3025986 - 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

Dismantling ( Reassembling ) Rotate the crankcase through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the alternator (1b).
1. Undo the bolts (1a) and remove the single drive pulley pulley (1b).2. Remove the timing drive belt.3. Undo the bolt (3a) and remove the timing belt tensioner (3b).4. Undo the bolts (4a) and remove the power steering pump mounting (4b) complete with power steering pump (4c), automatic tensioner for engine components drive belt (4d) and timing belt tensioner (4e). 5. Undo the bolts (5a) and remove the power unit rigid mounting, timing gear side (5b).
1. Fit the tool.

NameCountry
1Counter-torque1.820.624.000
2. Undo the bolt (2a) (left-hand) and remove the timing belt pulley (2b).3. Undo the bolts (3a) and remove the flywheel (3b).
1. Remove the tool.

NameCountry
1Counter-torque1.820.624.000
2. Fit the tool.

NameCountry
2Flange1.820.618.000
1. Undo the bolts (1a) and remove the oil pump (1b) complete with water-oil heat exchanger (1c), engine oil filter and intake duct (1d).2. Remove the gasket.3. Undo the bolts (3a) and remove the detonation sensors (3b).4. Remove the engine oil pressure switch.5. Undo the bolt (5a) and remove the rpm sensor (5b).6. Undo the bolts (6a) and remove the exhaust manifold mounting brackets (6b).7. Undo the bolts (7a) and remove the air intake chamber mounting (7b).8. Undo the bolts (8a) and remove the intermediate shaft mounting (8b).
Place the oil pump complete with water-oil heat exchanger, oil filter and intake duct in a vice fitted with protective jaws.1. Undo the bolts (1a) and remove the intake duct (1b).2. Remove the gasket.3. Remove the oil filter.4. Undo the bolts (4a) and remove the heat exchanger (4b) complete with pipes.5. Remove the gasket.
Rotate the crankcase through 180° on the overhauling stand.Check that the crankshaft end float is within the recommended values using a magnetic base fitted with a dial gauge.

MeasurementValue
-Crankshaft end float (mm)0.059 ÷ 0.221
If the end float of the crankshaft is not within the recommended values, when refitting, reface the seat in the cylinder block and use suitable oversize thrust washers.Rotate the crankshaft using the tool fitted previously until the pistons of cylinders no. 1 and no. 4 are at B.D.C.1. Undo the bolts (1a) and remove the connecting rod caps (1b) and bearing shells (1c) of cylinders no. 1 and no. 4.2. Remove the connecting rod-piston assemblies (2a) complete with bearing shell (2b) of cylinders no. 1 and no. 4.Do the same to remove the connecting rod-piston assemblies of cylinders no. 2 and no. 3.3. Remove the tool.

NameCountry
3Flange1.820.618.000
4. Undo the bolts (4a) and remove the cylinder block rear cover with integrated oil seal (4b).
1. Undo the bolts (1a) and remove the main bearing caps (1b) complete with bearing shells (1c).2. Remove the crankshaft.3. Remove the half-bearings.4. Remove the thrust washers.5. Undo the bolt (5a) and remove the oil jets (6b) from the cylinder block.
Undo the attachments and remove the cylinder block from the overhaul stand and place it on a suitable work bench.1. Undo the bolts (1a) and remove the flywheel guard (1b).
Proceed with removal  - 1028H60  piston, pin set - replace .Proceed with removal  - 1084B18  engine oil pump, removed - check at bench .Drill and remove the water/oil sealing plugs from the crankcase to allow washing. Reassembling ( Dismantling ) 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.

MeasurementValue
-Flatness of cylinder head supporting surface (mm)< 0.1
Measure the cylinder liner diameter and check that it is within the specified values.

MeasurementValue
-Cylinder bore diameter (mm)Category B82.010 ÷ 82.020
Category C82.020 ÷ 82.030
Class A82.000 ÷ 82.010
Check that the conicity of the cylinder liners/bores is within the recommended values.

MeasurementValue
-Cylinder bore taper (mm)< 0.010
Check that the ovality of the cylinder liners is within the recommended values.

MeasurementValue
-Cylinder bore ovalization (mm)<0.005
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.
If reboring is required, all the cylinder liners must be rebored to the same oversize.

MeasurementValue
-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.
2. Tighten the bearing cap bolts (1a) to the recommended torque

FasteningComponentØValue(daNm)
2----
Use a goniometer for the angular tightening of the bearing cap bolts.

NameCountry
-Protractor1.860.942.000
3. Check that the diameter of the bearing seats is within the recommended values.

MeasurementValue
3Main bearing seat diameter (mm)56.705 ÷ 56.718
Check that the crankshaft lubrication ducts are free from deposits.Check that the diameter of the main journals is within the recommended values.

MeasurementValue
-Main bearing journal diameter (mm)Category B52.988 ÷ 52.994
Category C52.982 ÷ 52.988
Classe A52.994 ÷ 53.000
If the diameter of the main journals is not within the recommended values, regrind them in accordance with the recommended undersize.

MeasurementValue
-Main journal diameter undersize (mm)0.127
Undersizes for bearings above the value mentioned adversely affect the structural resistance of the crankshaft (as a result of contact between the tool and the connectors). As far as the above is concerned, if the regrinding requires undersizes above 0.127 mm, the crankshaft must be replaced with a new one ordered from the Parts Dept. The half-bearings used for undersizes above 0.127 mm should no longer be requested from the Parts Dept. (even if the number is still shown).
The clearance between the main journals and the half-bearings is given below.

MeasurementValue
-Crankpin/bearing shell play (mm)0.031 ÷ 0.051
Check that the diameter of the crankpins is within the recommended values.

MeasurementValue
-Crankpin diameter (mm)Category B40.878 ÷ 40.884
Category C40.872 ÷ 40.878
Classe A40.884 ÷ 40.890
If the diameter of the crankpins is not within the recommended values, regrind them in accordance with the recommended undersize.

MeasurementValue
-Crankpin diameter undersize (mm)0.127
Undersizes for big end bearings above the value mentioned adversely affect the structural strength of the crankshaft (as a result of contact between the tool and the connectors). As far as the above is concerned, if the regrinding requires undersizes above 0.127 mm, the crankshaft must be replaced with a new one ordered from the Parts Dept. The half-bearings used for undersizes above 0.127 mm should no longer be requested from the Parts Dept. (even if the number is still shown).
The clearance between the main journals and the half-bearings is given below.

MeasurementValue
-Crankpin/big end bearing play (mm)0.030 ÷ 0.056
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  - 1028H58  connecting rod small end bush - replace .

MeasurementValue
-Small end bushes inner diameter (reaming) (mm)20.006 ÷ 20.012
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.

MeasurementValue
-Gudgeon pin outer diameter (mm)19.996 ÷ 20.000
Fit the seals in the cylinder liner/bore and check that the opening between the ends is within the recommended values; if this is not the case, replace the piston seals.

MeasurementValue
-Piston ring gap (mm)1˚ ring0.20 ÷ 0.35
2˚ seal0.25 ÷ 0.50

MeasurementValue
-Big end diameter (mm)Category B40.914 ÷ 40.934
Category C40.908 ÷ 40.928
Classe A40.920 ÷ 40.940
The size of the seals is given below.

MeasurementValue
-Thickness of piston rings (mm)1˚ ring1.19
2˚ seal1.2

MeasurementValue
-Thickness of oil scraper rings (mm)2.0
The seals are also available in the following oversizes.

MeasurementValue
-Piston ring thickness oversize (mm)0.1

MeasurementValue
-Piston ring thickness oversize (mm)0.4 (*)
Check that the outer diameter of the pistons is within the recommended values. if this is not the case, replace the piston complete with seals and gudgeon pin.
The outer diameter of the pistons should be measured perpendicular to the gudgeon pin axis and at 12.5 mm from the lower edge of the skirt.

MeasurementValue
-Piston outer diameter (mm)Category B81.960 ÷ 81.970
Category C81.968 ÷ 81.978
Class A81.952 ÷ 81.962
The clearance between the pistons and the cylinder liners/bores is given below.

MeasurementValue
-Piston/cylinder liner play (mm)Category B0.039 ÷ 0.061
Category A0.038 ÷ 0.058
Category C0.042 ÷ 0.062
Check that the endfloat between compression rings and their seats is within the specified values; if this is not the case, fit oversize seals.

MeasurementValue
-Seal end float (mm)1˚ ring0.030 ÷ 0.070
2˚ seal0.020 ÷ 0.055

MeasurementValue
-Piston oil scraper ring end float (mm)0.020 ÷ 0.055
Check that the diameter of the gudgeon pin housing in the piston is within the recommended values.

MeasurementValue
-Gudgeon pin housing diameter (mm)-
1. Fit the half-bearings and 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.

FasteningComponentØValue(daNm)
1c----
Use a goniometer for the angular tightening of the connecting rod cap fixing bolts.

NameCountry
-Protractor1.860.942.000
2. Check that the diameter of the big end is within the recommended values; if this is not the case, replace the connecting rods.

MeasurementValue
2Big end diameter (mm)Category B40.914 ÷ 40.934
Category C40.908 ÷ 40.928
Classe A40.920 ÷ 40.940
Proceed with refitting  - 1028H60  piston, pin set - replace .Proceed with refitting  - 1084B18  engine oil pump, removed - check at bench .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 guard and fix it to the cylinder block using the bolts.Mount the cylinder block on the overhaul stand.Fit the oil jets in the cylinder block and fix them using the bolts.Fit the thrust washers on the third main bearing.Main journal half-bearings have been fitted on crankshafts which have been selected so that the matching clearance is optimum.
The crankshaft is supplied,bythe Parts Dept.,without the appropriate half-bearingsfor 'normal' dimension main journals and crank pins; it is therefore necessary to select the main journal half-bearings to be fitted identifying the grade for each main journal and crank pin for the new crankshaft.
The following is needed for selecting the main journal half-bearings:

The following is needed for selecting the main journal half-bearings:

  • the code number stamped on the flywheel;
  • the paint mark, if present, next to the main journals.
Below is an example of the identification of main journal grades.
1 - Crank pin identification number: the number on the left refers to the first timing side bearing; the final 'N' is a code that does not matter for 4 cylinder engines. 2 - Main journal identification code: the first number on the left refers to the first timing side bearing; the final 'N' is a code that does not matter for 4 cylinder engines. 3 - Set of numbers (if present), in groups of two digits, which indicate the dimensions (thousandth part) of the main journals: the first two numbers on the left refer to the first bearing on the timing side.
Only use the codes in the key, all other codes on the flywheel should not be used.
For the identification of the main journal grade, refer to the numerical code for reference 2 in the key.In the case of the example, the numbers 11111N indicate that all five bearings are Grade A (red colour) as described below.A further method for identifying the grade of the bearings is to read reference 3 in the figure (if present).In the case of the example, the number 94 (first on the left) corresponds to the dimension 52.994 for the first bearing on the timing side which identifies Grade A (red colour); the same method can be used for all the other groups of two digits for the same reference 3 (97 - 95 - 95 - 94).MAIN JOURNAL IDENTIFICATIONGrade A main journal (normal), diameter 52.994 53.000 mm, RED paint mark, code number 1 (94 00)*Grade B main journal (normal), diameter 52.988 52.994 mm, BLUE paint mark, code number 2 (88 94)*Grade C main journal (normal), diameter 52.982 52.988 mm, YELLOW paint mark, code number 3 (82 88)*Grade D main journal (0.127mm undersize) diameter 52.867 52.873 mm, BROWN paint mark, code number 6 (67 73)*Grade E main journal (0.127 mm undersize) diameter 52.861 52.867 mm, GREEN paint mark, code 7 (61 67)* Grade F main journal (0.127 undersize) diameter 52.855 52.861 mm, BLACK paint mark, code number 8 (55 61)*(*) Last two numbers (thousandth part) of the dimensions of the main journals.If a crankshaft is being used where the maximum bearing undersize through regrinding is 0.127 mm, then the grade should be selected by measuring the dimensions of the diameter of the bearing with reference to the above. Having defined the grade and colour for each new or reground crankshaft bearing, it is necessary to select the pair and the size for the bearings which should be the same colour as the corresponding bearing; at the Parts Dept. it is possible to go back to the part no. of the pair of half-bearings required.The above is designed to ensure the optimum operating clearance for all bearings.

Lastly, we wish to point out that, usually, the clearance between the main journal and the half-bearing, produced by the selection method described above, should be between the following figures:

  • Minimum: 0.031 mm - Maximum: 0.051 mm; this value can be measured, as a final check, using the Plastic Gauge.
1. Fit the main bearing shells.2. Fit the crankshaft on the cylinder block/crankcase.3. Fit the main bearing caps (3a) complete with bearing shells (3b).
The bearing caps have progressive references (from zero to four starting from the front of the engine) which define their fitting position.
4. Tighten the bearing cap bolts (1a) to the recommended torque

FasteningComponentØValue(daNm)
4----
Use the tool for angular tightening of the main bearing cap bolts.

NameCountry
-Protractor1.860.942.000
1. Refit in its seating the oil cover, flywheel side (1a), and tighten the bolts (1b) to the specified torque.

FasteningComponentØValue(daNm)
1b----
1. Fit the tool.

NameCountry
1Flange1.820.618.000
Rotate the crankshaft until cylinders no. 1 and no. 4 are at B.D.C.2. Fit the connecting rod-piston assemblies (2a) complete with bearing shells (2b) for cylinders no. 1 and no. 4.
To select the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.
3. Fit the big end bearing caps (3a) complete with bearing shells (3b) and tighten the bolts (3c) to the recommended 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).

FasteningComponentØValue(daNm)
3c----
Use a goniometer for the angular tightening of the connecting rod cap fixing bolts.

NameCountry
-Protractor1.860.942.000
Do the same to fit the connecting rod-piston assemblies of cylinders no. 2 and no. 3.Remove the tool.

NameCountry
-Flange1.820.618.000
Place the oil pump in a vice fitted with protective jaws.Fit the heat exchanger complete with pipes and a new gasket and fix it to the oil pump with the bolt.Fit the oil filter.Fit the intake duct complete with gasket and fix it to the oil pump using the bolts.Fit the exhaust manifold mounting brackets and fix them to the cylinder block using the bolts.Fit the rpm sensor and secure it using the bolt.Fit the engine oil pressure switch and tighten it to the specified torque.

FasteningComponentØValue(daNm)
-----
Fit the knock sensor and fix it using the bolt.Fit the oil pump complete with water-oil heat exchanger, oil filter, intake duct and gasket and fix it to the cylinder block tightening the bolts to torque.

FasteningComponentØValue(daNm)
-----
Apply sealant to the entire perimeter of the crankcase sump.1. Fit the crankcase sump.2. Tighten the front and rear bolts (2a) fixing the crankcase sump to the recommended torque using tool (2b).

FasteningComponentØValue(daNm)
2a----

NameCountry
2bKey1.822.145.000
3. Tighten the side bolts (3a) for the crankcase sump to the recommended torque using the tool (3b).

FasteningComponentØValue(daNm)
3a----

NameCountry
3bKey1.822.144.000
Rotate the crankcase through 180° on the overhauling stand.Fit the power steering pump mounting complete with power steering pump, automatic tensioner for engine components drive belt and timing belt tensioner and tighten the bolts.Fit the timing belt pulley and fix it using the bolt (left-hand) without tightening it.Bring cylinder no. 1 to T.D.C.Position the cylinder head centring bushes on the cylinder block/crankcase.Fit a new cylinder head gasket.
The cylinder head gasket is of the Astadur type.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 fittingnot lubricate or get oil on the gasket and the contact surfaces.
Position the cylinder head on the cylinder block, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).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.
To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

FasteningComponentØValue(daNm)
1aBoltCYLINDER HEADM104.0+90˚+90˚+90˚

NameCountry
1bProtractor1.860.942.000
The value of 4.0 daNm should be implemented by tightening to 2.0 daNm and then increased by a torque of 2.0 daNm until the nominal value of 4.0 daNm is reached.
Fit the exhaust manifold gasket.Fit the gasket for the rigid coolant inlet pipe to the pump.Fit the coolant inlet pipe to the pump.Fit the engine oil dipstick and fix it using the bolts.Connect, to the rigid coolant inlet pipe to the pump, the connector for the coolant outlet pipe from the heat exchanger.Fit the exhaust manifold and fix it to the cylinder head, tightening the nuts to torque.

FasteningComponentØValue(daNm)
-----
Fit the intermediate shaft support and fix it using the bolts.Fit the air conditioner compressor support and fix it to the cylinder block using the bolts.Fit the air conditioner compressor mount and secure using the bolts.Fit the air intake chamber mounting and secure with its bolts.Fit the timing belt side guards and fix them using the bolts. Fit the timing belt.
Check that the camshaft pulley bolts are slackened to permit perfect timing adjustment.
1. Apply maximum tension to the timing belt using the tool.

NameCountry
1Key1.822.149.000
2. Tighten the timing belt tensioner nut to the specified torque.

FasteningComponentØValue(daNm)
2----
3. Tighten the bolts (3a) for the inlet side camshaft pulley to the recommended torque, using the tool (3b) for counter-torque.

FasteningComponentØValue(daNm)
3a----

NameCountry
3bCounter-torque1.822.155.000
4. Tighten to torque the bolt (4a) on the exhaust side camshaft pulley, using the tools (4b) for counter-torque.

FasteningComponentØValue(daNm)
4a----

NameCountry
4bCounter-torque1.822.146.000

NameCountry
4bCounter-torque1.822.156.000
Fit the camshaft caps removed previously and tighten the bolts to torque.

FasteningComponentØValue(daNm)
-----
Rotate the crankshaft through two revolutions.Slacken the timing belt tensioner nut.5. Line up the moving reference (5a) on the timing belt tensioner with the reference hole (5b) using the tool (5c).

NameCountry
5cKey1.822.149.000
Tighten the timing belt tensioner nut to the specified torque.

FasteningComponentØValue(daNm)
-----
Remove the tool complete with dial gauge.

NameCountry
-Extension1.825.013.000
Remove the tool.

NameCountry
-Flange1.820.618.000
Fit the flywheel and fix it using the bolts, without tightening them.Fit the tool.

NameCountry
-Counter-torque1.820.624.000
Tighten the flywheel bolts to torque.

FasteningComponentØValue(daNm)
-----
Tighten the timing belt pulley bolt (left-hand) to the specified torque.

FasteningComponentØValue(daNm)
-----
Remove the tool.

NameCountry
-Counter-torque1.820.624.000
Fit the spark plugs.Fit the rocker cover complete with gasket and fix it using the bolts.Fit the bracket complete with ignition coils and high-tension cables and fix it using the boltsConnect the high tension leads to the spark plugs.Connect the earth lead to the cylinder head.Tighten the bolts securing the mounting bracket to the intake chamber.Connect the oil vapour recovery pipe to the rocker cover.Connect the ignition switch electrical connectiond and secure the electrical wiring to the bands.Fix the electrical wiring form the rpm and timing sensor and knock sensor using the bands located under the air intake chamber.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the rpm sensor.Connect the electrical connection for the cam angle sensor.Fit the power steering fluid reservoir and tighten the bolts.Connect the electrical connection for the air conditioning compressor.Fit the timing belt upper guard and fix it using the bolts.Fit the engine components belt drive pulley and fix it tightening the bolts to the recommended torque.

FasteningComponentØValue(daNm)
-----
Fit the engine components drive belt guide pulley and fix it using the bolt.Fit the power unit rigid support, timing gear side, and fix it using the bolts.Fit the alternator and fix it using the bolts.Fit the auxiliary components drive belt, using a spanner to lever on the automatic belt tensioner.Proceed with refitting  - 1004D40  engine - position on stand and remove .