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. Undo the bolts (1a) and remove the engine oil intake duct (1b) complete with gasket.2. Undo the bolts (2a) and remove the support (2b).3. Using the flywheel lock fitted previously for counter-torque, undo the bolt (3a) and remove the timing drive pulley (3b).
1. Undo the bolt (1a) and remove the belt idler (1b).2. Undo the bolts (2a) and remove the upper rigid engine support (2b).
1. Loosen the bolts (1a) and remove the crankshaft oil seal front cover (1b) complete with engine oil heat exchanger (1c) and engine oil filter (1d).2. Remove the seal.3. Undo the bolt (3a) and remove the detonation sensor (3b).4. Undo the bolt (4a) and remove the rpm sensor (4b).5. Undo and remove the minimum engine oil pressure sensor.
1. Undo the bolts (1a) and remove the engine flywheel (1b).2. Remove the flywheel lock. | Description | Code |
|---|
| 2 | Counter-torque | 1.860.846.000 |
1. Undo the bolts (1a) and remove the engine flywheel rear guard (1b).
1. Undo the bolts (1a) and remove the crankshaft rear oil seal cover (1b).2. Fit the tool for rotating the crankshaft. | Description | Code |
|---|
| 2 | Flange | 1.860.815.000 |
Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge. | Measurement | | Value |
|---|
| - | End float (mm) | | 0.059 - 0.161 |
If the value for the crankshaft endfloat does not correspond to the recommended figures, when refitting regrind the crankcase seat according to the oversize of the thrust washers available as spares. | Measurement | | Value |
|---|
| - | Shim oversize (mm) | | 0.127 |
Rotate the crankshaft using the tool fitted previously until cylinders 1 and 4 are at B.D.C.1. Undo the bolts (1a) and remove the connecting rod caps (1b) complete with half-bearings (1c) for cylinders 1 and 4.2. Remove the cylinder 1 and 4 piston-connecting rod assemblies (2a) complete with half-bearings (2b)
Work in the same way to remove the piston/connecting rod assemblies for cylinders 2 and 3.Remove the tool for rotating the crankshaft. | Description | Code |
|---|
| - | Flange | 1.860.815.000 |
1. Undo the bolts (1a) and remove the main journal caps (1b) complete with half-bearings (1c).2. Remove the crankshaft.3. Remove the main journal half-bearings.4. Remove the thrust washers.5. Undo the bolts (5a) and remove the engine oil jets (5b) from the crankcase.
1024A28 RUOTA FONICA dell''albero motore per sensore di giri e fase - Sost. ad albero motore staccato. Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH. Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING.Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.
Refitting
(
Removing
)
Wash all the dismantled components.Apply LOCTITE 270 sealant to the water/oil sealing plugs, then fit them in the crankcase using suitable fitting tools.Lubricate all the mechanical components with engine oil.Check that the cylinder head support surface does not have cracks or superficial grooves.Check that cylinder head support surface flatness is within specified limits; if this is not the case, regrind it. | Measurement | | Value |
|---|
| - | Cylinder head support surface flatness (mm) | | < 0.1 |
Measure the diameter of the cylinder bores and check that they correspond to the recommended figures. | Measurement | | Value |
|---|
| - | Cylinder liner diameter (mm) | Category A | 82.000 ÷ 82.010 |
| Category B | 82.010 ÷ 82.020 |
| Category C | 82.020 ÷ 82.030 |
Check that the taper of the cylinder liners is within the recommended limits. | Measurement | | Value |
|---|
| - | Cylinder liner taper (mm) | | < 0.010 |
Check that the ovality of the cylinder liners is within the recommended limits. | Measurement | | Value |
|---|
| - | Cylinder liner ovality (mm) | | <0.005 |
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. |
| Measurement | | Value |
|---|
| - | Cylinder liner oversize (mm) | | 0.4 |
Clean the lubrication ports in the crankshaft using an air jet.Check the static balance of the crankshaft resting the main journals on suitable parallels.Measure the diameter of the main journals and check that they correspond to the recommended figures. | Measurement | | Value |
|---|
| - | Main journal diameter (mm) | Category A | 52.994 ÷ 53.000 |
| Category B | 52.988 ÷ 52.994 |
| Category C | 52.982 ÷ 52.988 |
If the diameter of the main journals is not correct, they should be reground to the recommended undersizes. | Measurement | | Value |
|---|
| - | Main journal undersize (mm) | | 0.254 - 0.508 |
Measure the diameter of the crankpins check that they correspond to the recommended figures. | Measurement | | Value |
|---|
| - | Crankpin diameter (mm) | Category A | 50.799 ÷ 50.805 |
| Category B | 50.793 ÷ 50.799 |
| Category C | 50.787 ÷ 50.793 |
If the diameter of the crankpins is not correct, they should be reground to the recommended undersizes. | Measurement | | Value |
|---|
| - | Crankpin undersize (mm) | | 0.254 / 0.508 |
| Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground. |
Visually inspect the crankshaft bearings and crankpins bearing in mind that no adjustments should be made to the half-bearings; if there are signs of grooves or traces of seizing they should be replaced.Place the half-bearings in their seats taking great care over cleanliness. | 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.3. Place the bearing cap (3a) in its seat and secure it by tightening the bolts (3b) to the recommended torque. | The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the fitting position. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3b | Bolt | CONNECTING ROD CAPS | M12 | 2.5 + 100° |
1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b). | Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time. |
| Measurement | | Value |
|---|
| 1b | Main journal/bearing clearance (mm) | Category A | 0.031 - 0.062 |
| Category B | 0.023 - 0.058 |
| Category C | 0.019 - 0.050 |
Clean any carbon residues carefully from the pistons.Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin. | The outer diameter of the pistons should be measured perpendicular to the gudgeon pin axis and 12.5 mm from the lower edge of the skirt. |
| Measurement | | Value |
|---|
| - | Outer diameter (mm) | Category A | 81.952 - 81.962 |
| Category B | 81.959 - 81.971 |
| Category C | 81.968 - 81.978 |
Position the piston in the cylinder bore and, using a feeler gauge, check that the clearance is within the recommended values. | Measurement | | Value |
|---|
| - | Clearance between piston - cylinder liner/bore (mm) | Category A | 0.038 - 0.058 |
| Category B | 0.039 - 0.061 |
| Category C | 0.042 - 0.062 |
Check that the inner diameter of the gudgeon pin housing in the piston is within the recommended values. | Measurement | | Value |
|---|
| - | Piston pin housing diameter (mm) | | 20.002 - 20.007 |
If the diameter of the gudgeon pin housing is not within the recommended values, ream it in accordance with the recommended oversize. | Measurement | | Value |
|---|
| - | Gudgeon pin housing diameter oversize () | | 0.2 |
Check that the outer diameter of the gudgeon pins corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin. | Measurement | | Value |
|---|
| - | Outer diameter (mm) | | 10.996 - 20.000 |
Check that the thickness of the piston rings is within the recommended values; if this is not the case, replace the piston rings. | Measurement | | Value |
|---|
| - | Thickness (mm) | 1st sealing ring | 1.160 - 1.180 |
| 2nd sealing ring | 1.170 - 1.190 |
| Oil scaper ring | 1.970 - 1.990 |
| The piston rings are available as spares in 0.4 mm oversizes. |
Fit the piston rings in the cylinder bore and, using a feeler gauge, check that the gap between the ends is within the recommended values; if this is not the case, replace the piston rings. | Measurement | | Value |
|---|
| - | Gap (mm) | 1st Ring | 0.200 - 0.350 |
| 2nd ring | 0.250 - 0.500 |
| Oil scaper ring | 0.250 - 0.500 |
Check that the small end bush diameter is within the recommended limits; if not, replace the small end bush (see op. 1028H58 BOCCOLA PIEDE di BIELLA (una) - Sost.). | Measurement | | Value |
|---|
| - | Inner diameter () | | 20.006 - 20.012 |
1. Fit the caps (1b) on the connecting rods (1a) and secure them tightening the bolts (1c) to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Bolt | CONNECTING ROD CAPS | M9 | 2.5 + 60° |
2. Check that the big end diameter is within the recommended limits; if not, replace the connecting rods. | Measurement | | Value |
|---|
| 2b | Big end diameter (mm) | | 53.897 - 53.909 |
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. 1024A28 RUOTA FONICA dell''albero motore per sensore di giri e fase - Sost. ad albero motore staccato.1. Place the engine oil jets (1a) in their housings in the crankcase and secure them using the bolts (1b).2. Fit the main journal half-bearings.3. Fit the crankshaft in the crankcase.4. Fit the thrust washers on the 3rd main journal.5. Fit the main bearing caps (5a) complete with half-bearings (5b). | The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the fitting position. |
6. Tighten the bolts fixing the bearing caps to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 6 | Bolt | CONNECTING ROD CAPS | M12 | 2.5 + 100° |
Fit the tool for rotating the crankshaft. | Description | Code |
|---|
| - | Flange | 1.860.815.000 |
Place the piston-connecting rod assemblies complete with half-bearings in their housings. | Use a suitable tool for compressing the piston rings and fitting them in the cylinder bore. |
| The pistons and connecting rods are fitted in the cylinder block/crankcase with the large references (for the inlet valves) on the piston crown facing the inlet side. |
Measure the bearing clearance as described below.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.2. Fit the cap (2a) complete with half-bearing and tighten the bolts (2b) to the recommended torque. | Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the big end. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | CONNECTING ROD CAPS | M9 | 2.5 + 60° |
1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b). | Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time. |
| Measurement | | Value |
|---|
| 1b | Main journal/bearing clearance (mm) | | 0.030 - 0.056 |
If the value measured is not within the recommended figures, replace the half-bearings.
Place the caps complete with half-bearings in their housings and secure them tightening the bolts to the recommended torque. | Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the big end. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CONNECTING ROD CAPS | M9 | 2.5 + 60° |
1. Remove the tool for rotating the crankshaft. | Description | Code |
|---|
| 1 | Flange | 1.860.815.000 |
2. Fit the crankcase rear cover (2a) with the oil seal incorporated and tighten the bolts (2b) to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | REAR COVER CRANKSHAFT | M6 | (Engine crankcase side) 0.8 -1.0 |
Place the flywheel rear guard in its housing and secure it using the bolts.1. Fit the flywheel lock. | Description | Code |
|---|
| 1 | Counter-torque | 1.860.846.000 |
2. Place the flywheel (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | FLYWHEEL (MECH.) | M12 | (Engine crankcase side) 12.1 -14.9 |
Remove the flywheel lock.
1. Place the minimum engine oil pressure sensor in its housing and tighten it to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 1 | - | INSUFFICIENT ENGINE OIL PRESSURE SWITCH | M14 | 2.6 - 3.2 |
2. Place the rpm sensor (2a) in its housing and secure it by tightening the bolt (2b) to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | RPM SENSOR | M6 | (Engine crankcase side) 0.8 -1.0 |
3. Position the detonation sensor (3a) in its housing and secure it tightening the bolt (3b) to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 3b | Bolt | KNOCK SENSOR | M8 | (Engine crankcase side) 1.9 -2.0 |
4. Place the crankshaft oil seal front cover gasket in its housing.5. Place the crankshaft oil seal front cover in its housing (5a) complete with engine oil heat exchanger (5b) and engine oil filter (5c) and secure it tightening the bolts (5d) to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 5d | Bolt | FRONT COVER CRANKSHAFT | M6 | (Engine crankcase side) 0.8 - 1.0 |
1. Fit a new crankshaft front oil seal (1a) using the tool (1b). | Description | Code |
|---|
| 1b | Fitting tool | 1.860.816.000 |
1. Fit the upper rigid engine support (1a) and tighten the fixing bolts (1b) to the recommneded torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | RIGID ENGINE MOUNT, TIMING SIDE | M10 X 1.25 | 5 |
2. Fit the belt idler (2a) and tighten the fixing bolt (2b) to torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | FIXED TENSIONER | M10 X 1.25 | (Timing side) 5 |
1. Position the toothed timing drive pulley (1a) in its housing and secure it without tightening the bolt (1b).2. Place the support (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | RIGID ENGINE MOUNT, TIMING SIDE | M10 | (Engine crankcase side) 4.3 -5.3 |
3. Position the engine oil intake duct (3a) complete with gasket in its housing and secure it using the bolts (3b).
Clean the matching surfaces between the crankcase sump and the cylinder block/crankcase.Apply silicon sealant to the entire perimeter of the crankcase sump.1. Place the crankcase sump in its housing.2. Tighten the side bolts (2a) fixing the crankcase sump to the recommended torque using the spanner (2b). | Fastening | Component | Ø | Value(daNm) |
|---|
| 2a | Side bolt | ENGINE OIL SUMP | M6 | (Engine crankcase side) 0.8 -1.0 |
| Description | Code |
|---|
| 2b | Spanner | 1.860.833.000 |
3. Tighten the front and rear bolts (3a) fixing the crankcase sump to the recommended torque using the spanner (3b). | Fastening | Component | Ø | Value(daNm) |
|---|
| 3a | Front and rear bolt | ENGINE OIL SUMP | M8 | (Engine crankcase side) 2.1 -2.6 |
| Description | Code |
|---|
| 3b | Spanner | 1.860.834.000 |
Place the cylinder head gasket in position. | The cylinder head gasket is the Astadur type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage. In order for the polymerization process to take place, it is necessary to: - keep the gasket sealed in its container until it is fitted; - do not lubricate the gasket or contact surfaces or get oil on them. |
Position the cylinder head on the cylinder block/crankcase taking care to ensure 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). | Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | CYLINDER HEAD | M10 | (Engine crankcase side) 4 + 90° + 90° + 90° |
| Description | Code |
|---|
| 1b | Torque wrench | 1.860.942.000 |
Connect the coolant supply pipe to the heat exchanger, thermostat side.Tighten the bolts fixing the coolant return pipe to the engine oil heat exchanger.Tighten the bolt fixing the exhaust manifold mounting bracket to the engine block.1. Loosen the bolt (1a) for the exhaust side driven timing pulley using tools (1b) and (1c) for counter-torque. | Description | Code |
|---|
| 1b | Support for counter-torque | 1.860.831.000 |
| Description | Code |
|---|
| 1c | Counter-torque | 1.860.848.000 |
2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque. | Description | Code |
|---|
| 2b | Counter-torque | 1.860.856.000 |
Unscrew the bolts and remove the third camshaft cap. | Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting. |
1. Fit the templates (1a) in place of the camshaft caps that have been removed and secure them tightening the bolts (1b) to the recommended torque. | Check that the camshaft cam profile and the templates are correctly aligned. |
| Description | Code |
|---|
| 1a | Templates | 1.870.697.000 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | TEMPLATES FOR ENGINE TIMING | M7 | (Cylinder head side) 1.0 |
1. Remove the engine oil pump fixing bolt.2. Fit the timing belt.3. Fit the pin for the tool for positioning the engine at T.D.C.4. Rotate the crankshaft using small movements to allow the pulley locating dowel (4a) to enter the opening in the tool (4b).5. Lock the tool in position using a nut (5a) and service bolt (5b).Complete the fitting of the timing toothed drive belt following the order:
- toothed drive pulley,
- fixed tensioner,
- exhaust side toothed driven pulley,
- inlet side toothed driven pulley,
- moving tensioner,
- water pump pulley.
| The belt is fitted with the arrow facing the direction of rotation of the engine. There are also three reference on the belt that should coincide during the initial fitting with the references on the toothed drive pulley and the exhaust and inlet side toothed driven pullies. |
1. Fit the tool in the opening in the moving timing tensioner support and rotate it until the maximum tension is applied to the timing belt. | Description | Code |
|---|
| 1 | Spanner | 1.860.845.000 |
2. Tighten the nut fixing the moving timing tensioner to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Nut | MOBILE TIMING TENSIONER | M8 | 2.1 ÷ 2.6 |
3. Tighten the bolts (3a) for the inlet side toothed timing driven pulley using the tool (3b) for counter-torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 3a | Bolt | TIMING DRIVEN PULLIES | M6 | (Inlet camshaft side) 0.8 - 1.0 |
| Description | Code |
|---|
| 3b | Counter-torque | 1.860.856.000 |
4. Tighten the bolt (4a) for the exhaust side toothed timing driven pulley using the tools (4b) and (4c) for counter-torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| 4a | Bolt | TIMING DRIVEN PULLIES | M12 | (Exhaust camshaft side) 10.2 -12.6 |
| Description | Code |
|---|
| 4b | Support for counter-torque | 1.860.831.000 |
| Description | Code |
|---|
| 4c | Counter-torque | 1.860.848.000 |
Undo the bolts and remove the tool. | Description | Code |
|---|
| - | Templates | 1.870.697.000 |
Remove the TDC positioning tool. | Description | Code |
|---|
| - | Template | 1.860.905.000 |
Fit the camshaft cams removed previously and tighten the bolts to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CAMSHAFT SUPPORTS | M7 | Cylinder head side 1.3 - 1.6 |
Rotate the crankshaft throught two revolutions in the direction of rotation.Loosen the moving timing tensioner nut.5. Fit the tool (5a) in the opening in the moving timing tensioner support and rotate it until the tensioner moving reference (5b) is aligned with the fixed reference (5c). | Description | Code |
|---|
| 5a | Spanner | 1.860.845.000 |
Tighten the nut fixing the moving timing tensioner to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | MOBILE TIMING TENSIONER | M8 | 2.1 ÷ 2.6 |
Fit the cam cover complete with gasket and secure it using the bolts.Position the ignition coils and secure them using the fixing bolts.Fit the flywheel lock. | Description | Code |
|---|
| - | Counter-torque | 1.860.846.000 |
Fit the auxiliary drive belt drive pulley and secure it tightening the bolts to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CRANKSHAFT PULLEY | M8 | (Counter-balance shaft belt pulley side) 2.1 - 2.6 |
Tighten the timing belt pulley bolt to the specified torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | DRIVE PULLEY(PULLIES) TIMING | M16 | (Engine crankcase side) 20.9 -23.1 |
Remove the flywheel lock. | Description | Code |
|---|
| - | Counter-torque | 1.860.846.000 |
Remove the engine oil filler plug.Place the ignition coil cover back in its housing and secure it using the bolts.Place the engine oil filler cap in its housing.Tighten the engine oil drain plug to the recommended torque. | Fastening | Component | Ø | Value(daNm) |
|---|
| - | - | ENGINE OIL DRAIN PLUG | M18 | (Engine oil sump side) 1.7 - 2.1 |
Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY | Type | Component | Description | Qty. |
|---|
| - | Oil | ENGINE OIL LEVEL CHECK AND TOP-UP | SELENIA 20K | - |
For the optimum operation of the engine in particularly harsh climate conditions (starting down to 35 °C) use the recommended oil for the engine lubrication circuit. | Type | Component | Description | Qty. |
|---|
| - | Oil | ENGINE OIL LEVEL CHECK AND TOP-UP | SELENIA PERFORMER | - |
Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.
