184000850 - 1028H10 PISTON WITH CONNECTING ROD - R R

Removing ( Refitting ) Position the vehicle on a lift.Drain the air conditioning refrigerant circuit    Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with the removal    Op. 4450B04 RIGHT FRONT WHEEL R R.Proceed with the removal    Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the removal    Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the removal    Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the removal    Op. 5530B10 BATTERY - R+R.Proceed with the removal    Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the removal    Op. 1060G90 DIESEL INJECTION WIRING HARNESS - R R.Proceed with the removal    Op. 1016B10 SINGLE CYLINDER HEAD EXTENSION - CHANGE GASKET.Proceed with the removal    Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL.1. Undo the bolts fixing the manual gearbox/engine bracket to the engine block.2. Undo the bolts fixing the manual gearbox/engine bracket to the gearbox.3. Remove the manual gearbox/engine bracket.
1. Undo the drain plug in the crankcase sump and leave the engine oil to drain into a suitable container.
Do not let the oil disperse into the atmosphere as this could cause pollution.
1. Undo the nuts (1a) and bolts (1b) securing the crankcase sump.2. Cut the crankcase sump sealant using the tool.
DescriptionCode
2Blade1.870.718.000
3. Remove the crankcase sump.
1. Undo the bolts (1a) and remove the crankcase oil sump partition (1b).
Remove the peg fitted previously from the opening in the gearbox.1. Working on the bolt fixing the pulley mounting flange to the crankshaft, rotate the crankshaft until the pistons for cylinders 1 and 4 are at B.D.C.2. Undo the bolts (2a) and remove the connecting rod caps (2b) complete with half-bearings (2c) for cylinders 1 and 4.
1. Release and remove the piston/connecting rod assemblies (1a) complete with half-bearings (1b) for cylinders 1 and 4.
Work in the same way to remove the piston/connecting rod assemblies for cylinders 2 and 3. Refitting ( Removing ) Clean the residues of sealan from the matching surfaces between the lower engine block and the crankcase sump.Fit the connecting rod-piston assemblies in accordance with the following references.1. Piston class (1a) and arrow (1b) indicating camshaft side.2. Area where the number of the matching cylinder liner is stamped.3. Exhaust (3a) on the piston skirt to be aligned with oil spray (3b).
1. Place the piston/connecting rod assemblies for cylinders 2 and 3 complete with half-bearings in their housings using a suitable fitting tool.
1. Place the connecting rod caps (1a) for cylinders 2 and 3 in their seats complete with half-bearings (1b) and secure them by tightening the bolts (1c) to the recommended torque.
FasteningComponentØ  Value(daNm)
1cBoltCONNECTING ROD CAPSM81.9 ÷ 2.1 + 40? ± 2?
Use the tool for the angular tightening of the connecting rod cap bolts.
DescriptionCode
-Torque wrench1.860.942.000
Work in the same way to fit the piston/connecting rod assemblies for cylinders 1 and 4.Fit a suitable peg via the special opening in the gearbox.Place the crankcase oil sump partition back in its housing and secure it using the bolts.1. Apply a strip of recommended silicon sealant to the contact surfaces between the crankcase sump and lower crankcase as shown in the diagram in the figure.
The sealant strip must be unbroken. The sealant strip diameter must be 3.5 0.5 mm
TypeComponentDescriptionQty.
1SealantENGINE OIL SUMPLOCTITE 5900-
1. Position the crankcase sump (1a) in its housing and secure it tightening the bolts (1b) and the nuts (1c) to the recommended torque.
Follow the order shown in the figure for each tightening sequence. The tightening to 0.8 - 1.0 daNm is performed in two stages: a pretightening to 0.4 daNm followed by an additional tightening of 0.8 - 1.0 daNm.
FasteningComponentØ  Value(daNm)
1bBoltENGINE OIL SUMPM6(Lower engine crankcase side) 0.8 - 1.0
FasteningComponentØ  Value(daNm)
1cNutENGINE OIL SUMPM6(Cam cover side) 0.8 ÷ 1.0
1. Tighten the drain plug in the crankcase sump to the recommended torque.
FasteningComponentØ  Value(daNm)
1-ENGINE OIL DRAIN PLUGM14(Crankcase sump side) 1.8 - 2.2
1. Position the manual gearbox/engine bracket (1a) in its housing and secure it tightening the bolts (1b) and (1c) to the recommended torque.
FasteningComponentØ  Value(daNm)
1bBoltGEARBOX/ENGINE COUPLING BRACKETM8(Gearbox side) 2.3 - 2.8
FasteningComponentØ  Value(daNm)
1cBoltGEARBOX/ENGINE COUPLING BRACKETM8(Engine crankcase side) 2.7 - 3.3
Proceed with the refitting    Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL.Proceed with the refitting    Op. 1016B10 SINGLE CYLINDER HEAD EXTENSION - CHANGE GASKET.Proceed with the refitting    Op. 1060G90 DIESEL INJECTION WIRING HARNESS - R R.Proceed with the refitting    Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the refitting    Op. 5530B10 BATTERY - R+R.Refill the engine oil lubrication system    Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP.Refill the engine cooling system    Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.Proceed with the refitting    Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the refitting    Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the refitting    Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the refitting    Op. 4450B04 RIGHT FRONT WHEEL R R.Refill the air conditioning refrigerant circuit    Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Remove the vehicle from the lift.