FIAT / DUCATO 244eLearn workshop manual · English · Offline edition
Procedures

1004D40 ENGINE - POSITION ON STAND AND REMOVE

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
Engines: 2.0 16V
- Secure and support the engine using a hydraulic lift fitted with chains.1. Fit the tool on the timing side engine mounting bracket.
Manual illustration 244000499DescriptionCodeFunction
1Brackets1.861.001.032Engine overhaul stand support
Manual illustration 244000734
Engines: 2.0 16V
1. Fit the tool (1a) using suitable length bolts (1b) and (1c) in the flywheel side crankcase openings.
Manual illustration 244000499DescriptionCodeFunction
1aBrackets1.861.001.034Engine overhaul stand support
Manual illustration 244000735
Engines: 2.0 16V
1. Fit the engine, complete with brackets, on the overhaul stand.
Manual illustration 244000736
Engines: 2.0 16V
- Release the engine from the hoist.- Secure and support the engine using a hydraulic lift fitted with chains.- Undo the fastenings and remove the engine complete with supporting tools.- Undo the fastenings and remove the engine supporting tools, then replace them.
Manual illustration 244000499DescriptionCodeFunction
.Brackets1.861.001.032Engine overhaul stand support
Manual illustration 244000499DescriptionCodeFunction
.Brackets1.861.001.034Engine overhaul stand support
Engines: 2.3 JTD 16V
- Secure and support the engine using a hydraulic hoist fitted with chains.1. Undo the bolt and release the retaining collar.2. Undo nut (2a) and remove the cold air intake pipe (2b) to the turbocharger.
Manual illustration 244000737
Engines: 2.3 JTD 16V
1. Undo bolts (1a), nuts (1b) and remove the EGR valve (1c) with gaskets (1d).
Manual illustration 244000738
Engines: 2.3 JTD 16V
1. Unscrew the fittings and disconnect the oil input pipe to the turbocharger (1a) and the oil return pipe to the sump (1b).2. Undo the nuts (2a) and remove the exhaust manifold complete with turbo unit (2b).3. Remove the seal.
Manual illustration 244000739
Engines: 2.3 JTD 16V
1. Undo bolts (1a) and remove the intermediate shaft mount (1b).
Manual illustration 244000740
Engines: 2.3 JTD 16V
1. Undo bolts (1a) and remove the rear bracket joining the gearbox to the engine (1b).
Manual illustration 244000741
Engines: 2.3 JTD 16V
1. Loosen tensioner bolt (1a) and remove compressor drive belt (1b).2. Use a wrench to adjust automatic tensioner (2a) and remove alternator and power steering pump drive belt (2b).
Manual illustration 244000742
Engines: 2.3 JTD 16V
1. Undo the upper bolt.2. Undo the bolts (2a) and remove the alternator (2b).
Manual illustration 244000743
Engines: 2.3 JTD 16V
1. Undo the bolts (1a) and remove the power steering pump (1b) complete with mount and pulleys.
Manual illustration 244000744
Engines: 2.3 JTD 16V
1. Undo bolts (1a) and remove the front bracket joining the gearbox to the engine (1b).
Manual illustration 244000745
Engines: 2.3 JTD 16V
1. Undo the bolts (1a) and remove the air conditioner compressor (1b).2. Undo bolts (2a) and remove the air conditioner compressor mount (1b).
Manual illustration 244000746
Engines: 2.3 JTD 16V
1. Fit the tool for supporting the engine, exhaust side.
Manual illustration 244000499DescriptionCodeFunction
1Brackets1.870.852.000Engine overhaul stand support
Manual illustration 244000747
Engines: 2.3 JTD 16V
1. Prise off the fuel pipe anchorage bracket and fit the tool for supporting the engine on the intake side.
Manual illustration 244000499DescriptionCodeFunction
1Brackets1.870.852.000Engine overhaul stand support
Manual illustration 244000748
Engines: 2.3 JTD 16V
- Fit the engine on the overhaul stand.- Release the engine from the hoist.- Drain the engine oil from the plug on the oil sump.- Secure and support the engine using a hydraulic hoist fitted with chains.- Undo the fastenings and remove the engine from the overhaul stand complete with supporting tools.- Undo the retaining bolts and remove the engine support tools.
Manual illustration 244000499DescriptionCodeFunction
.Brackets1.870.852.000Engine overhaul stand support
- Fit the air conditioner compressor mount and tighten the retaining bolts to the specified torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.2.5BoltCOMPRESSOR MOUNT (AC)M8 X 1.25
- Fit the air conditioner compressor and tighten the retaining bolts to the specified torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.2.5BoltAIR CONDITIONER ASSEMBLY COMPRESSORM8 X 1.25
- Fit the front bracket joining the gearbox to the engine and tighten the retaining bolts.- Fit the power assisted steering pump complete with support and pulleys and tighten the bolts to torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.2.5BoltPOWER STEERING PUMPM8 X 1.5
- Fit the alternator and tighten the retaining bolt and screws to torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(upper fastening) 4.9BoltALTERNATOR ASSEMBLYM10 X 1.5
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(lower fastening) 4.9BoltALTERNATOR ASSEMBLYM10 X 1.5
1. Fit the power steering pump and alternator drivebelt (1b) by using a wrench to adjust automatic belt tensioner (1a).2. Fit the air conditioner compressor belt (2a) and adjust tensioner by means of tensioner (2b).
Manual illustration 244000749
Engines: 2.3 JTD 16V
- Fit the rear bracket joining the gearbox to the engine and tighten the retaining bolts.- Fit the intermediate shaft mount and tighten the retaining bolts to the specified torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.5BoltFRONT DRIVE SHAFT BEARING MOUNTM10 X 1.25
- Position a new gasket, fit the exhaust manifold complete with turbocharger and tighten the retaining bolts to the specified torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.2.2BoltEXHAUST MANIFOLD/SM8 X 1.25
- Tighten the connectors for the oil inlet pipe to the turbocharger and oil return pipe to the sump to the specfied torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(Cylinder head) 0.9ConnectorCOOLANT HOSES TURBOCHARGER1/4" X 1.3
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(Cylinder block/crankcase) 1.7ConnectorCOOLANT HOSES TURBOCHARGER3/8" X 1.3
- Fit new gaskets, fit the EGR valve and tighten the retaning bolts and nuts- Position the cold air intake pipe to the turbocharger complete with collar and tighten the retaining collar nut and bolt.- Release the engine from the hoist.
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Secure and support the engine using a hydraulic hoist fitted with chains.1. Loosen the fixing bolts.2. Remove the compressor drive belt.
Manual illustration 244000750
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Loosen the fixing bolts.2. Remove the alternator drive belt.
Manual illustration 244000751
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the nuts (1a) and remove the intake pipe (1b).2. Undo the nuts (2a) and remove the bracket (2b).
Manual illustration 244000752
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the nuts fixing the exhaust manifold bracket to the cylinder block/crankcase.2. Undo the engine oil pressure sender unit and release the fluid inlet pipe from the turbocharger.3. Loosen the retaining bands and disconnect the sump fluid return pipe from the turbocharger.4. Undo the nuts (4a) and remove the exhaust manifold (4b) complete with turbo unit.- Remove the gasket.
Manual illustration 244000753
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the fixing bolts (1a), undo the fixing nuts (1a) and loosen the band (1c).2. Remove the thermostat-water pump pipe.3. Remove the crankcase plug.4. Undo the turbocharger fluid return connector from the crankcase.
Manual illustration 244000754
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the lower alternator fixing bolt (1a) and undo the upper nut (1b).2. Remove the alternator complete with belt tension adjustment device.
Manual illustration 244000755
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the (four) bolts fixing the compressor support.2. Remove the support complete with compressor and remove the fluid distick assembly.
Manual illustration 244000756
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Loosen the band (1a) and disconnect the oil vapour recovery pipe from the cylinder head (1b).2. Loosen the band (2a) and disconnect the condensation oil recovery pipe (2b) from the crankcase.3. Undo the oil vapour separator fixing bolts.4. Remove the engine oil vapour separator complete with pipes.5. Undo the bolt fixing the coolant pipes to the heat exchanger.6. Fold the coolant pipes to the heat exchanger downwards.
Manual illustration 244000757
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Fit the tool for supporting the engine, pressure pump side.
Manual illustration 244000499DescriptionCodeFunction
1Brackets1.861.001.033Engine overhaul stand support
Manual illustration 244000758
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Fit the tool for supporting the engine, manifold side.
Manual illustration 244000499DescriptionCodeFunction
1Bracket1.861.001.251Engine overhaul stand support
Manual illustration 244000759
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Fit the engine on the overhaul stand.- Release the engine from the hoist.- Secure and support the engine using a hydraulic hoist fitted with chains.- Undo the fastenings and remove the engine complete with supporting tools.- Undo the fastenings and remove the engine supporting tools, then replace them.- Position the heat exchanger coolant pipes and fasten them tightening the bolt.- Fit the oil vapour separator and secure it using the bolts.- Connect the oil vapour recovery pipe to the cylinder head and fasten it using the band.- Connect the condensation oil vapour recovery pipe to the crankcase and fasten it using the band.- Fit the support complete with compressor and secure it without tightening the bolts to torque.- Loosen the two bolts fixing the auxiliary unit, then tighten all the bolts to torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(engine crankcase side) 2.5Boltauxiliary unitM8
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(engine crankcase side) 6.0Boltauxiliary unitM12
- Fit the alternator complete with belt tension adjustment device and secure it without tightening the bolts.- Fit the thermostat-pump pipe and fasten it using the bolts, nuts and band.- Fit the intermediate propeller shaft support.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(cylinder block/crankcase side) 2.1NutPROPELLER SHAFT INTERMEDIATE SUPPORTM8
- Tighten the turbocharger fluid return connector to the crankcase.- Fit the exhaust manifold gasket.- Fit the exhaust manifold, complete with turbocharager and secure it tightening the nuts to the recommended torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
.(Cylinder head side) 2.1 -2.6NutEXHAUST MANIFOLD/SM8
- Connect the oil inlet pipe to the turbocharger and tighten the oil pressure sender unit.- Connect the sump oil return pipe to the turbocharger and secure it using the band.- Tighten the nuts fixing the exhaust manifold bracket to the cylinder block/crankcase.- Fit the inlet pipe and secure it using the bracket.- Fit the alternator drive belt.- Fit the compressor drive belt.
Engines: 2.0 JTD 8V
- Secure and support the engine using a hydraulic hoist fitted with chains.1. Loosen bolt (1a), then use a ¼" box wrench to adjust tensioner (1b) until a 4 mm diameter pin (1c) can be fitted into the reference hole.
Manual illustration 244000760
Engines: 2.0 JTD 8V
1. Leave tensioner (1b) and provisionally tighten bolt (1a), then remove accessory drivebelt (1c).
Manual illustration 244000761
Engines: 2.0 JTD 8V
1. Undo bolts (1a) and remove alternator (1b).
Manual illustration 244000762
Engines: 2.0 JTD 8V
1. Fit the tool into the holes on the injection side engine block.
Manual illustration 244000499DescriptionCodeFunction
1Brackets1.861.001.040Engine overhaul stand support
Manual illustration 244000763
Engines: 2.0 JTD 8V
1. Fit plate (1a) into the holes on the exhaust side engine block, then fit tool (1b) to the plate.
Manual illustration 244000499DescriptionCodeFunction
1bBrackets1.861.001.040Engine overhaul stand support
Manual illustration 244000764
Engines: 2.0 JTD 8V
- Fit the engine on the overhaul stand.- Release the engine from the hoist.- Secure and support the engine using a hydraulic hoist fitted with chains.- Undo the fastenings and remove the engine complete with supporting tools.- Undo the fastenings and remove the engine supporting tools, then replace them.
Manual illustration 244000499DescriptionCodeFunction
.Brackets1.861.001.040Engine overhaul stand support
1. Fit alternator (1a) and tigten bolts (1b).
Manual illustration 244000765
Engines: 2.0 JTD 8V
1. Version without air conditioner: fit the accessory drivebelt in the following order: (1a) crankshaft pulley, (1b) tensioner with wear gauge, (1c) power steering pump, (1d) tensioner with tension regulator, (1e) alternator, (1f) idler gear.
Manual illustration 244000766
Engines: 2.0 JTD 8V
1. Version with air conditioning: fit the accessory drivebelt in the following order: (1a) crankshaft pulley, (1b) tensioner with wear gauge, (1c) power steering pump, (1d) tensioner with tension regulator, (1e) alternator, (1f) air conditioner compressor.
Manual illustration 244000767
Engines: 2.0 JTD 8V
1. Fit accessory drivebelt (1a), loosen bolt (1b), then use a ¼" box wrench to adjust tensioner (1c) until a 4 mm diameter pin (1d) can be fitted into the reference hole
Manual illustration 244000768
Engines: 2.0 JTD 8V
1. Leave tensioner (1a) and tighten bolt (1b) to the specified torque.
Manual illustration 244000559Value - daNmFasteningComponentØ  
1b4,30BoltVARIOUS S D BELT CAM TENSIONER-
- Remove the 4 mm diameter pin.
Manual illustration 244000769