AUXILIARY UNIT, REMOVED - DISMANTLING AND REASSEMBLY

Operation 1020F20 · AUXILIARY UNIT

2.8 JTD 8V

Removing

- Place the head on the workbench.1. Fit the tool (1a) on the auxiliary unit (1b) and fasten it using the bolts (1c).

- Place the tool in the vice.1. Undo the centre fixing bolt (1a) and remove the heat exchanger/oil filter assembly (1b) complete with gasket (1c).

1. Undo the fixing bolts (1a) and remove the vacuum unit (1b) and the gasket (1c).2. Undo the fixing nuts (2a) and remove the pressure pump (2b).

Do not separate the spacer from the pump.

3. Undo the fixing bolts (3a) and remove the cover (3b).

1. Fit the tool.

2. Undo the fixing bolts (2a) and remove the driven timing pulley (2b).3. Undo the fixing bolts (3a) and remove the front cover (3b).4. Release the main gear.

1. Undo the fixing bolts (1a) and remove the cover (1b).

1. Release the oil pump driven gear.2. Remove the gear (2a) from the drive gear shaft (2b) for the oil pump using a hydraulic press (2c).

1. Undo the oil pressure relief valve cap.2. Release the spring (2a), the piston (2b) and the cylinder (2c).

Refitting

- Using a torque wrench, check that the specifications of the oil pressure relief valve spring correspond to the recommended figures; if this it not the case, replace it.

- Fit the spring, the piston and the cylinder for the oil pressure relief valve.- Tighten the cap to the recommended torque.

1. Fit the gear (1a) on the drive gear shaft (2b) for the oil pump using a hydraulic press (1c).

1. Fit the tool.

1. Fit the tool.

2. Using the tool (2a), tighten the oil pump drive gear (2b) to the recommended torque to check that it is correctly fitted on the shaft.

Trace a straight vertical line and check that after applying the recommended torque the trace remains aligned.

- Fit the oil pump driven gear.1. Check that the axial clearance between the gears and the pump casing plane is within the recommended limits.

1. Check that the radial clearance between the gears and the pump casing is within the recommended limits.

1. Using the tool (1a), fit the oil seal (1b) on the front cover.2. Fit the main gear.3. Fit the cover gasket.4. Fit the cover (4a) and tighten the fixing bolts (4b) to the recommended torque.

- Apply the sealant.

- Fit the oil pump cover and tighten the fixing bolts to the recommended torque.

- Fit the pressure pump and tighten the fixing nuts to the recommended torque.

- Fit the side cover and tighten the fixing bolts to the recommended torque.

1. Fit the gasket.2. Fit the vacuum unit (2a) and tighten the fixing bolts (2b) to the recommended torque.

Fit the dog correctly on the teeth on the oil pump gear.

- Fit the tool

- Fit the toothed driven pulley and tighten the fixing bolts to the recommended torque.

- Remove the tool.

- Remove the auxiliary unit from the vice.- Remove the support tool from the auxiliary unit.