3239063 - 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. Undo the nuts (1a) and remove the timing side rigid engine support
(1b). 2. Undo the bolts (2a) and remove the counter-rotating balancer
shaft drive belt drive pulley (2b).
1. Fit the flywheel lock.
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.001 |
1. Undo the bolt (left-hand thread) (1a) and remove the drive pulley
(1b).
1. Undo the bolts (1a) and remove the engine flywheel (1b). | The engine flywheel retaining
bolts are treated with a compound to prevent them coming undone;
they should therefore be replaced whenever they are removed. |
2. Remove the flywheel lock tool.
| Name | Country |
|---|
| 2 | Counter-torque | 1.860.846.001 |
1. Undo the bolts (1a) and remove the engine flywheel protection
(1b).
1. Undo the bolt securing the engine oil intake to the main bearing
cap.
1. Undo bolts (1a) and remove the crankshaft front cover (1b) with
built-in oil pump complete with inlet (1c), engine oil heat exchanger
(1d) and engine oil filter (1e). 2. Remove the gasket.
1. Position the front crankcase cover assembly in a vice with protective
jaws. 2. Undo the bolts (2a) and remove the engine oil inlet (2b).3. Remove the gasket.4. Remove the engine oil filter using a suitable tool.5. Undo pin (5a) and remove the heat exchanger (5b), complete with
pipes (5c). 6. Remove the gasket.7. Prise out the oil seal from the front crankcase cover. | Take care not to damage the oil
seal seat during removal. |
Proceed with removal.
- 1084B18 engine oil pump, removed
- check at bench1. Unscrew the bolts (1a) and remove mount (1b) with mobile timing
belt tensioner (1c) and fixed timing belt tensioner (1d).
1. Undo the bolt (1a) and remove the detonation sensor (1b).2. Undo the bolt (2a) and remove the rpm sensor (2b).3. Undo and remove the engine oil pressure warning light switch.
1. Fit the tool for rotating the crankshaft.
| Name | Country |
|---|
| 1 | Flange | 1.820.618.000 |
Rotate the crankshaft using the tool fitted
previously until the pistons for cylinders no. 1 and no. 4 are at B.D.C.1. Undo the bolts (1a) and remove the connecting rod caps (1b) and
bearing shells (1c) of cylinders no. 1 and no. 4. 2. Remove the piston-connecting rod assemblies (2a), complete with
half-bearings (2b) for cylinders 1 and 4.Proceed in the same way when removing the
connecting rod-piston assemblies for the remaining cylinders.3. Remove the tool for rotating the crankshaft.
| Name | Country |
|---|
| 3 | Flange | 1.820.618.000 |
Proceed with removal
- 1028H60 piston, pin set - replace
.
1. Undo the bolts (1a) and remove the crankcase rear cover with
the oil seal integrated (1b).
Check that the crankshaft end float is
within the recommended values using a magnetic base fitted with
a dial gauge.
| Measurement | | Value |
|---|
| - | Crankshaft end float (mm) | | 0.059 ÷ 0.221 |
1. Undo the bolts (1a) and remove the main bearing caps (1b) complete
with bearing shells (1c). 2. Remove the crankshaft pulley.3. Remove the main bearing shells.4. Remove the thrust washers.
1. Undo the bolts (1a) and remove the engine oil jets (1b) from
the engine block.
Rotate the engine through 180° on the
overhauling stand.1. Undo the bolts (1a) on the counter-balance shaft pulleys using
the tool (1b) for counter-torque.
| Name | Country |
|---|
| 1b | Counter-torque | 1.820.286.000 |
1. Remove the counter-balance shaft pulleys.2. Undo the bolts (2a) and remove the inlet side counter-rotating
balancer shaft front cover (2b) complete with oil seal (2c) and
O-ring. 3. Undo the bolts (3a) and remove the exhaust side counter-rotating
balancer shaft front cover (3b) complete with counter-rotating shaft
toothed drive belt tensioner (3c), oil seal (3d) and O-ring.
1. Completely undo the nut slackened previously (1a) and remove
the counter-rotating balancer shaft toothed drive belt tensioner
(1b) from the cover.2. Prise up the oil seals from the counter-rotating shaft front
covers and remove.3. Remove the O-rings from the counter-rotating balancer shaft covers.
1. Remove the spacers (1a) and O-rings (1b) from the counter-balance
shafts.2. Remove the counter-balance shafts (2a), complete with rear bearings
(2b), using a suitable drift (2c).3. Recover the counter-balance shaft rear plugs.
1. Remove the counter-balance shafts front bearings (1a) from the
cylinder block using the tools (1b) and (1c).
| Name | Country |
|---|
| 1b | Extractor | 1.840.207.815 |
| Name | Country |
|---|
| 1c | Counter weight | 1.847.017.002 |
Position the counter-rotating balancer
shaft in a vice fitted with protective jaws.1. Remove the circlip retaining the rear counter-balance shaft bearing.2. Remove the counter-rotating balancer shaft rear bearing (2a)
using a suitable drift (2b).Repeat the above operations for the remaining counter-rotating
shaft.
1. Remove the antireflux valve from the vertical channel on the
crankcase carrying oil to the cylinder heads.
Drill and remove the water/oil sealing
plugs from the crankcase to allow washing of the channels.
Reassembling
(
Dismantling
)
Wash all the dismantled components carefully.Clean the contact surfaces of crankcase
sump and cylinder block of sealant residues. Place new water/oil sealing plugs in their
housings in the crankcase using suitable commercial fitting tools. Refit the antireflux valve in its seat
on the vertical channel on the crankcase carrying oil to the cylinder heads. Lubricate all the components for the mechanical
couplings using engine oil. Check that there are no superficial cracks
or grooves in the cylinder head support surface.Check that the flatness of the cylinder
head surface is within the recommended values; if this is not the
case, regrind the cylinder head support surface.
| Measurement | | Value |
|---|
| - | Flatness of cylinder head supporting surface
(mm) | | < 0.1 |
Check that the inner diameter of the cylinder
liners/bores is within the recommended values.
| Measurement | | Value |
|---|
| - | Cylinder bore diameter (mm) | Category B | 83.010 ÷ 83.020 |
| Category A | 83.000 ÷ 83.010 |
| Category C | 83.020 ÷ 83.030 |
Check that the conicity of the cylinder
liners/bores is within the recommended values.
| Measurement | | Value |
|---|
| - | Maximum permitted cylinder liner taper (mm) | | < 0.010 |
Check that the ovality of the cylinder
liners is within the recommended values.
| Measurement | | Value |
|---|
| - | Maximum permitted cylinder liner ovality (mm) | | < 0.005 |
If the cylinder liners/bores dimensions
are not within the recommended values, ream the cylinder liners/bores
in accordance with the recommended oversizes. | If reboring is required, all the
cylinder liners must be rebored to the same oversize. |
| Measurement | | Value |
|---|
| - | Cylinder liner diameter oversize (mm) | | 0.1 |
Check that the diameter of the main journals
is within the recommended values.
| Measurement | | Value |
|---|
| - | Main bearing journal diameter (mm) | Category B | 52.988 ÷ 52.994 |
| Category A | 52.982 ÷ 52.988 |
| Category C | 52.994 ÷ 53.000 |
If the diameter of the main journals is
not within the recommended values, regrind them in accordance with the
recommended undersize. | If the grinding requires undersizes
greater than 0.127, the crankshaft must be replaced. |
| Measurement | | Value |
|---|
| - | Main journal diameter undersize (mm) | | 0.127 |
Check that the diameter of the crankpins
is within the recommended values.
| Measurement | | Value |
|---|
| - | Crankpin diameter (mm) | Category B | 50.793 ÷ 50.799 |
| Category A | 50.787 ÷ 50.793 |
| Category C | 50.799 ÷ 50.805 |
If the diameter of the crankpins is not
within the recommended values, regrind them in accordance with the
recommended undersize. | If the ginding requires undersizes
greater than 0.127, the crankshaft must be replaced. |
| Measurement | | Value |
|---|
| - | Crankpin diameter undersize (mm) | | 0.127 |
Check that the inner diameter of the small
end bushes is within the recommended limits; if this is not the case,
replace the worn small end bush
- 1028H58 connecting rod small
end bush - replace
.
| Measurement | | Value |
|---|
| - | Small end bushes inner diameter (reaming) (mm) | | 20.006 ÷ 20.012 |
Check the matching between the piston pin
and the housing in the piston: it should be possible to press in the
piston pin easily by hand and it should not slip out. Check that the outer diameter of the gudgeon
pins is within the specified values, otherwise replace the worn
gudgeon pins.
| Measurement | | Value |
|---|
| - | Gudgeon pin outer diameter (mm) | | 19.996 ÷ 20.000 |
Fit the seals in the cylinder liner/bore
and check that the opening between the ends is within the recommended
values; if this is not the case, replace the circlips.
| Measurement | | Value |
|---|
| - | Piston ring gap (mm) | 1° ring | 0.25 ÷ 0.50 |
| 2° seal | 0.25 ÷ 0.50 |
| from September 2003 sealing rings
with modified profiles are used; the gap for the 1st ring becomes
0.20 0.35 mm |
| from September 2003 sealing rings
with modified profiles are used; the gap for the 1st ring becomes
0.30 0.50 mm |
| Measurement | | Value |
|---|
| - | Piston oil scraper ring gap (mm) | | 0.25 ÷ 0.45 |
The size of the seals is given below.
| Measurement | | Value |
|---|
| - | Thickness of piston rings (mm) | 1° ring | 1.19 |
| 2° seal | 1.5 |
| from September 2003 sealing rings
with modified profiles are used; the thickness of the 2nd ring becomes
1.19 mm |
| Measurement | | Value |
|---|
| - | Thickness of oil scraper rings (mm) | | 2.0 |
The oil scaper rings are also available
in the following oversizes.
| Measurement | | Value |
|---|
| - | Piston ring thickness oversize (mm) | | 0.1 |
Check that the outer diameter of the pistons
is within the recommended values; if this is not the case, replace
the piston complete with rings and gudgeon pin. | The outer diameter of the pistons
should be measured perpendicular to the piston pin centre line
and at 10.0 mm from the lower edge of the skirt. |
| Measurement | | Value |
|---|
| - | Piston outer diameter (mm) | Category B | 82.959 ÷ 82.971 |
| Category C | 82.969 ÷ 82.978 |
| Class A | 82.952 ÷ 82.962 |
The clearance between the pistons and the
cylinder liners/bores is given below.
| Measurement | | Value |
|---|
| - | Piston - cylinder liner play
(mm) | Category B | 0.039 ÷ 0.061 |
| Category A | 0.038 ÷ 0.058 |
| Category C | 0.042 ÷ 0.062 |
Check that the endfloat between compression
rings and their seats is within the specified values. If not, fit oversize
compression rings.
| Measurement | | Value |
|---|
| - | Seal end float (mm) | 1° ring | 0.030 ÷ 0.070 |
| 2° seal | 0.020 ÷ 0.055 |
| Measurement | | Value |
|---|
| - | Piston oil scraper ring end float (mm) | | 0.020 ÷ 0.055 |
Check that the diameter of the gudgeon
pin housing in the piston is within the recommended values.
| Measurement | | Value |
|---|
| - | Gudgeon pin housing diameter (mm) | | 20.006 ÷ 20.012 |
Check that there are no signs of seizing
on the flywheel ring gear teeth; if this is not the case, replace
it.Check that the main bearing halves are
not scored and that they do not show traces of binding; if this
is not the case, replace them. | The bearing halves must not be
adapted in any way. |
Place the engine oil jets in their housings
and secure them using the bolts. | Specially-selected main and crankshaft
half-bearings are fitted to this engine to ensure that the matching
clearance is optimum. |
| The crankshaft is supplied, by
the Parts Dept., without the appropriate half-bearings for 'standard'
dimension main journals and crank pins; it is therefore necessary
to select the half-bearings to be fitted by identifying the grade
for each main journal and crank pin for the new crankshaft. |
The following is needed for selecting
the main journal half-bearings:
- the code number stamped on the phonic wheel;
- the paint mark, if present, next to the main journals.
Below is an example of the identification
of main journal grades.
1 - Crank pin identification number: the
number on the left refers to the first timing side bearing; the
final 'N' is a code that does not matter for 4 cylinder engines.
2 - Main journal identification code: the
first number on the left refers to the first timing side bearing;
the final 'N' is a code that does not matter for 4 cylinder engines.
3 - Set of numbers (if present), in groups
of two digits, which indicate the dimensions (thousandth part) of
the crankpins: the first two numbers on the left refer to the first
pin on the timing side. | Only use the codes in the key,
all other codes on the flywheel should not be used. |
For the identification of the main journal
grade, refer to the numerical code for reference 2 in the key. In the case of the example, the numbers
11111N indicate that all five bearings are Grade A (red colour)
as described below. A further method for identifying the grade
of the bearings is to read reference 3 in the figure (if present). In the case of the example, the number
84 (first on the left) corresponds to the dimension 52.984 for the
first bearing on the timing side which identifies Grade A (red colour);
the same method can be used for all 87 - 85 - 85 - 8497 - 95 -
95 - 94). MAIN JOURNAL IDENTIFICATIONGrade A main journal (standard), diameter
52.982 52.988 mm, RED paint mark, code number 1 (82 88)* Grade B main journal (normal), diameter
52.988 52.994 mm, BLUE paint mark, code number 2 (88 94)* Grade C main journal (standard), diameter
52.984 53.000 mm, YELLOW paint mark, code number 3 (94 00)* Grade D main journal (0.127 undersize)
diameter 52.855 52.861 mm, BROWN paint mark, code number 6 (55
61)* Grade E main journal (0.127 mm undersize)
diameter 52.861 52.867 mm, GREEN paint mark, code 7 (61 67)* Grade F main journal (0.127mm undersize)
diameter 52.867 52.873 mm, BLACK paint mark, code number 8 (67
73)* (*) Last two numbers (thousandth part)
of the dimensions of the main journals. If a crankshaft is being used where the
maximum bearing undersize through regrinding is 0.127 mm, then the
grade should be selected by measuring the dimensions of the diameter
of the bearing with reference to the above. Having defined the grade and colour for
each new or reground crankshaft bearing, it is necessary to select the
pair and the size for the bearings which should be the same colour
as the corresponding bearing; at the Parts Dept. it is possible
obtain the part no. of the pair of half-bearings required. The above is designed to ensure the optimum
operating clearance for all bearings. Lastly, we wish to point out that, usually,
the clearance between the main journal and the half-bearing, produced
by the selection method described above, should be 0.031 0.051 mm;
this value can be measured, as a final check, using the Plastic
Gauge as described below. Place the main half-bearings, selected
as described above, back in their housings in the cylinder block/crankcase.
| Observe scrupulous cleanliness
during assembly. |
1. Place the crankshaft back in its housing.2. Fit the calibrated wire (Plastigage) to measure the main journal
clearance.
1. Place the bearing cap (1a), complete with half-bearing, back
in its housing and secure it by tightening the nuts (1b) to the
recommended torque. | The bearing caps are marked with
progressive reference notches (from zero to four starting from the
front of the engine) which define their fitting position. |
| The safety notches on the crankcase
and main bearing caps must all be on the same side. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | MAIN BEARING CAPS | M12 | 2.4 ÷ 2.6 + 100? |
2. Use the tool for angular tightening of the main bearing cap bolts.
| Name | Country |
|---|
| 2 | Protractor | 1.860.942.000 |
1. Remove the bearing caps fitted previously and, using a suitable
graduated measuring instrument (1a), measure the clearance shown
by the calibrated wire (1b). | Measure the clearance at all the
bearings, taking care to carry out this operation, one bearing at
a time, without ever moving the crankshaft. |
| Measurement | | Value |
|---|
| 1 | Crankpin/bearing shell play (mm) | | 0.031 ÷ 0.051 |
| If the readings are not within
the specified range, replace the main bearing halves with new bearing
halves of appropriate size and category. |
Refit the main bearing halves.Place the thrust washers (thickness depending
on the crankshaft endfloat measured during the dismantling) back
in their housings in the third main bearing. | The lubrication ducts in the thrust
washers are fitted facing the crankshaft shoulder. |
Place the crankshaft back in its housing.1. Place the bearing caps (1a), complete with half-bearings, back
in their housings and secure them by tightening the nuts (1b) to
the recommended torque. | The bearing caps are marked with
progressive reference notches (from zero to four starting from the
front of the engine) which define their fitting position. |
| The safety notches on the crankcase
and main bearing caps must all be on the same side. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | MAIN BEARING CAPS | M12 | 2.4 ÷ 2.6 + 100? |
2. Use the tool for angular tightening of the main bearing cap bolts.
| Name | Country |
|---|
| 2 | Protractor | 1.860.942.000 |
<
