199000403 - 1004D40 ENGINE - POSITION ON STAND AND REMOVE

Rest the engine on the stand1. Fit the flywheel lock.
ToolDescriptionFunctionValidity
1860846000Counter-torqueFlywheel lock
2. Undo the bolts (2a) and remove the engine flywheel (2b).
- Remove the flywheel lock.1. Undo the bolt (1a) and remove the two engine flywheel guards (1b).
1. Loosen the bands and remove the heater water supply and return pipes.2. Loosen the band and remove the air hose from the throttle body.3. Loosen the band and remove the radiator water supply pipe.4. Disconnect the degassing pipe quick coupling, thermostat side.
1. Undo the connector (1a) and the nut (1b) and remove the turbocharger water supply pipe (1c).
1. Loosen the band, undo the bolt and remove the air outlet pipes from the turbocharger.2. Loosen the band and remove the water outlet hose from the radiator.3. Disonnect the electrical connection for the waste gate valve.
DescriptionConnector
3Waste gate solenoid valve    See L037 WASTE GATE SOLENOID VALVE
4. Loosen the bands and remove the waste gate solenoid valve complete with pipes.
1. Disconnect the electrical connection for the upper Lambda sensor.
DescriptionConnector
1Lambda sensor on pre-catalyzer    See K015 LAMBDA SENSOR ON PRE-CATALYZER
2. Undo the fastenings and remove the turbocharger heat shield.
1. Undo the fastenings and remove the catalytic converter heat shield.
1. Undo the bolts fixing the catalytic converter to the bracket on the crankcase.2. Undo the nuts (2a) and remove the catalytic converter (2b) complete with Lambda sensor.
1. Fit the support to the engine block and place the engine on the overhaul stand using the hydraulic lift.
ToolDescriptionFunctionValidity
1871000000Overhaul standEngine overhaul
Removal of engine from the stand- Support the engine using the tools and a hydraulic lift.- Undo the fastenings securing the engine block to the overhaul stand support.- Place the engine on a suitable board.- Place the catalytic converter complete with Lambda sensor back in its housing and tighten the nuts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Catalytic converter to turbochargerNutM82.3 ÷ 2.81.4 16v TJet
- Tighten the bolts fixing the catalytic converter to the bracket on the crankcase.- Place the catalytic converter heat shield back in its housing and tighten it it using the fastenings.- Place the turbocharger heat shield back in its housing and tighten it it using the fastenings.- Connect the electrical connection for the upper Lambda sensor.- Connect the electrical connection for the waste gate valve.- Connect the vacuum pipes for the waste gate valve, actuator side and turbine side and tighten the bands.- Place the radiator water outlet hose in its housing, water pump rigid return pipe side and tighten the band.- Place the turbocharger air outlet pipes back in their housings and tighten the bands.- Fit the turbocharger water supply pipe in place and tighten the nut and the connector to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Turbocharger water supply pipeConnectorM163.0 ÷ 3.61.4 16v TJet
- Connect the degassing pipe quick coupling, thermostat side.- Place the radiator water supply pipe back in its housing and tighten the band, thermostat side.- Place the throttle body air hose back in its housing and tighten the band.- Place the heater water supply and return pipes back in their housings and tighten the bands.- Place the two engine flywheel guards in position and tighten the bolt securing them to the engine oil sump.- Place the flywheel in its housing, fit the flywheel lock and tighten the new bolts to the recommended torque.
ToolDescriptionFunctionValidity
1860846000Counter-torqueFlywheel lock
ComponentFasteningdia  Value (daNm)Validity
Engine flywheelBolt (to be replaced)M91.9 ÷ 2.1 + 50° +/- 2°1.4 16v TJet