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 - Lancia - Ypsilon - eLearn

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

) 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 crankshaft sprocket lock tool (1a) as shown in the figure.

	Name	Country
1a	Counter-torque	1.870.744.000

Work with flywheel retainer 1860846000 fitted.

2. Undo the bolt securing the crankshaft sprocket 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 the bolts (1a) and remove the main bearing caps (1b).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	47.982 - 47.988
Classe A	47.994 - 48.000

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)	Category B	41.995 - 42.001
Category C	41.988 - 41.995
Classe A	42.001 - 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 main half-bearings in the crankcase housing so that the lubrification holes align. Ensure this is carried out in completely clean conditions. 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 special housing in the cylinder block/crankcase. 2. Fit the calibrated wire (Plastigage) to measure the main journal clearance.

1. Fit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque using angle wrench (1d).

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	MAIN BEARING CAPS	M10 x 1.25	2 + 90°

	Name	Country
1d	Protractor	1.860.942.000

1. Remove the main bearing caps and measure journal backlash by checking calibrated wire width using a graduated measuring device.

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, refit the main bearing caps complete with bearing shells and tighten the bolts to the specified torque. - 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
Classe A	70.760 ÷ 70.770
	from lower edge of piston skirt (mm)	8.5

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)	1° seal	0.040 ÷ 0.080
2° seal	0.020 ÷ 0.055
3° seal	0.020 ÷ 0.055

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.

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.

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 x 1	4.1

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
-	Clearance between big end bearings-Crankpins (mm)		0.024 - 0.062

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

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 1	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	-	OIL PRESSURE W/L	M14 x 1.5	3.2

1. Fit a new crankshaft front cover oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.903.000

1. Fit crankcase rear cover (1b) and secure by tightening bolts (1a) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	FLYWHEEL SIDE COVER	M6 x 1	1

1. Fit the crankshaft rear oil seal (1a) using the tools (1b) and (1c).

	Name	Country
1b	Grip	1.860.879.000

	Name	Country
1c	Fitting tool	1.860.881.000

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)
-	Bolt	FLYWHEEL	M8 x 1.25	4.4

1. Fit the crankshaft rear oil seal (1a) using the tools (1b) and (1c).

	Name	Country
1b	Grip	1.860.879.000

	Name	Country
1c	Fitting tool	1.860.881.000

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 x 1.25	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.

Rotate the engine on the overhauling stand.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	Sealant	CRANK CASE PLUGS	Loktite 270	-

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	0.7

Rotate the engine on the overhauling stand.Fit the centering pins on the crankcase.Position the cylinder head gasket with the wording 'ALTO' [TOP] facing you. Take care not to contaminate or lubricate the gasket and crankcase surface.

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.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

Fit the tappet cover, complete with seal, and fix it tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAM COVER	M6 x 1	1

Then adjust the engine as follows:Then adjust the engine as follows:1. Turn the toothed timing driven pulley so that the timing notches are aligned.2. Rotate the toothed pulley so that the timing notches are aligned. 3. Fit the timing belt.

1. Fit the tools (1a) and (1b) on the timing belt moving tensioner.

The weight for the tool (1b) should have the knurled part removed and should be positioned 65 mm away on the millimetric rod. The millimetric rod should be placed in a horizontal position acting on the tool joint.

	Name	Country
1a	Belt tensioner	1.860.745.300

	Name	Country
1a	Belt tensioner	1.860.745.100

Let the timing belt bed in by rotating the crankshaft through two revolutions in its direction of rotation.

During this stage the millimetric rod may move away from the horizontal position; if this is the case, adjust the joint on the tool and repeat the operation.

2. Tighten the nut fixing the timing belt moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8 x 1.25	2.8

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 x 1.25	2.2

Fit the rpm and TDC sensor and fix it with its bolts.Fit the engine oil dipstick.Refit the inlet manifold complete with injectors and throttle body.Fit the injection lead support bracket.Position the electrical wiring and connect the electrical connections.

	Name	Connector
-	Throttle position sensor	K56

	Name	Connector
-	Idle actuator	N74

	Name	Connector
-	Fuel vapour recovery solenoid	L10

	Name	Connector
-	Engine temperature sender unit	K36

	Name	Connector
-	Injector	N70

	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