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 - Alfa - 156 - eLearn

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

) Rotate the crankcase through 180° on the overhauling stand.1. Completely undo the side bolts (1a) loosened previously and remove the pressure pump (1b) complete with support (1c).2. Undo the upper alternator bolt.3. Undo the bolts (3a) and remove the alternator rear mounting bracket (3b).4. Undo the lower bolt (4a) and remove the alternator (4b).

	Name	Connector
4b	Alternator	A10

5. Undo the bolts (5a) and remove the intermediate shaft support (5b).

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Remove the timing belt.3. Undo the bolt (3a) and remove the fixed tensioner for the timing drive belt (3b).4. Undo the bolts (4a) and remove the power assisted steering pump (4b) complete with mounting bracket.

1. Undo the bolts (1a) and remove the air conditioning compressor (1b) complete with support (1c).2. Undo the bolts (2a) and remove the timing side power unit support (2b).3. Undo the bolts for the heat exchanger water inlet pipe mounting bracket.4. Release and remove the engine oil filter using a suitable tool.5. Unscrew the fitting.6. Remove the engine oil heat exchanger complete with pipes.Undo the connector and remove the oil supply pipe to the turbocharger.

1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Undo the bolt (left) (2a) and remove the drive pulley (2b).3. Undo the bolts (3a) and remove the flywheel (3b).Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Rotate the engine through 180° on the overhauling stand.1. Fit the tool.

	Name	Country
1	Flange	1.820.618.000

2. Undo the bolts (2a) and remove the engine oil inlet (2b).3. Remove the O-ring.4. Undo the bolts (4a) and remove the crankcase front cover with the oil pump (4b) integrated.5. Remove the gasket.Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.6. Undo the bolts (6a) and remove the connecting rod cap (6b).7. Remove the lower big end bearing shell.8. Remove the connecting rod - piston assembly.9. Remove the upper big end bearing shell.Proceed in the same way with the removal of the pistons and connecting rods for the remaining cylinders.

1. Check that the crankshaft end float is within the recommended values using a magnetic base fitted with a dial gauge.

	Measurement		Value
1	End float (mm)		0.049 - 0.211

If the end float of the crankshaft is not within the recommended values, when refitting, reface the seat in the cylinder block/crankcase and use suitable oversize thrust washers.

1. Undo the bolts (1a) and remove the crankcase rear cover (1b) with the oil seal integrated.2. Undo the bolts (2a) and remove the bearing caps (2b).3. Remove the lower main journal half-bearings.4. Remove the crankshaft.5. Remove the upper main journal half-bearings.6. Remove the thrust washers.7. Undo the bolts (7a) and remove the jets (7b) from the crankcase.8. Undo the bolt (8a) and remove the rpm and timing sensor (8b).9. Remove the mininum engine oil pressure warning light sensor.

1. Undo the bolts (1a) and remove the cylinder block/crankcase (1b) from the mounting brackets, then place it on a special workbench.2. Undo the bolts (2a) and remove the flywhell protection (2b).3. Remove the counter-balance shaft rear plug.4. Remove the counter-balance shaft front bearing circlip.5. Remove the counter-balance shaft (5a), complete with rear bearing (5b), using a suitable drift.

1. Remove the circlip retaining the front bearing to the cylinder block/crankcase.2. Remove the counter-balance shaft front bearing (2a) from the cylinder block/crankcase using the tools (2b) and (2c).

	Name	Country
2b	Extractor	1.820.626.000

	Name	Country
2c	Counter weight	1.840.206.001

Position the counter-balance shaft in a vice fitted with protective jaws.1. Remove the circlip retaining the rear bearing to the counter-balance shaft.2. Remove the counter-balance shaft rear bearing (2a) using a suitable drift (2b).

- 1028H60 piston, pin set - replaceUndo the bolts and remove the oil inlet from the oil pump. - 1084B18 engine oil pump, removed - check at benchDrill and remove the water/oil sealing plugs from the crankcase to allow washing.

Reassembling ( Dismantling

) Wash the dismantled components.Fit the water/oil sealing plugs in the crankcase, using suitable fitting tools.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 planarity of the cylinder head support 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

1. Measure the diameter of the cylinder liners/bores following the diagram illustrated.

	Measurement		Value
1	Cylinder bore diameter (mm)	Category B	82.010 - 82.020
Category C	82.020 - 82.030
Classe A	82.000 - 82.010

Check that the conicity of the cylinder liners/bores is within the recommended values.

	Measurement		Value
-	Cylinder bore taper (mm)		< 0.005

Check that the ovality of the cylinder liners is within the recommended values.

	Measurement		Value
-	Cylinder bore ovalization (mm)		< 0.05

If the diameter of the cylinder liners/bores is not within the recommended values, ream the cylinder liners/bores in accordance with the recommended oversizes.

In the case of reaming, all liners/bores must be the same oversize.

	Measurement		Value
-	Cylinder liner oversize (mm)		0.1

1. Fit the bearing caps.

The bearing caps have progressive references (from zero to four starting from the front of the engine) which define their fitting position.

1. Tighten the bearing cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MAIN BEARING CAPS	M12	(Engine crankcase side) 2.4 ÷ 2.6 +100?

	Name	Country
1b	Protractor	1.860.942.000

2. Check that the diameter of the bearing seats is within the recommended values.

	Measurement		Value
2	Main bearing seat diameter (mm)		63.691 - 63.732

Check that the crankshaft lubrication ducts are free from deposits.Check that the diameter of the main journals is within the recommended values.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	59.987 ÷ 59.993
Category C	59.982 ÷ 59.986
Classe A	59.994 ÷ 60.000

If the diameter of the main journals is not within the recommended values, regrind them in accordance with the recommended undersize.

	Measurement		Value
-	Main bearing journal undersize (mm)		0.127

Undersizes for big end bearings above the value mentioned adversely affect the structural strength of the crankshaft (as a result of contact between the tool and the connectors). As far as the above is concerned, if the regrinding requires undersizes above 0.127 mm, the crankshaft must be replaced with a new one ordered from the Parts Dept. The half-bearings used for undersizes above 0.127 mm should no longer be requested from the Parts Dept. (even if the number is still shown).

Check that the diameter of the crankpins is within the recommended values.

	Measurement		Value
-	Crankpin diameter (mm)	Category B	50.793 ÷ 50.799
Category C	50.787 ÷ 50.793
Classe A	50.799 ÷ 50.805

If the diameter of the crankpins is not within the recommended values, regrind them in accordance with the recommended undersize.

	Measurement		Value
-	Crankpin undersize (mm)		0.127

Undersizes for bearings above the value mentioned adversely affect the structural resistance of the crankshaft (as a result of contact between the tool and the connectors). As far as the above is concerned, if the regrinding requires undersizes above 0.127 mm, the crankshaft must be replaced with a new one ordered from the Parts Dept. The half-bearings used for undersizes above 0.127 mm should no longer be requested from the Parts Dept. (even if the number is still shown).

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 (refer to op. 1028H58 connecting rod small end bush - replace ).

	Measurement		Value
-	Inner diameter (mm)		26.006 - 26.012

Check that the inner diameter of the small end bushes is within the recommended limits; if this is not the case, replace the piston complete with rings, gudgeon pin and bushes.

	Measurement		Value
-	Piston bush bore (mm)		25.999 - 26.004

Check that the outer diameter of the gudgeon pins is within the recommended values. if this is not the case, replace the worn gudgeon pins.

	Measurement		Value
-	Outer diameter (mm)		25.982 - 25.988

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 piston seals.

	Measurement		Value
-	1° sealing ring gap (mm)		0.25 - 0.40

	Measurement		Value
-	2° sealing ring gap (mm)		0.25 - 0.50

	Measurement		Value
-	Scraper ring gap (mm)		0.25 - 0.50

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	81.930 ÷ 81.940
Category C	81.940 ÷ 81.950
Classe A	81.920 ÷ 81.930

The measurement should be made perpendicular to the gudgeon pin axis, 8 mm from the skirt lower edge.

1. Check that the end float (1a) between the second piston ring (1b) and the groove in the piston (1c) is within the recommended limits.

	Measurement		Value
1a	End float (mm)		0.020 ÷ 0.060

Check that the end float between the oil scraper ring and the groove in the piston is within the recommended limits.

	Measurement		Value
-	End float (mm)		0.030 - 0.065

1. Fit the caps (1b) on the connecting rods (1a) and fix them tightening the bolts (1c) to torque.

	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

2. Check that the diameter of the big end is within the recommended values; if this is not the case, replace the connecting rods.

	Measurement		Value
2	Big end diameter (mm)		53.883 ÷ 53.923

- 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at benchFit the inlet and fix it using the bolts.Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.1. Fit the rear bearing (1a) on the counter-balance shaft (1b) using a suitable drift (1c).Fix the rear bearing on the counter-balance shaft using the cirlip.

1. Fit the counter-balance shaft front bearing (1a) on the crankcase using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

Fix the counter-balance shaft front bearing to the crankcase using the circlip.

1. Fit the counter-balance shaft, complete with rear bearing (1a), in the cylinder block/crankcase using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

Fit the circlip retaining the counter-balance shaft to the front bearing.Fit the counter-balance shaft rear plug using the tool.

	Name	Country
-	Fitting tool	1.821.247.000

Fit the flywheel protection and tighten the bolts.Fit the cylinder block/crankcase on the rotating stand and fix it using the bolts.Fit the minimum engine oil pressure warning light sensor and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	OIL PRESSURE W/L	-	1.9 - 2.3

Fit the rpm and timing sensor and fix it with its bolts.Fit the jets in the cylinder block/crankcase and fix them using the bolt.Fit the thrust washers on the fourth bearing support.Starting from engine number 02030116, main journal half-bearings have been fitted on crankshafts which have been selected so that the matching clearance is optimum.

The crankshaft is supplied,bythe Parts Dept.,without the appropriate half-bearingsfor 'normal' dimension main journals and crank pins; it is therefore necessary to select the main journal half-bearings to be fitted 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 flywheel;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; For 4 cylinder engines, an 'N' is used instead of the last number relating to the 5th crankpin.2. Main journal identification code: the first number on the left refers to the first timing side bearing; For 4 cylinder engines, an 'N' is used instead of the last number relating to the 6th crankpin.3. Set of numbers (if present), in groups of two digits, which indicate the dimensions (thousandth part) of the main journals: the first two numbers on the left refer to the first bearing 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, reer to the numerical code for reference 2.In the case of the example, the numbers 111111 indicate that all six 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 94 (first on the left) corresponds to the dimension 59.994 for the first bearing on the timing side which identifies Grade A (red colour); the same method can be used for all the other groups of two digits for the same reference 3 (97 - 95 - 95 - 94 - 95).Grade A bearing - Normal, diameter 59.994 60.000 mm, RED paint mark, code number 1 (94 00)°Grade B bearing - Normal, diameter 59.987 59.993 mm, BLUE paint mark, code number 2 (87 93)°Grade C bearing - Normal, diameter 59.982 52.986 mm, YELLOW paint mark, code number 3 (82 86)°Grade D bearing - Undersize, diameter 59.867 59.873 (*) mm, BROWN paint mark, code number 6 (67 73)°Grade E bearing - Undersize, diameter 59.860 59.866 (*) mm, GREEN paint mark, code 7 (60 66)°Grade F bearing - Undersize, diameter 59.855 59.859 (*) mm, BLACK paint mark, code number 8 (55 59)° (*) 0.127 mm undersize (°) Last two numbers (thousandth part) of the dimensions of the main journalsIf 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 to go back to 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, generally, the clearance between the main journal and the half-bearing, obtained using the selection method indicated, should be between the following values:Minimum: 0.025 mm - Maximum: 0.052 mm; this value can be measured, as a final check, using the Plastic Gauge.Fit the main journal half-bearings in the cylinder block/crankcase.Fit the crankshaft on the cylinder block/crankcase.1. Fit the main journal caps complete with half-bearings.

The bearing caps have progressive references (from zero to four starting from the front of the engine) which define their fitting position.

1. Tighten the bearing cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MAIN BEARING CAPS	M12	2.4 - 2.6 + 100°

	Name	Country
1b	Protractor	1.860.942.000

1. Fit the tool.

	Name	Country
1	Flange	1.820.618.000

Rotate the cylinder block/crankcase through 90° on the overhauling stand.Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Fit the piston - connecting rod assembly (1a), complete with half-bearing, using the tool (1b).

The piston - connecting rod assemblies are fitted in the cylinder block/crankcase so that the explosion chamber in the piston is facing the inlet side.

To select the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.

2. Fit the big end bearing cap (2a) complete with half-bearing and fix it using the bolts (2b) without tightening them.

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).

Work in the same way when refitting the pistons and connecting rods for the remaining cylinders.

Rotate the cylinder block/crankcase through 90° on the overhauling stand.1. Tighten the bearing cap bolts (1a) to the recommended torque; use the tool (1b) for the angular tightening.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	BIG END BEARING CAPS	M9	2.4 ÷ 2.6 + 60?

	Name	Country
1b	Protractor	1.860.942.000

1. Fit the crankcase rear cover (1a) with the integrated oil seal using the tool (1b).

	Name	Country
1b	Fitting tool	1.820.619.000

2. Tighten the bolts securing the crankcase rear cover to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FLYWHEEL SIDE COVER	M6	0.8 - 1.0

Remove the tool.

	Name	Country
-	Fitting tool	1.820.619.000

Rotate the crankshaft so that the first cylinder is at T.D.C.1. Fit the crankcase front cover, complete with oil pump (1a) and gasket (1b), with the timing references aligned as described previously.2. Tighten the bolts for the crankcase front cover complete with oil pump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CRANKSHAFT FRONT COVER	M6	0.8 ÷ 1.0

3. Fit the engine oil inlet (3a), complete with O-Ring (3b), and fix it using the bolts (3c).

Apply sealant to the entire perimeter of the crankcase sump.

	Type	Component	Name	Qty.
-	Silicon sealant	OIL SUMP	-	-

1. Fit the crankcase sump.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	M6	(engine crankcase side) 0.7 ÷ 0.9

	Name	Country
2b	Key	1.822.144.000

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	M8	(Engine crankcase side) 2.1 ÷ 2.6

	Name	Country
3b	Key	1.822.145.000

Rotate the engine through 180° on the overhauling stand.1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Fit the flywheel (2a) and tighten the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FLYWHEEL	M12	13.6 - 16.8

3. Fit the drive pulley (3a) for the timing belt and tighten the bolt (left) (3b) to torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	30.6 - 37.8

Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

1. Measure the projection of the pistons at two points at 180° on the gudgeon pin axis using the tool and take the average of the two figures measured for each piston.

	Name	Country
1	Dial gauge mounting	1.820.253.000

Select the correct size cylinder head gasket, according to the maximum value of the averages of the projection for each individual piston.

	Measurement		Value
-	Maximum average piston projection thickness (mm)		0.795 - 0.881
	Gasket size no refs. (mm)	1.55 - 1.65

	Measurement		Value
-	Maximum average piston projection thickness (mm)		0.881 - 0.967
	Gasket size one ref. (mm)	1.65 - 1.75

	Measurement		Value
-	Maximum average piston projection thickness (mm)		0.967 - 1.055
	Gasket size two refs. (mm)	1.75 - 1.85

Position the cylinder head centring bushes on the cylinder block/crankcase.Fit the cylinder head gasket selected.

ASTADUR type cylinder head gaskets are fitted. The material from which these gaskets are made undergoes a polymerization process during the operation of the engine so that they become considerably harder during usage.

In order for the polymerization process to take place it is necessary to:

keep the gasket in its sealed container until fitting
not lubricate or get oil on the gasket and the contact surfaces.

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	M10	(Engine block side) 2.0 + 4.5 + 90° + 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	0.8 ÷ 1.0

Place the oil supply pipe to the turbocharger back in its housing and secure it to the cylinder block/crankcase using a new connector.

Use a new connector because this will have an oil filter.

Fit the heat exchanger complete with pipes.Tighten the connector securing the engine oil heat exchanger to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	ENGINE OIL HEAT EXCHANGER	-	3.0

Place the engine oil filter back in its housing and tighten it, but not fully, by hand after having lubricated the gasket with engine oil.Fix the heat exchanger water inlet pipe mounting bracket using the bolts.Fit the support, complete with power assisted steering pump, and fix it using the bolts.Fit the fixed timing belt tensioner and fix it tightening the bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FIXED TENSIONER	M8	2.1 - 2.6

Fit the intermediate shaft support and fix it using the bolts.Fit the plates connecting the crankcase sump to the intermediate shaft support and fix it using the bolts.Fit the support complete with pressure pump and fix it using the bolts.1. Undo the oil pump bolt shown in the diagram.Temporarily fit the timing drive belt on the drive pulley.2. Fit the tool (2a) and secure it gauged bolts (2b)

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

	Name	Country
2a	Template	1.860.905.000

	Name	Country
2b	Calibrated screw	1.860.905.010

1. Rotate the driven pulley so that the timing references line up.2. Completely fit the timing belt.3. Use a screwdriver to lever in the hole (3a) until the reference on the tensioner (3b) lines up with the reference hole (3c) and, in this position, tighten the belt tensioner nut (3d) to torque.

	Fastening	Component	Ø	Value(daNm)
3d	Nut	MOBILE TIMING TENSIONER	M10	4.2 ÷ 5.2

Remove the tools.

	Name	Country
-	Template	1.860.905.000

	Name	Country
-	Calibrated screw	1.860.905.010

Tighten the bolt on the oil pump removed previously.

1. Fit the tool in the special opening to keep the automatic belt tensioner for the drive belt in a 'fixed' position.

	Name	Country
1	Clip	1.870.645.000

Fit the crankshaft pulley and tighten the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.1 - 2.6

Fit the power unit support, timing gear side, and fix it using the bolts.Fit the air conditioning compressor complete with mounting and fix it using the bolts.Fit the timing drive belt guards and fix them using the bolts.Fit the power unit reaction rod mounting bracket and fix it using the bolts.Fit the auxiliary shaft belt tensioner and fix it tightening the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	2.1 ÷ 2.6

Fit the alternator and fix it using the lower bolt.Fit the alternator rear mounting and fix it using the bolts.Tighten the upper alternator bolt.Fit the single belt.1. Rotate the fixed tensioner (1a) for the drive belt using the tool (1b) A until the tool (1c) comes out, then tighten the bolt (1d) for the cam tensioner to torque.

	Name	Country
1b	Key	1.860.968.000

	Name	Country
1c	Clip	1.870.645.000

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	VARIOUS S D BELT CAM TENSIONER	M10	4.2 - 5.2

Fit the plastic plugs in the fixed tensioner and the cam tensioner for the drive belt.Fit the complete fuel filter and fix it using the nuts.Connect the fuel return pipe to the return manifold to the fuel filter.Fit the oil vapour separator, complete with pipes and bracket, and fix it using the nuts.Connect the condensation oil recovery pipe to the crankcase sump.Connect the oil vapour recovery pipe to the cylinder block/crankcase.Connect the water supply pipe to the water/oil heat exchanger to the thermostat.Connect the water outlet pipe from the heat exchanger to the manifold.Fit the exhaust manifold gasket.Fit the exhaust manifold, complete with turbocharger and E.G.R. valve, and fix it tightening the nuts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	2.1 - 2.6

Tighten the bolt securing the exhaust manifold bracket to the cylinder block/crankcase.Tighten the bolt securing the exhaust gas recirculation pipe bracket.Fit the exhaust gas recirculation pipe seal.Connect the exhaust gas recirculation pipe and fix it to the inlet manifold using the nuts.Connect the oil outlet pipe from the turbocharger to the crankcase sump.Fit the turbocharger oil outlet pipe protective guard and fix it using the bolts.Connect the oil inlet pipe to the turbocharger.Fit the engine oil dipstick and fix it using the bolts.Place the pipe from the pressure pump to the single fuel manifold back in its housing and fix it using the connectors without tightening them.Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12	(Pressure pump side) 2.2

Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side) 2.2

Connect the rubber pipe to the pressure pump. - 1004D40 engine - position on stand and remove