1036L10 CAMSHAFTS IN CAMSHAFT HOUSING - R.R. - INCLUDES CAMSHAFT HOUSING REPLACEMENT IF NECESSARY - Alfa - 159 - eLearn

939010482 - 1036L10 CAMSHAFTS IN CAMSHAFT HOUSING - R.R. - INCLUDES CAMSHAFT HOUSING REPLACEMENT IF NECESSARY

) - Position the vehicle on a lift. Op. 1016A10 SOUND-PROOFING COVER - R.R Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1084A16 OIL DIPSTICK PIPE - R.R Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R. Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R. Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. 1. Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

- Draw off the power assisted steering fluid from the reservoir using a suitable syringe.1. Undo the power assisted steering pump fixing bolt.2. Undo the connector (2a) and disconnect the supply pipe from the pump to the power assisted steering box (2b), power steering pump side.

1. Disconnect the rapid connector for the fuel return pipe to the tank, fuel return manifold side.

1. Disconnect the vacuum intake pipes from the vacuum reservoir.2. Loosen the bands and disconnect the engine oil vapour recovery pipes, engine oil vapour separator side.

1. Undo the bolts (1a) and remove the oil vapour recovery pipe between the separator and the turbo (1b).

1. Disconnect the flexible pipe from the rigid vacuum intake pipe from the vacuum pump.2. Disconnect the flexible pipe from the rigid vacuum intake pipe for the turbocharger vane position actuator control solenoid.3. Undo the bolts (3a) and remove the vacuum pipes (3b).

1. Loosen the band and disconnect the engine oil vapour recovery pipe, engine oil filler side.2. Disconnect the rapid connector for the vacuum intake pipe from the vacuum pump.3. Undo the bolts (3a) and disconnect the air supply hose from the heat exchanger to the intake manifold (3b), throttle body side.

1. Undo the bolt (1a) and move the air supply hose from the heat exchanger to the intake manifold (1b) to the side.

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

	Description	Connector
1	Air flow meter	See K041 AIR FLOW METER

1. Disconnect the electrical connection from the cam angle sensor.

	Description	Connector
1	Timing sensor	See K047 TIMING SENSOR

2. Disconnect the electrical connection of the air conditioner compressor.

	Description	Connector
2	Air conditioning compressor engagement electro-magnet	See L020 AIR CONDITIONING COMPRESSOR ENGAGEMENT ELECTRO-MAGNET

3. Disconnect the electrical connections from the injectors.

	Description	Connector
3	Injector	See N070 INJECTOR

4. Disconnect the electrical connection from the fuel pressure regulator on the injector single manifold.

	Description	Connector
4	Fuel pressure regulator on rail	See N087 FUEL PRESSURE REGULATOR ON RAIL

5. Disconnect the electrical connection from the fuel pressure sensor.

	Description	Connector
5	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

6. Disconnect the electrical connections from the heater plugs.

	Description	Connector
6	Heater plugs	See A040 HEATER PLUGS

1. Loosen the bands, undo botls (1a) and remove the coolant return pipe to the engine coolant reservoir (1b).2. Unscrew the connectors (2a) and (2b) and remove the pipes from the fuel manifold to injectors (2c).3. Manually push the clips and disconnect the pipe from the injectors to the fuel recovery manifold, injector side.4. Disconnect the pipe from the injectors to the fuel recovery manifold, fuel recovery manifold side and remove it.5. Undo the connectors (5a), (5b) and remove the pipe from the pressure pump to the fuel manifold (5c).6. Loosen the bands and remove the fuel return pipe from the fuel manifold to the fuel return manifold.7. Undo the fixing bolts (7a) and remove the single fuel manifold pipe (7b).

1. Undo the injector bracket retaining nuts.2. Remove the injectors (2a) complete with brackets using the tools (2b).

If the injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted.If a new injector/new inectors are fitted:- determine the identification code stamped on the top surface;- check, using an Examiner, the the new injector(s) is (are) recognized by the engine management control unit.

Start the removal beginning with the injector for cylinder no. 1 and continue with the injectors for cylinders 2, 3, 4 and 5.

Tool	Description	Function	Validity
1870897300	Extractor	Removing injectors	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

1. Undo the bolts (1a) and remove the engine oil filler (1b).2. Remove the gasket.

1. Undo the bolts (1a) and remove the vacuum unit (1b).2. Remove the gasket.

1. Undo the bolts (1a) and remove the protective timing cover (1b).

Op. 4410D16 BRACKET (ONE) RETAINING CHASSIS TO BODY - R R Op. 1092G10 SINGLE ENGINE BELT - R.R Op. 1092A10 CRANKSHAFT PULLEY - R + R - Position a hydraulic jack beneath the engine.1. Undo the bolts (1a), (1b), then remove the power unit timing side front support flexible mounting (1c).

1. Undo the bolts (1a) and remove the power unit timing side rigid support (1b) complete with fixed tensioner (1c).

1. Loosen the bolt retaining the timing belt moving tensioner.2. Release and remove the toothed timing drive belt.

- Fit the timing side power unit rigid support temporarily in its housing and secure it using the bolts.- Fit the timing side power unit front support flexible mounting temporarily in its housing and secure it using the bolts.- Remove the hydraulic jack from beneath the engine.1. Undo the bolts (1a) and (1b) and remove the camshaft housing assembly (1c).2. Remove the gasket.

1. Position the camshaft housing (1a) in a vice using the tool (1b).

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

1. Undo the bolt (1a) and remove the cam angle sensor (1b).

1. Remove plug (1a) and fit camshaft timing tools (1b) to the cylinder head extension.

Check that the tools are correctly fitted in the housings in the camshafts.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

1. Undo the bolts fixing the camshaft gears.

1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).

- Remove the camshaft timing tools from the camshaft housing.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

1. Wtihdraw the camshafts (1a), as far as necessary and remove the camshaft gears (1b).

1. Using a suitable drift, extract the inlet side camshaft (1a) and plug (1b).2. Using a suitable drift, extract the exhaust side camshaft (2a) and oil seal (2b).- Remove the exhaust side camshaft oil seal.

Refitting ( Removing

) - Place the camshafts in their housings.- Place the camshaft caps in their housings and secure them without tightening the bolts.1. Fit the camshaft timing tools.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

1. Tighten the camshaft gear fixing bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft gears	Bolt	M12	(camshaft side) 2.9 - 3.2 + 40°	1.9 JTD 16V2.4 JTD 20V

1. Fit the exhaust side camshaft front oil seal (1a) using the tool (1b).

Tool	Description	Function	Validity
1870896800	Fitting tool	Fitting exhaust camshaft oil seal	1.9 JTD 16V2.4 JTD 20V

- Fit the inlet side camshaft plug.- Place the exhaust side camshaft toothed drive pulley in its housing and secure it without tightening the bolt.1. Position the cam angle sensor (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Cam angle sensor	Bolt	M6	(cylinder head extension side) 0.8 - 1.0	1.9 JTD 16V2.4 JTD 20V

- Remove the support tool complete with camshaft housing from the vice and separate them.- Remove the intake camshaft timing tool and tighten the plug.1. Position the cylinder head locating bushes on the cylinder head as shown in the figure.

The locating bushes between the cylinder head and cylinder head extension are shorter (16.0 mm) than the bushes between the crankcase and the cylinder head. Take great care not to reverse them as this could impair engine operation.

- Replace the upper cylinder head gasket.1. Position the camshaft housing assembly (1a) in its housing and secure it by tightening the bolt (1b) and the new bolts (1c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M12	(engine block side) 6.2 - 6.8 + 90° + 90° + 90°	1.9 JTD 16V

Component	Fastening	dia	Value (daNm)	Validity
Pressure pump mounting	Bolt (pretreated to be replaced)	M8	(cylinder head extension side) 2.3 - 2.8	1.9 JTD 16V

- Position a hydraulic jack beneath the engine.1. Undo the bolts (1a), (1b), then remove the power unit timing side front support flexible mounting (1c) fitted temporarily.

1. Undo the bolts (1a) and remove the power unit timing side rigid support (1b) complete with fixed tensioner (1c) fitted temporarily.

1. Remove the plug (1a) and refit the exhaust camshaft template (1b).

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

Only fit the exhaust side camshaft template because the intake side template seat is not accessible.

1. Loosen the bolt (1a) fixing the exhaust side camshaft toohted pulley using tools (1b) and (1c) for counter-torque.

Tool	Description	Function	Validity
1870815000	Counter-torque	Loosen/ tighten nut securing front driveshaft to wheel hubLoosen/ tighten bolt securing exhaust side camshaft drive toothed drive pulley

Tool	Description	Function	Validity
1870836000	Pins	Loosen/ tighten bolt securing exhaust side camshaft drive toothed drive pulley	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

1. Undo the bolt fixing the crankcase front cover shown in the diagram.- Temporarily fit the toothed timing drive belt on the toothed drive pulley.2. Fit the tool and fasten it using the calibrated screw.

The crankshaft must be rotated, using small movements, to allow the locating dowel on the timing drive pulley to be inserted in the opening in the tool.

Tool	Description	Function	Validity
2000003000	Template	Engine tuning	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

1. Fit the toothed timing belt completely taking care to ensure that the yellow references on it are aligned with the references on the toothed pullies.2. Use a screwdriver for leverage on the tensioner arm until the reference (2a) for the tensioner is in the maximum tension position and tighten the tensioner bolt (2b) to the recommended torque in this position.

Component	Fastening	dia	Value (daNm)	Validity
Timing moving tensioner	Nut	M8	2.3 ÷ 2.8	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

3. Tighten the bolt fixing the exhaust side camshaft toothed pulley to the recommended torque using the tool for counter-torque.

Component	Fastening	dia	Value (daNm)	Validity
Driven toothed pulley	Bolt	M12	(camshaft side) 2.9 - 3.2 + 40°	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Tool	Description	Function	Validity
1870815000	Counter-torque	Loosen/ tighten nut securing front driveshaft to wheel hubLoosen/ tighten bolt securing exhaust side camshaft drive toothed drive pulley

Tool	Description	Function	Validity
1870836000	Pins	Loosen/ tighten bolt securing exhaust side camshaft drive toothed drive pulley	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Remove the timing tools.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

Remove the exhaust camshaft side template because the intake side camshaft has not been fitted.

Tool	Description	Function	Validity
2000003000	Template	Engine tuning	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Rotate the crankshaft through two revolutions.1. Loosen the moving timing tensioner nut.2. Use a screwdriver for leverage on the tensioner arm until the reference (2a) for the tensioner is in line with the reference opening (2b) and tighten the tensioner bolt (2c) to the recommended torque in this position.

Component	Fastening	dia	Value (daNm)	Validity
Timing moving tensioner	Nut	M8	2.3 ÷ 2.8	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Recheck the timing by refitting the timing tools.

Only fit the exhaust side camshaft template because the intake side template seat is not accessible.

- Tighten the bolt fixing the crankcase front cover removed previously.- Tighten the plug on the cylinder head extension for fitting the exhaust side timing tool.1. Place the power unit timing side rigid support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support	Bolt	M10	(engine crankcase side) 4.5 - 5.5	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

1. Place the timing power unit front support flexible mounting (1a) in its housing and secure it tightening the new bolts (1b), bolts (1c) and the new bolts (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt (to be replaced)	M12	(bodyshell side) 6.3 - 7.7 + 90°

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt	M10	(bodyshell side) 5.4 - 6.6

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt (to be replaced)	M12	(rigid support side) 6.3 - 7.7 + 90°

- Remove the hydraulic jack under the engine crankcase sump.

- Remove the hydraulic jack from beneath the engine. Op. 1092A10 CRANKSHAFT PULLEY - R + R Op. 1092G10 SINGLE ENGINE BELT - R.R Op. 4410D16 BRACKET (ONE) RETAINING CHASSIS TO BODY - R R - Fit the timing belt covers and secure them using the bolts.1. Place the gasket back in its housing.2. Place the vacuum unit (2a) in its housing and secure it by tightening the new bolts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Vacuum unit	Bolt (pretreated to be replaced)	M6	(cylinder head extension side) 0.5 + 50°	1.9 JTD 16V2.4 JTD 20V

1. Place the gasket back in its housing.2. Place the engine oil filler (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil filler	Bolt	M6	(cylinder head extension side) 0.8 - 1.0	1.9 JTD 16V2.4 JTD 20V

1. Refit the injectors (1a) complete with brackets and tighten nuts (1b) to the specified torque.

Start the refitting beginning with the injector for cylinder no. 4 and continue with the injectors for cylinders 3, 2, and 1.

Component	Fastening	dia	Value (daNm)	Validity
Injector brackets	Nut	M8	(cylinder head extension side) 2.3 - 2.8	1.9 JTD 16V2.4 JTD 20V

1. Place the single fuel manifold pipe (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Single fuel manifold pipe (rail)	Bolt	M8	(cylinder head extension side) 2.3 - 2.8	1.9 JTD 16V2.4 JTD 20V

2. Place the fuel return pipe from the fuel manifold to the fuel return manifold in its housing and tighten the bands.3. Place the pipe from the pressure pump to the fuel manifold pipe (3a) back in its housing and secure it tightening the connectors (3b) and (3c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M12	(pressure pump side) 2.2 - 2.4	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

4. Fit the pipe from the injectors to the fuel recovery manifold and connect to the fuel recovery manifold.5. Connect the pipe from the injectors to the fuel recovery manifold to the injectors and push home until the clips click into place.6. Place the pipes from the fuel manifold to the injectors (6a) in their housings and secure them tightening the connectors (6b) and (6c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 16V2.4 JTD 20V

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M12	(injector side) 2.4 - 2.6	1.9 JTD 16V2.4 JTD 20V

7. Place the coolant return pipe to the engine coolant reservoir (7a) in position and secure it using the bolts (7b) and tighten the bands.

- Connect the electrical connections to the heater plugs.- Connect the electrical connection to the fuel pressure sensor.- Connect the electrical connection to the fuel pressure regulator on the injector single manifold.- Connect the electrical connections to the injectors.- Connect the air conditioning compressor electrical connection.- Connect the electrical connection to the cam angle sensor.- Connect the electrical connection to the air flow meter.- Place the air supply pipe from the heat exchanger to the intake manifold back in its housing and secure it using the bolt.- Connect the air supply hose from the heat exchanger to the intake manifold, throttle body side and secure it using the bolts.- Connect the rapid connector for the vacuum intake pipe from the vacuum pump.- Connect the engine oil vapour recovery pipe, engine oil filler side and tighten the band.- Place the vacuum pipes in their housings and secure them using the bolts.- Connect the flexible pipe to the rigid vacuum intake pipe for the turbocharger vane position actuator control solenoid.- Connect the flexible pipe to the rigid vacuum intake pipe from the vacuum pump.- Place the oil vaopur recovery pipe between the separator and the turbo in its housing and secure it using the bolts.- Connect the engine oil vapour recovery pipes, engine oil vapour separator side and tighten the bands.- Connect the vacuum intake pipes to the vacuum reservoir.- Connect the rapid connector for the fuel return pipe to the tank, fuel return manifold side.1. Connect the supply pipe from the pump to the power assisted steering box (1a), power assisted steering pump side and tighten the connector (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Supply pipe from pump to power assisted steering box	Connector	M16	(power assisted steering pump side) 3.6 - 4.4

2. Tighten the power assisted steering intake pipe bolt.

- Tighten the coolant drain plug to the radiator. Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R. Op. 1084A16 OIL DIPSTICK PIPE - R.R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 1016A10 SOUND-PROOFING COVER - R.R - Remove the vehicle from the lift.