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. Undo the bolts (1a) and remove the engine oil intake duct (1b) complete with gasket.

1. Remove the engine oil filter (1a) using a suitable tool (1b).

1. Undo the nut (1a) and remove the engine oil heat exchanger (1b) complete with pipes (1c).

Undo the bolt loosened previously and remove the toothed timing drive pulley.1. Undo the bolts (1a) and remove the crankshaft oil seal front cover (1b) with engine oil pump incorporated.Remove the gasket.

1. Undo the bolts (1a) and remove the detonation sensors (1b).2. Undo the bolt (2a) and remove the rpm sensor (2b).3. Undo and remove the minimum engine oil pressure sensor.

1. Undo the bolts (1a) and remove the crankshaft rear oil seal cover (1b).

Fit the tool for rotating the crankshaft and rotate the crankshaft to gain access to the cap bolts.

	Description	Code
-	Flange	1.860.815.000

1. Undo the bolts (1a) and remove the connecting rod caps (1b) and half-bearings (1c).2. Remove the piston-connecting rod assemblies (2a) complete with half-bearings (2b).

Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.860.815.000

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

	Measurement		Value
-	Thrust half-washer thickness (mm)		2.469 - 2.485

	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)		<= 0.254

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.

1. Remove the circlips (1a) and (1b) fastening the counter-balance shaft front bearing.2. Remove the counter-balance shaft (2a) complete with rear bearing (2b) using a suitable drift.3. Keep the rear plug.

1. Remove the counter-balance shaft front bearing (1a) from the crankcase using tools (1b) and (1c).

	Description	Code
1b	Extractor	1.840.207.814

	Description	Code
1c	Mallet	1.840.206.000

Position the counter-balance shaft in a vice fitted with protective jaws.1. Remove the counter-balance shaft rear bearing circlip.2. Remove the counter-balance shaft rear bearing (2a) using a suitable drift (2b).

1. Undo the bolts (1a) and remove the engine oil jets (1b).

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	83.000 ÷ 83.010
Category B	83.010 ÷ 83.020
Category C	83.020 ÷ 83.030

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 cylinder bores must have the same oversize.

	Measurement		Value
-	Cylinder liner oversize (mm)		0.1

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	59.994 - 60.000
Category B	59.988 - 59.994
Category C	59.982 - 59.989

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

Measure the diameter of the crankpins check that they correspond to the recommended figures.

	Measurement		Value
-	Crankpin diameter (mm)	Category A	50.805 - 50.799
Category B	50.799 - 50.793
Category C	50.793 - 50.787

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

	Measurement		Value
-	Crankpin diameter undersize (mm)		0.127

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 progressive references (from zero to five starting from the front of the engine) which define the fitting position.

	Fastening	Component	dia	Value(daNm)
3b	Bolt	MAIN BEARING CAPS	M12	2.0 + 100°

Use the tool for the angular tightening of the bearing cap bolts.

	Description	Code
-	Torque wrench	1.860.942.000

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

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

Alternatively:

	Measurement		Value
-	Outer diameter (mm)	Category A	82.942 - 82.952
Category B	82.949 - 82.961
Category C	82.958 - 82.968

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	= 0.048
Category B	= 0.051
Category C	= 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
-	Piston pin outer diameter (mm)		19.996 ÷ 22.000

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 Ring	1.190 - 1.170
2nd ring	1.490 - 1.475
Oil scaper ring	2.990 - 2.975

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	0.250 - 0.500
2nd ring	0.300 - 0.500
Oil scaper ring	0.250 - 0.450

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 (mm)		20.006 - 20.014

1. Fit the caps (1b) on the connecting rods (1a) and secure them tightening the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	CONNECTING ROD CAPS	M9	2.0 + 60°

Use the tool for the angular tightening of the bearing cap bolts.

	Description	Code
-	Torque wrench	1.860.942.000

2. Check that the big end diameter is within the recommended limits; if not, replace the connecting rods.

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

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 staccatoPosition the counter-balance shaft in a vice fitted with protective jaws.1. Fit the rear bearing (1a) on the counter-balance shaft (1b) using a suitable drift (1c).Fasten the rear bearing to the counter-balance shaft using the circlip.

1. Fit the counter-balance shaft front bearing (1a) on the cylinder block/crankcase using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.816.000

Fasten the counter-balance shaft front bearing using the circlip.

1. Fit the counter-balance shaft complete with rear bearing (1a) in the cylinder block/crankcase using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.816.000

Place the counter-balance shaft rear plugs in their seats.Place the jets (1b) in their housings and tighten the bolts (1a) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	PISTON COOLING NOZZLES	-	0.9 - 1.2

1. Fit the main journal half-bearings.2. Fit the crankshaft in the crankcase.3. Fit the thrust washers on the centre bearing support.4. Fit the main bearing caps (4a) complete with half-bearings (4b).

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

5. Tighten the bolts fixing the bearing caps to the recommended torque.

	Fastening	Component	dia	Value(daNm)
5	Bolt	MAIN BEARING CAPS	M12	2.0 + 100°

Use the tool for the angular tightening of the bearing cap bolts.

	Description	Code
-	Torque wrench	1.860.942.000

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	dia	Value(daNm)
2b	Bolt	CONNECTING ROD CAPS	M9	2.0 + 60°

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

	Description	Code
-	Torque wrench	1.860.942.000

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	Crank pin/half-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	dia	Value(daNm)
-	Bolt	CONNECTING ROD CAPS	M9	2.0 + 60°

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

	Description	Code
-	Torque wrench	1.860.942.000

Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.860.815.000

1. Fit the crankcase rear cover (1a) with the oil seal incorporated and tighten the bolts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt pre-treated with eslok	REAR COVER CRANKSHAFT	M6	(Engine crankcase side) 0.9 -1.2

Place the minimum engine oil pressure sensor in its housing and tighten it to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	-	INSUFFICIENT ENGINE OIL PRESSURE SWITCH	M14	2.7 ÷ 4.0

Position the rpm sensor in its housing and secure it using the bolt.Fit the detonation sensors and secure them tightening the bolts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	KNOCK SENSOR	M8	(Engine crankcase side) 2.3 -3.3

Rotate the crankshaft so that cylinder no. 1 is at T.D.C.1. Fit the crankshaft front cover complete with gasket with the engine oil pump timing references aligned.2. Tighten the bolts securing the front crankshaft oil seal cover to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2	Bolt	FRONT COVER CRANKSHAFT	M6	(Engine crankcase side) 0.9 -1.2

Place the engine oil heat exchanger complete with pipes in its housing and secure it using the nut.

	Fastening	Component	dia	Value(daNm)
-	Nut	ENGINE OIL HEAT EXCHANGER	M20	3.3 - 4.8

Fit the engine oil filter and tighten it fully by hand.Position the engine oil intake duct complete with gasket in its housing and secure it using the olts.

	Fastening	Component	dia	Value(daNm)
-	Bolt	OIL SECTION PUMP	M6	0.9 - 1.2

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	dia	Value(daNm)
2a	Side bolt	ENGINE OIL SUMP	M6	(Engine crankcase side) 0.9 -1.2

	Fastening	Component	dia	Value(daNm)
-	Bolt	ENGINE OIL DRAIN PLUG	M8	1,8 - 2,7

	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	dia	Value(daNm)
3a	Front and rear bolt	ENGINE OIL SUMP	M8	(Engine crankcase side) 2.3 - 3.3

	Description	Code
3b	Spanner	1.860.834.000

Place the pipe from the thermostat to the crankcase in its housing and secure it using the bolts.1. Place the support on the engine for the reaction rod (1a) complete with moving timing tensioner (1b) in its housing and fasten it by tightening the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M8	(Cylinder block/crankcase side) 2.3 - 3.3

	Fastening	Component	dia	Value(daNm)
1c	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M10	(Cylinder block/crankcase side) 4.6 - 6.6

2. Position the fixed timing tensioner (2a) in its housing and secure it tightening the bolt (2b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2b	Bolt	FIXED TENSIONER	M10	4.6 ÷ 6.6

Place the rear flywheel 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	dia	Value(daNm)
2b	Bolt pre-treated with eslok	FLYWHEEL (MECH.)	M12	(Engine crankcase side) 14.7 -21.2

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

	Fastening	Component	dia	Value(daNm)
1b	Left hand bolt	DRIVE PULLEY(PULLIES) TIMING	M16	(Engine crankcase side) 32.9 -44.1

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.846.000

Position cylinder no. 1 at T.D.C.Position the cylinder head locating bushes on the engine block.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 casing until it is fittednot lubricate the gasket or the contact surfaces with oil.

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).

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

	Fastening	Component	dia	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 2 + 2 + 90° + 90° + 90°

	Description	Code
1b	Torque wrench	1.860.942.000

Connect the engine crankcase coolant tank supply pipe to the thermostat unit.Place the water pump rigid inlet pipe, complete with gasket, in position and secure it using the bolts.Connect the electrical connections for the detonation sensors.Connect the electrical connection for the rpm sensor.Connect the coolant outlet pipe from the engine oil heat exchanger to the water pump rigid inlet pipe.Connect the engine oil heat exchanger coolant supply pipe to the thermostat unit.Tighten the fastenings for the engine oil heat exchanger supply/return pipes.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

1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code
1a	Dial gauge support	1.860.895.000

Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. on the ignition stroke.Undo the bolts and remove the inlet side camshaft third cap and the exhaust side camshaft second cap.

Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting.

2. Fit the templates (2a) in place of the camshaft caps that have been removed and secure them tightening the bolts (2b) to the recommended torque.

Check that the camshaft cam profile and the templates are correctly aligned.

	Description	Code
2a	Templates	1.870.828.000

	Fastening	Component	dia	Value(daNm)
2b	Bolt	TEMPLATES FOR ENGINE TIMING	M7	(Cylinder head side) 1.4 -2.0

1. Fit the timing toothed drive belt in the following order:toothed drive pulley (1a),fixed tensioner (1b),exhaust side toothed driven pulley (1c),inlet side toothed driven pulley (1d),moving tensioner (1e),water pump pulley (1f).

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.

Using a screwdriver, rotate the moving timing tensioner until the timing belt is completely taut.1. Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 3.3

2. Tighten the bolts (2a) for the inlet side toothed timing driven pulley using tool (2b) for counter-torque.

	Fastening	Component	dia	Value(daNm)
2a	Bolt	TIMING DRIVEN PULLIES	M6	(Inlet camshaft side) 0.9 -1.2

	Description	Code
2b	Counter-torque	1.860.856.000

3. Tighten the bolt (3a) for the exhaust side toothed timing driven pulley using the tools (3b) and (3c) for counter-torque.

	Fastening	Component	dia	Value(daNm)
3a	Bolt	TIMING DRIVEN PULLIES	M12	(Exhaust camshaft side) 11.0 - 15.9

	Description	Code
3b	Support for counter-torque	1.860.831.000

	Description	Code
3c	Counter-torque	1.860.848.000

Undo the bolts and remove the tool.

	Description	Code
-	Templates	1.870.828.000

Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 1.4 - 2.0

Rotate the crankshaft throught two revolutions in the direction of rotation.Loosen the moving timing tensioner nut.4. Using a screwdriver, rotate the moving timing tensioner until the moving tensioner reference (4a) coincoides with the fixed reference (4b).Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 3.3

Remove the tool complete with dial gauge.

	Description	Code
-	Dial gauge support	1.860.895.000

Fit the spark plug for cylinder no. 1 and tighten it to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	-	SPARK PLUGS	M14	2.5 ÷ 3.6

Fit the cam cover complete with gasket and secure it using the bolts.Position the ignition coils and secure them using the fixing bolts.Connect the electrical connections to the ignition coils and secure the electrical wiring.Fit the timing belt protective cover and secure it using the 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	dia	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	(Counter-balance shaft drive belt pulley side) 2.3 - 3.3

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.846.000

Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.