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 - Alfa - 147 - eLearn

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

Rotate the crankcase through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the alternator (1b).

1. Loosen the nut for the counter-balance shaft toothed drive belt tensioner.2. Release and remove the counter-balance shaft drive belt.3. Remove the timing drive belt.4. Undo the bolts (4a) and remove the support on the engine for the reaction rod, various engine components and intermediate driveshaft (4b) complete with power assisted steering pump (4c) and single drive belt moving tensioner (4d).

1. Undo the bolts (1a) and remove the power unit rigid support, timing gear side (1b).2. Undo the bolts (2a) and remove the mounting (2b) complete with the moving tensioner (2c) and fixed tensioner (2d) for the timing drive belt.3. Undo the bolts (3a) and remove the counter-balance shaft drive belt drive pulley (3b).

1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.161.001

2. Undo the (left hand thread) bolt (2a) and remove the timing drive pulley (2b).3. Undo the bolts (3a) and remove the flywheel (3b).

1. Remove the flywheel lock.

	Name	Country
1	Counter-torque	1.860.161.001

2. Fit the tool.

	Name	Country
2	Flange	1.820.618.000

1. Undo the bolts (1a) and remove the crankshaft front cover (1b), complete with engine oil heat exchanger (1c), engine oil filter (1d) and intake (1e). 2. Remove the gasket.3. Undo the bolt (3a) and remove the detonation sensor (3b).4. Remove the insufficient engine oil pressure switch.5. Undo the bolt (5a) and remove the rpm sensor (5b).

Position the complete front oil seal cover 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 engine oil filter using a suitable tool.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.

	Measurement		Value
-	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.Proceed in the same way when removing the connecting rod-piston assemblies for cylinders no. 2 and 3.3. Remove the tool.

	Name	Country
3	Flange	1.820.618.000

4. Undo the bolts (4a) and remove the oil cover, flywheel side (4b).

1. Undo the bolts (1a) and remove the main bearing caps (1b) complete with bearing shells (1c).2. Remove the crankshaft pulley.3. Remove the main bearing shells4. Remove the thrust washers.5. Undo the bolt and remove the engne oil jets (5b) from the cylinder block/crankase.

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 engine flywheel protection (1b).

1. Undo the bolts (1a) on the counter-balance shaft pulleys using the tool (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.820.286.000

2. Remove the counter-balance shaft pulleys.3. Undo the bolts (3a) and remove the right counter-balance shaft front cover (3b) complete with oil seal and O-ring.4. Undo the bolts (4a) and remove the left counter-balance shaft front cover complete with oil seal, O-ring and counter-balance shafts drive belt moving tensioner. 5. Completely undo the nut (5a) and remove the counter-balance shaft drive belt tensioner (5b).

Remove the O-rings and oil seals from the counter-balance shafts front covers.1. Remove the spacers (1a) and O-rings (1b) from the counter-balance shafts.2. Remove the counter-balance shaft rear plugs.3. Remove the counter-balance shafts (3a) complete with rear bearings (3b) using a suitable drift (3c).

1. Remove the counter-balance shafts front bearings (1a) from the cylinder block using the tools (1b) and (1c).

	Name	Country
1b	Extractor	1.820.626.000

	Name	Country
1c	Counter weight	1.840.206.001

Position the counter-balance shaft in a vice fitted with protective jaws.1. Remove the circlip retaining the rear bearing to the counter-balance shaft.2. Remove the counter-balance shaft rear bearing (2a) using a suitable drift (2b).

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. Wash all 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

Measure the cylinder liner diameter and check that it is within the specified values.

	Measurement		Value
-	Cylinder bore diameter (mm)	Category B	83.010 ÷ 83.020
Category C	83.020 ÷ 83.030
Class A	83.000 ÷ 83.010

Check that the conicity of the cylinder liners/bores is within the recommended values.

	Measurement		Value
-	Cylinder bore taper (mm)		< 0.010

Check that the ovality of the cylinder liners is within the recommended values.

	Measurement		Value
-	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.

	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.

2. Tighten the bearing cap bolts to the recommended torque using the angular tightening tool.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	BIG END BEARING CAPS	M12	2.4 ÷ 2.6 + 100

	Name	Country
-	Protractor	1.860.942.000

3. Check that the diameter of the bearing seats is within the recommended values.

	Measurement		Value
3	Main 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.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	52.988 ÷ 52.994
Category C	52.982 ÷ 52.988
Classe A	52.994 ÷ 53.000

If the diameter of the main journals is not within the recommended values, regrind them in accordance with the recommended undersize.

	Measurement		Value
-	Main 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.

	Measurement		Value
-	Crankpin/bearing shell play (mm)		0.031 ÷ 0.051

Check that the crankpin diameter is within the specified 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 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.

	Measurement		Value
-	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 .

	Measurement		Value
-	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.

	Measurement		Value
-	Gudgeon pin outer diameter (mm)		19.996 ÷ 20.000

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
-	Cylinder liner oversize (mm)		0.1

From September 2003 sealing rings with modified profiles are used; the gap of the 1st ring becomes 0.20 0.35 mm.

	Measurement		Value
-	Piston oil scraper ring gap (mm)		0.25 ÷ 0.45

The size of the seals is given below.

	Measurement		Value
-	Thickness of piston rings (mm)	1˚ ring	1.19
2˚ seal	1.5

From September 2003 sealing rings with modified profiles are used; the thickness of the 2nd ring becomes 1.19 mm

	Measurement		Value
-	Thickness of oil scraper rings (mm)		2.0

The seals are also available in the following oversizes.

	Measurement		Value
-	Piston ring thickness oversize (mm)		0.1

	Measurement		Value
-	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 rings and gudgeon pin.

The outer diameter of the pistons should be measured perpendicular to the gudgeon pin axis 12.5 mm from the skirt lower edge.

	Measurement		Value
-	Piston outer diameter (mm)	Category B	82.959 ÷ 82.971
Category C	82.969 ÷ 82.978
Class A	82.952 ÷ 82.962

The clearance between the pistons and the cylinder liners/bores is given below.

	Measurement		Value
-	Piston/cylinder liner play (mm)	Category B	0.039 ÷ 0.061
Category A	0.038 ÷ 0.058
Category C	0.042 ÷ 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.

	Measurement		Value
-	Seal end float (mm)	1˚ ring	0.030 ÷ 0.070
2˚ seal	0.020 ÷ 0.055

	Measurement		Value
-	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.

	Measurement		Value
-	Gudgeon pin housing diameter (mm)		-

1. Fit the caps (1b) on the connecting rods (1a) and fix them tightening the bolts (1c) to torque using the angular tightening tool.

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.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	BIG END BEARING CAPS	M9	2.4 ÷ 2.6 +60

	Name	Country
-	Protractor	1.860.942.000

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

	Measurement		Value
2	Big end diameter (mm)		53.897 ÷ 53.909

Proceed with refitting - 1028H60 piston, pin set - replace .Proceed with refitting - 1084B18 engine oil pump, removed - check at benchCheck that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Place the counter-balance shafts in a vice fitted with special protection.1. Fit the rear bearings (1a) on the counter-balance shafts using a suitable fitting tool (1b).Fix the rear bearings to the counter-balance shafts using the circlips.

1. Fit the counter-balance shaft front bearings (1a) on the cylinder block using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

1. Fit the counter-balance shafts (1a) complete with rear bearings (1b) in the cylinder block using the tool (1c).

	Name	Country
1c	Fitting tool	1.821.247.000

Fit the counter-balance shafts rear plugs.Fit new O-rings and spacers on the counter-balance shafts.Fit new O-rings on the counter-balance shaft front covers.1. Fit new oil seals (1a) on the counter-balance shaft front covers using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

2. Fit the counter-balance shaft front covers (2a) and tighten the bolts (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COUNTER ROTATING SHAFT FRONT COVER	M6	0.8 ÷ 1.0

3. Fit the counter-balance shaft drive belt tensioner (3a) and fix it using the nut (3b) without tightening it.4. Fit the counter-balance shaft drive pullies (4a) and fix them tightening the bolts (4b) to the recommended torque using the tool (4c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
4b	Bolt	COUNTER-ROTATING SHAFT PULLEY	M10	(Counter balance shaft side) 4.5 ÷ 5.5

	Name	Country
4c	Counter-torque	1.820.286.000

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, by the Parts Dept., without the appropriate half-bearings for '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 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

	Fastening	Component	Ø	Value(daNm)
4	Bolt	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 100

Use the tool for angular tightening of the main bearing cap bolts.

	Name	Country
-	Protractor	1.860.942.000

1. Refit the flywheel side oil seal (with the gasket incorporated) (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CRANKSHAFT REAR COVER	M6	(Engine crankcase side) 0.8 ÷ 1.0

1. Fit the tool.

	Name	Country
1	Flange	1.820.618.000

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.

The piston-connecting rod assemblies should be fitted with the large references (for the inlet valves) on the piston crowns facing the inlet side.

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).

	Fastening	Component	Ø	Value(daNm)
3c	Bolt	BIG END BEARING CAPS	M9	2.4 ÷ 2.6 + 60

Use a goniometer for the angular tightening of the connecting rod cap fixing bolts.

	Name	Country
-	Protractor	1.860.942.000

Proceed in the same way when fitting the connecting rod-piston assemblies for the 2nd and 3rd cylinders.Remove the tool.

	Name	Country
-	Flange	1.820.618.000

Position the crankshaft front cover complete with oil seal in a vice fitted with protective jaws.Place the engine oil heat exchanger, complete with pipes, and new gasket, back in its housing and secure it using the pin.Refit the engine oil filter in its seating and tighten it fully by hand.Place the intake duct complete with gasket in its housing and fix it to the oil pump using the bolts.Replace the rear wheel rpm sensor in its housing and fix it using the bolt.Fit the insufficient engine oil pressure warning light switch in its seating and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	OIL PRESSURE W/L	M14	(Engine crankcase side) 2.7 ÷ 3.3

Replace the knock sensor in its housing and fix it using the bolt.Place the crankshaft front cover, complete with engine oil heat exchanger, engine oil filter, intake and gasket, back in its housing and secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	(Engine crankcase side) 0.8 ÷ 1.0

Clean the matching surfaces of crankcase sump and cylinder block. Apply silicone sealant around the edge of the crankcase sump. 1. Position the sump on the crankcase.2. Tighten the front and rear bolts (2a) fixing the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	OIL SUMP	M8	(Engine crankcase side) 2.3 ÷ 2.8

	Name	Country
2b	Key	1.822.145.000

3. Tighten the side bolts (3a) fixing the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Side bolt	OIL SUMP	M6	(Engine crankcase side) 0.8 ÷ 1.0

	Name	Country
3b	Key	1.822.144.000

Tighten the bolt fixing the crankcase sump to the support on the engine for the reaction rod.Rotate the crankcase through 180° on the overhauling stand.Place the support on the engine for the reaction rod, various engine components and intermediate driveshaft, complete with power assisted steering pump and single drive belt moving tensioner back in its housing and secure it by tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M8	(Engine crankcase side) 2.3 - 2.8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M10	(Engine crankcase side) 4.5 - 5.5

Place the support, complete with moving tensioner and fixed tensioner for the timing drive belt, back in its housing and secure it using the bolts.Place the drive pulley back in its housing and secure it without tightening the bolt (left hand thread).Position the cylinder head centring bushes on the cylinder block/crankcase.Place the cylinder head gasket back in its housing.

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 cylinder no. 1 at T.D.C.Position the cylinder head on the cylinder block taking care to ensure that the valves for cylinder no. 1 are closed. 1. Tighten the bolts (1a) fixing the cylinder head 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.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 4.0 + 90˚ + 90˚ + 90 ˚

	Name	Country
1b	Protractor	1.860.942.000

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.

Place the water pump rigid inlet pipe, complete with gasket, back in its housing and secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT PUMP RIGID INLET PIPE	M6	(Cylinder head side) 0.8 ÷ 1.1

Place a new exhaust manifold gasket in the housing.Place the bracket fastening the water pump rigid coolant inlet pipe back in its housing and fasten it using the nut and the bolt.Place the engine oil dipstick back in its housing and fix it using the bolt.Connect the coolant supply flexible pipe to the engine oil heat exchanger to the thermostat.Refit exhaust manifold and secure to the cylinder head by tightening bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.3 ÷ 2.8

Place the air conditioner compressor support back in its housing and fix it to the cylinder block using the bolts.Place the air conditioning compressor back in its housing and secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M8	(Support side) 2.3 ÷ 2.8

Tighten the bolts securing the mounting bracket to the intake chamber.Place the protective timing side covers back in their housings and secure them using the bolts. 1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Extension	1.825.013.000

Rotate the crankshaft in a clockwise direction until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.

If TDC is exceeded, do not turn backwards, but proceed by rotating the crankshaft through a further two revolutions in the same direction until the piston for cylinder no. 1 is at TDC.

1. Undo the bolts (1a) of the timing driven pulley, inlet side, using the tool (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.822.155.000

2. Loosen the bolt (2a) for the camshaft driven pulley, exhaust side, using tools (2b) and (2c) for counter-torque.

	Name	Country
2b	Counter-torque	1.822.156.000

	Name	Country
2c	Counter-torque	1.822.146.000

Undo the bolts and remove the camshaft third cap.1. Fit the tool (1a) in place of the camshaft caps removed and fix it tightening the bolts (1b) to the recommended torque.

Check that the camshaft cam profile matches the tool correctly.

	Name	Country
1a	Gauge	1.825.041.000

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE TIMING ADJUSTMENT TEMPLATES	M7	(Cylinder head side) 1.0

1. Fit the timing belt, following the order indicated in the diagram: toothed drive pulley (1a)fixed tensioner (1b)exhaust side toothed driven pulley (1c)

Before fitting the belt on the exhaust side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

inlet side toothed driven pulley (1d).

Before fitting the belt on the inlet side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

mobile tensioner (1e)coolant pump pulley (1f).

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation (clockwise - timing side).

1. Using the tool, rotate the timing moving tensioner until the maximum tension is applied to the timing belt.

	Name	Country
1	Key	1.822.149.000

2. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 2.8

1. Tighten the bolts (1a) for the camshaft driven pulley, inlet side, to the recommended torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M6	(Inlet camshaft side) 0.8 ÷ 1.0

	Name	Country
1b	Counter-torque	1.822.155.000

2. Tighten the bolt (2a) fixing the exhaust side timing driven pulley to the recommended torque, using the tools (2b) and (2c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Exhaust camshaft side) 10.8÷13.2

	Name	Country
2b	Counter-torque	1.822.156.000

	Name	Country
2c	Counter-torque	1.822.146.000

Remove the tool for timing the camshafts.

	Name	Country
-	Gauge	1.825.041.000

Place the previously removed camshaft caps back in their housings and secure them tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 1.4 ÷ 1.7

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) and ensure that the piston for cylinder no. 1 is at TDC. 1. Fit the tool (1a) for keeping the moving timing tensioner still and loosen the tensioner nut (1b).

	Name	Country
1a	Key	1.822.149.000

2. Rotate the tool (2a) in an anti-clockwise direction (timing side) until the tensioner moving reference (2b) coincides with the reference opening (2c).

	Name	Country
2a	Key	1.822.149.000

3. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 2.8

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) until cyllinder no. 1 is at TDC in the explosion stroke and check that the engine timing is correct using the tool.

	Name	Country
-	Gauge	1.825.041.000

Remove the tool to check T.D.C. from the cylinder 1 spark plug socket.

	Name	Country
-	Extension	1.825.013.000

Place the spark plugs for cylinder no. 1 back in their housings and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	SIDE SPARK PLUG	M10	(Cylinder head side) 1.0 ÷ 1.3

	Fastening	Component	Ø	Value(daNm)
-	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M8	(Support side) 2.3 ÷ 2.8

Place the counter-balance shafts belt drive pulley back in its housing and fix it using the bolts.1. Rotate the counter-balance shafts so that the references (1a) on the pullies are aligned with the ribs (1b).2. Temporarily fit the lower timing cover and the crankshaft pulley and check the alignment of the references. Fit the counter-balance shaft toothed drive belt.

1. Tension the counter-balance shaft drive belt using the tool (1a) so that the reference opening (1b) in the belt tensioner is at the centre of the rotation sector.

	Name	Country
1a	Key	1.822.154.000

2. Tighten the nut fixing the counter-balance shaft drive belt tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	COUNTER-ROTATING SHAFT BELT TENSIONER	M6	(.Left. counter balance shaft front) cover side 0.8÷1.0

Place the flywheel back in its housing and fix it using the bolts.Fit the tool.

	Name	Country
-	Counter-torque	1.860.161.001

Tighten the new bolts pre-treated with sealant fixing the flywheel to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL	M12	(Crankshaft side) 14.4 ÷ 17.6

Tighten the bolt (left hand thread) for the drive pulley to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	(Crankshaft side) 20.9 ÷ 23.1

Remove the tool.

	Name	Country
-	Counter-torque	1.860.161.001

Place the tapper cover, complete with gasket, back in its housing and fix it using the bolts.Connect the oil vapour recovery pipe to the rocker cover.Fit the plate complete with ignition coils and high-tension cables and fix it using the bolts.Connect the high tension leads to the spark plugs.Connect the earth lead to the ignition coils support plate.Connect the electrical connections to the ignition coils and position the electrical wiring in its housing.Connect the electrical connection to the air conditioner compressor. Connect the electrical connection for the rpm sensor.Connect the electrical connection for the detonation sensor.Secure the rpm sensor and knock sensor electrical wiring using the bands under the air chamber.Place the power assisted steering fluid reservoir mounting bracket back in its housing and secure it using the bolt.Connect the electrical connection for the cam angle sensor.Fit the lower protective timing cover and secure using the bolts.Place the timing belt upper cover back in its housing and secure it using the bolts.Fit the engine components belt drive pulley and fix it tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.3 ÷ 2.8

Place the power unit rigid support, timing gear side, back in its housing and fix it using the bolts.Place the alternator back in its housing and secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR ASSEMBLY	M10	4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR ASSEMBLY	M12	6.3 ÷ 7.7

Place the engine components single drive belt fixed tensioner back in its housing and fix it tightening the bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M10	4.5 ÷ 5.5

Place the plug back in the housing on the fixed tensioner.Adjust the moving tensioner and fit the engine components single drive belt using a spanner.Place the auxiliary units drive belt protection back in its housing and secure it using the bolts and the nut..Proceed with refitting - 1004D40 engine - position on stand and remove .