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

Dismantling ( Reassembling

) 1. Withdraw and remove the water pump rigid inlet pipe.

1. Undo the bolts (1a) and remove the water pump cover (1b) and gasket (1c).2. Remove the bracket.

1. Undo the fixing bolts (1a) and remove the water pump (1b).2. Remove the gasket.

1. Undo the bolts (1a) and remove the detonation sensors (1b).

1. Undo the nuts (1a) and remove the air conditioning compresor mounting (1b).2. Undo the bolt (2a) and remove the single drive belt tensioner (2b).

1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.779.000

1. Undo the nut (1a) and remove the crankshaft pulley (1b).2. Remove the timing drive belt.3. Remove the toothed drive pulley.

Rotate the engine throughi 180° on the overhauling stand.1. Unscrew the bolt securing the engine oil pump drive chain to the oil pump.2. Move the engine oil pump drive chain (2a) away from the pump using tool (2b).

	Name	Country
2b	Extractor	1.860.954.001

1. Undo the bolts (1a) and remove the engine oil pump (1b).

1. Remove the crankshaft key using a suitable drift.2. Undo the bolts (2a) and remove the crankcase front cover (2b).Remove the crankshaft front oil seal from the crankcase front cover.3. Remove the gasket.

1. Remove the engine oil pump drive chain.2. Undo the bolt (2a) and remove the connector (2b) for engine oil delivery to the engine block.

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.

	Name	Country
2	Counter-torque	1.860.779.000

1. Fit the tool for rotating the crankshaft.

	Name	Country
1	Flange	1.820.618.000

Turn the crankshaft to gain access to the big end bearing cap bolts on the right bank.2. Undo the bolts (2a) and remove the right big end bearing caps (2b).3. Remove the big end bearing shells.

Rotate the engine throughi 180° on the overhauling stand.1. Remove the liner retaining tools from the right bank.

	Name	Country
1	Liner/bore holder	1.820.279.000

2. Remove the right bank cylinder liner (2a), piston and connecting rod (2b) assemblies.Separate the piston/connecting rod assemblies from their cylinder liners.3. Remove the big end bearing shells.Do the same to remove the cylinder liners and connecting rod-piston assemblies for the left bank.

Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.820.618.000

Rotate the engine throughi 180° on the overhauling stand.Check that the crankshaft end float is within the recommended values using a magnetic base fitted with a dial gauge.

	Measurement		Value
-	End float (mm)		0.080 ÷ 0.265

1. Undo the nuts (1a) and remove the front and central main bearing caps (1b).2. Remove the half-bearings.

1. Undo the nuts (1a) and remove the rear main bearing cap (1b) using the tools (1c) and (1d).

	Name	Country
1c	Lever	1.821.006.001

	Name	Country
1d	Extractor	1.821.006.002

2. Remove the half-bearing.

1. Remove the crankshaft rear oil seal.

1. Remove the crankshaft.2. Remove the half-bearings.3. Remove the thrust washers.

Proceed with removal - 1028H60 piston, pin set - replace . Proceed with removal - 1084B18 engine oil pump, removed - check at bench . Drill and remove the water/oil sealing plugs from the crankcase to allow washing.

Reassembling ( Dismantling

) Wash all the dismantled components carefully.Clean any residues of sealant from the matching surfaces of the engine oil sump and the rear bearing cap with the engine block.Place the water/oil sealing plugs back in their housings in the crankcase using suitable fitting tools.Lubricate all the components for the mechanical couplings using engine oil.Check that the planarity 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

Remove the seals from the cylinder liners/bores.Check that the inner diameter of the cylinder liners/bores is within the recommended values. if this is not the case, replace them.

	Measurement		Value
-	Cylinder liner/bore inner diameter (mm)	Category B	92.995 ÷ 93.004
Category A	92.985 ÷ 92.994
Category C	93.005 ÷ 93.014

Check that the ovality of the cylinder liners is within the recommended values. if this is not the case, replace them.

	Measurement		Value
-	Maximum permitted cylinder liner/bore ovality, X - Y (mm)		< 0.01

Remove the lubrication duct plugs in the crankshaft using a suitable drift, then remove any residues.Clean the lubrication ducts thoroughly using hot petroleum, then dry them with a compressed air jet.Apply sealant (LOCTITE 270 GREEN) to the new plugs, then place them in the housings in the crankshaft using a suitable fitting tool and bevel them.Check that the diameter of the main journals is within the recommended values; if this is not the case, replace the crankshaft.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	59.967 - 59.973
Category C	59.961 - 59.967
Classe A	59.973 - 59.979

The nitriding treatment applied to the crankshaft does not allow grinding operations to be carried out.

Check that the diameter of the crankpins is within the recommended values; if this is not the case, replace the crankshaft.

	Measurement		Value
-	Crankpin diameter (mm)	Category B	51.980 - 51.990
Classe A	51.990 - 52.000

The nitriding treatment applied to the crankshaft does not allow grinding operations to be carried out.

Check that the inner diameter of the small end bushes is within the recommended limits; if this is not the case, replace the connecting rod assemblies.

	Measurement		Value
-	Small end bushes inner diameter (reaming) (mm)		20.005 ÷ 20.015

Check the matching between the gudgeon pin and the housing in the piston: it should be possible to insert the gudgeon pin using slight pressure and it should not slip out.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
-	Gudgeon pin outer diameter (mm)		19.996 ÷ 22.000

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 seals.

	Measurement		Value
-	Piston ring gap (mm)	1° ring	0.30 ÷ 0.50
2° seal	0.40 ÷ 0.60

	Measurement		Value
-	Piston oil scraper ring gap (mm)	Oil scraper ring	0.20 ÷ 0.40

1. If necessary, reface the ends of the piston rings using a suitable tool.

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.

	Measurement		Value
-	Piston outer diameter (mm)	Category B	92.915 ÷ 92.925
Category A	92.905 ÷ 92.915
Category C	92.925 ÷ 92.935

The measurement should be made perpendicular to the gudgeon pin axis, 13.1 mm from the skirt lower edge.

Check that the end float between the seals and the piston ring grooves is within the recommended limits. if this is not the case, replace the seals.

	Measurement		Value
-	Seal end float (mm)	1° ring	0.035 ÷ 0.070
2° seal	0.030 ÷ 0.075

	Measurement		Value
-	Piston oil scraper ring end float (mm)	Oil scraper ring	0.020 ÷ 0.065

Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it. Proceed with refitting - 1084B18 engine oil pump, removed - check at bench . Proceed with refitting - 1028H60 piston, pin set - replace . 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 half-bearings back in their housings in the cylinder block/crankcase.

Main bearing halves and main journals must be matched by combining parts of the same dimension category (same identification colour).

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 tightening the nuts (1b) to the recommended torque.

Main bearing caps are numbered progressively (from one to four from the camshaft end) to determine their assembly position.

The safety notches on the crankcase and main bearing caps must all be on the same side.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 77? ÷ 81?

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
1b	Main journal-bearing clearance (mm)	Category B	0.000 ÷ 0.024
Category A	0.000 ÷ 0.024
Category C	0.000 ÷ 0.025

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.Refit the thrust ring halves (thickness dependent on crankshaft end float measured upon dismantling) in their seats on the rear engine block.

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 tightening the nuts (1b) to the recommended torque.

Main bearing caps are numbered progressively (from one to four from the camshaft end) to determine their assembly position.

The safety notches on the crankcase and main bearing caps must all be on the same side.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	BIG END BEARING CAPS	M12	2.4 ÷ 2.6 + 77? ÷ 81?

2. Use the tool for angular tightening of the main bearing cap bolts.

	Name	Country
2	Protractor	1.860.942.000

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

The oil seal should be fitted in its housing so that it covers the small openings (1c).

	Name	Country
1b	Fitting tool	1.821.250.000

1. Apply the recommended sealant (1a) through the openings (1b) and check that it comes about 5 mm out of the openings (1c)

	Type	Component	Name	Qty.
1a	Sealant	ENGINE REAR MOUNT GASKETS	LOCTITE 5900	-

The oil sump should be fitted within 15 minutes of applying the sealant in the openings for the crankshaft rear support. If this is not the case, remove the edge of the sealant.

Rotate the engine throughi 180° on the overhauling stand.Refit new seals in their seats on the cylinder liners.1. Place the cylinder liners complete with seals (1b) back in their housings.2. Fit the cylinder liner retaining tools (2a) and tighten the nuts (2b) to the specified torque.

	Name	Country
2a	Liner/bore holder	1.820.279.000

	Fastening	Component	Ø	Value(daNm)
2b	Nut	LINER/BORE LOCK TOOLS	M12	2.4 ÷ 2.6 + 228? ÷ 232?

1. Measure the projection of the cylinder liners in relation to the crankcase (1a) plane using the tool (1b) fitted with a dial gauge (1c) and check that it is within the recommended limits.

	Measurement		Value
1a	Cylinder bore/liner projection from crankcase plane (mm)		0.01 ÷ 0.06

	Name	Country
1b	Dial gauge mounting	1.825.003.000

1. Place the piston-connecting rod assemblies (1a), complete with half-bearings (1b) back in the cylinder liners/bores using a suitable tool (1c).

The piston-connecting rod assemblies should be fitted so that the arrows on the piston crown are facing the timing side and the marking on the connecting rod is facing the timing side on the right side and the flywheel side on the left side.

Rotate the engine throughi 180° on the overhauling stand.Fit the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.820.618.000

Turn the crankshaft to gain access to the crankpins.1. Fit the calibrated wire (Plastigage) to measure the big end bearing clearance.

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

The safety notches on the connecting rod cap and connecting rod head must be on the same side.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	Connecting rod cap	M9	1.9 ÷ 2.1 + 48? ÷ 52?

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

	Name	Country
-	Protractor	1.860.942.000

1. Remove the big end 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 do it one bearing at a time without ever moving the crankshaft.

	Measurement		Value
1b	Main journals/bearing clearance (mm)	Category B	0.023 ÷ 0.063
Category A	0.020 ÷ 0.060

If the value measured does not correspond to the recommended figures, replace the connecting rod half bearings with new ones of appropriate size and category.

Turn the crankshaft to gain access to the crankpins.1. Refit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque.

The safety notches on the connecting rod cap and connecting rod head must be on the same side.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	Connecting rod cap	M9	1.9 ÷ 2.1 + 48? ÷ 52?

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

	Name	Country
-	Protractor	1.860.942.000

Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.820.618.000

Place the engine oil - crankcase connector back in its housing and secure it using the bolt.1. Place the power assisted steering pump (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE OIL PUMP	M10	(Main journal cap side) 4.5 ÷ 5.5

1. Place the engine oil pump drive chain (1a) back in its housing and secure it without tightening the bolt (1b).

1. Place the crankcase front cover (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CRANKSHAFT FRONT COVER	M6	(Engine crankcase side) 0.8 ÷ 1.0

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

	Name	Country
1b	Fitting tool	1.860.949.000

Refit the key in its seat on the crankshaft.Place the drive pulley back in its housing.1. Place the engine components single drive belt moving tensioner (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	SINGLE SERVICES MOBILE BELT TENSIONER	-	(Engine crankcase side) 2.7 ÷ 3.3

2. Place the air conditioning compressor mounting (2a) back in its housing and secure it tightening the nuts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	COMPRESSOR MOUNT (AC)	M8	(Engine crankcase side) 2.3 ÷ 2.8

1. Place the detonation sensors (1a) back in their housings and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FLYWHEEL SIDE KNOCK SENSOR	M8	(Engine crankcase side) 2.3 ÷ 2.8

1. Place the water pump (1a), complete with gasket (1b), back in its housing and tighten the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M6	(Engine crankcase side) 0.8 ÷ 1.0

1. Place the water pump cover (1a), complete with gasket (1b) and bracket (1c) back in its housing and tighten the bolts (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1d	-	-	-	-

Place the water pump rigid inlet pipe, complete with seals, back in its housing.1. Carry out a preliminary check on the camshaft timing: fit a spanner in the special opening (1a) in the centre of the camshafts and rotate them until the reference marks (1b) on the actual shafts coincide with the cylinder head upper surface.

The reference marks should be facing the centre of each cylinder head.

1. Remove the camshaft caps 4 and 7 from the left cylinder head.2. Remove the camshaft caps B and G from the right cylinder head.

1. Position the timing templates in place of the camshaft caps removed.

	Name	Country
1	Gauge	1.870.849.000

Remove the bore/liner locks.

	Name	Country
-	Liner/bore holder	1.820.279.000

Position the cylinder head centering bushes on the cylinder block/crankcase.1. Position the new cylinder head gaskets (1a) taking care to fit the seals (1b) for the lubrication ducts (two for each cylinder head).

The material from which the cylinder head 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 of the gasket 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 cylinder no. 1 at T.D.C. before fitting the cylinder heads on the cylinder block/crankcase.Position the cylinder heads on the cylinder block/crankcase.1. Tighten the nuts (1a) fixing the cylinder heads to the recommended torque using the angular tightening tools (1b) and (1c).

Lubricate the threads, nuts and washers with engine oil.

Follow the order shown in the diagram for each tightening sequence. The diagram shows the right cylinder head; the tightening order for the left cylinder head is symmetrical;

	Fastening	Component	Ø	Value(daNm)
1a	Nut	CYLINDER HEAD	M12	(Engine crankcase side) 2.4 ÷ 2.6 + 228? ÷ 232?

	Name	Country
1b	Protractor	1.860.942.000

	Name	Country
1c	Spanner	1.822.121.000

Refit the alternator bracket in its seating and fix it using the bolts.Place the rear protective timing covers back in their housings and secure them using the bolts.1. Place the timing belt fixed tensioners (1a) back in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED TENSIONER	M10	(Cylinder head side) 4.5 ÷ 5.5

2. Place the driven toothed pullies (2a) back in their housings and secure them without tightening the bolts (2b).

Tighten the bolt fixing the left rear timing belt protective cover to the right cylinder head.1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Fitting tool	1.821.225.000

Rotate the crankshaft, using small movements (in both directions), until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Make sure that the last crankshaft rotation is in the direction of operation.

1. Fit the timing drive belt starting from the drive pulley and continuing in an anti-clockwise direction, making sure that the drive sections are firmly taut.

1. Fit the tool (1a) and secure it with the bolt (1b) to the alternator bracket and with the bolt (1c) to the water pump.

The tool tooth should press on the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

2. Act on the nut (2a) for the belt tensioner tool until the moving reference on the belt tensioner (2b) is under the fixed reference.

1. Tighten the bolts (1a) fixing the driven pullies to the recommended toruqe using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Camshaft side) 7.2 ÷ 8.8

	Name	Country
1b	Counter-torque	1.822.146.000

Remove the tools for timing the camshafts.

	Name	Country
-	Gauge	1.870.849.000

Place the camshaft caps back in their housings in place of the tools removed and tighten the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS/	M8	(Cylinder head side) 1.8 ÷ 2.0

Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference on the timing belt moving tensioner lines up with the fixed reference.2. If the references do not line up, slightly discharge the tensioner acting on the tensioning tool nut and make sure that the references are aligned. 3. Tighten the bolts for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	(Cylinder head side) 1.9 ÷ 2.3

Remove the belt tensioner tool.

	Name	Country
-	Belt tensioner	1.860.950.000

Rotate the engine through 180° on the overhauling stand.1. Refit the engine flywheel in its housing and secure by tightening the bolts to the recommended torque.

The engine flyhwheel may only be refitted in one position because the retaining bolt holes are not equidistant.

2. Fit the flywheel lock.

	Name	Country
2	Counter-torque	1.860.779.000

3. Tighten the engine flywheel retaining bolts to the specified torque.

The engine flywheel retaining bolts are treated with a compound to prevent them coming undone they should therefore be replaced whenever they are removed.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	FLYWHEEL	M12	(Crankshaft side) 2.9 ÷ 3.2 + 48? ÷ 51?

Use the tool for angular tightening of the engine flywheelbolts.

	Name	Country
-	Protractor	1.860.942.000

1. Tighten the bolt fixing the engine oil pump drive chain to the oil pump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M10	(Engine oil pump side) 4.5 ÷ 5.5

2. Place the crankshaft pulley (2a) back in its housing and secure it tightening the nut (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Left thread nut	CRANKSHAFT PULLEY	M28	(Crankshaft side) 22.8 ÷ 25.2

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.779.000

Apply the recommended sealant to the entire perimeter of the crankcase sump.

	Type	Component	Name	Qty.
-	Sealant	OIL SUMP	LOCTITE 5900	-

1. Place the crankcase sump (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	OIL SUMP	M7	(Engine crankcase side) 1.4 ÷ 1.7

Refit the rpm sensor and mount.Replace the rear wheel rpm sensor in its housing and fix it using the bolts.1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	(Crankcase sump side) 2.3 ÷ 2.8

1. Place the cylinder head tappet covers (1a) complete with gaskets back in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM COVERS	M7	(Cylinder head side) 1.4 ÷ 1.7

1. Tighten the power steering pump bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER STEERING PUMP	M8	(Support side) 2.3 ÷ 2.8

2. Place the bracket (2a) back in its housing and secure it using the bolt (2b) and the bolts (2c).

Place the lower protective timing covers back in their housings and secure them using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.Connect the rapid connector for the fuel manifold pipes.1. Place the ignition coils (1a) back in their housings on the left cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	IGNITION COIL/REEL	M6	(Tappet cover side) 0.8 ÷ 1.0

Place the engine wiring back in its housing.Place the electrical wiring back in its housing and fasten it using the bolts.Connect the electrical connections to the left cylinder head ignition coils.Connect the electrical connections to the left cylinder head injectors.Fit the ignition coils cover in the housing on the left cylinder head and fix it using the bolts.Connect the earth lead to the left cylinder head and secure using the nut.Connect the electrical connection for the knock sensor flywheel side.Connect the electrical connection for the rpm sensor.1. Place the connector back in its housing.2. Place the thermostat (2a) back in its housing and secure it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	THERMOSTAT	M6	(Cylinder head side) 0.8 ÷ 1.0

Place the wiring and the connections in the connection box, then close the cover.Connect the electrical connection to the water temperature sensor.1. Place the ignition coils (1a) back in their housing on the right cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	IGNITION COIL/REEL	M6	(Tappet cover side) 0.8 ÷ 1.0

1. Plact the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM ANGLE SENSOR	M6	(Cylinder head side) 0.7 ÷ 0.8

Place the electrical wiring back in its housing and fasten it using the bolts.Connect the electrical connections to the right cylinder head ignition coils.Connect the electrical connections to the right cylinder head injectors.1. Place the intake manifolds (1a), complete with hoses (1b) and gaskets (1c) back in their housings and tighten the bolts (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	INLET MANIFOLD	M6	(Intake manifold side) 0.6 ÷ 0.9

Place the air chamber back in its housing and secure it using the bolts.Tighten the bolt fixing the reinforcement strut to the support on the engine for the reaction rod.Connect the earth lead to the air chamber and secure it using the bolt.Connect the electrical connection to the throttle body integrated with the D.V.L.Tighten the band fastening the engine oil vapour recovery pipe to the air chamber.Tighten the bands fixing the inlet ducts to the air chamber.Connect the electrical connection for the detonation sensor, timing side.Close the electrical connection box cover. Proceed with refitting - 1004D40 engine - position on stand and remove .

Dismantling ( Reassembling

) Rotate the crankcase through 180° on the overhauling stand.1. Disconnect the power assisted steering pump supply pipe.2. Remove the power assisted steering fluid reservoir, complete with pipe.

1. Undo the bolts (1a) and remove the alternator (1b).

1. Slacken the counter-balance shaft belt tensioner nut.2. Remove the counter-balance shaft belt.3. Remove the timing drive belt.4. Undo the bolts (4a) and remove the power steering pump mounting and intermediate shaft (4b) complete with power steering pump (4c) and engine components drive belt automatic tensioner (4d).

1. Undo the bolts (1a) and remove the power unit rigid support, timing gear side (1b).2. Undo the bolts (2a) and remove the mounting (2b) complete with timing belt tensioner (2c) and guide pulley (2d).3. Undo the bolts (3a) and remove the counter-balance shaft belt pulley (3b).

1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Undo the bolt (2a) (left-hand) and remove the timing belt pulley (2b).3. Undo the bolts (3a) and remove the flywheel (3b).

1. Remove the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Fit the tool.

	Name	Country
2	Flange	1.820.618.000

1. Undo the bolts (1a) and remove the oil pump (1b) complete with water-oil heat exchanger (1c), oil filter (1d) and intake duct (1e).2. Remove the gasket.3. Undo the bolts (3a) and remove the detonation sensors (3b).

	Name	Connector
3b	Detonation sensor - 1	K50

4. Remove the engine oil pressure switch.

	Name	Connector
4	Engine oil pressure sensor	K30

5. Undo the bolt (5a) and remove the engine rpm and timing sensor (5b).

	Name	Connector
5b	Rpm sensor	K46

6. Undo the bolts (6a) and remove the exhaust manifold mounting brackets (6b).

Place the oil pump complete with water-oil heat exchanger, oil filter and intake duct in a vice fitted with protective jaws.1. Undo the bolts (1a) and remove the intake duct (1b).2. Remove the gasket.3. Remove the oil filter.4. Undo the bolts (4a) and remove the heat exchanger (4b) complete with pipes.5. Remove the gasket.

Rotate the crankcase through 180° on the overhauling stand.Check that the crankshaft end float is within the recommended values using a magnetic base fitted with a dial gauge.

	Measurement		Value
-	End float (mm)		0.059 - 0.221

If the end float of the crankshaft is not within the recommended values, when refitting, reface the seat in the cylinder block and use suitable oversize thrust washers.Rotate the crankshaft using the tool fitted previously until the pistons of 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 connecting rod-piston assemblies (2a) complete with bearing shell (2b) of cylinders no. 1 and no. 4.Do the same to remove the connecting rod-piston assemblies of cylinders no. 2 and no. 3.3. Remove the tool.

	Name	Country
3	Flange	1.820.618.000

4. Undo the bolts (4a) and remove the cylinder block rear cover with integrated oil seal (4b).

1. Undo the bolts (1a) and remove the main bearing caps (1b) complete with bearing shells (1c).2. Remove the crankshaft.3. Remove the main bearing shells.4. Remove the thrust washers.5. Undo the bolt and remove the engne oil jets (5b) from the cylinder block/crankase.

Undo the attachments and remove the cylinder block from the overhaul stand and place it on a suitable work bench.1. Undo the bolts (1a) and remove the flywheel guard (1b).

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

2. Remove the counter-balance shaft pulleys.3. Undo the bolts (3a) and remove the inlet side counter-balance shaft front cover (3b) complete with oil seal and O-ring.4. Undo the bolts (4a) and remove the exhaust side counter-balance shaft front cover complete with oil seal, O-ring and counter-balance shafts drive belt tensioner.5. Completely undo the nut (5a) and remove the counter-balance shafts belt tensioner (5b).

Remove the O-rings and oil seals from the counter-balance shafts front covers.1. Remove the spacers (1a) and O-rings (1b) from the counter-balance shafts.2. Remove the counter-balance shaft rear plugs.3. Remove the counter-balance shafts (3a) complete with rear bearings (3b) using a suitable drift (3c).

1. Remove the counter-balance shafts front bearings (1a) from the cylinder block using the tools (1b) and (1c).

	Name	Country
1b	Extractor	1.820.626.000

	Name	Country
1c	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 - replace - 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

Measure the cylinder liner diameter and check that it is within the specified values.

	Measurement		Value
-	Cylinder bore diameter (mm)	Category B	83.010 - 83.020
Category C	83.020 - 83.030
Classe A	83.000 - 83.010

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

	Measurement		Value
-	Cylinder bore taper (mm)		< 0.010

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

	Measurement		Value
-	Cylinder bore ovalization (mm)		< 0.005

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

2. Tighten the main bearing cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 100?

Use the tool for angular tightening of the main bearing cap bolts.

	Name	Country
-	Protractor	1.860.942.000

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

	Measurement		Value
-	Main bearing seat diameter (mm)		56.705 - 56.718

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	52.988 ÷ 52.994
Category C	52.982 ÷ 52.988
Classe A	52.994 ÷ 53.000

If the diameter of the main bearing 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 crankpins above the value mentioned adversely affect the structural resistance of the crankshaft (as a result of contact between the tool and the rolled 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 crankpin diameter is within the specified 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)		20.006 - 20.012

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)		19.996 - 20.000

Fit the sealing rings in the cylinder liner/bore and check that the end gap is within the recommended values; if this is not the case, replace the piston sealing rings.

	Measurement		Value
-	1° sealing ring gap (mm)		0.25 - 0.50

From September 2003 sealing rings with modified profiles are used; the gap of the 1st ring becomes 0.20 0.35 mm.

	Measurement		Value
-	2° sealing ring gap (mm)		0.30 - 0.50

	Measurement		Value
-	Scraper ring gap (mm)		0.25 - 0.45

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.

	Measurement		Value
-	Outer diameter (mm) (**)	Category B	82.959 - 82.971
Category C	82.969 - 82.978
Classe A	82.952 - 82.962

Check that the endfloat between compression rings and their seats is within the specified values.

	Measurement		Value
-	1st° sealing ring end float (mm)		0.030 - 0.070

	Measurement		Value
-	2° sealing ring end float (mm)		0.020 . 0.055

	Measurement		Value
-	Oil scraper ring end float (mm)		0.020 - 0.055

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
-	Big end diameter (mm)		53.897 - 53.909

- 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at benchCheck that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Place the counter-balance shafts in a vice fitted with protective jaws.1. Fit the rear bearings (1a) on the counter-balance shafts using a suitable fitting tool (1b). Fix the rear bearings to the counter-balance shafts using the circlips.

1. Fit the counter-balance shaft front bearings (1a) on the cylinder block using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

1. Fit the counter-balance shafts (1a) complete with rear bearings (1b) in the cylinder block using the tool (1c).

	Name	Country
1b	Fitting tool	1.821.247.000

Fit new O-rings and spacers on the counter-balance shafts.Fit the counter-balance shafts rear plugs.Fit new O-rings on the counter-balance shaft front covers.1. Fit new oil seals (1a) on the counter-balance shaft front covers using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

2. Fit the counter-balance shaft front covers (2a) and tighten the bolts (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COUNTER ROTATING SHAFT FRONT COVER	M6	0.6 - 0.7

3. Fit the counter-balance shaft drive belt tensioner (3a) and fix it using the nut (3b) without tightening it.4. Fit the counter-balance shaft drive pullies (4a) and fix them with the bolts (4b) using the tool (4c) for counter-torque.

	Name	Country
4c	Counter-torque	1.820.286.000

Fit the flywheel guard and fix it to the cylinder block using the bolts.Mount the cylinder block on the overhaul stand.Fit the oil jets in the cylinder block and fix them using the bolts.Fit the thrust washers on the third main bearing.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, by the Parts Dept., without the appropriate half-bearings for '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; the final 'N' is a code that does not matter for 4 cylinder engines; for 5 cylinder engines the numerical code for the 5th crank pin is found in place of the 'N'.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; for 5 cylinder engines the numerical code for the 6th main journal is found in place of the 'N'.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, refer to the numerical code for reference 2. 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 94 (first on the left) corresponds to the dimension 52.994 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). Grade A bearing - Normal, diameter 52.994 - 53.000 mm, RED paint mark, code number 1 (94 00)°Grade B bearing - Normal, diameter 52.988 - 52.994 mm, BLUE paint mark, code number 2 (88 94)°Grade C bearing - Normal, diameter 52.982 - 52.988 mm, YELLOW paint mark, code number 3 (82 88)°Grade D bearing - Undersize, diameter 52.867- 52.873 (*) mm, BROWN paint mark, code number 6 (67 73)°Grade E bearing - Undersize, diameter 52.861 - 52.867 (*) mm, GREEN paint mark, code 7 (61 67)°Grade F bearing - Undersize, diameter 52.855 - 52.861 (*) mm, BLACK paint mark, code number 8 (55 61)° (*) 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. 1. Fit the main bearing shells.2. Fit the crankshaft on the cylinder block/crankcase.3. Fit the main bearing caps (3a) complete with bearing shells (3b).

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

4. Tighten the bearing cap bolts (1a) to the recommended torque

	Fastening	Component	Ø	Value(daNm)
4	Bolt	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 100?

Use the tool for angular tightening of the main bearing cap bolts.

	Name	Country
-	Protractor	1.860.942.000

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

	Name	Country
1b	Fitting tool	1.820.619.000

2. Tighten the bolts securing the cylinder block rear cover with integrated oil seal to 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

1. Fit the tool.

	Name	Country
1	Flange	1.820.618.000

Rotate the crankshaft until cylinders no. 1 and no. 4 are at B.D.C.2. Fit the connecting rod-piston assemblies (2a) complete with bearing shells (2b) for cylinders no. 1 and no. 4.

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

3. Fit the big end bearing caps (3a) complete with bearing shells (3b) and tighten the bolts (3c) to 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)
3c	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

Do the same to fit the connecting rod-piston assemblies of cylinders no. 2 and no. 3. Remove the tool.

	Name	Country
-	Flange	1.820.618.000

Place the oil pump in a vice fitted with protective jaws.Fit the heat exchanger complete with pipes and a new gasket and fix it to the oil pump with the bolt.Fit the oil filter.Fit the intake duct complete with gasket and fix it to the oil pump using the bolts.Fit the exhaust manifold mounting brackets and fix them to the cylinder block using the bolts.Fit the rpm and timing sensor and fix it with its bolts.Fit the engine oil pressure switch and tighten it to torque.

	Fastening	Component	Ø	Value(daNm)
-	-	OIL PRESSURE W/L	M14	2.5 - 3.1

Fit the detonation sensor and secure it using the bolt.Fit the oil pump complete with water-oil heat exchanger, oil filter, intake duct and gasket and fix it to the cylinder block tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	0.6 - 0.8

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 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 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 crankcase through 180° on the overhauling stand.Fit the power steering pump mounting and intermediate shaft complete with power steering pump and automatic tensioner for engine components drive belt and fix it using the bolts.Fit the mounting complete with timing belt tensioner and guide pulley and fix it using the bolts.Fit the timing belt pulley and fix it using the bolt (left-hand) without tightening it.Bring cylinder no. 1 to T.D.C. Position the cylinder head centring bushes on the cylinder block/crankcase.Fit a new cylinder head gasket.

The cylinder head gasket is of the Astadur type.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 of the gasket 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 cylinder block, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).1. Tighten the cylinder head bolts (1a) to 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	2.0 + 2.0 + 90° + 90° + 90°

	Name	Country
1b	Protractor	1.820.277.000

Fit the exhaust manifold gasket.Fit the gasket for the rigid coolant inlet pipe to the pump.Fit the coolant inlet pipe to the pump.Fit the engine oil dipstick and fix it using the bolts.Connect, to the rigid coolant inlet pipe to the pump, the connector for the coolant outlet pipe from the heat exchanger.Fit the exhaust manifold and fix it to the cylinder head, tightening the nuts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	1.7 - 2.1

Fit the air conditioner compressor support and fix it to the cylinder block using the bolts.Fit the air conditioning compressor and secure it using the bolts.Tighten the bolts securing the mounting bracket to the intake chamber.Fit the timing belt side guards and fix them using the bolts.1. Fit the tool (1a) complete with dial gauge (1b).

	Name	Country
1a	Extension	1.825.013.000

Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. at the power stroke.Undo the bolts an remove the third caps from the inlet and exhaust camshafts.2. Fit the tool (2a) in place of the removed camshaft caps, and fix it tightening the bolts (2b) to torque.

Check that the camshaft cam profile matches the tool perfectly.

	Name	Country
2a	Gauge	1.825.041.000

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE TIMING ADJUSTMENT TEMPLATES	M7	1.0

Fit the timing belt.

Check that the camshaft pulley bolts are slackened to permit perfect timing adjustment.

1. Apply maximum tension to the timing belt using the tool.

	Name	Country
1	Key	1.822.149.000

2. Tighten the timing belt tensioner nut to torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8	2.1 - 2.6

3. Tighten the bolts (3a) of the inlet side camshaft pulley, using the tool (3b) for counter-torque.

	Name	Country
3b	Counter-torque	1.822.155.000

4. Tighten to torque the bolt (4a) on the exhaust side camshaft pulley, using the tools (4b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	10.0 - 12.4

	Name	Country
4b	Counter-torque	1.822.146.000

	Name	Country
4b	Counter-torque	1.822.156.000

Undo the bolts and remove the tool.

	Name	Country
-	Gauge	1.825.041.000

Fit the camshaft caps removed previously and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

Rotate the crankshaft through two revolutions.Slacken the timing belt tensioner nut.5. Line up the moving reference (5a) on the timing belt tensioner with the reference hole (5b) using the tool (5c).

	Name	Country
5c	Key	1.822.149.000

Tighten the timing belt tensioner nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	MOBILE TIMING TENSIONER	M8	2.1 - 2.6

Rotate the crankshaft until the piston of cylinder no. 1 is at T.D.C.Fit the counter-balance shafts belt drive pulley and fix it using the bolts.1. Position the counter-balance shafts to that the references on the pulleys line up with those on the front covers.2. Fit the counter-balance shafts drive belt.

1. Tension the counter-balance shaft drive belt using the tool (1a) until the reference hole (1b) on the belt tensioner is at the centre of the rotation sector.

	Name	Country
1a	Key	1.822.154.000

2. Tighten the counter-balance shafts belt tensioner nut.

Remove the tool complete with dial gauge.

	Name	Country
-	Extension	1.825.013.000

Remove the tool.

	Name	Country
-	Flange	1.820.618.000

Fit the flywheel and fix it using the bolts, without tightening them.Fit the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Tighten the flywheel bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL	M12	12.1 - 14.9

Tighten the timing belt pulley bolt (left-hand) to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TOOTHED DRIVE PULLEY	M16	34.0 - 37.8

Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Fit the spark plugs.Fit the rocker cover complete with gasket and fix it using the bolts.Connect the oil vapour recovery pipe to the rocker cover.Fit the bracket complete with ignition coils and high-tension cables and fix it using the boltsConnect the high tension leads to the spark plugs.Connect the earth lead to the cylinder head.Place the electrical wiring back in its seating and fix it to the bands.Connect the electrical connections to the ignition coils.Fit the power assisted steering fluid reservoir, complete with pipe, and secure it using the bolts.Connect the fluid supply pipe to the power steering pump.Connect the electrical connection for the rpm and timing sensor.Connect the electrical connection for the knock sensor.Fix the electrical wiring form the rpm and timing sensor and knock sensor using the bands located under the air intake chamber.Connect the timing sensor electrical connection.Connect the electrical connection for the air conditioning compressor. Fit the lower timing belt guard and fix it using the bolts.Fit the upper timing belt guard and fix it using the bolts.Fit the engine components belt drive pulley and fix it tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.4 - 2.9

Fit the engine components drive belt guide pulley and fix it using the bolt.Fit the power unit rigid support, timing gear side, and fix it using the bolts.Fit the alternator and fix it using the bolts.Fit the auxiliary components drive belt, using a spanner to lever on the automatic belt tensioner.Fit the engine components drive belt guard and fix it using the nut and bolt. - 1004D40 engine - position on stand and remove