Idea Factory Service Manual (2003-2012): 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 unit7 pages
- Power unit with manual gearbox - r + r
- Power unit (manual gearbox), 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 re-build following operation 1004e10 - wash and check dismantled parts - re-fit cylinder head and
- Engine removed, general overhaul
- Compressor
Cylinder head/s9 pages
- Introduction - CYLINDER HEAD/S
- Cylinder head/s - various operations
- Single cylinder head extension - change gasket
- Single cylinder head extension - r r with timing belt removed - replace
- Cylinder head - r + r and replace gasket
- 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 covers15 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 for versions with oil pump on crank shaft, timing side
- Front crank shaft cover oil seal - replace
- 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
Timing system25 pages
- Belt timing system
- Timing system tensioners
- CHAIN AND GEARS for timing system - R.R. for timing or Replacement.
- Toothed timing belt - r + r for timing adjustment or replacement
- Toothed timing belt - r r with engine removed
- 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 driven pulley (one) - r + r
- MOVING timing TENSIONER - R.R. with timing belt/chain removed
- Mobile timing system tensioner - r + r for 24 valve engines
- Timing CHAIN TENSIONER PLATE - R.R.
- Timing system protective cover(s) - r + r
- Introduction - TIMING SYSTEM
- Camshaft (1) in top heads (2)
- Camshaft in cylinder head - r r on vehicle
- Camshaft in cylinder head - r r with head removed
- Hydraulic tappets all r r
- Camshafts in cylinder head extension - r r - includes cylinder head extension replacement if necessary
- CAMSHAFTS in camshaft housing - R.R. with camshaft housing removed - Includes possible. Replacement. of camshaft housing
- Camshaft idler gears - replace
- Front oil seal of intake camshaft in cylinder head extension replace
- Front oil seal intake camshaft in cylinder head extension replace with timing belt removed
- Front oil seal exhaust camshaft in cylinder head extension - replace
- Mount for seal on camshaft in cylinder head extension complete with coil/s - includes cleaning of mating surfaces sealan
Fuel tank and pipes15 pages
- Introduction - FUEL TANK AND PIPES
- Fuel tank and components
- Check supply voltage' and absorption current'
- Fuel tank - r + r and decant fuel
- Fuel tank - r + r for replacement
- Fuel filler pipe - r + r
- Fuel filler pipe union sleeve - r + r
- Plug for fuel filler pipe - r + r
- Submerged pump assembly complete with level guage control - r + r
- Inertia switch for electric pump supply circuit r + r
- Fuel delivery line - r r
- Front fuel delivery line - r r
- Rear fuel delivery line - r r
- Fuel line from manifolds - r r
- Fuel return line - r r
Fuel circuit pump/and devices4 pages
Engine air supply circuit13 pages
- Introduction - ENGINE AIR SUPPLY CIRCUIT
- Vacuum air circuit
- Air cleaner filtering element - replace
- Air cleaner filtering element - replace.
- Cold air intake - r r
- Sleeve from air cleaner to intake manifold - r + r
- Air inlet pipe to turbo charger - r + r
- Air delivery pipe between turbo charger and heat exchanger - replace
- Air delivery sleeve from heat exchanger to rigid pipe - replace
- Air supply HOSE from rigid pipe to intake manifold - R.R.
- Heat exchanger/manifold pipe - r r
- Heat exchanger duct - r r
- Turbo charger intercooler - r + r
Petrol injection system12 pages
- Introduction - PETROL INJECTION SYSTEM
- Throttle body intergral with mds - r r
- Coolant temperature sensor - r + r
- Cam angle sensor r + r
- Intake air pressure/temperature sensor - r r
- Single fuel manifold pipe, with injectors - r + r
- 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
- SWITCH on CLUTCH PEDAL - R.R.
- Injection/ignition system e.c.u. (one) - r + r
- Ignition/injection system control unit mount - r r
- System cable bundle - r + r
Diesel fuel injection30 pages
- Introduction - DIESEL FUEL INJECTION
- Diesel pressure pump
- Injectors and lines
- Pressure pump electric control
- Low return fuel pressure circuit check
- Low fuel pressure supply circuit check
- Injector high pressure fuel circuit check
- Check high pressure fuel circuit
- Check on efficiency of rpm sensor
- Check on operation of air flow meter
- Check on operation of timing sensor
- Check on operation of diesel high pressure sensor
- Pressure pump - r r
- 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 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
- Brake pedal switch - r r
- Clutch pedal switch - r r
- Ds electric injection control unit - r r
- Diesel injection wiring harness - r r
Accelerator controls2 pages
Exhaust emission control system22 pages
- Introduction - EXHAUST EMISSION CONTROL SYSTEM
- Exhaust emission control system
- Exhaust gas recirculation system (e.g.r.)
- Crankcase vapour/gas recirculation system
- Evaporation control system
- Smokiness at exhaust - check with opacimeter
- Catalytic converter - r + r
- Front lambda probe with catalitic converter r r
- Rear lambda probe with catalitic converter r r
- E.G.R. - VALVE HEAT EXCHANGER ASSEMBLY - Connector PIPES - R.R.
- Pipe carrying engine oil vapours from intake to separator - r + r
- Engine oil vapour intake pipe - 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.
- Engine oil vapour recirculation flame trap - repl.
- Active carbon filter for fuel vapours - r + r
- Enablement solenoid for flow of fuel vapour to inlet - r+r
- Pipe from fuel vapour separator to solenoid - r r
Engine lubrication system14 pages
- Introduction - ENGINE LUBRICATION SYSTEM
- Engine oil lubrication circuit
- Oil dip stick pipe - r r
- Engine oil pressure warning light switch - r + r
- 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
- RIGID air supply PIPE between air-air heat exchanger and intermediate hose - R.R.
- Engine oil HEAT EXCHANGER, complete with engine oil filler and filter - R.R.
Engine cooling19 pages
- Introduction - ENGINE COOLING
- Engine cooling radiator
- Water pump and thermostat
- Coolant temperature control devices
- Engine cooling tank - r + r
- Engine cooling radiator - r + r
- Engine cooling radiator support beam - r r
- Water pump - r + r
- 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
- Rigid pipe for coolant inlet to water pump - r + r
- RIGID supply or return PIPES for ENGINE OIL HEAT EXCHANGER - R.R.
- Radiator cooling fan - r + r
- Resistor for radiator cooling fan - r + r
Various engine component controls8 pages
- Introduction - VARIOUS ENGINE COMPONENT CONTROLS
- Crankshaft services PULLEY - R.R.
- Pulley support FLANGE on crankshaft - R.R.
- Air conditioner compressor/alternator drive belt - r + r
- Air conditioning compressor and alternator drive belt TENSIONER - R.R.
- Single engine belt r r
- Engine component single belt mobile tensioner - r + r
- Engine component single belt mobile temperature - r rwith belt removed