SINGLE CAMSHAFT HOUSING - REPLACE GASKET

Operation 1016B10 · CAMSHAFT HOUSING(S)

1.3 Multijet · 75 CV

Removing

- Position the vehicle on a lift.

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 1060G90 SYSTEM CABLE LOOM - R.R.

1. Disconnect the brake servo vacuum pipe from the vacuum pump.

1. Disconnect the fuel return pipe from the manifold.

2. Disconnect the fuel intake pipe from the pressure pump.

1. Disconnect the rapid connectors (1a) and (1b).

- Undo the bolts fixing the duct and remove it complete with front fuel supply and return pipes.

1. Manually push the clips (1a) and disconnect the return pipe from the injectors to the manifold (1b), injector side.

2. Loosen the band and disconnect the fuel return pipe from the pressure pump, pressure pump side.

3. Undo the connectors (3a) and remove the pipe from the pressure pump to the fuel manifold (3b).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

4. Unscrew the connectors (4a) and remove the pipes from the fuel manifold to the injectors (4b).

Use new pipes from the fuel manifold to the injectors when refitting.

5. Undo the bolts (5a) and remove the mounting brackets (5b) complete with single fuel manifold pipe (5c).

6. Undo the bolt (6a) and remove the cam angle sensor (6b).

1. Undo the injector fastening bracket nut.

2. Keep the washer (2a) and the tapered washer (2b).

3. Remove the injectors (3a), one at a time, using the tools (3b) and (3c).

- Remove the injectors complete with bracket.

- Repeat the above procedure to remove the remaining pair of injectors.

4. Remove the injector seals from the single camshaft housing.

These seals are replaced each time they are dismantled.

1. Remove the plugs (1a) and fit the tools (1b) on the camshafts in their place.

Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.

2. Fit a suitable (6 mm diameter) peg via the special opening in the gearbox.

Check that the peg is correctly inserted in the housing in the flywheel.

1. Use a spanner in an anti-clockwise direction on the moving tensioner (1a) and remove the engine components single drive belt (1b).

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).

1. Using the tools (1a) and (1b) for counter-torque, loosen the left bolt (1c) fixing the pulley mounting flange to the crankshaft.

1. Loosen the lower bolts fixing the alternator to the mounting.

1. Loosen the upper bolt fixing the alternator to the mounting.

2. Undo the bolt (2a) and disconnect the connector (2b) for the engine oil vapour recovery pipe from the chain drive timing cover.

3. Fit a suitable bracket for supporting the power unit and fasten it using the upper bolt securing the alternator to the mounting.

- Undo the lower bolts fixing the alternator to the mounting.

1. Fit the tool (1a) complete with support mountings (1b), then connect them to the bracket fitted previously using the rod (1c).

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

1. Undo the plug (1a) complete with the o-ring and the bolt (1b) fixing the exhaust side camshaft toothed drive pulley.

2. Undo the bolts (2a) and remove the cover (2b) complete with gasket.

- Release the exhaust side camshaft toothed pulley working via the opening in the timing cover and rest it on the timing cover inner ribs.

After this operation the timing moving tensioner piston will be fully extracted.

1. Undo the bolts fixing the timing cover to the single camshaft housing.

2. Keep the brackets.

3. Undo the bolts (3a) and (3b), then remove the single camshaft housing assembly (3c).

4. Remove the single camshaft housing gasket.

Refitting

1. Apply silicon sealant in the contact area between the cylinder head and the timing chain cover.

2. Position the camshaft housing centering bushes on the cylinder head as illustrated in the diagram.

The centering bushes between the cylinder head and the camshaft housing are longer (13.0 mm) than those between the engine block and the cylinder head; take care therefore not to mix them up because this could adversely affect the operation of the engine.

3. Position the gasket on the cylinder head by fitting it on the locating bushes.

4. Apply silicon sealant to the gasket between the lower cylinder head and the camshaft housing by the contact area with the timing cover.

5. Also apply a bead of sealant to the surface of the timing cover gasket following the black line of silicon on the actual gasket.

Apply a thin layer of sealant to the timing cover gasket so that it is not too thick and avoid excess sealant inside the timing cover.

- Working with the camshaft timing tools fitted, position the single camshaft housing taking care not to move the rocker arms out of position.

- Screw in the bolts securing the single camshaft housing to the cylinder head without tightening them.

1. Screw in and tighten the bolts fixing the timing cover to the single camshaft housing to torque.

During this stage do not tighten the remaining bolts fixing the timing cover.

1. Tighten the six rear bolts fixing the single camshaft housing to a torque of 0.9 daNm.

2. Loosen the bolts (2a) and (2b) fixing the timing cover tightened previously.

3. Continue tightening the bolts fixing the camshaft housing to a torque of 0.9 daNm following the order illustrated working gradually towards the timing cover.

1. Tighten the single cylinder head fixing bolts M8 (1a) to a pre-torque of 1.5 daNm and M7 (1b) to a pre-torque of 1.2 daNm

2. Tighten the bolts (2a) and (2b) securing the single camshaft housing to the specified torque.

Follow the order shown in the figure for each tightening sequence.

- Fit the remaining bolts fixing the timing cover to the single camshaft housing, then tighten all the bolts fixing the timing cover to the camshaft housing to the recommended torque.

- The non alignment between the single camshaft housing and the cylinder head should not exceed the recommended value.

It is only possible for the cylinder head extension to protrude from the cylinder head.

1. Fasten the tool to the timing cover, by the inspection window, so that the peg is against the moving plate rib; using the tool lever, retract the belt tensioner piston so that it is in the locked position.

- Fit the toothed pulley on the exhaust side camshaft working via the opening in the timing cover.

- Position the bolt fixing the gear and screw it in without tightening it in order to prevent the gear from accidentally coming out of the housing.

- Working on the tool lever, fully retract the belt tensioner piston so that the inner spring can be reloaded and the timing chain tension is correct.

- Release the chain tensioner piston checking that it is in contact with the moving plate.

- Remove the tool.

1. Working with the camshaft timing tools fitted, tighten the bolt fixing the exhaust side camshaft drive pulley fixing bolt to the recommended torque.

2. Tighten the plug with its O-ring.

3. Place the cover (3a) complete with gasket back in its housing and secure it using the bolts (3b).

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

- Remove the tools used for supporting the power unit.

- Undo the upper bolt, loosen the lower bolts fixing the alternator and remove the bracket used for supporting the power unit.

- Tighten the bolts fixing the alternator to the mounting to the recommended torque.

- Connect the connector for the engine oil vapour recovery pipe to the timing cover with drive chain and tighten the bolt.

Ensure the O-ring is present and correctly positioned.

- Tighten the left bolt fixing the pulley support flange on the crankshaft to the recommended torque using the tools for counter-torque.

- Position the crankshaft pulley in its housing and secure it tightening the bolts to the recommended torque.

- Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt.

- Remove the peg from the opening in the gearbox.

- Remove the camshaft timing tools and tighten the plugs.

- Connect the brake servo vacuum intake pipe, vacuum unit side and tighten the band.

- Place the new injector seals in the housings on the single camshaft housing.

1. Refit the injectors (1a) with brackets (1b) into their seats.

Before refitting, replace the copper seal on the injectors.

2. Refit the tapered washer (2a) and washer (2b) in their seats.

3. Tighten the nut securing the injector bracket to the specified torque.

- Place the cam angle sensor back in its housing and secure it tightening the bolt to the recommended torque.

Place the mounting brackets complete with single fuel manifold pipe back in their housings and secure them using the bolts.

- Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening.

- Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an appropriate commercial wrench.

- Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an appropriate commercial wrench.

Clean the threaded pipe seats on the manifold and injectors with heptane.

- Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them.

- Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

- Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a spanner.

- Connect the fuel return pipe from the pressure pump, pressure pump side and tighten the band.

- Place the duct complete with front supply and return fuel pipes in its housing and connect the rapid connectors.

- Cconnect the fuel intake pipe to the pressure pump.

- Connect the fuel return pipe to the manifold.

- Connect the brake servo vacuum pipe to the vacuum pump.

Op. 1060G90 SYSTEM CABLE LOOM - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

- Remove the vehicle from the lift.

1.3 Multijet · 90 CV

Removing

- Position the vehicle on a lift.

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 1060G90 SYSTEM CABLE LOOM - R.R.

1. Disconnect the brake servo vacuum pipe from the vacuum pump.

2. Disconnect the vacuum reservoir vacuum pipe from the vacuum pump.

1. Disconnect the fuel pipe from the manifold.

2. Disconnect the fuel intake pipe from the pressure pump.

1. Disconnect the rapid connectors (1a) and (1b).

- Undo the duct fixing bolts and remove it complete with front fuel supply and return pipes.

1. Manually push the clips (1a) and disconnect the return pipe from the injectors to the manifold (1b), injector side.

2. Loosen the band and disconnect the fuel return pipe from the pressure pump, pressure pump side.

3. Undo the connectors (3a) and remove the pipe from the pressure pump to the fuel manifold (3b).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

4. Unscrew the connectors (4a) and remove the pipes from the fuel manifold to the injectors (4b).

Use new pipes from the fuel manifold to the injectors when refitting.

5. Undo the bolts (5a) and remove the mounting brackets (5b) complete with single fuel manifold pipe (5c).

6. Undo the bolt (6a) and remove the cam angle sensor (6b).

1. Undo the injector fastening bracket nut.

2. Keep the washer (2a) and the tapered washer (2b).

3. Remove the injectors (3a), one at a time, using the tools (3b) and (3c).

- Remove the injectors complete with bracket.

- Repeat the above procedure to remove the remaining pair of injectors.

4. Remove the injector seals from the single camshaft housing.

These seals are replaced each time they are dismantled.

1. Remove the plugs (1a) and fit the tools (1b) on the camshafts in their place.

Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.

2. Fit a suitable (6 mm diameter) peg via the special opening in the gearbox.

Check that the peg is correctly inserted in the housing in the flywheel.

1. Use a spanner in an anti-clockwise direction on the moving tensioner (1a) and remove the engine components single drive belt (1b).

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).

1. Using the tools (1a) and (1b) for counter-torque, loosen the left bolt (1c) fixing the pulley mounting flange to the crankshaft.

1. Loosen the lower bolts fixing the alternator to the mounting.

1. Loosen the upper bolt fixing the alternator to the mounting.

2. Undo the bolt (2a) and disconnect the connector (2b) for the engine oil vapour recovery pipe from the chain drive timing cover.

3. Fit a suitable bracket for supporting the power unit and fasten it using the upper bolt securing the alternator to the mounting.

- Undo the lower bolts fixing the alternator to the mounting.

1. Fit the tool (1a) complete with support mountings (1b), then connect them to the bracket fitted previously using the rod (1c).

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

1. Undo the plug (1a) complete with the O-ring and the bolt (1b) fixing the exhaust side camshaft toothed drive pulley.

2. Undo the bolts (2a) and remove the cover (2b) complete with gasket.

- Release the exhaust side camshaft toothed pulley working via the opening in the timing cover and rest it on the timing cover inner ribs.

After this operation the timing moving tensioner piston will be fully extracted.

1. Undo the bolts fixing the timing cover to the single camshaft housing.

2. Keep the brackets.

3. Undo the bolts (3a) and (3b), then remove the single camshaft housing assembly (3c).

4. Remove the single camshaft housing gasket.

Refitting

1. Apply silicon sealant to the contact area between the cylinder head and the timing chain cover.

2. Position the camshaft housing centering bushes on the cylinder head as illustrated in the diagram.

The centering bushes between the cylinder head and the camshaft housing are longer (13.0 mm) than those between the engine block and the cylinder head; take care therefore not to mix them up because this could adversely affect the operation of the engine.

3. Position the gasket on the cylinder head by fitting it on the locating bushes.

4. Apply silicon sealant to the gasket between the lower cylinder head and the camshaft housing by the contact area with the timing cover.

5. Also apply a bead of sealant to the surface of the timing cover gasket following the black line of silicon on the actual gasket.

Apply a thin layer of sealant to the timing cover gasket so that it is not too thick and avoid excess sealant inside the timing cover.

- Working with the camshaft timing tools fitted, position the single camshaft housing taking care not to move the rocker arms out of position.

- Screw in the bolts securing the single camshaft housing to the cylinder head without tightening them.

1. Screw in and tighten the bolts fixing the timing cover to the single camshaft housing to torque.

During this stage do not tighten the remaining bolts fixing the timing cover.

1. Tighten the six rear bolts fixing the single camshaft housing to a torque of 0.9 daNm.

2. Loosen the bolts (2a) and (2b) fixing the timing cover tightened previously.

3. Continue tightening the bolts fixing the camshaft housing to a torque of 0.9 daNm following the order illustrated working gradually towards the timing cover.

1. Tighten the single cylinder head M8 fixing bolt (1a) to a pre-torque of 1.5 daNm and M7 (1b) to a pre-torque of 1.2 daNm

2. Tighten bolts (2a) and (2b) securing the single cylinder head extension to the specified torque.

Follow the order shown in the figure for each tightening sequence.

- Fit the remaining bolts fixing the timing cover to the single camshaft housing, then tighten all the bolts fixing the timing cover to the camshaft housing to the recommended torque.

- The non alignment between the single camshaft housing and the cylinder head should not exceed the recommended value.

It is only possible for the camshaft housing to protrude.

1. Fasten the tool to the timing cover, by the inspection window, so that the peg is against the moving plate rib; using the tool lever, retract the belt tensioner piston so that it is in the locked position.

- Fit the toothed pulley on the exhaust side camshaft working via the opening in the timing cover.

- Position the bolt fixing the gear and screw it in without tightening it in order to prevent the gear from accidentally coming out of the housing.

- Working on the tool lever, fully retract the belt tensioner piston so that the inner spring can be reloaded and the timing chain tension is correct.

- Release the chain tensioner piston checking that it is in contact with the moving plate.

- Remove the tool.

1. Working with the camshaft timing tools fitted, tighten the bolt fixing the exhaust side camshaft drive pulley fixing bolt to the recommended torque.

2. Tighten the plug with its O-ring.

3. Place the cover (3a) complete with gasket back in its housing and secure it using the bolts (3b).

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

- Remove the tools used for supporting the power unit.

- Undo the upper bolt, loosen the lower bolts fixing the alternator and remove the bracket used for supporting the power unit.

- Tighten the bolts fixing the alternator to the mounting to the recommended torque.

- Connect the connector for the engine oil vapour recovery pipe to the timing cover with drive chain and tighten the bolt.

Ensure the O-ring is present and correctly positioned.

- Tighten the left bolt fixing the pulley support flange on the crankshaft to the recommended torque using the tools for counter-torque.

- Position the crankshaft pulley in its housing and secure it tightening the bolts to the recommended torque.

- Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt.

- Remove the peg from the opening in the gearbox.

- Remove the camshaft timing tools and tighten the plugs.

- Connect the brake servo vacuum intake pipe, vacuum unit side and tighten the band.

- Place the new injector seals in the housings on the single camshaft housing.

1. Refit the injectors (1a) complete with brackets (1b) in their seats.

Before refitting, replace the copper seal on the injectors.

2. Refit the tapered washer (2a) and washer (2b) in their seats.

3. Tighten the nut securing the injector bracket to the specified torque.

- Place the cam angle sensor back in its housing and secure it tightening the bolt to the recommended torque.

- Place the mounting brackets complete with single fuel manifold pipe back in their housings and secure them using the bolts.

- Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening.

- Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an appropriate commercial wrench.

- Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an appropriate commercial wrench.

Clean the threaded pipe seats on the manifold and injectors with heptane.

- Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them.

- Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

- Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a spanner.

- Connect the fuel return pipe from the pressure pump, pressure pump side and tighten the band.

- Connect the fuel outlet pipe from the injectors, injector side and push in until the clips click into place.

- Place the duct complete with front fuel supply and return pipes in its housing and connect the rapid connectors.

- Connect the fuel supply pipe to the pressure pump.

- Connect the return pipe to the manifold.

- Connect the vacuum reservoir vacuum pipe to the vacuum pump.

- Connect the brake servo vacuum pipe to the vacuum pump.

Op. 1060G90 SYSTEM CABLE LOOM - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

- Remove the vehicle from the lift.