PISTON WITH CONNECTING ROD - R R

Operation 1028H10 · PISTONS AND CONNECTING RODS

2.0 16v

Removing

Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.

Op. 5010B18 CLIMATE CONTROL UNIT AIR INTAKE - R.R.

Op. 1048A39 SLEEVE FROM AIR CLEANER TO RIGID PIPE - R R

See in Op. 1048A10

See in Op. 1088B10

Op. 7055B54 UNDER-ENGINE GUARD - R R

Op. 4450B04 RIGHT FRONT WHEEL R R

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 4410D16 BRACKET (ONE) RETAINING CHASSIS TO BODY - R R

- < R1 > [Right side, front]

See in Op. 1092G10

See in Op. 1092A10

See in Op. 1032D12

See in Op. 1032B10

See in Op. 1084A16

See in Op. 1016C10

See in Op. 1020A20

See in Op. 1020A46

See in Op. 1084B28

1. Undo the bolts and remove the connecting rod caps complete with 2nd and 3rd cylinder lower connecting rod half-bearings.

- Lower the vehicle.

1. Release and remove the pistons (1a) and connecting rods (1b).

- Turn the crankshaft and proceed in the same way to remove the 1st and 4th cylinder pistons and connecting rods.

Refitting

- Fit the 1st and 4th pistons with connecting rods and connecting rod upper bearing halves using a suitable installing tool to compress the piston rings.

- Fit the connecting rod caps complete with 1st and 4th cylinder lower bearing halves and secure by tightening the bolts to the recommended torque. Carry out angular tightening separately and using an angle wrench for tightening.

Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the connecting rods.

- Proceed in the same way to fit the 2nd and 3rd cylinder pistons and connecting rods.

See in Op. 1084B28

See in Op. 1020A46

See in Op. 1020A20

See in Op. 1016C10

See in Op. 1084A16

See in Op. 1032B10

See in Op. 1032D12

See in Op. 1092A10

See in Op. 1092G10

Op. 4410D16 BRACKET (ONE) RETAINING CHASSIS TO BODY - R R

- < R1 > [Right side, front]

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 4450B04 RIGHT FRONT WHEEL R R

Op. 7055B54 UNDER-ENGINE GUARD - R R

See in Op. 1088B10

See in Op. 1048A10

Op. 1048A39 SLEEVE FROM AIR CLEANER TO RIGID PIPE - R R

Op. 5010B18 CLIMATE CONTROL UNIT AIR INTAKE - R.R.

Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.

Op. 0010T21 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY

2.0 16V JTD

Removing

Op. 4450B04 RIGHT FRONT WHEEL R R

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B54 UNDER-ENGINE GUARD - R R

Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.

Op. 5010B18 CLIMATE CONTROL UNIT AIR INTAKE - R.R.

both

Op. 5050B34 BRACCIO/I TERGITORE/I DEL TERGICRISTALLO ANTERIORE COMPLETO DI SPATOLA - S.R.

Op. 7055A18 L/H OR R/H SIDE RUBBING STRIP DECORATIVE SEAL - R+R

Op. 5050B38 WINDSCREEN WIPER ASSEMBLY - R+R OR REPAIR

Op. 1008C10 POWER UNIT UPPER REACTION LINK R R

Op. 1092G10 SINGLE ENGINE BELT R R

Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R

Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R.

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

Op. 1048B10 RIGID AIR DELIVERY PIPE BETWEEN TURBO CHARGER AND HEAT EXCHANGER - R + R

Op. 1032B44 TOOTHED DRIVE PULLEY - R + R WITH TIMING BELT REMOVED

Op. 1048B10 RIGID AIR DELIVERY PIPE BETWEEN TURBO CHARGER AND HEAT EXCHANGER - R + R

Op. 1048B22 AIR DELIVERY SLEEVE FROM HEAT EXCHANGER TO INTAKE MANIFOLD - R + R

Op. 1048A50 AIR INLET PIPE TO TURBO CHARGER - R + R

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R

Op. 5040A24 AIR CONDITIONING COMPRESSOR - PARTIALLY R.R. FROM THE ENGINE WITHOUT DISCONNECTING THE PIPES

Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION

1. Undo the bolts securing the front crankshaft oil seal cover.

2. Remove the front crankshaft oil seal cover from its seat.

1. Undo the fixing bolts.

2. Remove the oil pump (2a) complete with drive chain (2b), pinion (2c) and tab.

1. Undo the bolts and remove the connecting rod caps complete with 2nd and 3rd cylinder lower connecting rod half-bearings.

Lower the vehicle.

1. Withdraw and remove 2nd and 3rd cylinder pistons (1a) with connecting rods (1b) and upper connecting rod half bearings.

Turn the crankshaft and follow the same procedure to remove the pistons and the 1st and 4th cylinder connecting rods.

Refitting

Fit the pistons with the 1st and 4th cylinder connecting rods and upper half bearings using an appropriate installing tool to compress the piston rings.

Fit the connecting rod caps complete with the 1st and 4th cylinder lower half-bearings and secure by tightening the bolts to the specified torque. Tighten in the sequence described below, using the angular tightening tool to screw in the bolts:

Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the connecting rods.

Proceed in the same way to fit the pistons and the 2nd and 3rd cylinder connecting rods.

Fit the engine oil pump, tightening the bolts to the specified torque.

Fit the chain, pinion and pinion retaining tabs.

Remove the oil sealing ring from its seat on the front cover.

Because the oil seal must always be replaced, it may be destroyed when it is removed.

Apply sealant to the front cover contact surface.

Fit the cover and tighten the bolts to the specifed torque. Pretighten all the bolts and then tighten to the final torque.

1. Fit sealing ring (1a) using tool (1b).

Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION

Op. 5040A24 AIR CONDITIONING COMPRESSOR - PARTIALLY R.R. FROM THE ENGINE WITHOUT DISCONNECTING THE PIPES

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Op. 1048A50 AIR INLET PIPE TO TURBO CHARGER - R + R

Op. 1048B22 AIR DELIVERY SLEEVE FROM HEAT EXCHANGER TO INTAKE MANIFOLD - R + R

Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE

Op. 1032B44 TOOTHED DRIVE PULLEY - R + R WITH TIMING BELT REMOVED

Op. 1048B10 RIGID AIR DELIVERY PIPE BETWEEN TURBO CHARGER AND HEAT EXCHANGER - R + R

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

Op. 1008A46 CAM SHAFT LEFT RIGID MOUNT - R R

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

Op. 1092A12 PULEGGIA DELL''ALBERO MOTORE - S.R. PER VERSIONI CON CONDIZIONATORE ARIA

Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R

Op. 1092G10 SINGLE ENGINE BELT R R

Op. 1008C10 POWER UNIT UPPER REACTION LINK R R

Op. 5050B38 WINDSCREEN WIPER ASSEMBLY - R+R OR REPAIR

Op. 7055A18 L/H OR R/H SIDE RUBBING STRIP DECORATIVE SEAL - R+R

[both]

Op. 5050B34 BRACCIO/I TERGITORE/I DEL TERGICRISTALLO ANTERIORE COMPLETO DI SPATOLA - S.R.

Op. 5010B18 CLIMATE CONTROL UNIT AIR INTAKE - R.R.

Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.

Op. 7055B54 UNDER-ENGINE GUARD - R R

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 4450B04 RIGHT FRONT WHEEL R R

Bleed the air from the engine coolant system.

Op. 0010T10 ENGINE OIL CHECK LEVEL AND TOP UP

2.2 16V JTD

Removing

Op. 4450B04 RIGHT FRONT WHEEL R R

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B54 UNDER-ENGINE GUARD - R R

Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.

Op. 5010B18 CLIMATE CONTROL UNIT AIR INTAKE - R.R.

[both]

Op. 5050B34 BRACCIO/I TERGITORE/I DEL TERGICRISTALLO ANTERIORE COMPLETO DI SPATOLA - S.R.

Op. 7055A18 L/H OR R/H SIDE RUBBING STRIP DECORATIVE SEAL - R+R

Op. 5050B38 WINDSCREEN WIPER ASSEMBLY - R+R OR REPAIR

Op. 1008C10 POWER UNIT UPPER REACTION LINK R R

Op. 1092G10 SINGLE ENGINE BELT R R

Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R

Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R.

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

Op. 1048B10 RIGID AIR DELIVERY PIPE BETWEEN TURBO CHARGER AND HEAT EXCHANGER - R + R

Op. 1032B44 TOOTHED DRIVE PULLEY - R + R WITH TIMING BELT REMOVED

Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE

Op. 1048B22 AIR DELIVERY SLEEVE FROM HEAT EXCHANGER TO INTAKE MANIFOLD - R + R

Op. 1048A50 AIR INLET PIPE TO TURBO CHARGER - R + R

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R

Op. 5040A24 AIR CONDITIONING COMPRESSOR - PARTIALLY R.R. FROM THE ENGINE WITHOUT DISCONNECTING THE PIPES

Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION

1. Undo the bolts securing the front crankshaft oil seal cover.

2. Remove the front crankshaft oil seal cover from its seat.

1. Undo the fixing bolts.

2. Remove the oil pump (2a) complete with drive chain (2b), pinion (2c) and tab.

1. Undo the bolts and remove the connecting rod caps complete with 2nd and 3rd cylinder lower connecting rod half-bearings.

Lower the vehicle.

1. Withdraw and remove 2nd and 3rd cylinder pistons (1a) with connecting rods (1b) and 2nd and 3rd cylinder upper connecting rod half bearings (1c).

Turn the crankshaft and follow the same procedure to remove the pistons and the 1st and 4th cylinder connecting rods.

Refitting

Fit the pistons with the 1st and 4th cylinder connecting rods and upper half bearings using an appropriate installing tool to compress the piston rings.

Fit the connecting rod caps complete with the 1st and 4th cylinder lower half-bearings and secure by tightening the bolts to the specified torque. Tighten in the sequence described below, using the angular tightening tool to screw in the bolts:

- Step 1: tighten to the required torque

- Step 2: slacken by 180°;

- Step 3; pretighten to the required torque and then tighten through the required angle;

Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the connecting rods.

Proceed in the same way to fit the pistons and the 2nd and 3rd cylinder connecting rods.

Fit the engine oil pump, tightening the bolts to the specified torque.

Fit the chain, pinion and pinion retaining tabs.

Remove the oil sealing ring from its seat on the front cover.

Because the oil seal must always be replaced, it may be destroyed when it is removed.

Apply sealant to the front cover contact surface.

Fit the cover and tighten the bolts to the specifed torque. Pretighten all the bolts and then tighten to the final torque.

1. Fit sealing ring (1a) using tool (1b).

Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION

Op. 5040A24 AIR CONDITIONING COMPRESSOR - PARTIALLY R.R. FROM THE ENGINE WITHOUT DISCONNECTING THE PIPES

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Op. 1048A50 AIR INLET PIPE TO TURBO CHARGER - R + R

Op. 1048B22 AIR DELIVERY SLEEVE FROM HEAT EXCHANGER TO INTAKE MANIFOLD - R + R

Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE

Op. 1032B44 TOOTHED DRIVE PULLEY - R + R WITH TIMING BELT REMOVED

Op. 1048B10 RIGID AIR DELIVERY PIPE BETWEEN TURBO CHARGER AND HEAT EXCHANGER - R + R

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT

Op. 1008A46 CAM SHAFT LEFT RIGID MOUNT - R R

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R.

Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R

Op. 1092G10 SINGLE ENGINE BELT R R

Op. 1008C10 POWER UNIT UPPER REACTION LINK R R

Op. 5050B38 WINDSCREEN WIPER ASSEMBLY - R+R OR REPAIR

Op. 7055A18 L/H OR R/H SIDE RUBBING STRIP DECORATIVE SEAL - R+R

[both]

Op. 5050B34 BRACCIO/I TERGITORE/I DEL TERGICRISTALLO ANTERIORE COMPLETO DI SPATOLA - S.R.

Op. 5010B18 CLIMATE CONTROL UNIT AIR INTAKE - R.R.

Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.

Op. 7055B54 UNDER-ENGINE GUARD - R R

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 4450B04 RIGHT FRONT WHEEL R R

Bleed the air from the engine coolant system.

Op. 0010T10 ENGINE OIL CHECK LEVEL AND TOP UP