Figure 241
229346
Remove the engine wiring (1) as described in the relative procedure.
Remove the timing system upper cover (2) as described in the ”SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING” procedure.
Remove the timing system lower cover (3) as described in the relative procedure.
Remove the electric exhaust gas flap (5) as described in the relative procedure.
Remove the turbocharger/exhaust manifold group (4) as described in the relative procedure.
Remove the EGR group (6) as described in the relative procedure.
Figure 242
229347
Remove the low pressure fuel pipe group (3), together with the fuel return pipe as described in the relative procedure. Remove the high pressure fuel pipe from pump to rail (4) as described in the relative procedure.
Remove the fuel manifold pipe (2) as described in the relative procedure.
Remove the electro-injectors (1) as described in the relative procedure.
Remove the thermostat (5) as described in the relative procedure.
Remove the intake manifold (6) as described in the relative procedure.
Figure 243
229348
Undo the bracket screw (1) securing the coolant delivery pipes group (2) to the cylinder overhead.
Open the clip (6) securing the EGR exhaust gas temperature sensor.
Undo the screws (5) and remove the rear cover (3) and the relative gasket, together with the exhaust gas pipe (4) and the coolant delivery pipes group (2).
Ref. No. Description
(1) 1 M8x1.25
(5) 3 M8x1.25x35
(5) 4 M8x1.25x45
Figure 244
227805
Undo and remove the glow plugs (1) from the cylinder head. Ref. No. Description
(1) 4 M8x1
Figure 245
229350
Undo the two plugs (1) on the tappet cover in order to fit the timing tools 99360614.
Ref. No. Description
(1) 2 M14x1.5x10
Rotate the crankshaft and fit the timing tools 99360614 on the overhead and 99360615 onto the crankshaft.
Figure 246
229349
Undo and remove the chain anti-return hydraulic tensioner (1).
Ref. No. Description
(1) 1 M22x1.5x22
NOTE The chain hydraulic tensioners are equipped with an anti-return device; it is therefore necessary to replace the chain tensioners each time they are removed.
Figure 247
227815
Undo the screw (5), keep the washer (6) and remove the exhaust camshat gear (7).
Undo the screw (3), keep the washer (4), remove the intake camshaft gear (2) and the single link timing chain (1).
Ref. No. Description (3)
(5) 2 M12x1.75x40 Figure 248
227816
Remove the plug (4) and undo the screw (3).
Undo the retaining screw (2) and remove the side chain guide (1).
Undo the retaining screw (5) and remove the upper chain guide (6).
Ref. No. Description
(5) 2 M6x1 (2) (3) 2 M6x1x20 (4) 1 M26x1.5x16 Figure 249 229275
Undo the screws (1) and remove the bracket (2). Ref. No. Description
(1) 2 M8x1.25x16
Figure 250
230341
Undo the fixing screws (1) and take off the over-head (2) from the cylinder head (3).
Ref. No. Description (1) 10 M8x1.25x40 (1) 20 M8x1.25x77
Figure 251
88281
Remove the hydraulic tappets (1) with the rocker arms. Remove the gasket (2).
Figure 252
88282
Undo the screws (1) and remove the cylinder head (2). Ref. No. Description
(1) 6 M15x1.5x193 (1) 4 M12x1.5x165 (1) 4 M8x1.25x117 (1) 1 M8x1.25x58 Figure 253 224215
Remove the cylinder head gasket (1).
NOTE Check the protrusion of the pistons (2) as described under the relevant heading to check the possibility of facing the crankcase if it has deformed.
Refitting
Figure 254
224215
Check that contact surfaces of the cylinder head and crankcase are clean.
Place the cylinder head dowels on the crankcase (if they were removed previously).
Place a new cylinder head gasket (1) with the tickness indicated in the Section 6 ”Checking piston protrusion” paragraph with the writing ”TOP” facing the cylinder head.
!
It is absolutely necessary to keep the cylinder head gasket sealed in its packaging and remove it just before fitting to avoid getting it dirty.
Figure 255
α
88354
Mount the cylinder head (2) on the crankcase.
Screw down the fixing screws (3) and tighten them, in three successive stages, following the order and methods shown in the following figure, using tool 99395216 for the angle closing.
Figure 256
88355
Ref. No. Description Tightening
torques (1)÷(6) 6 M15x1.5x193 1stphase 130±6.5 Nm 2ndphase 90˚ 3rdphase 90˚ (7)÷(10) M12x1.5x165 4 1 stphase 65 ± 3.25 Nm 2ndphase 90˚ 3rdphase 60˚ A 4 M8x1.25x117 25 ± 2.5 Nm 1 M8x1.25x58 25 ± 2.5 Nm Figure 257 88356
Position the cylinder head extension dowels on the cylinder head (if they were removed previously).
Thoroughly clean the hydraulic tappets (2), lubricate them and place them in the cylinder head (3), positioning the rocker arms (1) on the valves correctly.
Place a new cylinder head extension gasket (5) in its seat. Insert the two tools SP. 2264 (4) into the electro-injector seats for subsequent centring of the overhead on the cylinder head.
Figure 258
230341
Mount the overhead (2) on the cylinder head (3) together with the tools 99360614 for the timing and tighten the fixing screws (1) to the torque indicated in the table.
Remove the tools SP. 2264 previously mounted. Ref. No. Description Tighteningtorques
(1) 10 M8x1.25x40 25±2.5
(1) 20 M8x1.25x77 25±2.5
Figure 259
229275
Fit the bracket (2) on the overhead and tighten the screws (1) to the torque indicated in the table.
Ref. No. Description Tightening
torques
Figure 260
227816
Fit the upper chain guide (6), drive in the screws (5) and tighten them to the torque indicated in the table.
Fit the side chain guide (1), drive in the screws (2 and 3) and tighten them to the torque indicated in the table.
Fit the plug (4) with a new gasket and tighten it to the torque indicated in the table.
Ref. No. Description Tightening
torques (2) (3) 2 M6x1x20 10±1 (4) 1 M26x1.5x16 50±5 (5) 2 M6x1 10±1 Figure 261 88358
Position the single link chain (1) on the drive gear (5) and on the intake camshaft gear (2).
Mount the gear in such a way that fitting on intake valve timing system shaft dowel makes slots A to result to be positioned as in figure.
Drive in the fastening screw (4) with the washer (3) without tightening it completely.
NOTE The chain arm (1) between the two gears must be tensioned.
Figure 262
229288
Position the single link chain (4) on the gear (3) and fit the latter on the camshaft of the exhaust valves.
Drive in the fastening screw (1) with the washer (2) without tightening it completely.
NOTE The gear (3) must be mounted with the markings inwards.
In the gear (3) there is a larger hole for adjustment, which fits onto the pin on the exhaust camshaft shank.
NOTE The chain arm (4) between the two gears must be tensioned.
Figure 263
230342
Screw on the chain anti-return hydraulic tensioner (2) and tighten to the torque indicated in the table.
Ref. No. Description Tighteningtorques
(2) 1 M22x1.5x22 50±2.5
From the opening in the overhead, press on the tab (3) of the secondary tensioner arm (4) with a screwdriver and push the piston (1) of the chain anti-return hydraulic tensioner (2) fully down.
Release the secondary tensioner arm (4) and check that the piston (1) protrudes from its seat, thus tensioning the chain (5).
!
The hydraulic chain tensioners (with anti-return device) can absolutely never be re-used.
Whenever the piston has inadvertently been made to come out of the new chain tensioner, it must be replaced; it cannot be reset.
Figure 264
229293
Tighten the fastening screw of the gear (1) on the intake valve camshaft to the torque indicated in the table.
Ref. No. Description Tighteningtorques
(1) 1 M12x1.75x40 110±5.5
Figure 265
229294
Make sure that the chain (1) in the tract between the gear (2) and gear (3) is tensioned.
Tighten the fastening screw of the gear (3) on the exhaust valve camshaft to the torque indicated in the table.
Ref. No. Description Tightening
torques
(3) 1 M12x1.75x40 110±5.5
Figure 266
230343
Remove tools 99360614 (1) and fit the two inspection caps in their housing tightening to the torque indicated in the table.
Ref. No. Description Tightening
torques
Figure 267
229348
Fit the exhaust gas pipe (4), on the cylinder head, together with the rear cover (3) and a new gasket and tighten the screws (5) to the torque indicated in the table.
Engage the EGR exhaust gas temperature sensor electrical connection (6) to the bracket and to the intermediate clips. Fit the bracket securing the coolant delivery pipes group (2) to the cylinder overhead and tighten the screw (1) to the torque indicated in the table.
Ref. No. Description Tightening
torques (1) 1 M8 x1.25 25±2.5 (5) 3 M8x1.25x35 25±2.5 (5) 4 M8x1.25x45 25±2.5 Figure 268 227805
Fit the pre/heater glow plugs (1) in their housing on the cylinder head using the SP.2275 tool and torque wrench 99389819, then tighten them to the torque indicated in the table.
Ref. No. Description Tightening
torques
Figure 269
229347
Remove the intake manifold (6) as described in the relative procedure.
Remove the thermostat (5) as described in the relative procedure.
Remove the electro-injectors (1) as described in the relative procedure.
Remove the fuel manifold pipe (2) as described in the relative procedure.
Remove the high pressure fuel pipe from pump to rail (4) as described in the relative procedure.
Remove the low pressure fuel pipe group (3), together with the fuel return pipe as described in the relative procedure.
Figure 270
229346
Remove the EGR group (6) as described in the relative procedure.
Remove the turbocharger/exhaust manifold group (4) as described in the relative procedure.
Remove the electric exhaust gas flap (5) as described in the relative procedure.
Remove the timing system lower cover (3) as described in the relative procedure.
Remove the timing system upper cover (2) as described in the ”SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING” procedure.
Remove the engine wiring (1) as described in the relative procedure.
OIL SUMP REMOVAL/REFITTING