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

Dismantling ( Reassembling ) 1. Position the flywheel retainer.

NameCountry
1Counter-torque1.860.846.000
2. Undo the fixing bolts (2a) and remove the clutch plate (2b).
1. Fit crankshaft sprocket lock tool (1a) as shown in the figure.

NameCountry
1aCounter-torque1.870.744.000
Work with flywheel retainer 1860846000 fitted.
2. Undo the bolt securing the crankshaft sprocket and remove.
1. Unscrew the bolts securing the flywheel.2. Remove the engine flywheel together with plate (2a) and the flywheel lock positioned previously.
1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).
1. Undo the bolts (1a) and remove the water pump rigid inlet pipe (1b), complete with O-Rings.2. Undo the bolts (2a) and nut (2b) and remove the heat shield (2c).
1. Remove the engine oil filter using a suitable tool.2. Fit the engine oil pressure sender unit.3. Undo the bolts (3a) and remove the crankcase front cover with the built-in oil pump (3b) complete with crankshaft front oil seal (3a) and inlet.4. Remove the gasket from the crankcase front cover.
1. Using the service bolts (1a), fit the tool for rotating the crankshaft.

NameCountry
1aFlange1.860.815.000
Rotate the crankshaft using the tool fitted previously until cylinders no. 1 and no. 4 are at T.D.C 1. Undo the bolts (1a) and remove the connecting rod caps (1b) for cylinders 1 and 4.2. Remove the lower connecting rod half bearings for cylinders no. 1 and no. 4. 3. Remove the connecting rod-piston assemblies for cylinders 1 and 4. 4. Remove the upper connecting rod half bearings for cylinders 1 and 4. Proceed in the same way to remove the pistons and connecting rods for cylinders 2 and 3. Remove the tool for rotating the crankshaft.

NameCountry
-Flange1.860.815.000
1. Check using a dial gauge with a suitable magnetic base that the crankshaft end float is within the recommended values.

MeasurementValue
1End 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 crankcase and use suitable 0.127 mm oversize thrust washers (secured to the central main bearing halves) 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 central main bearing halves incorporate crankshaft thrust half-rings.
Secure and support the engine for hoisting using a hydraulic hoist fitted with suitable chains and remove the crankcase from the brackets; place on a suitable work bench. - 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.
Check the condition of the piston cooling oil sprays.1. If they are blocked, remove the oil sprays (1a) using a steel drift (1b); fit the drift guide hole on the nozzle surface to prevent the drift slipping during removal and damaing the cylinder liner.

NameCountry
1bDrift1.860.395.000
Whenever the oil sprays are removed, they cannot be reused and must be replaced.
Reassembling ( Dismantling ) Wash and check the visible condition of all components removed.Fit the water/oil sealing plugs in the crankcase using suitable tools and sealant.

TypeComponentNameQty.
-SealantCRANK CASE PLUGSLoktite 270-
1. Use tool (1a) and a plastic mallet to fit new oil sprays (1b).

NameCountry
1aFitting tool1.860.313.000
1. Using a calibrated metal rule (1a) and a feeler gauge (1b), check the planarity of the cylinder head - cylinder block/crankcase support surface.2. If the measurement is not as specified, grind the cylinder head support surface.

MeasurementValue
2Flatness of cylinder head supporting surface (mm)< 0.1
1. Measure the cylinder liner diameter and check that it is within the specified values.

MeasurementValue
-Cylinder bore diameter (mm)Category B70.810 - 70.820
Category C70.820 - 70.830
Classe A70.800 - 70.810
Check that the ovality of the cylinder liners is within the recommended values.

MeasurementValue
-Cylinder bore ovalization (mm)± 0.05
Check that the conicity of the cylinder liners/bores is within the recommended values.

MeasurementValue
-Cylinder bore taper (mm)± 0.005
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.

MeasurementValue
-Cylinder liner/bore inner diameter oversize (mm)0.4
Using a compressed air gun, clean the oil ports in the crankshaft. Check the static balance of the crankshaft resting the main journals on suitable parallel bars. Check that the diameter of the main journals is within the recommended values.

MeasurementValue
-Main bearing journal diameter (mm)Category B47.988 - 47.994
Category C47.982 - 47.988
Classe A47.994 - 48.000
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.

MeasurementValue
-Main bearing journal undersize (mm)0.254 - 0.508
Check that the diameter of the crankpins is within the recommended values.

MeasurementValue
-Crankpin diameter (mm)Category B41.995 - 42.001
Category C41.988 - 41.995
Classe A42.001 - 42.008
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.

MeasurementValue
-Crankpin undersize (mm)0.254 / 0.508
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 main half-bearings in the crankcase housing so that the lubrification holes align. Ensure this is carried out in completely clean conditions. The central main bearing halves contain built-in thrust half-rings because they perform a load-bearing/thrust function. If the crankshaft has been reground, fit the new and oversize half-bearings to restore the original tolerance conditions.1. Fit the crankshaft in the special housing in the cylinder block/crankcase. 2. 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).

FasteningComponentØValue(daNm)
1cBoltMAIN BEARING CAPSM10 x 1.252 + 90°

NameCountry
1dProtractor1.860.942.000
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.

MeasurementValue
-Clearance between crankshaft bearings - big end bearings (mm)0.025 - 0.049
After checking all the main journals, refit the main bearing caps complete with bearing shells and tighten the bolts to the specified torque. - 1028H54  piston/cylinder liner - r rThoroughly clean any carbon residues from the piston.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.

MeasurementValue
-Outer diameter (mm)Category B70.770 ÷ 70.780
Category C70.780 ÷ 70.790
Classe A70.760 ÷ 70.770
from lower edge of piston skirt (mm)8.5
Position the piston in the cylinder bore/liner and, using a feeler gauge, measure the recommended clearance.

MeasurementValue
-Clearance between piston - cylinder liner/bore (mm)0.030 ÷ 0.050
Check that the inner diameter of the gudgeon pin housing is within the recommended value; if this is not the case, replace the gudgeon pin with an oversize one.

MeasurementValue
-Gudgeon pin housing diameter (mm)17.982 ÷ 17.986

MeasurementValue
-Gudgeon pin oversizel (mm)0.2
Check that the outer diameter of the gudgeon pins is within the recommended values; if this is not the case, replace the worn parts.

MeasurementValue
-Gudgeon pin external diameter (mm)17.970 ÷ 17.974
Using a micrometer, measure the thickness of the piston seals.

MeasurementValue
-Thickness (mm)1° seal1.170 ÷ 1.190
2° seal1.175 ÷ 1.190
3° seal2.475 - 2.490

MeasurementValue
-Seal oversize (mm)0.4
1. Fit the piston seals (1a) in the cylinder liner/bore and, using a feeler gauge (1b), check that the opening between the ends is within the recommended values. If this is not the case, replace the piston seals.

MeasurementValue
-Opening (mm)1° seal0.200 ÷ 0.400
2° seal0.250 ÷ 0.450
3° seal0.200 ÷ 0.450
1. Using a feeler gauge (1a), check the fitting clearance between the piston rings (1b) and the piston ring grooves (1c).

MeasurementValue
-End float (mm)1° seal0.040 ÷ 0.080
2° seal0.020 ÷ 0.055
3° seal0.020 ÷ 0.055
Check that the diameter of the connecting rod big end and the small end correspond to the recommended values.

MeasurementValue
-Big end diameter (mm)45.128 ÷ 45.138

MeasurementValue
-Small end diameter (mm)17.939 ÷ 17.956
 - 1028H60  piston, pin set - replace - 1028H54  piston/cylinder liner - r r - 1084B18  engine oil pump, removed - check at benchPosition the tool for rotating the crankshaft.

NameCountry
-Flange1.860.815.000
Rotate the crankshaft using the tool fitted previously.The connecting rod-piston assemblies are fitted with the references in the following positions.1. Piston grade and arrow indicating the timing side.2. Area where number of cylinder bore/liner to which the connecting rod belongs is stamped.3. Connecting rod pin offset.
1. Fit the connecting rod-piston assemblies (1a), complete with half-bearings, using the tool (1b) for compressing the piston rings and later introducing the piston in the liner/bore.

NameCountry
1bFitting tool1.860.700.000
Rotate the engine on the overhauling stand.1. Apply calibrated wire (plastigage) to measure crankpin backlash.
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).

FasteningComponentØValue(daNm)
1cBoltCONNECTING ROD CAP FASTENERSM8 x 14.1
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.

MeasurementValue
-Clearance between big end bearings-Crankpins (mm)0.024 - 0.062
If the value measured does not correspond to the recommended figures, replace the connecting rod bearings.Fit the connecting rod caps complete with half bearings and tighten the bolts to the specified torque. Remove the tool for rotating the crankshaft.

NameCountry
-Flange1.860.815.000
1. Position a new oil pump gasket.2. Fit the crankcase front cover (2a) with built-in oil pump, complete with inlet, and tighten the bolts (2b) to the recommended torque.

FasteningComponentØValue(daNm)
2bBoltENGINE OIL PUMPM6 x 11
3. Fit the oil filter.4. Fit the engine oil pressure sender unit and tighten to the specified torque.

FasteningComponentØValue(daNm)
4-OIL PRESSURE W/LM14 x 1.53.2
1. Fit a new crankshaft front cover oil seal (1a) using the tool (1b).

NameCountry
1bFitting tool1.860.903.000
1. Fit crankcase rear cover (1b) and secure by tightening bolts (1a) to the specified torque.

FasteningComponentØValue(daNm)
1aBoltFLYWHEEL SIDE COVERM6 x 11
1. Fit the crankshaft rear oil seal (1a) using the tools (1b) and (1c).

NameCountry
1bGrip1.860.879.000

NameCountry
1cFitting tool1.860.881.000
1. Fit the flywheel lock.

NameCountry
1Counter-torque1.860.846.000
2. Fit the flywheel (2a), complete with retaining shim (2b) and fix it tightening the bolts (2c) to the recommended torque.

FasteningComponentØValue(daNm)
-BoltFLYWHEELM8 x 1.254.4
1. Fit the crankshaft rear oil seal (1a) using the tools (1b) and (1c).

NameCountry
1bGrip1.860.879.000

NameCountry
1cFitting tool1.860.881.000
1. Fit the flywheel lock.

NameCountry
1Counter-torque1.860.846.000
2. Fit the flywheel (2a), complete with retaining shim (2b) and fix it tightening the bolts (2c) to the recommended torque.

FasteningComponentØValue(daNm)
2cBoltFLYWHEELM8 x 1.254.4
1. Line up the driven plate for fitting the clutch assembly (1a), using the centring pin (1b).

NameCountry
1bClutch centering1.870.418.000
2. Tighten the bolts fixing the clutch to the engine flywheel.Remove the engine flywheel lock applied previously.
Rotate the engine on the overhauling stand.Clean the crankcase and oil sump contact surfaces to remove traces of silicone sealant.1. Apply an unbroken bead 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.

TypeComponentNameQty.
1SealantCRANK CASE PLUGSLoktite 270-
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.

FasteningComponentØValue(daNm)
2bBoltOIL SUMPM61

FasteningComponentØValue(daNm)
2cNutOIL SUMPM60.7
Rotate the engine on the overhauling stand.Fit the centring pins on the crankcase.Position the cylinder head gasket with the wording 'ALTO' [TOP] facing you. Take care not to contaminate or lubricate the gasket and crankcase surface.
ASTADUR type cylinder head gaskets are fitted. These gaskets are made from a special material designed to undergo polymerization during the use of the engine. This means that they harden considerably during use.

In order for the polymerization process to take place it is necessary:

  • to keep the gasket in its sealed plastic bag;
  • not to take out of its container until ready to fit;
  • not to lubricate the gasket or contaminate with oil, and to ensure the crankcase and cylinder head surfaces are clean.
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.

FasteningComponentØValue(daNm)
1aBoltCYLINDER HEADM9 x 1.253 + 90° + 90°

NameCountry
1bProtractor1.860.942.000
Fit the tappet cover, complete with seal, and fix it tightening the bolts to torque.

FasteningComponentØValue(daNm)
-BoltCAM COVERM6 x 11
Then adjust the engine as follows:Then adjust the engine as follows:1. Turn the toothed timing driven pulley so that the timing notches are aligned.2. Rotate the toothed drive pulley so that the timing notches are aligned. 3. Fit the timing belt.
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 65 mm away on the millimetric rod. The millimetric rod should be placed in a horizontal position acting on the tool joint.

NameCountry
1aBelt tensioner1.860.745.300

NameCountry
1aBelt tensioner1.860.745.100
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.

FasteningComponentØValue(daNm)
2NutMOBILE TIMING TENSIONERM8 x 1.252.8
Refit the lower shield and the upper shield for the timing drive belt. Fit the auxiliary shaft drive pulley on the crankshaft and tighten the fixing bolts to the recommended torque.

FasteningComponentØValue(daNm)
-BoltCRANKSHAFT PULLEYM8 x 1.252.2
Fit the rpm and TDC sensor and fix it with its bolts.Fit the engine oil dipstick.Refit the inlet manifold complete with injectors and throttle body.Fit the injection lead support bracket.Position the electrical wiring and connect the electrical connections.

NameConnector
-Throttle position sensor K56

NameConnector
-Idle actuator N74

NameConnector
-Fuel vapour recovery solenoid L10

NameConnector
-Engine coolant temperature sensor/sender unit K36

NameConnector
-Injector N70

NameConnector
-Battery earth on engine C2

NameConnector
-Detonation sensor K50

NameConnector
-Engine oil pressure sensor K28

NameConnector
-Integrated air temperature sensor K43

NameConnector
-Rpm sensor K46
Position the part of the wiring concerned in the duct. - 1004D40  engine - position on stand and remove