3024850 - 1072B10 inlet manifold - r + r and replace seal

Removing ( Refitting ) Position the vehicle on the rampProceed with removal  - 1016A10  sound-proofing cover - r + r . Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Name	Connector
-	Battery	A1B

Proceed with removal  - 1008C10  power unit upper reaction link r r . Proceed with removal  - 1060G80  ds electric injection control unit - r r . Proceed with removal  - 4450B04  right front wheel r r . Proceed with removal  - 7055B54  under-engine guard - 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. . Proceed with removal  - 1092G20  engine component single belt fixed tensioner - one - r + r . Proceed with removal  - 1032D12  timing system protective cover(s) - r + r . Proceed with removal  - 1032B10  toothed timing belt - r + r for timing adjustment or replacement . Proceed with removal  - 5530B10  battery - r+r . 1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Engine temperature sender unit	K36

1. Disconnect the electrical connections from the heater plugs.

	Name	Connector
1	Heater plug	A40

1. Disconnect the electrical connection from the turbocharger vane actuator solenoid.

	Name	Connector
1	Variable geometry turbine solenoid valve	L36

1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

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

	Name	Connector
1	EGR solenoid	L30

2. Disconnect the electrical connection from the excess pressure sensor.

	Name	Connector
2	Turbocharging sensor	K82

Release the wiring from the bands near the thermostat. 1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side. 2. Loosen the band and disconnect the coolant outlet pipe from the cylinder head, engine coolant return pipe to the coolant reservoir side. 3. Loosen the band and disconnect the flexible coolant return pipe from the rigid coolant return pipe to the engine coolant reservoir. 4. Undo the bolts (4a) and remove hose (4b) carrying coolant to the coolant supply reservoir. 1. Loosen the band and disconnect the air intake hose from the connector on the throttle casing. 1. Undo the bolts (1a) and remove the connector on the throttle body (1b) complete with gasket (1c). 1. Disconnect the vacuum pipe from the pneumatic valve on the throttle body.2. Undo the bolts (2a) and remove the electropneumatically controlled throttle body (2b) complete with gasket (2c). Disconnect the vacuum pipe from the three-way connector on the brake servo vacuum intake pipe.Disconnect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve.1. Undo the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side. 1. Undo the nuts (1a) and move the oil vapour recovery pipe mounting bracket (1b) aside.2. Undo the bolts (2a) and remove the E.G.R. system solenoid valve (2b).3. Remove the gasket. 1. Disconnect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side. 2. Disconnect the rapid attachment for the fuel return pipe to the tank, return manifold pipe side. 3. Loosen the band and disconnect the fuel return pipe from the pressure pump, fuel return manifold pipe side. 1. Undo the bolts (1a) and remove the fuel return manifold pipe (1b) complete with the pipe from the injectors to the fuel recovery manifold (1c). 1. Undo the bolt fixing the guide pipe for the engine oil dipstick to the pressure pump mounting. 2. Disconnect the electrical connection from the fuel pressure regulator.

	Name	Connector
2	Fuel pressure regulator	N77

Release the electrical wiring from the band and move it to the side. 1. Loosen the band and disconnect the condensation oil recovery pipe from the crankcase sump. 1. Loosen the band and disconnect the oil vapour recovery pipe from the separator.2. Loosen the band and disconnect the oil vapour recirculation pipe from separator. Disconnect the electrical connection from the solenoid on the vacuum tank.

	Name	Connector
-	Butterfly casing solenoid valve	L62

1. Undo the bolts (1a) and remove the mounting bracket (1b) complete with oil vapour separator (1c) and vacuum reservoir (1d). 1. Stop the pressure pump pulley from rotating using two bolts. 2. Undo the pressure pump pulley nut.Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley. 1. Remove the pressure pump pulley (1a) using the tool (1b).

	Name	Country
1b	Extractor	1.860.854.001

1. Undo nuts (1a) and remove pressure pump (1b) from its mount. 1. Disconnect the electrical connection from the engine oil pressure warning light switch.

	Name	Connector
1	Engine oil pressure sensor	K30

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

	Name	Connector
2	Engine oil level sensor	K32

3. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
3	RPM sensor	K46

1. Disconnect the earth lead from the alternator.

	Name	Connector
1	Alternator	A10

2. Disconnect the earth lead from the starter motor.

	Name	Connector
2	Starter' motor	A20

1. Disconnect the electrical connection from the pre-heating control unit.

	Name	Connector
1	Plug preheating control unit	M15

1. Undo the bolts (1a) and remove the power steering pump drive pulley (1b). 1. Undo the bolts securing the power steering pump to its mounting. Remove the guide tube complete with engine oil dipstick. 1. Undo the bolts (1a) and remove the pressure pump mounting (1b). 1. Undo the nuts (1a) and remove the air chamber assembly (1b) complete with gasket (1c). Refitting ( Removing ) 1. Refit air chamber (1a) complete with gasket (1b) and secure it by tightening nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Nut	INLET MANIFOLD	M8	(Cylinder head side) 2.3 ÷ 2.8

1. Place the pressure pump support (1a) back in its housing and secure it tightening the bolts (1b).

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INJECTION PRESSURE PUMP MOUNT	M8	(Engine crankcase side) 2.3 ÷ 2.8

Refit the guide tube and engine oil dipstick.1. Place the power assisted steering pump back in its housing and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER STEERING PUMP	M8	(Support side) 2.3 ÷ 2.8

1. Place the power assisted steering pump pulley (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER STEERING PUMP DRIVE PULLEY	M8	(Power assisted steering pump side) 2.3 ÷ 2.8

Connect the electrical connection to the pre-heating control unit.Connect the earth lead to the starter motor.Connect the earth lead to the alternator.Connect the electrical connection for the rpm sensor.Connect the electrical connection for the engine oil level sensor. Connect the electrical connection to the engine oil pressure warning light switch.1. Fit the clutch pump (1a) back in its housing and tighten the nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	PRESSURE PUMP	M8	(Support side) 2.3 ÷ 2.8

1. Replace the pressure pump pulley in its housing.2. Stop the pressure pump pulley from rotating using two bolts. 3. Tighten the pressure pump pulley nut to torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	PRESSURE PUMP CONTROL PULLEY	M14	4.5 ÷ 5.5

Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley. Place the mounting bracket complete with oil vapour separator and vacuum reservoir back in its housing and secure it using the bolts.Connect the electrical connection to the solenoid on the vacuum tank.Connect the oil vapour recirculation pipe to the separator and tighten the band.Connect the oil vapour recovery pipe to the separator and tighten the band.Connect the condensation oil recovery pipe to the crankcase sump and tighten the band. Place the electrical wiring back in its housing and fix it to the band.Connect the electrical connection to the fuel pressure regulator. Tighten the bolt fixing the engine oil dipstick guide pipe to the pressure pump mounting.Place the fuel return manifold pipe complete with the pipe from the injectors to the fuel recovery manifold back in its housing and secure it using the bolts.Connect the fuel return pipe to the pressure pump, fuel return manifold pipe side and tighten the band.Connect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side.Connect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side. 1. Place the E.G.R. system solenoid valve (1a) complete with gasket (1b) back in its housing and fasten it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

2. Place the oil vapour recovery pipe mounting bracket (2a) back in its housing and secure it using the nuts (2b). 1. Tighten the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	WATER/GAS HEAT EXCHANGER FOR EGR SYSTEM	M8	(E.G.R.) solenoid valve side 2.3 ÷ 2.8

Connect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve. Connect the vacuum pipe to the three-way connector on the brake servo vacuum intake pipe.1. Replace the pneumatically-controlled throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

2. Connect the vacuum pipe to the pneumatic valve on the throttle body. 1. Replace the connector on the throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

Connect the air inlet hose to the connector on the throttle casing and tighten the band. Place the coolant return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts. Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band. Connect the coolant oulet pipe from the cylinder head, engine coolant return pipe to the supply reservoir side and tighten the band. Connect the engine coolant return pipe to the supply reservoir, thermostat side and tighten the band. Fasten the electrical wiring to the bands near the thermostat. Connect the electrical connection to the excess pressure sensor. Connect the electrical connection to the EGR solenoid.Connect the electrical connection to the air flow meter.Connect the electrical connection to the turbocharger vane actuator solenoid. Connect the electrical connections to the heater plugs. Connect the electrical connection to the engine coolant temperature sensor. Proceed with refitting  - 5530B10  battery - r+r .Proceed with refitting  - 1032B10  toothed timing belt - r + r for timing adjustment or replacement .Proceed with refitting  - 1032D12  timing system protective cover(s) - r + r .Proceed with refitting  - 1092G20  engine component single belt fixed tensioner - one - r + r .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  - 7055B54  under-engine guard - r r .Proceed with refitting  - 4450B04  right front wheel r r .Proceed with refitting  - 1060G80  ds electric injection control unit - r r .Proceed with refitting  - 1008C10  power unit upper reaction link r r .Connect the negative (-) battery terminalProceed with refitting  - 1016A10  sound-proofing cover - r + r .Remove the car from the ramps.