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).2. Undo bolts (2a) and remove rear alternator bracket (2b).3. Undo bolts (3a) and remove intermediate shaft mount (3b).
1. Undo bolts (1a) and remove air conditioner compressor (1b).2. Undo the bolts (2a) and remove the air conditioner compressor
mounting (2b).3. Remove the oil filter.4. Undo the nut fixing the coolant supply pipe to the engine oil
heat exchanger.5. Undo the connector (5a) and remove the heat exchanger (5b), complete
with pipes.
1. Fit the tool.
| Name | Country |
|---|
| 1 | Counter-torque | 1.820.624.000 |
1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Remove the timing belt.3. Undo bolt (anticlockwise) (2a) and remove toothed drive pulley
(2b).
1. Undo the bolts (1a) and remove the flywheel (1b).2. Remove the tool.
| Name | Country |
|---|
| 2 | Counter-torque | 1.820.624.000 |
1. Undo bolts (1a) and remove the power unit mount, timing gear
side (1b).2. Undo bolts (2a) and remove fixed timing belt tensioner (2b).3. Undo the bolt (3a) and remove the auxiliary drivebelt moving
tensioner (3b).4. Undo the bolts (4a) and remove the support (4b) together with
the power steering pump (4c) and timing belt tensioner.
1. Undo the bolts (1a) and remove the crankcase front cover with
built in oil pump (1b) and intake housing.Remove the gasket.
Fit the tool.
| Name | Country |
|---|
| - | Flange | 1.820.618.000 |
Rotate the crankcase through 180° on the
overhauling stand.Rotate the crankshaft using the tool fitted
previously until the cylinder concerned is at B.D.C.1. Undo the 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.Remove the tool.
| Name | Country |
|---|
| - | Flange | 1.820.618.000 |
5. Undo the bolts (5a) and remove the crankcase rear cover (5b)
with built-in oil seal.Check that the crankshaft end float is
within the recommended values using a magnetic base fitted with
a dial gauge.
| Measurement | | Value |
|---|
| - | End float (mm) | | 0.049 - 0.211 |
If the end float of the crankshaft is not
within the recommended values, when refitting, reface the seat in the
cylinder block/crankcase and use suitable oversize thrust washers. 6. Undo bolts (6a) and remove connecting rod caps (6b).7. Remove the lower main journal half-bearings.8. Remove the crankshaft.9. Remove the upper main journal half-bearings.10. Remove the thrust washers.11. Undo the bolts (11a) and remove the jets (11b) from the crankcase.12. Undo the bolt (12a) and remove the rpm sensor (12b).13. Remove the mininum engine oil pressure warning light sensor.
Rotate the cylinder block through 90° on
the overhauling stand.Undo the bolts and remove the crankcase
from the mounting brackets, then place it on a workbench.Unscrew the bolts and remove the flywheel
protection.Proceed with removal - 1028H60 piston, pin set - replace .Undo the bolts and remove the oil inlet
from the oil pump.Proceed with removal - 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 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 |
1. Measure the diameter of the cylinder liners/bores following the
diagram illustrated.
| Measurement | | Value |
|---|
| 1 | Cylinder bore diameter (mm) | Category B | 82.010 - 82.020 |
| Category C | 82.020 - 82.030 |
| Classe A | 82.000 - 82.010 |
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 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/bores
in accordance with the recommended oversizes. | In the case of reaming, all liners/bores
must be the same oversize. |
| Measurement | | Value |
|---|
| - | Cylinder liner oversize (mm) | | 0.1 |
1. Temporarily 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. |
1. Tighten the bearing cap bolts (1a) to the recommended torque
using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | MAIN BEARING CAPS | M12 | (Engine crankcase side) 2.4 ÷ 2.6 +100 |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
2. Check that the diameter of the bearing seats is within the recommended
values.
| Measurement | | Value |
|---|
| 2 | Main bearing seat diameter (mm) | | 63.691 ÷ 63.732 |
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 | 59.987 ÷ 59.993 |
| Category A | 59.994 ÷ 60.000 |
| Category C | 59.982 ÷ 59.986 |
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). |
Check that the diameter of the crankpins
is within the recommended 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 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). |
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, making sure that
they are scrupulously clean. | If the crankshaft has been reground,
fit the new and oversize half-bearings to restore the original tolerance
conditions. |
Fit the crankshaft in the special housing
in the cylinder block/crankcase.1. Fit the calibrated wire (Plastigage) to measure the main journal
clearance. | Check one journal at a time without
moving the crankshaft. |
1. Fit the main journal caps complete with half-bearings. | The bearing caps have progressive
references (from zero to four starting from the front of the engine)
which define their fitting position. |
1. Tighten the bearing cap bolts (1a) to the recommended torque
using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | MAIN BEARING CAPS | M12 | (Engine crankcase side) 2.4 ÷ 2.6 +100 |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
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) | | 0.011 ÷ 0.071 |
 | If the reading is not within
the specified range, replace the main bearing halves with new bearing halves
of appropriate size and category. |
Measure the clearance at all the bearings,
taking care to carry out this operation, one bearing at a time, without
ever moving the crankshaft.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 |
|---|
| - | Inner diameter (mm) | | 26.006 - 26.012 |
Check that the inner diameter of the small
end bushes is within the recommended limits; if this is not the case,
replace the piston complete with rings, gudgeon pin and bushes.
| Measurement | | Value |
|---|
| - | Piston bush bore (mm) | | 25.999 - 26.004 |
Check that the outer diameter of the piston
gudgeon pins is within the recommended values; if this is not the
case, replace the worn gudgeon pins.
| Measurement | | Value |
|---|
| - | Outer diameter (mm) | | 25.982 - 25.998 |
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.
| Measurement | | Value |
|---|
| - | Opening (mm) | 1˚ seal | 0.25 - 0.40 |
| 2˚ seal | 0.25 - 0.50 |
| Measurement | | Value |
|---|
| - | Opening (mm) | Oil scraper ring | 0.25 - 0.50 |
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.
| Measurement | | Value |
|---|
| - | Outer diameter (mm) | Category B | 81.930 ÷ 81.940 |
| Category A | 81.920 ÷ 81.930 |
| Category C | 81.940 ÷ 81.950 |
| The measurement should be made
perpendicular to the gudgeon pin axis, 8 mm from the skirt lower
edge. |
1. Check that the end float (1a) between the second piston ring
(1b) and the groove in the piston (1c) is within the recommended
limits.
| Measurement | | Value |
|---|
| 1a | End float (mm) | | 0.020 - 0.060 |
Check that the end float between the oil
scraper ring and the groove in the piston is within the recommended
limits.
| Measurement | | Value |
|---|
| - | End float (mm) | | 0.030 - 0.065 |
1. Fit the caps (1b) on the connecting rods (1a) and fix them tightening
the bolts (1c) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Bolt | BIG END BEARING CAPS | M9 | 2.4 ÷ 2.6 + 60 |
Use the tool for angular tightening of
the connecting rod cap bolts.
| 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) | | 53.883 - 53.923 |
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 protection to the crankcase
and tighten the bolts.Fit the cylinder block/crankcase on the
rotating stand and fix it using the bolts.Place the minimum engine oil pressure warning
light sensor back in its housing and tighten it to the recommended
torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | - | OIL PRESSURE W/L | - | 2.7 - 3.3 |
Replace the rear wheel rpm sensor in its
housing and fix it using the bolt.Place the jets back in their housings in
the crankcase and secure them using the bolts.Place the thrust washers back in their
housings in the third bearing support.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 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 59.867 59.873 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: 0.025 mm - Maximum: 0.052 mm; this value can
be measured, as a final check, using the Plastic Gauge.
Fit the main journal half-bearings in the
cylinder block/crankcase.Fit the crankshaft on the cylinder block/crankcase.1. Place the bearing caps complete with half-bearings back in their
housings. | The bearing caps have progressive
references (from zero to four starting from the front of the engine)
which define their fitting position. |
1. Tighten the bearing cap bolts (1a) to the recommended torque
using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | MAIN BEARING CAPS | M12 | (Engine crankcase side) 2.4 ÷ 2.6 +100 |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
1. Fit the tool.
| Name | Country |
|---|
| 1 | Flange | 1.820.618.000 |
Rotate the cylinder block through 90° on
the overhauling stand.Rotate the crankshaft using the tool fitted
previously until the cylinder concerned is at B.D.C.1. Place the connecting rod-piston assemblies (1a), complete with
half-bearings, back in their housings using the tool (1b). | To select the connecting rod half-bearings, follow
the procedure described previously for the main journal half-bearings. |
| The piston - connecting rod assemblies
are fitted in the cylinder block/crankcase so that the combustion
chamber in the piston is facing the intake side. |
1. Check the clearance of the connecting rod bearings, using the
calibrated wire (Plastigage).
Place the big end caps complete with half-bearings back
in their housings. | 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). |
1. Tighten bolts (1a) to the recommended torque using angular tightening
tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | BIG END BEARING CAPS | M9 | 2.4 ÷ 2.6 + 60 |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
Undo the nuts and remove the connecting
rod caps 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) | | 0.016 ÷ 0.070 |
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.Place the connecting rod cap, complete
with half-bearing, back in its housing and fix it using the bolts without
tightening them. | 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). |
1. Tighten the bolts (1a) for the connecting rod caps to the recommended
torque, using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | BIG END BEARING CAPS | M9 | 2.4 ÷ 2.6 + 60 |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
Remove the tool.
| Name | Country |
|---|
| - | Flange | 1.820.618.000 |
1. Fit the rear crankcase cover with its built-in oil sealing ring.2. Tighten the bolts securing the crankcase rear cover to the recommended
torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | FLYWHEEL SIDE COVER | M6 | (Engine crankcase side) 0.8 ÷ 1.0 |
Rotate the crankshaft so that cylinder
no. 1 is at T.D.C.1. Place the crankcase front cover, complete with built-in oil pump
(1a), intake casing (1b) and gasket back in its housing.2. Tighten the bolts for the crankcase front cover complete with
oil pump to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | CRANKSHAFT FRONT COVER | M6 | (Engine crankcase side) 0.8 - 1.0 |
1. Place the oil sealing ring (1a) in its housing in the oil pump
using the tool (1b).
| Name | Country |
|---|
| 1b | Fitting tool | 1.860.816.001 |
Apply sealant to the entire perimeter of
the crankcase sump.
| Type | Component | Name | Qty. |
|---|
| - | Silicon sealant | ENGINE REAR MOUNT GASKETS | Dow Corning 7091 | - |
1. Refit the crankcase sump2. Tighten the side bolts (2a) for the crankcase sump to the recommended
torque using the tool (2b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2a | Side bolt | OIL SUMP | M6 | (Engine crankcase side) 0.7 - 0.9 |
| Name | Country |
|---|
| 2b | Key | 1.822.144.000 |
3. Tighten the front and rear crankcase sump bolts (3a) to torque
in a crossed pattern using tool (3b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3a | Front and rear bolt | OIL SUMP | M8 | (Engine crankcase side) 2.1 ÷ 2.6 |
| Name | Country |
|---|
| 3b | Key | 1.822.145.000 |
Rotate the engine through 180° on the
overhauling stand.1. Fit the tool.
| Name | Country |
|---|
| 1 | Counter-torque | 1.820.624.000 |
2. Fit the flywheel (2a) in its housing, apply LOCTITE 573 to the
bolts (2b) and tighten them to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | FLYWHEEL | M12 | 14.4 ÷ 17.6 |
1. Fit toothed drive pulley (1a) and tighten bolt (anticlockwise)
(1b) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt with left hand thread | TOOTHED DRIVE PULLEY | M16 | 32.3 - 35.7 |
Remove the tool.
| Name | Country |
|---|
| - | Counter-torque | 1.820.624.000 |
Place the power assisted steering pump,
complete with mounting bracket, back in its housing.Fit the fixed timing belt tensioner and
secure by tightening the bolts.Place the timing side power unit support
back in its housing.Place the auxiliary drive belt moving tensioner
back in its housing and secure it using the bolt.Place the heat exchanger, complete with
pipes, back in its housing.Tighten the connector securing the heat
exchanger to the specified torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Connector | ENGINE OIL HEAT EXCHANGER | - | 6.0 |
Fit the oil filter in its housing, tightening
it fully by hand, after having lubricated the gasket using engine oil.Place the air conditioning compressor mounting
back in its housing and secure it using the bolts.Place the air conditioning compressor mounting
back in its housing and secure it using the bolts without tightening
them.Place the intermediate shaft support in
its housing and secure it using the bolts.Tighten the intermediate shaft support
bolt to the crankcase sump.Place the alternator rear mounting bracket
back in its housing and secure it using the bolts without tightening
them.Place the alternator back in its housing
and secure it using the bolts.Tighten the rear alternator bracket bolts.Place the support, complete with pressure
pump, back in its housing and secure it using the side bolts without tightening
them.1. Measure the projection of the pistons at two points at 180° on
the gudgeon pin axis using the tool and take the average of the
two figures measured for each piston.
| Name | Country |
|---|
| 1 | Dial gauge mounting | 1.820.253.000 |
Select the correct size cylinder head gasket,
according to the maximum value of the averages of the projection
for each individual piston.
| Measurement | | Value |
|---|
| - | Thickness with medium-maximum piston projection
(mm) | | 0.014 ÷ 0.104 |
| (no reference) (mm) | 0.770 ÷ 0.870 |
| Measurement | | Value |
|---|
| - | Thickness with medium-maximum piston projection
(mm) | | 0.105 ÷ 0.205 |
| (one reference) (mm) | 0.870 ÷ 0.970 |
| Measurement | | Value |
|---|
| - | Thickness with medium-maximum piston projection
(mm) | | 0.206 ÷ 0.294 |
| (two references) (mm) | 0.970 ÷ 1.070 |
Position the cylinder head centring bushes
on the cylinder block/crankcase.Place the cylinder head gasket back in
its housing. | ASTADUR type cylinder head gaskets
are fitted. 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
process to take place it is necessary to: keep the gasket in its sealed
container until it is fitted; not lubricate the gasket or the contact
surfaces with oil or get them dirty. |
Position the cylinder head on the crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque
using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | CYLINDER HEAD | M10 | (Engine crankcase side) 6.5 + 90˚ + 90˚ +
90˚ |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
| The value of 6.5 daNm should be
implemented by tightening to 2.0 daNm and then increased by a torque
of 4.5 daNm until the nominal value of 6.5 daNm is reached. |
| Follow the order shown in the
diagram for each tightening sequence. |
Fit the cam cover, complete with a gasket,
and fix it tightening the bolts to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CAM COVER | M6 | (Cylinder head side) 0.8 ÷ 1.0 |
Fit the pressure pump mounting front bolts
in their housings and tighten them together with the side bolts fitted
previously.1. Undo the bolt for the crankcase front cover shown in the diagram.Temporarily fit the timing drive belt on
the drive pulley.2. Fit the tool (2a) and secure it gauged bolts (2b) | To allow the engagement of the
locating dowel on the timing drive belt drive pulley in the opening
in the tool, rotate the crankshaft using small movements. |
| Name | Country |
|---|
| 2a | Template | 1.860.905.000 |
| Name | Country |
|---|
| 2b | Calibrated screw | 1.860.905.010 |
1. Rotate the driven pulley so that the timing references line up.2. Completely fit the timing belt.3. Use a screwdriver to lever in the hole (3a) until the reference
on the tensioner (3b) lines up with the reference hole (3c) and,
in this position, tighten the belt tensioner nut (3d) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3d | Nut | MOBILE TIMING TENSIONER | M10 | 4.2 ÷ 5.2 |
Remove the tools.
| Name | Country |
|---|
| - | Template | 1.860.905.000 |
| Name | Country |
|---|
| - | Calibrated screw | 1.860.905.010 |
Tighten the bolt for the crankcase front
cover previously removed.
Rotate the crankshaft through two revolutions.Check once again that the timing references
and the tensioning references on the timing belt tensioner coincide.Refit the bracket on the engine for the
reaction rod.Place the protective timing side covers
back in their housings and secure them using the bolts.Place the crankshaft pulley back in its
housing and secure it using the bolts.Place an exhaust manifold gasket in the
housing.Place the exhaust manifold, complete with
turbocharger, back in its housing and fix it tightening the nuts
to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | EXHAUST MANIFOLD/S | M8 | (Cylinder head side) 2.1 ÷ 2.6 |
Connect the engine oil delivery pipe to
the turbocharger, crankcase side, and tighten the connector.Replace the protection for the engine oil
return pipe from the turbocharger and fix it using the bolts.Place the turbocharger mounting bracket
back in its housing and secure it using the bolts.Tighten the bolts fixing the water/exhaust
gas heat exchanger for the E.G.R. system to the exhaust manifold.Fit the exhaust manifold heat shield and
fix it using the bolts.Connect the coolant outlet pipe from the
engine oil heat exchanger on the side of the water pump rigid inlet
pipe and tighten the band.Tighten the bolt securing the rigid coolant
supply pipe to the engine oil heat exchanger.Connect the flexible coolant supply pipe
to the rigid pipe to the engine oil heat exchanger and tighten the band.Place the vacuum reservoir back in its
housing and secure it.Connect the vacuum pipes to the vacuum
reservoir.Refit the pipe between vacuum reservoir
(EGR) to turbocharger vane position actuator solenoid and secure with
bolts.Place the pipe between the pressure pump
and the fuel return manifold pipe back in its housing and tighten the
bands.1. Place the pipe from the pressure pump to the single fuel manifold
back in its housing and fix it using the connectors without tightening
them.2. Tighten the connector for the pipe from the pressure pump to
the single fuel manifold, pump side, to the recommended torque using
a suitable spanner.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Connector | PRESSURE PUMP LINE TO FUEL MANIFOLD | M12 | (Pressure pump side) 2.2 |
3. Tighten the connector for the pipe from the pressure pump to
the single fuel manifold, fuel manifold side, to the recommended
torque using a suitable spanner.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3 | Connector | PRESSURE PUMP LINE TO FUEL MANIFOLD | M14 | (Fuel manifold side) 2.2 |
| Clean the threaded seats for the
above mentioned pipe on the manifold and the pressure pump using
heptane. |
Place the guide and engine oil dipstick
assembly back in its housing and fix it using the bolts.Place the engine components single drive
belt fixed tensioner back in its housing and fix it tightening the bolt
to the recommended torque.Fit the single engine component belt by
adjusting the moving tensioner using a wrench.Proceed with refitting - 1004D40 engine - position on stand
and remove .
