ENGINE - POSITION ON STAND AND REMOVE

Operation 1004D40 · REMOVE ENGINE AND WASH

2.2 JTS

Removing

- Remove the two manual gearbox locating bushes from the engine block.

1. Fit the overhaul stand flange on the engine block.

2. Use a mechanical hoist with chains to lift the engine and place it on the overhaul stand.

Refitting

- Use a hydraulic hoist with chains to remove the engine from the overhaul stand and place it on a platform.

- Remve the overhaul stand flange from the engine.

- Refit the two manual gearbox centering bushes in their seats on the engine block.

3.2 JTS

Rest on the stand

1. Fit the tool (1a) on the engine crankcase and, using a hydraulic lift, position the engine (1b) on the rotating overhaul stand.

Removal from the stand

- Support the engine using a hydraulic lift, undo the tool fastenings on the crankcase and then remove the engine from the overhaul stand.

2.4 JTD 20v

Secure and support the engine using a hydraulic lift fitted with chains.

1. Adjust the moving tensioner (1a) for the single drive belt using the spanner (1b), then insert the tool (1c) in the opening in the tensioner.

2. Remove the protective plug for the auxiliar shaft drive belt cam tensioner.

3. Undo the bolt retaining the cam tensioner.

4. Remove the auxiliary shaft drive belt.

1. Undo the fixing nut (1a) and disconnect the electrical connection from the alternator (1b).

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

1. Undo the fixing bolts (1a) and remove the alternator upper mounting bracket (1b).

1. Undo the bolts (1a) and remove the rear engine support (1b).

1. Disconnect the electrical connection for the engine oil level sensor.

2. Fit the rear bracket for positioning the engine on the overhaul stand.

1. Disconnect the electrical connection for the air conditioning compressor.

2. Undo the bolts (2a) and remove the air conditioning compressor and front engine support assembly (2b).

1. Fit the front bracket for positioning the engine on the overhaul stand.

1. Undo the fixing nuts (1a) and remove the heat shield (1b) for the exhaust manifold.

1. Open the band (1a) and disconnect the fluid return pipe from the turbocharger (1b).

2. Undo the connector (2a) and disconnect the oil supply pipe (2b) to the turbocharger from the crankcase.

1. Undo the bolts (1a) fixing the rigid EGR pipe (1b) to the exhaust manifold and remove the gasket (1c).

2. Undo the nuts (2a) securing the exhaust manifold (2b) to the cylinder head.

1. Undo the bolt fixing the turbine mounting bracket to the crankcase.

2. Remove the exhaust manifold and turbocharger assembly (2a) and the metal gasket (2b).

1. Undo the fixing bolt (1a) and remove the power assisted pump protective shield (1b).

2. Using a hydraulic lift, place the engine (2a) on the overhaul stand (2b).

It is possible to use the following stand as an alternative to the overhaul stand mentioned above:

Fasten the mounting brackets to the overhaul stand.

Release the engine from the hydraulic lift.

Proceed as follows to remove the engine from the overhaul stand.

Secure and support the engine using a hydraulic lift fitted with chains.

Undo the fastenings and remove the engine complete with mounting brackets.

Remove the brackets for positioning the engine on the overhaul stand from the crankcase.

1. Place a new metal gasket (1a) in position and then fit the exhaust manifold and turbine assembly (1b).

2. Tighten the bolt fixing the turbine mounting bracket to the crankcase.

1. Tighten the nuts (1a) fixing the exhaust manifold (1b) to the cylinder head and check the torque.

2. Place the new gasket (2a) in position and tighten the bolts (2b) fixing the rigid EGR pipe (2c) to the exhaust manifold/turbine tightening to torque.

1. Connect the oil return pipe from the turbocharger (1a) and secure it using the band (1b).

2. Connect the turbocharger oil supply pipe (2a) to the crankcase and tighten the connector (2b) to the recommended torque.

1. Place the exhaust manifold heat shield (1a) in position and tighten the fixing nuts (1b) checking the torque.

1. Place the air conditioning compressor and front engine support assembly (1a) in position and tighten the fixing bolts (1b) to the recommended torque.

2. Connect the electrical connection for the air conditioning compressor.

1. Connect the electrical connection for the engine oil level sensor.

2. Fit the protective shield (2a) for the power assisted steering pump in place and tighten the fixing bolt (2b).

1. Fit the rear engine support (1a) in place and tighten the fixing bolts (1b) to the recommended torque.

1. Fit the upper alternator mounting bracket (1a) and tighten the fixing bolts (1b) to the recommended torque.

1. Fit the alternator (1a) in place and tighten the fixing bolts (1b) to the recommended torque.

1. Connect the electrical connection to the alternator.

Place the engine components single belt in position using a spanner on the moving tensioner.

Release the engine from the hydraulic lift.