Engine - position on stand and remove

Operation 1004D40 · Remove engine and wash

1.2 8v

Dismantling

Support the engine in order to work on it in safety.

1. Use the automatic belt tensioner to slacken auxiliary drivebelt tension.

2. Remove the auxiliary drivebelt by prising off its drive pulleys.

1.2 16v

Dismantling

Support the engine in order to work on it in safety.

1. Use the automatic belt tensioner to slacken auxiliary drivebelt tension.

2. Remove the auxiliary drivebelt by prising off its drive pulleys.

1.4 16v

Dismantling

Support the engine in order to work on it in safety.

1. Use the automatic belt tensioner to slacken auxiliary drivebelt tension.

2. Remove the auxiliary drivebelt by prising off its drive pulleys.

1.3 JTD

SOLUTION A

1. Fit the two universal tool brackets.

1.2 8v

1. Disconnect the electrical connections (1a) from the air conditioner compressor and (1b) from the alternator.

2. Remove mount (2a) with alternator and air conditioner compressor by undoing nuts (2b) and bolts (2c).

3. Remove the engine mount, timing side.

1.2 16v

1. Disconnect the electrical connections (1a) from the air conditioner compressor and leads (1b) from the alternator.

2. Remove mount (2a) with alternator and air conditioner compressor by undoing nuts (2b) and bolts (2c).

3. Remove the engine mount, timing side.

1.4 16v

1. Disconnect the electrical connections (1a) from the air conditioner compressor and leads (1b) from the alternator.

2. Undo the nuts (2a) and the bolts (2b), then remove the mounting complete with air conditioning compressor (2c).

3. Remove the engine mount, timing side.

1.3 JTD

1. Undo the bolts (1a) and remove the timing side rigid engine support (1b) complete with engine lifting bracket (1c).

1.2 8v

1. Disconnect the electrical connections from the ignition coils.

2. Disconnect the HT leads from the spark plug sockets.

3. Remove the ignition coil.

1.2 16v

1. Disconnect the electrical connections for the ignition coil.

2. Disconnect the HT leads from the spark plug sockets.

3. Remove the ignition coil.

1.4 16v

1. Undo the fixing bolt (1a) and extract the timing sensor (1b).

2. Disconnect the electrical connections (2a) for the ignition coils, then undo the bolt (2b) fixing the coils to the cylinder head.

3. Remove the ignition coils.

1.3 JTD

1. Fit the two universal tool brackets.

1.2 8v

Secure and support the engine for hoisting using a hydraulic hoist fitted with suitable chains.

1. Position the engine bracket on the timing side.

1.2 16v

Secure and support the engine for hoisting using a hydraulic hoist fitted with suitable chains.

1. Position the engine bracket on the timing side.

1.4 16v

Secure and support the engine for hoisting using a hydraulic hoist fitted with suitable chains.

1. Position the engine bracket on the timing side.

1.3 JTD

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

Position the engine on the overhaul stand using the universal tool fitted previously.

1.2 8v

1. Position the engine bracket on the flywheel side.

Secure the engine to the overhaul stand using service bolts.

Release the engine from the hoist.

1.2 16v

1. Position the engine bracket on the flywheel side.

Secure the engine to the overhaul stand using service bolts.

Release the engine from the hoist.

1.4 16v

1. Position the engine bracket on the flywheel side.

Secure the engine to the overhaul stand using service bolts.

Release the engine from the hoist.

1.3 JTD

Release the engine from the hydraulic lift fastenings.

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

Undo the fastenings securing the universal tool to the overhaul stand, then position the engine on a suitable workbench using the hydraulic lift.

Undo the fastenings and remove the universal tool from the engine.

1. Place the timing side rigid engine support (1a), complete with engine lifting bracket (1b), in position and secure it tightening the bolts (1c) to the recommended torque.

1.2 8v

Reassembling

Secure and support the engine for hoisting using a hydraulic hoist fitted with suitable chains.

Undo the fixing bolts and remove the engine mounting brackets on the rotating stand.

Undo the fixings and remove the supporting tools from the engine, then place them down.

Fit the ignition coil

Fit the spark plug HT leads into their seats.

Connect the electrical connection to the ignition coil.

Fit the timing side engine mount

Fit the mount with alternator and air conditioner compressor.

Connect the alternator leads.

Connect the electrical connection to the air conditioner compressor

Fit the auxiliary drivebelt to the drive pulleys, then turn the automatic tensioner and fit the belt.

Remove the hooks and support devices positioned previously.

1.2 16v

Reassembling

Secure and support the engine for hoisting using a hydraulic hoist fitted with suitable chains.

Undo the fixing bolts and remove the engine mounting brackets on the rotating stand.

Undo the fixings and remove the supporting tools from the engine, then place them down.

Fit the ignition coil

Fit the spark plug HT leads into their seats.

Connect the electrical connection to the ignition coil.

Fit the timing side engine mount

Fit the mount with alternator and air conditioner compressor.

Connect the alternator leads.

Connect the electrical connection to the air conditioner compressor

Fit the auxiliary drivebelt to the drive pulleys, then turn the automatic tensioner and fit the belt.

Remove the hooks and support devices positioned previously.

1.4 16v

Reassembling

Secure and support the engine for hoisting using a hydraulic hoist fitted with suitable chains.

Undo the fixing bolts and remove the engine mounting brackets on the rotating stand.

Undo the fixings and remove the supporting tools from the engine, then place them down.

Fit the ignition coils in the seats in the cylinder head, then tighten the fixing bolts.

Fit the timing sensor on the cylinder head and tighten the fixing bolt.

Connect the electrical connections to the ignition coils.

Fit the timing side engine mount

Fit the mount with alternator and air conditioner compressor.

Connect the alternator leads.

Connect the electrical connection to the air conditioner compressor

Fit the auxiliary drivebelt to the drive pulleys, then turn the automatic tensioner and fit the belt.

Remove the hooks and support devices positioned previously.

1.3 JTD

SOLUTION B

1. Keep the flywheel lock in position. Refer to op. 1004D10 power unit (manual gearbox), removed, remove and re-build

1. Loosen the crankshaft pulley fixing bolts.

2. With the engine timed Refer to op. 1004D10 power unit (manual gearbox), removed, remove and re-build loosen the left hand bolt fixing the pulley mounting flange on the crankshaft.

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

2. Remove the flange.

The engine flywheel bolts are pretreated with sealant and must therefore be replaced whenever they are removed.

3. Remove the flywheel lock.

1. Fit the universal tool on the cylinder block/crankcase.

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

Position the engine on the overhaul stand using the universal tool fitted previously.

Release the engine from the hydraulic lift fastenings.

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

Undo the fastenings securing the universal tool to the overhaul stand, then position the engine on a suitable workbench using the hydraulic lift.

Undo the fastenings and remove the universal tool from the engine.

1. Fit the flywheel lock.

2. Place the engine flywheel (2a) complete with flange (2b) in position and secure it tightening the new bolts (2c) to the recommended torque.

1. With the timing template fitted on the exhaust side camshaft Refer to op. 1004D10 power unit (manual gearbox), removed, remove and re-build, tighten the left hand bolt fixing the pulley mounting flange to the crankshaft.

2. Tighten the bolts fixing the crankshaft pulley to the recommended torque.