Removing ( Refitting )

- Position the vehicle on the lift.

Op. 5530B54

- Disconnect the negative battery terminal.

   

Description

 

Connector

 

-

 

BATTERY

 

See A001

   Op. 4450B04 RIGHT FRONT WHEEL - R.R.

Op. 7055B91

Op. 7055B51

Op. 7055B56

   Op. 1092G10 AUXILIARY COMPONENTS SINGLE DRIVE BELT - R.R.

   Op. 1092A10 SERVICE PULLEY ON CRANKSHAFT - R.R.

   Op. 1092G15 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R.R. WITH BELT REMOVED

   Op. 5010B12 CLIMATE CONTROL UNIT AIR INTAKE DUCT - R.R.

   Op. 1064B31 WASTEGATE SOLENOID VALVE GUARD - R.R.

   Op. 1064B35 PRESSURIZED AIR SUPPLY PIPE TO WASTE GATE VALVE - R.R.

   Op. 1064B36 PRESSURIZED AIR SUPPLY PIPE TO WASTE GATE ACTUATOR - R.R.

   Op. 1064B44 WASTE GATE VALVE ACTIVATION SOLENOID VALVE - R.R.

   Op. 1064B30 WASTEGATE SOLENOID VALVE MOUNTING BRACKET - R.R.

   Op. 1048A39 SLEEVE FROM AIR CLEANER TO RIGID PIPE - R R

   Op. 1048A38 PIPE BETWEEN AIR FILTER/FLOW METER - R.R.

   Op. 1060G10 AIR FLOW METER - R.R.

   Op. 1048A42 SLEEVE FROM FLOW METER TO TURBO CHARGER AIR INLET PIPE - R + R

   Op. 1016A10 SOUND-PROOFING COVER - R.R

   Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

   Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

   Op. 1008A46 TIMING SIDE POWER UNIT RIGID SUPPORT - R.R.

   Op. 1032B10 TOOTHED TIMING BELT - R.R. FOR TIMING OR REPLACEMENT

- Fit the engine mounting without the pressure pump mounting fixing screw.

- Fit the timing side flexible mounting.

- Remove the hydraulic lift positioned previously under the engine for removing the timing drive belt.

   Op. 1040B28 DUPLEX FUEL SUPPLY/RETURN PIPE TO PRESSURE PUMP - R.R.

   Op. 1060F50 FUEL RETURN MANIFOLD - R.R.

   Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.




1. Undo the nut (1a) and remove the heater plugs control unit cover (1b).




1. Release the wiring retaining band.

2. Undo the nut (2a) fixing the heater plugs control unit (2b).




1. Turn the control unit (1a) upside down, disconnect the electrical connection (1b) and move the heater plugs wiring (1c) to one side.

   

Description

 

Connector

 

1

 

HEATER PLUG PRE-HEATING CONTROL UNIT

 

See M015




1. Undo the screw fixing the degassing pipe mounting bracket.

2. Undo the wiring mounting bracket fastener and move it to one side.

    Op. 5530A10 ALTERNATOR - R.R.




1. Disconnect the electrical connection for the fuel pressure regulator.

   

Description

 

Connector

 

1

 

FUEL PRESSURE REGULATOR

 

See N077




1. Undo the screws (1a) fixing the pressure pump mounting (1b) to the crankcase.




1. Undo the screw (1a) fixing the pressure pump mounting (1b) to the cylinder head and remove the mounting with pressure pump.

- Separate the pressure pump from the mounting, with reference to

    Op. 1060E42 PRESSURE PUMP SUPPORT - DISMANTLING AND REASSEMBLY AT THE BENCH

Refitting ( Removing )

- Fit the pressure pump on the mounting, with reference to

   Op. 1060E42 PRESSURE PUMP SUPPORT - DISMANTLING AND REASSEMBLY AT THE BENCH




1. Place the pressure pump mounting (1a) back in position and tighten the camshaft housing fixing screw (1b) to the prescribed torque.

 

Component

 

Fixing

 

Ø

 

Value (daNm)

 

Validity

 

Pressure pump support - cylinder head side

 

Screw

 

M10 x 1.25 x 40

 

4.5 ÷ 5.5

 

2.0 JTD 115 HP




1. Tighten the screws (1a) fixing the pressure pump mounting (1b) to the crankcase to the prescribed torque.

 

Component

 

Fixing

 

Ø

 

Value (daNm)

 

Validity

 

Pressure pump support - engine block side

 

Upper screw (pretreated with sealant - to be replaced)

 

M8 x 1.25 x 110

 

2.3 ÷ 2.8

 

2.0 JTD 115 HP

 

Component

 

Fixing

 

Ø

 

Value (daNm)

 

Validity

 

Pressure pump support - engine block side

 

Screw

 

M8 x 1.25 x 35

 

2.3 ÷ 2.8

 

2.0 JTD 115 HP

- Connect the electrical connection for the fuel pressure regulator.

   

Description

 

Connector

 

-

 

FUEL PRESSURE REGULATOR

 

See N077

    Op. 5530A10 ALTERNATOR - R.R.

- Tighten the wiring mounting bracket fastener.

- Tighten the screw fixing the degassing pipe mounting bracket.

- Connect the electrical connection for the heater plugs control unit.

   

Description

 

Connector

 

-

 

HEATER PLUG PRE-HEATING CONTROL UNIT

 

See M015

- Tighten the nut fixing the heater plugs control unit.

- Engage the wiring retaining band.

- Fit the heater plugs control unit cover and tighten the nut.

    Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.

    Op. 1060F50 FUEL RETURN MANIFOLD - R.R.

    Op. 1040B28 DUPLEX FUEL SUPPLY/RETURN PIPE TO PRESSURE PUMP - R.R.

- Position a hydraulic lift under the engine.

- Remove the timing side flexible mounting by undoing the engine mounting fixing screws and the body fixing nuts.

- Remove the engine mounting by undoing the fixing screws.

    Op. 1032B10 TOOTHED TIMING BELT - R.R. FOR TIMING OR REPLACEMENT

    Op. 1008A46 TIMING SIDE POWER UNIT RIGID SUPPORT - R.R.

    Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R

    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

    Op. 1016A10 SOUND-PROOFING COVER - R.R

    Op. 1048A42 SLEEVE FROM FLOW METER TO TURBO CHARGER AIR INLET PIPE - R + R

    Op. 1060G10 AIR FLOW METER - R.R.

    Op. 1048A38 PIPE BETWEEN AIR FILTER/FLOW METER - R.R.

    Op. 1048A39 SLEEVE FROM AIR CLEANER TO RIGID PIPE - R R

    Op. 1064B30 WASTEGATE SOLENOID VALVE MOUNTING BRACKET - R.R.

    Op. 1064B44 WASTE GATE VALVE ACTIVATION SOLENOID VALVE - R.R.

    Op. 1064B36 PRESSURIZED AIR SUPPLY PIPE TO WASTE GATE ACTUATOR - R.R.

    Op. 1064B35 PRESSURIZED AIR SUPPLY PIPE TO WASTE GATE VALVE - R.R.

    Op. 1064B31 WASTEGATE SOLENOID VALVE GUARD - R.R.

    Op. 5010B12 CLIMATE CONTROL UNIT AIR INTAKE DUCT - R.R.

    Op. 1092G15 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R.R. WITH BELT REMOVED

    Op. 1092A10 SERVICE PULLEY ON CRANKSHAFT - R.R.

    Op. 1092G10 AUXILIARY COMPONENTS SINGLE DRIVE BELT - R.R.

Op. 7055B56

Op. 7055B51

Op. 7055B91

    Op. 4450B04 RIGHT FRONT WHEEL - R.R.

- Connect the negative battery terminal.

   

Description

 

Connector

 

-

 

BATTERY

 

See A001

Op. 5530B54

- Remove the vehicle from the lift.