Fiat Ulysse Mk2 Workshop Manual

NUOVA BRAVO 1.4 16v POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. 1008A42 Removing ( Refitting ) Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE 1. Undo the bolt fixing the air pipe to the rigid support. 2. Undo the bolts (2a) and remove the rigid support (2b). Refitting ( Removing ) - Place the rigid mounting in its housing and tighten the bolts to the recommended torque. - Tighten the bolt fixing the air pipe to the rigid support. Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Component Fastening dia Value (daNm) Validity Gearbox side power unit rigid support Bolt (to be replaced) M10 5.0 ÷ 6.0 Page 1 of 1 - Contents 8/1/2024 file://C:\ 2024 Kia Soul 2024 Kia Soul 2024 Kia 2024 Kia So 2024 Kia So 2024 Kia So

NUOVA BRAVO 1.9 JTD 8v SINGLE CYLINDER HEAD OR (ONE) LEFT OR RIGHT, REMOVED - GRINDING 1016E38 - Check that the planarity of the lower cylinder head plane corresponds to the recommended values. 1. If the lower surface flatness of the lower cylinder head is not within specified values, grind from the nominal head height and then fit a new gasket with the number of notches determined as described below. a - The head may be levelled to 0.1 m if starting from a gasket with no references and using a new gasket with one reference. b - The head may be levelled to 0.2 m if starting from a gasket with no references and using a new gasket with two references. c - The head may be levelled to 0.1 m if starting from a gasket with one reference and using a new gasket with two references. Measurement Value Validity Engine cylinder head lower surface flatness (mm) < 0.1 When within limit conditions (head gasket with 2 notches before levelling), the lower cylinder head surface cannot be levelled. Measurement Value Validity Cylinder head nominal height (mm) 107 +/- 0.05 1.9 JTD 16v Page 1 of 1 - Contents 8/1/2024 file://C:\ html 2024 Kia Soul 2024 Kia Soul 2024 Kia Soul

NUOVA BRAVO 1.4 16v TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT 1032B10 Removing ( Refitting ) - Position the vehicle on a lift. Op. 4450B04 RIGHT FRONT WHEEL - R.R Op. 1016A10 SOUND-PROOFING COVER - R.R Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 1092G10 SINGLE ENGINE BELT - R.R Op. 1092A10 CRANKSHAFT PULLEY - R + R Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R + R Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - R + R Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R 1. Remove the front plug (1a) and fit the camshaft timing tool (1b) to the camshaft housing. Check that the tool is correctly inserted in the housing in the exhaust side camshaft, rotating the crankshaft until the pin for the tool can be heard engaging correctly in the housing in the camshaft. Tool Description Function Validity 1870896900 Templates Engine tuning 1.9 JTD 16v 1. Undo the bolt fixing the crankcase front cover shown in the diagram. 2. Fit the tool (2a) provisionally and fasten it using the calibrated screw (2b) and the nut. Tool Description Function Validity 1860905000 Template Engine tuning 1.9 JTD Page 1 of 4 - Contents 8/1/2024 file://C:\ html 2024 Kia Soul 2024 Kia Soul 2024 Kia Soul

Tool Description Function Validity 1860905010 Calibrated screw Engine tuning 1.9 JTD - Remove the timing tools positioned previously. 1. Loosen the nut retaining the timing belt moving tensioner. 2. Release and remove the toothed timing drive belt. Refitting ( Removing ) 1. Loosen the bolt securing the exhaust side timing belt toothed driven pulley. - Fit the timing drive belt on the drive gear, checking that the belt teeth are correctly inserted in the gear grooves. - Position the template for measuring TDC and fasten it using the calibrated screw. Tool Description Function Validity 1860905000 Template Engine tuning 1.9 JTD Page 2 of 4 - Contents 8/1/2024 file://C:\ html 2024 Kia Soul 2024 Kia Soul 2024 Kia Soul

1. Fully fit the toothed timing drive belt. 2. Use a screwdriver on the tensioner (2a) tab for leverage until the reference (2b) is in the maximum tension position, then lock the nut (2c) fixing the moving tensioner in this position. - Remove the timing tools. 3. Loosen the nut fixing hte moving tensioner and align the moving reference (3a) with the opening (3b), i.e. adjust to nominal tension position and then tighten nut (3c) securing the belt tensioner to torque. 4. Tighten the bolt fixing the exhaust side camshaft toothed driven pulley to the recommended torque. Tool Description Function Validity 1860905010 Calibrated screw Engine tuning 1.9 JTD Component Fastening dia Value (daNm) Validity Timing system moving tensioner Nut M8 2.3 ÷ 2.8 1.9 JTD Component Fastening dia Value (daNm) Validity Driven timing toothed pulley Bolt M12 2.8 ÷ 3.1 + 40° 1.9 JTD - Rotate the crankshaft through two revolutions. - Recheck the timing by refitting the timing tools. - Check the moving timing belt tensioner references are aligned. - Tighten the bolt fixing the previously removed crankcase front cover. Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R Only fit the exhaust side camshaft template because the intake side template seat is not accessible. Page 3 of 4 - Contents 8/1/2024 file://C:\ html 2024 Kia Soul 2024 Kia Soul 2024 Kia Soul

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Fiat Ulysse Mk2 Workshop Manual

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