas recirculation system
- Particle filter saturation check
- Check differential pressure sensor operation
- Preconverter output temperature sensor operation check
- Dpf input temperature sensor operation check
- Egr solenoid operation check
- Idling c.o. level - check with special equipment
- Idling co level - check using special equipment and adjust speed
- Exhaust fumes - check with opacimeter
- Catalytic pre-converter - r.r
- Catalytic converter - r + r
- Catalytic converter excess temperature thermocouple - r + r
- Particulate filter (d.p.f.) - r r
- Particulate filter differential pressure (d.p.f.) sensor - r r
- Exhaust gas temperature sensor on particulate filter (d.p.f.) - r r
- Lambda sensor - r.r.
- Front lambda sensor to with catalytic converter - r.r
- Rear lambda sensor to catalytic converter - r.r
- E.g.r. system solenoid - r + r
- Exhaust gas/water heat exchanger for EGR system - r.r
- Exhaust gas inlet piping from exhaust manifold to heat exchanger EGR - r r
- Oil vapour pipe from tappet cover to engine block - r.r
- Oil vapour pipe from tappet cover to intake - r.r
- Engine oil vapour separator - r + r
- Tank fuel vapour separator - r + r
- Active carbon filter for fuel vapours - r + r
- Enablement solenoid for flow of fuel vapour to inlet - r+r
- Intermediate fuel vapour pipe r r
- Fuel vapor hose between rigid pipe and cut off solenoid r r
- Air intake chamber fuel vapour intake pipe - r.r.
Engine lubrication19 pages
- Introduction - engine lubrication
- Oil dipstick pipe - r.r
- Engine oil filler - r.r.
- Engine oil level sensor - r + r
- Engine oil pressure warning light switch - r + r
- Engine oil pump, removed - check at bench
- Engine oil intake duct - r.r
- Engine oil intake pump - r + r with crankcase sump removed
- Engine oil filter - r.r
- Timing chain lubrication nozzle - r.r
- Cartridge engine oil filter support - r + r
- Engine oil filter mounting and heat exchanger - r.r
- Engine oil delivery pipe to turbocharger - r + r
- Engine oil return pipe from turbo - r + r
- Engine oil heat exchanger - r + r
- Engine oil cooling radiator - r + r
- Engine oil cooling radiator support bracket - r + r
- Engine oil delivery and return pipes to cooling radiator - r + r
- Air duct for engine oil cooling radiator - r.r.
Engine cooling32 pages
- Introduction - engine cooling
- Engine coolant supply reservoir - r.r.
- Engine coolant reservoir mount - r r
- Engine cooling radiator - r + r
- Air duct on radiant mass - r.r.
- Engine cooling radiator support (1), lh or rh - r r
- Lower pin supporting engine cooling radiator (one), lh or rh - r&r
- Upper pin supporting engine cooling radiator (one), lh or rh - r&r
- Water pump - r + r
- Water pump - r + r with timing belt(s) removed
- Water pump drive gear - r&r
- Water pump pulley - r.r.
- Thermostat unit - r+r
- Thermostat unit - r + r with cylinder head removed
- Thermostat support - r.r.
- Thermostat- r + r
- Lower radiator coolant outlet hose - r.r.
- Upper radiator coolant outlet hose - r.r.
- Water pump rigid coolant inlet pipe - r.r.
- Sleeve from coolant tank to intermediate rigid pipe - r r
- Water pump feed intermediate piping - r r
- Water pump feed rigid pipe fitting sleeve - r r
- Engine oil heat exchanger coolant inlet pipe - r.r.
- Rigid pipe between thermostat and oil filter mounting - r.r.
- Coolant pipe from cylinder head r r
- Engine oil heat exchanger delivery and return duplex rigid piping - r r
- Engine coolant return pipe to supply reservoir - r.r.
- Coolant supply pipe to throttle body - r.r.
- Coolant return pipe from throttle body - r.r.
- Radiator cooling fan - r + r
- Fans with single engine duct - r+r
- Resistor for radiator cooling fan - r + r
Engine component miscellaneous drives13 pages
- Introduction - engine components drive
- Introduction - various engine components drive
- Crankshaft pulley - r + r
- Belt from A/C compressor to alternator drive - r + r
- Water pump balancing shaft drive chain gears and components r r
- Water pump /balancing shaft drive chain hydraulic tensioner r r
- Water pump /balancing shaft drive chain tensioner pads r r
- Single engine belt - r.r
- Engine component single belt moving tensioner - r + r
- Engine component single belt moving tensioner - r.r. with belt removed
- Engine component single belt fixed tensioner - one - r + r
- Air conditioner compressor drive belt - r + r
- Air conditioner compressor belt mobile tensioner - r r