199002342 - 1020B10 COVER FOR TIMING SYSTEM WITH CHAIN DRIVE - R.R AND REPLACE GASKET

Removing ( Refitting )     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T12 ENGINE OIL AND FILTER - REPLACE     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R     Op. 4450B04 RIGHT FRONT WHEEL - R.R     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 1092G10 SINGLE ENGINE BELT - R.R     Op. 1092A10 CRANKSHAFT PULLEY - R + R 1. Remove plug (1a) and replace it with tool (1b) on the exhaust side camshaft.
Fit the tool positioning it with the millings horizontal and checking that it is correctly inserted in the housing in the camshaft.
ToolDescriptionFunctionValidity
1871000900TemplateEngine tuning1.3 Multijet
2. Fit a suitable (6 mm diameter) peg via the special opening in the gearbox.
Check that the peg is correctly inserted in the housing in the flywheel.
1. Loosen the lower bolts fixing the alternator to the mounting.
1. Loosen 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 chain drive timing cover.3. Fit a suitable bracket for supporting the power unit and fasten it using the upper bolt securing the alternator 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).
ToolDescriptionFunctionValidity
1870595000CrossmemberPower unit mount1.2 8v1.4 8v1.4 16v TJet1.3 Multijet
ToolDescriptionFunctionValidity
1870650000Support blocksPower unit mount1.2 8v1.4 8v1.4 16v TJet1.3 Multijet
    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE     Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R. 1. Using the tools (1a) and (1b) for counter-torque, unscrew the left-threaded bolt (1c) fixing the pulley mounting flange to the crankshaft.
ToolDescriptionFunctionValidity
1871000200Counter-torqueLock crankshaft1.3 Multijet
ToolDescriptionFunctionValidity
1860831000Support for counter-torqueLock crankshaft1.3 Multijet
2. Remove the pulley support flange on the crankshaft.
1. Undo the bolt (1a) and remove the engine components single belt moving tensioner (1b).
1. Undo the nuts (1a) and remove the coolant pump (1b) complete with gasket.
    Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R     Op. 1020A20 CRANKCASE OIL SUMP - R.R CLEAN SURFACES FOR SEALANT APPLICATION 1. Unscrew bolts (1a) and lower nuts (1b) securing the cover for the timing system.2. Remove the cover from the timing system (2a) complete with engine oil suction head (2b) and engine oil pump.3. Remove the timing cover gasket.
1. Working at the bench, unscrew bolts (1a) and separate the engine oil intake chamber (1b) with gasket (1c) from the timing system cover.
1. Remove the crankshaft front oil seal from the crankcase front cover.
Take care not to damage the oil seal seal during its removal.
Refitting ( Removing ) - Refit the timing cover and a new oil seal to the cover using the tool.
ToolDescriptionFunctionValidity
1860878000Fitting toolFitting crankshaft front oil seal1.3 Multijet
- Refit the engine oil intake chamber with gasket in its seat on the timing system cover and secure with bolts.- Refit a new timing system cover gasket back in its seat.- Fit the tool to the timing cover.
ToolDescriptionFunctionValidity
1870900600HoseTiming cover centering1.3 Multijet
- Refit the timing cover complete with engine oil suction device and engine oil pump in its seat and secure temporarily.- Tighten bolts and nuts securing the timing cover to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Crankshaft oil seal front coverBoltM60.8 ÷ 1.01.2 8v1.4 8v1.4 16v1.3 Multijet
ComponentFasteningdia  Value (daNm)Validity
Crankshaft oil seal front coverNutM60.8 ÷ 1.01.3 Multijet
- Unscrew the bolt and remove the tool fitted previously to the timing cover.- Secure the electrical wiring to the collars.    Op. 1020A20 CRANKCASE OIL SUMP - R.R CLEAN SURFACES FOR SEALANT APPLICATION     Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R - Place the water pump, complete with gasket in position, then tighten the nuts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Water pumpNutM60.8 ÷ 1.01.3 Multijet
- Position the engine components single belt moving tensioner in its housing and secure it tightening the bolt to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Auxiliary drive belt moving tensionerBoltM104.5 ÷ 5.51.3 Multijet
- Refit the pulley mounting flange to the crankshaft and tighten the left-threaded bolt to the specified torque using the tools as countertorque.
ComponentFasteningdia  Value (daNm)Validity
Pulley support flange on crankshaftLeft hand boltM144.7 ÷ 5.2 + 75° +/- 3°1.3 Multijet
ToolDescriptionFunctionValidity
1871000200Counter-torqueLock crankshaft1.3 Multijet
ToolDescriptionFunctionValidity
1860831000Support for counter-torqueLock crankshaft1.3 Multijet
    Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.     Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Remove the tools used for supporting the engine.- Connect the coupling of the oil vapour recovery pipe to the timing cover.
Ensure the o-ring is present and correctly positioned.
- Remove the peg from the opening in the gearbox.- Remove the exhaust camshaft timing tool and tighten the plug.    Op. 1092A10 CRANKSHAFT PULLEY - R + R     Op. 1092G10 SINGLE ENGINE BELT - R.R     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 4450B04 RIGHT FRONT WHEEL - R.R     Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 0010T12 ENGINE OIL AND FILTER - REPLACE     Op. 0010T20 ENGINE COOLANT - CHANGE