3237663 - 1028H10 connecting rod and piston set - r r

 - 1092E10  counter-rotating shaft drive toothed belt - r + r  - 1092E10  counter-rotating shaft drive toothed belt - r + r Removing ( Refitting ) Position the vehicle on the ramp Proceed with removal  - 1016A10  sound-proofing cover - r + rEnsure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Name	Connector
-	Battery	A1B

Proceed with removal  - 1008C10  power unit upper reaction link r r Proceed with removal  - 1060G80  ds electric injection control unit - r r Proceed with removal  - 4450B04  right front wheel r r Proceed with removal  - 7055B54  under-engine guard - r r Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R. Proceed with removal  - 1092G10  single engine belt r r Proceed with removal  - 1092A10  Crankshaft services PULLEY - R.R. Proceed with removal  - 1092G20  engine component single belt fixed tensioner - one - r + r Proceed with removal  - 1032D12  timing system protective cover(s) - r + r Proceed with removal  - 5530B10  battery - r+r Proceed with removal  - 1016C10  cylinder head - r + r and replace gasket1. Undo the plug and drain the engine oil.

Collect the engine oil in a suitable container. Engine oil contains substances harmful to the environment. Discard these substances in containers designed for their disposal.

1. Undo the bolt securing the intermediate drive shaft mounting to the crankcase oil sump. 2. Undo the bolts fixing the manual gearbox and differential to the cylinder block/crankcase. 1. Undo the front and rear bolts (1a) securing the crankcase sump using tool (1b).

	Name	Country
1b	Spanner	1.860.833.001

2. Undo the side bolts (2a) securing the crankcase sump using tool (2b).

	Name	Country
2b	Spanner	1.860.834.001

3. Use the tool to cut the crankcase sump sealant.

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump. 1. Undo the bolts (1a) and remove the connecting rod caps (1b), complete with half-bearings (1c). 1. Release and remove the piston-connecting rod assemblies (1a), complete with half-bearings (1b). Refitting ( Removing ) 1. Place the piston-connecting rod assemblies (1a), complete with half-bearings (1b), back in their housings using a suitable fitting tool.

The piston - connecting rod assemblies are fitted in the cylinder block/crankcase so that the discharge on the piston skirt is in line with the oil jet fitted on the cylinder block/crankcase.

1. Refit 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	BIG END BEARING CAPS	M9	2.4 ÷ 2.6 + 60?

Use the tool for angular tightening of the connecting rod cap bolts.

	Name	Country
-	Protractor	1.860.942.000

Thoroughly clean the contact surfaces of crankcase sump and cylinder block of sealant residues. Apply silicone sealant around the edge of the crankcase sump. 1. Refit the crankcase sump.

When fitting the crankcase sump, avoid major sideways movements which may remove the sealant.

2. Tighten the side bolts (2a) for the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Side bolts	OIL SUMP	M8	(Engine crankcase side) 2.3 ÷ 2.8

	Name	Country
2b	Spanner	1.860.833.001

3. Tighten the front and rear bolts (3a) for the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Front and rear bolt	OIL SUMP	M6	(Crankcase front/rear covers side 08 10

	Name	Country
3b	Spanner	1.860.834.001

1. Tighten the bolts securing the manual gearbox with differential to the crankcase to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	OIL SUMP	M10	(Manual gearbox side) 5.0 ÷ 6.1

2. Tighten the bolt securing the intermediate drive shaft mounting to the oil sump. Place a new engine oil drain plug, complete with new gasket, back in its housing and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Proceed with refitting  - 1016C10  cylinder head - r + r and replace gasket Proceed with refitting  - 5530B10  battery - r+r Proceed with refitting  - 1032D12  timing system protective cover(s) - r + r Proceed with refitting  - 1092G20  engine component single belt fixed tensioner - one - r + r Proceed with refitting  - 1092A10  Crankshaft services PULLEY - R.R. Proceed with refitting  - 1092G10  single engine belt r r Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R. Proceed with refitting  - 7055B54  under-engine guard - r r Proceed with refitting  - 4450B04  right front wheel r r Proceed with refitting  - 1060G80  ds electric injection control unit - r r Proceed with refitting  - 1008C10  power unit upper reaction link r r Refill the engine oil lubrication system - 0010T11 engine oil check level and top up . Refill the engine cooling system with coolant  - 0010T20  coolant change . Connect the negative (-) battery terminal Proceed with refitting  - 1016A10  sound-proofing cover - r + rRemove the car from the ramps.