Doblò Factory Service Manual (2000-2010): 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.
Engine and power unit11 pages
- Power unit with manual gearbox - r.r
- Power unit with manual gearbox - r+r for versions with a/c
- Power unit (manual gearbox), removed, remove and re-build
- Engine - position on stand and remove
- Power unit (manual gearbox), removed, remove and reassemble
- Engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal
- Engine - dismantle and re-build following operation 1004e10 - wash and check dismantled parts - re-fit cylinder head and
- COMPONENTS TRANSFER for half-finished engine
- Engine removed, general overhaul
- Compressor
- COMPONENTS TRANSFER for lighter engine
Power unit supports11 pages
- Introduction - POWER UNIT SUPPORTS
- Gearbox side power unit rigid support - r.r.
- Cam shaft left rigid mount - r r
- Timing side power unit rigid support - r.r.
- Power unit front mount (timing side) flexible block - replace
- Gearbox side mount flexible block - replace
- Gearbox side support flexible mounting(s) - replace
- Power unit upper reaction link r r
- Power unit lower reaction link r r
- Gearbox lower reaction rod ' -r.r.
- Bracket on gearbox for lower reaction rod - r.r.
Cylinder head – s14 pages
- Single cam cover - r + r and replace gasket
- Cam cover with fuel duct - r + r and replace gasket
- Cam cover with built in oil vapour separator r r
- Single cylinder head extension - change gasket
- Lh cylinder head extension - replace gasket
- Lh cylinder head extension - r r with timing belt removed - replace gasket
- Rh cylinder head extension - replace gasket
- Rh cylinder head extension -r r with timing belt removed -replace gasket
- Cylinder head - r + r and replace gasket
- Single cylinder head-r r gasket for versions with air conditioner
- Single cylinder head, removed - overhaul
- Single cylinder head valve guides - replace during operation 1016e10
- Single cylinder head, removed - r + r parts for grinding
- Single cylinder head or (one) l or r, removed - grinding
Crankcase sump and covers21 pages
- Introduction - CRANKCASE SUMP AND COVERS
- Crank case oil sump
- Oil seals on crank shaft
- Crank case oil sump - r + r clean seals for sealant application
- Crank case oil sump - r + r clean seals for sealant application with engine removed
- Engine oil drain plug - replace
- Oil sump bulkhead - r r
- Cover of timing system with chain drive - r + r replace oil seal and gasket
- Timing system cover oil seal - replace
- Front crank shaft oil seal cover - r + r and replace seals with timing belt removed
- Front crank shaft oil seal cover - r + r and replace seals
- Front crank shaft oil seal cover - r + r and replace seals for versions with oil pump on crank shaft, timing side
- Front crankshaft oil seal cover - r+r and replace gaskets for versions with airconditioner
- Engind front cover - r r
- Front crank shaft cover oil seal - replace
- Front crankshaft cover oil seal - replace for versions with air conditioner
- Flywheel side oil seal cover - r+r
- Oil seal cover, fly wheel side - r + r and replace seals
- Flywheel side oil seal - replace
- Flywheel end oil seal- r+r with flywheel removed
- Oil seal cover on auxiliary shaft - r + r with timing belt removed and replace gaskets
Crankshaft and flywheel8 pages
- 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 with clutch or gearbox removed
- Phonic wheel on flywheel - r r
- Engine flywheel protection - r.r
Pistons and connecting rods13 pages
- Pistons and connecting rods
- Introduction - PISTONS AND CONNECTING RODS
- Connecting rod and piston set - r r
- Piston connecting rod set - r r
- Set of pistons with connecting rods - r.r with cylinder head/s removed
- Piston with connecting rod - r r
- Piston connecting rod set - r r
- Piston with connecting rod - r r
- Piston with connecting rod - r r
- Piston with connecting rod - r r
- Piston/cylinder liner - r r
- Connecting rod small end bush - replace
- Piston, pin set - replace
Timing system48 pages
- Introduction - TIMING SYSTEM
- Chain timing system
- Timing system tensioners
- Toothed timing belt - r + r for timing adjustment or replacement
- Toothed timing belt - r + r for timing adjustment or replacement versions with air conditioner
- Toothed timing belt - r r with engine removed
- Toothed timing belt - r + r for timing adjustment or replacement versions with air conditioning
- Toothed-driven pulley (one) - r + r with timing belt removed
- Toothed drive pulley - r + r with timing belt removed
- Toothed drive pulley - r + r
- Toothed drive pulley - r r for versions with air conditioner
- Toothed driven pulley (one) - r + r
- Driven toothed pulley (one) - r r for versions with air conditioner
- Bolt pulley - r r
- Timing belt pulley - r r
- Timing belt toothed pulley - r.r. for versions with air conditioning
- CHAIN AND GEARS for timing system - R.R. for timing or Replacement.
- MOVING timing TENSIONER - R.R. with timing belt/chain removed
- Mobile timing system tensioner - r + r for 24 valve engines
- Mobile timing belt tensioner - r r for versions with air conditioner
- Fixed timing system tensioner - r + r with timing belt removed
- Fixed timing system tensioner (one) r + r
- Timing CHAIN TENSIONER PLATE - R.R.
- Timing belt tensioner mount - r r
- Timing belt tensioner mount - r r with timing belt removed
- Timing system protective cover(s) - r + r
- Timing system guard assemblies - r + r
- Timing system front protective cover (upper part) - r.r.
- Timing system front protective cover (lower part) - r.r.
- Introduction - TIMING SYSTEM
- Camshaft (1) in top heads (2)
- Overhead camshaft - r r on vehicle
- Overhead camshaft - r r on vehicle - with cylinder head removed
- Overhead camshaft front cover - r + r and replace seals with timing belt removed
- Camshaft seal support with ignition coil r + r including seal replacement
- Front crankshaft oil seal-r r with timing belt removed
- Camshaft controlling exhaust valves in top head - r + r with top head removed - includes replacement of top head
- Camshaft in lh head extension - r+r with head extension and timing belt removed
- Camshaft controlling intake valves in top head - r + r with top head removed - includes replacement of top head if neces
- Camshaft in rh head extension - r+r with head extension and timing belt removed
- Front oil seal of camshaft of one l/h or r/h top head - replace with timing belt removed
- Rear seal of camshaft of one l/h or r/h top head - r + r and replace seal
- Phase transformer on inlet camshaft in cylinder head - r.r.
- Valve tappets - check and adjust clearance
- Valve tappets - check clearance
- VALVE TAPPETS - Adjust. following clearance check
- Hydraulic tappets all r r
- CAMSHAFTS in camshaft housing - R.R. with camshaft housing removed - Includes possible. Replacement. of camshaft housing
Fuel tank and pipes25 pages
- Introduction - fuel tank and pipes
- Introduction - fuel tank and components
- Introduction - FUEL TANK AND PIPES
- Check supply voltage and absorption current
- Right CANISTER for CNG CANISTER ASSEMBLY - R.R.
- Fuel tank - r + r and decant fuel
- Fuel tank - r + r for replacement
- Fuel filler pipe - r + r
- Fuel filler pipe - rigid section - r r
- Fuel filler pipe union sleeve - r + r
- Fuel filler pipe housing seal - r r
- Plug for fuel filler pipe - r + r
- Submerged pump assembly complete with level guage control - r + r
- Submerged pump assembly complete with fuel guage - r r with tank removed
- 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
- Filter/carburettor line - r r
- Fuel RETURN PIPE from fuel filter to return manifold pipe - R.R.
- Fuel line from manifolds - r r
- Intermediate fuel return pipe r r
- Fuel return line - r r
- Fuel return line from injection pump to filter - r r
- Fuel pipe protection - r r
(methane) cng canister and pipes23 pages
- Methane gas cannister and tubes for re-charging
- Check on operation of methane cut out solenoid valve coil on canister
- Check on operation of methane cut out solenoid valve on canister
- C.N.G. - FUEL SYSTEM Safety check
- C.N.G. - FUEL SYSTEM check for any leaks using electronic detector following operations
- Injection system solenoid on cylinder r r
- Cng injection system one-way valve - r r
- Cng cylinder recharge valve cock - r r
- Cng cylinder recharge valve - r r
- Cng recharge pipe from recharge valve to connection sleeve - r r
- Cng recharge pipe connection sleeve - r r
- THREE-WAY CONNECTOR (one) for CNG repressurizing system' - R.R .
- Cng recharge pipe from connection sleeve to solenoid - r r
- PIPE (one) connecting CNG repressurizing system' - R.R.
- Left CANISTER for CNG CANISTER ASSEMBLY - R.R.
- Centre CANISTER for CNG CANISTER ASSEMBLY - R.R.
- PIPE between FUEL TANK and fuel filler pipe - R.R.
- Right CANISTER for CNG CANISTER ASSEMBLY - R.R. with centre canister removed
- CNG supply PIPE from solenoid valve to pressure reduction unit - R.R.
- Cng canister assembly shield/protection / - r.r.
- FRONT mounting BRACKET for CNG canister shield - R.R.
- CNG canisters LEFT mounting BRACKET - R.R.
- CNG canister shield RIGHT mounting BRACKET - R.R.
Fuel circuit pump/and devices15 pages
- Introduction - FUEL CIRCUIT PUMP/AND DEVICES
- Fuel filters
- Fuel heating device
- Gas pressure control device
- Check on operation of methane cut out solenoid valve coil on pressure reduction unit
- Check on methane low pressure circuit
- Fuel filter assembly - r + r or replace
- Fuel filter mounting, injection controlunit and pre-heating control unit - r.r. with interfering components removed.
- Delivery adjustment valve - r r
- Fuel filter filtering element - replace
- Thermostat valve on fuel return filter - r r
- Cng injection system pressure reduction unit - r r
- Gas pressure control valve on gas circuit - replace
- SOLENOID VALVE COIL on CNG injection system'' pressure reduction unit - R.R.
- Solenoid coil on cng system pressure reduction unit r r with pressure reduction unit removed
Engine air supply circuit16 pages
- Vacuum air circuit
- Introduction - vacuum air circuit
- Introduction - ENGINE AIR SUPPLY CIRCUIT
- Air cleaner filtering element - replace
- Air cleaner filtering element - replace.
- Filter input sleeve - r r
- Cold air intake - r r
- Vacuum air circuit resonator pipe - r+r
- Sleeve from air cleaner to intake manifold - r + r
- Sleeve from air cleaner to flow meter - r + r
- Air inlet pipe to turbo charger - r + r
- Air delivery pipe between turbo charger and heat exchanger - replace
- Rigid supply pipe (one) between turbocharger and heat exchanger -r.r.
- Air delivery sleeve from heat exchanger to intake manifold - r + r
- Turbo charger intercooler - r + r
- Air suply hose between heat exchanger and rigid pipe - replace
Petrol injection system18 pages
- Introduction - PETROL INJECTION SYSTEM
- Introduction - petrol fuel injection system
- Throttle case - r + r
- Throttle body intergral with mds - r r
- Coolant temperature sensor - r + r
- Air pressure sensor - r + r
- Cam angle sensor r + r
- Phase transformer electromagnet - r.r.
- Intake air pressure/temperature sensor - r r
- Single fuel manifold pipe, with injectors - r + r
- Single fuel manifold with injectors - r+r with air conveyor/box removed
- Set of injectors - r + r with fuel manifold pipe removed - includes seal replacement
- Injector (one) - r + r with fuel manifold pipe removed - includes seal replacemnt
- Run electronic ignition/injection control unit (single) self-learning procedure
- Injection/ignition system e.c.u. (one) - r + r
- Ignition/injection system control unit mount - r r
- Switch on clutch pedal - r.r (petrol engines)
- System cable bundle - r + r
Cng fuel system15 pages
- Introduction - CNG FUEL SYSTEM
- Check on operation of Methane pressure sensor
- Check on Methane injector coil
- Check on methane pressure in high pressure circuit
- Methane injector leakage test
- Methane high pressure circuit leakage test
- Check on operation of GAS/Petrol selector
- Cng/fuel switch - r r
- Cng pressure sensor - r r
- Single cng manifold pipe complete with injectors - r r
- Set of cng injection system injectors - r r with cng manifold pipe removed includes gasket replacement
- Set of cng injection system injectors - r r with cng manifold pipe removed includes gasket replacement
- Injector(1) of cng injection system - r rwith cng manifold pipe removed includes gasket replacement
- Cng injection unit control unit - r r
- Cng injection wiring harness - arrange
Diesel fuel injection47 pages
- Introduction - DIESEL FUEL INJECTION
- Diesel pressure pump
- Injectors and lines
- Pressure pump electric control
- Introduction - DIESEL FUEL INJECTION
- Low return fuel pressure circuit check
- Low fuel pressure supply circuit check
- Injector high pressure, fuel circuit leakage test
- Check high pressure fuel circuit
- Injection pump - r + r
- Injection pump - check timing and adjust
- Injection pump toothed pulley - r + r with timing belt removed
- Injection pump toothed drive pulley - r+r with timing belt removed
- Injection pump mount r r
- Injection pump mount r r with injection pump removed
- Injectors - r + r
- Coolant temperature sensor - r+r
- Rpm sensor - r+r
- Switch on brake pedal - r+r
- Switch on brake pedal - r+r
- Diesel injection system ecu - r+r
- Pressure pump - r r
- Pressure pump pulley - r r
- Supplementary pressure pump - r r
- Supplementary pressure pump - dismantle
- Fuel pressure REGULATOR - R.R.
- Fuel injectors
- Pressure pump/manifold pipe - r r
- Fuel delivery manifold - r r
- Lines to injectors - r r
- Lines to injectors - r r
- Fuel return manifold - r r
- Fuel return PIPE from INJECTORS - R.R.
- 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 - r r
- Water presence sensor on fuel filter r r
- Brake pedal switch - r r
- Clutch pedal switch - r r
- Electro-pneumatically controlled THROTTLE CASING - R.R.
- Vacum tank for controlling engine air intake r r
- Solenoid on vacuum tank for throttle body pneumatic valve r r
- Ds electric injection control unit - r r
- Diesel injection wiring harness - r r
Engine supercharging system6 pages
- TURBOCHARGER with CATALYTIC CONVERTER - R.R.
- Turbocharger - exhaust manifold - exhaust pipe connecting hose - r.r.
- Turbo/manifold/sleeve assembly dismantle
- Turbocharger bracket - r r
- Sleeve joining turbo charger and exhaust pipe - r + r and replace seal
- Solenoid controlling turbocharger vane position actuator r r
Inlet and exhaust manifolds9 pages
- Inlet manifolds
- Introduction - INLET AND EXHAUST MANIFOLDS
- Intake and exhaust system leakage check
- Inlet manifold - r + r and replace seal
- Inlet manifold - r+r and replace seal with air conveyor/box removed
- Sleeves connecting air capacity box to inlet manifold is - r+r
- Exhaust manifold - r + r and replace seal
- Exhaust manifold with catalytic converter - r r
- Exhaust manifold heat shield on bulkhead - r+r
Exhaust pipes and silencers11 pages
- Introduction - EXHAUST PIPES AND SILENCERS
- Exhaust pipe heat shield - r r
- Exhaust pipe assembly - r + r
- Rigid section of exhaust pipe between catalytic converter and silencer - r + r
- Rear exhaust silencer - r + r
- Intermediate exhaust silencer - r+r emission control versions
- Front catalytic converter attachment seal - replace
- Catalytic converter rear gasket - r r
- Exhaust pipe attachment to engine - r + r
- Exhaust pipe attachment to engine seal/s - replace
- Exhaust pipe between pre-catalytic converter and catalytic converter - r.r.
Emission control system40 pages
- Exhaust emission control system
- Introduction - EXHAUST EMISSION CONTROL SYSTEM
- Crankcase vapour/gas recirculation system
- Exhaust gas recirculation system (e.g.r.)
- Evaporation control system
- Smokiness at exhaust - check with opacimeter
- Idling c.o. level - check with special equipment
- Catalytic converter - r + r
- Catalytic pre-converter - r.r.
- Front lambda probe with catalitic converter r r
- Rear lambda probe with catalitic converter r r
- LAMBDA SENSORS (all) - R.R.
- E.g.r. valve - r + r
- E'G.R. system intake AIR MODULATOR . - R.R.
- E.g.r. system solenoid - r + r
- Motor for egr valve self-regulation - r r
- Rigid pipe from egr solenoid to throttle body r r
- Pipe carrying exhaust gas to e.g.r. valve - r + r
- Pipe carrying exhaust gas from e.g.r. valve to inlet manifold - r + r
- Exhaust gas water heat exchanger for egr valve r r
- E.G.R. - VALVE HEAT EXCHANGER ASSEMBLY - Connector PIPES - R.R.
- Pipe carrying engine oil vapours from intake to separator - r + r
- Oil vapour pipe from cam cover to rngine block r r
- Engine oil vapour intake pipe - r + r
- Idling engine oil vapour inlet line - r r
- Oil vapour recovery PIPE between rigid pipe and turbo inlet hose - R.R.
- Oil vapour recovery PIPE between separator and turbo - R.R.
- Oil vapour recovery PIPE between rigid pipe and separator - R.R.
- Engine oil recovery pipe - r + r
- Engine oil vapour separator - r + r
- Engine oil collection MANIFOLD - R.R.
- Tank fuel vapour separator - r + r
- Multifunctional valve r r
- Float valve (one) (preventing fuel emerging from tank) - r+r
- Fuel system ventilation/safety valve - 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 between fuel vapour SEPARATOR and ACTIVE CHARCOAL FILTER - R.R.
- Fuel vapour PIPE from INTERMEDIATE pipe to ACTIVE CHARCOAL FILTER - R.R.
- Pipe from fuel vapour separator to solenoid - r r
Engine lubrication19 pages
- Introduction - ENGINE LUBRICATION SYSTEM
- Engine oil lubrication circuit
- Introduction - engine lubrication
- ENGINE OIL - Check level and top up, if necessary
- Oil dip stick pipe - r r
- Engine oil filler - r r
- Engine oil pressure warning light switch - r + r
- Engine oil pump - r + r with crankcase sump removed
- Engine oil pump - r+r
- Engine oil pump - r+r with power unit removed
- Engine oil pump, removed - check at bench
- Emgine oil intake duct - r r
- Engine oil intake pump - r + r with crankcase sump removed
- Engine oil filter r r
- Engine oil delivery pipe to turbocharger - r + r
- Engine oil return pipe from turbo - r + r
- Timing mount oil pipe - r r
- Engine oil HEAT EXCHANGER, complete with engine oil filler and filter - R.R.
- Radiant mass for engine oil cooling - r + r
Engine cooling36 pages
- Introduction - engine cooling
- Introduction - engine cooling radiator
- Introduction - water pump and thermostat
- Introduction - coolant temperature control devices
- Engine COOLANT - Check density' and top up level, if necessary
- ENGINE COOLING SYSTEM - draining and refilling circuit and bleeding air
- Engine cooling tank - r + r
- Engine cooling radiator - r + r
- Engine cooling radiator - r r for air conditioned versions
- Engine cooling radiator AIR DUCT PROTECTION/ - R.R.
- Engine cooling radiator support beam - r r
- Engine cooling radiator support pin one left or right r r
- Water pump - r + r
- Water pump - r+r for versions with air conditioner
- Water pump - r + r with drive belt removed
- Water pump - r + r with engine removed
- Thermostat unit - r+r
- Thermostat unit - r + r with cylinder head removed
- Thermostat- r + r
- Lower sleeve for coolant outlet from radiator - r + r
- Upper sleeve for coolant inlet to radiator - r + r
- Sleeve from thermostat to rigid pipe carrying fluid to pump - r r
- Rigid pipe for coolant inlet to water pump - r + r
- Rigid intake pipe to water pump - r+r for versions with a/c
- Oil exchange sleeve - r r
- RIGID supply or return PIPES for ENGINE OIL HEAT EXCHANGER - R.R.
- Engine coolant RETURN PIPE to SUPPLY RESERVOIR - R.R.
- Cng injection system pressure reduction unit cooling circuit pipe(1) - r r
- Hose from engine oil water heat exchanger to rigid pipe for egr system exhaust gas water heat exchanger r r
- Rigid pipe for coolant between enginge oil water heat exchanger and exhaust gas water heat exchanger for egr system r r
- Hose from rigid pipe for coolant to heat exchanger and exhaust gas water heat exchanger for egr system r r
- Coolant PIPE between EXHAUST GAS/WATER HEAT EXCHANGER and thermost unit - R.R.
- Radiator cooling fan - r r with air conditioner
- Radiator cooling fan - r + r
- Fans with single engine duct - r+r
- Resistor for radiator cooling fan - r + r
Various engine component controls3 pages
Engine component miscellaneous drives21 pages
- Crankshaft services PULLEY - R.R.
- Crankshaft pulley - r+r for versions with air conditioner
- Alternator/air conditioner compressor drive belt - adjust tension
- Air conditioner compressor/alternator drive belt - r + r
- Alternator/water pump drive belt - adjust tension
- Air conditioning compressor and alternator drive belt tensioner - r.r.
- Alternator drive belt - r + r
- Alternator drive belt - adjust tension
- Belt from a/c compressor to alternator drive r + r
- Belt from air conditioner compressor to alternator drive -adjust and tension
- Auxilary belt mobile tensioner (one) -r+r
- Power steering and/or self-levelling suspension pump drive belt - r + r
- Power steering pump drive belt - r r for versions with air conditioner
- Power steering pump drive belt - adjust tension
- Power steering pump drive guard -arrange
- Power steering pump/self levelling suspension pump pulley - r + r with belt removed
- Air conditioner compressor drive belt - r + r
- Air conditioner compressor drive belt - adjust tension
- Single engine belt r r
- Engine component single belt mobile tensioner - r + r
- Engine component single belt fixed tensioner - one - r + r