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 - GT - eLearn

125000871 - 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

Removing ( Refitting

) 1. Release the water pump rigid inlet pipe and remove it.

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

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

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

1. Undo the nuts (1a) and remove the air conditioning compressor mounting (1b).2. Undo the bolt (2a) and remove the engine components single belt moving tensioner (2b).

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.779.000

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

Rotate the engine through 180° on the overhaul stand.1. Undo the bolt fixing the engine oil pump drive chain to the oil pump.2. Move the engine oil pump drive chain (2a) away from the pump using the tool (2b).

	Description	Code
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 engine block front cover (2b).Remove the crankshaft front oil seal from the crankcase front cover.3. Remove the seal.

1. Remove the engine oil pump drive chain.2. Undo the bolt (2a) and remove the engine oil supply connector (2b) in the crankcase.

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

The bolts fixing the flywheel have been treated with a special agent; therefore they should be replaced each time they are removed.

2. Remove the flywheel lock.

	Description	Code
2	Counter-torque	1.860.779.000

1. Fit the tool for rotating the crankshaft.

	Description	Code
1	Flange	1.820.618.000

Rotate the crankshaft so that the right bearing cap bolts are accessible.2. Undo the bolts (2a) and remove the bearing caps (2b) on the right side.3. Remove the crankpin half-bearings.

Rotate the engine through 180° on the overhaul stand.1. Remove the cylinder liner/bore lock tools from the right side.

	Description	Code
1	Cylinder bore lock	1.820.279.000

2. Remove the cylinder liner/bore (2), piston and connecting rod assemblies (2b) for the right side.Separate the connecting rod-piston assemblies from the cylinder liners/bores.3. Remove the crankpin half-bearings.Carry out the same operations for the removal of the cylinder liner/bore, piston and connecting rod assemblies for the left side.

Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.820.618.000

Rotate the engine through 180° on the overhaul stand.Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

	Measurement		Value
-	End float (mm)		0.080 ÷ 0.265

1. Undo the nuts (1a) and remove the front and centre crankshaft bearings.2. Remove the main journal half-bearings.

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

	Description	Code
1c	Lever	1.821.006.001

	Description	Code
1d	Extractor	1.821.006.002

2. Remove the main journal half-bearing.

1. Remove the crankshaft rear oil seal

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

Proceed with the removal Op. 1028H60 PISTON, PIN SET - REPLACE.Proceed with the removal Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH.Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

Refitting ( Removing

) Wash all the dismantled components thoroughly.Clean any residues of sealant from the matching surfaces for the engine oil sump and the rear bearing cap with the engine block.Place the crankcase water/oil sealing plugs back in their housings using suitable fitting tools.Lubricate all the mechanical components with engine oil.Check that the planarity of the cylinder head support surface corresponds to the recommended figure; if this is not the case, regrind the cylinder head support surface.

	Measurement		Value
-	Cylinder head support surface flatness (mm)		< 0.1

Remove the seals from the cylinder liners/bores.Check that the internal diameter of the cylinder liners/bores is within the recommended limits; if not, replace them.

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

Check that the ovality of the cylinder liners/bores is within the recommended limits; if not, replace them.

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

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

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

The nitriding treatment that the crankshaft has undergone means that no regrinding operations can be carried out.

Check that the crank pin diameter is within the recommended limits; if not, replace the crankshaft.

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

The nitriding treatment that the crankshaft has undergone means that no regrinding operations can be carried out.

Check that the small end bush internal diameter is within the recommended limits; if not, replace the connecting rod assemblies.

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

Check the matching between the gudgeon pin and the piston housing: it should be possible to insert the gudgeon pin by applying gentle pressure and it should not slip out.Check that the outer diameter of the gudgeon pins is within the recommended limits; if not, replace the worn gudgeon pins.

	Measurement		Value
-	Piston pin outer diameter (mm)		19.996 ÷ 22.000

Fit the piston rings in the cylinder bore and check that the opening between the ends is within the recommended values; if this is not the case, replace the circlips.

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

	Measurement		Value
-	Piston oil scraper ring gap (mm)	Oil scaper 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 corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin.

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

Measure perpendicular to the gudgeon pin axis, 13.1 mm from the lower edge of the skirt.

Check that the endfloat between the seals and the housings in the piston is within the recommended values; if this is not the case, replace the seals.

	Measurement		Value
-	Seal endfloat (mm)	1st Ring	0.035 ÷ 0.070
2nd ring	0.030 ÷ 0.075

	Measurement		Value
-	Oil scraper ring endfloat (mm)	Oil scaper 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 the refitting Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH.Proceed with the refitting Op. 1028H60 PISTON, PIN SET - REPLACE.Check that the half-bearings show no signs of grooves or traces of seizing; if this is not the case, they must be replaced.

No adjustment operations whatsoever should be carried out to the half-bearings.

Place the half-bearings in their seats in the engine block.

The half-bearings and the main journals should be matched so that parts of the same grade are used (same distinctive colour).

Great care should be taken over cleanliness when refitting.

1. Place the crankshaft in its housing.2. Fit the calibrated wire (plastigage) for measuring the bearing 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.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should be on the same side.

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

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

	Description	Code
2	Torque wrench	1.860.942.000

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.

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

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

Place the half-bearings in their seats.Place the thrust washers (with the size depending on the crankshaft endfloat measured during the dismantling) in their housings in the rear bearing support.

The thrust washer lubrication ducts should be facing the crankshaft thrust washers.

Place the crankshaft in its housing.1. Place the bearing caps (1a), complete with half-bearing, back in their housings and secure them tightening the nuts (1b) to the recommended torque.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should 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 the angular tightening of the bearing cap bolts.

	Description	Code
2	Torque wrench	1.860.942.000

1. Fit the crankshaft rear oil seal (1a) using the tool (1b).

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

	Description	Code
1b	Fitting tool	1.821.250.000

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

	Type	Component	Description	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 sealing the rear bearing support. If this is not the case, remove the excess sealant.

Rotate the engine through 180° on the overhaul stand.Fit new seals in the housings in the cylinder liners/bores.1. Fit the cylinder liners/bores (1a) in their housings complete with seals (1b).2. Fit the cylinder liner/bore lock tools (2a) and tighten the nuts to the recommended torque.

	Description	Code
2a	Cylinder bore lock	1.820.279.000

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

1. Measure the projection of the cylinder liners/bores in relation to the cylinder block/crankcase (1a) plane using the tool (1b) fitted with a dial gauge (1c) and check that it corresponds to the recommended values.

	Measurement		Value
1a	Cylinder liner/bore projection in relation to the cylinder block/crankcase (mm)		0.01 ÷ 0.06

	Description	Code
1b	Dial gauge support	1.825.003.000

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

The piston-connecting rod assemblies are fitted with the arrows stamped on the piston crowns facing the timing side and the reference on the connecting rods facing the timing side for the right side and the flywheel side for the left side.

Rotate the engine through 180° on the overhaul stand.Fit the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.820.618.000

Rotate the crankshaft so that the connecting rod pins are accessible.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Place the bearing cap (1a) in its seat complete with half-bearings (1b) and secure it by tightening the bolts (1c) to the recommended torque.

The references on the connecting rod cap and the big end should be on the same side.

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

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

	Description	Code
-	Torque wrench	1.860.942.000

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Carry out the operation of measuring the clearance for all the bearings, taking care to do it, one at a time.

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

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

Rotate the crankshaft so that the connecting rod pins are accessible.1. Place the bearing caps (1a) in their seats complete with half-bearings (1b) and secure them by tightening the bolts (1c) to the recommended torque.

The references on the connecting rod cap and the big end should be on the same side.

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

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

	Description	Code
-	Torque wrench	1.860.942.000

Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.820.618.000

Fit the engine oil supply connector in the crankcase and secure it using the bolt.1. Position the engine oil pump (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE OIL PUMP	M10	(Main bearing caps side) 4.5 - 5.5

1. Position the engine oil pump drive chain (1a) in its housing and secure it without tightening the bolt (1b) to the recommended torque.

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	FRONT COVER CRANKSHAFT	M6	(Engine crankcase side) 0.8 - 1.0

1. Fit the crankshaft front oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.949.000

Place the key in the housing in the crankshaft.Place the toothed drive pulley in its housing.1. Position the engine components single belt moving tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	SINGLE BELT MOVING TENSIONER VARIOUS	-	(Engine crankcase side) 2.7 - 3.3

2. Place the air conditining compressor mounting (2a) in its housing and secure it by 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) in their housings and secure them tightening 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. Position the water pump (1a), complete with gasket (1b), in its housing and secure it tightening 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. Position the water pump cover (1a), complete with gasket (1b) and bracket (1c), in its housing and secure it tightening the bolts (1d) to the recommended torque.

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

Place the water pump rigid coolant inlet pipe complete with seals in its housing.1. Carry out the initial timing of the camshafts. apply a wrench into seat (1a) in the centre of the camshafts and turn to align reference marks (b) on the shafts with the upper cylinder head surface.

The reference marks must face the middle of each cylinder head.

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

1. Repalce the removed camshaft caps with the timing templates.

	Description	Code
1	Templates	1.870.849.000

Remove the liner/bore locks.

	Description	Code
-	Cylinder bore lock	1.820.279.000

Place the cylinder head centering bushes on the cylinder block.1. Fit 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 these gaskets are made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage.In order for the polymerization process to take place, it is necessary to:keep the gaskets sealed in their casings until fitting;not lubricate the gasket or the contact surfaces with oil.

Set the 1st cylinder to TDC before fitting the cylinder heads on the engine block.Position the cylinder heads on the cylinder block/crankcase.1. Tighten nuts (1a) securing the cylinder heads to the specified torque using tools (1b) and (1c) for angular tightening.

Lubricate threads, nuts and washers with engine oil.

Follow the order shown in the figure for each tightening sequence. The right cylinder head is illustrated; 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?

	Description	Code
1b	Torque wrench	1.860.942.000

	Description	Code
1c	Spanner	1.822.121.000

Place the alternator bracket in its housing and secure it using the bolts.Fit the rear timing belt covers and secure them using the bolts.1. Place the fixed timing tensioners (1a) 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. Refit toothed driven pulleys (2a) and secure by screwing in bolts (2b) without tightening.

Tighten the bolt securing the left rear cover protecting the right cylinder head timing drivebelt.1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code
1a	Fitting tool	1.821.225.000

Rotate the crankshaft through small rotations (in both directions) until the piston for the right head timing side cylinder no. 1 is at T.D.C. in the combustion stroke.

Take care that the last rotation of the crankshaft 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 branches are properly taut.

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

The tooth for the tool should engage with the moving part of the mobile timing belt tensioner.

	Description	Code
1a	Belt tensioner	1.860.950.000

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

1. Tighten bolts (1a) for the right head toothed driven pullies to the specified torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING DRIVEN PULLIES	M12	(camshaft side) 7.2 - 8.8

	Description	Code
1b	Counter-torque	1.822.146.000

Remove the tools for timing the camshafts.

	Description	Code
-	Templates	1.870.849.000

Place the camshaft caps in their housings to replace the removed tools and secure them tightening 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 toothed timing belt to bed in.1. Check that the moving reference for the timing belt tensioner coincides with the fixed reference.2. If the references are not aligned, gently release the tensioner tension acting on the nut for the tensioning tool until the reference coincide.3. Tighten the nut fixing the moving timing 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.

	Description	Code
-	Belt tensioner	1.860.950.000

Rotate the engine through 180° on the overhaul stand.1. Place the flywheel in position and secure it without tightening the bolts.

The engine flywheel can only be fitted in one position because the openings for the fixing bolts are not equidistant.

2. Fit the flywheel lock.

	Description	Code
2	Counter-torque	1.860.779.000

3. Tighten the bolts securing the engine flywheel to the recommended torque.

The bolts fixing the flywheel have been treated with a special agent; therefore they should be replaced each time they are removed.

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

Use the tool for the angular tightening of the flywheel fixing bolts.

	Description	Code
-	Torque wrench	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. Position the crankshaft pulley (2a) in its housing and secure it tightening the nuts (2b) to the recommended torque.

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

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.779.000

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

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

1. Position the crankcase sump (1a) in its housing and secure 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

Place the rpm sensor complete with mounting in its housing.Place the rpm sensor guard in its housing and secure it using the bolts.1. Position the engine components single belt fixed tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

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

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

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

1. Tighten the bolt securing the power steering pump to the recommended torque.

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

2. Refit bracket (2a) and secure with bolt (2b) and bolts (2c).

Fit the lower timing belt covers and secure them using the bolts.Fit the upper timing belt covers and secure them using the bolts.Connect the rapid connector for the fuel manifold pipes.1. Replace the left cylinder head ignition coils (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

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

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

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

Refit the wiring and connections in the eletrical connection holder case, then close the cover.Connect the electrical connection to the water temperature sensor.1. Replace the right cylinder head ignition coils (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

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

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

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

Refit the electrical wiring conduit and secure with bolts.Connect the electrical connections to the right cylinder head ignition coils.Connect the electrical connections to the right cylinder head injectors.1. Refit the intake ducts (1a) wiht sleeves (1b) and gaskets (1c) and tighten bolts (1d) to the specified torque.

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

Fit the air capacity chamber and secure it using the bolts.Tighten the bolt securing the stiffening rod to the reaction link mount on the engine.Connect the earth lead to the air capacity chamber and secure with the bolt.Connect the electrical connection to the throttle casing with D.V.L.Tighten the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.Tighten the bands securing the intake manifolds to the air chamber.Connect the electrical connection for the timing side knock sensor.Close the electrical connection holder casing.Proceed with the refitting Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.