3315350 - 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 (Automatic transmission)
Dismantling
(
Reassembling
)
1. Fit the engine flywheel lock.
| Name | Country |
|---|
| 1 | Flywheel lock | 1.820.228.000 |
1. Undo the nut (1a) and remove the crankshaft pulley (1b).2. Remove the timing drive belt.3. Remove the timing drive belt drive pulley (3a) and the spacer
(3b).4. Undo the bolt (4a) and remove the single drive belt moving tensioner
(4b).
1. Undo the bolts (1a) and remove the alternator mounting bracket
(1b).2. Undo the bolts (2a) and remove the crankshaft front cover (2b),
complete with oil seal.3. Remove the gasket.
1. Remove the element from the crankshaft.2. Undo the blt fixing the chain drive to the oil pump.
1. Remove the oil pump drive chain (1a) using the tool (1b) to extract
it.
| Name | Country |
|---|
| 1b | Flange | 1.960.954.001 |
1. Undo the bolts (1a) and remove the engine oil pump (1b).2. Remove the connector complete with O-Rings.3. Undo the bolts (3a) and remove the engine oil supply connector
(3b) in the crankcase.
1. Undo and remove the engine oil level sensor.
1. Undo the bolts (1a) and remove the engine flywheel (1b).2. Fit the tool for rotating the crankshaft.
| Name | Country |
|---|
| 2 | Flange | 1.820.618.000 |
Remove the engine flywheel lock.
| Name | Country |
|---|
| - | Flywheel lock | 1.820.228.000 |
Rotate the crankshaft until the right connecting
rod caps are accessible.3. Undo the bolts (3a) and remove the right connecting rod caps
(3b) complete with half-bearings (3c).4. Remove the bore/liner locks.
| Name | Country |
|---|
| 4 | Liner/bore holder | 1.820.279.000 |
5. Remove the bores/liners, pistons and connecting rods for the
right side.Repeat the above operations for the left
side.
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 centre main journal
bearing caps (1b) using the tools (1c) and (1d).
| Name | Country |
|---|
| 1c | Connector | 1.865.089.001 |
| Name | Country |
|---|
| 1d | Counter weight | 1.840.206.001 |
2. Remove the half-bearings.
1. Undo the nuts (1a) and remove the rear main journal 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.2. Remove the crankshaft rear oil seal.3. Remove the half-bearings.4. Remove the thrust washers.5. Remove the piston cooling oil jets from the cylinder block/crankcase.
Rotate the engine throughi 180° on the
overhauling stand.1. Undo the bolts (1a) and remove the water pump rigid inlet pipe
(1b), complete with O-Rings.2. Undo the bolt (2a) and remove the rigid pipe support (2b).3. Undo the bolts (3a) and remove the detonation sensors (3b).
1. Undo the bolts (1a) and remove the water pump (1b).2. Remove the gasket.3. Undo the nuts (3a) and remove the timing side rigid engine support
(3b).
Separate the connecting rod - piston assemblies
from the cylinder liners/bores. - 1028H60 piston, pin set - replace
.
- 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 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 the planarity of the cylinder
head support surface is within the recommended values; if this is
not the case, regrind it.
| 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. otherwise replace
the cylinder liners.Check that the ovality of the cylinder
liners/bores is within the recommended values.Fit the main journal caps without the half-bearings. | The main journal caps are numbered
from 1 to 4 starting from the front of the engine. |
1. Tighten the nuts (1a) for the bearing caps to the recommended
torque using an angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Nut | MAIN BEARING CAPS | M12 | (Engine crankcase side) 2.4 ÷ 2.6 + 77? ÷
81? |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
1. Check that the diameter of the bearing seats is within the recommended
values.
| Measurement | | Value |
|---|
| 1 | Main bearing seat diameter (mm) | Category B | 63.663 - 63.669 |
| Category C | 63.669 - 63.676 |
| Classe A | 63.657 - 63.663 |
Check that the crankshaft lubrication ducts
are free from deposits.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 | 59.973 - 59.979 |
| Classe A | 59.961 - 59.967 |
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 |
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.
| Measurement | | Value |
|---|
| - | Inner diameter (mm) | | 20.004 - 20.014 |
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) | Category B | 21.997 - 22.000 |
| Classe A | 21.994 - 21.997 |
Fit the seals in the cylinder liner/bore
and check that the opening between the ends is within the recommended
values; otherwise replace the piston rings.
| Measurement | | Value |
|---|
| - | 1st° ring gap (mm) | | 0.30 - 0.50 |
| Measurement | | Value |
|---|
| - | 2° ring gap (mm) | | 0.30 - 0.50 |
| Measurement | | Value |
|---|
| - | Scraper ring gap (mm) | | 0.20 - 0.50 |
Check that the outer diameter of the pistons
is within the recommended values. if this is not the case, replace the
piston complete with seals and gudgeon pin.
| Measurement | | Value |
|---|
| - | Outer diameter (mm) | Category B | 79.945 - 79.955 |
| Category C | 79.955 - 79.965 |
| Classe A | 79.935 - 79.945 |
Check that the end float between the seals
and the piston ring grooves is within the recommended limits.
| Measurement | | Value |
|---|
| - | End float (mm) | 1° ring | 0.035 - 0.067 |
| 2° seal | 0.035 - 0.067 |
| Measurement | | Value |
|---|
| - | End float (mm) | Oil scraper ring | 0.025 - 0.057 |
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 | 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 |
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) | | 55.511 - 55.524 |
- 1084B18 engine oil pump, removed - check at bench
.
- 1028H60 piston, pin set - replace
.
1. Fit the piston-connecting rod assemblies in the cylinder liners/bores
(1b) using a suitable tool (1c).
1. Fit the timing side rigid engine support (1a) and fix it tightening
the nuts (1b) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Nut | ENGINE MOUNT TIMING SIDE | M8 | Engine crankcase side 1.9 - 2.3 |
2. Fit the water pump (2a), complete with gasket (2b) and fix it
tightening the bolts (2c) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2c | Bolt | COOLANT PUMP | M6 | Engine crankcase side 0.7- 0.9 |
Fit the detonation sensors and fix them
tightening the bolts to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | FLYWHEEL SIDE KNOCK SENSOR | M8 | 1.95 - 2.05 |
Fit the rigid pipe support and fix it using
the bolt.Place the water pump rigid inlet pipe,
complete with O-Rings, back in its housing and fix it using the
bolts.Rotate the engine throughi 180° on the
overhauling stand.Fit the piston cooling oil jets in the
cylinder bloc/crankcase and bevel them.Place the half-bearings back in their housings
in the cylinder block/crankcase.Place the thrust washers back in their
housings. | The lubrication ducts in the thrust
washers are fitted facing the crankshaft shoulder. |
Place the crankshaft back in its housing.Fit the main journal caps complete with
half-bearings. | The main journal caps are numbered
from 1 to 4 starting from the front of the engine. |
1. Tighten the nuts (1a) for the bearing caps to the recommended
torque using an angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Nut | MAIN BEARING CAPS | M12 | (Engine crankcase side) 2.4 ÷ 2.6 + 77? ÷
81? |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
1. Fit the crankshaft rear 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 | 1.821.150.000 |
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 through 180° on the
overhauling stand.Place the cylinder liners/bores, complete
with seals, pistons and connecting rods back in their housings. | The pistons are fitted with the
arrow stamped on the crown facing the front of the engine. |
1. Fit the liner/bore locks and tighten the nuts to a torque of
1.0 - 1.5 daNm.
| Name | Country |
|---|
| 1 | Liner/bore holder | 1.820.279.000 |
2. Measure the projection of the cylinder liners/bores in relation
to the cylinder block/crankcase (2a) plane using the tool (2b) fitted
with a dial gauge (2c) and check that it is within the recommended
limits.
| Measurement | | Value |
|---|
| 2a | Projection from cylinder block surface (mm) | | 0.01 ÷ 0.06 |
| Name | Country |
|---|
| 2b | Dial gauge mounting | 1.825.003.000 |
Rotate the engine through 180° on the
overhauling stand.1. Fit the connecting rod caps (1a), complete with half-bearings
(1b), and fix them tightening the bolts (1c) to the recommended
torque. | The connecting rod caps have the
number of the cylinder to which they belong on one side: when refitting,
this number should be on the same side as the one on the small end. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Bolt | BIG END BEARING CAPS | 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 |
2. Remove the tool for rotating the crankshaft.
| Name | Country |
|---|
| 2 | Flange | 1.820.618.000 |
Fit the engine flywheel lock.
| Name | Country |
|---|
| - | Flywheel lock | 1.820.228.000 |
3. Fit the engine flywheel (3a) and fix it tightening the bolt (3b)
to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3b | Bolt | FLYWHEEL | M12 | Crankshaft side 13.7 - 15.1 |
Fit the engine oil level sensor and tighten
it to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | - | OIL LEVEL DIPSTICK SENSOR | M12 | Crankcase sump side 1.7 - 2.1 |
1. Fit the engine oil supply connector (1a) in the cylinder block/crankcase
and fix it using the bolts (1b).2. Fit the connector complete with O-Rings.3. Fit the oil pump (3a) and fix it tightening the bolts (3b) to
the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3b | Bolt | ENGINE OIL PUMP | M10 | Main journal caps side 3.4 - 4.2 |
Place the oil pump drive chain back in
its housing and fix it tightening the bolt to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | ENGINE OIL PUMP DRIVE CHAIN | M10 | Engine oil pump side 4.3 - 5.3 |
Place the crankshaft element back in its
housing.Remove the flywheel lock.
| Name | Country |
|---|
| - | Flywheel lock | 1.820.228.000 |
1. Fit the crankshaft front cover (1a), complete with gasket (1b),
and fix it tightening the bolts (1c) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Bolt | CRANKSHAFT FRONT COVER | M6 | Engine crankcase side 0.7 - 0.9 |
2. Fit the alternator mounting bracket (2a) and fix it using the
bolts (2b).
1. Fit the crankshaft front oil seal (1a) using the tool (1b).
| Name | Country |
|---|
| 1b | Fitting tool | 1.860.949.000 |
Apply the recommended sealant to the entire
perimeter of the crankcase sump.
| Type | Component | Name | Qty. |
|---|
| - | Sealant | OIL SUMP | LOCTITE 5900 | - |
1. Fitt the crankcase sump (1a) and fix it tightening the bolts
(1b) and the bolt (1c) to the recommended torque. | The oil sump should be fitted
within 15 minutes of applying the sealant in the openings for the crankshaft
rear support otherwise the edge of the sealant must be removed from
the rear bearing cap. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | OIL SUMP | M7 | Engine crankcase side 1.3 - 1.6 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Bolt | OIL SUMP | M7 | Engine block side 0.9 - 1.2 |
2. Fit the timing and rpm sensor (2a) and fix it using the bolts
(2b).3. Fix the electrical wiring for the rpm and timing sensor on the
crankcase sump.
Fit the timing drive pulley complete with
spacer.Rotate the engine through 180° on the
overhauling stand.Remove the bore/liner locks.
| Name | Country |
|---|
| - | Liner/bore holder | 1.820.279.000 |
Fit the new cylinder head gaskets. | 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 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.
Place the cylinder heads back in their
housings.Tighten the nuts for the cylinder heads
(1a) to the recommended torque using the angular tightening tool (1b). | 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 ÷ 240? |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
Fix the electrical connections to the mounting
bracket on the left cylinder head.Fit the complete engine oil dipstick.Fit the engine mounting bracket on the
left cylinder head and fix it using the bolt.Tighten the bolt fixing the right rear
protection to the power unit reaction rod support.Tighten the bolt fixing the left rear protection
to the power unit reaction rod support.Fit the coolant outlet connector from the
right cylinder head and fix it using the bolts.Fit the complete thermostat support.Connect the coolant outlet hose from the
thermostat support to the water pump rigid inlet pipe.Tighten the band fixing the left cylinder
head connecting hose to the thermostat.Tighten the bolts fixing the thermostat
support to the right cylinder head.Fit the fuel manifold pipe, complete with
injectors, and fix it using the bolts.Fit the thermostat, complete with support,
ignition coil and connecting hose, and fix it using the bolts and nuts.Fit the ignition coil mounting brackets
and fix them using the bolts.Fit the ignition coil, complete with high
tension leads, and fix it using the bolts.Tighten the bolt fixing the high tension
lead mounting bracket.Remove the spark plug for cylinder no.
1.1. Fit the tool (1a), complete with dial gauge (1b), in the housing
of the spark plug for cylinder no. 1.
| Name | Country |
|---|
| 1a | Extension | 1.825.013.000 |
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. |
Fit the timing belt moving tensioner and
fix it using the bolts without tightening them.Fit the timing belt and check that the
timing references on the camshafts are aligned.1. Fit the tool (1a) and fix it using the bolt (1b) for the alternator
(having positioned a spacer previously) and the bolt (1c) to the
water pump. | The tool tooth (1d) 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.
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 tensioner
is aligned 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 timing belt tensioner to the recommended
torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3 | Bolt | MOBILE TIMING TENSIONER | M8 | Cylinder head side 1.7 - 2.1 |
Check once again that the timing references
on the camshafts are aligned.Remove the belt tensioner tool.
| Name | Country |
|---|
| - | Belt tensioner | 1.860.950.000 |
Remove the tool for checking top dead centre.
| Name | Country |
|---|
| - | Extension | 1.825.013.000 |
Fit the timing belt moving tensioner and
fix it using the bolt without tightening it.1. Fit the crankshaft lock.
| Name | Country |
|---|
| 1 | Flywheel lock | 1.820.228.000 |
Fit the crankshaft pulley and fix it tightening
the nut to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | CRANKSHAFT PULLEY | M28 | Crankshaft side 20.0 - 24.7 |
Remove the crankshaft lock.1. Fit the spark plug housing gaskets.2. Fit the right side tappet cover (2a), complete with gasket, and
fix it tightening the bolts (2b) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | CAM COVERS | M7 | Cylinder head side 1.0 - 1.3 |
3. Fit the engine mounting bracket (3a) on the right cylinder head
and fit is using the bolt (3b).
Fit the inlet ducts and fix them using
the bolts.Fit the air chamber, complete with oil
vapour separator and pipes, and fix it using the bolts.Connect the vacuum intake pipe for the
fuel pressure regulator to the air chamber.Place the high tension leads back in their
housings and fix them using the brackets.Connect the high tension leads to the right
cylinder head spark plugs.Connect the condensation oil return pipe
to the right cylinder head.Connect the oil vapour recovery pipe to
the tappet cover, right side.Tighten the bands fixing the inlet ducts
to the air chamber.1. Fit the tappet cover, left side (1a), complete with gasket, and
fix it tightening the bolts to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | CAM COVERS | M7 | Cylinder head side 1.0 - 1.3 |
Fit the engine oil dipstick mounting bracket
and fix it using the bolt.Connect the high tension leads to the left
cylinder head spark plugs.Fit left cylinder head spark plugs cover
and fix it using the bolts.Fit the engine oil filler cap.Fit the lower protective timing covers
and fix them using the bolts.Fit the upper protective timing gear cover
and fix it using the bolts.Fit the power assisted steering fluid reservoir
'drip tray'. - 1004D40 engine - position on stand and remove
.
