184000792 - 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. Position the flywheel retainer.

	Name	Country
1	Counter-torque	1.860.846.000

2. Undo the fixing bolts (2a) and remove the clutch plate (2b). 1. Fit the crankshaft gear locking tool as illustrated in the figure.

	Name	Country
1	Counter-torque	1.870.763.000

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 (2a) together with plate (2a) and 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 (1b) for rotating the crankshaft.

	Name	Country
1b	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously until cylinders no. 1 and no. 4 are at T.D.C1. 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.

	Name	Country
-	Flange	1.860.815.000

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

	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 seat in the cylinder block/crankcase and use a centre half-bearing which incorporates suitable oversize crankshaft thrust washers.1. Undo bolts (1a) and (1b) and remove the lower crankcase, which also acts as the main bearing caps.2. Remove the lower main journal half-bearings.3. Remove the crankshaft4. Remove the upper main journal half-bearings 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.    Op. 1028H60 PISTON, PIN SET - REPLACE    Op. 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.

	Name	Country
1b	Drift	1.860.395.000

Whenever the oil sprays are removed, they cannot be reused and must be replaced.

Refitting ( Removing ) Wash and check the visible condition of all components removed.Fit the water/oil sealing plugs in the crankcase using suitable tools and sealant.

	Type	Component	Name	Qty.
-	Sealant	CRANK CASE PLUGS	Loktite 270	-

1. Use tool (1a) and a plastic mallet to fit new oil sprays (1b).

	Name	Country
1a	Fitting tool	1.860.313.000

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.

	Measurement		Value
2	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)	Category B	72.010 ÷ 72.020
Category C	72.020 ÷ 72.030
Class A	72.000 ÷ 72.010

Check that the ovality of the cylinder liners is within the recommended values.

	Measurement		Value
-	Cylinder bore ovalization (mm)		± 0.05

Check that the conicity of the cylinder liners/bores is within the recommended values.

	Measurement		Value
-	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.

	Measurement		Value
-	Cylinder liner/bore inner diameter oversize (mm)		0.1

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.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	47.988 ÷ 47.994
Category C	47.982 ÷ 47.988
Class A	47.997 ÷ 48.003

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)		0.127

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

	Measurement		Value
-	Crankpin diameter (mm)		41.990 ÷ 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.

	Measurement		Value
-	Crankpin 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 upper main journal half-bearings in the upper cylinder block/crankcase. Ensure lubrication holes are aligned and maintain scrupulous cleanliness. 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 housing in the upper cylinder block/crankcase.2. Fit the calibrated wire (Plastigage) to measure the main journal clearance. 1. Position the main bearing halves to the lower crankcase.2. Fit the lower crankcase to the upper crankcase. check that codes (2a) stamped on both parts of the crankcase correspond because the crankcase components are not interchangeable. 1. Tighten bolts (1a) and bolts (1b) securing the lower crankcase. Use tool (1c) to for angular tightening.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CRANK CASE	M10 x 1.25	2 + 90°

	Name	Country
1c	Protractor	1.860.942.000

1. Remove the lower crankcase and check main journal clearance. Measure calibrated wire width using an appropriate gauge.

Check one pin at a time without turning the crankshaft.

	Measurement		Value
-	Clearance between crankshaft bearings and main journals (mm)		0.025 ÷ 0.040

After checking all the main journals, apply sealant to the mating surface between lower and upper crankcase. Then fit the lower crankcase by tightening the bolts to torque in the order shown previously.

Apply a 2 mm thick, unbroken sealant strip to the lower crankcase surface.

	Type	Component	Name	Qty.
-	Silicon sealant	LOWER CRANKCASE	LOCTITE 5900	2 mm

    Op. 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.

	Measurement		Value
-	Outer diameter (mm)	Category B	71.970 ÷ 71.980
Category C	71.980 ÷ 71.990
Class A	71.960 ÷ 71.970
	from lower edge of piston skirt (mm)	6

Position the piston in the cylinder bore/liner and, using a feeler gauge, measure the recommended clearance.

	Measurement		Value
-	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 piston.

	Measurement		Value
-	Gudgeon pin housing diameter (mm)		17.939 ÷ 17.956

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
-	Gudgeon pin external diameter (mm)		17.970 ÷ 17.974

Using a micrometer, measure the thickness of the piston seals.

	Measurement		Value
-	Thickness (mm)	1° seal	0.970 ÷ 0.990
2° seal	1.170 ÷ 1.190
3° seal	1.975 ÷ 1.990

	Measurement		Value
-	Seal oversize (mm)		0.1

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.

	Measurement		Value
-	Opening (mm)	1° seal	0.200 ÷ 0.400
2° seal	0.250 ÷ 0.450
3° seal	0.200 ÷ 0.400

1. Using a feeler gauge (1a), check the fitting clearance between the piston rings (1b) and the piston ring grooves (1c).

	Measurement		Value
-	End float (mm)	1° seal	0.03 ÷ 0.07
2° seal	0.02 ÷ 0.06
3° seal	0.02 ÷ 0.055

Check that the diameter of the connecting rod big end and the small end correspond to the recommended values.

	Measurement		Value
-	Big end diameter (mm)		45.128 ÷ 45.138

	Measurement		Value
-	Small end diameter (mm)		17.939 ÷ 17.956

    Op. 1028H60 PISTON, PIN SET - REPLACE    Op. 1028H54 PISTON/CYLINDER LINER - R R    Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCHPositin the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

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.

The letters for the cylinder bore/liner class are located on the cylinder block/crankcase.

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.

	Name	Country
1b	Fitting tool	1.860.700.000

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 using tool (1d) for the angular tightening.

The connecting rods come with split caps. if replaced, they are supplied pre-split by the manufacturer. Check that the components are free of burrs, blisters, scratches or any type of surface defect. Before installation, the parts must be thoroughly washed, cleaned and dried. 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).

Each connecting rod must be matched with its own cap, respecting the printed reference numbers. connecting rods and connecting rod caps are not interchangeable.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CONNECTING ROD CAP FASTENERS	M8	2 + 40°

	Name	Country
1d	Protractor	1.860.942.000

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.

	Measurement		Value
-	Big end bearings (mm)		0.024 - 0.060

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.

	Name	Country
-	Flange	1.860.815.000

Rotate the engine on the overhauling stand.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.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6 x 20	1

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6 x 32	1

3. Fit the oil filter.4. Fit the engine oil pressure sender unit and tighten to the specified torque.

	Fastening	Component	Ø	Value(daNm)
4	Bolt	OIL PRESSURE W/L	M14 x 1.5	3.2

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

	Name	Country
1b	Fitting tool	1.860.990.000

1. Fit the crankcse rear cover (1a) and secure by tightening bolts (1b) to the specified torque.

The rear crankcase cover comes with an oil seal.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FLYWHEEL SIDE COVER	M6 x 20	1

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FLYWHEEL SIDE COVER	M6 x 32	1

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	4.4

1. Fit the gear on the crankshaft.2. Fit the crankshaft locking tool.

	Name	Country
2	Counter-torque	1.870.763.000

3. Secure the crankshaft gear by tightening the bolt to the specified torque.

Work with flywheel lock 1860846000 fitted.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	TOOTHED DRIVE PULLEY	M12 x 1.25	2 + 90°

Apply a continuous line of recommended sealant to external edge of water pump.

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	1

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

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

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COOLANT PUMP RIGID INLET PIPE	M6	1

1. Line up the driven plate for fitting the clutch assembly (1a), using the centring pin (1b).

	Name	Country
1b	Clutch centering	1.870.418.000

2. Tighten the bolts fixing the clutch to the engine flywheel.Remove the engine flywheel lock applied previously. 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.

	Type	Component	Name	Qty.
1	Silicon sealant	OIL SUMP	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	1

	Fastening	Component	Ø	Value(daNm)
2c	Nut	OIL SUMP	M6	0.5

1. The timing is adjusted with the four pistons in line, i.e. half way along the effective travel. It is therefore essential to position the crankshaft so it is in line with the camshafts. Position approximately by turning crankshaft gear (1a) until locating dowel (1b) is positioned on the opposite side to the seat of rpm and TDC sensor (1c) and with the first cylinder piston descending, i.e. in intake stage. Remove the protective cover for the camshaft rear gears.1. Undo the camshaft housing side plugs. 1. Position tools (1a) into the seats of the caps unscrewed previously, then turn the camshafts until splines (1b) on each camshaft are aligned with tool pin (1c). The camshafts will be timed in this way.

	Name	Country
1a	Locating pin	1.860.985.000

Refit the cover protecting the rear camshaft gears.Fit the centring pins on the crankcase.1. Fit the seal on the crankcase with the the word ''ALTO'' [top] facing the operator, taking care not to dirty or lubricate the seal and the surface of the crankcase. The arrowed holes decrease in diameter from the 1st to the 4th cylinder so that coolant is distributed evenly over the entire crankcase.A = intake sideB = exhaust side

The cylinder head gasket is metallic.

Position the cylinder head on the crankcase and ensure the locating pins are aligned.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	M9 x 1.25	3 + 90° + 90°

	Name	Country
1b	Protractor	1.860.942.000

1. Fit the cylinder head extension gasket to the cylinder head mating surface.2. Position tappet retaining tools (2a) beneath the cylinder head extension, then position the cylinder head extension on the cylinder head and withdraw the tools.3. Use tool (3a) to tighten the cylinder head extension bolts (3b) to the specified torque.4. Refit caps and tighten to the specified torque.

	Name	Country
2	Tappet retaining tool	1.860.988.000

	Name	Country
3a	Key	1.860.834.000

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	CYLINDER HEAD EXTENSION	M8 x 1	1.5

	Fastening	Component	Ø	Value(daNm)
4	Bolt	CAMSHAFT HOUSING PLUGS	M16 x 1	1.5

Fit the camshaft drive pulley and tighten the retaining bolt.1. Position the tools (1a) in the housings for the spark plug for cylinders 1 and 2, tightening the components (1b) to a torque of 0.5 daNm.2. Turn the crankshaft in the normal sense of rotation until the tool mobile parts are aligned. When both tools positioned in the spark plugs seats are in this condition, the engine pistons are aligned with one another, i.e. half away along their effective travel.

The pistons were already approximately aligned previously.

Rotate the crankshaft gradually to prevent the pins for the tools being expelled by the piston compression.

The camshafts were timed previously through the fitting of the tools (3).

	Name	Country
1a	Bearings	1.860.992.000

	Name	Country
3	Locating pin	1.860.985.000

1. Proceed with fitting the timing drive belt, fitting it initially on the crankshaft gear (1a), the water pump pulley (1b), the camshaft drive pulley (1c) and, lastly, on the belt tensioner pulley (1d).

Make sure that this operation is carried out with the camshaft pulley (1c) slack.

1. Using suitable pliers, rotate the automatic tensioner placing it in the maximum tension position, i.e. with the moving reference (1a) positioned as illustrated in the diagram then lock the nut (1d) fixing the tensioner to the support. 1. Using the tool (1a) tighten the bolt (1b) fixing the camshaft pulley to the recommended torque.

	Name	Country
1a	Support for counter-torque	1.860.831.000

	Name	Country
1a	Spanner for camshaft pulley rotation	1.860.831.002

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	TIMING GEAR DRIVEN PULLEYS	M12 x 1.25	12

Remove the tools positioned previously for timing and locking the camshafts and rotate the crankshaft through two revolutions in its direction of rotation to let the timing drive belt bed in. 1. Loosen the nut fixing the tensioner and ensure that the moving reference (1a) coincides with the fixed reference (1b) retaining the tensioner using the special pliers so as not to release the tension suddenly.2. Once the two references are aligned, tighten the nut (2a) fixing the tensioner to the recommended torque.Rotate the crankshaft through a further two revolutions in its direction of rotation, then repositino the tools used for timing the engine and check that the timing is correct.Refit the side plugs in the camshaft housing.

	Fastening	Component	Ø	Value(daNm)
2a	Nut	MOBILE TIMING TENSIONER	M8	2.5

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT HOUSING SIDE PLUGS	M16 x 1.5	1.5

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.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.2

Fit the rpm and TDC sensor and fix it with its bolts.Refit the engine oil dipstick.Refit the inlet manifold complete with injectors and throttle body.Position the electrical wiring and connect the electrical connections.

	Name	Connector
-	Integrated throttle body actuator	N75

	Name	Connector
-	Fuel vapour recovery solenoid	L10

	Name	Connector
-	Engine temperature sender unit	K36

	Name	Connector
-	Injector junction	D81

	Name	Connector
-	Earth on engine	C40

	Name	Connector
-	Detonation sensor	K50

	Name	Connector
-	Integrated air temperature sensor	K43

	Name	Connector
-	Engine oil pressure sensor (switch)	K30

	Name	Connector
-	Rpm sensor	K46

Position the part of the wiring concerned in the duct.    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE