2429746 - 1004E20 engine - dismantle and re-build following operation 1004e10 - wash and check dismantled parts - re-fit cylinder head and oil sump - does not include repairs to cylinder head and auxiliary unit
Dismantling
(
Reassembling
)
1. Position the flywheel retainer.
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.000 |
2. Undo the fixing bolts (2a) and remove the clutch plate (2b).
1. Fit the crankshaft gear locking tool as illustrated in the figure.
| Name | Country |
|---|
| 1 | Counter-torque | 1.870.763.000 |
 | Work with flywheel retainer 1860846000
fitted. |
2. Undo the bolt securing the crankshaft gear and remove.
1. Unscrew the bolts securing the flywheel.2. Remove the engine flywheel together with plate (2a) and the
flywheel lock positioned previously.
1. Undo the fixing bolts (1a) and remove the crankshaft rear cover
(1b).
1. Undo the bolts (1a) and remove the water pump rigid inlet pipe
(1b), complete with O-Rings.2. Undo the bolts (2a) and nut (2b) and remove the heat shield (2c).
1. Remove the engine oil filter using a suitable tool.2. Fit the engine oil pressure sender unit.3. Undo the bolts (3a) and remove the crankcase front cover with
the built-in oil pump (3b) complete with crankshaft front oil seal
(3a) and inlet.4. Remove the gasket from the crankcase front cover.
1. Using the service bolts (1a), fit the tool for rotating the crankshaft.
| Name | Country |
|---|
| 1a | Flange | 1.860.815.000 |
Rotate the crankshaft using the tool fitted
previously until cylinders no. 1 and no. 4 are at T.D.C 1. Undo the bolts (1a) and remove the connecting rod caps (1b) for
cylinders 1 and 4.2. Remove the lower connecting rod half bearings for cylinders no.
1 and no. 4. 3. Remove the connecting rod-piston assemblies for cylinders 1 and
4. 4. Remove the upper connecting rod half bearings for cylinders 1
and 4. Proceed in the same way to remove the pistons
and connecting rods for cylinders 2 and 3. Remove the tool for rotating the crankshaft.
| Name | Country |
|---|
| - | Flange | 1.860.815.000 |
1. Check using a dial gauge with a suitable magnetic base that the
crankshaft end float is within the recommended values.
| Measurement | | Value |
|---|
| 1 | End float (mm) | | 0.055 ÷ 0.265 |
If the end float of the crankshaft is not
within the recommended values, when refitting, reface the seats
in the crankcase and use suitable 0.127 mm oversize thrust washers
(secured to the central main bearing halves) 1. Undo bolts (1a) and (1b) and remove the lower crankcase, which
also acts as the main bearing caps.2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings. | The central main bearing halves
incorporate crankshaft thrust half-rings. |
Secure and support the engine for hoisting
using a hydraulic hoist fitted with suitable chains and remove the
crankcase from the brackets. Place on a suitable work bench. - 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at bench1. Remove the crankcase coolant chamber caps using a suitable steel
drift.2. Remove the lubrication port plug from the crankcase using a
steel drift.
Check the condition of the piston cooling
oil sprays.1. If they are blocked, remove the oil sprays (1a) using a steel
drift (1b); fit the drift guide hole on the nozzle surface to prevent
the drift slipping during removal and damaing the cylinder liner.
| Name | Country |
|---|
| 1b | Drift | 1.860.395.000 |
| Whenever the oil sprays are removed,
they cannot be reused and must be replaced. |
Reassembling
(
Dismantling
)
Wash and check the visible condition of
all components removed.Fit the water/oil sealing plugs in the
crankcase using suitable tools and sealant.
| Type | Component | Name | Qty. |
|---|
| - | Sealant | CRANK CASE PLUGS | Loktite 270 | - |
1. Use tool (1a) and a plastic mallet to fit new oil sprays (1b).
| Name | Country |
|---|
| 1a | Fitting tool | 1.860.313.000 |
1. Using a calibrated metal rule (1a) and a feeler gauge (1b), check
the planarity of the cylinder head - cylinder block/crankcase support
surface.2. If the measurement is not as specified, grind the cylinder head
support surface.
| Measurement | | Value |
|---|
| 2 | Flatness of cylinder head supporting surface
(mm) | | < 0.1 |
1. Measure the cylinder liner diameter and check that it is within
the specified values.
| Measurement | | Value |
|---|
| - | Cylinder bore diameter (mm) | Category B | 70.810 - 70.820 |
| Category C | 70.820 - 70.830 |
| Classe A | 70.800 - 70.810 |
Check that the ovality of the cylinder
liners is within the recommended values.
| Measurement | | Value |
|---|
| - | Cylinder bore ovalization (mm) | | ± 0.05 |
Check that the conicity of the cylinder
liners/bores is within the recommended values.
| Measurement | | Value |
|---|
| - | Cylinder bore taper (mm) | | ± 0.005 |
If the diameter, taper or ovality of the
cylinder liners is not within the recommended values, ream the cylinder liners
in accordance with the recommended oversizes. | In the case of reaming, all liners/bores
must be the same oversize. |
| Measurement | | Value |
|---|
| - | Cylinder liner/bore inner diameter oversize
(mm) | | 0.4 |
Using a compressed air gun, clean the oil
ports in the crankshaft. Check the static balance of the crankshaft
resting the main journals on suitable parallel bars. Check that the diameter of the main journals
is within the recommended values.
| Measurement | | Value |
|---|
| - | Main bearing journal diameter (mm) | Category B | 47.988 - 47.994 |
| Category C | 47.994 - 48.000 |
| Class A | 47.982 - 47.988 |
If the diameter of the main journals is
not within the recommended values, regrind them in accordance with the
recommended undersize. | The shaft has undergone a nitriding
treatment; therefore if it needs regrinding it should undergo the
nitriding treatment again and the dimensions should then be checked. |
| Measurement | | Value |
|---|
| - | Main bearing journal undersize (mm) | | 0.254 - 0.508 |
Check that the diameter of the crankpins
is within the recommended values.
| Measurement | | Value |
|---|
| - | Crankpin diameter (mm) | | 41.990 ÷ 42.008 |
If the diameter of the crankpins is not
within the recommended values, regrind them in accordance with the
recommended undersize. | The shaft has undergone a nitriding
treatment; therefore if it needs regrinding it should undergo the
nitriding treatment again and the dimensions should then be checked. |
| Measurement | | Value |
|---|
| - | Crankpin undersize (mm) | | 0.254 / 0.508 |
Check the crankshaft bearings, taking into
account that no adjustment operations should be carried out on half-bearings.
If there are signs of grooves or seizing, they must be replaced.Fit the upper main journal half-bearings
in the upper cylinder block/crankcase. Ensure lubrication holes
are aligned and maintain scrupulous cleanliness. The central main
bearing halves contain built-in thrust half-rings because they perform
a load-bearing/thrust function. If the crankshaft has been reground, fit
the new and oversize half-bearings to restore the original tolerance conditions.1. Fit the crankshaft in the housing in the upper cylinder block/crankcase.2. Fit the calibrated wire (Plastigage) to measure the main journal
clearance.
1. Position the main bearing halves to the lower crankcase.2. Fit the lower crankcase to the upper crankcase. check that codes
(2a) stamped on both parts of the crankcase correspond because the
crankcase components are not interchangeable.
1. Tighten bolts (1a) and bolts (1b) securing the lower crankcase.
Use tool (1c) to for angular tightening.
| Name | Country |
|---|
| 1c | Protractor | 1.860.942.000 |
1. Remove the lower crankcase and check main journal clearance.
Measure calibrated wire width using an appropriate gauge. | Check one pin at a time without
turning the crankshaft. |
| Measurement | | Value |
|---|
| - | Clearance between crankshaft bearings - big
end bearings (mm) | | 0.025 - 0.049 |
After checking all the main journals, apply
sealant to the mating surface between lower and upper crankcase.
Then fit the lower crankcase by tightening the bolts to torque in
the order shown previously. | Apply a 2 mm thick, unbroken sealant
strip to the lower crankcase surface. |
- 1028H54 piston/cylinder liner - r rThoroughly clean any carbon residues from
the piston.Check that the outer diameter of the pistons
is within the recommended values. if this is not the case, replace the
piston complete with seals and gudgeon pin.
| Measurement | | Value |
|---|
| - | Outer diameter (mm) | Category B | 70.770 - 70.780 |
| Category C | 70.780 - 70.790 |
| Class A | 70.760 - 70.770 |
| from lower edge of piston skirt
(mm) | 6 |
Position the piston in the cylinder bore/liner
and, using a feeler gauge, measure the recommended clearance.
| Measurement | | Value |
|---|
| - | Clearance between piston - cylinder liner/bore
(mm) | | 0.030 ÷ 0.050 |
Check that the inner diameter of the gudgeon
pin housing is within the recommended value; if this is not the
case, replace the gudgeon pin with an oversize one.
| Measurement | | Value |
|---|
| - | Gudgeon pin housing diameter (mm) | | 17.982 ÷ 17.986 |
| Measurement | | Value |
|---|
| - | Gudgeon pin oversizel (mm) | | 0.2 |
Check that the outer diameter of the gudgeon
pins is within the recommended values. if this is not the case, replace
the worn parts.
| Measurement | | Value |
|---|
| - | Gudgeon pin external diameter (mm) | | 17.970 ÷ 17.974 |
Using a micrometer, measure the thickness
of the piston seals.
| Measurement | | Value |
|---|
| - | Thickness (mm) | 1° seal | 1.170 ÷ 1.190 |
| 2° seal | 1.175 ÷ 1.190 |
| 3° seal | 2.475 - 2.490 |
| Measurement | | Value |
|---|
| - | Seal oversize (mm) | | 0.4 |
1. Fit the piston seals (1a) in the cylinder liner/bore and, using
a feeler gauge (1b), check that the opening between the ends is
within the recommended values. If this is not the case, replace
the piston seals.
| Measurement | | Value |
|---|
| - | Opening (mm) | 1° seal | 0.200 ÷ 0.400 |
| 2° seal | 0.250 ÷ 0.450 |
| 3° seal | 0.200 ÷ 0.450 |
1. Using a feeler gauge (1a), check the fitting clearance between
the piston rings (1b) and the piston ring grooves (1c).
| Measurement | | Value |
|---|
| - | End float (mm) | 1st ring | 0 - 06 |
| 2nd ring | 0 - 0.055 |
| 3rd ring | 0 - 0.0055 |
Check that the diameter of the connecting
rod big end and the small end correspond to the recommended values.
| Measurement | | Value |
|---|
| - | Big end diameter (mm) | | 45.128 ÷ 45.138 |
| Measurement | | Value |
|---|
| - | Small end diameter (mm) | | 17.939 ÷ 17.956 |
- 1028H60 piston, pin set - replace - 1028H54 piston/cylinder liner - r r - 1084B18 engine oil pump, removed - check at benchPositin the tool for rotating the crankshaft.
| Name | Country |
|---|
| - | Flange | 1.860.815.000 |
Rotate the crankshaft using the tool fitted
previously.The connecting rod-piston assemblies are
fitted with the references in the following positions.1. Piston grade and arrow indicating the timing side.2. Area where number of cylinder bore/liner to which the connecting
rod belongs is stamped.3. Connecting rod pin offset. | The letters for the cylinder bore/liner
class are located on the cylinder block/crankcase. |
1. Fit the connecting rod-piston assemblies (1a), complete with
half-bearings, using the tool (1b) for compressing the piston rings
and later introducing the piston in the liner/bore.
| Name | Country |
|---|
| 1b | Fitting tool | 1.860.700.000 |
Rotate the engine on the overhauling stand.1. Apply calibrated wire (plastigage) to measure crankpin backlash.
1. Fit the connecting rod caps (1a), complete with half-bearings
(1b), and fix them tightening the bolts (1c) to the recommended
torque using tool (1d) for the angular tightening. | The connecting rod caps are fitted
so that the number stamped on them is facing the same side as the
one stamped on the big end (inlet side). |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Bolt | CONNECTING ROD CAP FASTENERS | M8 | 2 + 40° |
| Name | Country |
|---|
| 1d | Protractor | 1.860.942.000 |
1. Remove the main bearing caps and measure journal backlash by
recording calibrated wire width using a graduated measuring device. | Check the one connecting rod pin
at a time without rotating the crankshaft. |
| Measurement | | Value |
|---|
| - | Big end bearings (mm) | | 0.024 - 0.060 |
If the value measured does not correspond
to the recommended figures, replace the connecting rod bearings.Fit the connecting rod caps complete with
half bearings and tighten the bolts to the specified torque. Remove the tool for rotating the crankshaft.
| Name | Country |
|---|
| - | Flange | 1.860.815.000 |
Rotate the engine on the overhauling stand.1. Position a new oil pump gasket.2. Fit the crankcase front cover (2a) with built-in oil pump, complete
with inlet, and tighten the bolts (2b) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | ENGINE OIL PUMP | M6 x 20 | 1 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | ENGINE OIL PUMP | M6 x 32 | 1 |
3. Fit the oil filter.4. Fit the engine oil pressure sender unit and tighten to the specified
torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 4 | Bolt | OIL PRESSURE W/L | M6 | 1 |
1. Fit a new crankshaft front cover oil seal (1a) using the tool
(1b).
| Name | Country |
|---|
| 1b | Fitting tool | 1.860.990.000 |
1. Fit crankcase rear cover (1b) and secure by tightening bolts
(1a) to the specified torque. | The rear crankcase cover comes
with an oil seal. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | FLYWHEEL SIDE COVER | M6 x 20 | 1 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | FLYWHEEL SIDE COVER | M6 x 32 | 1 |
1. Fit the flywheel lock.
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.000 |
2. Fit the flywheel (2a), complete with retaining shim (2b) and
fix it tightening the bolts (2c) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2c | Bolt | FLYWHEEL | M8 | 4.4 |
1. Fit the gear on the crankshaft.2. Fit the crankshaft locking tool.
| Name | Country |
|---|
| 2 | Counter-torque | 1.870.763.000 |
3. Secure the crankshaft gear by tightening the bolt to the specified
torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | TOOTHED DRIVE PULLEY | M12 x 1.25 | 2 + 90° |
1. Fit the flywheel lock.
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.000 |
2. Fit the flywheel (2a), complete with retaining shim (2b) and
fix it tightening the bolts (2c) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2c | Bolt | FLYWHEEL | M8 | 4.4 |
1. Line up the driven plate for fitting the clutch assembly (1a),
using the centring pin (1b).
| Name | Country |
|---|
| 1b | Clutch centering | 1.870.418.000 |
2. Tighten the bolts fixing the clutch to the engine flywheel.Remove the engine flywheel lock applied
previously.
Clean the crankcase and oil sump contact
surfaces to remove traces of silicone sealant.1. Apply an unbroken bead of the recommended sealant to the entire
perimeter of the crankcase sump as shown in the figure. | Ensure a perfect join between
start and end section. |
| Type | Component | Name | Qty. |
|---|
| 1 | Silicon sealant | PISTON SET | LOCTITE 5900 | - |
2. Refit crankcase sump (2a) and secure by tightening bolts (2b)
and nuts (2c) to the specified torque. | When fitting the crankcase sump,
avoid major sideways movements which may remove the sealant. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | OIL SUMP | M6 | 1 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2c | Nut | OIL SUMP | M6 | 0.5 |
1. The timing is adjusted with the four pistons in line, i.e. half
way along the effective travel. It is therefore essential to position
the crankshaft so it is in line with the camshafts. Position approximately
by turning crankshaft gear (1a) until locating dowel (1b) is positioned
on the opposite side to the seat of rpm and TDC sensor (1c) and
with the first cylinder piston descending, i.e. in intake stage.
Remove the protective cover for the camshaft
rear gears.1. Undo the camshaft housing side plugs.
1. Position tools (1a) into the seats of the caps unscrewed previously,
then turn the camshafts until splines (1b) on each camshaft are
aligned with tool pin (1c). The camshafts will be timed in this
way.
| Name | Country |
|---|
| 1a | Locating pin | 1.860.985.000 |
Refit the cover protecting the rear camshaft
gears.Fit the centering pins on the crankcase.1. Position the cylinder head gasket with the wording 'ALTO' [TOP]
facing you. Take care not to contaminate or lubricate the gasket
and crankcase surface. The arrowed holes decrease in diameter from
the 1st to the 4th cylinder so that coolant is distributed evenly
over the entire crankcase.A = intake sideB = exhaust side | ASTADUR type cylinder head gaskets
are fitted. These gaskets are made from a special material designed
to undergo polymerization during the use of the engine. This means
that they harden considerably during use. |
In order for the polymerization process
to take place it is necessary:
- to keep the gasket in its sealed plastic bag;
- not to take out of its container until ready to fit
- not to lubricate the gasket or contaminate with oil, and to
ensure the crankcase and cylinder head surfaces are clean.
Position the cylinder head on the crankcase
and ensure the locating pins are aligned.1. Tighten the cylinder head bolts (1a) to the recommended torque
using the angular tightening tool (1b). | Follow the order shown in the
diagram for each tightening sequence. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | CYLINDER HEAD | M9 x 1.25 | 3 + 90° + 90° |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
1. Fit the cylinder head extension gasket to the cylinder head
mating surface.2. Position tappet retaining tools (2a) beneath the cylinder head
extension, then position the cylinder head extension on the cylinder
head and withdraw the tools.3. Use tool (3a) to tighten the cylinder head extension bolts (3b)
to the specified torque.4. Refit caps and tighten to the specified torque.
| Name | Country |
|---|
| 2 | Tappet retaining tool | 1.860.988.000 |
| Name | Country |
|---|
| 3a | Key | 1.860.834.000 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3b | Bolt | CYLINDER HEAD EXTENSION | M8 x 1 | 1.5 |
Fit the camshaft drive pulley and tighten
the retaining bolt.1. Position the tools (1a) in the housings for the spark plug for
cylinders 1 and 2, tightening the components (1b) to a torque of
0.5 daNm.2. Turn the crankshaft in its normal direction of rotation until
surface (2a) on the mobile part of the tool is aligned with surface
(2b) on the fixed part in the spark plug socket. When both tools
positioned in the spark plugs seats are in this condition, the engine
pistons are aligned with one another, i.e. half away along their effective
travel. | The pistons were already approximately
aligned previously. |
| Rotate the crankshaft gradually
to prevent the pins for the tools being expelled by the piston compression. |
| The camshafts were timed previously
through the fitting of the tools (3b). |
| Name | Country |
|---|
| 1a | Bearings | 1.860.992.000 |
| Name | Country |
|---|
| 3b | Locating pin | 1.860.985.000 |
1. Proceed with fitting the timing drive belt, fitting it initially
on the crankshaft gear (1a), the water pump pulley (1b), the camshaft
drive pulley (1c) and, lastly, on the belt tensioner pulley (1d). | Make sure that this operation
is carried out with the camshaft pulley (1c) slack. |
1. Using suitable pliers, rotate the automatic tensioner placing
it in the maximum tension position, i.e. with the moving reference
(1a) positioned as illustrated in the diagram then lock the nut
(1d) fixing the tensioner to the support.
1. Using the tool (1a) tighten the bolt (1b) fixing the camshaft
pulley to the recommended torque.
| Name | Country |
|---|
| 1a | Support for counter-torque | 1.860.831.000 |
| Name | Country |
|---|
| 1a | Spanner for camshaft pulley rotation | 1.860.831.002 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | TIMING GEAR DRIVEN PULLEYS | M12 x 1.25 | 12 |
Remove the tools positioned previously
for timing and locking the camshafts and rotate the crankshaft through
two revolutions in its direction of rotation to let the timing drive
belt bed in.
1. Loosen the nut fixing the tensioner and ensure that the moving
reference (1a) coincides with the fixed reference (1b) retaining
the tensioner using the special pliers so as not to release the
tension suddenly.2. Once the two references are aligned, tighten the nut (2a) fixing
the tensioner to the recommended torque.Rotate the crankshaft through a further
two revolutions in its direction of rotation, then repositino the tools
used for timing the engine and check that the timing is correct.Refit the side plugs in the camshaft housing.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2a | Nut | MOBILE TIMING TENSIONER | M8 | 2.5 |
Refit the lower shield and the upper shield
for the timing drive belt. Fit the auxiliary shaft drive pulley on
the crankshaft and tighten the fixing bolts to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CRANKSHAFT PULLEY | M8 | 2.2 |
Fit the rpm and TDC sensor and fix it
with its bolts.Refit the engine oil dipstick.Refit the inlet manifold complete with
injectors and throttle body.Position the electrical wiring and connect
the electrical connections.
| Name | Connector |
|---|
| - | Integrated throttle body actuator | N75 |
| Name | Connector |
|---|
| - | Fuel vapour recovery solenoid | L10 |
| Name | Connector |
|---|
| - | Engine temperature sender unit | K36 |
| Name | Connector |
|---|
| - | Injector junction | D81 |
| Name | Connector |
|---|
| - | Earth on engine | C40 |
| Name | Connector |
|---|
| - | Detonation sensor | K50 |
| Name | Connector |
|---|
| - | Engine oil pressure sensor (switch) | K30 |
| Name | Connector |
|---|
| - | Integrated air temperature sensor | K43 |
| Name | Connector |
|---|
| - | Rpm sensor | K46 |
Position the part of the wiring concerned
in the duct. - 1004D40 engine - position on stand and remove
