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 - Fiat - MULTIPLA - eLearn

2892331 - 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

) 1. Using the tool (1a), lock the gear, undo the fixing bolt (1b) and remove the gear (1c). 2. Remove the crankshaft gear from the housing on the shaft.

	Name	Country
1a	Counter-torque	1.860.765.000

1. Undo the bolts and the nut.2. Remove the timing belt lower rear shield.3. Undo the nut (3a) and remove the belt tensioner pulley (3b).

1. Undo the retaining bolts.2. Remove the oil seal cover (2a) and then remove the oil pump auxiliary shaft (2b).

1. Undo the retaining bolts.2. Remove the crankshaft front cover (2a) and the belt tensioner support (2b).

1. Undo the bolts fixing the water pump mounting to the cylinder block/crankcase.2. Remove the water pump complete with filler pipe.3. Undo the fixing bolts (3a) and remove the alternator mounting (3b).

1. Position the flywheel retainer.2. Undo the fixing bolts (2a) and remove the clutch plate (2b).

	Name	Country
1	Counter-torque	1.860.846.000

1. Undo the retaining bolts.2. Remove the engine flywheel together with the flywheel lock positioned previously.

1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).

1. Undo and remove the engine oil pressure sender unit.2. Undo the fixing bolt (2a) and remove the oil vapour separator (2b).3. Undo the fixing bolt (3a) and remove the detonation sensor (3b).

1. Undo the retaining bolts.2. Remove the engine oil pump (2a) complete with draught element (2b).Recover the oil pump gasket.3. Undo the fixing bolt (3a) and remove the section of the engine oil dipstick inside the cylinder block/crankcase (3b).4. Using an appropriate diameter drift, remove the protective cap (4a) and the oil pump gear (4b).

1. Using the service bolts (1a), fit the tool (1b) for rotating the crankshaft.

	Name	Country
1b	Flange	1.860.815.000

1. Undo the fixing 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.Using a suitable mangetic base and dial gauge, check that the crankshaft end float is within the recommended values.

	Measurement		Value
-	End float (mm)		0.055 ÷ 0.265

If the end float of the crankshaft is not within the recommended value, when refitting, reface the seat in the cylinder block/crankcase and use suitable 0.127 mm oversize thrust washers.5. Undo the fixing bolts (5a) and remove the bearing caps (5b).6. Remove the lower crankshaft bearings.7. Remove the crankshaft.8. Remove the upper crankshaft bearings.9. Remove the thrust rings.

Undo and remove the cylinder block/crankcase from the mounting brackets and place it on a suitable workbench. - 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at bench

Reassembling ( Dismantling

) Wash the dismantled components.Fit the water/oil sealing plugs in the crankcase using suitable tools and sealant.

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

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 plane.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 there are problems with the size, the cylinder block/crankcase support plane can be ground.

1. Measure the diameter of the cylinder liners/bores following the diagram illustrated.

	Measurement		Value
-	Cylinder bore diameter (mm)	Category B	86.410 - 86.420
Category C	86.420 - 86.430
Classe A	86.400 - 86.410

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/bores 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/bore in accordance with the recommended oversizes.

	Measurement		Value
-	Cylinder liner oversize (mm)		0.4

In the case of reaming, all liners/bores must be the same oversize.

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.Measure the diameter of the main journals and the crank pins.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	50.780 - 50.790
Classe A	50.790 - 50.800

	Measurement		Value
-	Crankpin diameter (mm)	Category B	45.503 - 45.513
Classe A	45.513 - 45.523

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

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

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.

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 half-bearings, ensuring that they are scrupulously clean and take care to position the half-bearing without splining on the centre bearing support.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.3. Fit the bearing caps.4. Tighten the bearing cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
4	Bolt	MAIN BEARING CAPS	M10	8

The bearing caps have progressive references from zero to four starting from the front of the engine which define their fitting position.

1. Remove the bearing caps fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

	Measurement		Value
1b	Clearance between crankshaft bearings - main journals (mm)		0.019 - 0.508

Measure the clearance at all the bearings, taking care to carry out this operation, one bearing at a time, without ever moving the crankshaft. - 1028H54 piston/cylinder liner - r rThoroughly clean any carbon residues from the piston.Measure the outer diameters of the pistons, perpendicular to the gudgeon pin axis, 10.2 mm from the lower edge of the piston skirt.

	Measurement		Value
-	Piston external diameter (mm)	Category B	86.359 - 86.371
Category C	86.368 - 86.378
Classe A	86.352 - 86.362

If the values measured differ from the recommended figures, replace the piston complete with seals and gudgeon pin.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)	Category B	0.039 - 0.061
Category C	0.042 - 0.062
Classe A	0.038 - 0.058

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.

	Measurement		Value
-	Gudgeon pin housing diameter (mm)		21.997 - 22.001

	Measurement		Value
-	Gudgeon pin oversizel (mm)		0.2

Check that the outer diameter of the gudgeon pin is within the recommended value; if this is not the case, replace the piston, complete with seals and gudgeon pin.

	Measurement		Value
-	Gudgeon pin external diameter (mm)		21.990 - 21.995

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

	Measurement		Value
-	Thickness (mm)	1° seal	1.470÷1.490
2° seal	1.470÷1.490
3° seal	2.935÷2,945

Piston seals are available as spares in 0.4 mm oversizes.

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 - 0.450
2° seal	0.250 - 0.500
3° seal	0.400 - 1.400

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	0.035 - 0.075
2° seal	0.020 - 0.060
3° seal	0.010 - 0.030

Check that the diameter of the connecting rod big end and the small end correspond to the recommended values. If this is not the case, replace the connecting rods.

	Measurement		Value
-	Big end diameter (mm)		48.630 - 48.646

	Measurement		Value
-	Small end diameter (mm)		23.939 - 23.972

- 1028H60 piston, pin set - replace - 1028H54 piston/cylinder liner - r rFit the crankshaft in the special housing in the cylinder block/crankcase.Check that the thickness of the thrust washers is within the recommended figures.

	Measurement		Value
-	Thickness of thrust washers (mm)		2.310 - 2.360

Fit the thrust washers on the first flywheel side support.Fit the bearing caps.Tighten the bearing cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MAIN BEARING CAPS	M10	8

The bearing caps have progressive references from zero to four starting from the front of the engine which define their fitting position.

Positin the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously.1. The connecting rod-piston assemblies are fitted with the engine rotation arrow stamped on the piston crown facing the inlet side.2. Check that the stamps for the cylinder bore/liner to which the connecting rod belongs are on the exhaust side.

1. Fit the connecting rod-piston assembly (1a), complete with half-bearing, using the tool (1b) for compressing the piston rings and the subsequent introduction of the piston in the liner/bore.

	Name	Country
-	Fitting tool	1.860.700.000

1. Check the clearance of the connecting rod bearings, using the calibrated wire (Plastigage).

Fit the connecting rod bearing.Tighten the nuts fixing the connecting rod caps to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CONNECTING ROD CAP FASTENERS	M9	5.1

Undo the nuts and remove the connecting rod cap fitted previously.1. Using a suitable graduate measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

	Measurement		Value
1b	Clearance between big end bearings-Crankpins (mm)		0.025 - 0.063

If the value measured does not correspond to the recommended figures, replace the connecting rod bearings.Carry out this check on all the connecting rod bearings, one at a time, without rotating the crankshaft.Fit the connecting rod bearing.Tighten the nuts fixing the connecting rod caps to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CONNECTING ROD CAP FASTENERS	M9	5.1

Fit the auxiliary pump drive idler gear in the special housing.Apply suitable sealant to the shutter plug, then fit it in the special housing.Fit the section of the engine oil dipstick inside the cylinder block/crankcase.Position a new oil pump gasket.Fit the oil pump tightening the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE OIL PUMP	M6	2.5

Fit the detonation sensor, the oil vapour separator and the engine oil pressure sender unit, tightening the fixings to torque.

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

Fit the crankshaft rear cover.Fit the engine flywheel, securing the fixing bolts.Fit the engine flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.000

Tighten the bolts fixing the flywheel to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL	M10	8.3

1. Line up the driven plate for fitting the clutch assembly (1a), using the centring pin (1b).2. Tighten the bolts fixing the clutch to the engine flywheel.

	Name	Country
1b	Clutch centering	1.870.447.000

Fit the water pump complete with filler pipe.Tighten the bolts fixing the water pump to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT PUMP	M6	2.5

Fit the mounting bracket and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR SUPPORT	M6	2.5

Fit the new cover gasket on the cylinder block/crankcase.1. Remove the gasket (1a) from the front cover using a drift in the slit (1b).

Fit the front cover to the engine block.Tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	0.7

1. Using the tool, fit the new oil seal in the housing.

	Name	Country
1	Fitting tool	1.860.878.000

Fit the belt tensioner support.1. Check that the diameter of the bearings (1a) and (1b) is within the recommended values. Also check that the clearance between the bearings and the bush housings in the cylinder block/crankcase are within the recommended values.

	Measurement		Value
1a	Gear-side pin outer diameter (mm)		35.593 - 35.618

	Measurement		Value
1b	Reverse idler side pin outer diameter (mm)		31.940 - 31.960

	Measurement		Value
1a	Clearance between gear-side pin - bush (mm)		0.046 - 0.091

	Measurement		Value
1b	Clearance between reverse idler side pin - bush (mm)		0.040 - 0.080

If the figures measured do not correspond to the recommended values, replace the shaft and the bushes refer to op. 1012B20 auxhiliary shaft crank case bushes - replace following operation 1004e20 .

Fit the shaft in the housing in the cylinder block/crankcase.1. Remove the gasket (1a), using a drift inserted in the special splining (1b) on the inner surface of the cover.

Position the cover on the engine crankcase in the auxiliary driveshaft.Tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	AUX SHAFT SEAL COVER	M6	1.1

1. Use tool (1a) to fit the new sealing ring (1b).

	Name	Country
1a	Fitting tool	1.860.882.000

Fit the timing belt lower rear shield.Fit the belt tensioner pulley.Fit the gear on the auxiliary drive shaft.Using a retaining tool, lock the gear and tighten the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	AUXILIARY SHAFT DRIVEN GEAR	M10	8

Clean the crankcase and oil sump contact surfaces to remove traces of silicone sealant.Apply silicon sealant around the edge of the crankcase sump.Fit the oil sump to the crankcase.Tighten the oil sump fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	OIL SUMP	M6	0.9

Clean the cylinder head and crankcase contact surfaces.Position the cylinder head gasket with the wording 'ALTO' [TOP] facing you.

ASTADUR type cylinder head gaskets are fitted. These gaskets are made out of special material designed to undergo polymerization during engine service. 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 container
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.

Before fitting the cylinder head, rotate the crankshft until the piston for cylinder no. 1 is approximately at T.D.C.Position the cylinder head on the crankcase.1. Tighten the cylinder head bolts, following the order shown in the figure below.2. Using the tool (2a), tighten the bolts (2b) fixing the head to torque, following the order illustrated previously.

	Name	Country
2a	Protractor	1.895.897.000

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CYLINDER HEAD	M10 x 1.25	4 + 90° + 90°

Connect the water pump engine coolant pipe.Fit the exhaust manifold to the cylinder head.Fit the power assisted steering pump mounting bracket on the exhaust manifold.Tighten the nuts fixing the exhaust manifold to the cylinder head .

	Fastening	Component	Ø	Value(daNm)
-	Bolt	EXHAUST MANIFOLD/S	M6	3

Fit the exhaust manifold heat shield.Tighten the nuts fixing the bulkhead.Fit a new cylinder head gasket.Fit the camshaft housing, taking care not to let the hydraulic tappets drop.Tighten the cylinder head fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CYLINDER HEAD EXTENSION GASKET	M6	(exhaust side) 1,5

Position the new inlet side camshaft housing gasket.Fit the camshaft housing, taking care not to let the hydraulic tappets drop.Tighten the cylinder head fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CYLINDER HEAD EXTENSION GASKET	M6	(inlet side) 1,5

Fit the timing belt rear protection.Fit the timing belt fixed tensioner, tightening the fixing bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FIXED TENSIONER	M12 x 1.25	8.7

Fit the camshaft pullies, without tightening the fixing bolts.Remove the camshaft rear covers from the camshaft housing.With the piston set to the newly-obtained TDC position, adjust camshaft timing.1. Position camshaft timing adjustment tools.2. When fitting the tools, align shaft seat (2a) with key (2b) on the tools.3. Tighten the tool retaining nuts.

	Name	Country
1	Template	1.860.874.000

The tools are stamped with the letters 'A' (intake) and 'S' (exhaust) to facilitate correct positioning on the shafts. The tools are not interchangeable.

Remove the spark plugs from their sockets on the cylinder head.1. Position a dial gauge (1a), supported by a pointer (1b) in the housing for the spark plug for cylinder no. 1. Turn the crankshaft with small, even movements until the dial gauge shows the cylinder no. 1 piston is at TDC.

	Name	Country
1b	Probe mount	1.860.895.000

Proceed with fitting the timing drive belt, fitting it initially on the crankshaft gear (1a), the oil pump gear (1b), the fixed pulley (1c), the inlet camshaft pulley (1d), the exhaust camshaft pulley (1e) and, lastly, on the automatic tensioner (1f).

1. Undo the retaining bolt.2. Position the toothed belt tensioning tool.

	Name	Country
2	Belt tensioner	1.860.876.000

1. Adjust the tool until the belt is as taut as possible, i.e. when the moving belt tensioner pointer is at the end of its travel.2. Tighten the tensioner retaining nut.

Use the pulley tightening tool to tighten the camshaft pulley retaining bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	12

	Name	Country
-	Support for counter-torque	1.860.831.000

	Name	Country
-	Adaptor	1.860.885.000

Remove the camshaft timing tools.

	Name	Country
-	Template	1.860.874.000

Remove the dial gauge together with the probe.

	Name	Country
-	Probe mount	1.860.895.000

Rotate the crankshaft through two revolutions in its normal direction of rotation.1. Loosen the belt tensioner retaining nut and use tool (1a) to slightly release belt tension until moving reference (1b) is aligned with fixed reference (1c) on the tensioning device.2. Tighten the tensioning device retaining nut to the specified torque.

	Name	Country
1a	Belt tensioner	1.860.876.000

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MOBILE TIMING TENSIONER	M6	2.5

Remove the tool and tighten the retaining bolt removed previously to the specified torque in order to fit the tensioning tool.

It is good practice to check timing again by refitting the tools to the camshafts and adjusting the engine until cylinder no. 1 is set to TDC, measured using the dial gauge and probe.If the engine timing is not correctly adjusted or the timing belt is found to be faulty, the removal-refitting and engine timing adjustment operation must be repeated.

Fit the camshaft rear covers.Fit the support for the ignition coils, tightening the nuts fixing the support and the covers to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	INTAKE AND EXHAUST CAMSHAFT REAR COVER	M6	0.9

Position the flywheel retainer.

	Name	Country
-	Counter-torque	1.860.846.000

Fit the crankshaft pulley with its phonic wheel.Tighten the pulley retaining nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CRANKSHAFT PULLEY	M20	19

Remove the flywheel lock.Fit the timing belt single shield.Fit the oil dipstick at the same time as the inlet manifold.Fit the wiring duct on the inlet manifold.Tighten the lower bolt fixing the oil dipstick and the nuts fixing the inlet manifold.

	Fastening	Component	Ø	Value(daNm)
-	Nut	INLET MANIFOLD	M8	2.5

Fit the air intake casing.Tighten the bolts and nuts securing the casing to the cylinder head extension.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	INLET AIR DUCT	M7	1.5

Tighten the bolts and nuts to the intake manifold. Fit the shield and fix it using the nuts.Connect the coolant pipe.Fit the engine oil filler pipe.Tighten the fixing bolts and connect the oil vapour inlet pipe.Fit the ignition coils on the mounting bracket, tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	IGNITION COIL/REEL	M6	0.9

Connect the supply connections for the coils to the spark plugs.Position the power assisted steering pump complete with supports.1. Fit the drive belt on the water pump and power assisted steering pump pullies.2. Acting on the adjustment nut and bolt, tension the power assisted steering pump drive belt.3. Using a dynamometer, check that the belt tension is correct.4. Tighten the bolts fixing the power assisted steering pump brackets to torque.Fit the pump plastic shield.

	Name	Country
3	Torque wrench	1.895.762.000

	Measurement		Value
-	Power steering pump new belt tension (daN)		32 - 45

	Fastening	Component	Ø	Value(daNm)
4	Nut	POWER STEERING PUMP SUPPORT/BRACKET	M10	5

Position the electrical wiring and connect the electrical connections.

	Name	Connector
-	Detonation sensor	K50

	Name	Connector
-	RPM sensor	K46

	Name	Connector
-	Brake fluid level sensor (switch)	K30

	Name	Connector
-	Alternator	A10

	Name	Connector
-	Injector	N70

	Name	Connector
-	Ignition coil	A30

	Name	Connector
-	Engine coolant temperature sensor	K45

	Name	Connector
-	Throttle position sensor	K56

	Name	Connector
-	Idle actuator	N74

	Name	Connector
-	Integrated air temperature sensor	K43

Position the part of the wiring concerned in the duct. - 1004D10 power unit (manual gearbox), removed, remove and re-build