1. Engine top
CAUTION : Observe the tightening order.
1.1. Cylinder head
Identification | Description | Tightening torque |
(1) | bolts (Ignition coils ) | 0,8 daNm |
(2) | bolts (Oil separator) (*) | 0,4 daNm |
1 daNm | ||
(3) | bolts (Vacuum pump) | 1 daNm |
(4) | bolts (Camshaft carrier) (*) | Pre-tightening to 0,5 daNm |
1 daNm | ||
(5) | Studs (Turbocharger) | 0,8 daNm |
(6) | bolts (Cylinder head) (*) (**) | Pre-tightening to 1 daNm |
Tightening to 3 daNm | ||
Angular tightening to 230° | ||
(7) | bolts (Cylinder head) (*) (**) | Pre-tightening to 1 daNm |
Tightening to 3 daNm | ||
Angular tightening to 180° | ||
(8) | bolts (Cylinder head / Cylinder block ) (*) (**) | Tightening to 2 daNm |
(9) | Spark plugs | 2,3 daNm |
(*) Observe the tightening order (**) Always to be replaced whenever removed |
1.2. Sequence of tightening the bolts (2)
(2) bolts (Oil separator).
1.3. Sequence of tightening the bolts (4)
(4) bolts (Camshaft carrier).
1.4. Sequence of tightening the bolts (6), (7), (8)
(6), (7), (8) bolts (Cylinder head).
2. Engine bottom
CAUTION : Observe the tightening order.
2.1. Cylinder block
Identification | Description | Tightening torque |
(1) | bolts (Casing) | 2 daNm |
(2) | bolts (Knock detector) | 2 daNm |
(3) | bolts (Closing plate) | 0,8 daNm |
(4) | bolts (Engine speed sensor) | 0,6 daNm |
(5) | bolts (Timing cover) (*) (**) | Pre-tightening to 0,5 daNm |
1 daNm | ||
(6) | bolts (Counterbalance shaft housing) | 0,8 daNm |
(*) Observe the tightening order (**) Always to be replaced whenever removed |
2.2. Sequence of tightening the bolts (5)
(5) bolts (Timing cover).
2.3. Reciprocating gear
Identification | Description | Tightening torque |
(7) | bolts (Counterbalance shaft ) (**) | Tightening to 2 daNm |
Angular tightening to 180° | ||
(8) | bolts (Big end caps) (**) | Pre-tightening to 0,5 daNm |
Tightening to 1,5 daNm | ||
Angular tightening to 115° | ||
(9) | bolts (Engine flywheel) (*) (**) | Pre-tightening to 0,8 daNm |
Tightening to 3 daNm | ||
Angular tightening to 90° | ||
(10) | bolts (Crankshaft bearing cap) (**) | Tightening to 2 daNm |
Angular tightening to 150° | ||
(11) | bolts (Timing gear) (**) | Tightening to 5 daNm |
Angular tightening to 190° | ||
(12) | bolts (Ancillary drive pulley) (*) (**) | Pre-tightening to 1,5 daNm |
Tightening to 2 daNm | ||
Angular tightening to 60 ± 5° | ||
(*) Observe the tightening order (**) Always to be replaced whenever removed |
2.4. Sequence of tightening the bolts (12)
(12) bolts (Ancillary drive pulley).
2.5. Sequence of tightening the bolts (9)
(9) bolts (Engine flywheel).
3. Lubrication
3.1. Engine lubrication
Identification | Description | Tightening torque |
(1) | bolts (Oil pump) | 1 daNm |
(2) | bolts (Piston head jet) | 2 daNm |
(3) | Engine oil pressure sensor (Cylinder block ) | 2,2 daNm |
(4) | bolts (Dipstick guide tube) (*) | 0,8 daNm |
(5) | bolts (Electric oil gauge) | 0,8 daNm |
(6) | Oil filter (**) | 2 daNm |
(7) | drain cap (Steel casing) | 3 daNm |
(8) | Bolt-nut assembly (Lower oil sump) (Steel casing) | 0,8 daNm |
(9) | bolts (Oil pump solenoid valve) | 0,8 daNm |
(10) | bolts (Upper oil sump ) | 1 daNm |
(10a) | bolts (Upper oil sump / Oil pump) | 1 daNm |
(*) Observe the tightening order (**) Always to be replaced whenever removed |
3.2. Sequence of tightening the bolts (4)
(4) Bolt (Dipstick guide tube).
3.3. Oil cooler
Identification | Description | Tightening torque |
(11) | bolts (Oil cooler) (*) | Pre-tightening to 0,6 daNm |
Tightening to 1 daNm | ||
(*) Observe the tightening order |
3.4. Sequence of tightening the bolts (11)
(11) bolts (Oil cooler).
3.5. Turbocharger lubrication
Identification | Description | Tightening torque |
(12) | Banjo bolt (Oil inlet / Turbocharger) | Tightening to 3,5 daNm |
(13) | Screw (Lubrication pipe / Turbocharger) | 0,8 daNm |
(14) | Banjo bolt (Oil inlet / Cylinder block ) (**) | 3 daNm |
(16) | bolts (Turbocharger oil return pipe) | 1 daNm |
(**) Always to be replaced whenever removed |
N.B. : If removing the turbocharger, replace the old banjo bolt (14) with the new banjo bolt fitted with the removable strainer filter (15).
4. Timing gear
CAUTION : Observe the tightening order.
4.1. Camshafts
Identification | Description | Tightening torque |
(1) | bolts (Camshaft bearing caps) (*) | Pre-tightening to 0,5 daNm |
Tightening to 1 daNm | ||
(2) | bolts (Cap / Camshaft carrier) (*) | 3 daNm |
(*) Observe the tightening order |
4.2. Sequence of tightening the bolts (1)
(1) bolts (Camshaft bearing caps).
4.3. Timing controls
Identification | Description | Tightening torque |
(3) | bolts (Cylinder reference sensors/Inlet) | 0,8 daNm |
(4) | bolts (Cylinder reference sensors/Exhaust) | 0,8 daNm |
(5) | bolts (Variable timing actuator (exhaust) ) | Tightening to 0,8 daNm |
(6) | bolts (Variable timing actuator (Inlet) ) | Tightening to 0,8 daNm |
(**) Always to be replaced whenever removed |
Identification | Description | Tightening torque |
(7) | bolts (Inlet camshaft pinion ) (**) | Tightening to 3,2 daNm |
Angular tightening to 30° | ||
(8) | bolts (Exhaust camshaft pinion ) (**) | Tightening to 3,2 daNm |
Angular tightening to 30° | ||
(9) | bolts (Cassette / Cylinder head) | 1,8 daNm |
(10) | bolts (Cassette / Cylinder block ) | 1,8 daNm |
(11) | bolts (Timing chain tensioner ) | Tightening to 1 daNm |
(**) Always to be replaced whenever removed |
5. Engine air supply
5.1. Air filter housing - Air unions
Identification | Description | Tightening torque |
(1) | Pillar screws (Air filter housing) | 0,8 daNm |
(2) | bolts (Turbocharger air inlet union ) | 0,8 daNm |
(3) | bolts (The turbocharger air outlet connector ) | 1 daNm |
(4) | bolts (Air union ) | 0,8 daNm |
5.2. Air unions - air/air heat exchanger
Identification | Description | Tightening torque |
(5) | bolts (Air union / Reversible alternator ) | 0,8 daNm |
5.3. Air inlet manifold - Motorised throttle housing
Identification | Description | Tightening torque |
(6) | bolts (Air inlet manifold) | Pre-tightening to 0,5 daNm |
Tightening to 1 daNm | ||
(7) | bolts (Air union / Motorised throttle housing/Air inlet manifold) | 1 daNm |
(8) | bolts (Air inlet pressure upstream sensor) | 0,4 daNm |
(9) | Nut (Air inlet manifold) | Tightening to 1 daNm |
(10) | bolts (Air inlet pressure downstream sensor) | 0,8 daNm |
6. Turbocharging : Turbocharger
Identification | Description | Tightening torque |
(1) | bolts (Turbocharger discharge electrovalve / Turbocharger) | 0,8 daNm |
(2) | Bolt (Front heat shield / Turbocharger) | 0,8 daNm |
(3) | Nuts (Turbocharger / Cylinder head) | 3 daNm |
(4) | Stud ( cylinder head) | 0,8 daNm |
7. Fuel supply
7.1. Tightening torques
Identification | Description | Tightening torque |
(1) | bolts (Fuel high pressure common injection rail ) (*) | 2 daNm |
(2) | bolts ( high pressure fuel pump) (*) | Pre-tightening to 1,5 daNm |
Tightening to 2 daNm | ||
(3) | Union (Fuel supply pipe on fuel supply rail) (*) (**) | Pre-tightening to 1 daNm |
Angular tightening to 55° | ||
Union (Fuel supply pipe on fuel high pressure pump) (*) (**) | Pre-tightening to 1 daNm | |
Angular tightening to 55° | ||
(*) Observe the tightening order (**) Always to be replaced whenever removed |
7.2. Sequence of tightening the bolts (1)
(1) Bolt (Fuel high pressure common injection rail ).
7.3. Sequence of tightening the bolts (2) and the unions (3)
(2) Bolt (High pressure fuel pump).
(3) Union (Fuel supply pipe on fuel supply rail).
8. Cooling system
8.1. Engine cooling circuit
Identification | Description | Tightening torque |
(1) | bolts (Coolant pump) | 0,8 daNm |
(2) | bolts (Coolant inlet manifold) | 0,8 daNm |
(3) | bolts (Coolant outlet housing) | Pre-tightening to 0,5 daNm |
1 daNm |
8.2. Sequence of tightening the bolts (3)
(3) bolts (Coolant outlet housing).
8.3. Turbocharger cooling
Identification | Description | Tightening torque |
(4) | bolts (Union / Turbocharger) | 1 daNm |
(5) | Bolt (Electric coolant pump / Support ) | 0,8 daNm |
(6) | Bolt (Support / Electric coolant pump/Cylinder block ) | 2 daNm |
(7) | bolts (Union / Cylinder block ) | 0,8 daNm |
9. Accessories support
9.1. Tightening torques
Identification | Description | Tightening torque |
(1) | bolts (Dynamic tensioner roller ) | 2 daNm |
(2) | bolts (Accessories support /Cylinder block ) (*) | 2,5 daNm |
(3) | bolts (Accessories support /Upper oil sump ) (*) | 2,5 daNm |
(*) Observe the tightening order |
9.2. Sequence of tightening the bolts (2),(3)
(2), (3) bolts (Accessories support).
10. Reversible alternator
Identification | Description | Tightening torque |
(1) | bolts (Reversible alternator ) | 4,5 daNm |
(2) | Nut (Reversible alternator supply wire ) | 1,5 daNm |
11. Air conditioning compressor
Identification | Description | Tightening torque |
(1) | bolts (Air conditioning compressor) | 2,5 daNm |
12. Ancillary drive belt protector
Identification | Description | Tightening torque |
(1) | Nut (Protector / Accessories support) | 0,8 daNm |
(2) | bolts (Protector / Upper oil sump ) | 0,8 daNm |
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