Refitting

Position the vehicle on a lift.

Disconnect the negative battery terminal.

   Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

1. Remove the air filter (1a) complete with air flow meter (1b) releasing it firstly from the pegs underneath and then from the rear fastening.

1. Loosen the band and disconnect the radiator lower coolant outlet hose.

Drain the coolant into a suitable container.

1. Remove plug (1a) and replace it with tool (1b) on the exhaust side camshaft.

Check the tool is correctly fitted in its seat on the camshaft.

2. Fit a suitable (8 mm diameter) peg via the special opening in the gearbox.

1. Undo the bolt (1a) and disconnect the pipe from the expansion valve to the compressor (1b).

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

    Op. 1088B10 ENGINE COOLANT RESERVOIR - R.R.

Remove the hydraulic lift from beneath the crankcase sump.

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

1. Undo the bolt (1a) and remove the engine components single belt moving tensioner (1b).

1. Undo the nuts (1a) and remove the coolant pump (1b) complete with gasket.

    Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R

1. Unscrew bolts (1a) and nuts (1b) securing the cover for the chain-driven timing system.

2. Remove the cover from the chain-driven timing system (2a) complete with engine oil suction head (2b) and engine oil pump.

3. Remove the chain-driven timing system cover gasket.

1. Working at the bench, unscrew bolts (1a) and separate the engine oil intake (1b) with gasket (1c) from the chain-driven timing system cover.

1. Remove the crankshaft from oil seal from the chain-driven timing system cover.

Take care not to damage the oil seal seat during its removal.

Removing

1. Place a new crankshaft front oil seal (1a) in its seat on the chain-driven timing system cover using tool (1b).

Fit the engine oil intake chamber with gasket in its seat on the chain-driven timing system cover and secure with bolts.

1. Fit a new gasket for the chain-driven timing system cover.

2. Fit the tool to the chain-driven timing system cover.

3. Refit the chain-driven timing system cover (3a) with engine oil suction head (3b) and engine oil pump in its seat and then secure provisionally with bolt (3c).

1. Tighten the bolts fixing the timing cover following the order illustrated.

Connect the connector for the engine oil vapour recovery pipe to the chain-driven timing system cover and tighten the bolts.

Ensure the o-ring is present and correctly positioned.

Secure the electrical wiring to the collars.

    Op. 1020A20 CRANKCASE SUMP- R.R. CLEAN SEALING SURFACES AND APPLY SEALANT

1. Position the auxiliary drivebelt moving tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

1. Fit the pulley mounting flange to crankshaft (1a) and tighten the left-threaded bolt (1b) to the specified torque using tools (1c) and (1d) as counter-torque.

    Op. 1092A12 CRANKSHAFT PULLEY - R+R FOR VERSIONS WITH AIR CONDITIONING

Remove the peg from the opening in the gearbox.

Remove the camshaft timing tool and tighten the plug.

Connect the radiator lower coolant outlet hose and tighten the band.

Fit the air filter with air flow meter in its seat.

Connect the turbocharger air inlet hose and tighten the band.

Connect the electrical connection to the air flow meter.

Connect the negative battery terminal.

    Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY