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. Undo the fastenings (1a) and remove the support complete with compressor and alternator (1b).2. Remove the engine oil dipstick tube.3. Undo the bolt and remove the knock sensor.
1. Fit tool (1a), unscrew bolt (1b) and remove the crankshaft gear (1c).
ToolNameOperationFunctionValidity
2000004500Dima1004E201032B10Fasatura albero motore1.4 8v
2. Undo the bolt (2a) and remove the rpm sensor (2b).
1. Undo the bolts (1a) and remove the rigid water return pipe to the pump (1b).2. Undo the bolts (2a), nuts (2b) remove the water pump (2c).
1. Remove the oil filter cartridge.2. Remove the minimum engine oil pressure switch.3. Undo bolts (3a) and remove the engine block front cover (3b) with the built-in oil pump complete with crankshaft front oil seal (3c) and intake chamber (3d).4. Remove the engine block front cover gasket.
1. Undo the bolts (1a) and remove the crankshaft rear cover (1b).
1. Undo the bolts (1a) and remove the connecting rod cap (1b).2. Remove the lower connecting rod half-bearings.3. Remove the connecting rod - piston assemblies.4. Remove the upper connecting rod half-bearings.- Carry out the same operations for removing the remaining pistons.
1. Check that the crankshaft end float is within specified limits.
Gioco assiale albero motore0.055 ÷ 0.265 mm1.4 8v
- If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable thrust washers (fastened to the central main bearing half) oversized by 0.127 mm.1. Undo the bolts (1a) and remove the connecting rod 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 half incorporates the crankshaft thrust ring halves.
    Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH- Unscrew the coolant chamber plugs from the crankcase.- Remove the lubrication duct plug from the crankcase.- Check the condition of the piston cooling oil sprays.1. If oil sprays (1a) are blocked, remove them using tool (1b).
Insert the drift guide hole on the nozzle surface to prevent the drift from slipping and damaging the cylinder liner during the removal operation.
ToolNameOperationFunctionValidity
1860395000Battitoio1004E20Rimozione spruzzatori olio motore1.4 8v
Refitting ( Removing ) - Wash and check the appearance of all compents removed.- Tighten the water/oil sealing plugs to the upper crankcase.1. Use tool (1a) to fit new oil sprays (1b).
ToolNameOperationFunctionValidity
1860313000Introduttore1004E20Introduzione spruzzatori olio1.4 8v
- Check that the planarity of the cylinder head support surface corresponds to the recommended figure; if this is not the case, regrind the cylinder head support surface.
Planarità piano di appoggio testa cilindri< 0.1 mm1.4 8v
- Measure the diameter of the cylinder bores and check that they correspond to the recommended figures.
Diametro interno canne cilindri - Classe A72.000 ÷ 72.010 mm1.4 8v
Diametro interno canne cilindri - Classe B72.010 ÷ 72.020 mm1.4 8v
Diametro interno canne cilindri - Classe C72.020 ÷ 72.030 mm1.4 8v
- Check that the ovality of the cylinder liners is within the recommended limits.
Ovalizzazione canne cilindri± 0.05 mm1.4 8v
- Check that the taper of the cylinder liners/bores is within the recommended limits.
Conicità canne cilindri± 0.005 mm1.4 8v
- If the cylinder bore, taper or ovality measurements are not within the recommended limits, ream the cylinder bores following the recommended oversizes.
In the case of reaming, all the bores must have the same oversize.
Maggiorazione diametro interno canne cilindri0.1 mm1.4 8v
- Check that the diameter of the main journals corresponds to the recommended figures.
Diametro perni di banco albero motore - Classe A47.873 ÷ 47.867 mm1.4 8v
Diametro perni di banco albero motore - Classe B47.867 ÷ 47.861 mm1.4 8v
Diametro perni di banco albero motore - Classe C47.861 ÷ 47.855 mm1.4 8v
- If the diameter of the main journals is not correct, they should be reground to the recommended undersize.
Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.
Minorazione diametro perni di banco albero motore0.127 mm1.4 8v
- Check that the diameter of the crankpins corresponds to the recommended figures.
Diametro perni di biella albero motore41.881 ÷ 41.863 mm1.4 8v
- If the diameter of the crankpins is not correct, they should be reground to the recommended undersize.
Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.
Minorazione diametro perni di biella albero motore0.127 mm1.4 8v
- Fit the crankshaft into its seat on the crankcase.- Fit the calibrated wire (plastigage) for measuring the main journal backlash.- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.
ComponentFasteningØValue (daNm)Validity
CAPPELLI DI BANCOViteM102 + 90°1.4 8v
- Remove the main bearing caps and check the main journal backlash. Use an appropriate gauge to measure the width of the plastigage.
Check one main journal at a time, without rotating the crankshaft.
Gioco cuscinetti di banco - perni di banco albero motore1.4 8v
- After checking all the main journals, refit the main bearing caps with half-bearings and secure by tightening the bolts to the specified torque.
ComponentFasteningØValue (daNm)Validity
CAPPELLI DI BANCOViteM102 + 90°1.4 8v
    Op. 1028H54 PISTON/CYLINDER LINER - R R- Clean any carbon residues carefully from the pistons.- Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin.
Diametro esterno pistoni - Classe A71.960 ÷ 71.970 mm1.4 8v
Diametro esterno pistoni - Classe B71.970 ÷ 71.980 mm1.4 8v
Diametro esterno pistoni - Classe C71.980 ÷ 71.990 mm1.4 8v
- Position the piston in the cylinder liner and use a feeler gauge to measure the specified clearance.- Check that the pin seat bore diameter is within specified values, otherwise replace the pin with an oversized pin.
Diametro sedi spinotti pistoni17.982 ÷ 17.986 mm1.4 8v
Maggiorazione diametro sedi spinotti pistoni1.4 8v
- Check that the outer diameter of the gudgeon pins is within the recommended limits; if not, replace the worn gudgeon pins.
Diametro esterno spinotti pistoni17.970 ÷ 17.974 mm1.4 8v
- Check that the thickness of the piston rings is within the recommended limits.
Spessore 1^ anello di tenuta compressione cilindri0.970 ÷ 0.990 mm1.4 8v
Spessore 2^ anello di tenuta compressione cilindri1.170 ÷ 1.190 mm1.4 8v
Spessore 3^ anello di tenuta compressione cilindri1.975 ÷ 1.990 mm1.4 8v
Maggiorazione spessore anelli di tenuta compressore cilindri0.1 mm1.4 8v
- Fit the sealing rings in the cylinder liner and check the gap between the seal ends is within specified limits. Otherwise replace the sealing rings.
Luce 1^ anello di tenuta compressione cilindri0.20 ÷ 0.40 mm1.4 8v
Luce 2^ anello di tenuta compressione cilindri0.25 ÷ 0.45 mm1.4 8v
Luce 3^ anello di tenuta compressione cilindri0.20 ÷ 0.40 mm1.4 8v
- Check that the mating clearance between the piston rings and the grooves on the piston is within specified limits.
Gioco assiale 1^ anello di tenuta compressione cilindri0.030 ÷ 0.070 mm1.4 8v
    Op. 1028H54 PISTON/CYLINDER LINER - R R    Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH- Fit the connecting rod-piston assemblies and align in accordance with the following references.1. Piston class and arrow indicating timing side.2. Area where the number of the matching cylinder liner is stamped.3. Piston pin offset
- Fit the connecting rod-piston assemblies with half-bearings using the tool to compress the piston rings and then fit the piston into the liner.- Rotate the engine through 180° on the overhaul stand.- Apply the calibrated wire (plastigate) for measuring the crankpin clearance.- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.
The connecting rod caps are fracture type. If replaced, they are supplied pre-fractured by the manufacturer.Check that the parts are free of burrs, blisters, scratches or any other surface defect. Before installation, parts must be thorougly washed, cleaned and dried. Fit the connecting rod caps so that the number stamped on each cap faces towards the same side as the number stamped on the big end.
Each connecting rod must be paired with its cap, respecting the numerical references stamped on the parts. Connecting rods and connecting rod caps are not interchangeable.
ComponentFasteningØValue (daNm)Validity
CAPPELLI DI BIELLAViteM82 + 40°1.4 8v
- Remove the connecting rod caps and check the crankpin backlash. Use an appropriate gauge to measure the width of the plastigage.
Gioco cuscinetti di biella - perni di biella albero motore0.024 ÷ 0.062 mm1.4 8v
Check one crankpin at a time, without rotating the crankshaft.
- If the value measured is not within the recommended figures, replace the connecting rod bearings.- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.
ComponentFasteningØValue (daNm)Validity
CAPPELLI DI BIELLAViteM82 + 40°1.4 8v
- Position a new oil pump gasket.- Fit the front crankcase cover with built-in oil pump complete with intake chamber and secure by tightening bolts to the specified torque.- Fit the engine oil filter.- Fit the minimum engine oil pressure switch.- Fit the oil seal to the crankshaft front cover using the tool.
ToolNameOperationFunctionValidity
1860903000Introduttore1004E201016E10Montaggio paraolio anteriore albero motore1.4 8v
- Fit the crankcase rear cover and secure by tightening the bolts to the specified torque.
ComponentFasteningØValue (daNm)Validity
COPERCHIO POST. ALBERO MOTOREViteM6 x 2011.2 16v1.4 16v1.4 8v
- Fit a new rear camshaft oil seal using the tools.
ToolNameOperationFunctionValidity
1860879000Impugnatura1004E201016E10Montaggio paraolio posteriore albero motore1.4 8v
ToolNameOperationFunctionValidity
1860881000Introduttore1004E201016E10Montaggio paraolio posteriore albero motore1.4 8v
- Fit the water pump and secure with the bolts and nut.- Fit the rigid coolant return pipe to the pump and secure to the crankcase with the bolt.- Fit the crankshaft gear.- Position the tool and tighten the crankshaft gear bolt to the specified torque.
ToolNameOperationFunctionValidity
2000004500Dima1004E201032B10Fasatura albero motore1.4 8v
ComponentFasteningØValue (daNm)Validity
INGRANAGGIO ALBERO MOTOREViteM112 + 90°1.4 8v
- Remove the tool fitted previously.- Rotate the engine on the overhaul stand.- Clean the crankcase and oil sump contact surfaces, removing the silicon sealant residues.1. Apply a strip of the specified sealant continuously without any breaks over the entire perimeter of the crankcase sump as shown in the figure.
Join the end to the beginning seamlessly.
2. Fit crankcase sump (2a) and secure by tightening bolts (2b) and nuts (2c) to the specified torque.
When positioning the crankcase sump, avoid significant sideways movements that could remove the sealant.
ComponentFasteningØValue (daNm)Validity
COPPA OLIO MOTOREViteM60.7 ÷ 1.11.4 8v
ComponentFasteningØValue (daNm)Validity
COPPA OLIO MOTOREDadoM60.7 ÷ 1.11.4 8v
- Clean the contact surfaces between the cylinder head and engine block.- Fit the locating bushes for the cylinder block/crankcase.- Position the cylinder head gasket on the cylinder block/crankcase.1. Fit the cylinder head and tighten the fixing bolts to the recommended torque.
ComponentFasteningØValue (daNm)Validity
CYLINDER HEAD EXTENSIONBoltM8(Lower cylinder head side) 2.51.3 JTD 16v
Follow the order illustrated below for the tightening of the cylinder head bolts.
- Fit the intake chamber and tighten the nuts to the specified torque.
ComponentFasteningØValue (daNm)Validity
COLLETTORE/I ASPIRAZIONEDadoM82.71.4 8v
1. Fit the template to the camshaft rear shank.
ToolNameOperationFunctionValidity
2000004400Dima1004E201032B10Fasatura albero distribuzione1.4 8v
1. Fit the timing belt.
1. Fit the crankshaft timing template to the drive pulley.
ToolNameOperationFunctionValidity
2000004500Dima1004E201032B10Fasatura albero motore1.4 8v
1. Proceed as shown in the figure to adjust the automatic tensioner reference fork until it is in contact.
1. Fit reaction tool (1a) and tighten variable valve timing bolt (1b) to the specified torque.
ToolNameOperationFunctionValidity
2000004200Anticoppia1004E20Bloccaggio puleggia condotta distribuzione1.4 8v
ComponentFasteningØValue (daNm)Validity
FISSAGGIO VARIATORE DI FASEViteM122 + 55°1.4 8v
- Fit the variable valve timing bolt plug and secure to the specified torque.
ComponentFasteningØValue (daNm)Validity
TAPPO CHIUSURA VARIATORE DI FASETappoM272.5 ÷ 2.91.4 8v
- Remove both templates and the reaction tool fitted previously and turn the engine through a couple of revolutions to settle the timing belt.- Loosen the belt tensioner nut and adjust the front fork until it is aligned with the rear fork.- Tighten the belt tensioner nut to the recommended torque.
ComponentFasteningØValue (daNm)Validity
TENDITORE MOBILE DISTRIBUZIONEDadoM82.5 ÷ 3.01.4 8v
- Fit the templates removed previously to check the engine timing adjustment.1. Position cam cover (1a) on the cylinder head and tighten bolts (1b).2. Fit the cam cover locating tool.
ToolNameOperationFunctionValidity
2000004300Dima1004E201032B10Centraggio coperchio punterie1.4 8v
- Tighten the previously screwed in cam cover bolts to the specified torque.
ComponentFasteningØValue (daNm)Validity
CAMSHAFT CAPSBoltM71.3 - 1.61.9 JTD 8v
- Remove the cam cover locating tool fitted previously.1. Fit the timing sensor.2. Fit the injection control unit mount.
- Fit the rpm sensor and tighten the bolt.- Fit the knock sensor and tighten the bolt to the specified torque.
ComponentFasteningØValue (daNm)Validity
SENSORE DI BATTITOViteM82.2 ÷ 2.71.4 8v
- Fit the engine oil dipstick tube.- Fit the mount with compressor and alternator and secure the fastenings.
ComponentFasteningØValue (daNm)Validity
SUPPORTO COMPRESSORE-ALTERNATOREViteM104.5 ÷ 5.51.4 8v
- Fit the timing belt protective covers and secure them using the bolts.- Fit the crankshaft pulley and tighten the bolts to the recommended torque.
ComponentFasteningØValue (daNm)Validity
PULEGGIA ALBERO MOTOREViteM82.2 ÷ 2.71.4 8v
- Fit the auxiliary drivebelt by adjusting the automatic belt tensioner.- Fit the timing side rigid power unit mount and tighten the bolts to the specified torque.
ComponentFasteningØValue (daNm)Validity
ENGINE MOUNT TIMING SIDENutM10(Chamber side) 4.5 ÷ 5.51.9 JTD 8v
ComponentFasteningØValue (daNm)Validity
ENGINE MOUNT TIMING SIDENutM10(Bodyshell side) 4.1 ÷ 5.01.9 JTD 8v
- Connect the electrical connection for the coolant temperature sensor.- Connect the electrical connection for the timing sensor.- Connect the electrical connection to the ignition coil module.- Connect the electrical connection for the throttle casing.- Connect the electrical connection for the knock sensor.- Connect the air conditioning compressor electrical connection.- Connect the earth lead to the crankcase.- Connect the electrical connection for the absolute pressure sensor.- Connect the electrical connection for the air pressure/temperature sensor.- Connect the electrical connection for the variable valve timing electromagnet.- Remove the engine from the overhaul stand.