Engind front cover - r r

Operation 1020D17 · Oil seals on crank shaft

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Removing

- 1004D40 engine - position on stand and remove.

1. Fit the flywheel lock.

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Removing

Adjust the automatic belt tensioner with a wrench to slacken the tension of the single engine component drive belt.

1. Remove the single drive belt.

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1. Undo the bolts (1a) and remove the single engine component belt drive pulley (1b).

2. Loosen the mobile timing belt tensioner nut.

3. Remove the timing belt.

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

2. Undo the bolt (2a) and remove the single drive belt fixed guide pulley (2b).

3. Undo the bolts (2a) and remove the power unit reaction rod attachment bracket (2b).

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1. Undo the bolt (1a) and remove the tmiing belt drive pulley (1b).

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

3. Disconnect the water outlet pipe from the oil heat exchanger.

Remove the flywheel lock.

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1. Undo the bolts (1a) and remove the timing drive belt guard (1b).

2. Loosen the timing belt tensioner nut.

3. Remove the timing drive belt.

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1. Undo the bolts (1a) and remove the right (1b) and left (1c) side protection for the timing belt.

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1. Fit the tool.

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1. Undo the bolt (1a) and remove the idler belt (1b).

2. Undo the bolts (2a) and remove the upper rigid engine support (2b).

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1. Undo the bolt (left) (1a) and remove the drive pulley (1b).

2. Undo the bolts (2a) and remove the timing side power unit support (2b).

3. Disconnect the water inlet and outlet pipes from the water-oil heat exchanger.

4. Undo the bolt (4a) and remove the timing belt fixed tensioner (4b).

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Rotate the engine through 180° on the overhauling stand.

1. Undo the front and rear bolts (1a) for the crankcase sump using tool (1b).

2. Undo the side bolts (2a) for the crankcase sump using tool (2b).

3. Use the tool to cut the crankcase sump sealant.

4. Remove the crankcase sump.

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1. Undo the bolts (1a) and remove the alternator (1b).

2. Undo the bolt (2a) and remove the auxiliary shaft drive belt automatic tensioner (2b).

3. Undo the bolts (3a) and remove the support (3b), complete with power steering pump (3c) and timing belt tensioner.

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1. Undo the bolts (1a) and remove the crankshaft front cover (1b) complete with inlet (1c), engine oil heat exchanger (1d) and engine oil filter (1e).

2. Remove the gasket.

3. Remove the crankshaft front cover oil seal.

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1. Undo the bolts (1a) and remove the complete oil dipstick (1b).

2. Disconnect the condensation oil return pipe to the sump.

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Refitting

Place the crankshaft front cover, complete with intake, engine oil heat exchanger, oil filter and a new gasket, back in its housing, then secure it tightening the bolts to the recommended torque.

1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

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Rotate the engine through 180° on the overhauling stand.

1. Undo the bolt connecting the oil sump to the intermediate shaft support.

2. Undo the front and rear bolts (2a) for the crankcase sump using the tool (2b).

3. Undo the side bolts (3a) for the crankcase sump using the tool (3b).

4. Remove the crankcase sump. To release the crankcase sump, tap it gently with a a resin hammer, then use a screwdriver to lever on the special projections at the side of the crankcase sump.

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Clean the matching surfaces of crankcase sump and cylinder block.

Apply silicon sealant around the edge of the crankcase sump.

1. Refit the crankcase sump

2. Tighten the side bolts (2a) for the crankcase sump to the recommended torque using the spanner (2b).

3. Tighten the front and rear bolts (3a) for the crankcase sump to the recommended torque using the spanner (3b).

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1. Remove the oil filter.

2. Remove the pin (2a) and remove the water-oil heat exchanger (2b).

3. Undo the bolts (3a) and remove the crankcase front cover with the built-in oil pump (3b) complete with inlet.

Remove the crankshaft front oil seal.

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Rotate the engine through 180° on the overhauling stand.

Tighten the connector on the water outlet pipe from the engine oil heat exchanger.

Fit the engine rigid support and secure it tightening the bolts to the recommended torque.

Fit the toothed belt idler and secure it tightening the bolt to the recommended torque.

Fit the timing belt side guards and fix them using the bolts.

Fit the lower support and secure it tightening the bolts to the recommended torque.

Fit the timing belt drive pulley and fix it using the bolt, without tightening it.

1. Disconnect the electrical connections from the ignition coils.

2. Undo the bolts (2a) and remove the ignition coils (2b).

Disconnect the oil vapour recovery pipe from the rocker cover.

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Refitting

1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

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Undo the bolts and remove the rocker cover complete with gasket.

1. Undo the bolt (1a) for the timing driven pulley, exhaust side using the tools (1b) and (1c) for counter-torque.

2. Slacken the bolts (2a) on the inlet side camshaft pulley, using the tool (2b) for counter-torque.

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Fit the crankcase front cover with built-in oil pump, complete with inlet, and tighten the bolts to the recommended torque.

Place the heat exchanger back in its housing.

Tighten the connector securing the heat exchanger to the specified torque.

Fit the oil filter tightening it to the recommended torque after having lubricated the gasket with engine oil.

Apply sealant to the entire perimeter of the crankcase sump.

Fit the crankcase sump.

Tighten the side bolts for the crankcase sump to torque using the special tool.

Tighten the front and rear bolts for the crankcase sump to torque using the special tool.

Tighten the bolt securing the oil sump to the intermediate shaft support.

Rotate the engine through 180° on the overhauling stand.

Connect the condensate oil return pipe to the crankcase sump and fix it using the band.

Fit the engine oil dipstick assembly and fix it using the bolts.

Fit the support complete with power steering pump and timing belt tensioner and fix it using the bolts.

Fit the auxiliary shaft belt tensioner and fix it using the relevant bolt.

Fit the alternator and fix it using the bolts.

Fit the fixed timing belt tensioner and secure it using the bolts.

Connect the water inlet and outlet pipes from the water-oil heat exchanger and fix them using the bands.

Fit the power unit support, timing gear side, and fix it using the bolts.

1. Fit toothed drive pulley (1a) and tighten the bolt (anticlockwise) (b) to torque.

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Undo the bolts and remove the camshaft third cap.

Mark the position of the camshaft caps following removal so that they can be positioned correctly upon refitting.

1. Fit templates (1a) in place of the camshaft caps removed and fix it tightening the bolts (1b) to the recommended torque.

Check that the camshaft cam profile matches the tool correctly.

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Remove the tool.

1. Remove the bolt for the oil pump shown.

Temporarily fit the single toothed timing drive belt to the drive pulley.

2. Fit the tool. To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

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1. Remove the engine oil pump retaining bolt.

2. Fit the timing belt.

3. Fit the pin of the tool for setting the engine to TDC.

4. Turn the crankshaft a little at a time to allow locating dowel (4a) on the pulley to fit into the hole on tool (4b).

5. Lock the tool in position using a nut (5a) and ordinary bolt (5b).

Complete the fitting of the toothed timing belt following the order: - toothed drive pulley,

fixed tensioner,

exhaust side toothed driven pulley,

intake side toothed driven pulley

moving tensioner,

coolant pump pulley

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1. Rotate the driven pulley so that the timing references line up.

2. Completely fit the timing belt.

3. Use a screwdriver to lever in the hole (3a) until the reference on the tensioner (3b) lines up with the reference hole (3c) and, in this position, tighten the belt tensioner nut (3d) to torque.

Remove the tool.

Rotate the crankshaft through two revolutions.

Check once again that the timing references and the tensioning references on the timing belt tensioner coincide.

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1. Fit the tool into the hole on the timing belt mobile tensioner and turn to apply maximum tension to the timing belt.

2. Tighten the nut for the moving tensioner to the recommended torque.

3. Tighten the bolts (3a) for the camshaft toothed driven pulley, inlet side, to the recommended torque using the tool (3b) for counter-torque.

4. Tighten the bolt (4a) for the exhaust side timing driven pulley to the recommended torque using the tools (4b) and (4c) for counter-torque.

Undo the bolts and remove the tool.

Remove the engine positioning and TDC tool.

Fit the camshaft caps removed previously and tighten the bolts to torque.

Rotate the crankshaft through two revolutions in its normal direction of rotation.

Loosen the moving tensioner nut.

5. Fit tool (5a) in the hole on the mobile timing belt tensioner mount and turn to align the tensioner moving pointer (5b) with fixed reference (5c).

Tighten the nut for the moving tensioner to the recommended torque.

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Fit the timing drive belt guards and fix them using the bolts.

Fit the power unit reaction rod attachment bracket and fix it using the bolts.

Fit the engine component single drive belt guide pulley and fix it using the bolt.

Fit the crankshaft pulley.

Fit the single engine component belt by adjusting the automatic belt tensioner using a wrench.

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Fit the rocker cover complete with gasket and fix it using the bolts.

Connect the oil vapour recovery pipe to the rocker cover.

Place the ignition coils back in their housings and tighten them using the bolts.

Connect the electrical connections to the ignition coils.

Fit the flywheel lock.

Fit the single drive belt pulley and tighten the bolts to torque.

Tighten the bolt fixing the timing belt drive pulley to the recommended torque.

Remove the flywheel lock.

- 1004D40 engine - position on stand and remove.