1020B10 COVER OF TIMING SYSTEM WITH CHAIN DRIVE - R + R REPLACE OIL SEAL AND GASKET - Fiat - IDEA - eLearn

2400192 - 1020B10 cover of timing system with chain drive - r + r replace oil seal and gasket

) Position the vehicle on the rampMake sure that the ignition key is in the OFF position. then disconnect the battery negative (-) terminal.

	Name	Connector
-	Battery	A1B

Drain the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Loosen the band and disconnect the the turbocharger air inlet sleeve from the rigid pipe, air flow meter side.

1. Remove the air filter (1a) complete with air flow meter (1b) by releasing from the underlying pins and then from the rear fastenings.

1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, radiator side.

Collect the engine coolant in a suitable container.

1. Remove the plug (1a) and, in its place, fit the tool (1b) on the exhaust side camshaft.

Fit the tool positioning it with the references in a horizontal direction and checking that it is correctly inserted in the housing in the camshaft.

	Name	Country
1b	Template	1.871.000.900

2. Fit a suitable (8 mm diameter) pin via the special opening in the gearbox.

Check that the pin is correctly inserted in the housing in the engine flywheel.

1. Undo the bolt (1a) and disconnect the pipe from the expansion valve to the compressor (1b), compressor side.

Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system.

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir.2. Loosen the band and disconnect the supply pipe, reservoir side, from the engine coolant reservoir.3. Undo nut (3a), bolt (3b) and remove engine coolant reservoir (3c).

Proceed with removal - 4450B04 right front wheel r r Proceed with removal - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R. Proceed with removal - 1092G10 single engine belt r r Proceed with removal - 1092A10 Crankshaft services PULLEY - R.R.1. Loosen the lower bolts fixing the alternator to the mounting.

1. Undo the upper bolt fixing the alternator to the mounting.2. Undo the bolt (2a) and disconnect the connector (2b) for the engine oil vapour recovery pipe from the timing cover with the chain drive.3. Fit a suitable bracket for supporting the power unit and secure it using the upper alternator fixing bolt to the mounting.

Tighten the lower bolts fixing the alternator to the mounting.1. Fit the tool (1a), complete with support mountings (1b), then connect them to the bracket fitted previously using the rod (1c).

	Name	Country
1a	Crossmember	1.870.595.000

	Name	Country
1b	Support mountings	1.870.650.000

1. Undo the nut fixing the air conditioning system pipes mounting bracket.2. Undo the nuts (2a) and (2b), then remove the timing side power unit support flexible mounting (2c).

1. Undo the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.

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

1. Using tools (1a) and (1b) for counter-torque, undo the left hand bolt (1c) fixing the pulley support flange to the crankshaft.

	Name	Country
1a	Counter-torque	1.871.000.200

	Name	Country
1b	Support for counter-torque	1.860.831.000

2. Remove the pulley flange on the crankshaft.

1. Undo the bolt (1a) and remove the single drive belt tensioner (1b).

1. Undo the bolts (1a) and remove the water pump (1b) complete with gasket.

Proceed with removal Proceed with removal - 2110A60 manual gearbox/engine coupling bracket - r+r Proceed with removal - 1020A20 crank case oil sump - r + r clean seals for sealant application1. Release the electrical wiring (1a) from the bands (1b).2. Undo the upper bolts fixing the timing cover with the chain drive.3. Recover the brackets.

1. Undo the lower bolts (1a) and the nuts (1b) fixing the chain drive timing cover. 2. Remove the chain drive timing cover (2a), complete with engine oil suction unit (2b) and engine oil pump.3. Remove the chain drive timing cover gasket.

1. At the bench, undo the bolts (1a) and separate the engine oil intake (1b), complete with gasket (1c) from the chain drive timing cover.

1. Remove the crankshaft front oil seal from the chain drive timing cover.

Take care not to damage the oil seal seat during removal.

Refitting ( Removing

) 1. Place the chain drive timing cover in position with a new crankshaft front oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.878.000

Place the engine oil intake complete with gasket in its housing in the chain drive timing cover and secure it using the bolts.1. Place a new chain drive timing cover gasket in position.2. Fit the tool on the chain drive timing cover.

	Name	Country
2	Hose	1.879.900.600

3. Place the chain drive timing cover (3a), complete with engine oil suction unit (3b) and engine oil pump, in position, then secure it temporarily using the bolt (3c). 4. Tighten the chain drive timing cover fixing nuts and bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

	Fastening	Component	Ø	Value(daNm)
4	Nut	TIMING COVER	M6	0.8 ÷ 1.0

Undo the bolt and remove the tool from the chain drive timing cover.

	Name	Country
-	Hose	1.879.900.600

Fix the electrical wiring using the bands. Proceed with refitting - 1020A20 crank case oil sump - r + r clean seals for sealant application . Proceed with refitting - 2110A60 manual gearbox/engine coupling bracket - r+r . 1. Place the water pump (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	COOLANT PUMP	M6	(Upper engine crankcase side) 0.8 ÷ 1.0

1. Place the engine components single drive belt moving tensioner (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	SINGLE SERVICES MOBILE BELT TENSIONER	M10	(Upper engine crankcase side) 4.5 ÷ 5.5

1. Place the pulley support flange in position on the crankshaft (1a) and tighten the left hand bolt (1b) to the recommended torque using tools (1c) and (1d) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Left hand thread bolt	PULLEY SUPPORT FLANGE ON CRANKSHAFT	M14	(Crankshaft side) 21.9 ÷ 24.2

	Name	Country
1c	Counter-torque	1.871.000.200

	Name	Country
1d	Support for counter-torque	1.860.831.000

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.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Upper engine crankcase side) 5.7 ÷ 6.3

Tighten the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.1. Place the timing side power unit support flexible mounting (1a) in position and secure it tightening the nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT RUBBER MOUNTS	M10	(Rigid support side) 4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Nut	FRONT RUBBER MOUNTS	M10	(Bodyshell side) 4.1 ÷ 5.0

2. Tighten the nut securing the air conditioning system pipe bracket to the power unt flexible mounting block, timing side.

Remove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.870.595.000

	Name	Country
-	Support mountings	1.870.650.000

Undo the upper bolt, loosen the lower bolts fixing the alternator and remove the bracket used for supporting the power unit.Tighten the bolts fixing the alternator to the mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR ASSEMBLY	M8	(Support side) 2.3 ÷ 2.8

Connect the connector for the engine oil vapour recovery pipe to the chain drive timing cover and tighten the bolt.

Make sure that the O-Ring is correctly positioned.

Proceed with refitting - 1092A10 Crankshaft services PULLEY - R.R. . Proceed with refitting - 1092G10 single engine belt r r . Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with refitting - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with refitting - 4450B04 right front wheel r r . Refit the coolant reservoir in its seating and secure with the nut and bolt.Connect the engine coolant reservoir supply pipe and tighten the band.Connect the coolant return pipe to the engine coolant reservoir and tighten the band.1. Connect the pipe from the evaporator pipe connector to the compressor (1a), compressor side and fix it tightening the bolt (1b) to the recommended torque.

Replace the O-Ring seals for the connectors using green coloured seals only, resistant to R134A refrigerant fluid.Lubricate the thread of the connectors using anti-freeze. .

	Fastening	Component	Ø	Value(daNm)
1b	Nut	EXPANSION VALVE - COMPRESSOR PIPE	M6	(Compressor side) 0.7 ÷ 1.1

Remove the pin from the hole on the gearbox.Remove the tool for timing the exhaust side camshaft and tighten the plug.

	Name	Country
-	Template	1.871.000.900

Connect the lower coolant outlet hose from the radiator, radiator side, and tighten the band.Replace the air filter, complete with air flow meter, in its housing.Connect the air intake sleeve to the turbocharger, air flow meter side, and tighten the band.Connect the electrical connection to the air flow meter.Connect the negative (-) battery terminal. Refill the engine oil lubrication system - 0010T11 engine oil check level and top up . Refill the engine cooling system with coolant - 0010T20 coolant change . Fill the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with refitting . Remove the car from the ramps.