SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

Operation 1016C10 · SINGLE CYLINDER HEAD

1.4 8v

Removing

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

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

Op. 1056B87 IGNITION/INJECTION SYSTEM CONTROL UNIT SUPPORT - R.R

Op. 5510C14 IGNITION COIL/S - R.R.

Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 1092B60 ALTERNATOR DRIVE BELT - R + R

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

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

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

Op. 1016A20 SINGLE TAPPET COVER -R.R AND REPLACE GASKET

- Position an arm lift underneath the engine.

1. Disconnect the check valve from the brake servo.

1. Disconnect the electrical connection for the absolute pressure sensor.

2. Disconnect the electrical connection for the air temperature/pressure sensor.

3. Disconnect the intermediate rapid connector for the fuel vapour pipe.

1. Disconnect the injector wiring junction.

2. Disconnect the electrical connection for the throttle casing.

3. Disconnect the electrical connection to the fuel vapour solenoid valve.

4. Disconnect the fuel pipe rapid connector.

1. Disconnect the electrical connection for the air temperature sensor.

2. Loosen collar (2a) and disconnect the water delivery sleeve to radiator (2b).

3. Loosen collar (3a) and disconnect the water delivery sleeve to heater (3b).

4. Disconnect the degassing pipe rapid connector.

1. Undo the bolts (1a) and remove the cylinder head assembly (1b).

- Remove the cylinder head gasket.

1. Position the cylinder head in the vice using the tool.

2. Undo the nuts (2a), bolt (2b) and remove the intake manifold (2c).

- To finish removing the heat levelling components, refer to

Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Refitting

- Clean the contact surfaces between the cylinder head and engine block.

- Position the cylinder head gasket on the cylinder block/crankcase.

1. Fit the cylinder head and tighten the fixing bolts to the recommended torque.

Follow the order illustrated below for the tightening of the cylinder head bolts.

- Replace the intake manifold in its housing and secure it by tightening the nuts and bolt to the recommended torque.

- Connect the degassing pipe rapid connector.

- Connect the water supply pipe to the heater.

- Connect the water supply pipe to the radiator.

- Connect the electrical connection for the coolant temperature sensor.

- Connect the fuel pipe rapid connector.

- Connect the electrical connection to the fuel vapour solenoid valve.

- Connect the electrical connection for the throttle casing.

- Connect the injector wiring junction.

- Connect the intermediate rapid connector for the fuel vapour pipe.

- Connect the electrical connection for the air temperature/pressure sensor.

- Connect the electrical connection for the absolute pressure sensor.

- Connect the check valve from the brake servo.

- Remove the hydraulic jack from underneath the engine.

Op. 1016A20 SINGLE TAPPET COVER -R.R AND REPLACE GASKET

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

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

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R.

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1092B60 ALTERNATOR DRIVE BELT - R + R

Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R.

Op. 5510C14 IGNITION COIL/S - R.R.

Op. 1056B87 IGNITION/INJECTION SYSTEM CONTROL UNIT SUPPORT - R.R

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

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

Op. 0010T20 ENGINE COOLANT - CHANGE

1.2 8v

Removing

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

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

Op. 1056B87 IGNITION/INJECTION SYSTEM CONTROL UNIT SUPPORT - R.R

Op. 5510C14 IGNITION COIL/S - R.R.

Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 1092B60 ALTERNATOR DRIVE BELT - R + R

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

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

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

Op. 1016A20 SINGLE TAPPET COVER -R.R AND REPLACE GASKET

- Position an arm lift underneath the engine.

1. Disconnect the check valve from the brake servo.

1. Disconnect the electrical connection for the absolute pressure sensor.

2. Disconnect the electrical connection for the air temperature/pressure sensor.

3. Disconnect the intermediate rapid connector for the fuel vapour pipe.

1. Disconnect the injector wiring junction.

2. Disconnect the electrical connection for the throttle casing.

3. Disconnect the electrical connection to the fuel vapour solenoid valve.

4. Disconnect the fuel pipe rapid connector.

1. Disconnect the electrical connection for the air temperature sensor.

2. Loosen collar (2a) and disconnect the water delivery sleeve to radiator (2b).

3. Loosen collar (3a) and disconnect the water delivery sleeve to heater (3b).

4. Disconnect the degassing pipe rapid connector.

1. Undo the bolts (1a) and remove the cylinder head assembly (1b).

- Remove the cylinder head gasket.

1. Position the cylinder head in the vice using the tool.

2. Undo the nuts (2a), bolt (2b) and remove the intake manifold (2c).

- To finish removing the heat levelling components, refer to

Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Refitting

- Clean the contact surfaces between the cylinder head and engine block.

- Position the cylinder head gasket on the cylinder block/crankcase.

1. Fit the cylinder head and tighten the fixing bolts to the recommended torque.

Follow the order illustrated below for the tightening of the cylinder head bolts.

- Replace the intake manifold in its housing and secure it by tightening the nuts and bolt to the recommended torque.

- Connect the degassing pipe rapid connector.

- Connect the water supply pipe to the heater.

- Connect the water supply pipe to the radiator.

- Connect the electrical connection for the coolant temperature sensor.

- Connect the fuel pipe rapid connector.

- Connect the electrical connection to the fuel vapour solenoid valve.

- Connect the electrical connection for the throttle casing.

- Connect the injector wiring junction.

- Connect the intermediate rapid connector for the fuel vapour pipe.

- Connect the electrical connection for the air temperature/pressure sensor.

- Connect the electrical connection for the absolute pressure sensor.

- Connect the check valve from the brake servo.

- Remove the hydraulic jack from underneath the engine.

Op. 1016A20 SINGLE TAPPET COVER -R.R AND REPLACE GASKET

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

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

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R.

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1092B60 ALTERNATOR DRIVE BELT - R + R

Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R.

Op. 5510C14 IGNITION COIL/S - R.R.

Op. 1056B87 IGNITION/INJECTION SYSTEM CONTROL UNIT SUPPORT - R.R

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

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

Op. 0010T20 ENGINE COOLANT - CHANGE

1.3 Multijet

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.

Op. 1084B40 ENGINE OIL DELIVERY PIPE TO TURBOCHARGER - R + R

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1084B42 ENGINE OIL RETURN PIPE FROM TURBO - R + R

Op. 1064A11 TURBOCHARGER WITH CATALYTIC CONVERTER - R.R.

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

Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET

Op. 0010T20 ENGINE COOLANT - CHANGE

1. Loosen the band and disconnect the upper radiator coolant inlet hose, thermostat side.

2. Loosen the band and disconnect the oil vapour recircuation hose from the rigid pipe.

3. Loosen the band and remove the air intake pipe to the turbocharger.

4. Loosen the collar securing the coolant supply pipe to the engine oil heat exchanger, thermostat side.

5. Loosen the band and disconnect the coolant outlet pipe from the climate control system heater, water pump rigid inlet pipe side.

1. Undo the bolts and disconnect the pipe from the heat exchanger to the air capacity chamber, chamber side.

2. Loosen the collar and disconnect the pipe carrying coolant to the climate control system heater, on the EGR system exhaust gas/water heat changer side.

1. Undo retaining bolt (1a) and remove the engine oil dipstick tube (1b).

2. Loosen the band and disconnect the condensed engine oil recovery pipe (2a) from the separator (2b).

- Loosen the band and disconnect the condensed engine oil recovery pipe, oil vapour separator side.

1. Unscrew the bolt securing the water/exhaust gas heat exchanger for the EGR to the crankcase.

1. Working through the hole in the camshaft cover, unscrew the bolt securing the pad fastening the timing chain to the cylinder head.

2. Undo the bolts fixing the timing cover to the cylinder head.

1. Undo the bolts (1a) and remove the cylinder head assembly (1b).

2. Remove the cylinder head gasket.

Refitting

1. Measure the piston projection in two places at 180° on the gudgeon pin axis using the gauge and support and take the average of the two values measured for each piston.

- Select the correct size cylinder head gasket depending on the maximum value between of the averages of the projection for each individual piston.

1. Apply silicon sealant in the contact area between the crankcase and timing cover.

2. Position the cylinder head locating bushes on the crankcase as shown in the figure.

The locating bushes between the crankcase and cylinder head are shorter (10.0 mm) than the bushes between the cylinder head and the cylinder head extension. Take gret care not to reverse them as this could impair engine operation.

3. Position the cylinder head gasket in the thickness selected previously and fit onto the locating bushes.

4. Apply silicon sealant to the cylinder head gasket in the contact area with the timing cover.

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

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

- Position the cylinder head on the engine block, fitting into the locating bushes.

Before moving the cylinder head, apply grease to the belt tensioner piston to prevent it emerging accidentally during moving.

1. Screw in and tighten the bolts fixing the timing cover to the cylinder head to torque.

During this stage, do not tighten the bolt into hole (a).

- Position the cylinder head bolts in their seats and screw in partly without tightening.

1. Tighten only the two bolts shown in the figure securing the cylinder head to the engine block to the specified torque of 2.5 daNm.

2. Loosen the bolts fixing the timing cover tightened previously.

3. Continue tightening the bolts fixing the camshaft housing to a torque of 2.5 daNm following the order illustrated working gradually towards the timing cover.

1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

1. Insert the third bolt securing the timing cover to the cylinder head, then tighten the three bolts securing the timing cover to the cylinder head to the specified torque.

- Tighten the bolt securing the timing belt fixed pad to the cylinder head.

- Tighten the bolt securing the water/exhaust gas heat exchanger for the EGR to the crankcase.

- Connect the condensed engine oil recovery pipe, oil vapour separator side, and tighten the collar.

- Place the engine oil dipstick pipe back in its housing and fasten it with the bolt.

- Connect the pipe carrying coolant to the climate control system heater, on the EGR system exhaust gas/water heat changer side and tighten the band.

- Connect the pipe from the heat exchanger to the air capacity chamber, chamber side, and tighten the band.

- Connect the upper coolant input sleeve to the radiator, thermostat side, and tighten the band.

Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET

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

Op. 1064A11 TURBOCHARGER WITH CATALYTIC CONVERTER - R.R.

Op. 1084B42 ENGINE OIL RETURN PIPE FROM TURBO - R + R

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1084B40 ENGINE OIL DELIVERY PIPE TO TURBOCHARGER - R + R

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

Op. 0010T20 ENGINE COOLANT - CHANGE

- Remove the vehicle from the lift.

1.9 Multijet

Removing

- Position the vehicle on a lift.

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 5530B10 BATTERY - R+R

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

Op. 0010T20 ENGINE COOLANT - CHANGE

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

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

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

Op. 1092G10 SINGLE ENGINE BELT - R.R

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

1. Unscrew the bolts (1a), loosen the band (1b) and remove the throttle casing rigid air intake pipe (1c).

2. Disconnect the rapid connector for the vacuum intake pipe from the vacuum pump.

3.Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side.

1. Disconnect the vacuum pipes from the vacuum reservoir.

2. Disconnect the vacuum pipe from the turbocharger vane position actuator control solenoid valve.

3. Disconnect the vacuum pipe from the vacuum pump.

4. Undo the fastenings (4a) and remove the vacuum pipes (4b).

1. Disconnect the electrical connection from the throttle casing.

2. Disconnect the electrical connection from the fuel pressure sensor on the fuel manifold.

1. Disconnect the electrical connection from the engine coolant temperature sensor.

2. Loosen the band and disconnect the coolant return pipe to the engine coolant reservoir, thermostat side.

1. Loosen the bands (1a), undo the bolts (1b) and remove the coolant return pipe to the engine coolant reservoir (1c).

2. Loosen the colllar and disconnect the oil vapour pipes from the cam cover.

1. Disconnect the electrical connection from the EGR system solenoid valve

2. Disconnect the electrical connection for the pressure relief sensor.

1. Disconnect the electrical connections from the injectors.

2. Undo the bolts (2a) and rmove the electrical wiring (2b) aside.

1. Disconnect the pipes (1a), undo the bolts (1b), then remove the fuel return manifold (1c).

2. Disconnect the electrical connection from the fuel pressure regulator on the pressure pump.

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

2. Undo the connectors securing the pipes from the fuel manifold to the injectors, injector side.

1. Unscrew the connectors (1a) and remove the pipes from the fuel manifold to the injectors (1b).

2. Undo the connectors (2a), (2b) and remove the pipe from the pressure pump to the fuel manifold (2c).

3. Undo the nuts (3a) and remove the single fuel manifold assembly pipe (3b).

1. Undo the nuts fixing the injector mounting brackets.

2. Position the tool (2a) for extracting the injectors, taking care to position the lifting bracket (2b) under the polygonal area (2c) of the injector.

3. Position the second tool lifting bracket (3a) under the injector securing bracket (3b).

4. Tighten the tool nut (4a) and remove the injector assembly (4b).

- Repeat the operation for the remaining injectors.

1. Loosen the band and disconnect the coolant outlet pipe from the coolant/exhaust gas heat exchanger for the EGR system.

2. Loosen the band and disconnect the coolant return pipe from the engine oil heat exchanger on the water pump rigid inlet pipe side.

3. Loosen the band and disconnect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side.

4. Undo the upper bolt securing the engine oil dipstick tube.

5. Undo the bolts (5a) and remove the water pump inlet pipe (5b).

- Remove the gasket.

1. Undo the bolts (1a) and remove the side protective timing cover (1b).

1. Undo the two upper bolts fixing the exhaust manifold heat shield.

1. Undo the lower bolt securing the engine oil dipstick tube.

1. Undo the nuts (1a) and the bolt (1b) securing the exhaust manifold heat shield.

- Working via the engine compartment, remove the pipe for the engine oil dipstick and the exhaust manifold heat shield.

1. Undo the bolts securing the engine oil return pipe from the turbocharger, crankcase side.

2. Undo the connector fastening the engine oil supply pipe to the turbocharger, crankcase side.

1. Undo the bolts (1a), loosen the collar (1b) and remove the exhaust gas intake pipe from the exhaust manifold to the E.G.R. heat exchanger (1c).

2. Remove the seals.

1. Undo the nuts (1a) and move the turbocharger and exhaust manifold assembly (1b) away from the cylinder head.

1. Undo the bolts fixing the exhaust gas outlet hose from the E.G.R. solenoid valve, E.G.R. solenoid valve side.

2. Undo the bolts (2a) and remove the throttle body (2b).

- Remove the gasket.

1. Undo the bolts (1a) and remove the vacuum unit (1b).

- Remove the gasket.

1. Loosen the bands and disconnect the pipes from the thermostat.

2. Undo the bolts (2a) and remove the thermostat (2b).

- Remove the gasket.

1. Loosen the collar (1a) and disconnect the exhaust gas outlet hose from the exhaust gas/water heat exchanger for the E.G.R. system (1b), heat exchanger side.

2. Undo the fixing bolts (2a) and remove the E.G.R. system solenoid valve (2b) complete with hose.

- Remove the gasket.

1. Undo the fastenings (1a) and remove the water/exhaust gas heat exchanger for the E.G.R. system (1b).

2. Loosen the band and disconnect the oil vapour pipe from the tappet cover to the crankcase, tappet cover side.

1. Undo the nuts (1a) and remove the vacuum reservoir for the engine air intake management (1b).

1. Undo the fastenings (1a) and remove the vacuum reservoir mounting (1b).

2. Disconnect the electrical connections from the heater plugs.

1. Undo the bolts (1a) and remove the cam cover (1b) complete with gasket.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R

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

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

1. Fit the timing side power unit rigid support (1a) temporarily in its housing and secure it using the bolts (1b).

- Fit the timing side power unit front support flexible mounting temporarily in its housing and secure it using the bolts.

- Remove the hydraulic jack from underneath the front suspension frame.

1. Undo the bolts (1a), (1b) and remove the cylinder head (1c).

2. Remove the cylinder head gasket.

- To check the flatness of the lower cylinder head surface and grind if necessary, refer to

Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Refitting

1. Measure the piston projection in two places at 180° on the gudgeon pin axis using the tool and take the average of the two values measured for each piston.

- Select the correct size cylinder head gasket depending on the maximum value between of the averages of the projection for each individual piston.

- Place the cylinder head centering bushes on the cylinder block.

- Refit the new cylinder head gasket in its seat.

- Position the cylinder head on the cylinder block/crankcase.

1. Tighten the bolts securing the cylinder head to the cylinder block to the recommended torque following the order illustrated and using the angular tightening tool.

- Tighten the new bolt fixing the pressure pump mounting to the cylinder head to the recommended torque.

- Position a hydraulic jack under the front suspension frame.

- Remove the flexible mounting for the timing side power unit front support fitted provisionally.

- Remove the timing side rigid power unit support fitted provisionally.

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

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

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

- Place the tappet cover in position and secure it tightening the bolts to the recommended torque.

- Connect the electrical connections to the heater plugs.

-- Place the vacuum reservoir mounting back in its housing and secure it.

- Place the vacuum reservoir for the engine air intake management back in its housing and secure it using the nuts.

- Connect the oil vapour pipe from the tappet cover to the crankcase, tappet cover side and tighten the band.

- Place the exhaust gas/water heat exchanger for the E.G.R. system back in its housing and secure it.

- Place the gasket for the E.G.R. system solenoid valve in its housing.

1. Place the E.G.R. system solenoid valve (1a) complete with hose in its housing and fasten it tightening the bolts (1b) to the recommended torque.

2. Connect the exhaust gas outlet hose from the exhaust gas/water heat exchanger for the E.G.R. system (2a), heat exchanger side and tighten the collar (2b).

- Place the gasket for the thermostat back in its housing.

1. Place the thermostat (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

2. Connect the pipes to the thermostat and tighten the bands.

- Place the gasket for the vacuum unit back in its housing.

1. Place the vacuum unit (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

- Place the gasket for the throttle body back in its housing.

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

2. Tighten the bolts fixing the exhaust gas outlet hose from the E.G.R. solenoid valve, E.G.R. solenoid valve side.

1. Place the turbocharger and exhaust manifold assembly (1a) in its housing and tighten the nuts (1b) to the recommended torque.

1. Place the exhaust gas intake pipe from the exhaust manifold to the E.G.R. heat exchanger (1a) back in its housing complete with gaskets (1b), then secure it tightening the collar (1c) and the bolts (1d) to the recommended torque.

1. Tighten the connector securing the engine oil delivery pipe to the turbocharger, crankcase side to the recommended torque.

2. Tighten the bolts securing the engine oil return pipe from the turbocharger, crankcase side, to the specified torque.

- Working via the engine compartment, place the pipe for the engine oil dipstick and the exhaust manifold heat shield in their housings.

- Tighten the lower nuts and the bolt securing the exhaust manifold heat shield.

- Tighten the lower bolt securing the engine oil dipstick tube.

- Tighten the two upper bolts fixing the exhaust manifold heat shield.

- Place the water pump rigid inlet pipe gasket in its housing.

1. Place the water pump rigid inlet pipe (1a) in position and secure it tightening the bolts (1b) to the recommended torque.

- Fit the timing belt side protective cover and secure it using the bolts.

- Tighten the upper bolt securing the engine oil dipstick tube.

- Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.

- Connect the return pipe from the engine oil heat exchanger, water pump rigid inlet pipe and tighten the band.

- Connect the coolant oulet pipe from the coolant/exhaust gas heat exchanger for the EGR system and tighten the band.

- Place the injectors (1a) in their seats complete with brackets and fasten them tightening the nuts to the recommended torque.

1. Place the single fuel manifold pipe (1a) in its housing and secure it tightening the nuts (1b) to the recommended torque.

2. Place the pipe from the pressure pump to the fuel manifold pipe (2a) back in its housing and secure it tightening the connectors (2b) and (2c) to the recommended torque.

3. Place the pipes from the fuel manifold to the injectors (3a) in their housings and secure them tightening the connectors (3b) and (3c) to the recommended torque.

- Place the pipe from the injectors to the fuel recovery manifold in its housing and connect it to the injectors and push home until the clips click into place.

- Connect the electrical connection to the fuel pressure regulator on the pressure pump.

- Place the fuel return manifold in its housing, secure it using the bolts and connect the pipes.

- Place the electrical wiring in position and fasten it using the bolts.

- Connect the electrical connections to the injectors.

- Connect the electrical connection for the pressure relief sensor.

- Connect the electrical connection to the EGR system solenoid valve

- Connect the engine oil vapour recovery pipe to the tappet cover.

- Place the coolant return pipe to the engine coolant reservoir in position and secure it using the bolts and tighten the bands.

- Connect the electrical connection to the engine coolant temperature sensor.

- Connect the electrical connection to the fuel pressure sensor on the fuel manifold.

- Connect the electrical connection to the throttle casing.

- Place the vacuum pipes in their housings and secure them.

- Connect the vacuum pipe to the vacuum unit.

- Connect the vacuum pipe to the turbocharger vane position actuator control solenoid valve.

- Connect the vacuum pipes to the vacuum reservoir.

- Connect the radiator upper coolant inlet hose, thermostat side, and tighten the band.

- Connect the vacuum pipe rapid connector to the vacuum pump.

- Place the hose and the throttle body rigid air inlet pipe in their housings, then fasten them using the band and the bolts.

- Tighten the coolant drain plug to the radiator.

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1092G10 SINGLE ENGINE BELT - R.R

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

Op. 4450B04 RIGHT FRONT WHEEL - R.R

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

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

Op. 5530B10 BATTERY - R+R

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

- Remove the vehicle from the lift.

1.4 16v

Removing

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

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

Op. 1056B60 SINGLE FUEL MANIFOLD PIPE, WITH INJECTORS - R.R.

Op. 5520B10 STARTER MOTOR - R+R

Op. 1072B50 AIR CHAMBER - R.R.

Op. 1016B12 SINGLE CAMSHAFT HOUSING - R.R. WITH TIMING BELT REMOVED - REPLACE GASKET

Op. 0010T20 ENGINE COOLANT - CHANGE

1. Undo the bolt (1a) and remove the timing belt inner guard (1b).

1. Disconnect the electrical connection for the coolant temperature sensor.

2. Loosen the band and disconnect the engine coolant supply pipe to the heater, thermostat side.

3. Loosen the band and disconnect the radiator coolant supply hose, thermostat side.

4. Disconnect the degassing pipe rapid connector from the thermostat.

1. Undo the bolts (1a) and remove the cylinder head (1b).

2. Remove the cylinder head gasket.

Refitting

- Fit a new left cylinder head gasket on the cylinder block.

- Position the cylinder head on the crankcase by aligning the locating pins.

1. Tighten the bolts securing the cylinder head to the recommended torque.

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

- Connect the degassing pipe rapid connector to the thermostat.

- Connect the radiator engine coolant supply hose, thermostat side, and secure it using the band.

- Connect the engine coolant supply pipe to the heater, thermostat side, and secure it using the band.

- Connect the electrical connection for the coolant temperature sensor.

- Place the timing belt inner guard in its housing and secure it using the bolt.

Op. 1016B12 SINGLE CAMSHAFT HOUSING - R.R. WITH TIMING BELT REMOVED - REPLACE GASKET

Op. 1072B50 AIR CHAMBER - R.R.

Op. 5520B10 STARTER MOTOR - R+R

Op. 1056B60 SINGLE FUEL MANIFOLD PIPE, WITH INJECTORS - R.R.

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

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

Op. 0010T20 ENGINE COOLANT - CHANGE