1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT - Fiat - STILO - eLearn

3363549 - 1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT

Removing ( Refitting

) 1. Remove the toothed drive pulley

1. Undo the retaining bolt.2. Remove the timing belt idler roller.

1. Undo the retaining bolts.2. Remove the alternator.

1. Unscrew the bolt (1a) securing the compressor (1b) to the engine block.

1. Undo the retaining bolts.2. Remove the oil pump module (2a) complete with compressor (2b) and water pump (2c).

1. Remove the oil gasket.

1. Remove the locating dowels from the engine block.

1. Undo the retaining bolt.2. Remove the detonation sensor.

1. Undo and remove the engine oil pressure sensor.

1. Undo the retaining bolt.2. Remove the engine rpm sensor.

1. Undo the retaining bolts.2. Remove the wiring anchorage bracket.

1. Undo the retaining bolts.2. Remove the exhaust manifold mounting bracket.

1. Undo and remove the engine oil filter.

Using the tool positioned previously on the crankshaft, rotate the latter until pistons 2 and 3 are at BDC.

	Description	Code	Function
-	Flange	1.860.815.000	Crankshaft rotation

1. Mark the connecting rod cap and the connecting rod.

The breaking surfaces of the connecting rods and the connecting rod caps match individually and should not be swapped or damaged under any circumstances.

1. Undo the bolts (1a) and remove the connecting rod caps (1b) complete with lower half-bearings (1c).2. Remove the pistons (2a) complete with connecting rods (2b) and gudgeon pins.3. Remove the upper connecting rod half-bearings.Using the tool fitted previously on the crankshaft, rotate the latter so that pistons 1 and 4 are at BDC and remove the pistons and connecting rods.

	Description	Code	Function
-	Flange	1.860.815.000	Crankshaft rotation

Remove the engine rotation tool positioned previously.

	Description	Code	Function
-	Flange	1.860.815.000	Crankshaft rotation

1. Remove the flywheel side seal.2. Undo the retaining bolts.3. Remove the main journal caps.4. Remove the lower main journal half-bearings.

The thrust washer is incorporated in the centre half-bearing.

5. Remove the crankshaft.6. Remove the upper main journal half-bearings.

The thrust washer is incorporated in the centre half-bearing.

If the crankshaft is being replaced, proceed as described below.Position the crankshaft in a vice.1. Undo the retaining bolts.2. Remove the flywheel.Remove the crankshaft from the vice.

Remove the water/oil sealing plugs from the crankcase.Undo the fixing bolts and remove the engine block from the overhaul stand.

	Description	Code	Function
-	Plate	1.871.001.000	Engine fastening to rotating overhaul stand

	Description	Code	Function
-	Rotating stand	1.871.001.000	Overhaul engine

Position the engine block on a suitable workbench. Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCH Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH

Refitting ( Removing

) Wash all the dismantled components.Fit the water/oil sealing plugs in the engine block applying thread-locking agent.Lubricate all the mechanical components with engine oil.Check that the cylinder head support surface does not have cracks or grooves.1. Using a calibrated metal rule and a feeler gauge, check the flexible yield, widthwise and lengthwise and the diagonal defromation of the engine block surfaces.

1. The following information is stamped on the engine block: production date (1a), direction of cylinder 1 opening (1b), direction of cylinder 2 opening (1c), direction of cylinder 3 opening (1d), direction of cylinder 4 opening (1e), code for main journal half-bearing housing in engine block (1f).

1. Measure the diameter of the cylinder bores as illustrated in the diagram below using a guage for the interior.

	Subject	Value
-	Cylinder liner diameter (mm)	78.992 - 79.008

Check that the taper of the cylinder liners is within the recommended limits.

	Subject	Value
-	Cylinder liner taper (mm)	< 0.005

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

	Subject	Value
-	Cylinder liner ovality (mm)	< 0.05

If the cylinder bore measurements are not within the recommended limits, ream the cylinder bores following the recommended oversizes.

In the case of reaming, all the cylinder bores must have the same oversize.

After reaming the original code must be invalidated and the new code stamped on the engine block.

	Subject	Value
-	Cylinder liner diameter (0.5 mm oversize)	79.492 - 79.508

If the crankshaft is being replaced, proceed as described below.Position the crankshaft in a vice.Fit the flywheel and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
-	1.5	Bolt	-	-

Remove the crankshaft from the vice.Clean the crankshaft lubrication ports using an air jet.1. The crankshaft and half-bearings are marked by colours in order to be able to match them more easily depending on the recommended clearances: crankshaft colour marking (1a), half-bearing colour marking (1b), half-bearing colour marking (1c).

Check the static balance of the crankshaft resting the main journals on suitable parallels.Measure the diameter of the main journals and the diameter of the crank pins.

	Subject	Value
-	Main journal diameter (mm)	54.980 - 54.997 (brown)
-	Main journal diameter (mm)	54.980 - 54.997 (green)

	Subject	Value
-	Crankpin diameter (mm)	42.971 - 42.987

If the diameter of the main journals is not correct, they should be reground to the recommended undersize.

	Subject	Value
-	Main journal diameter (0.25 mm undersize)	54.730 - 54.747 (brown)
-	Main journal diameter (0.25 mm undersize)	54.730 - 54.747 (green)

	Subject	Value
-	Main journal diameter (0.50 mm undersize)	54.482 - 54.495 (brown)
-	Main journal diameter (0.50 mm undersize)	54.482 - 54.495 (green)

If the diameter of the crankpins is not correct, they should be reground to the recommended undersize.

	Subject	Value
-	Crankpin diameter (0.25 mm undersize)	42.721 - 42.737 (blue)

	Subject	Value
-	Crankpin diameter (0.50 mm undersize)	42.471 - 42.487 (white)

Measure the width of the main journal 3 (guide bearing).

	Subject	Value
-	Main journal 3 width (mm)	26.000 - 26.052

If the width of main journal 3 (guide bearing) is not within the recommended values, it should be reground to the recommended undersize.

	Subject	Value
-	Main journal 3 width (0.20 mm undersize)	26.200 - 26.252

	Subject	Value
-	Main journal 3 width (0.40 mm undersize)	26.400 - 26.452

Check the main half-bearings, noting that the half-bearings should not be adapted.If there are grooves or traces of seizing or wear, replace the half-bearings.1. Fit the upper half-bearings on the engine block making sure that they are perfectly clean and have been lubricated with engine oil.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

1. Fit the crankshaft in the crankcase.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.Fit the lower half-bearings on the connecting rod caps making sure that they are perfectly clean and have been lubricated with engine oil.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

3. Fit the connecting rod caps (3a) in the fitting position (3b) marked on them.4. Tighten the connecting rod cap fixing bolts to the specified torque.

The fixing bolts removed previously can be reused just to check the bearing clearance.

	Value daNm	Fastening	Component	Ø
4	5 + 45° + 15°	Bolt	-	-

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

Check the clearance for all the main journals taking care to do it one bearing at a time without ever moving the crankshaft.

	Subject	Value
1a	Main bearing clearance (mm)	0.005 - 0.059

If the values are not within the recommended limits, replace the half-bearings and repeat the operation of checking the clearance.

	Subject	Value
-	Main bearing half thickness (mm)	1.987 - 1.993 (brown)
-	Main bearing half thickness (mm)	1.993 - 1.999 (green)

	Subject	Value
-	Half-bearing thickness (0.25 mm undersize)	2.112 - 2.118 (brown/blue)
-	Half-bearing thickness (0.25 mm undersize)	2.118 - 2.124 (green/blue)

	Subject	Value
-	Half-bearing thickness (0.50 mm undersize)	2.237 - 2.243 (brown/white)
-	Half-bearing thickness (0.50 mm undersize)	2.243 - 2.249 (green/white)

1. Position a dial gauge with a magnetic base (1a) on the engine block and check the crankshaft (1b) longitudinal clearance.

	Subject	Value
-	Crankshaft endfloat (mm)	0.100 - 0.202

If the value is not within the recommended limits, replace the half-bearings for main journal 3 and repeat the checking operation.

	Subject	Value
-	Main journal 3 half-bearing width (mm)	25.850 - 25.900 (brown - green)

	Subject	Value
-	Main journal 3 half-bearing width (0.25 mm undersize)	26.050 - 26.100 (brown/blue - green/blue)

	Subject	Value
-	Main journal 3 half-bearing width (0.50 mm undersize)	26.250 - 26.300 (brown/white - green/white)

Remove the main journal caps fitted previously.1. Position a dial gauge with a magnetic base (1a) on the engine block and check the eccentricity by rotating the crankshaft (1b) evenly.

	Subject	Value
-	Crankshaft eccentricity (mm)	< 0.03

1. Apply adhesive in the splining for main journal cap 5.2. Fit the connecting rod caps (2a) in the fitting position (2b) marked on them.3. Tighten the new connecting rod cap fixing bolts to the specified torque.

	Value daNm	Fastening	Component	Ø
3	5 + 45° + 15°	Bolt	-	-

Clean any carbon residues carefully from the pistons.1. Measure the outer diameter of the pistons perpendicular to the gudgeon pin axis 14.5 mm from the lower edge.

	Subject	Value
-	Piston diameter (mm)	78.833 - 78.847

	Subject	Value
-	Piston diameter (excess measurement 0.5 mm)	79.433 - 79.447

If these values do not correspond to the recommended figures, replace the piston complete with piston rings and gudgeon pin.Calculate the clearance between the cylinder bores/liners and the piston and check that it is within the recommended values.

	Subject	Value
-	Clearance between piston - cylinder liner/bore (mm)	0.045 - 0.175

Check that the gudgeon pin seat bore diameter in the connecting rod and the piston is within specified values, otherwise replace the pin with an oversized pin.

	Subject	Value
-	Gudgeon pin housing diameter in connecting rod (mm)	-

	Subject	Value
-	Gudgeon pin housing diameter in piston (mm)	-

Check that the diameter of the gudgeon pin corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin.

	Subject	Value
-	Gudgeon pin diameter (mm)	17.994 - 18.000

Check that the clearance between the gudgeon pin and the housings in the connecting rod and piston are within the recommended values.

	Subject	Value
-	Gudgeon pin - connecting rod clearance (mm)	0

	Subject	Value
-	Gudgeon pin - piston clearance (mm)	0.009 - 0.015

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

	Subject	Value
-	Piston ring 1 thickness (mm)	1.175 - 1.190

	Subject	Value
-	Piston ring 2 thickness (mm)	1.170 - 1.190

	Subject	Value
-	Oil scraper ring thickness (mm)	1.190 - 1.198

1. Fit the piston rings (1a) in the cylinder bore and, using a feeler guage (1b), check that the gap between the two ends is within the recommended values, or else the piston rings have to be replaced.

	Subject	Value
1b	Piston ring 1 gap (mm)	0.25 - 0.50

	Subject	Value
1b	Piston ring 2 gap (mm)	0.25 - 0.50

	Subject	Value
1b	Oil scraper ring gap (mm)	0.25 - 0.75

1. Partly fit the piston rings (1a) in the housing in the piston and, using a feeler gauge (1b), check that the clearance is within the recommended values, or else the piston rings have to be replaced.

	Subject	Value
1b	Piston ring 1 clearance (mm)	0.040 - 0.075

	Subject	Value
1b	Piston ring 2 clearance (mm)	0.030 - 0.070

	Subject	Value
1b	Oil scraper ring clearance (mm)	0.03 - 0.13

Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCHFit the tool for rotating the crankshaft.

	Description	Code	Function
-	Flange	1.860.815.000	Crankshaft rotation

Rotate the crankshaft so that cylinders no. 1 and 4 are at BDC.Lubricate the piston with engine oil.Fit the upper connecting rod half-bearings on the connecting rod making sure that they are perfectly clean and have been lubricated with engine oil.1. Fit the 1st and 4th pistons complete with connecting rods and half-bearings (1a) using the tool for compressing the circlips and then fitting them in the cylinder liner/bore.2. Position the piston