Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir DRIVE GEAR WITH MANUAL GEARBOX - UI 1004B10

Remove ( Install )

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 0010T40 OIL MANUAL BOX - REPL.

edit. 0010T84 AIR CONDITIONING REFRIGERANT - DRYING AND FILLING

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 5530B10 BATTERY - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 1088B10 ENGINE COOLING SYSTEM EXPANSION RESERVOIR - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7210E10 ONION FRONT BUMPER

edit. 5540B07 LEFT HEADLIGHT UNIT - UI

edit. 5540B08 RIGHT HEADLIGHT UNIT - UI

edit. 7025A34 BONNET LOCK (ONLY) - UI OR REPAIR

edit. 7210A08 LOWER ENERGY ABSORBING ELEMENT (1), LI OR RE, FRONT BUMPER - UI

(both)

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 7210A02 UI COMPLETE FRONT-END

edit. 4450B12 WHEELS (TWO) FRONT - UI

edit. 5050A12 FILL HOSE (IN ENGINE COMPARTMENT) FOR WINDSCREEN WASHER RESERVOIR - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 7210A51 UI LOWER CREEK ZONE LI

edit. 7210A52 ONION LOWER CRUSH ZONE RE

edit. 7055B65 DUST PLATE ENGINE COMPARTMENT IN LEFT FRONT FAIRING - UI

edit. 2710A14 RIGHT DRIVE SHAFT COMPLETE WITH COUPLINGS AND INTERPLACEMENT SHAFT - UI

edit. 1008C32 GEARBOX LOWER REACTION ROD - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 2125C31 GEAR SHIFT SUPPORT - UI

1. Loosen the lock on the hub nut on the drive shaft.

Machine Translated by Google

1. Install the locking tool on the brake disc.

Tools Description Function Validity

Loosen drive shaft

1870815000 mounting nut to
Blocking tool front wheel hub
/tighten

2. Loosen the hub nut.

1. Loosen the tie rod ball mounting nut on the hub carrier.

1. Loosen the tie rod ball (1b) from the hub carrier using tool (1a).

Tools Description Function Validity

Pull the track

1871000700 Pulls rod off the
hub carrier

1. Loosen the wishbone mounting bolt on the hub carrier.

Machine Translated by Google

- Remove the left drive shaft from the differential using suitable tools
1. Support the left drive shaft appropriately.

1. Disconnect the fuel supply and return lines (1a) and the fuel vapor line (1b).

1. Disconnect the connecting plug between the front/motor cables.

Description Plug

PLUG FOR / See D004 PLUG

1
MOTOR FRONT / ENGINE

2. Disconnect the plug from the injection control unit.

Description Plug

See M010
2 INJECTION RULE UNIT
INJECTION RULE UNIT

1. Loosen the retaining nut and disconnect the low-pressure A/C line from the expansion valve. (1b).

2. Disconnect the quick couplings of the hoses from the heater radiator.
Machine Translated by Google

1. Loosen the starter motor cable (1b) retaining nut (1a).

2. Loosen the fixing nuts of the cables on the battery terminal.

1. Loosen the fixing bolts (1a) and open the fuse box cover (1b).

1. Disconnect the plug in the connection cable from the switch for the reversing lights.

Description Plug

PLUG CABLES See D007 PLUG

1
FRONT / CHARGING SYSTEM DYNAMO

1. Loosen the fixing nut of the ground connection on the body.

Description Plug

PULP See C045 GROUND

Machine Translated by Google

1 ELECTRIC VENTILATOR ELECTRIC VENTILATOR

1. Loosen the quick coupling in the vacuum pump line.

1. Unscrew the brake/clutch fluid reservoir cap and install the tool.

Tools Description Function Validity

2000001400 Pressurize brake system/clutch

Dop control

1. Open the retaining clip (1a) and disconnect the oil supply hose (1b) from the clutch slave cylinder.

2. Loosen the bolt and remove the ground cable.

3. Disconnect the lambda sensor plug.

Description Plug

FRONT STAND SENSOR See K095 FRONT POSITION SENSOR

3
CLUTCH ACTUATOR CLUTCH ACTUATOR

4. Disconnect the reverse light switch connector.

Description Plug

SWITCH FOR See I020 FRONT SWITCH

4
REVERSING LIGHTS REVERSING LIGHTS

1. Support the power unit using a workshop crane and the special tools, attaching the snap hooks as shown in
the picture.
Machine Translated by Google

Tools Name function Validity

1871001700 Equator Remove and install engine/

gearbox

1. Loosen the mounting bolts of the suspension rubber of the fixed engine/box support (gearbox side).

- Remove the drive unit from the engine compartment and place it on a stand.

- Detach the support tools from the drive unit.

Install ( Remove )

- Install the drive unit.

1. Tighten the mounting bolts of the suspension rubber to the fixed engine/box support with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Rubber mount of
engine/bucket support Bolt (replaced with new M12 7.7 ÷ 9.3
(gearbox side) on body one)

- Connect the plug to the switch for the reversing lights.

Description Plug

-
SWITCH FOR See I020 FRONT SWITCH
REVERSING LIGHTS REVERSING LIGHTS

- Connect the lambda sensor plug

Description Plug

FRONT STAND SENSOR

-
See K095
CLUTCH ACTUATOR
Machine Translated by Google

- Tighten the bolt of the ground cable.

- Connect the oil supply hose to the clutch slave cylinder and fit the corresponding circlip.

- Remove the tool and screw the cap onto the brake/clutch fluid reservoir.

Tools Description Function Validity

2000001400 Pressurize brake system/clutch control

Dop

- Connect the quick coupling in the pipe of the vacuum pump.

- Tighten the fixing nut of the ground connection on the body.

Description Plug

See C045 GROUND

-
MASSA ELEKTROVENTILATEUR
ELECTRIC FAN

- Connect the plug in the connection cable of the switch for the reversing lights.

Description Plug

PLUG CABLES FOR /

-
See D007 PLUG ALTERNATOR
LOADING SYSTEM

- Place the cover on the fuse box and tighten the fixing bolts.

- Tighten the fixing nuts of the cables on the battery terminal.

- Tighten the starter motor cable retaining nut.

- Connect the quick couplings of the hoses to the heater radiator.

- Connect the low pressure air conditioning line to the expansion valve and tighten the fixing nut.

- Connect the plug to the injection control unit.

Description Plug

See M010
-
INJECTION RULE UNIT
INJECTION RULE UNIT

- Connect the plug between the front/motor cable bundle.

Description Plug

See D004 PLUG FOR /

-
PLUG FOR / ENGINE
MOTOR

- Connect the fuel supply and return lines and the fuel vapor line.

- Place the left drive shaft correctly in the differential.

1. Tighten the new hub carrier mounting bolt to the wishbone arm with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Lower Bolt nut

Machine Translated by Google

wishbone to hub (replaced by M10 6.3 ÷ 7.7

carrier new)

1. Install the tie rod ball to the hub carrier and tighten the new nut with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Tie rod end to Nut (replaced M10 3.6 ÷ 4.4

hub carrier with new)

1. Secure the hub nut to the drive shaft as shown below.

edit. 2125C31 GEAR SHIFT SUPPORT - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008C32 GEARBOX LOWER REACTION ROD - UI

edit. 2710A14 RIGHT DRIVE SHAFT COMPLETE WITH COUPLINGS AND INTERPLACEMENT SHAFT - UI

edit. 7055B65 DUST PLATE ENGINE COMPARTMENT IN LEFT FRONT FAIRING - UI

edit. 7210A52 ONION LOWER CRUSH ZONE RE

Bew. 7210A51 UI LOWER CREEK ZONE LI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 5050A12 FILL HOSE (IN ENGINE COMPARTMENT) FOR WINDSCREEN WASHER RESERVOIR - UI

edit. 4450B12 WHEELS (TWO) FRONT - UI

edit. 7210A02 UI COMPLETE FRONT-END

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 7210A08 LOWER ENERGY ABSORBING ELEMENT (1), LI OR RE, FRONT BUMPER - UI

(both)
Machine Translated by Google

edit. 7025A34 BONNET LOCK (ONLY) - UI OR REPAIR

edit. 5540B08 RIGHT HEADLIGHT UNIT - UI

edit. 5540B07 LEFT HEADLIGHT UNIT - UI

edit. 7210E10 ONION FRONT BUMPER

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1088B10 ENGINE COOLING SYSTEM EXPANSION RESERVOIR - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 5530B10 BATTERY - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 0010T84 AIR CONDITIONING REFRIGERANT - DRYING AND FILLING

edit. 0010T40 OIL MANUAL BOX - REPL.

- Connect the negative terminal to the battery.

Description Plug

-
BATTERY See A001 BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir DRIVE GEAR (MANUAL TRANSMISSION), REMOVED - SEPARATE AND ASSEMBLY 1004D10

Remove ( Install )

1. Support the drive unit (1b) with tool (1a) as shown in the figure.

Tools Name function Validity

1871001700 Equator Removing and

installing engine/gearbox

1. Loosen the flywheel cover mounting bolt on the gearbox.

2. Loosen the gearbox mounting bolts to the engine oil pan.

1. Loosen the remaining flywheel cover mounting bolts on the gearbox.

1. Open the protective cover, loosen the nut and disconnect the starter motor wiring.

1. Loosen the bolt and loosen the cable support bracket.

1. Loosen the bolts (1a) and remove the starter motor (1b).
Machine Translated by Google

1. Unhook the lifting points from the gearbox side drive unit and hook the engine onto the indicated point.

1. Loosen the gearbox mounting nut on the engine.

1. Loosen the upper gearbox mounting bolts on the engine.

2. Loosen the side mounting bolt of the gearbox on the engine.

3. Remove the gearbox from the engine.

Install ( Remove )

1. Install the gearbox, connecting the stud on the side.

2. Tighten the gearbox side mounting bolt to the engine with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Manual gearbox
on engine (cylinder End M10 3.6 ÷ 4.4 1.6 16v MJet
block side)

3. Tighten the upper gearbox mounting bolts to the engine with torque.

Component Confirmation ISLAND

Value (daNm) Validity
Machine Translated by Google

Manual gearbox
on engine (cylinder End M10 3.6 ÷ 4.4 1.6 16v MJet
block side)

1. Tighten the gearbox mounting nut to the engine with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Manual gearbox
on engine (cylinder End M12 4.8 ÷ 7.2
block side)

- Place the cable support bracket and tighten the upper mounting bolt on the gearbox.
1. Place the starter motor (1a) in the seat and tighten the bolts (1b) with torque.

Component Confirmation ISLAND

Value (daNm) Validity

starter motor End M8 2.4 ÷ 3.0

- Connect the wiring to the starter motor, tighten the corresponding nut and close the protective cover.

- Tighten the flywheel cover fixing bolts on the intake side.

1. Tighten the gearbox mounting bolts to the engine oil pan with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Manual gearbox
on engine (cylinder End M10 3.6 ÷ 4.4 1.6 16v MJet
block side)

2. Tighten the flywheel cover mounting bolt on the gearbox.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE - PLACE ON BOOK/TAKE FROM BOK 1004D40

Place engine on stand

1. Loosen the clamps and disconnect the radiator coolant supply and return hoses from the
thermostat.

2. Loosen the clamp and disconnect the radiator coolant supply hose from the thermostat.

1. Loosen the clamp and disconnect the coolant return hose from the water pump.

2. Loosen the bolt (2a), loosen the clamp (2b) and remove the air exhaust hoses from the turbocharger.

1. Loosen the bolt on the intermediate bracket for the coolant supply hose.

1. Loosen the bolts and disconnect the supply/return lines from the A/C compressor.

- Loosen three pressure plate mounting bolts, offset by 120°.

1. Install the flywheel locking tool.

Tool Description Function Validity

1860846000 Locking Tool Flywheel Locking Tool

2. Install the clutch centering kit.

Tools Description Function Validity

Machine Translated by Google

1. Assemble the tool as shown in the figure and turn the crank until the pins are against the flange.

Tools Name function Validity

1.4 16v TJet

1871003100 Remove/ 2.0 16v MJet

De-/montagehulpstuk
install clutch
1.9 16v Twin Turbo MJet

2. Loosen the remaining clutch pressure plate mounting bolts on the flywheel.
- Turn the tool handle back until the pressure group diaphragm spring is relaxed.

- Remove the tools with the pressure group.

1. Remove the centering tool (1a) together with the clutch plate (1b).

Tools Description Function Validity

1. With the flywheel locking attachment (1a) installed, loosen the bolts (1b) and remove the flywheel (1c).

Tools Description Function Validity

1860846000 Blocking tool Flywheel Locking Attachment

1. Loosen the bolt (1a) and remove the flywheel covers (1b).

1. Install the support bracket on the cylinder block.

Tools Name function Validity

Place the
1871000000 Bracket motor on a
rotating stand
Machine Translated by Google

1. Place the engine on a revision stand using a workshop crane.

Tools Name function Validity

Place the
1871000000 Bracket motor on a
rotating stand

Remove engine from trestle

- Support the engine with the support tools using a workshop crane.

- Loosen the fixings of the cylinder block on the bracket of the revision stand.

- Place the engine on a suitable stand.

- Install the flywheel guards and tighten the mounting bolt on the oil pan.
1. Install the flywheel (1a), install the flywheel locking attachment (1b) and tighten the previously hand-tightened
new bolts (1c) to torque.

Tools Description Function Validity

1860846000 Blocking tool Flywheel Locking Attachment

Component Confirmation ISLAND

Value (daNm) Validity

Bolt (replaced with M9 1.9 ÷ 2.1 + 50 ° +/- 2 ° 1.4 16v TJet

Flywheel
new one)
1. Install the centering tool (1a) and the clutch plate (1b).

Tools Description Function Validity

When installing the clutch disc, pay attention to the mounting direction "lato motore" (engine
side) or "lato cambio" (gearbox side).
Handle the clutch disc carefully and do not touch the liners with your hands.

1. Fit the pressure plate and mount the tools (1a) and (1b).

Tools Description Function Validity

Tools Name function Validity

1.4 16v TJet

Remove/ 2.0 16v MJet

1871003100 De-/montagehulpstuk
install clutch
1.9 16v Twin Turbo
MJet

- Turn the handle of the tool until the pins are against the flange.

2. Hand-tighten the indicated available pressure plate mounting bolts.

- Turn the tool handle back until the pressure group diaphragm spring is relaxed.
- Remove the pre-mounted tools except the clutch centering tool.
Machine Translated by Google

- Tighten the three remaining pressure plate mounting bolts by hand.

1. Tighten the pressure plate mounting bolts evenly crosswise until the specified torque is reached.

Component Confirmation ISLAND

Value (daNm) Validity

Clutch Mechanism Bolt M6 1.2 ÷ 1.5 1.4 16v TJet

2. Remove the clutch centering tool.

Tools Description Function Validity

- Remove the flywheel locking tool.

Tool Description Function Validity

1860846000 Locking Tool Flywheel Locking Tool

1. Install the air conditioning pipes, connect them to the compressor and tighten the bolts with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Nipple from pipe End M6 0.7 ÷ 1.1 1.4 16v TJet

to compressor

- Tighten the mounting bolts of the brackets for the air conditioning pipes.

- Connect the exhaust air hoses to the turbocharger, tighten the clamp and tighten the bolt of the support bracket.

- Connect the return hose to the water pump and tighten the corresponding clamp.

- Connect the radiator coolant supply hose to the thermostat and tighten the corresponding clamp.

- Connect the coolant supply and return hoses from the heater radiator to the thermostat and tighten the corresponding
clamps.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE, REMOVED - CYLINDER HEAD AND OIL PAN REMOVAL FOR INSPECTION -
INCLUDES BOX PLACE AND REMOVAL 1004E10

1. Loosen the engine oil drain plug and drain the engine oil.

1. Loosen the clamp and disconnect the crankcase ventilation hose from the manifold housing.

1. Loosen the bolts (1a) and remove the complete oil separator (1b).

1. Loosen the bolts (1a) and remove the rear timing cover (1b).

1. Disconnect the engine speed sensor connector.

Description Plug

See K046
1 Speed sensor
RPM SENSOR

2. Disconnect the engine oil pressure sensor connector.

Description Plug
Machine Translated by Google

See K030 SENSOR

(INTERRUPTER) FRONT
2
MOTOROLIEDRUK
Oil pressure sensor (interrupter)

1. Disconnect the turbo pressure regulation bypass solenoid valve.

Description Plug

See L102 BYPASS

1
Turbocharger Bypass SOLENOID VALVE FRONT
Solenoid Valve TURBOCOMPRESSOR

1. Loosen the bolt and remove the ground cable.

2. Disconnect the plugs from the ignition coils.

Description Plug

2 Reel See A030 COIL

3. Loosen the mounting bolts of the cable tray on the valve cover.

1. Disconnect the connectors from the MULTIAIR actuators.

Description Plug

See N197
MULTIAIR
1 MULTIAIR
actuator
ACTUATOR

1. Disconnect the air temperature/pressure sensor connector.

Description Plug

See K044
1
Air temperature/pressure sensor INTAKE AIR TEMPERATURE
AND PRESSURE SENSOR

2. Open the retaining clips and disconnect the cable bundle.

1. Loosen the bolt and remove the ground cable from the compressor support.

1. Disconnect the plug in the cable of the injection valves.

Machine Translated by Google

Description Plug

See D081 PLUG

1
Plug injection valves INJECTION VALVES

2. Disconnect the fuel vapor shut-off valve.

Description Plug

See L010
2 Fuel vapor shut-off valve FUEL VAPOR VALVE

1. Disconnect the knock sensor plug.

Description Plug

See K050
1
Pingelsensor VOLTAGE SENSOR

1. Disconnect the air conditioning compressor plug.

Description Plug

See L020
Solenoid for A/C compressor activation ELECTROMAGNETIC
1
LINK OF
AIRCOCOMPRESSOR

2. Loosen the nut and disconnect the alternator ground cable.

1. Operate the retaining clips and open the cable tray.

1. Open the retaining clips and disconnect the cable bundle.

1. Disconnect the throttle body connector.

Machine Translated by Google

Description Plug

See N075 ACTUATOR

1
Actuator integrated in INTEGRATED IN
throttle body THROTTLE BODY

2. Disconnect the oil temperature sensor in the UNIAIR module.

Description Plug

See K029
2 Motor temperature sensor ENGINE SLUDGE TEMPERATURE SENSOR

1. Disconnect the coolant temperature sensor connector.

Description Plug

See K036
1
Coolant temperature sensor/- COOLANT TEMPERATURE SENSOR/-
transmitter
TRANSMITTER

2. Unplug the phase sensor.

Description Plug

2 Phase sensor See K047 PHASE SENSOR

- Remove the engine wiring harness.

1. Adjust the adjustable tensioner, lock the tensioner with a suitable pin and remove the accessory drive belt.

1. Loosen the bolts (1a) and remove the air conditioning compressor (1b).

1. Loosen the bolts (1a) and remove the alternator (1b).

Machine Translated by Google

1. Loosen the fasteners (1a) and remove the bracket (1b) for the alternator and the air conditioning compressor complete
with the adjustable tensioner.

1. Loosen the bolts (1a) and remove the support (1b) for the intermediate shaft bearing.

1. Loosen the bolt (1a) and remove the oil dipstick tube (1b) complete with the dipstick.

1. Loosen fasteners (1a) and remove reinforcement bracket (1b) from manifold housing.
Machine Translated by Google

1. Loosen bolts (1a) and remove manifold housing (1b).

1. Loosen the bolts (1a) and remove the cable support bracket (1b).

1. Loosen the bolts (1a) and remove the heat shields for the engine oil cooler (1b).

1. Loosen the oil return line mounting bolts on the turbocharger.

2. Loosen the oil return line fixing bolt for the turbocharger on the cylinder block.

3. Loosen the turbocharger oil return line connector on the engine oil cooler and remove the line.

1. Loosen the coolant supply line connection to the engine oil cooler.

2. Unscrew the engine oil cooler coolant supply line connection to the thermostat.

3. Loosen the nut and remove the coolant supply line from the engine oil cooler.
Machine Translated by Google

1. Loosen the coolant return line connection to the engine oil cooler.

2. Loosen the engine oil cooler coolant return line connection to the water pump return tube and remove
the line.

1. Loosen the connection from the turbocharger oil supply line to the engine oil cooler.

1. Unscrew the oil supply line connection to the turbocharger and remove the line.

1. Loosen the coolant return line connection on the turbocharger.

1. Loosen the mounting bolt of the connection on the turbocharger coolant return line on the return
tube of the water pump and remove the line complete with the O-ring.

1. Loosen the heat shield front mounting nuts on the exhaust manifold.

2. Remove the heat shield mounting stud from the exhaust manifold using a suitable tool.
Machine Translated by Google

1. Loosen the heat shield front mounting nut on the exhaust manifold.

2. Remove the heat shield mounting stud from the exhaust manifold using a suitable tool.

1. Loosen the nuts (1a) and remove the turbocharger (1b) complete with the gasket.

- Remove the heat shield from the exhaust manifold.

1. Loosen the nuts and remove the bracket.

2. Loosen the remaining nuts (2a) and remove the exhaust manifold (2b).

1. Remove the gasket complete with the heat shield for the turbocharger.

1. Loosen the water pump return tube retaining bolt on the cylinder head.
Machine Translated by Google

1. Loosen the water pump return tube retaining bolt on the cylinder block.

2. Remove the coolant return tube for the water pump complete with the sealing ring.

1. Loosen the mounting bolts of the oil filter support and the engine oil cooler on the cylinder block.

2. Loosen the mounting (2a) of the oil filter bracket and engine oil cooler (2b) on the front crankshaft cover and
remove the bracket.

1. Install the crankshaft turning tool.

Tools Name function Validity

turn
1860815000 Flange
crankshaft

1. Loosen the bolts (1a) and remove the crankshaft pulley (1b).

1. Loosen the bolts (1a) and remove the timing covers (1b).
Machine Translated by Google

1. Loosen the bolts (1a) and remove the engine mount (timing side) (1b).

1. Loosen the bolts (1a) and remove the vacuum pump (1b) complete with the gasket.

1. Install the tool in the vacuum pump seat to lock the camshaft.

Tools Name function Validity

1. Slightly loosen the retaining nut of the adjustable timing belt tensioner.

2. Remove the timing belt.

Machine Translated by Google

1. Loosen the camshaft pulley mounting bolt.

1. Loosen the mounting bolts (1a) and remove the ignition coils (1b).

1. Remove the spark plugs using a suitable wrench.

1. Loosen the bolts (1a) and remove the valve cover (1b) complete with the gasket.

1. Fit the tool to compress the plates of the pump elements in the UNIAIR module.

Tools Name function Validity

1. Loosen the bolts (1a) and remove the UNIAIR module (1b).
Machine Translated by Google

1. Remove the gasket (1a) and the centering bushes (1b) from the UNIAIR module.

1. Remove the previously loosened bolt (1a) and remove the crankshaft gear (1b).

1. Loosen the bolts and remove the tool.

Tool Name function Validity

- Check with a clock micrometer with a magnetic foot whether the axial play of the camshaft is within the tolerance.

Measurement Where the Validity

1.6 16v MJet

Axial cam play (mm) 0.100 ÷ 0.230 2.0 16v MJet

1.9 16v Twin Turbo MJet

1. Loosen the bolts (1a) and remove the camshaft bearing caps (1b).
Machine Translated by Google

1. Remove the camshaft.

- To check the camshaft dimensions, see:

edit. 1016E10 CYLINDER HEAD, REMOVAL - REV.

1. Remove the hydraulic valve lifters.

1. Loosen the bolts (1a) and remove the cylinder head (1b).

- Remove the gasket and the centering bushes.

1. Loosen the oil pan mounting bolts (1a) and nuts (1b) on the cylinder block.

1. Use a tool to cut the silicone gasket on the mating surface of the engine oil pan.
Machine Translated by Google

Tools Name function Validity

1870718000 Blade Cut through kit

2. Remove the engine oil pan.

- Carefully clean the mating surfaces between the cylinder block and the oil pan.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE - DISASSEMBLE/ASSEMBLE CONTINUED ON MOV. 1004E10 - CLEAN
DISASSEMBLE PARTS./CONT. - INSTALL CYLINDER HEAD AND OIL PAN - DOES NOT INCLUDE HEAD AND AUXILIARY
REPAIRS 1004E20

Remove ( Install )

1. Loosen the bolts (1a) and remove the oil suction tube (1b).

1. Remove the O-ring from the oil suction tube.

2. Loosen the bolts (2a) and remove the connecting rod bearing caps (2b) with the lower bearing shells.

1. Remove the connecting rod/piston groups complete with the bearing shells.

An arrow for the mounting direction is provided on the piston bottom, which must point to the distribution side.

The connecting rod has a "BROKEN" bearing cap and thus a prescribed mounting position; in addition, a
number is stamped which indicates the cylinder number.
edit. 1028H60 PISTON, PISTON PIN AND RINGS KIT - REPL. ON PISTONS/CONNECTING RODS
ON THE WORKBENCH - INCLUDES ANGLES AND BALANCE
1. Install the crankshaft turning tool.

Tools Name function Validity

turn
1860815000 Flange
crankshaft

1. Using the previously mounted tool as a locking aid, loosen the bolt (1a) and remove the crankshaft
gear (1b).
Machine Translated by Google

1. Loosen the bolt (1a) and remove the speed sensor (1b).

1. Loosen the fasteners (1a) of the water pump (1b), cut the gasket using a tool and remove the water pump.

Tools Name function Validity

1870718000 Blade Cut through kit

2. Loosen the bolts (2a) and remove the front crankshaft cover (2b) complete with the gasket.

1. Loosen the bolts (1a), cut the gasket with the tool and remove the rear crankshaft cover (1b) with the integrated
oil seal.

Tools Name function Validity

1870718000 Blade Cut through kit

- Remove the previously mounted flange for turning the crankshaft.

1. Check with a clock micrometer whether the crankshaft axial play is within tolerance.

Measurement Where the Validity

Crankshaft Axial Clearance (mm) 0.155 ÷ 0.355 1.4 16v TJet

- Remove the clock micrometer.

If the crankshaft clearance deviates, the seats must be ground into the block and a center main bearing with
integrated crankshaft bearings with an appropriate oversize must be installed.
1. Loosen the bolts (1a) and remove the lower block (1b) complete with the lower main bearing shells.
Machine Translated by Google

1. Remove the lower main bearing shells from the cylinder block.

1. Remove the crankshaft.

1. Remove the upper main bearing shells from the cylinder block.

2. Remove the thrust bearings.

3. Remove the centering bushes between the lower block and the cylinder block.

1. Loosen the mounting bolt and remove the knock sensor.

- Remove the freeze plugs from the cylinder block using a suitable steel stamp.

- Remove the plug in the oil channel from the cylinder block using a suitable steel stamp.
1. Remove the oil nozzles as described below.
Machine Translated by Google

1. Remove the oil nozzles (1a) using tool (1b).

Tools Name function Validity

1860395000 Remove oil jets in 1.4 16v TJet

rubber stamp
engine
Insert the punch pilot hole onto the nozzle surfaces to prevent the punch from slipping and damaging the cylinder
wall during removal.
Only use new oil nozzles for installation.

Install ( Remove )

- Clean and check the condition of all disassembled components.

- Place the cylinder block on a rotatable stand.

- Mount the plugs in the coolant and oil channels in the cylinder block using suitable stamps and sealant.

- Mount the centering bushes in the cylinder block.

1. Install the new oil nozzles (1b) using the tool (1a) and a plastic hammer.

Tools Name function Validity

1860313000 Mounting tool Install oil nozzles 1.4 16v TJet

1. Check with a calibrated row (1a) and feeler gauges (1b) whether the flatness of the cylinder head/block is within
tolerance.

2. If the value is not within tolerance, flatten the mating surface.

Measurement Where the Validity

Flatness of cylinder head lower < 0.1

mating surface (mm)

- Check whether the diameter of the cylinders is within tolerance.

Measurement Where the Validity

Cylinders Inside Diameter - Class A

72.000 ÷ 72.010 1.4 16v TJet
(mm)
Machine Translated by Google

Measurement Where the Validity

Cylinders Inside Diameter - Class

72.010 ÷ 72.020 1.4 16v TJet
B (mm)

Measurement Where the Validity

Cylinders Inner Diameter - Class C

72.020 ÷ 72.030 1.4 16v TJet
(mm)

- Check whether the ovality of the cylinders is within tolerance.

Measurement Where the Validity

Ovality cylinders (mm) +/- 0.05 1.4 16v TJet

- Check whether the conicity of the cylinders is within tolerance.

Measurement Where the Validity

Conicity of cylinders (mm) +/- 0.005 1.4 16v TJet

- In the case of a deviating diameter, conicity or ovality, the cylinders must be honed to the prescribed excess.

All cylinders should be honed to the same excess.

Measurement Where the Validity

Oversize cylinders (mm) 0.1

- Check whether the diameter of the main bearing pins is within tolerance.

Measurement Where the Validity

Main Bearing Stud Diameter - Class A 47.994 ÷ 48.000 1.4 16v TJet
(mm)

Measurement Where the Validity

Main Bearing Stud Diameter - Class B 47.988 ÷ 47.994 1.4 16v TJet
(mm)

Measurement Where the Validity

Main Bearing Pin Diameter - Class C 47.982 ÷ 47.988 1.4 16v TJet
(mm)

- With a deviating diameter, the main bearing pins must be ground to the prescribed undersize.

The crankshaft is nitrided; therefore, a crankshaft must be re-nitrided after grinding, after which the dimensions
must be checked.

Measurement Where the Validity

Machine Translated by Google

Undersize of main bearing journals 0.127

(mm)

- Check whether the diameter of the connecting rod bearing journals is within tolerance.

Measurement Where the Validity

Diameter of connecting rod bearing 41.990 ÷ 42.008 1.4 16v TJet

journals (mm)

- With a deviating diameter, the connecting rod bearing pins must be ground to the prescribed undersize.

The crankshaft is nitrided; therefore, a crankshaft must be re-nitrided after grinding, after which the dimensions must be checked.

Measurement Where the Validity

Diameter of connecting rod bearing 41.990 ÷ 42.008 1.4 16v TJet

journals (mm)

- Check the main bearings; Please note that the bearing shells must not be machined. If they show scratches or signs of eating,
they should be replaced.

- Fit the main bearing shells in the cylinder block, with the lubrication openings in front of the oil channels and all parts must be carefully
cleaned. The center main bearing shell contains the crankshaft axial bearings. This scale has a supporting and a centering task.

- If the crankshaft has been ground, fit new oversize bearing shells so that the prescribed clearance is maintained.

1. Install the upper main bearing shells and crankshaft in the cylinder block.

2. Apply a gauge wire (plastigage) to determine the main bearing clearance.

- Place the main bearing shells on the lower block.

1. Mount the lower block on the cylinder block and check whether the stamped numbers on the two parts are opposite each other.
The individual parts of the cylinder block cannot be replaced separately.

- The thickness of the main bearing shells is given below.

Measurement Where the Validity

Main bearing shell thickness - Class 1.836 ÷ 1.840 1.4 16v TJet
1 (red) (mm)

Measurement Where the Validity

Main bearing shell thickness - Class 1.843 ÷ 1.847 1.4 16v TJet
2 (blue) (mm)

Measurement Where the Validity

Main bearing shell thickness - Class 1.848 ÷ 1.852 1.4 16v TJet
3 (yellow) (mm)
Machine Translated by Google

Measurement Where the Validity

Oversize of main bearing shells 0.127 1.4 16v TJet

(mm)

- Tighten the fixing bolts of the lower block on the cylinder block with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Cylinder block central end M10 1.9 ÷ 2.1 + 80° 1.4 16v TJet

Component Confirmation ISLAND

Value (daNm) Validity

Cylinder block side bolt M8 2.9 ÷ 3.2 1.4 16v TJet

1. Remove the lower block and check the main bearing clearance by measuring the width of the test strip.

Check one tap at a time without moving the crankshaft.

Measurement Where the Validity

Main Bearing Clearance 0.025 ÷ 0.040 1.4 16v TJet

- Main Bearing Studs (mm)

- After checking all the taps, apply the sealant to the contact surfaces of the lower block and the cylinder block, install
the lower block and tighten the corresponding bolts to the specified torque.

Apply a 2 mm thick bead of sealant to the contact surface of the lower block.

- Check whether the piston diameters are within tolerance; if necessary, replace the pistons complete with the piston rings and
the piston pins.

Measurement Where the Validity

Piston Outer Diameter - Class A 71.960 ÷ 71.970 1.4 16v TJet

(mm)

Measurement Where the Validity

Piston Outer Diameter - Class B 71.970 ÷ 71.980 1.4 16v TJet

(mm)

Measurement Where the Validity

Piston Outer Diameter - Class C 71.980 ÷ 71.990 1.4 16v TJet

(mm)

Take the measurement perpendicular to the piston pin 9 mm from the bottom edge of the piston skirt.

- Place the pistons in the corresponding cylinders and measure the play with a feeler gauge.

Measurement Where the Validity

Piston - Cylinder Clearance (mm) 0.030 ÷ 0.050 1.4 16v TJet

- Check whether the inner diameter of the piston pin bores is within tolerance; replace the pistons if necessary.
Machine Translated by Google

Measurement Where the Validity

Piston Pin Bore Diameter (mm) 17.978 ÷ 17.982 1.4 16v TJet

- Check whether the outer diameter of the piston pins is within the tolerance; replace worn parts if necessary.

Measurement Where the Validity

Piston pin outer diameter (mm) 17.970 ÷ 17.974 1.4 16v TJet

- Measure the thickness of the piston rings of the pistons using a micrometer.

Measurement Where the Validity

Thickness 1st compression piston ring (mm) 1.170 ÷ 1.195 1.4 16v TJet

Measurement Where the Validity

Thickness 2nd compression piston ring (mm) 1,170 ÷ 1,190 1.4 16v TJet

Measurement Where the Validity

Thickness 3rd compression piston ring (mm) 1.970 ÷ 1.990 1.4 16v TJet

Measurement Where the Validity

Piston Ring Oversize Thickness (mm) 0.1 1.4 16v TJet

1. Place the piston rings (1a) in the cylinders and check with a feeler gauge (1b) whether the lock play is within
tolerance. If necessary, replace the piston rings.

Measurement Where the Validity

Clearance 1st compression piston ring (mm) 0.20 ÷ 0.35 1.4 16v TJet

Measurement Where the Validity

Clearance 2nd compression piston ring (mm) 0.40 ÷ 0.60 1.4 16v TJet

Measurement Where the Validity

Clearance 3rd compression piston ring (mm) 0.20 ÷ 0.40 1.4 16v TJet

- Check that the piston ring grooves are within tolerance.

Measurement Where the Validity

Piston Ring Groove - 1st Piston Ring (mm) 1,220 ÷ 1,240 1.4 16v TJet

Measurement Where the Validity

Machine Translated by Google

Piston Ring Groove - 2nd Piston Ring (mm) 1,210 ÷ 1,230 1.4 16v TJet

Measurement Where the Validity

Piston Ring Groove - 3rd Piston Ring (mm) 2.010 ÷ 2.030 1.4 16v TJet

1. Using a feeler gauge (1a), check the clearance between the piston rings (1b) and the associated piston ring grooves (1c).

Measurement Where the Validity

Axial Clearance 0.025 ÷ 0.070 1.4 16v TJet

1st Compression Piston Ring (mm)

Measurement Where the Validity

Axial Clearance 0.020 ÷ 0.060 1.4 16v TJet

2nd Compression Piston Ring (mm)

Measurement Where the Validity

Axial Clearance 0.020 ÷ 0.060 1.4 16v TJet

3rd Compression Piston Ring (mm)

- Check whether the diameter of the connecting rod eyes and the connecting rod bearing bores is within tolerance.

Measurement Where the Validity

Diameter of connecting rod bearing 45.138 ÷ 45.148 1.4 16v TJet

bore (mm)

Measurement Where the Validity

Diameter connecting rod eye with bearing 1.4 16v TJet

17.993 ÷ 18.000
bush (mm)

The connecting rod bushing cannot be removed from the connecting rod.

Therefore, Dept. Only parts the bus in combination with the connecting rod.

edit. 1028H60 PISTON, PISTON PIN AND RINGS KIT - REPL. ON PISTONS/CONNECTING RODS
ON THE WORKBENCH - INCLUDES ANGLES AND BALANCE

- Fit the crankshaft turning tool.

Tools Name function Validity

1860815000 Flange turn crankshaft

The connecting rod has a "BROKEN" bearing cap and thus a prescribed mounting position; in addition, a number is
stamped which indicates the cylinder number.

Letters are applied to the cylinder block, which indicate the class of the cylinders.

1. Assemble the connecting rod/piston groups complete with the bearing shells using appropriate tools for
compressing the piston rings and mounting the assembly in the cylinders.
Machine Translated by Google

An arrow (a) for the mounting direction is provided on the piston bottom, which must point to the distribution side.

1. Apply a gauge wire (Plastigage) to determine the connecting rod bearing play.

- The thickness of the connecting rod bearing shells is given below.

Measurement Where the Validity

Thickness of connecting 1.544 ÷ 1.548 1.4 16v TJet

rod bearing shell standard (mm)

Measurement Where the Validity

Oversize
connecting rod bearing 0.127 1.4 16v TJet
shell 1 (mm)

Measurement Where the Validity

Oversize
connecting rod bearing 0.254 1.4 16v TJet
shell 2 (mm)

Measurement Where the Validity

Oversize
connecting rod bearing 0.508 1.4 16v TJet
shell 3 (mm)

- Reassemble the connecting rod bearing caps with the bearing shells and tighten the corresponding bolts with tightening torque
vast.

The connecting rods are of the "broken" bearing cap type; when replaced, they are supplied "pre-broken" by the manufacturer.
Check the components for burrs, blowholes, scratches and all other surface defects. The parts must be carefully rinsed, cleaned
and dried before assembly.
The connecting rod bearing caps must be fitted with the number stamped on the same side as the number on the connecting rods.
Machine Translated by Google

Component Confirmation ISLAND

Value (daNm) Validity

Connecting Rod Bearing Caps Bolt M8 1.9 ÷ 2.1 + 40 ° +/- 2 ° 1.4 16v TJet

1. Remove the connecting rod bearing caps and check the connecting rod bearing clearance by measuring the width of the test strip.

Check one tap at a time without moving the crankshaft.

Measurement Where the Validity

Connecting Rod Bearing

0.024 ÷ 0.060 1.4 16v TJet
Clearance - Connecting Rod Bearing Studs (mm)

- If the play deviates, the connecting rod bearing shells must be replaced.
- Reassemble the connecting rod bearing caps with the bearing shells and tighten the corresponding bolts to the
specified torque.

- Tilt the motor onto the rotating trestle.

- Place the knock sensor in the seat and tighten the new bolt with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

- Fit a new oil pump gasket.

- Install the front crankshaft cover with the built-in oil pump and the oil suction tube and tighten the corresponding bolts with
torque.

Component Confirmation ISLAND

Value (daNm) Validity

Motor pomp End M6 0.9 ÷ 1.1 1.4 16v TJet

- Install the front crankshaft seal using the tool.

Tools Name function Validity

1.4 16v TJet

1860990000 Mounting tool Install camshaft seal
1.8 DI Turbo

- Apply a bead of silicone gasket to the new rear crankshaft cover, install the cover and tighten the bolts with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Rear
crankshaft cover to End M6 0.8 ÷ 1.0 1.4 16v TJet
cylinder block

- Install the crankshaft gear.

- Using the tool as a blocking aid, tighten the sprocket mounting bolt on the crankshaft to torque.

Tools Name function Validity

1860815000 Flange turn crankshaft

Machine Translated by Google

Component Confirmation ISLAND

Value (daNm) Validity

1.9 ÷ 2.1 + 107° ÷

crankshaft gear End M12 1.4 16v TJet
113°

- Place the speed sensor in the seat and tighten the corresponding bolt with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Speed sensor - M6 0.9 1.4 16v TJet

- Apply silicone sealant in the groove in the mounting flange for the water pump on the cylinder block.

- Place the water pump in the seat and tighten the corresponding bolts and the nut with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

water pump End M6 0.9 ÷ 1.1 1.4 16v TJet

Component Confirmation ISLAND

Value (daNm) Validity

water pump Nut M6 0.9 ÷ 1.1 1.4 16v TJet

- Remove the silicone gasket residue from the mating surfaces on the lower block and on the oil pan.

- Continuously apply a bead of sealant along the entire rim of the oil pan.

- Place the oil pan in the seat and tighten the corresponding bolts and nuts with tightening torque.

The oil pan must not be moved horizontally during installation as this could scrape the sealant off.

Component Confirmation ISLAND

Value (daNm) Validity

Motorola End M6 0.8 ÷ 1.0 1.4 16v TJet

Component Confirmation ISLAND

Value (daNm) Validity

Motorola Nut M6 0.8 ÷ 1.0 1.4 16v TJet

- Mount the centering bushes in the cylinder block.

- Fit a new head gasket on the cylinder block.

- Place the cylinder head on the cylinder block over the centering bushes.

1. Tighten the cylinder head mounting bolts to torque.

For each stage of tightening, follow the tightening sequence shown in the illustration.

Component Confirmation ISLAND

Value (daNm) Validity

Cylinder head End M9 3.0 + 90° + 90° 1.4 16v TJet

- Fit the centering bushes and place a new camshaft housing gasket on the cylinder head.

- Install the camshaft housing and tighten the bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity
Machine Translated by Google

Camshaft Housing Bolt M8 1.3 ÷ 1.6 1.4 16v TJet

- Place the hydraulic valve lifters in the seats.

- Place the camshaft in the seat.

1. Install the indicated camshaft bearing caps, matching the debossed letters on the cylinder head and on the bearing
caps.

The letter “V” indicates the flywheel side.

The letter “D” indicates the distribution side.

The letter "C" indicates the middle position.

- Apply a bead of "LOCTITE 5203 type F" anaerobic sealant to the camshaft housing mating surface for the front and
rear camshaft bearing cover.
- Install the front and rear camshaft bearing caps.
1. Tighten the camshaft bearing cap mounting bolts to torque.

Value
Component Confirmation ISLAND
Validity
(daNm)

1. Install a new camshaft seal using the tool.

Tools Name function Validity

1. Install the tool in the vacuum pump seat to lock the camshaft.

Tools Name function Validity

- Fit the toothed camshaft pulley and hand-tighten the corresponding bolt.
- Fit the centering bushes and the gasket of the MULTIAIR module.

- Place the MULTIAIR module in the seat and tighten the bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

- Remove the tool used to compress the plates of the pump elements in the MULTIAIR module.
Machine Translated by Google

Tools Name function Validity

1. Before installing the valve cover, apply "LOCTITE 5900" to the indicated areas of the camshaft housing
sealant.

- Fit the valve cover complete with the new gasket and tighten the bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

- Fit the spark plugs and tighten them with a tightening torque using the appropriate tool.

Component Confirmation ISLAND

Value (daNm) Validity

Candles -
M12 1.6 ÷ 2.0 1.4 16v TJet

- Place the ignition coils in the seats and tighten the corresponding bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Coils End M6 0.9 1.4 16v TJet

1. Install the crankshaft adjustment tool.

Tools Name function Validity

Machine Translated by Google

2000004500 Times Adjust crankshaft 1.4 16v TJet

2. Replace the timing belt; start at the crankshaft sprocket, then the water pump pulley, the camshaft pulley, and finally the
adjustable tensioner.

Carry out this work with the camshaft pulley not fully tightened.

1. Tension the timing belt by turning the adjustable tensioner (1b) counterclockwise using the tool (1a); fix the tensioner
when the adjusting fork (1c) is against the stop (1d).

Tools Name function Validity

Toothed timing belt

1860987000 Key 1.4 16v TJet
tighten

- Tighten the camshaft pulley mounting bolt to torque.

Component Confirmation ISLAND

Value (daNm) Validity

camshaft pulley End M12 10.8 ÷ 13.2 1.4 16v TJet

- Remove the adjustment tools and turn the crankshaft two turns.

1. Slightly loosen the adjusting tensioner retaining nut and adjust the front fork using the tool (1a) so that it is aligned with
the rear fork (1b).

2. Tighten the adjustable tensioner mounting nut to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Adjustable tensioner
from Nut M8 2.2 ÷ 2.7 1.4 16v TJet
distributieaandrijving

- Turn the crankshaft two more turns in the normal direction of rotation, fit the timing adjusting tools and check the adjustment.

- Remove the tools used for timing timing adjustment.

- Mount the vacuum pump complete with the new gasket and tighten the bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

- Place the fixed support for the drive unit on the distribution side and tighten the bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Engine
End M10 5.4 ÷ 6.6 1.4 16v TJet
mount (distribution side)

- Fit the timing covers and tighten the corresponding bolts.

- Install the crankshaft pulley and tighten the corresponding bolts with tightening torque.
Machine Translated by Google

Value
Component Confirmation ISLAND
Validity
(daNm)

Crankshaft Pulley Bolt M8 2.3 ÷ 2.8 1.4 16v TJet

- Tighten the mounting connection of the oil filter support and the engine oil cooler on the front crankshaft cover
with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Support for oil filter and

oil cooler (oil pump side) End M20 4.1 ÷ 4.5 1.4 16v TJet

- Tighten the mounting bolt of the oil filter support and the engine oil cooler on the cylinder block with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Support for oil filter and

oil cooler (cylinder block End M10 4.5 ÷ 5.5 1.4 16v TJet
side)

- Fit the return pipe for the water pump complete with a new sealing ring and tighten the corresponding bolts.
- Install the gasket for the exhaust manifold complete with the heat shield for the turbocharger.
- Place the exhaust manifold and the bracket on the distribution side.

- Tighten the new exhaust manifold mounting nuts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

1.4 ÷ 1.6 + 30°

Exhaust Manifold Nut M8 1.4 16v TJet
+/- 3°

- Place the heat shield in front of the exhaust manifold.

- Install the mounting stud for the exhaust manifold heat shield using a suitable tool.

- Tighten the new heat shield mounting nuts on the exhaust manifold with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Exhaust manifold
Nut M6 0.8 ÷ 1.0 1.4 16v TJet
heat shield

- Fit the turbocharger complete with a new gasket and tighten the new nuts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

1.4 16v TJet

Turbocharger on Nut (replaced by M8 2.3 ÷ 2.8
exhaust manifold new)
1.6 16v MJet

- Place the turbocharger coolant return line on the water pump return tube complete with a new O-ring and tighten the
bolt with torque.

Component Confirmation ISLAND

Value (daNm) Validity

- Tighten the coolant return line connection to the turbocharger.

Machine Translated by Google

The pipe must be held back when tightening the connections. Any displacement through an angle greater than 3°
will damage the sealing of the connections.
- Fit the turbocharger oil supply line and tighten the connection on the turbocharger with tightening torque
vast.

The pipe must be held back when tightening the connections. Any displacement through an angle greater than 3°
will damage the sealing of the connections.

Component Confirmation ISLAND

Value (daNm) Validity

- Tighten the connection of the turbocharger oil supply line to the engine oil cooler with tightening torque.

The pipe must be held back when tightening the connections. Any displacement through an angle greater than 3°
will damage the sealing of the connections.

Component Confirmation ISLAND

Value (daNm) Validity

Oil supply line to

turbocharger (cooler Connection M6 0.8 ÷ 1.0 1.4 16v TJet
side)

- Install the coolant return line from the engine oil cooler and tighten the corresponding connection on the oil cooler
with tightening torque.

The pipe must be held back when tightening the connections. Any displacement through an angle greater than 3°
will damage the sealing of the connections.

Component Confirmation ISLAND

Value (daNm) Validity

- Tighten the connection of the coolant return line from the engine oil cooler to the return tube of the water pump with
tightening torque.

The pipe must be held back when tightening the connections. Any displacement through an angle greater than 3°
will damage the sealing of the connections.
- Install the engine oil cooler coolant supply line and tighten the nut on the intermediate bracket.

- Tighten the bolts of the coolant supply line on the engine oil cooler with torque.

Component Confirmation ISLAND

Value (daNm) Validity

1. Fit the turbocharger oil return line (1a) complete with new gaskets and tighten the bolt (1b) on the slotted hole flange
first and then the remaining bolt (1c) with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Engine oil return line End M6 0.8 ÷ 1.0 1.4 16v TJet
from turbocharger

2. Tighten the oil return line fixing bolt for the turbocharger onto the cylinder block with tightening torque
vast.

Component Confirmation ISLAND

Value (daNm) Validity

Motorolieretourleiding Bolt M6 0.8 ÷ 1.0 1.4 16v TJet

from turbocharger

3. Tighten the oil return line coupling for the turbocharger to the oil filter support with torque.

The pipe must be held back when tightening the connections. Any displacement through an angle greater than 3°
will damage the sealing of the connections.

Component Confirmation ISLAND

Value (daNm) Validity
Machine Translated by Google

Turbocharger oil return

line (oil filter support M16 3.0 ÷ 3.6 1.4 16v TJet
Connection
side)

- Place the heat shields on the engine oil cooler and tighten the corresponding bolts.
- Place the cable support bracket and tighten the corresponding bolts.
- Assemble the manifold housing complete with the new gasket and tighten the bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Bolt (replaced M7 1.3 ÷ 1.6 1.4 16v TJet

Manifold housing
with new one)

- Place the reinforcement bracket in front of the manifold housing and tighten the corresponding fasteners.

- Install the complete oil dipstick tube and tighten the corresponding bolt.
- Place the bearing support for the intermediate shaft in the seat and tighten the bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Bearing support for End M8 2.3 ÷ 2.8 1.4 16v TJet

intermediate shaft

- Fit the support for the alternator and the air conditioning compressor complete with the adjustable tensioner and tighten the
corresponding fasteners with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Compressorsteun End M10 4.5 ÷ 5.5

Component Confirmation ISLAND

Value (daNm) Validity

Compressorsteun Nut M8 2.3 ÷ 2.7 1.4 16v TJet

Component Confirmation ISLAND

Value (daNm) Validity

Compressorsteun Nut M10 4.5 ÷ 5.5 1.4 16v TJet

- Place the alternator in the seat and tighten the bolts with tightening torque.

Value
Component Fixing ISLAND
Validity
(daNm)

Dynamo End M10 4.5 ÷ 5.5

Value
Component Fixing ISLAND
Validity
(daNm)

Dynamo End M8 2.3 ÷ 2.7

- Install the air conditioning compressor and tighten the corresponding bolts with tightening torque.

Value
Component Confirmation ISLAND
Validity
(daNm)
Machine Translated by Google

Compressor End M8 2.3 ÷ 2.7

- Put on the new accessory drive belt and adjust the belt tensioner to remove the locking pin.

- Place the engine wiring harness in the seat.

- Connect the plug to the phase sensor.

- Connect the coolant temperature sensor connector.

- Fasten the retaining clips of the cable to the corresponding bracket.

- Connect the plug of the oil temperature sensor in the UNIAIR module.

- Connect the plug to the throttle body.

- Secure the engine harness retaining clips under the manifold housing.
- Connect the alternator ground cable and tighten the corresponding nut.

- Connect the plug of the air conditioning compressor.

- Connect the knock sensor plug.
- Connect the plug to the fuel vapor shut-off valve.

- Connect the plug in the cable of the injection valves.

- Connect the ground cable to the compressor support and tighten the corresponding bolt.
- Connect the plug to the air temperature and pressure sensor and fasten the retaining clips of the corresponding cable.
- Fasten the retaining clips of the cable tray, place the cable tray and tighten the mounting bolts on the valve cover
vast.

- Connect the plugs to the control solenoids for the inlet valves.
- Connect the plugs to the ignition coils.

- Connect the ground cable and tighten the corresponding bolt.

- Connect the plug to the bypass solenoid valve for the turbo pressure regulation.
- Connect the engine oil pressure sensor connector.

- Connect the plug of the speed sensor.

- Fit the rear timing cover and tighten the corresponding bolts.
- Install the complete oil separator and tighten the corresponding bolts.
- Connect the crankcase ventilation hose to the manifold housing and tighten the corresponding clamp.
- Tighten the new engine oil drain plug with tightening torque.

Value
Component Fixing ISLAND
Validity
(daNm)

Engine oil
Dop
-
1.8 ÷ 2.2 1.4 16v TJet
drain plug
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir DRIVE GEAR FIXED SUPPORT - GEARBOX SIDE - UI 1008A42

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 5530B10 BATTERY - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

- Place a hydraulic jack under the drive unit.

1. Open the clamps (1a) and (1b), and disconnect the cable bundle (1c).

1. Loosen the mounting bolts (1a) of the suspension rubber (1b) on the gearbox side.

1. Loosen the mounting bolts (1a) and remove the engine/box mount (1b).

Install ( Remove )

1. Place the engine/box support (1a) in the seat and tighten the mounting bolts (1b) with torque.

Component Confirmation ISLAND

Value (daNm) Validity

engine mount
Machine Translated by Google

(gearbox side) Bolt M12 8.1 ÷ 9.9 1.4 16v TJet

1. Install the suspension rubber (1a) and tighten the fastening bolts (1b) with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Rubber mount of
engine/bucket Bolt (replaced with M10 5.4 ÷ 6.6
support (gearbox new one)
side) on body

Component Confirmation ISLAND

Value (daNm) Validity

Rubber mount of
engine/bucket Bolt (replaced with M12 7.7 ÷ 9.3
support (gearbox new one)
side) on body

- Place the cable bundle and close the corresponding clamps.

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 5530B10 BATTERY - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Place the car on a lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI 1008A46

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

1. Loosen the bolts (1a) and remove the engine mount (timing side) (1b).

Install ( Remove )

1. Place the fixed support for the drive unit on the timing side (1a) and tighten the bolts (1b) with tightening
torque.

Component Confirmation ISLAND

Value (daNm) Validity

Engine
End M10 5.4 ÷ 6.6 1.4 16v TJet
mount (distribution side)

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SUPPORT RUBBER FRONT (DISTRIBUTION SIDE) OF DRIVE GENERATOR - REPL. 1008B10

Remove ( Install )

- Place the car on a lift bridge.

- Loosen the fixing bolts (1a) and drain the coolant from the expansion tank (1b).

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Place a suitable hydraulic jack under the engine.
1. Loosen the bolts (1a) and (1b) and remove the rubber mounting (1c) from the engine/box support (distribution side).

Install ( Remove )

1. Install the engine/box support mounting rubber (1a) (distribution side) and tighten the bolts (1b) and
(1c) with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Component Confirmation ISLAND

Value (daNm) Validity

- Install the expansion tank and tighten the fixing bolts. - Remove the jack.
- Remove the jack.
edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI
- Remove the car from the lift bridge.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SUPPORT SUPPORT GEARBOX SIDE - REPL. 1008B30

Remove ( Install )

- Place the car on a lift bridge.

- Place a hydraulic jack under the car and support the drive unit appropriately.

edit. 5530B10 BATTERY - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 1008A42 DRIVE GEAR FIXED SUPPORT - GEARBOX SIDE - UI

edit. 5505A28 HOLDER FOR ADDITIONAL FUSES AND RELAY BOX IN ENGINE ROOM - UI

1. Loosen the mounting bolts (1a) and remove the rubber mounting (1b) from the engine/box support
(gearbox side).

Install ( Remove )

1. Place the rubber mounting (1a) of the bracket on the gearbox side and tighten the mounting bolts (1b) with
tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Rubber mount of
engine/bucket Bolt (replaced with M10 5.4 ÷ 6.6
support (gearbox new one)
side) on body

Component Confirmation ISLAND

Value (daNm) Validity

Rubber mount of
engine/bucket Bolt (replaced with M12 7.7 ÷ 9.3
support (gearbox new one)
side) on body

edit. 5505A28 HOLDER FOR ADDITIONAL FUSES AND RELAY BOX IN ENGINE ROOM - UI

edit. 1008A42 DRIVE GEAR FIXED SUPPORT - GEARBOX SIDE - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 5530B10 BATTERY - UI

- Remove the hydraulic jack.

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir GEARBOX LOWER TRACTION ROD - UI 1008C32

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

1. Loosen the lower reaction rod mounting bolt on the suspension subframe.

2. Loosen the lower reaction rod mounting bolt on the bracket on the gearbox.

3. Remove the lower reaction rod.

Install ( Remove )

1. Install the lower reaction rod (1a) and tighten the new mounting bolt/nut (1b) to the bracket on the
gearbox with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Gearbox lower 1.4 16v TJet

reaction rod (side of Bolt/nut (replace with M12 7.2 ÷ 8.8
bracket on gearbox) new)
1.6 16v MJet

2. Tighten the new lower reaction rod mounting bolt to the subframe with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Gearbox lower torque

rod on Bolt (replaced by M12 12.2 ÷ 14.7
subframe of new) suspension

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir BRACKET ON GEARBOX FOR LOWER TRACTION ROD - UI 1008C34

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Place a hydraulic jack under the gearbox side of the drive unit.
1. Loosen the lower reaction rod mounting bolt on the bracket on the gearbox.

Install ( Remove )

1. Place the bracket (1a) for the lower reaction rod on the gearbox and tighten the corresponding bolts (1b) with
tightening torque.

- Fit a new gasket on the flange of the front muffler.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SOUND INSULATION COVER - UI 1016A10

Remove ( Install )

1. Loosen the insulation cap from the retaining pins and remove the cap.

Install ( Remove )

- Place the insulating cover in the seat and fasten the cover to the locking pins.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir VALVE COVER COMPLETE - UI AND GASKET REPLACED 1016A20

Remove ( Install )

edit. 5530B10 BATTERY - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

Machine Translated by Google

Install ( Remove )

Value
Component Fixing Ø Validity
(daNm)

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

Machine Translated by Google

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 5530B10 BATTERY - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CAM HOUSING COMPLETE - UI WITH EXTENDED TIMING BELT.- GASKET
REPLACE 1016B12

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 3330D30 PRESSURE PUMP - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT

Bew. 1036F20 UNIAIR-MODULE - U.I.

edit. 1036F11 CAMSHAFT IN CAM HOUSING - UI

edit. 1036H57 HYDRAULIC LIFTS (ALL) - UI

See K047
PHASESENSOR
Machine Translated by Google

Install ( Remove )

edit. 1036H57 HYDRAULIC LIFTS (ALL) - UI

edit. 1036F11 CAMSHAFT IN CAM HOUSING - UI

Bew. 1036F20 UNIAIR-MODULE - U.I.

edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 3330D30 PRESSURE PUMP - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CYLINDER HEAD COMPLETE - UI AND GASKET REPLACED 1016C10

Remove ( Install )

See
A001
BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 3330D30 PRESSURE PUMP - UI

edit. 4450B04 FRONT WHEEL RIGHT - UI

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT

Bew. 1036F20 UNIAIR-MODULE - U.I.

edit. 1036F11 CAMSHAFT IN CAM HOUSING - UI

edit. 1036H57 HYDRAULIC LIFTS (ALL) - UI

edit. 1016B12 CAM HOUSING COMPLETE - UI WITH EXTENDED TIMING BELT.- GASKET
TO REPLACE

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1080B62 CATALYST - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1064A27 PIPE BETWEEN PRESSURE RESERVOIR AND SOLENOID CONTROL VALVE OF
Machine Translated by Google

ACTUATOR - UI

edit. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - ONION

Machine Translated by Google
Machine Translated by Google

Install ( Remove )

Value
Component Fixing Ø Validity
(daNm)
Machine Translated by Google

Cylinder Head Bolt M9 3.0 + 90° 1.4 16v

+ 90° TJet

Component Confirmation ISLAND

Value (daNm) Validity

Coolant Supply Line M16 3.0 ÷ 3.6 1.4 16v TJet

to engine oil cooler Connection

edit. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - ONION

edit. 1064A27 PIPE BETWEEN PRESSURE RESERVOIR AND SOLENOID CONTROL VALVE OF
ACTUATOR - UI

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1080B62 CATALYST - UI

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016B12 CAM HOUSING COMPLETE - UI WITH EXTENDED TIMING BELT.- GASKET
TO REPLACE

edit. 1036H57 HYDRAULIC LIFTS (ALL) - UI

edit. 1036F11 CAMSHAFT IN CAM HOUSING - UI

Bew. 1036F20 UNIAIR-MODULE - U.I.

edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

Machine Translated by Google

VERV.

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 4450B04 FRONT WHEEL RIGHT - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

See
A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CYLINDER HEAD, REMOVED, TRANSFER PARTS - REPL. 1016C20

Remove ( Install )

- Place the cylinder head in the vice.

Tool Name function Validity

1860470000 Support Overhaul

cylinder head

1. Loosen the retaining nut (1a) and remove the timing belt tensioner (1b).

1. Loosen the fixing bolts (1a) and remove the thermostat unit (1b).

- Remove the gasket.

1. Loosen the mounting bolts (1a) and remove the intake manifold (1b).

1. Unscrew and remove the spark plugs.

Machine Translated by Google

Install ( Remove )

- Fit the spark plugs and tighten them with tightening torque.

Value
Component Fixing ISLAND
Validity
(daNm)

1.4 16v
Candles
-
M12 1.6 ÷ 2.0
TJet

- Install the intake manifold and tighten the mounting bolts.

- Fit the thermostat unit with a new gasket and tighten the mounting bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Thermostat End M6 0.9 ÷ 1.1 1.4 16v TJet

- Fit the timing belt tensioner and tighten the fastening nut with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Adjustable tensioner
from Nut M8 2.2 ÷ 2.7 1.4 16v TJet
distributieaandrijving

- Remove the cylinder head from the vice.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CYLINDER HEAD, REMOVED - REV. 1016E10

Remove ( Install )

1. Place the cylinder head (1a) in the vice using the tool (1b).

Tools Name function Validity

1860470000 support
Overhaul
cylinder head

2. Install the valve support tool.

Tools Name function Validity

1860786000 Stop 1.4 16v TJet

foot plate
valves
1. Loosen the bolts (1a) and remove the thermostat (1b) complete with the O-ring.

1. Loosen the nut (1a) and remove the adjustable timing belt tensioner (1b).

1. Press in the valve springs using tools (1a) and (1b) to remove the valve keys (1c).

Tools Name function Validity

1860644000 lever
Removing/installing valves

Tools Name function Validity

1.4 16v TJet

1870890000 Sleeve Remove valves
1.8 DI Turbo

1. Remove the top valve spring seats.

2. Remove the valve springs.

Machine Translated by Google

1. Using the tool (1a), remove the valve stem seals (1b).

Tools Name function Validity

1870894000 Trekker Remove valve stem seals 1.4 16v TJet

1. Remove the lower valve spring seats.

The lower plates on the exhaust side, in which the letter "S" is stamped, have a thickness of 0.8 mm.

The lower plates on the intake side, in which the letter "A" is debossed, have a thickness of 3.2 mm.

- Remove the locking tool and remove the inlet and outlet valves.

- Open the vice and remove the cylinder head.

- Remove the support tool from the cylinder head.

edit. 1016E14 CYLINDER HEAD VALVE GUIDES - REPL. DURING PROCESS 1016E10

Install ( Remove )

- Decarbonize and clean the valve seats and associated channels.

- Remove the gasket residue from the lower mating surface of the cylinder head.

- Check whether the flatness of the cylinder head is within tolerance.

Measurement Where the Validity

Flatness of cylinder
head lower mating < 0.1
surface (mm)

- If necessary, flatten the lower mating surface of the cylinder head. It is allowed to flatten the cylinder head 0.1 mm below the
minimum head height (production size).

Measurement Where the Validity

Cylinder head height (production size) 77 1.4 16v TJet

(mm)

1. Check that the indicated parts of the combustion chambers have not changed shape due to the flattening.
Replace the head if necessary.
Machine Translated by Google

- In addition, check the combustion chambers as follows.

1. Temporarily install the valves and spark plugs. Use a burette with a graduated scale. Fill the burette with a specified
amount of engine oil.

2. Place a glass plate with holes at the level of the combustion chambers on the cylinder head.

3. Fill the combustion chamber completely with engine oil, taking care not to spill engine oil outside the combustion
chamber.

- Allow the engine oil to settle for about 10 minutes.

- Determine the amount of oil in the burette and calculate the difference compared to the oil originally present in the
burette. This difference is the content of the combustion chamber.

- Check whether this value is within tolerance. Replace the cylinder head if the value is out of tolerance.

Measurement Where the Validity

Combustion chamber volume (cm3) 14.30 1.4 16v TJet

- Check the valve stem for grooves and fretting.

- Check that the valve stem diameter is within tolerance; replace worn valves.

Measurement Where the Validity

Valve Stem Diameter - Inlet (mm) 5.982 ÷ 6.000 1.4 16v TJet

Measurement Where the Validity

Valve Stem Diameter - Outlet (mm) 5.974 ÷ 5.992 1.4 16v TJet

- Check whether the diameter of the valve disc is within the tolerance; replace worn valves.

Measurement Where the Validity

Inlet valve outer diameter (mm) 26.75 ÷ 27.05 1.4 16v TJet

Measurement Where the Validity

Machine Translated by Google

Exhaust valve outer diameter (mm) 22.25 ÷ 22.55 1.4 16v TJet

- Check whether the inner diameter of the valve guide and the clearance with the corresponding valve is within tolerance; replace
the valve guide if necessary.

Measurement Where the Validity

Valve guide inner diameter (mm) 6.022 ÷ 6.040 1.4 16v TJet

Measurement Where the Validity

Clearance Valves/Valve Guides - Inlet 0.022 ÷ 0.058 1.4 16v TJet

(mm)

Measurement Where the Validity

Clearance valves/valve guides - outlet 0.030 ÷ 0.066 1.4 16v TJet

(mm)

- If necessary, replace the valve guides; see

edit. 1016E14 CYLINDER HEAD VALVE GUIDES - REPL. DURING PROCESS 1016E10

- Check with suitable tools whether the specifications of the valve springs are within tolerance; replace valve springs if necessary.

Measurement Where the Validity

Free height valve springs (mm) 46.9 1.4 16v TJet

Measurement Where the Validity

Height of valve springs under a 37.52 1.4 16v TJet

load of 14.9 ÷ 16.5 daN (mm)

Measurement Where the Validity

Height of springs under a load of 31.1 ÷ 30.0 1.4 16v TJet

34.1 daN (mm)

- Fit the lower valve spring seats.

The lower plates on the exhaust side, in which the letter "S" is stamped, have a thickness of 0.8 mm.

The lower plates on the intake side, in which the letter "A" is debossed, have a thickness of 3.2 mm.

1. Install the new valve stem seal rubbers onto the valve guides using the tool.

Tools Name function Validity

Seal of valve
1860993000 Montagedoorn guide 1.4 16v TJet
to assemble

- Install the valves, springs, top spring seats and valve keys using the same tool used for removal.

- Fit the adjustable timing belt tensioner and hand-tighten the corresponding nut.
Machine Translated by Google

- Mount the thermostat complete with a new O-ring and tighten the mounting bolts with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Thermostat End M6 0.9 ÷ 1.1 1.4 16v TJet

- Loosen the nuts and remove the cylinder head from the support tool.
- Check that the camshaft bearing pins and the lift height are within tolerance.

Measurement Where the Validity

Measurement Where the Validity

1.4 16v TJet

Rated valve lift - inlet (mm) 7.5
150pk

Measurement Where the Validity

1.4 16v TJet

Rated valve lift - outlet 7
(mm)
150pk
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CYLINDER HEAD VALVE GUIDES - REPL. DURING PROCESS 1016E10 1016E14

Remove ( Install )

1. Remove the valve guides using a tool.

Tool Name function Validity

Install ( Remove )

- Check that the diameter of the valve guide bores is within tolerance.

Measurement Where the Validity

Diameter klepgeleiderboring 9.959 ÷ 9.981 1.4 16v TJet

(mm)

- If necessary, ream the valve guide bore.

- Measure the new valve guide.

- Note the valve guide bore diameter after reaming.

- The valve guides are available with the following outer diameter from Dept. Components.

Measurement Where the Validity

Outer diameter valve guide 10.010 ÷ 10.030

(mm)

Measurement Where the Validity

Oversize on valve guide outer 0.05 - 0.10 - 0.25

diameter (mm)

- The interference fit between the valve guide and the corresponding bore in the cylinder head is as follows.

Measurement Where the Validity

Clamping pliers - bearing 0.029 ÷ 0.071 1.4 16v TJet

piles (mm)

- Heat the cylinder head to approximately 100°C before installing the new valve guides.
1. Install the new inlet valve guides using the tool.

Tools Name function Validity

Machine Translated by Google

1. Install the new exhaust valve guides using tools (1a) and (1b).

Tools Description Function Validity

Valve guide extraction /

2000024700 Extractor / introducer 1.6 JTDM
introduction

Tools Name function Validity

- If the valve guides are slightly deformed during installation, ream the internal surface with a reamer of appropriate diameter.

- After reaming, check that the inner diameter of the valve guide and the clearance with the corresponding valve is within
tolerance.

Measurement Where the Validity

Valve guide inner diameter (mm) 6.022 ÷ 6.040 1.4 16v TJet

Measurement Where the Validity

Clearance Valves/Valve Guides - Inlet 0.022 ÷ 0.058 1.4 16v TJet

(mm)

Measurement Where the Validity

Clearance valves/valve guides - outlet 0.030 ÷ 0.066 1.4 16v TJet

(mm)
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE OIL PAN - CLEAN UI FITTINGS AND APPLY LIQUID GASKET 1020A20

Remove ( Install )

- Place the vehicle on a lift bridge.

See A001 BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Drain the engine oil and consult

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

edit. 1080B95 LAMBDA PROBE BEHIND THE CATALYST - UI

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

1. Loosen the mounting bolt on the lower left flywheel cover on the left.

1. Loosen the mounting bolt on the lower flywheel cover on the right side.

1. Loosen the gearbox mounting bolts on the oil pan.

1. Loosen the oil pan mounting bolts (1a) and nuts (1b) on the engine block.
Machine Translated by Google

1. Cut the sealant with the tool (1a) and remove the oil pan (1b) complete with lower flywheel cover.

Tools Name function Validity

1870718000 Blade Cut through kit

1. Place the oil pan in the vise with protected jaws, loosen the bolt (1a) and remove the lower flywheel
cover (1b).

1. Carefully remove the sealant residue from the surface of the oil sump.
1. Carefully remove the sealant residue from the lower surface of the engine block.

Install ( Remove )

- Replace the lower flywheel cover and tighten the corresponding bolts.

- Apply sealant to the entire surface of the oil sump.

- Replace the oil pan, making sure that the hole in the lower flywheel cover is aligned with the
centering pin on the gearbox.
1. Tighten the gearbox mounting bolts to the oil pan to the specified torque.
Machine Translated by Google

Component Confirmation ISLAND

Value (daNm) Validity

Manual gearbox on End M10 3.6 ÷ 4.4

oil pan

- Tighten the two studs previously removed from the oil pump.
1. Tighten the oil pan mounting nuts (1a) and bolts (1b) to the engine block to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

Motorola End M6 0.8 ÷ 1.0 1.4 16v TJet

Component Confirmation ISLAND

Value (daNm) Validity

Motorola Nut M6 0.8 ÷ 1.0 1.4 16v TJet

- Tighten the side mounting bolts of the lower flywheel cover.

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1080B95 LAMBDA PROBE BEHIND THE CATALYST - UI

- Top up engine oil and consult

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

See A001 BATTERY

- Remove the vehicle from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE OIL DRAIN PLUG - REPL. 1020A30

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the engine oil drain plug and drain the engine oil into a suitable container.

Motor oil is harmful to the environment; uncontrolled disposal of finished product can cause environmental pollution.

Install ( Remove )

1. Tighten the new engine oil drain plug to torque.

Value
Component Fixing ISLAND
Validity
(daNm)

Engine oil
Dop
-
1.8 ÷ 2.2 1.4 16v TJet
drain plug

edit. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP up if necessary.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FRONT CRANKSHAFT COVER - ONION AND REPL. SEALS FOR ENGINES WITH OIL PUMP ON
DISTRIBUTION SIDE CRANKSHAFT 1020D14

Remove ( Install )

- Place the vehicle on a lift bridge.

See
A001
BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 4450B04 FRONT WHEEL RIGHT - UI

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1080B62 CATALYST - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

- Tighten the lower swivel and the bolt of the rod between the coolant supply line and the engine oil cooler, therefore
reference is made to

edit. 1088D55 COOLANT SUPPLY HOSE TO ENGINE OIL COOLER - UI

edit. 1088D51 COOLANT RETURN HOSE FROM ENGINE OIL COOLER - UI

- Loosen the lower swivel of the engine oil supply line to the turbocharger, therefore reference is made to

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1084B36 BRACKET FOR ENGINE OIL FILTER AND COOLER - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.
- Provisionally mount the rigid engine support and associated suspension rubber on the distribution side and
remove the lifting device used for removing the timing belt.

- Raise the vehicle and remove the engine oil pan; see for this

edit. 1020A20 ENGINE OIL PAN - ONION CLEAN FITTINGS AND LIQUID GASKET
APPLY
edit. 1032B44 TIMED CRANKSHAFT PULLEY - ONION WITH EXTENDED TIMING BELT
1. Disconnect the plug from the oil pressure switch.
Machine Translated by Google

Description Plug

See K030 SENSOR

1 Oil pressure sensor (interrupter) (INTERRUPTER) FRONT
MOTOROLIEDRUK

2. Disconnect the engine speed sensor connector.

Description Plug

See K046
2 Speed sensor
RPM SENSOR

1. Loosen the bolt (1a) and remove the speed sensor (1b).

1. Loosen the bolts (1a) and remove the front crankshaft cover (1b).

1. Remove the gasket and sealant residue.

Machine Translated by Google

Install ( Remove )

1. Replace the front crankshaft cover (1a) with its gasket and tighten the bolts (1b) to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

Front Crankshaft Cover Bolt M6 0.8 ÷ 1.0 1.4 16v TJet

1. Install a new front crankshaft seal using the tool.

Tools Name function Validity

1.4 16v TJet

1860990000 camshaft seal
Mounting tool to assemble
1.8 DI Turbo

1. Replace the speed sensor (1a) and tighten the bolt (1b) to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

Speed sensor End M6 0.8 ÷ 1.0 1.4 16v TJet

Machine Translated by Google

- Connect the plug of the speed sensor.

- Connect the plug to the oil pressure switch.

- Install the engine oil pan; see for this

edit. 1020A20 ENGINE OIL PAN - ONION CLEAN FITTINGS AND LIQUID GASKET
APPLY
edit. 1032B44 TIMED CRANKSHAFT PULLEY - ONION WITH EXTENDED TIMING BELT
- Place the garage jack under the engine oil pan and remove the engine support and the rubber mounting on the distribution side.
edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI
DISTRIBUTION TIMING OR PAINT.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1084B36 BRACKET FOR ENGINE OIL FILTER AND COOLER - UI

- Tighten the lower swivel of the engine oil supply line to the turbocharger, therefore reference is made to

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1088D51 COOLANT RETURN HOSE FROM ENGINE OIL COOLER - UI

- Tighten the lower swivel and the bolt of the rod between the coolant supply line and the engine oil cooler,
therefore reference is made to

edit. 1088D55 COOLANT SUPPLY HOSE TO ENGINE OIL COOLER - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1080B62 CATALYST - UI

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 4450B04 FRONT WHEEL RIGHT - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Machine Translated by Google

See A001
BATTERY

- Remove the vehicle from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FRONT CRANKSHAFT COVER SEAL - UI 1020D18

Remove ( Install )

- Place the vehicle on a lift bridge.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032B44 TIMED CRANKSHAFT PULLEY - ONION WITH EXTENDED TIMING BELT
1. Remove the front crankshaft seal taking care not to damage the seat.

Install ( Remove )

1. Install a new front crankshaft seal using the tool.

edit. 1032B44 TIMED CRANKSHAFT PULLEY - ONION WITH EXTENDED TIMING BELT

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

Machine Translated by Google

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1016A10 SOUND INSULATION COVER - UI

- Remove the vehicle from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FLYWHEEL - UI ON MANUAL VERSIONS

GEARBOX 1024B10

Remove ( Install )

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 0010T40 OIL MANUAL BOX - REPL.

edit. 0010T84 AIR CONDITIONING REFRIGERANT - DRYING AND FILLING

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 5530B10 BATTERY - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 1088B10 ENGINE COOLING SYSTEM EXPANSION RESERVOIR - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7210E10 ONION FRONT BUMPER

edit. 5540B07 LEFT HEADLIGHT UNIT - UI

edit. 5540B08 RIGHT HEADLIGHT UNIT - UI

edit. 7025A34 BONNET LOCK (ONLY) - UI OR REPAIR

edit. 7210A08 LOWER ENERGY ABSORBING ELEMENT (1), LI OR RE, FRONT BUMPER - UI

(both)

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 7210A02 UI COMPLETE FRONT-END

edit. 4450B12 WHEELS (TWO) FRONT - UI

edit. 5050A12 FILL HOSE (IN ENGINE COMPARTMENT) FOR WINDSCREEN WASHER RESERVOIR - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 7210A51 UI LOWER CREEK ZONE LI

edit. 7210A52 ONION LOWER CRUSH ZONE RE

edit. 7055B65 DUST PLATE ENGINE COMPARTMENT IN LEFT FRONT FAIRING - UI

edit. 2710A14 RIGHT DRIVE SHAFT COMPLETE WITH COUPLINGS AND INTERPLACEMENT SHAFT - UI

edit. 1008C32 GEARBOX LOWER REACTION ROD - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 2125C31 GEAR SHIFT SUPPORT - UI

edit. 1004B10 DRIVE GEARBOX WITH MANUAL GEARBOX - UI

edit. 1004D10 DRIVE GENERATOR (MANUAL TRANSMISSION), REMOVED - SEPARATE AND

BUILD TOGETHER

edit. 1810A20 COUPLER - UI

1. With the flywheel locking attachment (1a) installed, loosen the bolts (1b) and remove the flywheel (1c).
Machine Translated by Google

Tools Description Function Validity

1860846000 Blocking tool Flywheel Locking Attachment

The flywheel mounting bolts are pre-treated with locking compound and must therefore be replaced after
disassembly.

Install ( Remove )

1. Install the flywheel (1a) and tighten the new bolts (1b) with tightening torque.

Value
Component Confirmation ISLAND
Validity
(daNm)

Bolt
1.9 ÷ 2.1 + 50°
Flywheel (replaced M9 1.4 16v TJet
+/- 2°
with new one)

2. Remove the flywheel locking tool.

Tools Description Function Validity

1860846000 Locking Tool Flywheel Locking Tool

edit. 1810A20 COUPLER - UI

edit. 1004D10 DRIVE GENERATOR (MANUAL TRANSMISSION), REMOVED - SEPARATE AND

BUILD TOGETHER

edit. 1004B10 DRIVE GEARBOX WITH MANUAL GEARBOX - UI

edit. 2125C31 GEAR SHIFT SUPPORT - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008C32 GEARBOX LOWER REACTION ROD - UI

edit. 2710A14 RIGHT DRIVE SHAFT COMPLETE WITH COUPLINGS AND INTERPLACEMENT SHAFT - UI

edit. 7055B65 DUST PLATE ENGINE COMPARTMENT IN LEFT FRONT FAIRING - UI

edit. 7210A52 ONION LOWER CRUSH ZONE RE

Bew. 7210A51 UI LOWER CREEK ZONE LI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 5050A12 FILL HOSE (IN ENGINE COMPARTMENT) FOR WINDSCREEN WASHER RESERVOIR - UI

edit. 4450B12 WHEELS (TWO) FRONT - UI

edit. 7210A02 UI COMPLETE FRONT-END

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 7210A08 LOWER ENERGY ABSORBING ELEMENT (1), LI OR RE, FRONT BUMPER - UI

(both)

edit. 7025A34 BONNET LOCK (ONLY) - UI OR REPAIR

edit. 5540B08 RIGHT HEADLIGHT UNIT - UI

edit. 5540B07 LEFT HEADLIGHT UNIT - UI

Machine Translated by Google

edit. 7210E10 ONION FRONT BUMPER

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1088B10 ENGINE COOLING SYSTEM EXPANSION RESERVOIR - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 5530B10 BATTERY - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 0010T84 AIR CONDITIONING REFRIGERANT - DRYING AND FILLING

edit. 0010T40 OIL MANUAL BOX - REPL.

- Connect the negative terminal to the battery.

Description Plug

-
BATTERY See A001 BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FLYWHEEL - REMOTE CLUTCH UI FOR MANUAL GEARBOX VERSIONS 1024B22

Remove ( Install )

- Place the car on a lift bridge.

1. With the flywheel locking attachment (1a) installed, loosen the bolts (1b) and remove the flywheel (1c).

Tools Description Function Validity

1860846000 Blocking tool Flywheel Locking Attachment

The flywheel mounting bolts are pre-treated with locking compound and must therefore be replaced after
disassembly.

Install ( Remove )

1. Install the flywheel (1a) and tighten the new bolts (1b) with tightening torque.

Value
Component Confirmation ISLAND
Validity
(daNm)

Bolt
1.9 ÷ 2.1 + 50°
Flywheel (replaced M9 1.4 16v TJet
+/- 2°
with new one)

2. Remove the flywheel locking tool.

Tools Description Function Validity

1860846000 Locking Tool Flywheel Locking Tool

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FLYWHEEL PROTECTOR - UI 1024B54

Remove ( Install )

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 0010T40 OIL MANUAL BOX - REPL.

edit. 0010T84 AIR CONDITIONING REFRIGERANT - DRYING AND FILLING

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 5530B10 BATTERY - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 1088B10 ENGINE COOLING SYSTEM EXPANSION RESERVOIR - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7210E10 ONION FRONT BUMPER

edit. 5540B07 LEFT HEADLIGHT UNIT - UI

edit. 5540B08 RIGHT HEADLIGHT UNIT - UI

edit. 7025A34 BONNET LOCK (ONLY) - UI OR REPAIR

edit. 7210A08 LOWER ENERGY ABSORBING ELEMENT (1), LI OR RE, FRONT BUMPER - UI

(both)

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 7210A02 UI COMPLETE FRONT-END

edit. 4450B12 WHEELS (TWO) FRONT - UI

edit. 5050A12 FILL HOSE (IN ENGINE COMPARTMENT) FOR WINDSCREEN WASHER RESERVOIR - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 7210A51 UI LOWER CREEK ZONE LI

edit. 7210A52 ONION LOWER CRUSH ZONE RE

edit. 7055B65 DUST PLATE ENGINE COMPARTMENT IN LEFT FRONT FAIRING - UI

edit. 2710A14 RIGHT DRIVE SHAFT COMPLETE WITH COUPLINGS AND INTERPLACEMENT SHAFT - UI

edit. 1008C32 GEARBOX LOWER REACTION ROD - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 2125C31 GEAR SHIFT SUPPORT - UI

edit. 1004B10 DRIVE GEARBOX WITH MANUAL GEARBOX - UI

edit. 1004D10 DRIVE GENERATOR (MANUAL TRANSMISSION), REMOVED - SEPARATE AND

BUILD TOGETHER

1. Loosen the mounting bolts (1a) and remove the lower (1b) and upper (1c) flywheel guards.
Machine Translated by Google

Install ( Remove )

- Install the lower and upper flywheel guards and tighten the corresponding mounting bolts.
edit. 1004D10 DRIVE GENERATOR (MANUAL TRANSMISSION), REMOVED - SEPARATE AND
BUILD TOGETHER

edit. 1004B10 DRIVE GEARBOX WITH MANUAL GEARBOX - UI

edit. 2125C31 GEAR SHIFT SUPPORT - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008C32 GEARBOX LOWER REACTION ROD - UI

edit. 2710A14 RIGHT DRIVE SHAFT COMPLETE WITH COUPLINGS AND INTERPLACEMENT SHAFT - UI

edit. 7055B65 DUST PLATE ENGINE COMPARTMENT IN LEFT FRONT FAIRING - UI

edit. 7210A52 ONION LOWER CRUSH ZONE RE

Bew. 7210A51 UI LOWER CREEK ZONE LI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 5050A12 FILL HOSE (IN ENGINE COMPARTMENT) FOR WINDSCREEN WASHER RESERVOIR - UI

edit. 4450B12 WHEELS (TWO) FRONT - UI

edit. 7210A02 UI COMPLETE FRONT-END

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 7210A08 LOWER ENERGY ABSORBING ELEMENT (1), LI OR RE, FRONT BUMPER - UI

(both)

edit. 7025A34 BONNET LOCK (ONLY) - UI OR REPAIR

edit. 5540B08 RIGHT HEADLIGHT UNIT - UI

edit. 5540B07 LEFT HEADLIGHT UNIT - UI

edit. 7210E10 ONION FRONT BUMPER

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1088B10 ENGINE COOLING SYSTEM EXPANSION RESERVOIR - UI

edit. 5530B52 BATTERY HOLDER/SUPPORT - UI

edit. 5530B10 BATTERY - UI

edit. 0010T40 OIL MANUAL BOX - REPL.

edit. 0010T84 AIR CONDITIONING REFRIGERANT - DRYING AND FILLING

Bew. 0010T20 ENGINE COOLANT - PAINT.

- Connect the negative terminal to the battery.

Machine Translated by Google

Description Plug

-
BATTERY See A001 BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PISTON WITH CONNECTING ROD - UI 1028H20

Return to PISTONS WITH CONNECTING RODS - UI

Remove ( Install )

- Place the vehicle on a lift bridge.

See A001 BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Drain the engine oil and consult

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1080B62 CATALYST - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - ONION

edit. 1064A27 PIPE BETWEEN PRESSURE RESERVOIR AND SOLENOID CONTROL VALVE OF
ACTUATOR - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1008B10 SUPPORT RUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR - REPL.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.
Machine Translated by Google

edit. 1016B12 CAM HOUSING COMPLETE - UI WITH EXTENDED TIMING BELT.- GASKET
TO REPLACE

edit. 1016C10 CYLINDER HEAD COMPLETE - REPLACE ONION AND GASKET

1. Install the motor support crossmember (1a) with the blocks (1b).

Tools Name function Validity

1870595000 Subframe Support drive unit

Tools Name function Validity

1870650000 Support blocks Support drive unit

Tools Name function Validity

1860851000 Subframe Support drive unit

Tools Name function Validity

edit. 1020A20 ENGINE OIL PAN - ONION CLEAN FITTINGS AND LIQUID GASKET
APPLY

edit. 1084B28 ENGINE OIL SUCTION TUBE - REMOVAL OIL PAN ONION
1. Loosen the bolts (1a) and remove the connecting rod bearing cap (1b) complete with the bearing shell.

- Remove the piston with connecting rod.

Install ( Remove )

1. Assemble the connecting rod/piston assembly complete with bearing shell using a suitable tool for compressing
the piston rings and mounting the piston in the cylinder.

1. Replace the connecting rod bearing cap complete with associated bearing shell.
Machine Translated by Google

2. Tighten the connecting rod bearing cap mounting bolts to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

1.9 ÷ 2.1 + 40° +/-

Connecting Rod Bearing Caps Bolt M8 1.4 16v TJet
2°

edit. 1084B28 ENGINE OIL SUCTION TUBE - REMOVAL OIL PAN ONION

edit. 1020A20 ENGINE OIL PAN - ONION CLEAN FITTINGS AND LIQUID GASKET
APPLY
- Place a hydraulic jack under the oil pan to support the drive unit.

- Remove the tools used to support the drive unit.

edit. 1016C10 CYLINDER HEAD COMPLETE - REPLACE ONION AND GASKET

edit. 1016B12 CAM HOUSING COMPLETE - UI WITH EXTENDED TIMING BELT.- GASKET
TO REPLACE

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

- Remove the jack to support the drive unit.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1064A27 PIPE BETWEEN PRESSURE RESERVOIR AND SOLENOID CONTROL VALVE OF
ACTUATOR - UI

edit. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - ONION

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

Machine Translated by Google

edit. 1080B62 CATALYST - UI

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

- Top up engine oil and consult

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

See A001 BATTERY

- Remove the vehicle from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PISTON WITH CONNECTING ROD - UI 1028H20

Remove ( Install )

- Place the vehicle on a lift bridge.

See A001 BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Drain the engine oil and consult

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1080B62 CATALYST - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - ONION

edit. 1064A27 PIPE BETWEEN PRESSURE RESERVOIR AND SOLENOID CONTROL VALVE OF
ACTUATOR - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1008B10 SUPPORT RUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR - REPL.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.
Machine Translated by Google

edit. 1016B12 CAM HOUSING COMPLETE - UI WITH EXTENDED TIMING BELT.- GASKET
TO REPLACE

edit. 1016C10 CYLINDER HEAD COMPLETE - REPLACE ONION AND GASKET

1. Install the motor support crossmember (1a) with the blocks (1b).

Tools Name function Validity

1870595000 Subframe Support drive unit

Tools Name function Validity

1870650000 Support blocks Support drive unit

Tools Name function Validity

1860851000 Subframe Support drive unit

Tools Name function Validity

edit. 1020A20 ENGINE OIL PAN - ONION CLEAN FITTINGS AND LIQUID GASKET
APPLY

edit. 1084B28 ENGINE OIL SUCTION TUBE - REMOVAL OIL PAN ONION
1. Loosen the bolts (1a) and remove the connecting rod bearing cap (1b) complete with the bearing shell.

- Remove the piston with connecting rod.

Install ( Remove )

1. Assemble the connecting rod/piston assembly complete with bearing shell using a suitable tool for compressing
the piston rings and mounting the piston in the cylinder.

1. Replace the connecting rod bearing cap complete with associated bearing shell.
Machine Translated by Google

2. Tighten the connecting rod bearing cap mounting bolts to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

1.9 ÷ 2.1 + 40° +/-

Connecting Rod Bearing Caps Bolt M8 1.4 16v TJet
2°

edit. 1084B28 ENGINE OIL SUCTION TUBE - REMOVAL OIL PAN ONION

edit. 1020A20 ENGINE OIL PAN - ONION CLEAN FITTINGS AND LIQUID GASKET
APPLY
- Place a hydraulic jack under the oil pan to support the drive unit.

- Remove the tools used to support the drive unit.

edit. 1016C10 CYLINDER HEAD COMPLETE - REPLACE ONION AND GASKET

edit. 1016B12 CAM HOUSING COMPLETE - UI WITH EXTENDED TIMING BELT.- GASKET
TO REPLACE

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

- Remove the jack to support the drive unit.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1064A27 PIPE BETWEEN PRESSURE RESERVOIR AND SOLENOID CONTROL VALVE OF
ACTUATOR - UI

edit. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - ONION

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

Machine Translated by Google

edit. 1080B62 CATALYST - UI

edit. 1076B72 EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

- Top up engine oil and consult

Bew. 0010T12 ENGINE OIL AND FILTER - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

See A001 BATTERY

- Remove the vehicle from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PISTON WITH CONNECTING ROD - BENCH DISASSEMBLE 1028H54

Remove ( Install )

Install ( Remove )
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir KIT PISTONS, PISTON PINS AND PISTON RINGS - REPL. FOR PISTONS/CONNECTING RODS ON
THE WORKBENCH - INCLUDES CUTTING AND BALANCING 1028H60

Remove ( Install )

Install ( Remove )
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TIMING DRIVE TIMING BELT - UI FOR ADJUSTING
DISTRIBUTION TIMING OR PAINT. 1032B10

Remove ( Install )

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

Machine Translated by Google

Install ( Remove )

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 7055B66 DUST PLATE ENGINE COMPARTMENT IN RIGHT FRONT FAIRING - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Machine Translated by Google
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TIMED CAM PULLEY (1) - TIMING BELT REMOVAL 1032B40 ONION

Remove ( Install )

1. Remove the bolt (1a), which was loosened when removing the timing belt, and remove the
camshaft pulley (1b).

Install ( Remove )

- Install the camshaft pulley and hand-tighten the corresponding mounting bolt.

The camshaft pulley mounting bolt is tightened to torque during the timing belt installation procedure.

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TIMED CRANKSHAFT PULLEY - ONION WITH REMOVED TIMING BELT 1032B44

Remove ( Install )

- Temporarily fit the engine mount and the rubber suspension on the timing belt and remove the garage jack used
to remove the timing belt.
1. Insert a suitable pin (6 mm diameter) through the appropriate hole in the gearbox into the flywheel as a
locking aid.

Check that the pin fits correctly into the corresponding seat in the flywheel.

1. Mount the tool.

This is necessary, even though the flywheel locking tool is installed, to lock the pulley and avoid torsional forces
that can occur during loosening/tightening of the retaining bolt and damage the internal centering cam.

Tools Name function Validity

2000004500 Times Adjust crankshaft 1.4 16v TJet

2. Loosen the gear drive pulley retaining bolt.

- Remove the mold.

3. Remove the toothed drive pulley.

Install ( Remove ) 1. Place the toothed pulley in the seat.2. Mount the tool.

Tools Name function Validity

2000004500 Times Adjust crankshaft 1.4 16v TJet

3. Tighten the gear drive pulley mounting bolt to torque.

Component Confirmation ISLAND

Value (daNm) Validity

1.9 ÷ 2.1 + 107° ÷

crankshaft gear End M12 1.4 16v TJet
113°

- Remove the mold.

- Remove the pin, which has been used as a locking aid, from the hole in the gearbox.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TOOTH CRANKSHAFT PULLEY(S) - UI 1032B46

Remove ( Install )

See
A001
BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032B44 TIMED CRANKSHAFT PULLEY - ONION WITH EXTENDED TIMING BELT

Install ( Remove )

edit. 1032B44 TIMED CRANKSHAFT PULLEY - ONION WITH EXTENDED TIMING BELT

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

See
A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ADJUSTABLE TENSIONER OF DISTRIBUTION DRIVE - UI ON EXTENDED
TIMING BELT/CHAIN 1032C10

Remove ( Install )

1. Completely loosen the slightly loosened nut (1a) and remove the adjustable timing tensioner (1b).

Install ( Remove )

- Fit the adjustable timing tensioner and hand-tighten the corresponding nut.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ADJUSTABLE TENSIONER OF TIMING DRIVE - UI 1032C18

Remove ( Install ) - Place the car on a lift.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 3330D30 PRESSURE PUMP - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR REV.

edit. 1032C10 ADJUSTABLE TENSIONER OF DISTRIBUTION DRIVE - UI ON EXTENDED

TIMING BELT/CHAIN

Install ( Remove )

edit. 1032C10 ADJUSTABLE TENSIONER OF DISTRIBUTION DRIVE - UI ON EXTENDED

TIMING BELT/CHAIN

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR REV.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 3330D30 PRESSURE PUMP - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Place the car on a lift bridge. - Remove the car from the lift bridge.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TIMING COVER (UPPER PART) - UI 1032D26

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

1. Open the fuel vapor line retaining clip.

2. Open the turbocharger coolant supply hose retaining clip.

- Loosen the bolts (1a) and remove the front timing cover at the top (1b).

Install ( Remove )

- Fit the upper timing cover at the front and tighten the corresponding bolts.

- Close the fuel vapor line retaining clip.

- Close the retaining clip of the coolant supply hose for the turbocharger.
edit. 1016A10 SOUND INSULATION COVER - UI
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TIMING COVER (LOWER PART) - UI 1032D27

Remove ( Install )

- Place the car on a lift bridge.

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1032D26 TIMING COVER (UPPER PART) - UI

Install ( Remove )

- Fit the lower timing cover and tighten the corresponding bolts.
edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PULLEY ON CRANKSHAFT - UI 1092A10

Return To CRANKSHAFT PULLEY(S) TOOTH - UI

Remove ( Install )

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

1. Loosen the bolts (1a) and remove the crankshaft pulley (1b).

Install ( Remove )

1. Install the crankshaft pulley (1) and tighten the bolts (1b) to the specified torque.

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir DRIVE BELT VARIOUS BODIES - UI 1092G10

Return To CRANKSHAFT PULLEY(S) TOOTH - UI

Remove ( Install )

1. Adjust the belt tensioner, install a locking pin (1a) and remove the drive belt for the auxiliaries (1b).

Install ( Remove )

- Reverse the drive belt for the auxiliaries and adjust the belt tensioner to remove the locking pin.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PRESSURE PUMP - UI 3330D30

Return To CRANKSHAFT PULLEY(S) TOOTH - UI

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

Machine Translated by Google

Install ( Remove )

Value
Component Fixing Ø Validity
(daNm)

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CAMSHAFT IN CAM HOUSING - UI 1036F11

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 3330D30 PRESSURE PUMP - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR REV.

edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT
Machine Translated by Google

Install ( Remove )

edit. 1036F30 FRONT SEAL ON CAMSHAFT IN CAMSHAFT HOUSING - REPL. WHEN EXTENDED
TIMING BELT
edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR REV.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 3330D30 PRESSURE PUMP - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

Machine Translated by Google

edit. 5510C14 IGNITION COILS - ONION

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir UNIAIR-MODULE - UI 1036F20

Removal ( Installation )

After replacing the UNIAIR module, the Examiner must be connected, the "active diagnosis" selected and the self-adaptation
procedure carried out.

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

1. Disconnect the connectors from the MULTIAIR actuators.

Description Plug

See N197
MULTIAIR
-
MULTIAIR
actuator
ACTUATOR

1. Disconnect the plug from the oil temperature sensor in the UNIAIR module.

Description Plug

See K029
1
Motor temperature sensor ENGINE SLUDGE TEMPERATURE SENSOR

2. Mount the tool on the UNIAIR module.

Tools Name function Validity

3. Loosen the bolts (3a) and remove the UNIAIR module (3b).

During all this work, the UNIAIR module must not be tilted upwards with the hydraulic valve lifters.

1. Remove the metal gasket.

Machine Translated by Google

Install ( Remove )

- Fit a new metal gasket on the camshaft housing.

1. Install the UNIAIR module (1a) complete with the tool and tighten the bolts (1b) with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

2. Remove the tool from the UNIAIR module.

Tools Name function Validity

3. Connect the plug of the oil temperature sensor in the UNIAIR module.

Description Plug

See K029
3 Motor temperature sensor ENGINE SLUDGE TEMPERATURE SENSOR

- Connect the plugs to the MULTIAIR actuators.

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

- Connect the negative terminal to the battery.

Description Plug

-
BATTERY See A001 BATTERY

1. When replacing the UNIAIR module with a new one, an initial oil filling must be carried out, pressing the indicated ball
of the valve using a suitable tool.

The amount of oil for the first filling is 240 cc.

Machine Translated by Google

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir UNIAIR MODULE OIL TEMPERATURE SENSOR - UI 1036F21

Removal ( Installation )

After removal, the oil temperature sensor of the UNIAIR module must not be reused and must therefore be replaced with a
new one.

After mounting the new oil temperature sensor in the UNIAIR module, the Examiner must be connected, the "active diagnosis"
selected and the self-adaptation procedure performed.
- Disconnect the negative terminal from the battery.

Description Plug

See A001
-
BATTERY
BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the plug from the oil temperature sensor in the UNIAIR module.

Description Plug

See K029
1
Motor temperature sensor ENGINE SLUDGE TEMPERATURE SENSOR

1. Using the tool, unscrew the oil temperature sensor from the UNIAIR module and remove the sensor.

Tools Name function Validity

Install ( Remove )

- Fit the oil temperature sensor of the UNIAIR module using the tool and tighten the sensor with tightening torque.

Tools Name function Validity

Component Confirmation ISLAND

Value (daNm) Validity

- Connect the plug to the oil temperature sensor in the UNIAIR module.
edit. 1016A10 SOUND INSULATION COVER - UI

- Connect the negative terminal to the battery.

Description Plug
Machine Translated by Google

See A001
-
BATTERY
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE OIL FILTER OF UNIAIR MODULE - UI 1036F22

Removing ( Installing )
After disassembly, the engine oil filter of the UNIAIR module must not be reused and must therefore be replaced
with a new one.

After mounting the new engine oil filter of the UNIAIR module, the Examiner must be connected, the "active
diagnosis" selected and the self-adaptation procedure performed.
edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

1. Unscrew and remove the engine oil filter from the UNIAIR module.

Install ( Remove )

1. Install the engine oil filter of the UNIAIR module and tighten it with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FRONT SEAL ON CAMSHAFT IN CAMSHAFT - REPL. WHEN EXTENDED
TIMING BELT 1036F30

Remove ( Install )

1. Remove the bolt (1a), which was loosened when removing the timing belt, and remove the
camshaft pulley (1b).

1. Remove the front camshaft seal.

Avoid damaging the oil seal seat while removing the seal.

Install ( Remove )

1. Install a new front camshaft seal using the tool.

Tools Name function Validity

- Fit the camshaft pulley and hand-tighten the corresponding bolt.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TUMBERS FROM HYDRAULIC VALVE PUSHERS - UI 1036H51

Removing ( Installing )
After replacing the rocker arms of the hydraulic valve lifters, the Examiner must be connected, the "active diagnosis" selected and
the self-adjustment procedure performed.

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

Bew. 1036F20 UNIAIR-MODULE - U.I.

1. Loosen the rocker arm retaining rings and remove the rocker arms.

Install ( Remove )

- Place the rocker arms and fit the circlips.

Bew. 1036F20 UNIAIR-MODULE - U.I.

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

- Connect the negative terminal to the battery.

Description Plug

-
BATTERY See A001 BATTERY
Machine Translated by Google

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir HYDRAULISCHE KLEPSTOTERS (ALLE) - UI 1036H57

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 3330D30 PRESSURE PUMP - UI

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT

edit. 1036F11 CAMSHAFT IN CAM HOUSING - UI

Install ( Remove )

edit. 1036F11 CAMSHAFT IN CAM HOUSING - UI

edit. 1032B40 TIMING BELT TIMING PULLEY (1) - ONION WITH REMOVED TIMING BELT

edit. 1032B10 TIMING DRIVE TIMED BELT - TIMING DRIVE ADJUSTMENT UI

DISTRIBUTION TIMING OR PAINT.

edit. 1032D27 TIMING COVER (LOWER PART) - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 1008A46 DRIVE GEAR FIXED SUPPORT - DISTRIBUTION SIDE - UI

edit. 1008B10 SUPPORT GRUBBER FOR (DISTRIBUTION SIDE) OF DRIVE GENERATOR -

VERV.

edit. 1092A10 PULLEY ON CRANKSHAFT - ONION

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

Machine Translated by Google

edit. 3330D30 PRESSURE PUMP - UI

edit. 1016A20 VALVE COVER COMPLETE - REPLACE ONION AND GASKET

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 5510C14 IGNITION COILS - ONION

edit. 1080D34 OIL SEPARATOR CRANKCASE VENTILATION - UI

edit. 1080D24 CRANK VAPOR SUCTION HOSE - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FUEL TANK - ONION AND FUEL CONNECTION 1040A10
Machine Translated by Google
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FUEL TANK - UI FOR REPL. 1040A14

Remove ( Install )

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

See
-
BATTERY A001
BATTERY

- Remove the fuel from the tank using suitable equipment.

edit. 7050A20 ONE PIECE REAR SEAT - UI

edit. 4450B08 RIGHT RIGHT - UI

edit. 4420A40 REAR SUSPENSION SCREW SPRING (1) LI OR RE - UI

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

edit. 1076B30 FRONT MUFFLER - UI

edit. 1040A37 FUEL FILLING PIPE SEAL - UI

edit. 7055B80 SIDE PROTECTION UNDER FLOOR PLATE (1), LI OR RE - UI

edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

edit. 1040A71 SUBMERSIBLE PUMP UNIT COMPLETE WITH TANK FLOAT - UI ON EXTENDED
FUEL TANK

Install ( Remove )

edit. 1040A71 SUBMERSIBLE PUMP UNIT COMPLETE WITH TANK FLOAT - UI ON EXTENDED
FUEL TANK

edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

edit. 7055B80 SIDE PROTECTION UNDER FLOOR PLATE (1), LI OR RE - UI

edit. 1040A37 FUEL FILLING PIPE SEAL - UI

edit. 1076B30 FRONT MUFFLER - UI

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

edit. 4420A40 REAR SUSPENSION SCREW SPRING (1) LI OR RE - UI

edit. 4450B08 RIGHT RIGHT - UI

edit. 7050A20 ONE PIECE REAR SEAT - UI

- Connect the negative terminal to the battery.

Description Plug

See
-
BATTERY A001
BATTERY

- Remove the car from the lift bridge.

edit. 4450A40 REAR WHEEL ALIGNMENT - CHECK WITH OPTICAL EQUIPMENT - INCLUDES EV.
FINE TUNE
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir REFITTING FUEL FILL PIPE SEAL - UI 1040A37

Remove ( Install )

- Open the fuel filler flap.

1. Unscrew the fuel cap (1a) and disconnect the cable from the valve (1b).

2. Loosen the seat seal retaining bolt for the fuel filler pipe.

3. Remove the fuel filler pipe seat seal along with the valve.

- On the workbench, proceed as follows:

1. Using a suitable tool, loosen the valve (1a) from the fuel filler pipe seal (1b).

Install ( Remove )

- On the workbench, attach the trim of the fuel filler cap to the seal of the fuel filler pipe.

- Fit the valve complete with the seal and tighten the corresponding bolt.

- Tighten the fuel cap and attach the cable to the valve.

- Check the opening and closing of the tank valve.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TANK CAP - UI 1040A40

Remove ( Install )

- Open the fuel filler flap.

1. Unscrew the fuel cap (1a) and disconnect the cable from the valve (1b).

Install ( Remove )

- Tighten the fuel cap until it clicks and attach the cable to the valve.

- Close the tank valve.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FUEL LEVEL TRANSMITTER IN FUEL PUMP UNIT - REPL. 1040A66

Remove ( Install )

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

See
-
BATTERY A001
BATTERY

edit. 7050A20 ONE PIECE REAR SEAT - UI

edit. 1040A70 SUBMERGING FUEL PUMP COMPLETE WITH TANK FLOAT - UI

1. Press the retaining tab and disconnect the fuel level sensor connector.

Description Plug

See N040 ELECTRIC

1
Electric fuel pump and fuel float FUEL PUMP EN
TANK PLOTS

1. Push in the spring clips (1a), lift the fuel level sensor (1b) and remove it completely with the float

Install ( Remove )

- Place the fuel level sensor complete with the float in the seat and fix the sensor to the pump housing with the corresponding
spring clips.

- Connect the fuel level sensor plug.

Description Plug

See N040 ELECTRIC

1
Electric fuel pump and fuel float FUEL PUMP EN
TANK PLOTS

- Check the float movement.

edit. 1040A70 SUBMERGING FUEL PUMP COMPLETE WITH TANK FLOAT - UI

edit. 7050A20 ONE PIECE REAR SEAT - UI

- Connect the negative terminal to the battery.

Machine Translated by Google

Description Plug

See
-
BATTERY A001
BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SUBMERGED FUEL PUMP COMPLETE WITH TANK FLOAT - UI 1040A70

Remove ( Install )

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

See
-
BATTERY A001
BATTERY

edit. 7050A20 ONE PIECE REAR SEAT - UI

1. Loosen the bolts (1a) and remove the inspection cover (1b) from the fuel pump unit.

1. Disconnect the fuel pump plug.

Description Plug

See N040 ELECTRIC

1
Electric fuel pump and fuel float FUEL PUMP EN
TANK PLOTS

2. Disconnect the quick connectors from the fuel lines.

- Close the disconnected pipes and connections appropriately.

1. Fit the tool (1a), loosen the retaining ring (1b) and remove the fuel pump.

Tools Name function Validity

1. Remove the sealing ring that must be replaced each time after loosening the retaining ring nut of the fuel pump unit.
Machine Translated by Google

Install ( Remove )

- Place a new sealing ring on the fuel tank.

1. Install the submersible pump unit.

2. Tighten the fastening ring nut of the pump unit with a torque tool.

Tools Name function Validity

Component Confirmation ISLAND

Value (daNm) Validity

ring nut from -

5.4 ÷ 6.6
Ringmoer
brandstofpompunit

- Connect the quick couplings of the fuel lines.

- Connect the plug to the fuel pump.

Description Plug

See N040 ELECTRIC

1
Electric fuel pump and fuel float FUEL PUMP EN
TANK PLOTS

- Install the access cover on the fuel pump and tighten the mounting bolts.

edit. 7050A20 ONE PIECE REAR SEAT - UI

- Connect the negative terminal to the battery.

Description Plug

See
-
BATTERY A001
BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SUBMERSIBLE PUMP UNIT COMPLETE WITH TANK FLOAT - UI ON EXTENDED
FUEL TANK 1040A71

Remove ( Install )

1. Fit the tool (1a), loosen the retaining ring (1b) and remove the fuel pump.

Tools Name function Validity

1. Remove the sealing ring that must be replaced each time after loosening the retaining ring nut of the fuel
pump unit.

Install ( Remove )

- Place a new sealing ring on the fuel tank.

1. Install the submersible pump unit.

2. Tighten the fastening ring nut of the pump unit with a torque tool.

Tools Name function Validity

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FUEL SUPPLY LINE - UI 1040B30

Remove ( Install )

- Place the car on a lift bridge.

- Remove the fuel from the tank using suitable equipment.

edit. 1040E22 FUEL LINE PROTECTION - UI

edit. 7050A20 ONE PIECE REAR SEAT - UI

edit. 4450B08 RIGHT RIGHT - UI

edit. 4420A40 REAR SUSPENSION SCREW SPRING (1) LI OR RE - UI

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

edit. 1076B30 FRONT MUFFLER - UI

edit. 1040A37 FUEL FILLING PIPE SEAL - UI

edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

1. Disconnect the fuel supply line quick disconnect from the manifold housing.

1. Loosen mounting bolts (1a) of the support bracket (1b).

- Release the pipe from the retaining clamps.

- Remove the fuel supply line.

Install ( Remove )

- Install the fuel supply line.

- Fasten the pipe to the retaining clamps.

- Tighten the mounting bolts of the support bracket.

- Connect the quick connector of the fuel supply line to the manifold housing.
edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

edit. 1040A37 FUEL FILLING PIPE SEAL - UI

edit. 1076B30 FRONT MUFFLER - UI

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

Machine Translated by Google

edit. 4420A40 REAR SUSPENSION SCREW SPRING (1) LI OR RE - UI

edit. 4450B08 RIGHT RIGHT - UI

edit. 7050A20 ONE PIECE REAR SEAT - UI

edit. 1040E22 FUEL LINE PROTECTION - UI

- Remove the car from the lift bridge.

edit. 4450A40 REAR WHEEL ALIGNMENT - CHECK WITH OPTICAL EQUIPMENT - INCLUDES EV.
FINE TUNE
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FUEL RETURN PIPE (COMPLETE) - UI 1040B52

Remove ( Install )

- Place the car on a lift bridge.

- Remove the fuel from the tank using suitable equipment.

edit. 1040E22 FUEL LINE PROTECTION - UI

edit. 7050A20 ONE PIECE REAR SEAT - UI

edit. 4450B08 RIGHT RIGHT - UI

edit. 4420A40 REAR SUSPENSION SCREW SPRING (1) LI OR RE - UI

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

edit. 1076B30 FRONT MUFFLER - UI

edit. 1040A37 FUEL FILLING PIPE SEAL - UI

edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

1. Disconnect the fuel return line quick disconnect from the manifold housing.

1. Loosen mounting bolts (1a) of the support bracket (1b).

- Release the pipe from the retaining clamps.

- Remove the fuel return line.

Install ( Remove )

- Install the fuel return line.

- Fasten the pipe to the retaining clamps.

- Tighten the mounting bolts of the support bracket.

- Connect the fuel return line quick connector to the manifold housing.
edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

edit. 1040A37 FUEL FILLING PIPE SEAL - UI

edit. 1076B30 FRONT MUFFLER - UI

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

Machine Translated by Google

edit. 4420A40 REAR SUSPENSION SCREW SPRING (1) LI OR RE - UI

edit. 4450B08 RIGHT RIGHT - UI

edit. 7050A20 ONE PIECE REAR SEAT - UI

edit. 1040E22 FUEL LINE PROTECTION - UI

- Remove the car from the lift bridge.

edit. 4450A40 REAR WHEEL ALIGNMENT - CHECK WITH OPTICAL EQUIPMENT - INCLUDES EV.
FINE TUNE
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir COMPLETE AIR FILTER - UI 1048A10

Remove ( Install )

- Place the car on a lift bridge.

edit. 4450B04 FRONT WHEEL RIGHT - UI

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

1. Loosen the mounting bolts (1a) and move the wheel arch guard (1b).

1. Loosen the turbocharger air supply hose retaining clip on the air filter.

1. Loosen the bolt (1a) and remove the complete air filter (1b).

Install ( Remove )

- Fit the complete air filter and tighten the corresponding bolt.

- Fasten the turbocharger air supply hose retaining clip to the air filter.
- Fit the wheel arch guard and tighten the mounting bolts.

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

edit. 4450B04 FRONT WHEEL RIGHT - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SUPPORT FOR AIR FILTER - UI 1048A13

Remove ( Install )

- Place the car on a lift bridge.

edit. 4450B04 FRONT WHEEL RIGHT - UI

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

edit. 1048A10 COMPLETE AIR FILTER - UI

- Loosen the retaining clip of the cable bundle.
1. Loosen the fasteners (1a) and remove the air filter support (1b).

Install ( Remove )

- Install the air filter support and tighten the corresponding fasteners.

- Install the retaining clip of the cable bundle.

edit. 1048A10 COMPLETE AIR FILTER - UI

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

edit. 4450B04 FRONT WHEEL RIGHT - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir AIR FILTER FILTER ELEMENT - REPL. 1048A14

Remove ( Install )

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

1. Loosen the bolts (1a) and remove the air cleaner cover (1b).

1. Remove the air filter element.

Install ( Remove )

- Place the new air filter element in the seat.

- Install the air filter cover and tighten the corresponding bolts.

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir COLD AIR INTAKE FOR AIR FILTER - UI 1048A23

Remove ( Install )

1. Loosen and remove the air inlet.

Install ( Remove )

- Mount the air inlet and connect the connecting tube to the resonator.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CONNECTION TUBE BETWEEN RESONATOR AND AIR FILTER - UI 1048A37

Remove ( Install )

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

Install ( Remove )

edit. 1048A23 COLD AIR INTAKE FOR AIR FILTER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI 1048A50

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

1. Loosen the clamp and disconnect the turbocharger air supply hose from the air filter.

1. Loosen the crankcase ventilation hose mounting bolt.

1. Loosen the clamp and disconnect the fuel vapor hose from the turbocharger air supply hose.

2. Loosen the clamp and disconnect the crankcase ventilation hose from the turbocharger air supply hose.

3. Loosen the clamp and disconnect the waste-gate solenoid air return hose from the supply hose to the
turbocharger.

4. Loosen the clamp and remove the air supply hose to the turbocharger.

Install ( Remove )

- Fit the air supply hose to the turbocharger and fasten the corresponding clamp on the turbocharger.

- Connect the air return hose from the waste gate solenoid valve to the supply hose to the turbocharger and
tighten the corresponding clamp.

- Connect the crankcase ventilation hose to the turbocharger air supply hose and tighten the corresponding clamp.

- Connect the fuel vapor hose to the turbocharger air supply hose and tighten the corresponding clamp.

- Tighten the crankcase ventilation pipe fixing bolt.

- Connect the turbocharger air supply hose to the air filter and fit a new retaining clip.
edit. 1016A10 SOUND INSULATION COVER - UI
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TUBE (1) FOR AIR SUPPLY BETWEEN TURBO AND INTERCOOLER - UI 1048B10

Remove ( Install )

- Place the car on a lift bridge.

edit. 7210E10 ONION FRONT BUMPER

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B17 INTERCOOLER AIR SUPPLY HOSE - UI

1. Open the retaining clip (1a) and disconnect the exhaust air hose from the turbocharger (1b).

1. Loosen the mounting bolts (1a) and remove the air supply tube (one) between turbocharger and intercooler (1b).

Install ( Remove )

- Fit the air supply tube (one) between the turbocharger and the intercooler and tighten the fixing bolts.

- Connect the exhaust air hose from the turbocharger.

edit. 1048B17 INTERCOOLER AIR SUPPLY HOSE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 7210E10 ONION FRONT BUMPER

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir INTERCOOLER AIR SUPPLY HOSE - UI 1048B17

Remove ( Install )

- Place the car on a lift bridge.

edit. 7210E10 ONION FRONT BUMPER

1. Loosen the clamp (1a) and disconnect the air supply hose (1b).

Install ( Remove )

- Place the complete connecting pipe, connect it to the hose and to the intercooler, attach the corresponding clamps and
tighten the bolts.
edit. 7210E10 ONION FRONT BUMPER

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TURBO COMPRESSOR AIR DRAIN HOSE - UI 1048B19

Return to AIR SUPPLY CONNECTION TUBE BETWEEN TURBO AND INTERCOOLER - UI

Remove ( Install )

- Place the car on a lift bridge.

1. Loosen the air exhaust hose retaining clip from the turbocharger.

2. Loosen the fixing bolt of the connecting bracket for the exhaust air tube of the turbocharger.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the retaining clip of the sleeve between the pipe and the connecting pipe.

1. On the workbench, loosen the clamp and remove the exhaust air hose from the turbocharger.

Install ( Remove )

- On the workbench, connect the exhaust air hose from the turbocharger to the pipe and fasten the corresponding clamp.

- Place the air supply pipes in front of the intercooler, tighten the corresponding clamps and tighten the bolt of the
support bracket.
edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TURBO COMPRESSOR AIR DRAIN HOSE - UI 1048B19

Remove ( Install )

- Place the car on a lift bridge.

1. Loosen the air exhaust hose retaining clip from the turbocharger.

2. Loosen the fixing bolt of the connecting bracket for the exhaust air tube of the turbocharger.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the retaining clip of the sleeve between the pipe and the connecting pipe.

1. On the workbench, loosen the clamp and remove the exhaust air hose from the turbocharger.

Install ( Remove )

- On the workbench, connect the exhaust air hose from the turbocharger to the pipe and fasten the corresponding clamp.

- Place the air supply pipes in front of the intercooler, tighten the corresponding clamps and tighten the bolt of the
support bracket.
edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir HOSE FOR AIR SUPPLY FROM INTERCOOLER TO TUBE - REPL. 1048B20

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Open the retaining clip (1a) and retaining spring (1b) and remove the air supply hose between the intercooler and the tube (1c).

Install ( Remove )

- Fit the air supply hose between the intercooler and the pipe and secure it with a new retaining clip and retaining spring.
edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CONNECTION TUBE BETWEEN INTERCOOLER AND INTAKE MANIFOLD - UI 1048B25

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

1. Loosen the clamp and disconnect the air hose from the tube.

1. Loosen the fixing nut of the connecting tube between the intercooler and the throttle body on the corresponding bracket on the gearbox.

1. Loosen the mounting bolt of the connecting tube between the intercooler and the throttle body on the connector bracket.

1. Unplug the air pressure sensor.

Description Plug

See K082
1 Turbo pressure sensor
TURBO PRESSURE SENSOR

2. Loosen the clamp and remove the connecting tube between the intercooler and the throttle body.
Machine Translated by Google

- If necessary, loosen the bolt and remove the air pressure sensor from the tube.

Install ( Remove )

- Place the connecting tube between the intercooler and the throttle body and fasten the corresponding clamp.

- Tighten the fixing nut of the connecting tube between the intercooler and the throttle body to the corresponding bracket on
the gearbox.

- Connect the sleeve to the air supply pipe between the intercooler and the throttle body and tighten the corresponding clamp.
edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL. 1048B30

Remove ( Install )

1. Loosen clamps (1a) and remove air supply hose between tube and throttle body (1b).

Install ( Remove )

- Fit the air supply hose between the tube and the throttle body and tighten the corresponding clamps.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir AIR SUPPLY TUBE BETWEEN INTERCOOLER AND THROTTLE BODY - UI 1048B47

Remove ( Install )

- Place the car on a lift bridge.

edit. 7210E10 ONION FRONT BUMPER

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B54 AIR EXHAUST HOSE FROM COOLER (1), LI OR RE - UI

1. Open the retaining clip (1a) and disconnect the air supply hose between the intercooler and the tube (1b).

1. Loosen the mounting bolts (1a) and remove the air supply tube between the intercooler and the throttle body (1b).

Install ( Remove )

1. Install the air supply tube between the intercooler and the throttle body and tighten the mounting bolts.

- Connect the air supply hose between the intercooler and the pipe.

edit. 1048B54 AIR EXHAUST HOSE FROM COOLER (1), LI OR RE - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 7210E10 ONION FRONT BUMPER

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir INTERCOOLER VAN TURBODRUKVULLING - UI 1048B50

Remove ( Install )

- Place the car on a lift bridge.

edit. 7210E10 ONION FRONT BUMPER

edit. 1048B17 INTERCOOLER AIR SUPPLY HOSE - UI

edit. 1048B54 AIR EXHAUST HOSE FROM COOLER (1), LI OR RE - UI

1. Loosen the mounting bolts (1a) and move the air guide (1b).

1. Disconnect the intercooler and remove the intercooler.

Install ( Remove )

- Install the intercooler.

- Install and tighten the intercooler mounting bolts.

edit. 1048B54 AIR EXHAUST HOSE FROM COOLER (1), LI OR RE - UI

edit. 1048B17 INTERCOOLER AIR SUPPLY HOSE - UI

edit. 7210E10 ONION FRONT BUMPER

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir UI FRONT BUMPER 7210E10

Return to AIR EXHAUST HOSE FROM COOLER (1), LI OR RE - UI

Remove ( Install )

- Place the car on a lift bridge.

- Raise the car.

1. Loosen the front mounting bolts (1a) of the front wheel arch guards (1b) on both sides of the car.

2. Loosen the mounting bolts (2a) of the bumper (2b) on the mudguards.

3. Release the front part (1b) of the wheel arch guards from the seat and move them to the side.

1. Loosen the lower mounting bolts (1a) of the bumper.

2. Loosen the bolts (2a) slightly.

- Lower the car.

1. Loosen the upper bumper mounting bolts.

2. Release the ends (2a) on the side of the bumper from the seats (2b).

3. Loosen the top lock (3a).

1. Move the front bumper (1a) slightly and disconnect the connector (1b) from the front bumper harness.

Description Plug
Machine Translated by Google

1b PLUG FOG LAMPS See D050 PLUG

FOG LAMPS

2. Remove the front bumper.

- If necessary, disassemble the bumper.

edit. 7205E10 FRONT BUMPER STRIPS

Install ( Remove )

- Check the front bumper for damage.

- Assemble the bumper if necessary.

edit. 7205E10 FRONT BUMPER STRIPS

- Connect the plug in the cable bundle of the front bumper.

- Fit the bumper and secure the top lock.

- Fix the ends on the side of the bumper in the seats.

1. Tighten the upper bumper mounting bolts.

Value
Component Fixing Ø Validity
(daNm)

Front Bumper Bolt M6 0.6 ÷ 1.0

- Raise the car.

- Tighten the lower mounting bolts of the bumper.

- Fit the front part of the wheel arch protection in the seat.

- Tighten the mounting bolts of the bumper to the mudguards.

- Loosen the front fastening bolts of the front wheel arch guards.

- Lower the car.

- If necessary, adjust the front bumper in relation to the hood.

edit. 7055B11 FRONT BUMPER - ALIGN WITH BONNET

- Remove the car from the lift bridge.

APPLICABLE TO VERSIONS WITH: Headlight Washers

Remove ( Install )

APPLICABLE TO VERSIONS WITH: Headlight Washers

Machine Translated by Google

APPLICABLE TO VERSIONS WITH: Headlight Washers

APPLICABLE TO VERSIONS WITH: Headlight Washers

See D050
PLUG
FOG LAMPS

APPLICABLE TO VERSIONS WITH: Headlight Washers

Machine Translated by Google

APPLICABLE TO VERSIONS WITH: Headlight Washers

edit. 7205E10 FRONT BUMPER STRIPS

APPLICABLE TO VERSIONS WITH: Headlight Washers

Install ( Remove )

edit. 7205E10 FRONT BUMPER STRIPS

APPLICABLE TO VERSIONS WITH: Headlight Washers

Value
Component Fixing Ø Validity
(daNm)

Front Bumper Bolt M6 0.6 ÷ 1.0

APPLICABLE TO VERSIONS WITH: Headlight Washers

edit. 7055B11 FRONT BUMPER - ALIGN WITH BONNET

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir AIR EXHAUST HOSE FROM COOLER (1), LI OR RE - UI 1048B54

Remove ( Install )

- Place the car on a lift bridge.

edit. 7210E10 ONION FRONT BUMPER

1. Open the retaining clips (1a) and remove the intercooler air exhaust hose (1b).

Install ( Remove )

- Fit the air exhaust hose from the intercooler.

edit. 7210E10 ONION FRONT BUMPER

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir BY-PASS VALVE FOR TURBO PRESSURE FILL - UI 1048B58

Remove ( Install )

- Disconnect the negative terminal from the battery.

Description Plug

See A001
-
Battery
BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the air line from the vacuum pump.

2. Loosen the air line fixing bolt on the cylinder head.

1. Disconnect the turbocharger bypass solenoid valve connector.

Description Plug

See L102 BYPASS

1
Turbocharger Bypass SOLENOID VALVE FRONT
Solenoid Valve TURBOCOMPRESSOR

2. Loosen the clamp and disconnect the air line from the turbocharger bypass solenoid.

3. Loosen the clamp and disconnect the air hose from the line.

4. Loosen the bolts and remove the turbocharger bypass solenoid complete with the support bracket.

Install ( Remove )

- Install the turbocharger bypass solenoid complete with the support bracket and tighten the mounting bolts
vast.

- Connect the air hose to the pipe and tighten the corresponding clamp.

- Connect the air line to the turbocharger bypass solenoid valve and tighten the corresponding clamp.

- Connect the plug to the bypass solenoid valve for the turbocharger.

- Install the air line and tighten the mounting bolt on the cylinder head.

- Connect the air line to the vacuum pump.

edit. 1016A10 SOUND INSULATION COVER - UI

- Connect the negative terminal to the battery.

Description Plug

-
Battery See A001 BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir THROTTLE BODY - UI 1056B14

Removing ( Installing )
After replacing the throttle body, connect the Examiner, select the "active diagnosis" and perform the self-adjustment procedure.

- Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

1. Disconnect the throttle body connector.

Description Plug

See N075 ACTUATOR

1
Actuator integrated in INTEGRATED IN
throttle body THROTTLE BODY

1. Release the pipe (1a) from the retaining clip (1b).

2. Loosen the mounting bolt (2a) and remove the cable support bracket (2b).

1. Loosen mounting bolts (1a) and nuts (1b) and remove throttle body (1c).- Remove O-ring from manifold body.

Install ( Remove )

1. Install a new O-ring on the manifold housing.

Machine Translated by Google

- Place the throttle body in the seat and tighten the corresponding bolts.

- Place the cable support bracket and tighten the mounting bolts.

- Fasten the pipe in the retaining clip.

- Connect the plug to the throttle body.

See N075 ACTUATOR INTEGRATED IN THROTTLE BODY

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

- Connect the negative terminal to the battery.

Description Plug

-
BATTERY See A001 BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SWITCH ON BRAKE PEDAL - UI 1056B28

Remove ( Install )

See
A001
BATTERY

Remove ( Install )

See
A001
BATTERY

See I030
BRAKE PEDAL SWITCH
Machine Translated by Google

See I030
BRAKE PEDAL SWITCH

Install ( Remove )

See
A001
BATTERY

Install ( Remove )

See I030
BRAKE PEDAL SWITCH

See A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir AIR PRESSURE SENSOR - UI 1056B44

Remove ( Install )

1. Unplug the air pressure sensor.

Description Plug

See K082
1 Turbo pressure sensor
TURBO PRESSURE SENSOR

2. Loosen the bolt (2a) and remove the air pressure sensor (2b).

Install ( Remove )

- Fit the air pressure sensor, tighten the corresponding bolt and connect the plug.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir COOLANT TEMPERATURE SENSOR - UI 1056B50

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

1. Disconnect the coolant temperature sensor connector.

Description Plug

See K036
1
Coolant temperature sensor/- COOLANT TEMPERATURE SENSOR/-
transmitter
TRANSMITTER

1. Unscrew the coolant temperature sensor.

Install ( Remove )

- Install the coolant temperature sensor and tighten it with tightening torque.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PHASESENSOR - UI 1056B51

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

Install ( Remove )

edit. 1048B25 INTERCOOLER AND INTAKE MANIFOLD CONNECTION TUBE - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ABSOLUTE PRESSURE/AIR TEMPERATURE SENSOR - UI 1056B54

Remove ( Install )

See A001
BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the inlet temperature/pressure sensor.

2. Loosen the bolt and remove the inlet temperature/pressure sensor.

Description Plug

1
Integrated See K043
air temperature sensor

Install ( Remove )

- Install the inlet temperature/pressure sensor and tighten the corresponding bolt.

- Connect the plug to the inlet temperature/pressure sensor.

edit. 1016A10 SOUND INSULATION COVER - UI

See A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FUEL DISTRIBUTION LINE COMPLETE WITH ELECTRO INJECTION VALVES -
UI 1056B60

Remove ( Install )

- Open the cover of the fuse box in the engine compartment, remove fuse F21 and start the engine several times until
the fuel pressure in the distribution pipe is reduced to zero.
- Fit the previously removed fuse and close the fuse box cover.
edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

1. Disconnect the plug in the cable of the injection valves.

Description Plug

See D081 PLUG

1
Plug injection valves INJECTION VALVES

1. Disconnect the vacuum hose for the fuel pressure regulator from the manifold housing.

2. Disconnect the quick connector from the fuel return line to the tank.

1. Disconnect the front fuel supply line quick disconnect from the fuel distribution line.

2. Loosen the fuel manifold mounting bolts on the manifold housing.

- Remove the fuel distribution line complete with the injection valves and the associated cable bundle.

1. Disconnect the vacuum hose from the fuel pressure regulator.

2. Disconnect the injector valves, disconnect the harness from the retaining clips, and remove the harness
from the fuel manifold.
Machine Translated by Google

Install ( Remove )

- Connect the plugs to the injection valves and fasten the retaining clips of the cable bundle to the
fuel distribution line.

- Connect the vacuum hose to the fuel pressure regulator.

- Mount the fuel distribution line complete with the injection valves and the associated cable bundle.

- Tighten the fuel manifold mounting bolts to the manifold housing.

- Connect the quick coupler of the front fuel supply line to the fuel distribution line.

- Connect the quick connector from the fuel return line to the tank.

- Connect the vacuum hose for the fuel pressure regulator to the manifold housing.

- Connect the plug in the cable of the injection valves.

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SET OF ELECTRO INJECTION VALVES - UI ON EXTENDED
FUEL DISTRIBUTION - INCLUDES REPL. OF SEALS 1056B68

Remove ( Install )

edit. 1056B70 ELECTRO INJECTION VALVE (1) - ONION WITH EXTENDED FUEL DISTRIBUTION LINE -
INCLUDES REF. OF SEAL

Install ( Remove )

edit. 1056B70 ELECTRO INJECTION VALVE (1) - ONION WITH EXTENDED FUEL DISTRIBUTION LINE -
INCLUDES REF. OF SEAL
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SWITCH ON CLUTCH PEDAL - UI ON RIGHT VERSIONS
SEND 1056B77

Remove ( Install )

See
A001
BATTERY

See I031
CLUTCH PEDAL SWITCH

Install ( Remove )
Machine Translated by Google

See
A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir INJECTION/IGNITION CONTROL UNIT - UI 1056B82

Remove ( Install )

See A001
BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the plugs from the injection control unit.

Description Plug

See M010
1
Engine Control Unit INJECTION RULE UNIT

Install ( Remove )

1. - Fit the injection control unit (1a) and tighten the fastening nuts (1b) with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Control unit for Nut M6 0.7 ÷ 0.9 1.4 16v TJet

injection/ignition

See M010
INJECTION RULE UNIT

edit. 1016A10 SOUND INSULATION COVER - UI

See A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SYSTEM CABLE HARNESS - UI 1056B90

Remove ( Install )

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

-
Battery See A001 BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 5530B10 BATTERY - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Disconnect the plug from the oil pressure switch.

Description Plug

See K030 SENSOR

1 Oil pressure sensor (interrupter) (INTERRUPTER) FRONT
MOTOROLIEDRUK

2. Disconnect the speed sensor plug.

Description Plug

See K046
2 Speed sensor
RPM SENSOR

1. Disconnect the turbocharger bypass solenoid valve connector.

Description Plug

See L102 BYPASS

1
Turbocharger Bypass SOLENOID VALVE FRONT
Solenoid Valve TURBOCOMPRESSOR

1. Disconnect the plugs from the ignition coils.

Description Plug

1 Reel See A030 COIL

2. Loosen the bolt and disconnect the ground cable from the valve cover.
Machine Translated by Google

1. Disconnect the connectors from the MULTIAIR actuators.

Description Plug

See N197
MULTIAIR
1 MULTIAIR
actuator
ACTUATOR

1. Loosen the mounting bolt of the crankcase ventilation hose for the turbocharger.

2. Loosen the fixing bolts of the cable tray.

1. Disconnect the inlet temperature/pressure sensor.

Description Plug

1
Integrated See K043
air temperature sensor

2. Loosen the bolt and disconnect the ground cable from the compressor.

1. Disconnect the air conditioning compressor plug.

Description Plug

See L020
Solenoid for A/C compressor activation ELECTROMAGNETIC
1
LINK OF
AIRCOCOMPRESSOR

- Release the cable bundle from the retaining clips.

1. Disconnect the plug from the injection control unit.

Description Plug
Machine Translated by Google

See M010
1
Injection control unit INJECTION RULE UNIT

2. Disconnect the plug in the cable of the injection valves.

Description Plug

See D081 PLUG

2 Plug injection valves INJECTION VALVES

1. Disconnect the front connector in the engine harness.

Description Plug

See D004
1 Plug for / motor PLUG FOR /
MOTOR

1. Disconnect the fuel vapor shut-off valve.

Description Plug

See L010
1
Fuel vapor shut-off valve FUEL VAPOR VALVE

1. Disconnect the coolant temperature sensor connector.

Description Plug

See K036
1
Coolant temperature sensor/- COOLANT TEMPERATURE SENSOR/-
transmitter
TRANSMITTER

1. Unplug the phase sensor.

Description Plug

See K047
Machine Translated by Google

1 Phase Sensor PHASE SENSOR

1. Unplug the air pressure sensor.

Description Plug

See K082
1 Turbo pressure sensor
TURBO PRESSURE SENSOR

1. Unplug the oil temperature sensor.

Description Plug

See K029
1
Motor temperature sensor ENGINE SLUDGE TEMPERATURE SENSOR

2. Disconnect the throttle body connector.

Description Plug

See N075 ACTUATOR

2
Actuator integrated in INTEGRATED IN
throttle body THROTTLE BODY

1. Disconnect the knock sensor plug.

Description Plug

See K050
1
Pingelsensor VOLTAGE SENSOR

1. Loosen the nut and disconnect the alternator ground cable.

Machine Translated by Google

1. Loosen the engine harness trough mounting bolts on the manifold housing.

1. Operate the locking tabs (1a) and open the cable tray (1b).

1. Remove the engine wiring harness.

Install ( Remove )

- Place the cable bundle and close the gutter.

- Tighten the engine wiring harness trough mounting bolts to the manifold housing.

- Connect the alternator ground cable and tighten the corresponding nut.
Machine Translated by Google

- Connect the knock sensor plug.

Description Plug

Pingelsensor See K050 PING SENSOR

- Connect the plug to the throttle body.

Description Plug

See N075 ACTUATOR

-

Actuator integrated in throttle body INTEGRATED IN

THROTTLE BODY

- Connect the plug to the engine oil temperature sensor.

Description Plug

-
See K029
Motor temperature sensor ENGINE SLUDGE TEMPERATURE SENSOR

- Connect the plug of the air pressure sensor.

Description Plug

-
Turbo pressure sensor See K082 TURBO PRESSURE SENSOR

- Unplug the phase sensor.

Description Plug

-
Phase sensor See K047 PHASE SENSOR

- Connect the coolant temperature sensor connector.

Description Plug

See K036
-
Coolant temperature sensor/- COOLANT TEMPERATURE SENSOR/-
transmitter
TRANSMITTER

- Connect the plug to the fuel vapor shut-off valve.

Description Plug

-
See L010
Fuel vapor shut-off valve FUEL VAPOR VALVE

- Connect the front plug in the engine wiring harness.

Description Plug
Machine Translated by Google

-
Plug for / motor See D004 PLUG FOR /
MOTOR

- Connect the plug in the cable of the injection valves.

Description Plug

-
See D081 PLUG
Plug injection valves INJECTION VALVES

- Connect the plug to the injection control unit.

Description Plug

-
See M010
Injection control unit INJECTION RULE UNIT

- Fasten the cable bundle in the retaining clips.

- Connect the plug of the air conditioning compressor.

Description Plug

See L020
-
Solenoid for A/C compressor activation ELECTROMAGNETIC
LINK OF
AIRCOCOMPRESSOR

- Connect the ground cable to the compressor and tighten the bolt.

- Connect the plug to the inlet temperature/pressure sensor.

Description Plug

Integrated air temperature sensor See K043

- Tighten the fixing bolts of the cable tray.

- Tighten the mounting bolt of the crankcase ventilation hose for the turbocharger.

- Connect the plugs to the MULTIAIR actuators.

Description Plug

-
MULTIAIR-actuator See N197 MULTIAIR ACTUATOR

- Connect the plugs to the ignition coils.

Description Plug

-
Reel See A030 COIL

- Connect the plug to the bypass solenoid valve for the turbocharger.

Description Plug
Machine Translated by Google

Turbocharger Bypass Solenoid See L102 BYPASS

Valve SOLENOID VALVE FRONT
TURBOCOMPRESSOR

- Connect the plug of the speed sensor.

Description Plug

-
Speed sensor See K046 RPM SENSOR

- Connect the plug to the engine oil pressure switch.

Description Plug

See K030 SENSOR

Oil pressure sensor (interrupter) (INTERRUPTER) FRONT
-

MOTOROLIEDRUK

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1032D26 TIMING COVER (UPPER PART) - UI

edit. 5530B10 BATTERY - UI

edit. 1016A10 SOUND INSULATION COVER - UI

- Connect the negative terminal to the battery.

Description Plug

-
Battery See A001 BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ELECTRO INJECTION VALVES CABLE HARNESS - UI 1056B95

Remove ( Install ) - Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the plugs from the injection valves.

Description Plug

See N070 ELECTRO

1
Electric injection valve INJECTION VALVE

2. Disconnect the coupler connector, release the wiring harness for the injection valves (2b) from the retaining clips on the fuel
manifold and remove the wiring harness.

Description Plug

See D081 PLUG

2a Plug injection valves INJECTION VALVES

Install ( Remove )

- Position the wiring harness for the injection valves and secure the wiring harness to the retaining clips on the
fuel distribution line.

- Connect the coupling plug and the plugs to the injection valves.
edit. 1016A10 SOUND INSULATION COVER - UI

- Connect the negative terminal to the battery.

Description Plug

See A001
-
BATTERY
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PIPE BETWEEN PRESSURE RESERVOIR AND SOLENOID CONTROL VALVE OF
ACTUATOR - U.I. 1064A27

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1080B62 CATALYST - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

Machine Translated by Google

Install ( Remove )
Machine Translated by Google

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1048A50 AIR SUPPLY HOSE TO TURBO COMPRESSOR - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1080B62 CATALYST - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TURBO COMPRESSOR HEAT SHIELD - UI 1064A31

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

1. Loosen nuts (1a) and bolts (1b) and remove heat shield (1c).

Install ( Remove )

- Place the heat shield in front of the turbocharger and tighten the corresponding fasteners.
edit. 1016A10 SOUND INSULATION COVER - UI
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SOLENOID VALVE FOR WASTEGATE TURBO PRESSURE CONTROL - UI 1064B38

Remove ( Install )

- Disconnect the negative terminal from the battery.

Description Plug

See
-
BATTERY A001
BATTERY

1. Open the retaining clips (1a) and disconnect the air lines from the wastegate solenoid valve (1b).

1. Disconnect the wastegate solenoid valve.

Description Plug

See L037 SOLENOID VALVE

1
Waste-gate solenoid valve FOR WASTE GATE

2. Open retaining clip and remove wastegate solenoid complete with support bracket and pipes.

1. On the workbench, open the locking clamps (1a) and disconnect the pipes (1b).

2. Remove the support bracket (2a) from the solenoid valve (2b).

Install ( Remove )

- Mount the solenoid valve on the support bracket on the workbench.

- Connect the pipes to the solenoid valve and fit new retaining clips.

- Mount the solenoid valve complete with pipes and support bracket in the seat.

- Connect the plug to the wastegate solenoid valve.

Machine Translated by Google

Description Plug

See L037
-

Waste-gate solenoid valve SOLENOID VALVE FRONT

WASTE-GATE

- Connect the lines of the solenoid valve and fit new retaining clips.

- Connect the negative terminal to the battery.

Description Plug

See
-
BATTERY A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir THROTTLE WITH BUILT-IN GASKET SENSOR - UI 1068A20

Remove ( Install ) 1. Disconnect the accelerator pedal.

Description Plug

See K055
1
Accelerator pedal sensor
GASPEDAL SENSOR

2. Loosen the bolt (2a) and remove the accelerator pedal (2b).

Install ( Remove )

- Place the accelerator pedal and tighten the corresponding bolts.

- Connect the plug to the accelerator pedal.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SOUND INSULATION COVER - UI 1016A10

Return to MANIFOLD HOUSING REINFORCING BRACKET - UI

Remove ( Install )

1. Loosen the insulation cap from the retaining pins and remove the cap.

Install ( Remove )

- Place the insulating cover in the seat and fasten the cover to the locking pins.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir TURBO COMPRESSOR HEAT SHIELD - UI 1064A31

Return to EXHAUST MANIFOLD HEAT SHIELD - UI

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

1. Loosen nuts (1a) and bolts (1b) and remove heat shield (1c).

Install ( Remove )

- Place the heat shield in front of the turbocharger and tighten the corresponding fasteners.
edit. 1016A10 SOUND INSULATION COVER - UI
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir BRANCH HOUSE - UI 1072B50

Remove ( Install )

- Open the cover of the fuse box in the engine compartment, remove fuse F21 and start the engine several times until the fuel pressure
in the distribution pipe is reduced to zero.

- Fit the previously removed fuse and close the fuse box cover.

- Place the car on a lift bridge.

- Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1056B65 NOISE INSULATION COVER OF INJECTION VALVES - UI

edit. 1056B82 INJECTION/IGNITION CONTROL UNIT - UI

edit. 1056B87 SUPPORT FOR INJECTION/IGNITION CONTROL UNIT - UI

edit. 1056B14 THROTTLE BODY - UI

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

1. Release the retaining clips from the cable tray.

1. Disconnect the fuel vapor shut-off valve.

Description Plug

See L010
1
Fuel vapor shut-off valve FUEL VAPOR VALVE

1. Open the retaining clamps (1a) and disconnect the pipes (1b).
Machine Translated by Google

1. Disconnect the quick connectors in the fuel vapor recovery system lines.

1. Disconnect the plug in the cable of the injection valves.

Description Plug

See D081 PLUG

1
Plug injection valves INJECTION VALVES

1. Disconnect the inlet temperature/pressure sensor.

Description Plug

See K044
1
Air temperature/pressure sensor INTAKE AIR TEMPERATURE
AND PRESSURE SENSOR

1. Open the retaining clip (1a) and disconnect the crankcase ventilation hose (1b).

2. Disconnect the brake booster vacuum hose.

Machine Translated by Google

1. Loosen mounting bolts (1a) and remove manifold housing (1b).

- On the workbench, proceed as follows:

1. Open the fuel vapor line retaining clips.

2. Open the quick coupling retaining clips for the fuel lines.

3. Loosen clamp and disconnect fuel vapor line for idle discharge.

4. Loosen the bolts (4a) and remove the solenoid and check valves complete with hoses from the manifold
housing (4b).

1. Loosen the bolts (1a) and remove the fuel manifold complete with the injectors and the wiring harness (1b).

1. Loosen the bolt (1a) and remove the air temperature/pressure sensor (1b).

2. Loosen the mounting bolt (2a) and remove the cable support bracket (2b).
Machine Translated by Google

1. Loosen the clamp and disconnect the crankcase ventilation hose.

2. Disconnect the brake booster vacuum hose.

Install ( Remove )

- On the workbench, proceed as follows:

- Connect the brake booster vacuum hose.

- Connect the crankcase ventilation hose and fit a new retaining clip.

- Place the cable bracket and tighten the fixing bolt.

- Install the air temperature/pressure sensor and tighten the mounting bolt.

- Assemble the fuel distribution line complete with the injection valves and the associated cable bundle and tighten the
mounting bolts.

- Install the solenoid valve and the check valves complete with the hoses from the manifold housing and tighten the
mounting bolts.

- Connect the fuel vapor line for discharge at idle speed and install a new retaining clip.

- Fasten the quick couplings of the fuel lines to the retaining clips.

- Fasten the fuel vapor lines to the corresponding retaining clips.

1. Install the manifold housing (1a) and tighten the mounting bolts (1b) to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Bolt (replaced M7 1.3 ÷ 1.6 1.4 16v TJet

Manifold housing
with new one)

- Connect the brake booster vacuum hose.

- Connect the crankcase ventilation hose and fit a new retaining clip.
Machine Translated by Google

Connect the plug to the inlet temperature/pressure sensor.

Description Plug

See K044
Air temperature/pressure sensor INTAKE AIR TEMPERATURE
AND PRESSURE SENSOR

- Connect the plug in the cable of the injection valves.

Description Plug

-
Plug See D081 PLUG
injection valves INJECTION VALVES

- Connect the quick couplings in the pipes of the fuel vapor collection system.

- Fasten the pipes in the corresponding retaining clamps.

- Connect the plug to the fuel vapor shut-off valve.

Description Plug

-
See L010
Fuel vapor shut-off valve FUEL VAPOR VALVE

1. Close the cable tray retaining clips.

edit. 1048B30 HOSE FROM AIR SUPPLY TUBE TO THROTTLE BODY - REPL.

edit. 1056B14 THROTTLE BODY - UI

edit. 1056B87 SUPPORT FOR INJECTION/IGNITION CONTROL UNIT - UI

edit. 1056B82 INJECTION/IGNITION CONTROL UNIT - UI

edit. 1056B65 NOISE INSULATION COVER OF INJECTION VALVES - UI

edit. 1072B53 MANIFOLD HOUSING REINFORCING BRACKET - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Connect the negative terminal to the battery.

Description Plug

See
-
BATTERY A001
BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir STRENGTHENING BRACKET FROM SPRAYER HOUSE - UI 1072B53

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the plug from the bracket.

2. Open the retaining clips (2a), loosen the bolt (2b) and nuts (2c) and remove the reinforcement bracket from the
manifold housing (2d).

Install ( Remove )

- Install the manifold housing reinforcement bracket and tighten the associated fasteners.

- Close the retaining clips of the pipe and fix the plug to the bracket.
edit. 1016A10 SOUND INSULATION COVER - UI
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir EXHAUST MANIFOLD HEAT SHIELD - UI 1072C44

Remove ( Install )

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1080B62 CATALYST - UI

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

Install ( Remove )

edit. 1088D50 COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR - UI

edit. 1080B62 CATALYST - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1084B40 OIL SUPPLY PIPE TO TURBO COMPRESSOR - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Machine Translated by Google

191 - Juliet 1.4 Turbo MultiAir CATALYST - UI 1080B62

Return to EXHAUST MANIFOLD HEAT SHIELD - UI

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the mounting bolts (1a) of the support bracket (1b) of the catalytic converter on the cylinder block.

1. Loosen the bolts (1a) and remove the support bracket (1b) for the catalytic converter.

2. Loosen the catalytic converter mounting nuts on the exhaust pipe.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

1. Disconnect the upper lambda sensor connector.

Description Plug

Lambda probe on See K015 LAMBDA PROBE

1
precatalyst ON PRECATALYST

1. Loosen the collar nut (1a) and remove the catalytic converter (1b) and lambda sensor (1c).

- Remove the gaskets.

- If necessary, unscrew the lambda probe and remove the probe.

Machine Translated by Google

Install ( Remove )

1. Install the catalytic converter (1a) complete with new gaskets and tighten the collar retaining nut (1b) to torque.

Component Confirmation ISLAND

Value (daNm) Validity

1. Connect the upper lambda probe connector.

Description Plug

Lambda probe See K015 LAMBDA PROBE

1
on precatalyst ON PRECATALYST

1. Install the catalytic converter support bracket (1a) and tighten the mounting bolts (1b) on the cylinder block
to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Catalyst Support End M8 2.3 ÷ 2.8 1.4 16v TJet

Bracket

1. Tighten the mounting bolts (1a) of the support bracket (1b) on the catalytic converter to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Support bracket from

Machine Translated by Google

catalyst End M8 2.3 ÷ 2.8 1.4 16v TJet

2. Tighten the catalytic converter mounting nuts to the exhaust pipe with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Exhaust intermediate Nut M8 2.3 ÷ 2.8 1.4 16v TJet

pipe with flexible part

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016A10 SOUND INSULATION COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir COOLANT DRAIN PIPE TO ENGINE FROM TURBO COMPRESSOR -
U.I. 1088D50

Return to EXHAUST MANIFOLD HEAT SHIELD - UI

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

1. Act on the retaining clip (1a) and move the waste gate solenoid (1b) to the side.

1. Unscrew the connection (1a) of the turbocharger coolant discharge line (1b) from the water pump return tube.

1. Loosen the connection (1a) and remove the coolant discharge line (1b) from the turbocharger.

Install ( Remove )

- Install the turbocharger coolant discharge line and tighten the corresponding connections.

The pipe must be held back when tightening the connections.

Any displacement through an angle greater than 3° will damage the sealing of the connections.
- Install the waste-gate valve and tighten the corresponding circlip.
Machine Translated by Google

Value
Component Fixing Ø Validity
(daNm)

Component Confirmation ISLAND

Value (daNm) Validity

Turbocharger Oil
Supply Line - M12 1.8 ÷ 2.2 1.4 16v TJet
Connection
Turbocharger Side

Component Confirmation ISLAND

Value (daNm) Validity

Turbocharger Oil
Supply Line - M12 1.8 ÷ 2.2 1.4 16v TJet
Connection
Turbocharger Side

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir Front Muffler HEAT SHIELD - UI 1076A42

Remove ( Install )

- Place the car on a lift bridge.

1. Remove the rear rivets (1a) from the heat shield (1b) using a drill.

1. Loosen the toothed clamps (1a) and remove the front rivets (1b) from the heat shield using a drill.

1. Loosen the mounting bolts (1a) silent block bracket front muffler (1b).

1. Loosen the bolts (1a) and remove the heat shield (1b).

Carefully lower the heat shield, as the four center bolts also secure the gear lever bracket.
Machine Translated by Google

Install ( Remove )

1. Install the heat shield (1a) and tighten the bolts (1b) to the specified torque.

Value
Component Confirmation ISLAND
Validity
(daNm)

Gear lever bracket Bolt M8 2.7 ÷ 3.3

on the body

1. Tighten the mounting bolts (1a) silent block bracket front muffler (1b) to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

Support bracket for the

front End M8 2.2 ÷ 2.7
suspension muffler

- Tighten the toothed clamps and fit new pop rivets on the front and back of the heat shield.
- Remove the car from the lift bridge.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CATALYST HEAT SHIELD - UI 1076A48

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

Install ( Remove )

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir EXHAUST PIPE HEAT SHIELD ON FUEL TANK - UI 1076A51

Remove ( Install )

- Place the car on a lift bridge.

1. Squeeze and remove the parking brake cable retaining clip.

1. Loosen the heat shield toothed retaining clip on the body.

Install ( Remove )

- Place the heat shield and tighten the corresponding fasteners.

Component Confirmation ISLAND

Value (daNm) Validity

Support bracket for the

front End M8 2.2 ÷ 2.7
suspension muffler

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir MIDDLE Muffler HEAT SHIELD - UI 1076A52

Remove ( Install )

- Place the car on a lift bridge.

edit. 1076B20 REAR MUFFLER - UI

1. Loosen the toothed retaining clip (1a) of the heat shield (1b) on the body.

Install ( Remove )

- Install the heat shield and tighten the corresponding toothed clamps.
edit. 1076B20 REAR MUFFLER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir REAR EXHAUST MUFFLER - UI 1076B20

Remove ( Install )

- Place the car on a lift bridge.

1. Loosen the bolt (1a) and remove the rear muffler (1b).

- If necessary, remove the rear silent block.

Install ( Remove )

1. Install the rear muffler (1a) and tighten the bolt (1b) to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

Support bracket for

the rear suspension End M10 4.5 ÷ 5.5
muffler

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FRONT EXHAUST - UI 1076B30

Remove ( Install )

- Place the car on a lift bridge.

1. Loosen the mounting nuts of the front exhaust pipe flange on the front muffler.

2. Loosen the mounting bolts of the suspension rubbers of the front muffler.

1. Loosen the mounting collar of the front muffler on the muffler.

Install ( Remove )

- Place the front muffler and fix it to the rear suspension rubber.

Component Confirmation ISLAND

Value (daNm) Validity

Support bracket for

the front suspension End M8 2.2 ÷ 2.7
muffler

1. Tighten the front muffler mounting collar on the front muffler to the specified torque.

Component Confirmation ISLAND

Value (daNm) Validity

Connecting
flange front part Nut M8 2.2 ÷ 2.7 1.4 16v TJet
to front muffler

Component Confirmation ISLAND

Value (daNm) Validity

Support bracket for End M8 2.2 ÷ 2.7

the front
Machine Translated by Google

suspension muffler
- Remove the car from the lift bridge.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir EXHAUST SYSTEM END PIECE - REPL. 1076B38
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir EXHAUST INTERMEDIATE PIPE WITH FLEXIBLE PART - UI 1076B72

Remove ( Install )

- Place the car on a lift bridge.

See A001 BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the mounting nuts (1a) of the exhaust intermediate pipe (1b) on the flange of the front muffler.

1. Loosen the mounting bolt (1a) of the exhaust intermediate pipe (1b) on the engine oil pan.

See K017
LAMBDA SENSOR
ON
CATALYST

1. Loosen the nuts (1a) and remove the exhaust intermediate pipe (1b).
Machine Translated by Google

- Remove the gaskets.

Install ( Remove )

Component Confirmation ISLAND

Value (daNm) Validity

lambda probe -
M18 4.0 ÷ 5.0

1. Install the exhaust intermediate pipe (1a) complete with new gaskets and tighten the nuts (1b) with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Exhaust intermediate Nut M8 2.3 ÷ 2.8 1.4 16v TJet

pipe with flexible part

See K017
LAMBDA SENSOR
ON
CATALYST

1. Tighten the mounting bolt (1a) of the exhaust intermediate pipe (1b) on the engine oil pan to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Exhaust
intermediate pipe End M10 4.5 ÷ 5.5 1.4 16v TJet
with flexible part - oil pan side

1. Tighten the mounting nuts (1a) of the exhaust intermediate pipe (1b) to the flange of the front muffler
with torque.

Component Confirmation ISLAND

Value (daNm) Validity
Machine Translated by Google

Exhaust intermediate Nut M8 2.3 ÷ 2.8 1.4 16v TJet

pipe with flexible part

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

See A001 BATTERY

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CO PERCENTAGE AT Idle RPM - CONTROL WITH SPECIAL
EQUIPMENT 1080A10

Take the measurement with all emission reduction systems active and the engine running at the prescribed idle speed.

- Insert the probe of an exhaust gas tester at least 30 cm into the exhaust pipe.
If the shape of the exhaust pipe does not allow the probe to be inserted deeply enough, the exhaust must be extended with a
suitable length of pipe, whereby the connection must be gas-tight.

- Wait until the indications on the exhaust gas tester have stabilized.

- Check whether the CO2 percentage at idle speed is within the tolerance.

Measurement Where the Validity

CO2 emissions through the exhaust according to

156 1.4 16v TJet 120PK
EU / 1999/100 standards (g / km)
Machine Translated by Google

191 - Juliet 1.4 Turbo MultiAir CATALYST - UI 1080B62

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the mounting bolts (1a) of the support bracket (1b) of the catalytic converter on the cylinder block.

1. Loosen the bolts (1a) and remove the support bracket (1b) for the catalytic converter.

2. Loosen the catalytic converter mounting nuts on the exhaust pipe.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

1. Disconnect the upper lambda sensor connector.

Description Plug

Lambda probe on See K015 LAMBDA PROBE

1

precatalyst ON PRECATALYST

1. Loosen the collar nut (1a) and remove the catalytic converter (1b) and lambda sensor (1c).

- Remove the gaskets.

- If necessary, unscrew the lambda probe and remove the probe.

Machine Translated by Google

Install ( Remove )

1. Install the catalytic converter (1a) complete with new gaskets and tighten the collar retaining nut (1b) to torque.

Component Confirmation ISLAND

Value (daNm) Validity

1. Connect the upper lambda probe connector.

Description Plug

Lambda probe See K015 LAMBDA PROBE

1
on precatalyst ON PRECATALYST

1. Install the catalytic converter support bracket (1a) and tighten the mounting bolts (1b) on the cylinder block
to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Catalyst Support End M8 2.3 ÷ 2.8 1.4 16v TJet

Bracket

1. Tighten the mounting bolts (1a) of the support bracket (1b) on the catalytic converter to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Support bracket from

Machine Translated by Google

catalyst End M8 2.3 ÷ 2.8 1.4 16v TJet

2. Tighten the catalytic converter mounting nuts to the exhaust pipe with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Exhaust intermediate Nut M8 2.3 ÷ 2.8 1.4 16v TJet

pipe with flexible part

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1076A48 CATALYST HEAT SHIELD - ONION

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016A10 SOUND INSULATION COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir LAMBDA PROBE FOR THE CATALYST - UI 1080B94

Remove ( Install )

See K015
LAMBDASONDE OP
PRECATALYST

Install ( Remove )
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir LAMBDA PROBE BEHIND THE CATALYST - UI 1080B95

Remove ( Install )

See A001 BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Disconnect the lambda sensor behind the catalytic converter.

Name Plug

See K017
Lambda probe on the
1 LAMBDASONDE OP
catalytic converter
CATALYST

Install ( Remove )

- Mount the lambda probe behind the catalytic converter and tighten the probe to the prescribed torque.

Component Confirmation ISLAND

Value (daNm) Validity

lambda probe -
M18 4.0 ÷ 5.0

- Connect the connector of the lambda sensor to the rear of the catalytic converter and secure the associated cables in the retaining
spring.

See K017 LAMBDA PROBE OP

CATALYST

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

See A001 BATTERY

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CRANK VAPOR SUCTION HOSE - UI 1080D24

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

Install ( Remove )

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir CRANKCASE VENTILATION HOSE FOR IDLING DRAIN - UI 1080D26

Remove ( Install )

Install ( Remove )
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir OIL SEPARATOR CRANKCASE VENTILATION - UI 1080D34

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

Install ( Remove )

edit. 1016A10 SOUND INSULATION COVER - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SUPPLY VALVE FOR PETROL VAPOR TO INLET - UI 1080E20

Remove ( Install )

edit. 4450B06 REAR WHEEL LEFT - UI

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

Install ( Remove )

edit. 7055B45 RIGHT REAR WHEEL TRAY GUARD - UI

edit. 4450B06 REAR WHEEL LEFT - UI

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PIPE FROM ACTIVE CARBON FILTER TO GASOLINE VAPOR VALVE - UI 1080E28

Remove ( Install ) - Disconnect the negative terminal from the battery.

Description Plug

-
BATTERY See A001 BATTERY

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1056B82 INJECTION/IGNITION CONTROL UNIT - UI

1. Disconnect the fuel vapor supply line quick disconnect from the inlet on the turbocharger.

2. Disconnect the quick disconnect of the fuel vapor supply hose from the solenoid valve.

1. Disconnect the fuel vapor shut-off valve.

Description Plug

See L010
1
Fuel vapor shut-off valve FUEL VAPOR VALVE

1. Open the fuel vapor line retaining clips.

2. Open the quick coupling retaining clips for the fuel lines.

3. Loosen clamp and disconnect fuel vapor line for idle discharge.

4. Loosen the bolts and remove the solenoid and check valves complete with hoses from the manifold housing.

Install ( Remove )

- Fit the solenoid valve and the non-return valves complete with the hoses and fix the retaining clips.

- Tighten the fuel vapor shut-off valve mounting bolts on the manifold housing and connect the corresponding connector
at.

- Connect the quick coupling of the fuel vapor supply hose to the solenoid valve.

- Connect the quick connector of the fuel vapor supply line to the inlet of the turbocharger.
Machine Translated by Google

- Connect the fuel vapor line for discharge at idle speed and tighten the corresponding clamp.

edit. 1056B82 INJECTION/IGNITION CONTROL UNIT - UI

edit. 1016A10 SOUND INSULATION COVER - UI

- Connect the negative terminal to the battery.

Description Plug

-
BATTERY See A001 BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir FUEL VAPOR PIPE FROM SOLENOID VALVE TO TURBO COMPRESSOR -
U.I. 1080E37

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the quick disconnect (1a) from the fuel vapor line from the solenoid valve to the turbocharger
(1b) from the manifold housing.

1. Open the fuel vapor line intermediate retaining clips between the solenoid valve and the turbocharger.

1. Loosen clamp (1a) and remove fuel vapor line (1b) between solenoid valve and turbocharger.

Install ( Remove )

- Place the fuel vapor line between the solenoid valve and the turbocharger and tighten the corresponding clamp.

- Close the intermediate retaining clips of the fuel vapor line between the solenoid valve and the turbocharger.

- Connect the quick connect coupling of the fuel vapor line from the solenoid valve to the turbocharger
to the manifold housing.
edit. 1016A10 SOUND INSULATION COVER - UI
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PIPE FROM ACTIVE CARBON FILTER TO GASOLINE VAPOR VALVE - UI 1080E62

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B44 REAR LEFT WHEEL TRAY GUARD - UI

edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

edit. 1040E22 FUEL LINE PROTECTION - UI

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the line quick disconnect from the manifold housing.

1. Loosen mounting bolts (1a) of the support bracket (1b).

- Release the pipe from the retaining clamps.

1. Disconnect the quick coupling (1a) and remove the line (1b) between the activated charcoal filter and the solenoid valve.

Install ( Remove )

- Connect the quick coupling of the line between the activated charcoal filter and the solenoid valve to the activated charcoal filter.

- Fasten the pipe in the locking clamps.

1. Connect the hose quick coupler to the manifold housing.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 1040E22 FUEL LINE PROTECTION - UI

Machine Translated by Google

edit. 1040A10 FUEL TANK - ONION AND FUEL POUR

edit. 7055B44 REAR LEFT WHEEL TRAY GUARD - UI

- Remove the car from the lift bridge.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE OIL STICKER - UI 1084A16

Remove ( Install )

edit. 1016A10 SOUND INSULATION COVER - UI

1. Disconnect the harness spring clip from the dipstick tube bracket.

1. Remove the oil dipstick.

2. Loosen the bolt and remove the oil dipstick tube.

Install ( Remove )

- Fit the oil dipstick tube and tighten the corresponding bolt.

- Place the oil dipstick in the seat.

- Attach the spring clip of the wiring harness to the bracket for the oil dipstick tube.
edit. 1016A10 SOUND INSULATION COVER - UI
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir OIL PRESSURE WARNING LIGHT SWITCH - UI 1084A42

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the bolts (1a) and remove the engine/box support (1b).

Install ( Remove )

1. Install the engine/box mount (1a) and tighten the bolts (1b) to torque.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE OIL SUCTION TUBE - REMOTE OIL PAN 1084B28 UI

Remove ( Install )

1. Loosen the bolts (1a) and remove the oil suction tube (1b).

1. Remove the O-ring from the oil suction tube.

Install ( Remove )

- Fit the oil suction tube complete with a new O-ring and tighten the corresponding bolts.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir MOTOROLIEFILTER - UI 1084B30

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Unscrew the oil filter cover using a suitable wrench and remove it completely.

- Remove the filter element and O-ring.

Install ( Remove )

1. Install a new O-ring on the oil filter cover.

2. Clamp a new filter element to the oil filter cover (2a) while tightening the retaining clips (2b).

1. Install the new engine oil filter and tighten the cover with torque.

Value
Component Fixing ISLAND
Validity
(daNm)

Engine oil - -
2.5
filter cover

edit. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP up if necessary.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir SUPPORT FOR ENGINE OIL FILTER AND COOLER - UI 1084B36

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1084B42 PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI

edit. 1088D51 COOLANT RETURN HOSE FROM ENGINE OIL COOLER - UI

1. Loosen the mounting bolts (1a) of the oil filter support and the cooler on the support bracket (1b).

- Place a container under the car that is suitable for engine oil.

1. Loosen the bolts (1a) and (1b) and remove the oil filter support and cooler (1c).

1. Remove the oil filter cover complete with the filter element.

2. Remove the O-ring on the oil pump side.

Install ( Remove )

1. Install a new O-ring on the support on the oil pump side.

Machine Translated by Google

2. Install a new oil filter element and tighten the corresponding cover with tightening torque.
1. Install the oil filter support and oil cooler (1a) and tighten the corresponding bolts (1b) and (1c) to torque.

- Tighten the oil filter support and cooler mounting bolts to the support bracket.

edit. 1088D51 COOLANT RETURN HOSE FROM ENGINE OIL COOLER - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PIPE FOR SUPPLY OF OIL TO TURBO COMPRESSOR - UI 1084B40

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1016A10 SOUND INSULATION COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

1. Loosen the connection (1a) and disconnect the oil supply line (1b) from the turbocharger.

1. Loosen the connection (1a) and remove the oil supply line (1b) from the turbocharger.

Install ( Remove )

1. Install the turbocharger oil supply line (1a) complete with new gaskets and tighten the corresponding connection
(1b) with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Oil supply line to

turbocharger (cooler Connection M6 0.8 ÷ 1.0 1.4 16v TJet
side)

1. Tighten the connection (1a) of the oil supply line (1b) on the turbocharger to torque.

The pipe must be held back when tightening the connection.

Any displacement through an angle greater than 3° will damage the seal of the connection.

Component Confirmation ISLAND

Value (daNm) Validity
Machine Translated by Google

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1064A31 TURBO COMPRESSOR HEAT SHIELD - UI

edit. 1016A10 SOUND INSULATION COVER - UI

edit. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP up if necessary.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PIPE FOR OIL RETURN FROM TURBO COMPRESSOR - UI 1084B42

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

1. Loosen the mounting bolts (1a) of the engine oil return line (1b) on the turbocharger.

1. Loosen the connection of the oil return line for the turbocharger on the oil filter support.

2. Loosen the fixing bolt (2a) and disconnect the oil return line (2b) of the turbocharger from the cylinder block and
remove the line.

1. Remove the O-ring (1a) and gasket (1b) from the turbocharger oil return line (1c).

Install ( Remove )

1. Fit the turbocharger oil return line (1a) complete with new gaskets and tighten the bolt (1b) on the slotted hole flange
first and then the remaining bolt (1c) with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Motorolieretourleiding Bolt M6 0.8 ÷ 1.0 1.4 16v TJet

from turbocharger
Machine Translated by Google

1. Tighten the mounting bolt (1a) of the oil return line (1b) for the turbocharger to the cylinder block with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Engine oil return line End M6 0.8 ÷ 1.0 1.4 16v TJet
from turbocharger

2. Tighten the oil return line connection for the turbocharger to the oil filter support with torque.

Component Confirmation ISLAND

Value (daNm) Validity

Turbocharger oil
return line (oil filter M16 3.0 ÷ 3.6 1.4 16v TJet
Connection
support side)

edit. 1084C22 HEAT SHIELD ON ENGINE OIL COOLER - UI

edit. 1048B19 TURBO COMPRESSOR AIR EXHAUST HOSE - UI

edit. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP up if necessary.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir HEAT SHIELD ON ENGINE OIL COOLER - UI 1084C22

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

1. Loosen the mounting bolts (1a) of the support bracket (1b) of the catalytic converter on the engine.

1. Loosen the bolts (1a) and remove the support bracket (1b) for the catalytic converter.

1. Loosen the bolts (1a) and remove the top heat shield (1b).

1. Loosen the bolts (1a) and remove the lower heat shield (1b).
Machine Translated by Google

Install ( Remove )

- Place the two heat shields on the engine oil cooler and tighten the corresponding bolts.
1. Install the catalytic converter support bracket (1a) and tighten the bolts (1b) to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Catalyst Support End M8 2.3 ÷ 2.8 1.4 16v TJet

Bracket

1. Tighten the mounting bolts (1a) of the catalytic converter support bracket (1b) on the cylinder block to torque.

Component Confirmation ISLAND

Value (daNm) Validity

Catalyst Support End M8 2.3 ÷ 2.8 1.4 16v TJet

Bracket

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE COOLING SYSTEM EXPANSION RESERVOIR - UI 1088B10

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

1. Loosen the clamp (1a) and disconnect the line between the expansion tank and the engine cooling radiator
(1b) from the tank.

2. Loosen the bolts (2a) and remove the expansion tank (2b).

Install ( Remove )

- Place the expansion tank in the seat and tighten the corresponding fixing bolts.

- Connect the pipe between the expansion tank and the engine cooling radiator to the expansion tank and
tighten the corresponding clamp.
Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE COOLING SYSTEM RADIATOR - UI 1088B20

Remove ( Install )

See A001 BATTERY

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

edit. 7210E10 ONION FRONT BUMPER

edit. 7210A18 UI AUXILIARY FRONT TRAVERSE

See O010 RESISTANCE

IN FRONT OF

SPEED CONTROL
ELECTRIC FAN -
1
Machine Translated by Google
Machine Translated by Google

Install ( Remove )

See O010 RESISTANCE

IN FRONT OF

SPEED CONTROL
ELECTRIC FAN -
1

edit. 7210A18 UI AUXILIARY FRONT TRAVERSE

edit. 7210E10 ONION FRONT BUMPER

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

See A001 BATTERY

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir RADIATOR DRAIN PLUG - UI 1088B25

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Drain circuit

- With the engine cold, remove the cap from the expansion tank.

Do not remove the reservoir cap when the engine is warm; burn hazard.

1. Open the drain valve on the radiator, then remove the radiator drain plug.

Collect the coolant in a suitable container.

Install ( Remove )

- Close the drain valve of the engine cooling system.

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir AIR GUIDE ON COOLING ELEMENT - UI 1088B26

Remove ( Install )

edit. 7210E10 ONION FRONT BUMPER

edit. 7210A18 UI AUXILIARY FRONT TRAVERSE

Install ( Remove )

edit. 7210A18 UI AUXILIARY FRONT TRAVERSE

edit. 7210E10 ONION FRONT BUMPER

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir BRACKET FOR RADIATOR OF ENGINE COOLING SYSTEM (1), LI OR RE - UI 1088B29

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

- Place a suitable hydraulic jack to support the radiator.

1. Loosen the mounting bolts (1a) and remove the radiator bracket (1b).

Install ( Remove )

- Place the radiator support and tighten the corresponding bolts.

- Remove the hydraulic jack.

edit. 7055B59 FRONT UNDER ENGINE GUARD/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir WATER PUMP - UI WITH EXTENDED TIMING BELT 1088C14

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

1. Loosen the bolt (1a) and remove the timing cover (1b).

1. Loosen the water pump mounting bolts (1a) and nut (1b).

1. Use tool (1a) to cut through the sealant and remove the water pump (1b).

1. Remove the sealant residue from the cylinder block using suitable tools.

1. Remove the sealant residue from the water pump using suitable tools.
Machine Translated by Google

Install ( Remove )

- Apply a bead of silicone gasket to the contact surfaces of the water pump and the cylinder block.
1. Install the water pump (1a) and tighten the bolts (1b) and the nut (1c) with torque.

- Fit the timing cover and tighten the corresponding bolt.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir THERMOSTAT - UI 1088C40

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

2. Loosen the clamp and disconnect the radiator coolant supply hose from the thermostat.

3. Disconnect the quick connector from the breather hose.

1. Disconnect the coolant temperature sensor connector.

Description Plug

See K036
1
Coolant temperature sensor/- COOLANT TEMPERATURE SENSOR/-
transmitter
TRANSMITTER

2. Loosen the clamp and disconnect the supply hose from the heater radiator.

1. Loosen the bolts (1a) and remove the thermostat (1b).

Machine Translated by Google

1. Remove the O-ring from the thermostat.

2. If necessary, remove the coolant temperature sensor.

Install ( Remove )

- Fit a new O-ring in the groove on the thermostat.

1. Reassemble the thermostat (1a) and tighten the bolts (1b) to the specified torque.

- Connect the supply hose of the heater radiator and fasten the corresponding clamp.

- Connect the coolant temperature sensor connector.

1. Tighten the coolant supply hose connection to the engine oil cooler to the specified torque and
provide new gaskets.

The pipe must be held back when tightening the connection. Any displacement through an angle greater than
3° will damage the seal of the connection.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE COOLING SYSTEM ELECTRO FAN - UI 1088E10

Remove ( Install )

- Place the car on a lift bridge.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

Bew. 0010T20 ENGINE COOLANT - PAINT.

1. Disconnect the resistor plug.

Description Plug

See O010 RESISTANCE FOR

1
Electric fan speed control SPEED CONTROL
resistance - 1
ELECTRIC FAN - 1

2. Disconnect the quick coupling of the supply hose from the radiator.

1. Unplug the electric fan.

Description Plug

Motor for See N011 ENGINE VAN

1
electric fan ELECTRIC FAN

1. Loosen the bolts (1a) and remove the electric fan (1b).

1. Loosen the bolt and remove the resistor.

Machine Translated by Google

1. Loosen the nuts (1a) and remove the electric fan (1b) from the air guide.

Install ( Remove )

- Place the electric fan on the air guide and tighten the corresponding nuts.

- Place the resistor and tighten the corresponding bolt.

- Fit the electric fan and tighten the corresponding bolts.

- Connect the plug to the electric fan.

- Connect the quick coupling of the supply hose to the radiator.

- Connect the plug to the resistor.

Bew. 0010T20 ENGINE COOLANT - PAINT.

edit. 7055B54 UNDER ENGINE COMPARTMENT PROTECTION/COVER - UI

- Remove the car from the lift bridge.

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir RESISTOR OF ENGINE COOLING SYSTEM ELECTRO FAN - UI 1088E20

Remove ( Install )

See
A001
BATTERY

1. Disconnect the electrical fan resistor plug.

See O010 RESISTANCE

IN FRONT OF

SPEED CONTROL
ELECTRIC FAN -
1

2. Loosen the bolt (2a) and remove the resistance for the electric fan (2b).

Install ( Remove )

- Place the resistor in front of the electric fan and tighten the corresponding fixing bolt.

- Connect the plug to the resistor for the electric fan.

See
A001
BATTERY
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ENGINE COOLING SYSTEM ELECTRO FAN(S) CABLE HARNESS - UI OR REPL. 1088E80

Remove ( Install )

- Disconnect the negative terminal from the battery.

See
A001
BATTERY

1. Loosen the bolt and remove the fuse and relay box cover from the retaining clips.

1. Disconnect the front/radiator connector.

Description Plug

See D009 PLUG

1 Plug for / radiator
FRONT / RADIATOR

1. Disconnect the resistor plug.

Description Plug

See O010 RESISTANCE FOR

1
Electric fan motor resistance control SPEED CONTROL
-1
ELECTRIC FAN - 1

2. Unplug the electric fan.

Description Plug

See N011 ENGINE VAN

2 Motor for Electric Fan
ELECTRIC FAN

- Remove the electric fan wiring harness from the intermediate retaining clips.

Install ( Remove )

- Place the electric fan wiring harness, connect the electric fan plug and the resistor plug.

- Connect the front/radiator plug and fit it in its seat.

Machine Translated by Google

- Place the fuse and relay box cover, attach the retaining clips and tighten the fixing bolt.

- Close the intermediate retaining clips of the electric fan harness.

- Connect the negative terminal to the battery.

See A001 BATTERY

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir UI HULPFRONTTRAVERSE 7210A18

Return to ENGINE COOLING SYSTEM RADIATOR - UI

Remove ( Install )

edit. 7210E10 ONION FRONT BUMPER

1. Loosen the locks (1b) of the damping rubber and remove the rubber (1a).

1. Loosen the fastening bolts (1a) of the auxiliary crossbar (1b) on the body.

2. Loosen the attachment nuts (2a) of the auxiliary crossbar at the front end.

3. Remove the auxiliary crossbar.

Install ( Remove )

- Check the auxiliary crossbar for damage.

1. Place the auxiliary crossbar.

2. Tighten the attachment nuts of the auxiliary crossbeam on the front end with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

3. Tighten the attachment bolts of the auxiliary crossmember to the body with tightening torque.

Component Confirmation ISLAND

Value (daNm) Validity

Fastening
crash box End M10 2.4 ÷ 3.6
auxiliary traverse front
Machine Translated by Google

- Place the damping rubber on the auxiliary crossbar and tighten the locks.

edit. 7210E10 ONION FRONT BUMPER

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir UI FRONT BUMPER 7210E10

Return to ENGINE COOLING SYSTEM RADIATOR - UI

Remove ( Install )

- Place the car on a lift bridge.

- Raise the car.

1. Loosen the front mounting bolts (1a) of the front wheel arch guards (1b) on both sides of the car.

2. Loosen the mounting bolts (2a) of the bumper (2b) on the mudguards.

3. Release the front part (1b) of the wheel arch guards from the seat and move them to the side.

1. Loosen the lower mounting bolts (1a) of the bumper.

2. Loosen the bolts (2a) slightly.

- Lower the car.

1. Loosen the upper bumper mounting bolts.

2. Release the ends (2a) on the side of the bumper from the seats (2b).

3. Loosen the top lock (3a).

1. Move the front bumper (1a) slightly and disconnect the connector (1b) from the front bumper harness.

Description Plug
Machine Translated by Google

1b PLUG FOG LAMPS See D050 PLUG

FOG LAMPS

2. Remove the front bumper.

- If necessary, disassemble the bumper.

edit. 7205E10 FRONT BUMPER STRIPS

Install ( Remove )

- Check the front bumper for damage.

- Assemble the bumper if necessary.

edit. 7205E10 FRONT BUMPER STRIPS

- Connect the plug in the cable bundle of the front bumper.

- Fit the bumper and secure the top lock.

- Fix the ends on the side of the bumper in the seats.

1. Tighten the upper bumper mounting bolts.

Value
Component Fixing Ø Validity
(daNm)

Front Bumper Bolt M6 0.6 ÷ 1.0

- Raise the car.

- Tighten the lower mounting bolts of the bumper.

- Fit the front part of the wheel arch protection in the seat.

- Tighten the mounting bolts of the bumper to the mudguards.

- Loosen the front fastening bolts of the front wheel arch guards.

- Lower the car.

- If necessary, adjust the front bumper in relation to the hood.

edit. 7055B11 FRONT BUMPER - ALIGN WITH BONNET

- Remove the car from the lift bridge.

APPLICABLE TO VERSIONS WITH: Headlight Washers

Remove ( Install )

APPLICABLE TO VERSIONS WITH: Headlight Washers

Machine Translated by Google

APPLICABLE TO VERSIONS WITH: Headlight Washers

APPLICABLE TO VERSIONS WITH: Headlight Washers

See D050
PLUG
FOG LAMPS

APPLICABLE TO VERSIONS WITH: Headlight Washers

Machine Translated by Google

APPLICABLE TO VERSIONS WITH: Headlight Washers

edit. 7205E10 FRONT BUMPER STRIPS

APPLICABLE TO VERSIONS WITH: Headlight Washers

Install ( Remove )

edit. 7205E10 FRONT BUMPER STRIPS

APPLICABLE TO VERSIONS WITH: Headlight Washers

Value
Component Fixing Ø Validity
(daNm)

Front Bumper Bolt M6 0.6 ÷ 1.0

APPLICABLE TO VERSIONS WITH: Headlight Washers

edit. 7055B11 FRONT BUMPER - ALIGN WITH BONNET

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir PULLEY ON CRANKSHAFT - UI 1092A10

Remove ( Install )

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

1. Loosen the bolts (1a) and remove the crankshaft pulley (1b).

Install ( Remove )

1. Install the crankshaft pulley (1) and tighten the bolts (1b) to the specified torque.

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir DRIVE BELT VARIOUS BODIES - UI 1092G10

Remove ( Install )

1. Adjust the belt tensioner, install a locking pin (1a) and remove the drive belt for the auxiliaries (1b).

Install ( Remove )

- Reverse the drive belt for the auxiliaries and adjust the belt tensioner to remove the locking pin.
Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ADJUSTABLE TENSIONER FOR DRIVE BELT ASSISTANTS - UI 1092G14

Remove ( Install )

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

1. Adjust the belt tensioner and remove the locking pin.

2. Loosen the bolt (2a) and remove the adjustable accessory belt tensioner (2b).

Install ( Remove )

1. Install the adjustable belt tensioner (1a) for the attachments and tighten the bolt (1b) to the specified
torque.

2. - Adjust the belt tensioner and mount the locking pin.

edit. 1092G10 DRIVE BELT VARIOUS ORGANS - ONION

Machine Translated by Google

191 - Giulietta 1.4 Turbo MultiAir ALGEMEEN - ENGINE

PAY ATTENTION!

All work must be performed with maximum concentration and care to avoid injury. The engine
compartment contains several moving and hot parts, and cables that are under tension. Carefully
observe the following safety standards when working in the engine compartment: switch off the engine
and wait until it has cooled down, do not smoke, do not use open flames and check whether a fire
extinguisher is immediately available. For some operations, the use of special tools is prescribed . The use
of this tool is indispensable for safe work. Observe the safety regulations that apply in the workshop. Where
necessary, special points of attention are mentioned in the workshop manual that must be observed to prevent
hazardous working conditions. When working with chemical products, carefully follow the instructions in the
manufacturer's manual. The manufacturer is obliged to provide this manual with the respective product. The
electronic ignition system supplies voltages of 20,000 V and higher, which can be very dangerous to persons,
especially those with cardiac arrhythmias. Use extreme caution when performing any work on or near any of
the components of this system.

IMPORTANT TIPS
All work must be performed with maximum concentration and care to avoid damage to components.
To "release" stuck parts, tap metal components carefully with an aluminum or lead hammer and use a
wooden or plastic hammer on light metal components. When disassembling, check that parts to be marked
have a mark. When assembling, lubricate the parts as necessary to prevent seizing during initial operation.
Always observe the tightening torques and the adjustment data when carrying out installation work. When
installing, use only new gaskets, seals, spring washers, retaining plates, self-locking nuts, pre-treated bolts,
stretch bolts and replace all parts that are deformed. Protect those parts of the engine that are uncovered
during dismantling and where dust or other contamination can get in with self-adhesive paper or clean cloths.
When replacing components, only use original parts: only in this way is it guaranteed that the part is
interchangeable and the components on the work properly.

Before carrying out any work on the electrical system (plugs, components, cables, etc.), first turn the ignition
key to STOP and disconnect the battery.
Machine Translated by Google