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 - Fiat - PANDA - eLearn

2753368 - 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 engine on the overhauling stand.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.000

2. Undo the bolt (2a) and remove the timing drive pulley (2b).

Rotate the engine on the overhauling stand.1. Undo the bolts (1a) and remove the safety plate (1b) and the engine flywheel (1c).2. Remove the flywheel lock.

	Name	Country
2	Counter-torque	1.860.846.000

Rotate the engine on the overhauling stand.1. Undo the bolt (1a) and remove the alternator drive belt tensioner (1b).2. Remove the alternator drive belt.

1. Undo the front alternator fixing bolts.2. Undo the rear alternator mounting bracket fixing bolts.3. Remove the alternator

1. Undo the bolts (1a) and remove the rod (1b) connecting the air conditioning compressor to the cylinder block/crankcase.2. Undo the bolts (2a) and remove the air conditioning compressor (2b).

1. Undo the bolts (1a) and remove the air conditioning compressor and alternator mounting (1b).

1. Undo the bolt (1a) and remove the rigid water pump inlet pipe (1b) complete with O-Ring.2. Undo the bolts (2a) and the nut (2b) and remove the water pump (2c).

1. Remove the engine oil filter using a suitable tool.2. Undo the bolts (2a) and remove the crankcase front cover with the built-in oil pump (2b) complete with crankshaft front oil seal (2c) and inlet (2d).3. Remove the gasket from the crankcase front cover.

1. Undo the bolts (1a) and remove the crankcase rear cover (1b) complete with crankshaft rear oil seal (1c) and gasket (1d).2. Fit the tool for rotating the crankshaft.

	Name	Country
2	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously until cylinders no. 2 and no. 3 are at T.D.C1. Undo the bolts (1a) and remove the connecting rod caps (1b) for cylinders 2 and 3.2. Remove the lower connecting rod half bearings for cylinders no. 2 and no. 3.3. Remove the connecting rod-piston assemblies for cylinders 2 and 3.4. Remove the upper connecting rod half bearings for cylinders 2 and 3.Proceed in the same way to remove the pistons and connecting rods for cylinders 1 and 4.Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

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

	Measurement		Value
1	End float (mm)		0.055 ÷ 0.265

If the end float of the crankshaft is not within the recommended values, when refitting, reface the seats 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.

The centre main journal half-bearing has all the crankshaft thrust washers fitted on it.

Secure the cylinder block/crankcase using a hydraulic hoist fitted with suitable chains.1. Undo the bolts (1a) fixing the tool (1b) to the cylinder block/crankcase.

	Name	Country
1b	Bracket	1.861.001.034

2. Remove the engine flywheel protection.

1. Undo the nuts (1a) and the bolt (1b) fixing the timing side engine support (1c) to the cylinder block/crankcase.Position the engine block on a special workbench using the hydraulic hoist.

- 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at bench1. Remove the crankcase coolant chamber caps using a suitable steel drift.2. Remove the lubrication port plug from the crankcase using a steel drift.

Reassembling ( Dismantling

) Wash and check the visible condition of all components removed.1. Apply sealant to the lubrication duct plug (1a) and fit it in the cylinder block/crankcase using the tool (1b).

	Name	Country
1b	Fitting tool	1.886.014.000

Apply sealant to the coolant chamber plugs and fit them in the crankcase using suitable fitting tools.Check that the planarity of the cylinder head support surface is within the recommended values; if this is not the case, regrind the cylinder head support surface.

	Measurement		Value
-	Flatness of cylinder head supporting surface (mm)		< 0.1

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

	Measurement		Value
-	Cylinder bore diameter (mm)	Class A	70.000 - 70.010
Class B	70.010 - 70.020
Class C	70.020 - 70.030

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, taper or ovality of the cylinder liners is not within the recommended values, ream the cylinder liners 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)		0.4

Check that the diameter of the main journals is within the recommended values.

	Measurement		Value
-	Main bearing journal diameter (mm)	Class A	43.994 - 44.000
Class B	43.998 - 43.994
Class C	43.982 - 43.988

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

The shaft has undergone a nitriding treatment; therefore if it needs regrinding it should undergo the nitriding treatment again and the dimensions should then be checked.

	Measurement		Value
-	Main bearing journal undersize (mm)		0.254 - 0.508

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

	Measurement		Value
-	Crankpin diameter (mm)		37.990 - 38.008

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

The shaft has undergone a nitriding treatment; therefore if it needs regrinding it should undergo the nitriding treatment again and the dimensions should then be checked.

	Measurement		Value
-	Crankpin undersize (mm)		0.254 - 0.508

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

	Measurement		Value
-	Outer diameter (mm)		17.970 - 17.974

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)	Class A	69.960 - 69.970
Class B	69.970 - 69.980
Class C	69.980 - 69.990

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

	Measurement		Value
1	End float (mm)	1° ring	0.040 - 0.080
2° seal	0.020 - 0.055
Oil scraper ring	0.020 - 0.055

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

If necessary, reface the ends of the piston rings because they are supplied as oversize from the Parts Dept.

	Measurement		Value
-	Gap (mm)	1° ring	0.25 - 0.45
2° seal	0.25 - 0.45
Oil scraper ring	0.20 - 0.45

Lubricate all the components for the mechanical couplings using engine oil. - 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at bench1. Fit the timing side rigid engine support (1a) on the crankcase and secure it tightening the nuts (1b) and the bolt (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ENGINE MOUNT TIMING SIDE	M8	(Crankcase) 2.5

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ENGINE MOUNT TIMING SIDE	M10	(Crankcase) 5.9

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Crankcase) 5.9

Secure the engine block using a hydraulic hoist fitted with suitable chains.Place the engine flywheel guard in position, then place the crankcase on the overhaul stand fitted with mounting brackets.

	Name	Country
-	Bracket	1.861.001.032

	Name	Country
-	Bracket	1.861.001.034

1. Fit the upper main bearing halves.

The centre main journal half-bearing has the crankshaft thrust washers fitted on it.

2. Fit the crankshaft.

1. Fit the calibrated wire (Plastigage) to measure the main journal clearance.

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

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	MAIN BEARING CAPS	M10	(Crankcase) 4 + 90°

	Name	Country
1d	Protractor	1.860.942.000

1. Remove the main bearing caps and measure journal backlash by checking calibrated wire width using a graduated measuring device.

Check one pin at a time without turning the crankshaft.

Fit the connecting rod caps complete with half bearings and tighten the bolts to the specified torque.Rotate the cylinder block/crankcase on the overhaul stand.1. Fit the tool for rotating the crankshaft.

	Name	Country
1	Flange	1.860.815.000

Rotate the crankshaft until cylinders no. 1 and no. 4 are at B.D.C.The connecting rod-piston assemblies are fitted with the references in the following positions.1. Rotation arrow stamped on the piston crown (seen from the timing side).2. Number of cylinder to which it belongs3. Gudgeon pin offset

1. Fit the connecting rod-piston assemblies (1a), complete with half-bearings, using the tool (1b).

Rotate the engine on the overhauling stand.1. Fit the calibrated wire (Plastigage) to measure the big end bearing clearance.

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

The 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)
1c	Bolt	BIG END BEARING CAPS	M8	(Big end) 4.1

1. Remove the main bearing caps and measure journal backlash by recording calibrated wire width using a graduated measuring device.

Check the one connecting rod pin at a time without rotating the crankshaft.

Fit the connecting rod caps complete with half bearings and tighten the bolts to the specified torque.Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

1. Fit the rear crankcase cover (1a), complete with gasket, and fasten t tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FLYWHEEL SIDE COVER	M6	(Crankcase) 1.0

1. Fit the crankshaft rear oil seal (1a) using the tools (1b) and (1c).

	Name	Country
1b	Grip	1.860.879.000

	Name	Country
1c	Fitting tool	1.860.881.000

1. Fit the crankcase front cover (1a) complete with intake (1b) and gasket and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CRANKSHAFT FRONT COVER	M6	(Crankcase) 1

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

	Name	Country
1d	Fitting tool	1.860.903.000

Fit a new engine oil filter and tighten it fully by hand.Apply the recommended sealant to the entire perimeter in an unbroken strip.

Ensure a perfect join between start and end section.

	Type	Component	Name	Qty.
-	Silicon sealant	COOLANT PUMP	-	-

1. Fit water pump (1a) and fix it tightening the bolts (1b) and nut (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	COOLANT PUMP	M6	(Crankcase) 0.8

	Fastening	Component	Ø	Value(daNm)
1c	Nut	COOLANT PUMP	M6	(Crankcase) 0.8

2. Fit the water pump rigid inlet pipe (2a) with o-ring and tighten the bolt (2b).

1. Fit the air conditioning compressor and alternator mounting (1a) and secure it using the bolts (1b).

1. Fit the air conditioning compressor (1a) and secure it using the bolts (1b).2. Fit the rod (2a) connecting the air conditioning compressor to the cylinder block/crankcase and secure it using the bolts (2b).

1. Fit the alternator (1a) and fasten it with the rear mounting bracket (1b). 2. Tighten the front bolts fixing the alternator to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	ALTERNATOR ASSEMBLY	M10	(Crankcase) 6.0

Fit the alternator drive belt.Fit the alternator drive belt and secure it using the bolt. Tension the alternator drive belt ( - 1092B64 alternator drive belt - adjust tension ). Rotate the engine on the overhauling stand.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.000

2. Fit the flywheel (2a), complete with retaining shim (2b) and fix it tightening the bolts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	FLYWHEEL	M8	(Flywheel) 4.4

Rotate the engine on the overhauling stand.1. Fit the timing drive pulley (1a) and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	TOOTHED DRIVE PULLEY	M10	(Engine) 8.0

2. Remove the flywheel lock.

	Name	Country
2	Counter-torque	1.860.846.000

Rotate the engine on the overhaul stand.1. Apply an unbroken strip of the recommended sealant to the entire perimeter of the crankcase sump as shown in the figure.

Ensure a perfect join between start and end section.

	Type	Component	Name	Qty.
-	Silicon sealant	PISTON SET	LOCTITE 5900	-

2. Refit crankcase sump (2a) and secure by tightening bolts (2b) and nuts (2c) to the specified torque.

When fitting the crankcase sump, avoid major sideways movements which may remove the sealant.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	OIL SUMP	M6	(Oil sump) 0.8

	Fastening	Component	Ø	Value(daNm)
2c	Nut	OIL SUMP	M6	(Oil sump) 0.8

Fit the cylinder head centering dowels.

Wait at least 1 hour after fitting the engine block sump before replenishing it with engine oil.

Fit the cylinder head gasket.

The cylinder head gasket is fitted with the word 'ALTO' facing the operator.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 fittingnot lubricate or get oil on the gasket and the contact surfaces.- Position the cylinder head on the cylinder block/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 EXTENSION	M9	Cylinder head) 3 + 90° + 90°

	Name	Country
1b	Protractor	1.860.942.000

Fit the tappet cover, complete with seal, and fix it tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAM COVER	M6	(Cylinder head) 0.8

Fit the support complete with ignition coils and high tension leads and secure it using the nuts.Connect the high tension leads to the spark plugs and secure them to the fastening bands.1. fit the intake manifold (1a) complete with injector turret (1b) and secure it tightening the nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Nut	INLET MANIFOLD	M8	(Inlet manifold) 2.7

1. Fit the exhaust manifold gasket.2. Fit the exhaust manifold (2a) complete with air duct (2b) and engine mounting bracket (2c) and secure it tightening the nuts (2d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1d	Nut	EXHAUST MANIFOLD/S	M8	(Exhaust manifold) 2.7

1. Turn the toothed timing driven pulley so that the timing notches are aligned.2. Rotate the toothed drive pulley shaft so that the timing notches are aligned.3. Fit the timing belt.

The timing belt should be fitted with the arrows pointing in the direction of rotation of the engine.

1. Fit the tools (1a) and (1b) on the timing belt moving tensioner.

The weight for the tool (1b) should have the knurled part removed and should be positioned 80 mm away on the millimetric rod.The millimetric rod should be placed in a horizontal position acting on the tool joint.

	Name	Country
1a	Belt tensioner	1.860.745.200

	Name	Country
1b	Belt tensioner	1.860.745.100

Let the timing belt bed in by rotating the crankshaft through two revolutions in its direction of rotation.

During this stage the millimetric rod may move away from the horizontal position; if this is the case, adjust the joint on the tool and repeat the operation.

2. Tighten the nut fixing the timing belt moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8	(Tensioner) 2.8

Fit the timing belt protective covers and fix them using the bolts.Fasten the rpm sensor electrical cable to the fastenings on the timing belt protective covers.Fit the pipe mounting bracket and secure it using the bolt.Fit the engine oil dipstick.1. Fit the crankshaft pulley (1a) and secure it without tightening the bolts (1b).2. Fit the air conditioning compressor drive belt moving tensioner (2a) and secure it using the bolt (2b).3. Fit the air conditioning compressor drive belt. Tension the air conditioning compressor drive belt ( ).

Tighten the crankshaft pulley bolts.Fit the rpm and T.D.C. sensor and fasten it using the bolt.

	Name	Connector
-	Rpm sensor	K46

Refill the engine with the recommended oil.

	Type	Component	Name	Qty.
-	Oil	ENGINE OIL LEVEL CHECK AND TOP-UP	VS MAX	4.0

- 1004D40 engine - position on stand and remove