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. 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.

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 Rotate the engine through 180° on the overhauling stand.1. Undo the fixing bolts (1a) and remove the single drive belt automatic tensioner (1b).2. Undo the fixing bolts (2a) and remove the automatic tensioner mounting bracket (2b).

1. Undo the engine oil filter cartridge and remove it.2. Undo the threaded filler (2a) and remove the water/oil heat exchanger (2b).

1. Undo the bolt (left) (1a) and remove the toothed drive pulley (1b).

1. Undo the bolts (1a) and remove the crankshaft front cover oil seal (1b) with the engine oil pump incorporated.Remove the gasket.

1. Undo the bolt (1a) fixing the timing belt tensioner (1b) and remove it.2. Undo the fixing bolts (2a) and remove the power assisted steering pump, alternator and timing belt tensioner mounting (2b).

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

	Name	Country
1	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C. 2. Undo the bolts (2a) and remove the big end bearing cap (2b).3. Remove the lower big end bearing shell.4. Remove the connecting rod - piston assembly.5. 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.

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

Remove the crankcase from the overhaul stand and place it on a special workbench. - 1028H60 piston, pin set - replace . Undo the bolts and remove the oil inlet from the oil pump. - 1084B18 engine oil pump, removed - check at bench . Drill and remove the water/oil sealing plugs from the crankcase to allow washing. 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)		< 0.10

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

	Measurement		Value
-	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	BIG END BEARING CAPS	M12	(Engine block side) 2.5 + 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)		63.705 ÷ 63.718

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	59.988 ÷ 59.994
Category C	59.982 ÷ 59.988
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 diameter undersize (mm)		0.127

Check the crankshaft bearings, taking into account that no adjustment operations should be carried out on half-bearings. If there are signs of grooves or seizing, they must be replaced. Fit the half-bearings, making sure that they are scrupulously clean.

If the crankshaft has been reground, fit the new and oversize half-bearings to restore the original tolerance conditions.

Fit the crankshaft in the special housing in the cylinder block/crankcase. 1. Fit the calibrated wire (Plastigage) to measure the main journal clearance.

Check one journal at a time without moving the crankshaft.

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	BIG END BEARING CAPS	M12	(Engine block side) 2.5 + 100°

	Name	Country
1b	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).

	Measurement		Value
1b	Clearance between crankshaft bearings - main journals (mm)		0.011 ÷ 0.071

If the reading is not within the specified range, replace the main bearing halves with new bearing halves of appropriate size and category.

Measure the clearance at all the bearings, taking care to carry out this operation, one bearing at a time, without ever moving the crankshaft. 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).

	Measurement		Value
-	Inner diameter (mm)		26.006 ÷ 26.014

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 - 25.987

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
-	Opening (mm)	1° seal	0.20 ÷ 0.35
2° seal	0.60 ÷ 0.80

	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 rings and gudgeon pin.

	Measurement		Value
-	Outer diameter (mm)	Category B	81.930 ÷ 81.940
Category A	81.920 ÷ 81.930
Category C	81.940 ÷ 81.950

The measurement should be made perpendicular to the gudgeon pin axis, 9 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)		0.041 ÷ 0.09

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)		0.021 ÷ 0.07

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	2.5 + 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)		53.897 ÷ 53.909

- 1028H60 piston, pin set - replace . - 1084B18 engine oil pump, removed - check at bench . Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.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	M14	2.7 ÷ 4.0

Fit the thrust washers on the fourth bearing support.

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, refer 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 in the Table.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, as in the Table, 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, paint mark, code number 1 (94 00)Grade B bearing- Normal, diameter 59.988 59.994 mm, paint mark, code number 2 (88 94)Grade C bearing - Normal, diameter 59.982 59.988 mm, paint mark, code number 3 (82 88)Grade D bearing - Undersize, diameter 59.867 59.873 (*) mm, paint mark, code number 6 (67 73)Grade E bearing - Undersize, diameter 59.861 59.867 (*) mm, paint mark, code 7 (61 67)Grade F bearing - Undersize, diameter 59.855 59.861 (*) mm, paint mark, code 8 (55 61)(*) 0.127 mm undersize() 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 Table. 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: -- Maximum: -; this value can be measured, as a final check, using the Plastic Gauge.1. Fit the bolts (1a) and fasten the jets (1b) to the crankcase at the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	PISTON COOLING NOZZLES	-	0.9 - 1.2

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 five starting from the engine pulley side) 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	2.5 + 100°

	Name	Country
1b	Protractor	1.860.942.000

Fit the tool.

	Name	Country
-	Flange	1.860.815.000

Rotate the cylinder block 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 through 90° on the overhauling stand. 1. Check the clearance of the connecting rod bearings, using the calibrated wire (Plastigage).

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	2.5 + 60°

	Name	Country
1b	Protractor	1.860.942.000

Undo the fixing bolts and remove the connecting rod caps complete with half-bearings.1. Using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

	Measurement		Value
-	Clearance between big end bearings-crankpins (mm)		0,016 - 0,070

If the value measured does not correspond to the recommended figures, replace the connecting rod bearings.Carry out this check on all the connecting rod bearings, one at a time, without rotating the crankshaft.Fit the connecting rod caps with half-bearings, tightening the fixing bolts.Tighten the bearing cap bolts to the recommended torque; use the special tool for the angular tightening.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	BIG END BEARING CAPS	M9	2.5 + 60°

	Name	Country
-	Protractor	1.860.942.000

1. Fit the crankcase rear cover (1a) with integrated oil seal and tighten the fixing bolts (1b).

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FLYWHEEL SIDE COVER	M6	0.9 - 1.2

Rotate the crankshaft so that the first cylinder is at T.D.C. Fit the crankcase front cover complete with oil pump and sealTighten the bolts for the crankcase front cover complete with oil pump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	0.9 - 1.3

Fit the engine oil inlet complete with O-ring and fix it using the bolts.

	Fastening	Component	Ø	Value(daNm)
-	-	OIL SECTION PUMP	-	0.9 - 1.3

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

	Type	Component	Name	Qty.
-	Silicon sealant	OIL SUMP	Dow Corning 7091	-

1. Fit the crankcase sump.2. Tighten the fixing bolts (2a) for the crankcase sump to the recommended torque using the tools (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Side bolt	OIL SUMP	M6	(Engine block side) 0.9 ÷ 1.2

	Name	Country
2b	Spanner	1.860.834.001

	Fastening	Component	Ø	Value(daNm)
2a	Front and rear bolt	OIL SUMP	M8	(Engine crankcase side) 2.1 ÷ 2.6

	Fastening	Component	Ø	Value(daNm)
2a	Front and rear bolt	OIL SUMP	M8	(Engine crankcase side) 2.3 ÷ 3.3

	Name	Country
2b	Spanner	1.860.833.001

Rotate the engine through 180° on the overhauling stand.Fit the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.000

Fit the engine flywheel and tighten the bolts to the recommended torque with thread locking agent.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL	M12	(Crankshaft side) 14.7 - 21.2

Fit the timing belt toothed drive pulley and tighten the bolt (left) to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	(Crankshaft side) 32.9 - 44.1

Remove the tool.

	Name	Country
-	Counter-torque	1.860.846.000

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	1.870.404.000

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

	Measurement		Value
-	Size (no ref.) (mm)		0.82

	Measurement		Value
-	Maximum average piston projection (mm)		0.020 ÷ 0.100

	Measurement		Value
-	Size (one ref.) (mm)		0.92

	Measurement		Value
-	Maximum average piston projection (mm)		0.101 ÷ 0.200

	Measurement		Value
-	Size (two refs.) (mm)		1.02

	Measurement		Value
-	Maximum average piston projection (mm)		0.201 ÷ 0.295

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	M12	2 + 6.5 + 90° + 90° + 90°

The value of 2 daNm in the table below is a figure which must be adhered to for all the bolts following the tightening order illustrated in the diagram.

	Name	Country
1b	Protractor	1.860.942.000

Fit the tappet cover, complete with seal, and fix it tightening the bolts to torque.Fit the alternator mounting, power assisted steering pump and timing belt in place and tighten the fixing bolts.Fit the timing belt fixed tensioner and tighten the fixing bolt.Place the water/oil heat exchanger in position and tighten the threaded filler.Tighten the engine oil filter cartridge.Fit the single drive belt automatic tensioner mounting bracket in place and tighten the fixing bolts.Fit the automatic tensioner and tighten the fixing bolts.1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the upper cylinder head.

Check that the tools, marked with the letter 'A', are correctly inserted in the housings in the camshafts.

	Name	Country
1b	Gauge	1.870.986.900

1. Place the complete upper cylinder head (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque. 2. Tighten the fixing bolts to the specified torque.Loosen the exhaust side camshaft toothed drive pulley fixing bolt. Remove the inlet side camshaft timing tool and tighten the plug.

1. Undo the bolt for the crankcase front cover 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

Place the engine oil filler metal gasket in position.Fit the engine oil filler in place and tighten the fixing bolts.Place the vacuum unit metal gasket in position.Fit the vacuum unit in place and tighten the fixing bolts.Fit the heater plugs in position.Fit the cooling system rigid pipe gasket in place. Fit the cooling system rigid pipe in place and tighten the fixing bolts.Fit the EGR heat exchanger in position and tighten the fixing bolts.Fit the EGR heat exchanger pipes in place and renew the fastening bands.Fit the intake manifold metal gasket in position.Fit the intake manifold in place and tighten the fixing nuts.

	Fastening	Component	Ø	Value(daNm)
-	Nut	INLET MANIFOLD	M8	2.5

Fit the rigid EGR pipe in place and tighten the fixing bolts. Fit the power assisted steering pump in place.Fit the pressure pump mounting in place and tighten the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	INJECTION PRESSURE PUMP MOUNT	M8	(Cylinder block/crankcase side) 2.5

Tighten the bolts fixing the power assisted steering pump.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER STEERING PUMP	M8	2.5

Fit the pressure pump in position and tighten the fixing nuts.

	Fastening	Component	Ø	Value(daNm)
-	Nut	PRESSURE PUMP	M8	2.5

Fit the pressure pump pulley in place.Stop the pressure pump pulley from rotating using two bolts. Tighten the nut fixing the pressure pump drive pulley.

	Fastening	Component	Ø	Value(daNm)
-	Nut	PRESSURE PUMP CONTROL PULLEY	M14	5

Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley.1. Loosen the timing pulley fixing bolt.2. Completely fit the timing belt.3. Use a screwdriver for leverage on the tensioner (3a) until the reference (3b) is in the maximum tension position, then lock the moving tensioner fixing nut (3c) in this position. Remove the tools used for setting the timing.Tighten the bolt fixing the front cover removed previously.

	Name	Country
-	Template	1.860.905.000

	Name	Country
-	Calibrated screw	1.860.905.010

	Name	Country
-	Gauge	1.870.986.900

Remove the exhaust camshaft template, as the inlet camshaft has already been removed.

Rotate the crankshaft through two revolutions.4. Check that the timing references are aligned, loosen the nut fixing the moving tensioner and position the moving reference (4a) in line with the opening (4b), i.e. in the nominal tension position, then tighten the nut (4c) fixing the belt tensioner to torque.

	Fastening	Component	Ø	Value(daNm)
4c	Nut	MOBILE TIMING TENSIONER	M8	2.5

Tighten the exhaust side camshaft toothed drive pulley fixing bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	12

Rotate the crankshaft through two revolutions.Check once again that the timing is correct by refitting the timing tools.

Only fit the exhaust camshaft side template because the inlet side one is not accessible.

Check that the tensioning references on the timing belt tensioner are aligned.Tighten the bolt for the crankcase front cover previously removed. Tighten the plug in the camshaft housing for fitting the exhaust side timing tool. Fit the injectors complete with brackets in their housings and tighten the fixing nuts.

Start the refitting beginning the with the injector for cylinder no. 5, continuing with 4, 3, 2, 1.

Fit the rigid fuel pipe on the pump and tighten the connector.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14 x 1.5	(Pump side) 2.3

Fit the fuel vapour recovery tank in place and tighten the fixing bolts, then connect the pipes to the pressure pump and to the injectors.Place the oil vapour recovery tank in position and tighten the fixing bolts.Fit the oil vapour recovery pipes in the housings in the engine oil sump, cylinder head and engine block and renew the fastening bands.Fit the oil level dipstick and tighten the fixing bolts.Fit the rigid pipe for the cooling system in place and tighten the fixing bolts, then connect the pipes renewing the fastening bands.Fit the single fuel pipe in place and tighten the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	INJECTOR FUEL MANIFOLD (DIESEL)	M8	2.5

Fit the new rigid fuel pipes from the single fuel pipe to the injectors and tighten the connectors.

	Fastening	Component	Ø	Value(daNm)
-	Connector	FUEL MANIFOLD LINE TO INJECTORS	M12 x 1.5	(Injector side) 2

	Fastening	Component	Ø	Value(daNm)
-	Connector	FUEL MANIFOLD LINE TO INJECTORS	M12 x 1.5	(Manifold side) 2

Clean the threaded seats for the above-mentioned pipe on the manifold and the injectors using heptane.

Tighten the connector for the rigid fuel pipe for the pressure pump to the single fuel pipe.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14 x 1.5	(Manifold side) 2.3

Fit the rigid pipe and tighten the fixing bolts.Fit the protective timing covers and tighten the fixing bolts.Place the flywheel lock in position.

	Name	Country
-	Counter-torque	1.860.846.001

Fit the crankshsaft pulley in place and tighten the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.5

Fit the single drive belt fixed tensioner in place and tighten the fixing bolt.Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

Fit the engine wiring complete with duct and tighten the fixing bolts.Connect the timing sensor connection.Connect the electrical connections to the injectors.

	Name	Connector
-	Injector	N70A

	Name	Connector
-	Injector	N70B

	Name	Connector
-	Injector	N70C

	Name	Connector
-	Injector	N70D

	Name	Connector
-	Injector	N70E

Connect the electrical connections for the heater plugs.

	Name	Connector
-	Heater plug	A40A

	Name	Connector
-	Heater plug	A40B

	Name	Connector
-	Heater plug	A40C

	Name	Connector
-	Heater plug	A40D

	Name	Connector
-	Heater plug	A40E

Connect the electrical connection to the turbocharging sensor.

	Name	Connector
-	Turbocharging sensor	K82

Connect the electrical connection for the fuel pressure regulator.

	Name	Connector
-	Fuel pressure regulator	N77

Connect the electrical connection to the fuel pressure senor.

	Name	Connector
3	Fuel pressure sensor	K83

Connect the EGR solenoid electrical connection.

	Name	Connector
-	EGR solenoid	L30

Connect the electrical connection for the rpm sensor.

	Name	Connector
-	Rpm sensor	K46

Connect the electrical connection for the engine coolant temperature sensor.

	Name	Connector
-	Engine temperature sender unit	K36