1004E24 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 FOR VERSIONS WITH COUNTER-ROTATING SHAFTS - Fiat - STILO - eLearn

3363574 - 1004E24 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 for versions with counter-rotating shafts

) 1. Undo the bolts (1a) and remove the engine oil inlet (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 idler belt (1b).2. Undo the bolts (2a) and remove the upper rigid engine support (2b).

1. Undo the bolts (1a) and remove the crankshaft front cover (1b) complete with engine oil heat exchanger (1c) and engine oil filter (1d).2. Remove the gasket.3. Undo the bolts (3a) and remove the detonation sensors (3b).4. Undo the bolt (4a) and remove the rpm sensor (4b).5. Undo and remove the minimum engine oil pressure warning light sensor.

1. Undo the bolts (1a) and remove the engine flywheel (1b).2. Remove the flywheel lock.

	Name	Country
2	Counter-torque	1.860.846.000

1. Undo the bolts (1a) and remove the rear engine flywheel shield (1b).

1. Undo the bolts (1a) and remove the crankshaft rear cover (1b).2. Fit the tool for rotating the crankshaft.

	Name	Country
2	Flange	1.860.815.000

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)		0.059 - 0.161

If the end float of the crankshaft is not within the recommended value, when refitting, reface the seat in the cylinder block and use suitable oversize thrust washers.

	Measurement		Value
-	Shim oversize (mm)		0.127

Rotate the crankshaft using the tool fitted previously until the pistons for cylinders no. 1 and no. 4 are at B.D.C.1. Undo the bolts (1a) and remove the connecting rod caps (1b) and half-bearings (1c) for cylinders 1 and 4.2. Remove the piston-connecting rod assemblies (2a), complete with half-bearings (2b) for cylinders 1 and 4.

Follow the same procedure to remove the connecting rod-piston assemblies for cylinders no. 2 and no. 3.Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

1. Undo the bolts (1a) and remove the main bearing caps (1b) complete with bearing shells (1c).2. Remove the crankshaft.3. Remove the half-bearings.4. Remove the thrust washers.5. Undo the bolts (5a) and remove the engne oil jets (5b) from the cylinder block/crankase.

- 1024A28 crankshaft phonic wheel for rpm and timing sensor-replace with crankshaft removed . - 1084B18 engine oil pump, removed - check at bench . - 1028H60 piston, pin set - replace . Drill and remove the water/oil sealing plugs from the crankcase to allow washing.

Reassembling ( Dismantling

) Wash all the dismantled components.Apply LOCTITE 270 sealant to the water/oil sealing plugs, then fit them in the crankcase using suitable 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 plane.Check that the planarity of the cylinder head support surface is within the recommended values; if this is not the case, reface it.

	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	82.010 ÷ 82.020
Category C	82.020 ÷ 82.030
Class 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)		< 0.010

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)		0.4

Using compressed air gun, clean the lubrication ports in the crankshaft.Check the static balance of the crankshaft resting the main journals on suitable parallels.Measure the main journal diameter and check that it is within the specified 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 bearing journal undersize (mm)		0.254 - 0.508

Measure the main journal diameter and check that it 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 undersize (mm)		0.254 - 0.508

The shaft has undergone a nitriding treatment; therefore if it needs regrinding it should undergo the nitriding treatment again and the dimensions should then be checked.

Visually check the crankshaft bearings, taking into account that no adjustment operations should be carried out to the half-bearings; if there are grooves or signs of seizing then they must be replaced. Place the half-bearings back in their housings, making sure they are perfectly clean.

If the crankshaft has been reground, fit the new and oversize half-bearings to restore the original tolerance conditions.

1. Fit the crankshaft in the special housing in the cylinder block/crankcase.2. Fit the calibrated wire (Plastigage) to measure the main journal clearance.3. Replace the bearing cap (3a) in its housing and fix it tightening the bolts (3b) to the recommended torque.

The bearing caps have progressive references (from zero to four starting from the front of the engine) which define their fitting position.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 100?

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

Measure the clearance at all the bearings, taking care to carry out this operation, one bearing at a time, without ever moving the crankshaft.

	Measurement		Value
1b	Main journal / bearing clearance (mm)	Category B	0.023 - 0.058
Category C	0.019 - 0.050
Class A	0.031 - 0.062

Thoroughly clean any carbon residues from the pistons.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
-	Outer diameter (mm)	Category B	81.959 - 81.971
Category C	81.968 - 81.978
Class A	81.952 - 81.962

Position the piston in the cylinder bore/liner and, using a feeler gauge, check that the clearance is within the recommended value.

	Measurement		Value
-	Piston / cylinder liner-bore clearance (mm)	Category B	0.039 - 0.061
Category C	0.042 - 0.062
Class A	0.038 - 0.058

Check that the inner diameter of the gudgeon pin housing is within the recommended value.

	Measurement		Value
-	Gudgeon pin housing diameter (mm)		20.002 - 20.007

If the gudgeon pin diameter is not within the recommended values, ream it in accordance with the recommended oversizes.

	Measurement		Value
-	Gudgeon pin housing diameter oversize ()		0.2

Check that the outer diameter of the gudgeon pins 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)		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 seals.

	Measurement		Value
-	Thickness (mm)	1st ring	1.160 - 1.180
2nd ring	1.170 - 1.190
Oil scraper ring	1.970 - 1.990

Piston rings are available as spares in 0.4 mm oversizes.

Fit the rings in the cylinder liner/bore and, using a feeler gauge, check that the end gap is within the recommended values; if this is not the case, replace the seals.

	Measurement		Value
-	Opening (mm)	1st ring	0.200 - 0.350
2nd ring	0.250 - 0.500
Oil scraper ring	0.250 - 0.500

Check that the inner diameter of the small end bushes is within the recommended limits; if this is not the case, replace the small end bush ( - 1028H58 connecting rod small end bush - replace ).

	Measurement		Value
-	Inner diameter ()		20.006 - 20.012

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?

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
-	Big end diameter (mm)		53.897 - 53.909

- 1028H60 piston, pin set - replace . - 1084B18 engine oil pump, removed - check at bench . - 1024A28 crankshaft phonic wheel for rpm and timing sensor-replace with crankshaft removed . 1. Place the engine oil jets (1a) back in their housings in the crankcase and secure them using the bolts (1b).2. Fit the main bearing shells.3. Fit the crankshaft on the cylinder block/crankcase.4. Fit the thrust washers on the 3rd main bearing.5. Fit the main bearing caps (5a) complete with main bearing shells (5b).

The bearing caps are numbered progressively (from zero to four starting from the front of the engine) which defines their fitting position.

6. Tighten the bearing cap bolts (1a) to the recommended torque

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

Fit the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

Place the piston-connecting rod assemblies, complete with half-bearings, back in their housings.

Use a suitable tool for compressing the seals and then introducing them in the cylinder liner/bore.

Fit the connecting rod - piston assembly in the crankcase with the large grooves (for the inlet valves) on the piston crowns facing towards the inlet side.

Measure the big end bearing clearance, following the instructions given below.1. Fit the calibrated wire (Plastigage) to measure the big end bearing clearance.2. Fit the big end bearing cap (2a) complete with half-bearing and fix it using the bolts (2b) 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)
2b	Bolt	BIG END BEARING CAPS	M9	2.4 ÷ 2.6 + 60?

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

Measure the clearance at all the bearings, taking care to carry out this operation, one bearing at a time, without ever moving the crankshaft.

	Measurement		Value
1b	Clearance between main journals/bearings (mm)		0.030 - 0.056

If the value measured does not correspond to the recommended figures, replace the connecting rod half-bearings.

Place the connecting rod bearing caps, complete with half-bearings, back in their housings and fix them tightening the bolts 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)
-	Bolt	BIG END BEARING CAPS	M9	2.4 ÷ 2.6 + 60?

1. Remove the tool for rotating the crankshaft.

	Name	Country
1	Flange	1.860.815.000

2. Fit the crankcase rear cover (2a) with the oil seal incoroporated and tighten the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FLYWHEEL SIDE COVER	M6	(Engine crankcase side) 0.8 ÷ 1.0

Place the engine flywheel rear shield back in its housing and secure it using the bolts.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.000

2. Refit the engine flywheel (2a) in its housing and secure by tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FLYWHEEL	M12	(Crankshaft side) 14.4 - 17.6

Remove the flywheel lock.

1. 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)
1	-	OIL PRESSURE W/L	M14	2.7 - 3.3

2. Place the rpm sensor (2a) back in its housing and secure it 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. Place the detonation sensor (3a) back 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 front cover back in its housing.5. Place the crankshaft front cover (5a), complete with engine oil heat exchanger (5b) and engine oil filter (5c), back in its housing and secure it tightening the bolts (5d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
5d	Bolt	CRANKSHAFT FRONT COVER	M6	(Engine crankcase side) 0.8 ÷ 1.0

1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.816.000

1. Fit the upper rigid engine support (1a) and tighten the fixing bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE MOUNT TIMING SIDE	M10 x 1.25	5

2. Fit the belt idler (2a) and tighten the fixing bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FIXED TENSIONER	M10 x 1.25	(Timing side) 5

1. Fit the timing drive pulley (1a) and secure it without tightening the bolt (1b).2. Place the support (2a) back in its housing and secure it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Crankcase side) 4.5 ÷ 5.5

3. Place the engine oil intake (3a), complete with gasket, back in its housing and secure it using the bolts (3b).

Clean the matching surfaces of crankcase sump and cylinder block.Apply silicon sealant around the edge of the crankcase sump.1. Refit the crankcase sump2. Tighten the side bolts (2a) for the crankcase sump to the recommended torque using the spanner (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Side bolt	OIL SUMP	M6	(Engine crankcase side) 0.8 - 1.0

	Name	Country
2b	Key	1.860.833.000

3. Tighten the front and rear bolts (3a) for the crankcase sump to the recommended torque using the spanner (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Front and rear bolt	OIL SUMP	M8	(Engine crankcase side) 2.3 ÷ 2.8

	Name	Country
3b	Key	1.860.834.000

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 fitting
not lubricate or get oil on the gasket and the contact surfaces.

Position the cylinder head on the cylinder block, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).1. Tighten the bolts (1a) fixing the cylinder head 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°

	Name	Country
1b	Protractor	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 bolts securing the exhaust manifold bracket to the crankcase.1. Undo the bolt (1a) for the timing driven pulley, exhaust side using the tools (1b) and (1c) for counter-torque.

	Name	Country
1b	Support for counter-torque	1.860.831.000

	Name	Country
1c	Counter-torque	1.860.848.000

2. Slacken the bolts (2a) on the inlet side camshaft pulley, using the tool (2b) for counter-torque.

	Name	Country
2b	Counter-torque	1.860.856.000

Undo the bolts and remove the camshaft third cap.

Mark the position of the camshaft caps following removal so that they can be positioned correctly upon refitting.

1. Fit templates (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	1.870.697.000

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

1. Remove the engine oil pump retaining bolt.2. Fit the timing belt.3. Fit the pin of the tool for setting the engine to TDC.4. Turn the crankshaft a little at a time to allow locating dowel (4a) on the pulley to fit into the hole on tool (4b).5. Lock the tool in position using a nut (5a) and ordinary bolt (5b).Complete the fitting of the toothed timing belt following the order:

Complete the fitting of the toothed timing belt following the order:

toothed drive pulley
fixed tensioner,
exhaust side toothed driven pulley,
intake side toothed driven pulley
moving tensioner,
coolant pump pulley

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation. Three notches on the belt must also line up with notches on the toothed drive pulley and on the intake and exhaust toothed driven pulleys

1. Fit the tool into the hole on the timing belt mobile tensioner and turn to apply maximum tension to the timing belt.

	Name	Country
1	Key	1.860.845.000

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

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

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	TIMING GEAR DRIVEN PULLEYS	M6	(Inlet/camshaft side) 0.8 - 1.0

	Name	Country
3b	Counter-torque	1.860.856.000

4. Tighten the bolt (4a) for the exhaust side timing driven pulley to the recommended torque using the tools (4b) and (4c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Exhaust camshaft side) 10.8 ÷ 13.2

	Name	Country
4b	Support for counter-torque	1.860.831.000

	Name	Country
4c	Counter-torque	1.860.848.000

Undo the bolts and remove the tool.

	Name	Country
-	Gauge	1.870.697.000

Remove the engine positioning and TDC tool.

	Name	Country
-	Template	1.860.905.000

Fit the camshaft caps removed previously and tighten the bolts to 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 normal direction of rotation.Loosen the moving tensioner nut.5. Fit tool (5a) in the hole on the mobile timing belt tensioner mount and turn to align the tensioner moving pointer (5b) with fixed reference (5c).

	Name	Country
5a	Key	1.860.845.000

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

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

Fit the rocker cover complete with gasket and fix it using the bolts.Place the ignition coils back in their housings and tighten them using the bolts.Fit the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.000

Fit the single drive belt pulley and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	(Counter.balance. shaft. belt pulley side.) 2.3 ÷ 2.8

Tighten the bolt fixing the timing belt drive pulley to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TOOTHED DRIVE PULLEY	M16	(Crankshaft side) 20.9 - 23.1

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.000

Remove the engine oil filler cap.Place the ignition coils cover back in its housing and secure it using the bolts.Place the engine oil plug back in its housing.Tighten the engine oil drain plug to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	-	ENGINE OIL DRAIN PLUG	M18	(Engine oil sump side) 1.8 ÷ 2.2

Top up the engine oil lubrication circuit using the recommended oil.

	Type	Component	Name	Qty.
-	Oil	ENGINE LUBRICATION CIRCUIT	SELENIA 20K	-

For the optimum operation of the engine in particularly harsh climatic conditions (starting at temperatures as low as -35 °C), use the recommended oil for the engine lubrication circuit.

	Type	Component	Name	Qty.
-	Oil	ENGINE LUBRICATION CIRCUIT	SELENIA PERFORMER	-

- 1004D40 engine - position on stand and remove