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
)
Rotate the crankcase through 180° on the overhauling stand.1. Remove oil filter (1a) using tool (1b).2. Undo pin (2a) and remove heat exchanger (2b).
1. Fit the tool.
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.000 |
1. Undo the bolts (1a) and remove the clutch (1b).
1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Remove the timing belt.3. Undo bolt (anticlockwise) (2a) and remove toothed drive pulley (2b).
1. Undo the bolts (1a) and remove the flywheel (1b).2. Remove the tool.
| Name | Country |
|---|
| 2 | Counter-torque | 1.860.846.000 |
1. Undo bolts (1a) and remove the power unit mount, timing gear side (1b).2. Undo bolts (2a) and remove fixed timing belt tensioner (2b).3. Undo bolts (3a) and remove the automatic auxiliary drivebelt tensioner (2b).4. Undo bolts (4a) and remove the mount (4b) together with power steering pump (4c) and timing belt tensioner.
1. Undo the bolts (1a) and remove the crankcase front cover with built in oil pump (1b) and intake housing.Remove the gasket
Fit the tool.
| Name | Country |
|---|
| - | Flange | 1.860.815.000 |
Rotate the crankcase through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the connecting rod cap (1b).2. Remove the lower big end bearing shell.3. Remove the connecting rod - piston assembly.4. Remove the upper big end bearing shell.Proceed in the same way with the removal of the pistons and connecting rods for the remaining cylinders.Remove the tool.
| Name | Country |
|---|
| - | Flange | 1.860.815.000 |
Unscrew the bolts and remove the flywheel protection.5. Undo the bolts (5a) and remove the crankcase rear cover (5b) with built-in oil seal.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) | | 0.049 - 0.211 |
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 suitable oversize thrust washers.6. Undo bolts (6a) and remove connecting rod caps (6b).7. Remove the lower main journal half-bearings.8. Remove the crankshaft9. Undo bolts (9a) and remove crankshaft phonic wheel (9b).10. Remove the upper main journal half-bearings11. Remove the thrust washers.12. Unscrew bolts (12a) and remove jets (12b) from the crankcase.13. Undo the bolt (13a) and remove the rpm and timing sensor (13b). | Name | Connector |
|---|
| 13b | Rpm sensor | K46 |
14. Remove the mininum engine oil pressure warning light sensor.
1. Undo bolts (1a) and remove flange (1b) with the oil return pipe to the sump from the turbocharger.2. Undo connector (2a) and remove the oil supply pipe to the turbocharger (2b).3. Undo bolts (3a) and remove the turbocharger bracket (3b).
Rotate the cylinder block/crankcase through 90° on the overhauling stand.Undo the bolts and remove the crankcase from the mounting brackets, then place it on a workbench. Op. 1028H60 PISTON, PIN SET - REPLACE.Undo the bolts and remove the oil inlet from the oil pump. Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH.
Refitting
(
Removing
)
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 there are no superficial cracks or grooves in the cylinder head support surface.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 diameter of the cylinder liners/bores following the diagram illustrated.
| Measurement | | Value |
|---|
| - | Cylinder bore diameter (mm) | Category B | 82.010 - 82.020 |
| Category C | 82.020 - 82.030 |
| Classe A | 82.000 - 82.010 |
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 of the cylinder liners/bores is not within the recommended values, ream the cylinder liners/bores 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) | | 0.1 |
1. Fit the bearing caps. | The bearing caps have progressive references (from zero to four starting from the front of the engine) which define their fitting position. |
1. Tighten the bearing cap bolts (1a) to torque using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | MAIN BEARING CAPS | M12 | 2.4 - 2.6 + 100° |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
2. Check that the diameter of the bearing seats is within the recommended values.
| Measurement | | Value |
|---|
| 2 | Main bearing seat diameter (mm) | | 63.691 - 63.732 |
Undo the bolts (1a) and remove the connecting rod caps.
Check that the crankshaft lubrication ducts are free from deposits.Check that the diameter of the main journals is within the recommended values.
| Measurement | | Value |
|---|
| - | Main bearing journal diameter (mm) | Category B | 59.987 ÷ 59.993 |
| Category C | 59.982 ÷ 59.986 |
| Classe A | 59.994 ÷ 60.000 |
If the diameter of the main journals is not within the recommended values, regrind them in accordance with the recommended undersize.
| 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) | Category B | 50.793 ÷ 50.799 |
| Category C | 50.787 ÷ 50.793 |
| Classe A | 50.799 ÷ 50.805 |
If the diameter of the crankpins is not within the recommended values, regrind them in accordance with the recommended undersize.
| Measurement | | Value |
|---|
| - | Crankpin undersize (mm) | | 0.127 |
Check that the inner diameter of the small end bushes is within the recommended limits; if this is not the case, replace the worn small end bush ( - 1028H34 piston/cylinder liner set - r r ).
| Measurement | | Value |
|---|
| - | Inner diameter (mm) | | 26.006 - 26.012 |
Check that the inner diameter of the small end bushes is within the recommended limits; if this is not the case, replace the piston complete with rings, gudgeon pin and bushes.
| Measurement | | Value |
|---|
| - | Piston bush bore (mm) | | 25.999 - 26.004 |
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) | | 25.982 - 25.988 |
Fit the sealing rings in the cylinder liner/bore and check that the end gap is within the recommended values; if this is not the case, replace the piston sealing rings.
| Measurement | | Value |
|---|
| - | Opening (mm) | 1° ring | 0.25 - 0.40 |
| 2° seal | 0.25 - 0.50 |
| Oil scraper ring | 0.25 - 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 rings and gudgeon pin.
| Measurement | | Value |
|---|
| - | Outer diameter (mm) (**) | Category B | 81.793 - 81.807 |
| Category C | 81.803 - 81.817 |
| Classe A | 81.783 - 81.797 |
| The measurement should be made perpendicular to the gudgeon pin axis, 8 mm from the skirt lower edge. |
1. Check that the end float (1a) between the second piston ring (1b) and the groove in the piston (1c) is within the recommended limits.
| Measurement | | Value |
|---|
| 1a | End float (mm) | | 0.002 - 0.006 |
Check that the end float between the oil scraper ring and the groove in the piston is within the recommended limits.
| Measurement | | Value |
|---|
| - | End float (mm) | | 0.030 - 0.065 |
1. Fit the caps (1b) on the connecting rods (1a) and fix them tightening the bolts (1c) to 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 | M9 | 2.4 - 2.6 + 60° |
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) | | 53.883 ÷ 53.923 |
Op. 1028H60 PISTON, PIN SET - REPLACE. Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH.Fit the intake case and secure it to the front crankcase cover using the bolts.Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Fit the flywheel protection to the crankcase and tighten the bolts.Fit the cylinder block/crankcase on the rotating stand and fix it using the bolts.Fit the turbocharger bracket and secure it using the bolts.Fit the engine oil delivery pipe to the turbocharger and tighten the connector.Fit the flange together with the oil return pipe from the turbocharger to the sump and secure it using the bolts.Fit the minimum engine oil pressure warning light sensor and tighten it to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | - | OIL PRESSURE W/L | - | 1.9 - 2.3 |
Fit the rpm and timing sensor and fix it with its bolts. | Name | Connector |
|---|
| - | Rpm sensor | K46 |
Fit the jets in the cylinder block/crankcase and fix them using the bolt.Fit the flywheel on the crankshaft and fix it using the bolts.Fit the upper main bearing halves.Fit the crankshaft on the cylinder block/crankcase.Fit the thrust washers on the third main bearing.1. Fit the main journal caps complete with half-bearings. | The bearing caps have progressive references notches (from zero to four starting from the front of the engine) plus a point to define their fitting position. |
1. Tighten the bolts (1a) for the bearing caps to torque using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | MAIN BEARING CAPS | M12 | 2.4 - 2.6 + 100° |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
1. Fit the tool.
| Name | Country |
|---|
| 1 | Flange | 1.860.815.000 |
Rotate the crankshaft using the tool fitted previously until the crankpin corresponding to the cylinder concerned is at B.D.C.1. Fit the piston - connecting rod assembly (1a), complete with half-bearing, using tool (1b). | Fit the piston - connecting rod assemblies in the cylinder block so that the piston oil spray guard faces the intake side. |
2. Fit the big end bearing cap (2a) complete with half-bearing and fix it using the bolts (2b) without tightening them. | 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). |
Work in the same way when refitting the pistons and connecting rods for the remaining cylinders.
1. Tighten the big end bearing cap bolts (1a) to torque; use the tool (1b) for the angular tightening. | When tightening the connecting rod cap, place a side shim between connecting rod and crankshaft. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | BIG END BEARING CAPS | M9 | 2.4 - 2.6 + 60° |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
Remove the tool.
| Name | Country |
|---|
| - | Flange | 1.860.815.000 |
1. Fit the rear crankcase cover with its built-in oil sealing ring.2. Tighten the crankcase rear cover bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | FLYWHEEL SIDE COVER | M6 | 0.8 - 1.0 |
1. Fit the crankcase front cover, complete with built-in oil pump (1a), intake casing (1b) and gasket .2. Tighten the bolts for the crankcase front cover, complete with pump, to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | CRANKSHAFT FRONT COVER | M6 | 0.8 ÷ 1.0 |
1. Fit oil sealing ring (1a) to the oil pump using tool (1b).
| Name | Country |
|---|
| 1b | Fitting tool | 1.860.816.000 |
Apply sealant to the entire perimeter of the crankcase sump.
| Type | Component | Name | Qty. |
|---|
| - | Silicon sealant | OIL SUMP | - | - |
1. Fit the crankcase sump.2. Tighten the side bolts (2a) for the crankcase sump to torque using the tool (2b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2a | Side bolts | OIL SUMP | M8 | 2.1 - 2.6 |
| Name | Country |
|---|
| 2b | Key | 1.860.834.000 |
3. Tighten the front and rear crankcase sump bolts (3a) to torque in a crossed pattern using tool (3b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3a | Front and rear bolts | OIL SUMP | M6 | 0.7 - 0.9 |
| Name | Country |
|---|
| 3b | Key | 1.860.833.000 |
Rotate the engine through 180° on the overhauling stand.1. Fit the tool.
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.000 |
2. Fit flywheel (2a) and spread bolts (2b) with LOCTITE 573 before tightening to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | FLYWHEEL | M12 | 13.6 - 16.8 |
1. Fit clutch (1a) and tighten bolts (1b) to the recommended torque.
1. Fit toothed drive pulley (1a) and tighten the bolt (anticlockwise) (b) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt with left hand thread | TOOTHED DRIVE PULLEY | M16 | 30.6 - 37.8 |
Remove the tool.
| Name | Country |
|---|
| - | Counter-torque | 1.860.846.000 |
Fit the power steering pump with its bracket.Fit the fixed timing belt tensioner and secure it using the bolts.Fit the timing end power unit mount .Fit the auxiliary shaft belt tensioner and fix it using the relevant bolt.Fit the heat exchanger and secure it using the pin.Fit the oil filter.1. Measure the projection of the pistons at two points at 180° on the gudgeon pin axis using the tool and take the average of the two figures measured for each piston.
| Name | Country |
|---|
| 1 | Dial gauge mounting | 1.870.404.000 |
Select the correct size cylinder head gasket, according to the maximum value of the averages of the projection for each individual piston.
| Measurement | | Value |
|---|
| - | Thickness with medium-maximum piston projection (mm) | | 0.795 - 0.881 |
| (no reference) (mm) | 1.55 - 1.65 |
| Measurement | | Value |
|---|
| - | Thickness with medium-maximum piston projection (mm) | | 0.881 - 0.967 |
| (one reference) (mm) | 1.65 - 1.75 |
| Measurement | | Value |
|---|
| - | Thickness with medium-maximum piston projection (mm) | | 0.967 - 1.055 |
| (two references) (mm) | 1.75 - 1.85 |
Position the cylinder head centring bushes on the cylinder block/crankcase.Fit the cylinder head gasket selected. | 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.
- Position the cylinder head on the cylinder block/crankcase.
1. Tighten the cylinder head bolts (1a) to 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 | M10 | 2.5 |
| 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 | 0.8 ÷ 1.0 |
Fit the mount complete with pressure pump and secure it using the side and front bolts.Fit the power steering pump outlet pipe bracket and secure it using the bolts.Connect the pipe and tighten the fitting.1. Remove the bolt for the oil pump shown.Temporarily fit the timing drive belt on the drive pulley.2. Fit the tool. | To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements. |
| Name | Country |
|---|
| 2 | Template | 1.860.905.000 |
1. Rotate the driven pulley so that the timing references line up.2. Completely fit the timing belt.3. Use a screwdriver to lever in the hole (3a) until the reference on the tensioner (3b) lines up with the reference hole (3c) and, in this position, tighten the belt tensioner nut (3d) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3d | Nut | MOBILE TIMING TENSIONER | M10 | 4.2 - 5.2 |
Remove the tool.
| Name | Country |
|---|
| - | Template | 1.860.905.000 |
Rotate the crankshaft through two revolutions.Check once again that the timing references and the tensioning references on the timing belt tensioner coincide.
Fit the timing drive belt guards and fix them using the bolts.Fit the power unit reaction rod mounting bracketFit the crankshaft pulley and secure it with the bolts.Fit the exhaust manifold gasket.Fit the exhaust manifold, complete with turbocharger and E.G.R. valve, and fix it tightening the nuts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | EXHAUST MANIFOLD/S | M8 | (Cylinder head side) 2.1 ÷ 2.6 |
Fit the coolant manifold and secure using the bolts.Connect the oil intake pipe to the turbocharger.Connect the oil return pipe to the sump to the turbocharger.Fit the protection for the oil return pipe from the turbocharger to the sump and secure it using the bolts.Tighten the nut securing the exhaust manifold bracket to the crankcase.Fit the gasket.Connect the exhaust gas recirculation pipe and secure using the nuts.Fit the exhaust gas recirculation pipe heat shield and tighten the bracket bolt.Fit the turbocharger protective heat shield and secure using the bolts.Fit the bracket.Replace the oil vapour separator complete with bracket and secure using the nuts.Connect the condensed oil recovery pipe to the crankcase sump.Connect the oil vapour recovery pipe to the crankcase and cylinder head.Use a fixed wrench to bring the fittings on the pipes from fuel manifold to injectors, injector side, into contact and then tighten to torque using a fork-type torque wrench.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Connector | FUEL MANIFOLD LINE TO INJECTORS | M14 | Injector side 1.9 - 2.3 |
Tighten the connectors for the pipes from the fuel manifold to the injectors, manifold side, to torque using the tool.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Connector | FUEL MANIFOLD LINE TO INJECTORS | M14 | (Mainifold side) 2.6 ÷ 3.2 |
| Name | Country |
|---|
| - | Key | 1.852.138.000 |
Fit the diesel delivery pressure regulator to the pressure pump and secure using bolts.Connect the pipes to the pressure regulator.Fit the engine oil dipstick assembly and secure it using the bolts.Fit the engine component single drive belt guide pulley and fix it using the bolt. Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.
