Stilo Factory Service Manual (2001-2007): 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 unit11 pages
- Power unit with manual gearbox - r + r
- Power unit with manual gearbox - r+r for versions with a/c
- Power unit with manual gearbox with hydraulic selection - 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 - 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
Power unit supports11 pages
- Introduction - POWER UNIT SUPPORTS
- Gear box left rigid mount - r r
- Gear box left rigid mount - r r
- Cam shaft left rigid mount - r r
- Power unit front mount (timing side) flexible block - replace
- Gearbox side mount flexible block - replace
- Power unit lower reaction link r r
- Gearbox lower reaction rod ' -r.r.
- Bracket on engine for lower reaction rod - r.r.
- Bracket on gearbox for lower reaction rod - r.r.
- Power unit lower reaction link r r
Cylinder head/s21 pages
- Introduction - CYLINDER HEAD/S
- Cam covers
- Cylinder head/s - various operations
- Sound-proofing cover - r + r
- Single cam cover - r + r and replace gasket
- Ignition coil cover on cylinder head- r+r
- Single cylinder head extension - change gasket
- Single cylinder head extension - r r with timing belt removed - replace
- Lh cylinder head extension - replace gasket
- Left camshaft housing - replace. gasket on versions with air conditioning
- Lh cylinder head extension - r r with timing belt removed - replace gasket
- Rh cylinder head extension - replace gasket
- Right camshaft housing - replace . gasket on versions with air conditioning
- 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, 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 covers19 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
- Crankcase sump - r r clean mating surfaces and apply sealant for vehicle with air conditioner
- 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 crankshaft oil seal cover- r+r and replace gaskets for versions with air conditioner
- 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
Crankshaft and flywheel8 pages
- Introduction - CRANKSHAFT AND FLYWHEEL
- Crank shaft
- Engine flywheel
- Crank shaft - r + r with engine removed - check main and connecting rod bearingand replace if necessary
- Crankshaft phonic wheel for rpm and timing sensor-replace with crankshaft removed
- Engine flywheel - r + r for versions with manual gearbox
- Engine flywheel - r r with clutch or gearbox removed
- Flywheel crown wheel - replacement for versions with manual gearbox
Pistons and connecting rods10 pages
- Pistons and connecting rods
- Connecting rod and piston set - r r
- Piston connecting rod set - r r
- 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 system51 pages
- Introduction - TIMING SYSTEM
- Belt timing system
- Timing system tensioners
- 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 system tensioner (one) r + r
- Timing belt tensioner mount - r r
- Timing belt tensioner mount - r r with timing belt removed
- Timing system protective cover(s) - r + r
- Timing system guard assemblies - r + r
- Introduction - TIMING SYSTEM
- Overhead camshaft
- Overhead camshafts (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 in cylinder head - r r on vehicle
- Camshaft in cylinder head - r r with head removed
- Front oil seal of one overhead camshaft - replace with timing belt removed
- Timing variator on cylinder head intake camshaft - r r
- Timing variator on inlet camshaft in cylinder head r + r with shaft 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
- Hydraulic tappet (one) - replaced with camshaft removed
- Hydraulic tappet (one) - replace with cylinder head extension removed
- Hydraulic tappets all r r
- Hydraulics tappets all r r camshaft removed
- 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 housing seal - 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
- Front fuel delivery line - r r
- Rear fuel delivery line - r r
- Filter/carburettor line - r r
- Fuel line from manifolds - r r
- Fuel return line - r r
Engine air supply circuit17 pages
- Introduction - ENGINE AIR SUPPLY CIRCUIT
- Vacuum air circuit
- Air cleaner filtering element - replace
- Air cleaner filtering element - replace.
- Filter input sleeve - r r
- Cold air intake - r r
- Vacuum air circuit resonator pipe - r+r
- RIGID PIPE between air filter and intake manifold - R.R.
- Sleeve from air cleaner to intake manifold - r + r
- Air inlet pipe to turbo charger - r + r
- Air supply hose between turbocharger and rigid pipe for supply manifold - r.r.
- Rigid air delivery pipe between turbo charger and heat exchanger - r + r
- Rigid pipe carrying air between turbocharger and inlet manifold - r+r
- Air delivery pipe between turbo charger and heat exchanger - replace
- Air delivery sleeve from heat exchanger to rigid pipe - replace
- Heat exchanger/manifold pipe - r r
- Turbo charger intercooler - r + r
Petrol injection system17 pages
- Introduction - PETROL INJECTION SYSTEM
- Air flow meter - r + r
- Throttle case - r + r
- Throttle body intergral with mds - r r
- Timing variator solenoids - r + r
- Coolant temperature sensor - r + r
- Cam angle 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
- Run electronic ignition/injection control unit (single) self-learning procedure
- Injection/ignition system e.c.u. (one) - r + r
- Ignition/injection system control unit mount - r r
- System cable bundle - r + r
Diesel fuel injection33 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
- Pressure pump - r r
- Pressure pump pulley - r r
- Supplementary pressure pump - r r
- Supplementary pressure pump - dismantle
- 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
- Fuel pressure sensor - r r
- Water presence sensor on fuel filter r r
- Electro-pneumatically controlled THROTTLE CASING - R.R.
- Electro-pneumatically controlled throttle casing - replacement
- Solenoid valve on vacuum reservoir for throttle casing pneumatic valve - r.r.
- Vacum tank for controlling engine air intake r r
- Ds electric injection control unit - r r
- Diesel injection wiring harness - r r
Engine turbocharging system10 pages
- Introduction - ENGINE TURBOCHARGING SYSTEM
- Turbo charger assembly
- Control/safety devices
- Check the supercharging pressure
- Variable geometry turbocharger actuator leakage test
- Turbocharger - exhaust manifold - exhaust pipe connecting hose - r.r.
- Turbo/manifold/sleeve assembly dismantle
- Variable geometry turbocharger exhaust manifold assembly sleeveleading to exhaust pipe r r
- Variable geometry turbocharger exhaust manifold sleeve leading to exhaust pipe dismantle at bench
- Solenoid valve for turbocharger vane actuator - r.r.
Inlet and exhaust manifolds11 pages
- Inlet manifolds
- Modular inlet manifold (v.i.s.)
- Inlet manifold - r + r and replace seal
- Inlet manifold - r+r and replace seal with air conveyor/box removed
- Sleeves connecting air capacity box to inlet manifold is - r+r
- Sleeves connecting air capacity box to inlet manifold is - r+r
- Exhaust manifold - r + r and replace seal
- Exhaust manifold with catalytic converter - r r
- Exhaust manifold heat shield on bulkhead - r+r
- Device (vis) with adjustable air ducts - r r
- Actuator for vis device with adjustable air ducts - r r
Exhaust pipes and silencers13 pages
- Introduction - EXHAUST PIPES AND SILENCERS
- Exhaust pipe heat shield - r r
- Catalytic converter heat shield - r r
- Heat shield for exhaust pipe attachment to manifold - r r
- Rigid section of exhaust pipe between catalytic converter and silencer - r + r
- Rear exhaust silencer - r + r
- Intermediate exhaust silencer - r+r emission control versions
- Front catalytic converter attachment seal - replace
- Centre exhaust pipe complete with: flexible connector - torque converter and centre silencer -r.r.
- Centre exhaust pipe complete with flexible connector : catalytic converter and centre silencer - dismantling and reassem
- Exhaust pipe attachment to engine - r + r
- Exhaust pipe attachment to engine seal/s - replace
- Exhaust pipe between pre-catalytic converter and catalytic converter - r r
Exhaust emission control system31 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
- Left upper lambda sensor r r
- Right upper lambda sensor r r
- Front lambda probe with catalitic converter r r
- Rear lambda probe with catalitic converter r r
- LAMBDA SENSORS (all) - R.R.
- E.g.r. system solenoid - r + r
- Motor for egr valve self-regulation - r r
- Pipe carrying exhaust gas to e.g.r. valve - r + r
- Vacuum reservoir - r.r.
- E.g.r. - electrical valve r.r.
- Expansion joint on e.g.r. - 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
- PIPE from engine oil vapour separator to filler - 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
- 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 system21 pages
- Introduction - ENGINE LUBRICATION SYSTEM
- Engine oil lubrication circuit
- Oil dip stick pipe - r r
- Engine oil filler - r r
- Engine oil level sensor - r + r
- Engine oil pressure warning light switch - r + r
- Engine oil temperature sender unit - 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
- 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
- Timing mount oil pipe - r r
- Engine oil heat exchanger - r + r
- Radiant mass for engine oil cooling - r + r
- Engine oil cooling radiator - r + r
- Engine oil delivery and return pipes to cooling radiator - r + r
Engine cooling25 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 - r r for air conditioned versions
- Water pump - r + r
- Water pump - r+r for versions with air conditioner
- 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
- Thermostat - r + r with cylinder head removed
- Three-way connector between radiator and thermostat - r.r.
- Hose between three-way connector and 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
- Oil exchange sleeve - r r
- Radiator cooling fan - r + r
- Resistor for radiator cooling fan - r + r
Various engine component controls16 pages
- Introduction - VARIOUS ENGINE COMPONENT CONTROLS
- Crankshaft services PULLEY - R.R.
- Crankshaft pulley - r+r for versions with air conditioner
- Alternator/air conditioner compressor drive belt - adjust tension
- Alternator/water pump drive belt - adjust tension
- Alternator drive belt - r + r
- Alternator drive belt - adjust tension
- Belt from a/c compressor to alternator drive r + r
- Auxiliary belt fixed tensioner (one) - r+r
- Auxilary belt mobile tensioner (one) -r+r
- Air conditioner compressor drive belt - 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
- Engine component single belt fixed tensioner - one - r + r
- Engine component single belt fixed tensioner - r rwith belt removed