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

) 1. Undo the bolts (1a), then remove the flywheel side oil seal cover (1b).

1. Undo bolts (1a) and remove the timing side engine support (1b).

1. Undo the bolt (1a) and remove the engine components single belt moving tensioner (1b).2. Undo the bolt (2a) and remove the fixed timing tensioner (2b).

1. Undo the bolts (1a) and remove the support (1b) complete with moving timing belt tensioner (1c).

1. Undo the bolt (1a) and remove the engine rpm sensor (1b).2. Undo and remove the engine oil pressure warning light switch.

1. Undo the bolts (1a) and remove the crankshaft oil seal front cover (1b) with engine oil pump incorporated.2. Remove the gasket.

1. Place the crankshaft oil seal front cover in a vice fitted with protective jaws.2. Undo and remove the engine oil filter using a suitable tool.3. Undo the connector (3a) and remove the engine oil filter mounting (3b) with built-in thermostatic valve.Remove the gasket.4. Remove the crankshaft front oil seal.5. Undo the bolts (5a) and remove the engine oil intake duct (5b).6. Remove the gasket.

1. Fit the tool.

	Description	Code
1	Flange	1.820.618.000

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.2. Undo the bolts (2a) and remove the connecting rod cap (2b).3. Remove the lower connecting rod half-bearing.4. Remove the connecting rod-piston assembly.5. Remove the upper connecting rod half-bearing.Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.

Remove the tool.

	Description	Code
-	Flange	1.820.618.000

1. Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

	Measurement		Value
1	End float (mm)		0.049 - 0.211

If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable oversize thrust washers.

1. Undo the bolts (1a) and remove the connecting rod caps (1b).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.5. Remove the thrust washers.6. Undo the bolts (6a) and remove the jets (6b) from the crankcase.

Undo the bolts and remove the crankcase from the mounting brackets, then place it on a special workbench.Proceed with the removal Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING.Proceed with the removal Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH.Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

Refitting ( Removing

) Wash the dismantled components.Fit the water/oil sealing plugs 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 the planarity of the cylinder head support surface corresponds to the recommended figure; if this is not the case, regrind the cylinder head support surface.

	Measurement		Value
-	Cylinder head support surface flatness (mm)		< 0.1

1. Measure the cylinder bore diameter using the diagram illustrated.

	Measurement		Value
1	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)		< 0.005

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

	Measurement		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 bores must have the same oversize.

	Measurement		Value
-	Cylinder liner oversize (mm)		0.1

1. Temporarily fit the bearing caps.

The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the 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	-	-	2.5 + 100°

	Description	Code
1b	Torque wrench	1.860.942.000

2. Check that the diameter of the main journal seats is within specified limits.

	Measurement		Value
2	Main journal seat diameter (mm)		63.705 ÷ 63.718

Check that there are no deposits or blockages in the crankshaft lubrication ducts.Check that the diameter of the main journals is within specified limits.

	Measurement		Value
-	Main journal diameter (mm)	Category A	59.994 ÷ 60.000
Category B	59.988 ÷ 59.994
Category C	59.982 ÷ 59.988

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

	Measurement		Value
-	Main journal diameter undersize (mm)		0.127

Crankpin undersizes higher than the value mentioned will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires undersizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the Parts Dept. The half-bearings used for undersizes of more than 0.127 mm should not be ordered from the Parts Dept. (even if the number is still quoted).

Check that the diameter of the crankpins corresponds 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 undersize.

	Measurement		Value
-	Crankpin undersize (mm)		0.127

Check the main bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.Fit the half-bearings making sure they are scrupulously clean.

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

Fit the crankshaft in the crankcase.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

Check one journal at a time, without rotating the crankshaft.

1. Fit the main bearing caps complete with half-bearings.

The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the 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	-	-	2.5 + 100°

	Description	Code
1b	Torque wrench	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 main bearings - crankshaft main journals (mm)		0.011 ÷ 0.071

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.Check that the small end bush internal diameter is within the recommended limits; if not, replace the worn small end bush. 1028H58 BOCCOLA PIEDE di BIELLA (una) - Sost..

	Measurement		Value
-	Inner diameter (mm)		26.006 ÷ 26.014

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

	Measurement		Value
-	Piston bush internal diameter (mm)		25.999 - 26.004

Check that the outer diameter of the piston pins is within the recommended limits; if not, replace the worn piston pins.

	Measurement		Value
-	Outer diameter (mm)		25.982 ÷ 25.987

Fit the piston rings in the cylinder liner and check that the opening between the ends is within the recommended values; if this is not the case, replace the circlips.

	Measurement		Value
-	Gap (mm)	1st sealing ring	0.20 ÷ 0.35
2nd sealing ring	-

	Measurement		Value
-	Gap (mm)	Oil scaper ring	0.25 - 0.50

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.

	Measurement		Value
-	Outer diameter (mm)	Category A	81.920 ÷ 81.930
Category B	81.930 ÷ 81.940
Category C	81.940 ÷ 81.950

Measure perpendicular to the gudgeon pin axis, 9 mm from the lower edge of the skirt.

1. Check that the backlash (1a) between the second ring (1b) and the housing in the piston (1c) corresponds to the recommeded figure.

	Measurement		Value
1a	Backlash, 2nd ring (mm)		0.050 ÷ 0.090

Check that the backlash between the oil scraper ring and the housing in the piston corresponds to the recommeded figures.

	Measurement		Value
-	End float (mm)		0.030 ÷ 0.070

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	-	-	2.5 + 60°

Use the tool for the angular tightening of the connecting rod cap bolts.

	Description	Code
-	Torque wrench	1.860.942.000

2. - Check that the diameter of the big end corresponds to the recommended figures; if not, replace the connecting rods.

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

Proceed with the refitting Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING.Proceed with the refitting Op. 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.Place the engine block on the overhaul stand using the mounting brackets.

	Description	Code
-	Brackets	1.861.001.139

Place the jets in their housings in the crankcase and secure them using the bolts.Place the thrust washers in their seats on the third main bearing.The main journal half-bearings fitted on the crankshaft have been selected for their optimum fitting clearance.

The crankshaft supplied by the Parts Dept. comes without half-bearings and the main journals and crankpins are the "normal" size; the half-bearings to be fitted must therefore be selected identifying the class of each main journal and crankpin for the new crankshaft.

The following must be determined for the selection of main journal half-bearings: the numerical code 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 - Crankpin identification numerical code: the left number refers to the first timing side bearing; the final "N" is an insignificant code for 4 cylinder engines.2 - Main journal identification numerical code: the first number refers to the first timing side bearing; the final "N" is an insignificant code for 4 cylinder engines.3 - Series 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 timing side bearing

Only use the codes that relate to 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) as indicated below.A further method for identifying the grade of the bearings is to read reference 3 (if present) in the diagram.In the case of the example, the number 94 (first on the left) corresponds to the dimensions 52.994 for the first timing side bearing which identifies Grade A (red); the same method should be applied for other groups of two digits for the same reference 3 (97 -95 -95 -94).MAIN JOURNAL IDENTIFICATIONMain journal grade A (normal), diameter 59.994.60.000 mm, RED paint mark, numerical code 1 (94 00)*Main journal grade B (normal), diameter 59.988.59.994 mm, BLUE paint mark, numerical code 2 (88 94)*Main journal grade C (normal), diameter 59.982.59.998 mm, YELLOW paint mark, numerical code 3 (82 88)*Main journal grade D (0.127 mm undersize), diameter 59.867.59.873 mm, BROWN paint mark, numerical code 6 (67 73)*Main journal grade E (0.127 mm undersize), diameter 59.861.59.867 mm, GREEN paint mark, numerical code 7 (61 67)*Main journal grade F (0.127 mm undersize), diameter 59.855.59.861 mm, BLACK paint mark, numerical code 8 (55 61)*(*): Last two numbers (thousandth part) of the main journal dimensions.- In the case of the usage of a crankshaft where the maximum undersize for the bearings is 0.127 mm through grindings, the grade should be selected through the measurement of the diameter of the bearing using the above as a reference.Having defined the grade and the colour of each new or reground crankshaft bearings, it is necessary to select the thickness of the bearings that should be the same colour as the corresponding bearing; the pair of half-bearings required can be ordered from the Parts Dept. by quoting the order no.The above is designed to guarantee the optimum operational clearances for all the bearings.Lastly, we wish to point out that, generally, the clearance between the main journal and the half-bearing, obtained through the selection method indicated above, should be within the following values: Minimum: 0.011 mm - Maximum: 0.071 mm; this value can be measured, as a final check, using the calibrated wire (plastic gauge).Place the upper main bearing half-bearings in their seats in the engine block.Place the crankshaft in its housing in the crankcase.1. Place the bearing caps complete with lower half-bearings in position.

The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the 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	-	-	2.5 + 100°

	Description	Code
1b	Torque wrench	1.860.942.000

1. Fit the tool.

	Description	Code
1	Flange	1.820.618.000

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Place the piston and connecting rod assembly (1a) in its housing complete with half-bearing using a suitable tool (1b).

For the selection of the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.

The piston-connecting rod assemblies should be fitted in the cylinder block/crankcase so that the drain on the piston skirt is aligned with the oil jet on the engine block.

Carry out the same operations to fit the pistons and connecting rods for the remaining cylinders.

1. Test the crankpin clearance by applying plastigage to measure crankpin installation clearance.

Place the crank pin caps complete with half-bearings in their seats.

Fit the connecting rods so that the number stamped on each rod faces toward the same side as the number stamped on the big end (inlet side).

1. Tighten the bolts (1a) to torque, using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	-	-	2.5 + 100°

	Description	Code
1b	Torque wrench	1.860.942.000

Undo the nuts and remove the connecting rod caps with the half-bearings fitted previously.1. Use an appropriate graduated measuring tool (1a) to measure the clearance indicated by the plastigage (1b).

	Measurement		Value
1b	Clearance between connecting rod bearings - crankpins (mm)		0.016 ÷ 0.070

If the value measured is not within the recommended figures, replace the connecting rod bearings.Carry out this test on all the crankpins, one at a time, without ever turning the crankshaft.Fit the connecting rod cap complete with half-bearing and secure it without tightening the bolts.

Fit the connecting rods so that the number stamped on each rod faces toward the same side as the number stamped on the big end (inlet side).

1. Tighten the connecting rod cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	-	-	2.5 + 60°

	Description	Code
1b	Torque wrench	1.860.942.000

2. Remove the tool.

	Description	Code
2	Flange	1.820.618.000

1. Place the crankshaft oil seal front cover in a vice fitted with protective jaws.2. Position the engine oil intake duct (2a) complete with gasket (2b) in its housing and secure it using the bolts (2c).3. Place the engine oil filter mounting (3a) with built-in thermostatic valve in its housing complete with gasket and secure it tighteining the connector (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	-	-	-	-

4. Lubricate the seal with engine oil and fit the engine oil filter tightening it fully by hand.

1. Place the crankshaft front cover (1a) in its seat complete with gasket (1b) and tighten the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	-	-	0.9

1. Place the crankshaft front cover (1a) in its seat using the tool (1b).

	Description	Code
1b	Fitting tool	1.821.247.000

1. Place the engine oil pressure warning light switch in its housing and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	3

2. Place the engine 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	-	-	0.9

1. Place the support (1a) complete with moving timing tensioner (1b) in its housing and fasten it by tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

1. Position the fixed timing tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	2.5

2. Position the engine components single belt moving tensioner (2a) in its housing and secure it tightening the bolt (2b).

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	-	-	5

1. Place the timing side rigid engine support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	5

1. Place the flywheel side cover (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	0.9

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 tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	-	-	2.5

	Description	Code
2b	Spanner	1.860.833.001

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

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	-	-	2.5

	Description	Code
3b	Spanner	1.860.834.001

Place the flywheel guard in its housing and secure it using the bolts.1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.001

2. Place the flywheel (2a) in its housing and secure it by tightening the new bolts (2b) which have been pretreated with sealant to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FLYWHEEL (MECH.)	M12	(Engine crankcase side) 14.4 -17.6

Use the tool for the angular tightening of the flywheel fixing bolts.

	Description	Code
-	Torque wrench	1.860.942.000

1. Position the toothed timing drive pulley (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	34

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.846.001

1. Measure the piston projection in two places at 180° on the gudgeon pin axis using the tool and take the average of the two values measured for each piston.

	Description	Code
1	Dial gauge support	1.870.404.001

Select the correct size cylinder head gasket depending on the maximum value between of the averages of the projection for each individual piston.

	Measurement		Value
-	Cylinder head gasket size (no hole) (mm)		0.82 ± 0.05
	Average - maximum piston projection (mm)	-0.020 ÷ +0.100

	Measurement		Value
-	Cylinder head gasket size (one hole) (mm)		0.92 ± 0.05
	Average - maximum piston projection (mm)	+0.101 ÷ +0.200

	Measurement		Value
-	Cylinder head gasket size (two holes) (mm)		1.02 ± 0.05
	Average - maximum piston projection (mm)	+0.201 ÷ +0.295

Position the first cylinder at T.D.C.; rotate the crankshaft a further two teeth of the toothed timing drive pulley to lower the pistons thereby preventing any interference with the valves whilst fitting the cylinder head.

Position the cylinder head locating bushes on the engine block.Fit the new cylinder head gasket selected.Position the cylinder head on the cylinder block/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	-	-	6.5 + 90° + 90° + 90°

	Description	Code
1b	Torque wrench	1.860.942.000

Follow the order shown in the figure for each tightening sequence.

1. Refit the glow plugs and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	-	-	0.8

Refit the upper timing belt protective cover and secure it using the bolt.1. Fit the air chamber (1a) complete with gasket back in its housing and secure it tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	2.5

1. Fit the pressure pump mounting (1a) complete with pressure pump (1b) back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	-	-	2.5

1. If not already carried out during cylinder head overhaul, remove plugs (1a) and fit camshaft timing adjustment tools (1b) to the cylinder head extension.

Check that the tools are correctly fitted in the housings in the camshafts.

	Description	Code
1b	Templates	1.870.896.900

Remove the intake camshaft timing tool and tighten the plug.

1. Place the lower valve rockers in their housings.2. Place the camshaft housing gasket in position.3. Position the cylinder head extension assembly (3a) in its housing and secure it by tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	-	-	2.5

If this has not already been done during the overhauling of the cylinder head, loosen the bolt fixing the exhaust side camshaft drive pulley fixing bolt.1. Undo the bolt fixing the crankcase front cover shown in the diagram.Temporarily fit the toothed timing drive belt on the drive pulley.2. Fit the tool (2a) and fasten it using the calibrated screw (2b).

The crankshaft must be rotated, using small movements, to allow the locating dowel on the timing drive pulley to be inserted in the opening in the tool.

	Description	Code
2a	Template	1.860.905.000

	Description	Code
2b	Calibrated screw	1.860.905.010

1. Fully fit the toothed timing drive belt.2. Use a screwdriver for leverage in the opening (2a) until the reference for the tensioner (2b) is aligned with the opening reference (2c) and, in this position, tighten the nut (2d) for the belt tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2d	-	-	-	-

Tighten the bolt fixing the exhaust side camshaft toothed pulley to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	-	-	3 + 40°

Remove the timing tools.

	Description	Code
-	Templates	1.870.896.900

Remove the exhaust side camshaft template as the inlet side one has already been removed.

	Description	Code
-	Template	1.860.905.000

	Description	Code
-	Calibrated screw	1.860.905.010

Rotate the crankshaft through two revolutions.Recheck the timing by refitting the timing tools.

nly fit the exhaust side camshaft template because the intake side template seat is not accessible.

Check the timing belt tensioner references are aligned.Tighten the bolt fixing the crankcase front cover removed previously.Tighten the plug on the cylinder head extension for fitting the exhaust side timing tool.1. Fit the injectors (1a) in their seats complete with brackets (1b) and tighten the nuts (1c) to the recommended torque.

Start the refitting beginning with the injector for cylinder no. 4 and continue with the injectors for cylinders 3, 2, and 1.

	Fastening	Component	Ø	Value(daNm)
1c	Nut	-	-	2.5

1. Place the power steering pump (1a) in its housing and secure it by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	2.5

1. Place the power steering pump pulley (1a) in its housing and secure it by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	2.5

Place the power steering pump/alternator guard in its housing and secure it using the bolts.1. Fit the single fuel manifold pipe (1a) complete with fuel pressure sensor (1b) and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	-	-	2.5

2. Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening.3. Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	Ø	Value(daNm)
3	-	-	-	2.5

4. Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	Ø	Value(daNm)
4	-	-	-	2.5

Clean the threaded pipe seats on the manifold and injectors with heptane.

5. Connect the pipe from the injectors to the fuel recovery manifold (5a) to the injectors and push home until the clips (5b) click into place.6. Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them.7. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

	Fastening	Component	Ø	Value(daNm)
7	-	-	-	2.3

8. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a spanner.

	Fastening	Component	Ø	Value(daNm)
8	-	-	-	2.3

Clean the threaded pipe seats on the manifold and on the pressure pump using heptane.

Place the fuel return manifold pipe in its housing and secure it using the bolts.Connect the pipe from the pressure pump to the fuel return manifold, fuel return manifold side and tighten the band.Connect the pipe from the injectors to the fuel return manifold, fuel return manifold side.Place the coolant return pipe to the engine coolant reservoir in position and secure it using the bolts.Connect the coolant outlet pipe to the cylinder head, coolant return pipe to the engine coolant reservoir side and tighten the band.Connect the coolant return pipe to the coolant reservoir, thermostat side, and tighten the band.1. Position the bracket on the engine for the reaction rod (1a) in its housing and secure it tightening the bolts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	5

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	-	-	5

Fit the timing belt covers and secure them using the bolts.1. Position the engine components single belt fixed tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	5

Fit the flywheel lock.

	Description	Code
-	Counter-torque	1.860.846.001

2. Position the crankshaft pulley (2a) in its housing and secure it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	-	-	2.5

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.846.001

Place the bracket complete with engine oil vapour separator and pipes in position, then secure it using the bolts.Connect the condensed oil recirculation pipe to the crankcase sump and tighten the band.Connect the oil vapour recovery pipe to the engine block and tighten the band.Connect the engine oil vapour recovery pipe to the engine oil filler, tighten the band and secure it using the fastening.Refit the engine wiring.Connect the electrical connection to the engine oil pressure warning light switch.Connect the electrical connection to the E.G.R. system solenoid valve.Connect the electrical connection to the fuel pressure regulator.Secure the electrical wiring to the band.Connect the electrical connection for the pressure relief sensor.Connect the electrical connection to the fuel pressure sensor.Connect the electrical connections to the heater plugs.Fasten the electrical wiring to the bands on the coolant return pipe to the engine coolant reservoir.Tighten the cable duct fixing bolts.Connect the electrical connections to the injectors.Connect the electrical connection for the cam angle sensor.Fasten the electrical wiring to the band on the timing cover.1. Place the exhaust manifold (1a), complete with turbocharger (1b) and gaske (1c) back in its housing and secure it tightening the nuts (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1d	Nuts	-	-	2.5

1. Connect the turbocharger engine oil supply pipe (1a), engine block side and tighten the connector (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	1.5

Tighten the bolts securing the engine oil return pipe from the turbocharger, engine block side.1. Refit the water/exhaust gas heat exchanger for the E.G.R. system (1a) complete with gaskets (1b).2. Tighten the bolts fixing the E.G.R. system water/exhaust gas heat exchanger exhaust gas inlet pipe, exhaust manifold side to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	-	-	2.5

Connect the E.G.R. system water/exhaust gas heat exchanger coolant inlet pipe, heat exchanger side and tighten the band.Tighten the bolts securing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.1. Tighten the bolts fixing the exhaust gas outlet from the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

Place the exhaust manifold heat shield in its housing, then secure it using the nuts.Place the water pump rigid inlet pipe, complete with gasket, in position and secure it using the bolts.Connect the coolant delivery pipe from the coolant/exhaust gas heat exchanger for the EGR system, heat exchanger side. and tighten the collarTighten the bolt fixing the protective timing cover to the water pump rigid coolant inlet pipe.Remove the engine from the overhaul stand Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.