ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 6To
be uncoupled:
- acceleration cable end ( 7) from the
valve control lever and extract it from the
sleeve ( 8) from support;
Po wer train group
Dismount the connection screw between the
gears control rod and gearbox control connecting
rod.
- hoses from gases evacuation vessel;
- petrol vapors recycling pipes from the
carbon can and from can purging valve; - fuel supply pipes (supply and return) from
injection ramp by means of the MOT.1311-06
device.
7
- speedometer cable from the gearbox
(push the two clamps and extract it); -cable for right headlamp adjustment
and place it near carriage body. Disconnect the servobrake pipe from the
intake manifold.
Di
smount the clutch control cable from
gearbox.
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42 - 2
FRONT U PPER STRUCTURE
Front wing lining
2
45
6 7 8
3
RE PLAC EMEN T
This operation shall be performed only on the c hecking/repair bench. For the specific sup-
ports mounting on the bench, please see the 40 sub-chapter.
DISMOUNTING
Dismount t he damaged elements, which are
in contact with the front wing lining. Detach the welding points of the front wing
lining (1), which are in contact with :
- upper longitudinal girder in (2) area;
- front cross member in the area ( 3);
- headlamp support in the area ( 4);
- closing plate in the area ( 5) ;
- front floor in the area (6);
- cowl panel in the area ( 7);
- climate control box in the area ( 8)
Str aig h ten the area resulted from
dismounting. Grind the area resulted from dismounting.
REMOU NT I NG
Position and center the new element by
means of the repairing bench. Weld the front wing lining (1) following the
assembling outlines 2, 3, 4, 5, 6, 7 and 8.
Pr otect th e perfo rmed welding with a
corrosion-preventing product.
Protect the front wing lining with a noise
absorbent product and paint the a ffected area
in the carriage body color. Mount the connection elements by pe rform-
ing the dismounting operations in the reverse
order.
1
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42 - 3
FRONT U PPER STRUCTURE
Radiator upper cross member
2
1
3
54
DISMOUNTIN
G
Dismount the elements, which are in c on-
tact with the radiator upper cross member. Detach the welding poi nts of t he ra diator
upper cross member ( 1), wh i ch a re in
connection with:
- front wing lining in the area ( 3);
- headlamp support in the a rea (4);
- side wall in the a rea ( 5);
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the radia-
tor upper cross member. Weld t he radiator upper cross member (1)
following the welding outlines (3), (4) and (5).
Pro t ect the welds with a corrosion-
preventing product.
Mount the elements, which are in connection
w ith the radiator upper cross member, by
performing the dismounting operations in the
reverse order.
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42 - 4
FRONT U PPER STRUCTURE
Headlamp support
7
86DISMOUNTIN G
Dismount the elements, which are in contact
with the headlamp support. Detach the welding points of the headlamp
support (2), which are in connection with : -front wing lining in the area ( 6)
- radiator upper cross member in the area (7);
- front cross member in the area ( 8).
Straighten the areas resulted by dismounting.
Grind the areas resulted by dismounting.
REMOU NT I NG
Position and center the new element.
Check the correct positioning of the headlamp support.
W eld the headlamp support (2) following the welding outlines (6), (7) and (8).
Protect the welding with a corrosion-preventing product.
Mount the elements, which are in connection with the headlamp support, by performing the
dismounting o perations in the reverse order.
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INSIDE ACCESSORIES
Dashboa rd .......................................................... 57-1
Inside rear view mirror ..................................... 57-8
S un visors ........................................................... 57-9
Central console ................................................. 57-10
Handbrake case ................................................ 57-11
Turning handle .................................................. 57-12
SECU RITY ELEMENTS
Fr ont safety belts ............................................... 59 - 1
Re ar safety belts ............................................... 59 - 2
HEATING
General .............................................................. 61-1
Operating principle ........................................... 61-2
C limate c ontrol unit .......................................... 61-4
Ve n t ilation- climate control air
distributor (RACV) .......................................... 61-5
Heating radiator ................................................ 61-6
C ontrol panel ..................................................... 61-7
C ontrol cable s ................................................... 61-9
Motor fan control resistance............................ 61-10
Diagnose ............................................................. 61-11
AIR CONDITIONING
General ............................................................... 62-1
Draining – filling the refrigerant circuit ......... 62-3
Air conditioning unit operating diagram ........ 62-4
Operating principle ........................................... 62-5
Part icles filter .................................................... 62-7
Cold ai r blowing device (DSAF) ...................... 62-8
Evaporator ........................................................ 62-10
Control panel ..................................................... 62-11
Comp ressor ........................................................ 62-12
C ondenser .......................................................... 62-13
Pressu re controller ............................................ 62-14
F ilter reser voir ................................................... 62-15
Unit piping ......................................................... 62-16
Thermostatic expansion valve ......................... 62-19
C limate c ontrol blower ..................................... 62-20
Blow er control resistance .................................. 62-21
Rec ycling flap motor fan ................................. 62-22
Diagnose ............................................................. 62-23
CARRIAGE BODY SEALING
Ca rriage body se aling ....................................... 64 - 1 OPENINGS SEALING
Opennings sealing ............................................. 65 - 1 GLASSES SEALING
Glasses gaskets .................................................. 66 - 1
Inside wipers ..................................................... 66 - 2
Outside wipers ................................................... 66 - 3
Fr ont door glass channel ................................. 66 - 4
Rear door gla ss run channel ............................ 66 - 5
CARRIAGE BODY INSIDE TRIMS
C arriage body inside trims ............................. 71-1
Upper front pillar trim ..................................... 71-2
Mi ddle pillar trim ............................................. 71-3
Rear quarter panel tr im ................................... 71-4
R oof lining ......................................................... 71-5
Trunk carpet ...................................................... 71-6
Cowl panel noise absor bent ............................. 71-7
Cockpit carpet ................................................... 71-8
LATERAL OPENINGS TRIMS
Fr ont door panel ................................................ 72-1
R ear door panel ................................................. 72-2
REAR TABLE
Lateral table ....................................................... 74-1 FRONT SEATS SLIDES GUIDES
Fr ont seat ........................................................... 75-1
Fr ont seats slides guide s ................................... 75-2
SEATS / R EAR BENCH
R ear bench ......................................................... 76-1
BATTERY - FRONT HEADLIGHTS
Battery ... ............................................................ 80-1
Headlamp assembly .......................................... 80-4
F og projectors ................................................... 80-5
Bulbs ... ................................................................ 80-6
Headlamps adjustment .................................... 80-9
Repl acement of the headlamps mechanic
adjustment control ........................................... 80-1157
Mechanisms and accesoires5
59
61
62
Climatisation6
64
65
66
71
72
74
75
76
80
Echuipment electr ique8
Garnishing and tack room7
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57 - 4
INSIDE ACCESSORIES
19 20
17 16
15
18
Remove the access cover of the fuse box.
Di
smount the three a ttachment screws (14)
of the fuse box.
21
14
Remove the access cover to the fuse box.
Swing over the little caps from the dashboard
lower part and dismount the attachment screws
(15) on the driving post cross member.
Dismou nt :
- attachment scre ws (16) of the climate
maintenance p anel on the lower part dashboard;
- attachment screw (17) of the lower part
dashboard on the vent-AC distributor (RACV);
- attachment screws (18) of the lower part
dashboard on the driving post cross member;
-upper attachment screws (19) of the
lower part dashboard on the driving post cross
member.
Extract :- headlamps adjustment knob;
-cigarette lighter.
Detach from clips the connectors: - hazard;
-r
ear window defrosting.
Disconnect the connectors:
- cigarette lighter;
-r ear window defrosting.
Di smount the attachment nut (21) of the
headlamps adjustment control.
Disconnect the connectors:
- hazard;
- climate maintenance control.
D etach from clips the l eft a nd right side
aeration ducts.
Take out t he dashboard from cockpit.
Dashboard
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BATTERY - FRONT HEADLIGHTS
80
80 - 4
NOTE :
After headlamps dismounting, their adjustment must be performed.
DISMOUNTING
Disconnect the battery (-) plug.
Pull backwards the gasket of the headlamp adjustment cor rection control (1).
Dismount the headlamp adjustment correction control from the headlamp adjustment
device (see replacement of the headlamps mechanic adjustment control).
Disconnect the connector ( 2) of the headlamp bulb.
Disconnect the connector ( 3) of the turning light bulb.
Rotate and remove the holder ( 5) of the parking lamp bulb.
Dismount the front grill.
Dismount the 4 attachment screws TORX 20 (6) of the headlamp-turning lamp assembly .
Carefully remove the headlamp assembly from its place.
REMOU NT I NG
In point (6) placed at headlamp lower part, the closest to the turning bulb, introduce a TORX
20 screw.
Carefully introduce the headlamp assembly in its place, taking care that screw is not falling
down.
Mount this screw, by means of a TORX 20 screwdriver.
M ount the other three screws (6 ).
Mount the front grill.
Position the holder ( 5) in its place a nd rotate it, ensuring its good attachment.
Position the holder ( 4) in its place a nd rotate it, ensuring its good attachment.
Reconnect the turning bulb connector (3)
Reconnect the headlamp bulb connector ( 2).
Mount the headlamp adjustment control at the headlamp adjusting connector (see replacemen t
of the headlamps mechanic adjustment control).
Reconnect the battery (-) plug.
Check the operation of the bulbs of the headlamp-turning lamp assembly .
Headlamp assembly
6
6
6 6
5
4
3
1
2
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BATTERY - FRONT HEADLIGHTS
80
80 - 6
Bulbs
FOG PROJEC TOR B ULB RE PLACEMENT
DISMOUNTING
Suspend the vehicle on an elevator.
Disconnect the fog projector connector
Rotate the bulb holder ( F) an d extract it from its place.
REMOU NT I NG
Perform the dismounting operations in the reverse order, correctly positioning the bulb holder in
its place. Perform fog projector adjustment
NOTE :
Because the fog projector is equipped with a halogen bulb, do not touch the bulb glass
ba lloon directly by hand.
HEADLAMP BULB REPLACEMENT
DISMOUNTIN G
Disconnect the connector (2 ).
Remove the rubber protector ( 7). Mark its mounting position.
Release the atta chment clamp (8) and remove th e h e adlamp bulb
REMOU NT I NG
Perform the dismounting operations in the reverse order. Position correctly the rubber protector
( 7) observing the mounting position before dismounting. Perform headlamp adjustment.
NOTE :
Because the headlamp is equipped with a halogen bulb, do not touch the bulb glass balloon
d irectly by hand.
72 3 4
8
5
10
10
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