SINGLE CYLINDER HEAD - R.R. and Replace gasket

Operation 1016C10 · SINGLE CYLINDER HEAD - REMOVING AND REFITTING

2.4 JTD 10V

Removing

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 1032D12 Timing system protective COVER(S) - R.R.

See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement

1. Undo the fixing nuts (1a) and remove the bonnet lock (1b) from its housing in the crossmember.

2. Undo the lower nut (2a) and remove the lock reinforcement bracket (2b).

1. Undo the fixing bolts.

2. Remove the upper front crossmember.

1. Remove the cold air intke pipe from the connector on the air filter.

1. Disconnect the heat exchanger pipe from the intake air pipe.

2. Undo the fixing bolts.

3. Remove the metal air intake pipe.

4. Remove the vapour recirculation pipe disconnecting it from the tappet cover (4a) and from the air hose (4b).

5. Disconnect the air vacuum pipe from the connector on the vacuum unit.

1. Undo the fixing bolts.

2. Disconnect the flexible vacuum pipes from the actuator solenoid valve and the vacuum reservoir.

3. Remove the rigid section of the EGR vacuum pipe.

1. Disconnect the engine coolant pipes.

2. Undo the bolts fixing the rigid pipe to the cylinder head.

3. Remove the rigid water pump inlet pipe.

1. Undo the bolts fixing the rigid EGR pipe to the exhaust manifold.

2. Undo the turbocharger reinforcement bracket fastenings.

3. Remove the bracket.

4. Undo the fixing nuts (4a) and release the exhaust manifold/turbocharger assembly (4b) from the cylinder head pins.

1. Disconnect the electrical connection for the engine coolant temperature sensor.

1. Disconnect the electrical connections (1a), (1b), (1c), (1d), (1e), (1f), (1g) and (1h).

2. Undo the fixing bolts (2a) and remove the injection wiring (2b) from the work area.

1. Disconnect the upper pipe from the connector on the radiator.

2. Disconnect the oil radiator engine coolant pipe (Modine).

3. Disconnect the two heater coolant supply and return pipes.

1. Undo the nuts fixing the return manifold to the intake manifold.

2. Disconnect the recirculation pipe.

3. Remove the rigid supply pipe from the pressure pump to the single fuel delivery manifold.

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

2. Undo the bolt fixing the intake manifold to the pressure pump support.

1. Undo the fixing bolts.

2. Remove the tappet cover.

- Draw off the engine oil from the chambers in the cylinder head.

1. Loosen the bolts fixing the cylinder head.

2. Position a bracket (2a) fastened to the exhaust manifold stud and secure the hook (2b) for manoeuvring the cylinder head later on safely to it.

3. Position a second hook on the intake manifold.

- Secure the chains to a hydraulic lift.

4. Lift and remove the cylinder head, complete with intake manifold.

- Keep the cylinder head gasket.

Refitting

- Fit a new cylinder head gasket on the cylinder block taking care to ensure that it is the same size as the one removed.

The cylinder head gasket is the ASTADUR type.

- On account of the special material from which these gaskets are made they undergo a polymerization process whilst the engine is working, becoming considerably harder during usage. In order to ensure that the polymerization process takes place, observe the precautions described below:

- Keep the gasket sealed in its nylon container and only take it out shortly before fitting.

- Do not lubricate the gasket or get oil or grease on it.

- Position the cylinder head on the cylinder block/crankcase.

- Release the supporting hooks and remove the mounting bracket.

1. Tighten the bolts fixing the cylinder head to the cylinder block to the recommended torque following the order illustrated and using the angular tightening tool.

The figure of 2 daNm in the table below is a tightening value for all the bolts following the order illustrated in the diagram.

- Remove the brackets, chains and hooks positioned previously for lifting the cylinder head.

- Fit the tappet cover on the cylinder head.

- Tighten the bolts fixing the tappet cover to torque.

- Tighten the bolt fixing the intake manifold to the pressure pump support to torque.

- Fit the bracket joining the intake manifold - pump support.

- Fit the new pipe from the pressure pump to the fuel manifold.

Each time work is carried out on the pipe from the pressure pump to the fuel manifold, it has to be replaced with a new pipe to prevent fuel leaking from the connectors.

- Tighten the connectors on the pressure pump and the single fuel delivery manifold to torque.

- Position the return manifold in the special housing in the intake manifold and tighten the fixing nuts.

- Connect the fuel recirculation pipe to the injectors.

- Connect the two heater coolant supply and return pipes to the heater.

- Connect the oil radiator engine coolant pipe (Modine) to the thermostat.

- Connect the upper pipe to the connector on the radiator.

- Connect the electrical connections for the injection wiring disconnected previously.

- Tighten the bolts fixing the cable loom to the intake manifold.

- Connect the engine coolant temperature sensor electrical connection.

- Position the exhaust manifold in the special housing on the cylinder head pins.

- Tighten the nuts fixing the manifold to the cylinder head to torque.

- Fit the exhaust manifold reinforcement bracket on the cylinder head.

- Tighten the nuts and the bolt fixing the bracket to the head and themanifold to torque.

- Position the EGR exhaust gas supply pipe and tighten the bolts fixing it to the exhaust manifold.

- Position the new gasket for the rigid water pump inlet pipe.

- Fit the rigid inlet water pipe on the pump.

- Tighten the bolts fixing the rigid pipe to the cylinder head to torque.

- Connect the engine coolant pipes to the pump rigid water inlet pipe.

- Fit the pipe assembly.

- Connect the flexible pipe to the actuator solenoid valve.

- Connect the flexible pipe from the vacuum reservoir.

- Tighten the bolts fixing the rigid section of the pipe.

- Connect the air vacuum pipe to the connector on the vacuum unit.

- Fit the vapour recirculation pipe connecting it to the tappet cover and to the turbocharger air hose.

- Fit the metal air intake pipe on the throttle casing and tighten the fixing bolts.

- Connect the air/air heat exchanger flexible pipe to the rigid section.

- Fit the cold air intake pipe to the connector on the air filter.

- Fit the upper front crossmember and tighten the fixing bolts to torque.

- Fit the bonnet lock complete with bracket and tighten the nuts fixing it to the upper crossmember and to the lower crossmember.

See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement

See in Op. 1032D12 Timing system protective COVER(S) - R.R.

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 0010T20 Engine REFRIGERANT FLUID - Change

See in Op. 0010T21 ENGINE COOLANT - Check density and top up if necessary

- [0010T21]

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

- Close the bonnet and remove the vehicle from the lift.

2.4 20V

Removing

- Position the vehicle on a lift.

- Open the boot, remove the cover on the left hand side and disconnect the negative battery lead.

- Raise the vehicle on the lift.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

- Position a suitable container for collecting the engine coolant.

- Raise the lift.

1. Disconnect the lower radiator pipe.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 1048A28 vacuum air circuit resonator pipe - r+r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1048A23 Cold AIR INTAKE for air filter - R.R.

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

1. Disconnect the coolant pipe retaining band on the cylinder head.

2. Undo the nut fixing the expansion tank (this nut also fastens the windscreen washer fluid reservoir).

3. Disconnect the electrical connection for the engine coolant level.

4. Disconnect the pipe (4a) and lift up the expansion tank (4b) and remove it.

1. Undo the fixing nuts (1a) and remove the bonnet lock (1b) from the housing in the crossmember.

2. Undo the lower bolt (2a) and remove the lock reinforcement bracket (2b).

1. Undo the fixing nuts

2. Remove the front crossmember.

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.

1. Disconnect the retaining band for the throttle casing hose.

2. Disconnect the pipe on the tappet cover connected to the hose on the throttle casing.

3. Release the electrical connector (3a) and remove the hose (3b).

1. Disconnect the engine cooling system pipes on the thermostat.

2. Disconnect the electrical connection for the coolant temperature sensor.

3. Disconnect the heater return pipe on the cylinder head.

1. Disconnect the electrical connections (1a) for the injection control unit, then undo the bolt (1b) fixing the injection control unit mounting bracket.

2. Disconnect the earth lead (2a) and the electrical connector (2b) for the throttle casing actuator.

3. Undo the four fixing bolts and remove the throttle casing complete with injection control unit and mounting bracket.

1. Disconnect the electrical connections for the ignition coils (1a), the injectors (1b) and the phase transformer solenoid (1c); release the wiring from the retaining bands.

2. Disconnect the connectors for the front Lambda sensor (2a), the rear Lambda sensor (2b) and the air conditioning compressor coupling.

3. Disconnect the earth lead, then release the engine wiring from the retaining bands on the intake chamber and place it to the side.

- Discharge the fuel pressure with the tool connected to the valve on the single fuel manifold pipe.

1. Disconnect the fuel supply pipe from the manifold.

2. Disconnect the oil vapour recovery pipe from the tappet cover.

3. Disconnect the fuel vapour recovery pipe.

1. Disconnect the electrical connection (1a) on the intake chamber for the left detonation sensor and the electrical connection (1b) for the rpm sensor, then undo the bolts fixing the connector; release the wiring from the retaining bands.

1. Disconnect the electrical connection (1a) for the timing sensor and the connector (1b) for the right detonation sensor on the intake chamber, then undo the bolts fixing the connectors.

2. Undo the bolt fixing the engine oil dipstick pipe.

1. Undo the bolt (1a), loosen the bolt (1b) and rotate the reaction rod connecting rod.

1. Undo the bolt (1a), open the retaining brackets (1b) and remove the engine coolant recovery pipe (1c).

1. Undo the three fixing bolts (1a) and remove the fuel manifold (1b) complete with injectors.

- Raise the vehicle.

1. Undo the nut fixing the intake chamber to the mounting bracket.

- Release the wiring from the mounting bracket.

- Lower the vehicle on the lift.

1. Undo the bolt fixing the intake chamber to the manifold.

1. Disconnect the bands joining the intake chamber to the hoses connected to the intake manifold, then release the chamber from the hoses.

1. Undo the fixing nuts (1a) and the bolt (1b) and remove the intake manifold complete with hoses connected to the intake chamber.

1. Disconnect the electrical connections for the V.I.S.control actuator solenoid valve (1a) and the fuel vapour recovery solenoid valve (1b), then remove the intake chamber (1c).

1. Remove the rigid coolant pipe (1a), acting on the fixing nut (1b).

2. Disconnect the two pipes (2a) from the connector (2b) on the coolant pump.

1. Undo the nuts securing the exhaust manifold to the cylinder head.

2. Extract the exhaust manifold from the studs on the head; keep the gasket which is underneath.

1. Undo the two bolts (1a) and remove the thermostat (1b).

- Position a hydraulic lift under the gearbox bellhousing.

1. Undo the bolts fixing the engine support to the gearbox.

- Gradually lower the hydraulic lift and rest the gearbox on the front crossmember.

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner

1. Undo the bolt fixing the auxiliary shaft drive belt idle pulley.

2. Undo the five bolts (2a) and remove the timing belt guard (2b).

1. Undo the bolts (1a) and remove the ignition coils (1b).

2. Undo the bolts (2a) and remove the tappet cover (2b) complete with gasket.

1. Undo the automatic tensioner nut, in order to loosen the timing belt tension.

2. Remove the timing drive belt from the pullies.

1. Undo the bolt fixing the guard behind the exhaust side timing pulley to the cylinder head.

2. Undo the bolts (2a) using the spanner (2b) and remove the cylinder head (2c).

- Remove the gasket underneath the cylinder head.

Refitting

- Position the cylinder head gasket on the cylinder block/crankcase.

The cylinder head gasket is the Astadur type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage. The cylinder head gasket is the Astadur type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage. In order for the polymerization process to take place, it is necessary to: - keep the gasket sealed in its container until it is fitted; - not lubricate the gasket or contact surfaces or get oil on them.

- Position the cylinder head on the cylinder block/crankcase taking care to ensure that the camshafts are positioned with the front cams facing outwards (valves closed).

1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque, in stages, using the spanner (1b) and the spanner (1c) for angular tightening.

Follow the order shown in the figure for each tightening sequence.

- Position the intake chamber in the vehicle, then connect the electrical connection for the V.I.S. control actuator solenoid valve and the electrical connection for the fuel vapour recovery solenoid valve.

- Insert the threaded pin which is in the rear part of the chamber into the opening in the mounting bracket.

- Position the intake manifold complete with gasket underneath and hoses connected to the intake chamber.

- Tighten the nuts and the bolt fixing the intake manifold to the cylinder head to the recommended torque.

- Fit the intake chamber ducts on the hoses connected to the intake manifold and secure them using the retaining bands.

- Tighten the bolt fixing the intake chamber to the manifold.

- Raise the vehicle on the lift.

- Tighten the nut fixing the intake chamber to the mounting bracket.

- Lower the vehicle on the lift.

- Position the fuel manifold complete with injectors and secure it using the fixing bolts.

- Position the thermostat and fasten it tightening the fixing bolts to the recommended torque.

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

2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque.

- Remove the spark plug for cylinder no. 1.

1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

- Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.

2. With cylinder no. 1 at T.D.C., check that the reference on the crankshaft drive gear is in line with the reference on the crankshaft front cover.

- Undo the bolts and remove the inlet side camshaft third cap and the exhaust side camshaft second cap.

Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting.

1. Fit the templates (1a) in place of the camshaft caps that have been removed and secure them using the bolts (1b).

Check that the camshaft cam profile and the templates are correctly aligned.

1. Fit the timing toothed drive belt in the following order:

1. - toothed drive pulley (1a)

1. - moving tensioner (1e)

1. - exhaust side toothed driven pulley (1c)

1. - fixed tensioner (1b)

1. - inlet side toothed driven pulley (1d)

1. - water pump pulley (1f).

The belt is fitted with the arrow facing the direction of rotation of the engine. There are also three reference on the belt that should coincide during the initial fitting with the references on the toothed drive pulley and the exhaust and inlet side toothed driven pullies.

1. Using a screwdriver, apply force to the tab (1a) for the automatic tensioner so that the tensioner is in the maximum tension position, then tighten the nut (1b) fixing the tensioner to the support.

1. Tighten the bolts (1a) for the inlet side toothed timing driven pulley using tool (1b) for counter-torque.

2. Tighten the bolt (2a) for the exhaust side toothed timing driven pulley using the tools (2b) and (2c) for counter-torque.

- Undo the fixing botls and remove the templates.

- Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

- Rotate the crankshaft throught two revolutions in the direction of rotation.

- Loosen the moving timing tensioner nut.

3. Using a screwdriver, rotate the moving timing tensioner until the moving tensioner reference (3a) coincoides with the fixed reference (3b).

4. Tighten the nut fixing the moving timing tensioner to the recommended torque.

- Remove the tool complete with dial gauge.

- Fit the spark plug for cylinder no. 1 and tighten it to the recommended torque.

- Position the timing drive belt cover and secure it using the fixing bolts.

- Tighten the bolt fixing the auxiliary shaft drive belt idle pulley.

See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner

See in Op. 1092G10 Engine components single drive BELT - R.R.

- Position a hydraulic lift under the gearbox bellhousing.

- Screw in and tighten the bolt fixing the engine support to the gearbox to the recommended torque.

- Position the exhaust manifold on the cylinder head studs and tighten the fixing nuts to torque.

- Position the rigid coolant pipe and secure it using the bolt.

- Connect the two engine coolant pipes to the water pump connector.

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.

- Fit the upper front crossmember.

- Fit the bonnet lock on the crossmember complete with reinforcement bracket.

- Connect the engine cooling system pipes and the heater pipes to the thermostat.

- Connect the connecting rod to the reaction rod and secure it using the bolts.

- Tighten the bolt fixing the engine oil dipstick pipe.

- Position the tappet cover and secure it using the fixing bolts.

- Position the ignition coils cover and secure them using the fixing bolts.

- Position the injection control unit mounting bracket together with the throttle casing and fasten the assembly to the intake chamber.

- Connect the earth lead and the electrical connector for the throttle casing actuator.

- Connect the electrical connections on the injection control unit, then tighten the bolt fixing the engine mounting bracket to the intake manifold.

- Connect the electrical connections for the injectors

- Connect the electrical connection for the phase transformer solenoid

- Connect the electrical connections for the ignition coils.

- Connect the electrical connections for the front Lambda sensor, the rear Lambda sensor and the air conditioning compressor coupling.

- Connect the electrical connections for the engine coolant temperature sensor.

- Connect the earth lead on the cylinder head.

- Secure the engine wiring to the retaining bands on the intake chamber.

- Connect the fuel supply pipe to the manifold.

- Connect the fuel vapour recovery pipe.

- Connect the oil vapour recovery pipe to the tappet cover.

- Connect the electrical connection for the left detonation sensor and the electrical connection for the rpm sensor to the intake chamber; secure the wiring to the retaining bands.

- Connect the electrical connection for the timing sensor and the electrical connector for the right detonation sensor to the intake chamber.

- Position the rigid coolant recovery pipe and secure it using the bolt and the retaining brackets.

- Position the expansion tank and secure it using the nut.

- Connect the pipes and the electrical connection for the engine coolant level.

- Position the hose on the throttle casing and secure it using the retaining band.

- Connect the oil vapour recovery pipe to the tappet cover.

See in Op. 1048A23 Cold AIR INTAKE for air filter - R.R.

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1048A28 vacuum air circuit resonator pipe - r+r

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

- Connect the lower radiator pipe.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

- Connect the negative battery lead, then close the boot.

See in Op. 0010T20 Engine REFRIGERANT FLUID - Change

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

- Remove the vehicle from the lift.

2.0 TB

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then open the boot, remove the cover on the left hand side and disconnect the negative battery lead.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 5040A10 Air conditioning coolant circuit - Drying and Repressurizing

See in Op. 1084A16 Engine oil dip stick PIPE - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

- Position a suitable container for collecting the engine coolant.

- Raise the lift.

1. Disconnect the lower radiator pipe.

- Lower the lift.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1080D24 engine oil vapour intake pipe - r + r

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

1. Undo the fixing nuts (1a) and remove the bonnet lock (1b) from the housing in the crossmember.

2. Undo the lower bolt (2a) and remove the lock reinforcement bracket (2b).

1. Undo the four fixing bolts.

2. Remove the upper crossmember.

1. Undo the fixing bolt on the compressor (1a) and the bolt fixing the flange (1b) and remove the coolant return pipe (1c).

1. Disconnect the electrical connections for the engine cables/fradiator fan cables coupling.

1. Undo the nut (1a) and disconnect the earth lead (1b) from the bodyshell.

1. Disconnect the upper hose from the radiator (rapid connector)

1. Disconnect the electrical connection.

2. Undo the four bolts fixing the fan to the radiator and extract it.

1. Disconnect the electrical connection for the rear Lambda sensor.

2. Disconnect the electrical connection for the front Lambda sensor.

1. Undo the nuts (1a) and the bolt (1b) and extract the heat shield (1c) upwards.

1. Undo the fixing bolts (1a) and remove the two half-rings (1b) between the catalytic preconverter and the turbine.

- Raise the lift.

- Support the catalytic preconverter appropriately.

1. Undo the nuts fixing the catalytic converter to the centre section of the exhaust pipe.

2. Remove the catalytic converter mounting bracket.

1. Remove the catalytic preconverter complete with Lambda sensors.

1. Disconnect the turbocharger by-pass solenoid valve pneumatic connections.

1. Undo the fixing bolts (1a) and remove the protection (1b) for the sump oil return pipe from the turbocharger.

2. Disconnect the sump oil return pipe from the turbochager.

3. Undo the connector (3a) and disconnect the turbocharger oil supply pipe (3b).

4. Undo the fixing bolts (4a) and nuts (4b) and remove the turbocharger mounting bracket (4c).

- Lower the lift.

1. Disconnect the turbochrger air inlet hose.

2. Disconnect the air oulet hose from the turbochager.

3. Disconnect the coolant inlet (3a) and outlet (3b) pipes from the turbocharger.

1. Undo the nuts securing the exhaust manifold to the cylinder head.

2. Remove the turbocharger (2a) complete with exhaust manifold (2b).

3. Remove the exhaust manifold gasket from the studs on the cylinder head.

1. Undo the bolt (1a), release the pipes (1c) from the retaining springs (1b) and disconnect them, then remove the coolant return pipe from the turbocharger to the chamber (1d).

1. Disconnect the electrical connections for the ignition coils (1a), the injectors (1b), the injection control unit (1c), the phase transformer solenoid (1d), the throttle casing actuator (1e), the coolant temperature sensor (1f), the air temperature and pressure sensor (1g), the air conditioning compressor engagement solenoid (1h) and the timing sensor (1i).

- Release the wiring from the fastening springs located on the chamber, the cylinder head and the fuel manifold and turn it over onto its side.

1. Disconnect the retaining band for the throttle casing hose and release the hose.

2. Disconnect the fuel supply pipe (2a) and the return pipe (2b) from the fuel manifold.

1. Disconnect the pneumatic connections for the supercharging air by-pass valve (1a), the brake servo (1b) and the evaporation control circuit (rapid connector) (1c).

- Raise the lift.

1. Undo the fixing bolts (1a) and nuts (1b) and disconnect the earth lead (1c).

- Lower the lift.

2. Release the wiring from the springs and remove the chamber mounting bracket.

1. Undo the fixing bolt (1a) and nuts (1b) and remove the intake manifold (1c) complete with intake chamber and throttle casing.

2. Remove the seal.

1. Disconnect the coolant pipe retaining band on the cylinder head.

2. Undo the nut fixing the expansion tank (this nut also fastens the windscreen washer fluid reservoir).

3. Disconnect the electrical connection for the engine coolant level.

4. Raise the expansion tank and remove it.

1. Disconnect the tank return pipe on the cylinder head.

2. Undo the bolts fixing the thermostat.

1. Undo the bolt (1a), loosen the bolt (1b) and rotate the reaction rod connecting rod.

- Position a hydraulic lift under the gearbox bellhousing.

1. Undo the bolts fixing the engine support to the gearbox.

- Gradually lower the hydraulic lift and rest the gearbox on the front crossmember.

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner

1. Undo the bolt fixing the auxiliary shaft drive belt idle pulley.

2. Undo the five bolts (2a) and remove the timing belt guard (2b).

1. Undo the bolts (1a) and remove the ignition coils (1b).

2. Undo the bolts (2a) and remove the tappet cover (2b) complete with gasket.

1. Undo the automatic tensioner nut, in order to loosen the timing belt tension.

2. Remove the timing drive belt from the pullies.

1. Undo the bolt fixing the guard behind the exhaust side timing pulley to the cylinder head.

2. Undo the bolts (2a) using the spanner (2b) and remove the cylinder head (2c).

- Remove the gasket underneath the cylinder head.

Refitting

- Position the cylinder head gasket on the cylinder block/crankcase.

The cylinder head gasket is the Astadur type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage. In order for the polymerization process to take place, it is necessary to:

- Position the cylinder head on the cylinder block/crankcase taking care to ensure that the camshafts are positioned with the front cams facing outwards (valves closed).

1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque, in stages, using the spanner (1b) and the spanner (1c) for angular tightening.

Follow the order shown in the figure for each tightening sequence.

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

2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque.

- Remove the spark plug for cylinder no. 1.

1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

- Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.

2. With cylinder no. 1 at T.D.C., check that the reference on the crankshaft drive gear is in line with the reference on the crankshaft front cover.

- Undo the bolts and remove the inlet side camshaft third cap and the exhaust side camshaft second cap.

Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting.

1. Fit the templates (1a) in place of the camshaft caps that have been removed and secure them using the bolts (1b).

Check that the camshaft cam profile and the templates are correctly aligned.

1. Fit the timing toothed drive belt in the following order: toothed drive pulley (1a), fixed tensioner (1b), exhaust side toothed driven pulley (1c), inlet side toothed driven pulley (1d), moving tensioner (1e), water pump pulley (1f).

The belt is fitted with the arrow facing the direction of rotation of the engine. There are also three reference on the belt that should coincide during the initial fitting with the references on the toothed drive pulley and the exhaust and inlet side toothed driven pullies.

1. Using a screwdriver, apply force to the tab (1a) for the automatic tensioner so that the tensioner is in the maximum tension position, then tighten the nut (1b) fixing the tensioner to the support.

1. Tighten the bolts (1a) for the inlet side toothed timing driven pulley using tool (1b) for counter-torque.

2. Tighten the bolt (2a) for the exhaust side toothed timing driven pulley using the tools (2b) and (2c) for counter-torque.

- Undo the fixing botls and remove the templates.

- Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

- Rotate the crankshaft throught two revolutions in the direction of rotation.

- Loosen the moving timing tensioner nut.

3. Using a screwdriver, rotate the moving timing tensioner until the moving tensioner reference (3a) coincoides with the fixed reference (3b).

4. Tighten the nut fixing the moving timing tensioner to the recommended torque.

- Remove the tool complete with dial gauge.

- Fit the spark plug for cylinder no. 1 and tighten it to the recommended torque.

- Position the timing drive belt cover and secure it using the fixing bolts.

- Tighten the bolt fixing the auxiliary shaft drive belt idle pulley.

- Position the tappet cover and secure it using the fixing bolts.

- Position the ignition coils cover and secure them using the fixing bolts.

See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner

See in Op. 1092G10 Engine components single drive BELT - R.R.

- Position a hydraulic lift under the gearbox bellhousing.

- Raise the gearbox placing in a position that allows the engine support to be connected to the gearbox

- Screw in and tighten the bolt fixing the engine support to the gearbox to the recommended torque.

- Connect the connecting rod to the reaction rod and secure it using the bolt.

- Fasten the thermostat and tightening the fixing bolts to the recommended torque.

- Connect the chamber return hose to the thermostat.

- Position the expansion tank and secure it using the nut.

- Connect the pipes and the electrical connection for the engine coolant level.

- Position the intake manifold complete with gasket and intake chamber.

- Position the intake manifold complete with gasket and intake chamber.

- Tighten the nuts and the bolt fixing the intake manifold to the cylinder head to the recommended torque.

- Positin the chamber mounting bracket on the vibration damper supports and secure it using the nuts.

- Raise the lift.

- Tighten the bolts fixing the bracket and fasten the earth lead.

- Lower the lift.

- Connect the pneumatic connections for the supercharging air by-pass valve, the brake servo and the evaporation control circuit (rapid connector).

- Position the air inlet hose on the throttle casing and secure it using the retaining band.

- Connect the fuel supply and return pipe to the fuel manifold.

- Secure the fuel pipes to the springs.

- Position the coolant return pipe on the retaining springs and tighten the fixing bolt.

- Position the coolant return pipe from the turbocharger, secure it using the bolt and connect the tank side and thermostat side pipes.

- Fit the new exhaust manifold gasket in the special housing on the cylinder head.

- Fit the turbocharger-exhaust manifold assembly.

- Tighten the nuts fixing the exhaust manifold to the cylinder head.

- Fit the reaction bracket for the turbocharger and tighten the fixing bolts.

- Connect the turbochrger air inlet hose.

- Connect the air oulet hose from the turbochager.

- Connect the coolant inlet and outlet pipes from the turbocharger.

- Connect the turbocharger fluid supply pipe connector.

- Connect the sump oil return pipe to the turbochager.

- Fit the protection for the turbocharger sump oil return pipe.

- Connect the turbocharger by-pass solenoid valve pneumatic connections.

- Connect the lower radiator pipe.

- Position the catalytic preconverter.

- Position the gasket and tighten the nuts fixing the catalytic preconverter to the centre section of the exhaust pipe.

- Fit the catalytic converter mounting bracket.

- Lower the lift.

- Fit the half-rings securing the catalytic preconverter to the turbine and tighten the bolts.

- Position the heat shield bulkhead.

- Tighten the bolt and the nuts fixing the heat shield bulkhead.

- Lower the lift.

- Position the radiator cooling fan and secure it using the bolts.

- Connect the engine fan motor electrical connection.

- Connect the electrical connections for the engine cables/radiator fan cables coupling.

- Connect the earth lead to the bodyshell.

- Connect the upper hose to the radiator.

- Connect the electrical connections for the ignition coils, the injectors, the injection control unit, the throttle casing actuator, the phase transformer solenoid, the coolant temperature sensor, the air temperature and pressure sensor, the air conditioning compressor engagement solenoid, the timing sensor, the front Lambda sensor and the rear Lambda sensor.

- Fasten the wiring to the retaining springs.

- Fit the coolant return pipe and tighten the fixing bolt on the compressor and the flange fixing bolt.

- Fit the upper crossmember and tighten the fixing bolts.

- Fit the bonnet lock on the crossmember complete with reinforcement bracket.

See in Op. 1080D24 engine oil vapour intake pipe - r + r

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 1084A16 Engine oil dip stick PIPE - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 5040A10 Air conditioning coolant circuit - Drying and Repressurizing

- Connect the negative battery terminal, then close the boot.

See in Op. 0010T20 Engine REFRIGERANT FLUID - Change

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

- Remove the vehicle from the lift.

2.4 JTD 20V

Removing

- Position the vehicle on a lift.

- Disconnect the negative battery terminal.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.

See in Op. 1048A56 UPPER RESONATOR - R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1064A24 TURBOCHARGER - EXHAUST MANIFOLD - HOSE CONNECTED TO EXHAUST PIPE - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 1092G21 Engine components single belt FIXED TENSIONER - R.R. with belt removed

See in Op. 1092A10 Crankshaft PULLEY - R.R.

See in Op. 1032D12 Timing system protective COVER(S) - R.R.

1. Loosen the nut retaining the timing belt moving tensioner.

2. Release and remove the toothed timing drive belt.

1. Disconnect the electrical connection for the timing sensor.

2. Undo the fixing bolt (2a) and remove the sensor (2b) from the housing in the camshaft housing.

1. Undo the connectors (1a) and (1b) and remove the pipes from the fuel manifold to the injectors (1c).

Use new pipes from the fuel manifold to the injectors when refitting.

1. Disconnect the electrical connections from the injectors.

2. Undo the fixing bolts (2a) and release the injection wiring (2b) moving it outside the work area.

3. Manually push the clips (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injector side, and move it sideways.

1. Undo the nuts fixing the injector brackets.

2. Remove the injectors (2a) complete with brackets using the tools (2b) and (2c).

Start the removal beginning with the injector for cylinder no. 1 and continue with the injectors for cylinders 2, 3, 4 and 5.

1. Undo the fixing bolts (1a) from the fuel return manifold (1b) and move it away from the intake manifold.

1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold. (1c).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

1. Disconnect the electrical connection from the fuel pressure sensor.

2. Undo the bolts (2a) and remove the single fuel manifold pipe (2b) complete with fuel pressure sensor (2c).

1. Disconnect the electrical wiring from the heater plugs.

2. Disconnect the flexible sections of the vacuum pipes frm the variable geometry solenoid valve (2a) and the vacuum reservoir solenoid valve (2b).

3. Undo the retaining bolts.

4. Remove the rigid section of the vacuum pipe.

1. Disconnect the vacuum pipe from the vacuum unit.

2. Disconnect the engine oil filler pipe from the separator.

1. Disconnect the E.G.R. electrical connection.

2. Disconnect the supercharging sensor.

3. Disconnect the compressor electro-magnet coupling.

4. Disconnect the electrical connection for the variable geometry solenoid valve.

5. Disconnect the coolant temperature sensor from the thermostat, release the electrical wiring from the bands and move it sideways outside the work area.

1. Disconnect the heater unit coolant supply pipe from the thermostat.

1. Remove the upper coolant supply pipe from the thermostat to the radiator.

1. Undo the upper bolts fixing the vacuum reservoir and engine oil separator mounting bracket to the cylinder head.

1. Undo the fixing bolts (1a), then remove the single camshaft housing (1b).

- Recover the underlying gasket.

1. Remove the hydraulic tappet assembly (1a) and rocker arms (1b).

1. Undo the bolts fixing the cylinder head to the engine block.

2. Remove the cylinder head.

- Keep the gasket underneath and the centering bushes.

Refitting

- Clean the contact areas between the engine block and the cylinder head thoroughly.

Cover the cylinder liners/bores and pistons to prevent the penetration of impurities or foreign bodies.

- Place the cylinder head centering bushes on the cylinder block.

- Fit a new cylinder head gasket taking care to ensure that it is the same size as the one removed.

Position the first cylinder at T.D.C.; rotate the crankshaft a further two teeth of the toothed timing drive pulley to lower the pistons thereby preventing any interference with the valves whilst fitting the cylinder head.

- Position the cylinder head on the cylinder block/crankcase.

1. Follow the order illustrated below for the tightening of the cylinder head.

1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b):

The figure of 2 daNm in the table below is a tightening value for all the bolts following the order illustrated in the diagram.

Follow the order shown in the previous figure for each tightening sequence.

- Fit the hydraulic tappet assemblies and rocker arms.

- Place a new gasket on the cylinder head.

1. Remove the plugs (1a) and fit the camshaft timing tools (1b) on the camshaft housing.

Check that the tools are correctly inserted in the housings in the camshafts.

- Remove the inlet side timing tool and tighten the plug.

1. Fit the camshaft housing assembly (1a) and secure it tightening the bolts (1b) to the recommended torque.

2. Loosen the exhaust side camshaft pulley fixing bolt.

1. Undo the bolt fixing the crankcase front cover shown in the diagram.

- Fit the timing drive belt on the drive gear, checking that the belt teeth are correctly inserted in the gear grooves.

2. Fit the tool (2a) and fasten it using the calibrated screw (2b).

The crankshaft must be rotated, using small movements, to allow the locating dowel to be fitted on the timing drive pulley.

1. Fully fit the toothed timing drive belt.

2. Use a screwdriver for leverage in the opening (2a) until the reference for the tensioner (2b) is aligned with the opening reference (2c) and, in this position, tighten the nut (2d) for the belt tensioner to the recommended torque.

3. Tighten the exhaust side camshaft pulley fixing bolt to the recommended torque.

- Remove the timing tools.

- Rotate the crankshaft through two revolutions.

- Check that the timing is correct by refitting the timing tools.

Fit the exhaust camshaft side template only because the inlet side one is not accessible.

- Check the alignment of the references for tensioning the timing moving tensioner.

- Tighten the bolt fixing the crankcase front cover removed previously.

- Tighten the plug in the camshaft housing for fitting the exhaust side timing tool.

- Tighten the upper bolts fixing the vacuum reservoir and engine oil separator mounting bracket to the cylinder head.

- Fit the upper coolant supply pipe from the thermostat to the radiator.

- Connect the heater supply pipe to the thermostat unit.

- Position the engine wiring and connect the electrical connections disconnected previously.

- Connect the engine oil filler pipe to the separator.

- Connect the vacuum pipe to the vacuum unit.

- Fit the rigid section of the vacuum pipe.

- Tighten the fixing bolts and connect the flexible sections of the vacuum pipes to the variable geometry solenoid valve and to the vacuum reservoir solenoid valve.

- Connect the electrical wiring to the heater plugs.

1. Fit the single fuel manifold pipe (1a) complete with fuel pressure sensor (1b) and secure it tightening the bolts (1c) to the recommended torque.

2. Connect the electrical connection to the fuel pressure sensor.

1. Fit a new pipe from the pressure pump to the single fuel manifold and secure it using the connectors without tightening them.

2. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

3. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a spanner.

- Tighten the bolts fixing the fuel return manifold to the recommended torque.

1. Fit the injectors (1a) in their seats complete with brackets and tighten the nuts (1b) to the recommended torque.

Start the refitting beginning with the injector for cylinder no. 5 and continue with the injectors for cylinders 4, 3, 2, and 1.

1. Fit the new pipes from the fuel manifold to the injectors and secure them without tightening the connectors.

2. Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an ordinary spanner.

3. Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an ordinary spanner.

Clean the threaded seats for the above mentioned pipe on the manifold and on the injectors using heptane.

- Connect the pipe from the injectors to the fuel recovery manifold pushing it until the clips can be heard clicking.

- Place the electrical wiring in position and tighten the cable duct fixing bolts.

- Connect the electrical connections for the injectors.

- Fit the timing sensor and tighten the retaining bolt.

- Connect the electrical connection to the timing sensor.

See in Op. 1032D12 Timing system protective COVER(S) - R.R.

See in Op. 1092A10 Crankshaft PULLEY - R.R.

See in Op. 1092G21 Engine components single belt FIXED TENSIONER - R.R. with belt removed

See in Op. 1092G10 Engine components single drive BELT - R.R.

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.

See in Op. 1064A24 TURBOCHARGER - EXHAUST MANIFOLD - HOSE CONNECTED TO EXHAUST PIPE - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A56 UPPER RESONATOR - R.R.

See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

- Fill the engine cooling system as described in the operation:

See in Op. 0010T20 Engine REFRIGERANT FLUID - Change

- Top up or, if necessary, change the engine oil referring to operation:

See in Op. 0010T10 ENGINE OIL - Change

- Or:

See in Op. 0010T11 ENGINE OIL - Check level and top up if necessary

- Remove the vehicle from the lift.