Procedures

1020D13 FRONT CRANKSHAFT OIL SEAL COVER- R+R AND REPLACE GASKETS FOR VERSIONS WITH AIR CONDITIONER

Engines: 2.0 16V, 2.8 JTD 8V

Engines: 2.0 16V

Removing

Op. 7055B54 UNDER-ENGINE GUARD - R R Op. 1092C11 POWER STEERING PUMP DRIVE BELT - R R FOR VERSIONS WITH AIR CONDITIONER Op. 1092B40 AIR CONDITIONER COMPRESSOR/ALTERNATOR DRIVE BELT - R + R See in Op. 1092A12 See in Op. 1032D12 See in Op. 1032B14 See in Op. 1032B44 See in Op. 1032B47 Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R Op. 1020A26 CRANKCASE SUMP - R R CLEAN MATING SURFACES AND APPLY SEALANT FOR VEHICLE WITH AIR CONDITIONER See in Op. 1092G15 Op. 5530A14 ALTERNATOR - R+R FOR VERSIONS WITH AIR CONDITIONER Op. 5530A40 ALTERNATOR BRACKETS/MOUNT/SPACER - R R1. Undo the bolts securing the front crankshaft oil seal cover.2. Remove the front crankshaft oil seal cover from its seat.

Engines: 2.0 16V

Refitting

Removing

- Remove the oil sealing ring from its seat on the front cover.- Apply sealant to the front cover.

	Description	Qty.	Component	Type	Classification
.	DOW CORNING 7091	-	FRONT COVER CRANKSHAFT	Silicone sealant	-

- Fit the cover and tighten the bolts to the recommended torque.1. Fit the seal using the tool.

	Description	Code	Function
.	Fitting tool	1.860.855.000	Fitting crankshaft front oil seal

Engines: 2.0 16V

Op. 5530A40 ALTERNATOR BRACKETS/MOUNT/SPACER - R R Op. 5530A14 ALTERNATOR - R+R FOR VERSIONS WITH AIR CONDITIONER See in Op. 1092G15 Op. 1020A26 CRANKCASE SUMP - R R CLEAN MATING SURFACES AND APPLY SEALANT FOR VEHICLE WITH AIR CONDITIONER Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R See in Op. 1032B47 See in Op. 1032B44 See in Op. 1032B14 See in Op. 1032D12 See in Op. 1092A12 Op. 1092B40 AIR CONDITIONER COMPRESSOR/ALTERNATOR DRIVE BELT - R + R Op. 1092C11 POWER STEERING PUMP DRIVE BELT - R R FOR VERSIONS WITH AIR CONDITIONER Op. 7055B54 UNDER-ENGINE GUARD - R R

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

Removing

Refitting

1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

1. Undo the centre fixing bolt.2. Remove the engine components drive pulley.- Remove the tool.

	Description	Code	Function
.	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

1. Remove the lubricant filler cap.2. Undo the bolts (2a) and remove the upper timing drive belt cover (2b).3. Undo the bolts (3a) and remove the intermediate timing drive belt cover (3b).4. Undo the bolts (4a) and remove the lower timing drive belt cover (4b).

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

1. Fit the tool.

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

2. Rotate the crankshaft until the camshaft references are alinged (cylinder no. 1 at T.D.C.).

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

1. Loosen the bolt fixing the belt tensioner.2. Remove the timing belt.3. Undo the fixing bolts (3a) and remove the fixed pulley (3b) and the guard (3c) underneath.

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

- Rotate the engine through 180° on the overhaul stand.1. Undo the bolts (1°) and remove the crankcase front cover (1b) with the oil seal incorporated.

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

Refitting

Removing

- Fit the crankcase front cover with the oil seal incorporated and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(engine crankcase side) 2.3	Bolt	FRONT COVER CRANKSHAFT	M8

- Rotate the engine through 180° on the overhaul stand.1. Check that the reference on the timing gear is in a vertical position.2. Check that the camshaft references are aligned.3. Fit the tool.

	Description	Code	Function
3	Calibrated shim	1.860.638.000	Timing belt tensioning

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

1. Fully fit the toothed timing drive belt.- Remove the tool.

	Description	Code	Function
.	Calibrated shim	1.860.638.000	Timing belt tensioning

- Rotate the crankshaft through two revolutions.- Check once again that the timing references on the crankshaft and the camshaft are aligned.2. Tighten the belt tensioner nut to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(cylinder head side) 2.5	Nut	MOBILE TIMING TENSIONER	M8

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

- Remove the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

- Fit the timing belt covers and secure them using the bolts.- Fit the oil filler plug.- Fit the tool.

	Description	Code	Function
.	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

- Fit the crankshaft pulley and tighten the bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(crankshaft side) 20	Bolt	CRANKSHAFT PULLEY	M20

- Remove the tool.

	Description	Code	Function
.	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

Engines: 2.8 JTD 8V

Removing

Refitting

Op. 7055B54 UNDER-ENGINE GUARD - R R See in Op. 1008B10 See in Op. 1032D12 See in Op. 1032B141. Undo the fixing bolts.2. Remove the front crankshaft oil seal cover.

Engines: 2.8 JTD 8V

Refitting

Removing

- Fit the crankshaft front cover with the oil seal incorporated.- Tighten to torque.

	Value - daNm	Fastening	Component	Ø
.	(engine crankcase side) 2.3	Bolt	FRONT COVER CRANKSHAFT	M8

See in Op. 1032B14 See in Op. 1032D12 See in Op. 1008B10 Op. 7055B54 UNDER-ENGINE GUARD - R R