Multipla Factory Service Manual (1998-2010): 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 unit10 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
- 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 supports10 pages
- Introduction - POWER UNIT SUPPORTS
- Gear box left rigid mount - r r
- Rear rigid mount - r r
- Cam shaft left rigid mount - r r
- Power unit front mount (timing side) flexible block - replace
- Power unit intermediate mount flexible block - replace
- Gearbox side mount flexible block - replace
- Power unit upper reaction link r r
- Engine link bracket - r r
- Body link bracket - r r
Cylinder head/s12 pages
- Introduction - CYLINDER HEAD/S
- Sound-proofing cover - r + r
- Single cam cover - r + r and replace 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
Crankcase sump and covers17 pages
- Introduction - CRANKCASE SUMP AND COVERS
- 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
- Oil seal cover on auxiliary shaft - r + r with timing belt removed and replace gaskets
- 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
Pistons and connecting rods12 pages
- Introduction - PISTONS AND CONNECTING RODS
- 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 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 system30 pages
- Introduction - TIMING SYSTEM
- 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-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
- 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 tensioner - r r
- Fixed timing system tensioner (one) r + r
- Timing system protective cover(s) - r + r
- Camshaft (1) in top heads (2)
- Overhead camshaft - r r on vehicle
- Overhead camshaft - r r on vehicle - with cylinder head removed
- 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 camshaft seal, lh or rh - r r with mount and coil/s removed
- Valve tappets - check and adjust clearance
- Valve tappets - check clearance
- VALVE TAPPETS - Adjust. following clearance check
Fuel tank and pipes16 pages
- Introduction - fuel tank and pipes
- Fuel tank and components
- Fuel tank - r + r and decant fuel
- Fuel tank - r + r for replacement
- Fuel tank - r + r and decant fuel for versions with evaporation control system
- Fuel tank - r + r for versions with evaporation control system for replacement
- Fuel filler pipe - 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
- Fuel delivery line - r r
- Fuel filler pipe union sleeve - r + r
- Rear fuel delivery line - r r
- Filter/carburettor line - r r
- Fuel line from manifolds - r r
Methane gas cannister and tubes23 pages
- Methane gas cannister and tubes for re-charging
- Check operation of coil winding of methane cut-off solenoid on cylinder
- Check operation of methane cut out solenoid valve on canister
- Checking power uptake of solenoid on cylinder
- C.n.g. - fuel system safety check
- C.n.g. - fuel system check for any leaks using electronic detector following operations
- Cng cylinder unit - r r
- (One), side CANISTER left or right, for CNG CANISTER ASSEMBLY - R.R.
- (One), centre CANISTER left or right, for CNG CANISTER ASSEMBLY - R.R.
- 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 repressurizing PIPE from hose to three-way connector - R.R.
- Cng repressurizing pipe from repressurizing valve to single-acting valve - r.r.
- Cng recharge pipe connection sleeve - r r
- THREE-WAY CONNECTOR (one) for CNG repressurizing system' - R.R .
- Pipe (1) connecting cng recharging system solenoids - r r
- Left cylinder of cng cylinder unit r r
- Central cylinder of cng cylinder unit r r
- Right cylinder of cng cylinder unit r r
- Cng supply line from solenoid to pressure reduction unit - r r
- Cng canister assembly shield/protection / - r.r.
Lgp tank and pipes30 pages
- Gpl tank
- Gpl fuel circuit pipes
- Check operation of LPG pump
- Graphic analysis of LPG pump operating signal
- Check operation of LPG solenoid valve on tank valve unit
- Check operation of LPG level sensor
- LPG level potentiometer operation check
- Check on operation of LPG cut out solenoid valve on pressure regulator
- LPG pressure sensor check
- LPG injector seal check
- Lpg system lines pipe draining operations
- Gpl system and pipes check for leaks
- Gpl tank complete with submerged fuel tank and valve unit r r
- Lpg tank check seal
- Lpg tank 80 percent filling valve r r with lpg tank removed
- Gpl system pipes/connections - r r
- Gpl filler fitting r r
- Filler pipe from fitting to gpl tank r r
- Cover of gpl tank valve unit with submerged fuel pump ecu r r with gpl tank removed
- Lpg fuel system submerged pump r r with tank and valve unit cover removed
- SOLENOID VALVE on LPG 'system submerged electric pump - R.R. with LPG tank and valve unit cover removed
- Gpl level gauge control r r
- Float controlling lpg level guage r r
- Intermediate fitting of delivery or return pipes between gpl resevior and pressure regulator r r
- Lpg delivery and return pipes from tank to intermediate connector complete with submerged pump wiring r r with lpg tank
- Pressure regulaton for gpl supply complete with delivery and return lines from intermediate connector r r
- Pressure regulator for lpg fuel system complete with delivery and return pipes from intermediate connector dismantle and
- Pressure regulator stop solenoid coil r r
- Coil of lpg fuel system intake solenoid r rwith tank and valve unit cover removed
- Gpl tank guard protection r r
Fuel circuit pump/s and devices13 pages
- Introduction - FUEL CIRCUIT PUMP/AND DEVICES
- Gas pressure control device
- Check operation of coil for methane cut out solenoid valve on pressure reduction unit
- Check power uptake of solenoid on reducer
- Fuel filter assembly - r + r or replace
- Fuel filter filtering element - replace
- Fuel heater - r + r
- Thermal switch for fuel heater - 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
- Cng injection system pressure reduction unit mounting bracket - r.r.
Engine air supply circuit12 pages
- Introduction - ENGINE AIR SUPPLY CIRCUIT
- Vacuum air circuit
- Air cleaner filtering element - replace
- Air cleaner support - r r with air cleaner assembly removed
- Air cleaner filtering element - replace.
- Cold air intake - r r
- Sleeve from air cleaner to intake manifold - r + r
- Sleeve from debimeter to turbocharger - r r
- Air delivery pipe between turbo charger and heat exchanger - replace
- Air delivery sleeve from heat exchanger to intake manifold - r + r
- Heat exchanger duct - r r
- Turbo charger intercooler - r + r
Petrol injection system15 pages
- Introduction - PETROL INJECTION SYSTEM
- Multi-point injection system (mpi)
- Introduction - PETROL INJECTION SYSTEM
- Checking engine coolant temperature sensor operation
- Throttle case - r + r
- Throttle case throttle position switch - r + r
- Coolant temperature sensor - r + r
- Intake air pressure/temperature sensor - r r
- Engine idle speed self-adjustment motor - 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
- Injection/ignition system e.c.u. (one) - r + r
- System cable bundle - r + r
Lpg fuel system.7 pages
- Introduction - LPG FUEL SYSTEM.
- Petrol/LPG switch operation check
- LPG pressure check
- Check operation of LPG injectors
- Gpl injector unit with connection pipes to pressure regulator r r
- Gpl injector unit with connection pipes to pressure regulator dismantle and rebuild at bench
- Gpl injection system control unit r r
Gas circuit19 pages
- Introduction - cng fuel system
- Gas circuit multi point injection
- Pressure sensor check
- Check methane injector coil
- Check gas level signal
- Check gas/petrol selection button
- Gas/petrol selection fuel supply check
- Check methane pressure in high pressure circuit
- Check methane injector seal
- Methane pressure in low pressure circuit check
- Methane temperature and pressure sensor check
- Cng/fuel switch - r r
- Cng/fuel switch - r r
- Cng pressure/temperature sensor on single manifold pipe - r.r.
- Engine coolant temperature sensor for cng injection system - 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
- Injector(1) of cng injection system - r rwith cng manifold pipe removed includes gasket replacement
- Cng injection unit control unit - r r
Diesel fuel injection34 pages
- Introduction - DIESEL FUEL INJECTION
- Diesel pressure pump
- Injectors and lines
- Pressure pump electric control
- Introduction - DIESEL FUEL INJECTION
- Check low pressure fuel circuit
- Check low pressure fuel circuit
- Check high pressure fuel circuit
- Check high pressure fuel circuit
- Checking engine coolant temperature sensor operation
- 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
- Fuel temperature sensor - r r
- Engine RPM SENSOR - R.R.
- Cam angle sensor - r r
- POTENTIOMETER on ACCELERATOR pedal - R.R.
- Clutch pedal switch - r r
- Electro-pneumatically controlled THROTTLE CASING - R.R.
- Solenoid valve on vacuum reservoir for throttle casing pneumatic valve - r.r.
- Ds electric injection control unit - r r
- Diesel injection wiring harness - r r
Inlet and exhaust manifolds7 pages
- Measuring absolute pressure inside intake manifold
- Inlet manifold - r + r and replace seal
- Inlet manifold - r+r and replace seal with air conveyor/box removed
- Inlet manifold, removed - replace with fuel manifold and injectors removed
- Sleeves connecting air capacity box to inlet manifold is - r+r
- Exhaust manifold - r + r and replace seal
- Exhaust manifold heat shield on bulkhead - r+r
Exhaust pipes and silencers8 pages
- Introduction - EXHAUST PIPES AND SILENCERS
- Heat shield for exhaust pipe attachment to manifold - r r
- Exhaust pipe assembly r+r emission control versions
- Rear exhaust silencer - r + r
- Front catalytic converter attachment seal - replace
- Cat rear sealing ring - replace
- Exhaust pipe attachment to engine - r + r
- Exhaust pipe attachment to engine seal/s - replace
Exhaust emission control system29 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
- Catalytic pre-converter - r r
- Lambda sensor - r.r.
- Catalytic converter - r + r
- Front lambda probe with catalitic converter r r
- Rear lambda probe with catalitic converter r r
- E.g.r. valve - r + r
- E.g.r. valve modulator - r + r
- Pipe carrying exhaust gas from e.g.r. valve to inlet manifold - r + r
- E.g.r. system vacuum pipe - arrange
- Vacuum reservoir - r.r.
- E.g.r. - electrical valve r.r.
- Exhaust gas water heat exchanger for egr valve r r
- Pipe carrying engine oil vapours from intake to separator - r + r
- Pipe from engine oil vapour separator to intake - r + r
- Engine oil vapour intake pipe - r + r
- Idling engine oil vapour inlet line - r r
- Engine oil recovery pipe - r + r
- Engine oil vapour separator - r + r
- Tank fuel vapour separator - r + r
- Multifunctional valve r r
- Fuel system ventilation/safety valve - r + r
- Active carbon filter for fuel vapours - r + r
- Fuel vapour by-pass valve/solenoid - r + r
- Tank - separator line - r r
Engine lubrication system15 pages
- Introduction - ENGINE LUBRICATION SYSTEM
- Engine oil lubrication circuit
- 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
- Engine oil intake pump - r + r with crankcase sump removed
- Engine oil filter r r
- Engine oil delivery pipe to turbocharger - r + r
- Timing mount oil pipe - r r
- Engine oil heat exchanger - r + r
Engine cooling22 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 for versions with air conditioner
- Water pump - r + r with drive belt 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
- Cng injection system pressure reduction unit cooling circuit pipe(1) - r r
- Radiator cooling fan - r + r
- Resistor for radiator cooling fan - r + r
- Sender unit for water temperature gauge - r + r
Various engine component controls11 pages
- Crankshaft services PULLEY - R.R.
- Crankshaft pulley - r+r for versions with air conditioner
- Alternator/air conditioner compressor drive belt - adjust 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 - adjust tension
- Power steering pump/self levelling suspension pump pulley - r + r with belt removed
- Air conditioner compressor drive belt - r + r
- Single engine belt r r
- Engine component single belt mobile tensioner - r + r
- Engine component single belt fixed tensioner - one - r + r