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. Position the flywheel lock.
DescriptionCode
1Counter-torque1.860.846.000
2. Undo the bolts (2a) and remove the clutch plate (2b).
1. Position crankshaft gear locking tool as shown in the figure.
DescriptionCode
1Counter-torque1.870.763.000
Work with flywheel retaining tool 1860846000 fitted.
2. Undo the bolt securing the crankshaft gear and remove it.
1. Undo the bolts fixing the engine flywheel.2. Remove the engine flywheel together with plate (2a) and the flywheel retainer positioned previously.
1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).
1. Undo bolt (1a) and remove the rigid engine coolant pump inlet pipe (1b) with sealing ring.2. Undo the bolts (2a) and nut (2b) remove the water pump (2c).
1. Remove the engine oil filter using a suitable tool.2. Remove the oil pressure sending unit.3. Undo bolts (3a) and remove the engine block front cover (3b) with the built-in oil pump complete with crankshaft front oil seal (3c) and intake chamber (3d).4. Remove the engine block front cover gasket.
1. Using the service bolts, fit tool (1a) to rotate the crankshaft.
DescriptionCode
1aFlange1.860.815.000
Rotate the crankshaft using the tool fitted previously until cylinders 1 and 4 are at T.D.C.1. Undo the bolts (1a) and remove the connecting rod cap (1b) for cylinders 1 and 4.2. Remove the cylinders 1 and 4 connecting rod lower half-bearings.3. Remove the cylinders 1 and 4 connecting rod - piston assemblies.4. Remove the cylinders 1 and 4 connecting rod upper half-bearings.Carry out the same operations to remove the pistons and connecting rods for cylinders 2 and 3.Remove the tool for rotating the crankshaft.
DescriptionCode
-Flange1.860.815.000
1. Use a dial gauge on a magnetic base to check that the crankshaft end float is within specified values.
MeasurementValue
1End float (mm)0.055 ÷ 0.265
If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable thrust washers (fastened to the central main bearing half) oversized by 0.127mm.1. Unscrew bolts (1a) and (1b) and remove the lower crankcase that acts as the main bearing caps.2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.
The central main bearing half incorporates the crankshaft thrust ring halves.
Hoist the crankcase using a hydraulic hoist with chains and remove the crankcase from the support brackets. Place on a suitable workbench.    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 BENCH1. Remove the coolant chamber plugs from the crankcase using a steel drift.2. Remove the lubrication duct plug from the crankcase using a steel drift.
Check the condition of the piston cooling oil sprays.1. If they are blocked, remove the oil sprays (1a) using a steel drift (1b). Insert the drift guide hole on on the nozzle surface to prevent the drift from slipping during the extraction operation and removing the cylinder liner.
DescriptionCode
1bDrift1.860.395.000
Whenever the oil sprays are removed, they must not be reused but must be replaced.
Refitting ( Removing ) Wash and check the appearance of all compents removed.Fit the water/oil sealing plugs in the crankcase using suitable fitting tools and spread with a suitable sealant.
TypeComponentDescriptionQty.
-SealantCRANKCASE PLUGSLoktite 270-
1. Use tool (1a) and a plastic mallet to fit the new oil sprays (1b).
DescriptionCode
1aFitting tool1.860.313.000
1. Using a calibrated metal rule (1a) and a feeler gauge (1b), check the planarity of the cylinder head - cylinder block/crankcase support surface.2. If the measurement does not correspond to the recommended values, regrind the cylinder head support surface.
MeasurementValue
2Cylinder head support surface flatness (mm)< 0.1
1. Measure the diameter of the cylinder bores and check that they correspond to the recommended figures.
MeasurementValue
-Cylinder liner diameter (mm)Category A70.800 - 70.810
Category B70.810 - 70.820
Category C70.820 - 70.830
Check that the ovality of the cylinder liners is within the recommended limits.
MeasurementValue
-Cylinder liner ovality (mm)± 0.05
Check that the taper of the cylinder liners is within the recommended limits.
MeasurementValue
-Cylinder liner taper (mm)± 0.005
If the cylinder bore, taper or ovality 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.
MeasurementValue
-Cylinder liner bore diameter 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.Check that the diameter of the main journals is within specified limits.
MeasurementValue
-Main journal diameter (mm)Category A47.982 - 47.988
Category B47.988 - 47.994
Category C47.994 - 48.000
If the diameter of the main journals is not correct, they should be reground to the recommended undersize.
Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.
MeasurementValue
-Main journal undersize (mm)0.254 - 0.508
Check that the diameter of the crankpins corresponds to the recommended figures.
MeasurementValue
-Crankpin diameter (mm)41.990 ÷ 42.008
If the diameter of the crankpins is not correct, they should be reground to the recommended undersize.
Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.
MeasurementValue
-Crankpin undersize (mm)0.254 / 0.508
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 main bearing halves in their seats on the upper crankcase, aligning the lubrication holes and ensuring scrupulous cleaninliness. The centre crankshaft bearing has thrust half-washers incorporated becuase it acts as a thrust carrier.If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.1. Fit the crankshaft in its seat on the crankcase.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.
1. Fit the main journal half-bearings in the lower cylinder block/crankcase.2. Fit the lower crankcase to the upper crankcase, checking that the codes stamped on both parts of the crankcase are aligned because the crankcase components are not interchangeable.
1. Tighten bolts (1a) and bolts (1b) securing the lower crankcase. Use tool (1c) for angular tightening.
DescriptionCode
1cTorque wrench1.860.942.000
1. Remove the lower crankcase and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage.
Check one main journal at a time, without rotating the crankshaft.
MeasurementValue
-Clearance between main bearings - crankshaft journals (mm)0.025 - 0.049
After checking all the main journals, apply sealant to the contact surfaces between the lower crankcase and upper crankcase. Then fit the lower crankcase permanently by tightening the bolts to torque in the order described previously.
Apply a 2 mm thick sealant strip continuously to the lower crankcase surface.
    Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCHClean 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.
MeasurementValue
-Outer diameter (mm)Category A70.760 - 70.770
Category B70.770 - 70.780
Category C70.780 - 70.790
from the lower edge of the piston skirt (mm)6
Position the piston in the cylinder liner and user a feeler gauge to measure the specified clearance.
MeasurementValue
-Clearance between piston - cylinder liner (mm)0.030 ÷ 0.050
Check that the pin seat bore diameter is within specified values, otherwise replace the pin with an oversized pin.
MeasurementValue
-Piston pin housing diameter (mm)17.982 ÷ 17.986
MeasurementValue
-Pin oversize (mm)0.2
Check that the outer diameter of the piston pins corresponds to the recommended figures; if not, replace the worn components.
MeasurementValue
-Piston pin outer diameter (mm)17.970 ÷ 17.974
User a micrometer gauge to measure the thickness of the piston sealing rings.
MeasurementValue
-Thickness (mm)1st sealing ring1.170 ÷ 1.190
2nd sealing ring1.175 ÷ 1.190
3rd sealing ring2.475 - 2.490
MeasurementValue
-Sealing ring oversize (mm)0.4
1. Fit the sealing rings (1a) in the cylinder liner and use a feeler gauge (1b) to check the gap between the seal ends is within specified limits. Otherwise replace the sealing rings.
MeasurementValue
-Gap (mm)1st sealing ring0.200 ÷ 0.400
2nd sealing ring0.250 ÷ 0.450
3rd sealing ring0.200 ÷ 0.450
1. Use a feeler gauge (1a) to check the mating clearance between the retaining rings (1b) and the grooves on the piston (1c).
MeasurementValue
-End float (mm)1st sealing ring0 - 06
2nd sealing ring0 - 0.055
3rd sealing ring0 - 0.0055
Check that the big end and small end diameters are within specified limits.
MeasurementValue
-Big end diameter (mm)45.128 ÷ 45.138
MeasurementValue
-Small end diameter (mm)17.939 ÷ 17.956
    Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING    Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCH    Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCHPosition the tool for rotating the crankshaft.
DescriptionCode
-Flange1.860.815.000
Turn the crankshaft using the tool fitted previously.Fit the connecting rod-piston assemblies and align in accordance with the following references.1. Piston class and arrow indicating camshaft side.2. Area where the number of the matching cylinder liner is stamped.3. Gudgeon pin offset.
Letters identifying the cylinder liner classes are shown on the crankcase.
1. Fit the connecting rod-piston assemblies (1a) with half-bearings using tool (1b) to compress the piston rings and then fit the piston into the liner.
DescriptionCode
1bFitting tool1.860.700.000
Rotate the engine on the overhaul stand.1. Apply the calibrated wire (plastigate) for measuring the crankpin clearance.
1. Fit the connecting rod caps (1a) complete with half-bearings (1b) and secure by tightening bolts (1c) to the specified torque using tool (1d) for angular tightening.
Fit the connecting rod caps so that the number stamped on each cap faces towards the same side as the number stamped on the big end.
FasteningComponentØ  Value(daNm)
1cBoltCONNECTING ROD CAP FASTENERSM82 + 40°
DescriptionCode
1dTorque wrench1.860.942.000
1. Remove the connecting rod caps and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage.
Check one crankpin at a time, without rotating the crankshaft.
MeasurementValue
-Crankshaft crankpins (mm)0.024 - 0.060
If the value measured is not within the recommended figures, replace the connecting rod bearings.Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.Remove the tool for rotating the crankshaft.
DescriptionCode
-Flange1.860.815.000
Rotate the engine on the overhaul stand.1. Position a new oil pump gasket.2. Fit the front crankcase cover (2a) with built-in oil pump complete with intake chamber and secure by tightening bolts (2b) to the specified torque.
FasteningComponentØ  Value(daNm)
2bBoltENGINE OIL PUMPM6 X 201
FasteningComponentØ  Value(daNm)
2bBoltENGINE OIL PUMPM6 X 321
3. Fit the engine oil filter.4. Fit the engine oil pressure sending unit and tighten it to the recommended torque.
FasteningComponentØ  Value(daNm)
4BoltINSUFFICIENT ENGINE OIL PRESSURE SWITCHM61
1. Fit the oil seal to the crankshaft front cover (1a) using the tool (1b).
DescriptionCode
1bFitting tool1.860.990.000
1. Fit the crankcase rear cover (1b) and secure by tightening bolts (1a) to the specified torque.
The crankcase rear cover comes complete with an oil seal.
FasteningComponentØ  Value(daNm)
1aBoltREAR COVER CRANKSHAFTM6 X 201
FasteningComponentØ  Value(daNm)
1aBoltREAR COVER CRANKSHAFTM6 X 321
1. Fit the flywheel lock.
DescriptionCode
1Counter-torque1.860.846.000
2. Fit engine flywheel (2a) using retaining washer (2b) and secure by tightening bolts (2c) to the specified torque.
FasteningComponentØ  Value(daNm)
2cBoltFLYWHEEL (MECH.)M84.4
1. Position the gear on the crankshaft.2. Fit the crankshaft locking tool.
DescriptionCode
2Counter-torque1.870.763.000
3. Secure the crankshaft gear by tightening the bolt to the specified torque.
FasteningComponentØ  Value(daNm)
-BoltDRIVE PULLEY(PULLIES) TIMINGM12 X 1.252 + 90°
1. Fit the flywheel lock.
DescriptionCode
1Counter-torque1.860.846.000
2. Fit engine flywheel (2a) using retaining washer (2b) and secure by tightening bolts (2c) to the specified torque.
FasteningComponentØ  Value(daNm)
2cBoltFLYWHEEL (MECH.)M84.4
1. Align the driven plate to install clutch assembly (1a), using locating pin (1b).
DescriptionCode
1bClutch locating tool1.870.418.000
2. Tighten the bolts fixing the clutch to the engine flywheel.Remove the flywheel locking tool applied previously.
Clean the crankcase and oil sump contact surfaces, removing the silicon sealant residues.1. Apply the specified sealant continuously without any breaks over the entire perimeter of the crankcase sump as shown in the figure.
Join the end to the beginning seamlessly.
TypeComponentDescriptionQty.
1Silicon sealantPISTON SETLOCTITE 5900-
2. Fit crankcase sump (2a) and secure by tightening bolts (2b) and nuts (2c) to the specified torque.
When positioning the crankcase sump, avoid significant sideways movements that could remove the sealant.
FasteningComponentØ  Value(daNm)
2bBoltENGINE OIL SUMPM61
FasteningComponentØ  Value(daNm)
2cNutENGINE OIL SUMPM60.5
1. Because the timing is adjusted with the four pistons in line, i.e. half-way along their effective strokes, it is essential to position the crankshaft in phase with the camshafts. They can be approximately positioned by turning the crankshaft gear (1a) until the locating dowel (1b) is positioned opposite to the rpm and TDC sensor seat (1c) with the first cylinder piston in descending phase, i.e. intake.
Remove the protective cover for the rear camshaft gears.1. Unscrew the cylinder head extension side plugs.
1. Position tools (1a) in place of the plugs unscrewed previously, then turn the camshafts until the groove (1b) on the each camshaft is aligned with tool pin (1c). In ths way, the camshafts are in phase.
DescriptionCode
1aLocating pins.1.860.985.000
Refit the protective cover for the rear camshaft gears.Fit the locating dowels in the cylinder block/crankcase.1. Position the gasket on the cylinder block/crankcase with the working "ALTO" [TOP] uppermost, taking care not to get the gasket or the surface of the cylinder block/crankcase dirty or covered in oil. The diameters of the arrowed holes decrease in order from cylinders 1 to 4 in order to distribute the coolant evenly over the entire crankcase.A = intake sideB = exhaust side.
The cylinder head gasket is 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 in its sealed, nylon container;
  • only take it out shortly before fitting;
  • not lubricate the gasket or get oil on it, taking care to ensure that the surfaces of the cylinder block/crankcase and cylinder head are clean.
Position the cylinder head on the crankcase by aligning the locating pins.1. Tighten the cylinder head bolts (1a) to the recommended torque using tool (1b) for angular tightening.
Follow the order shown in the figure for each tightening sequence.
FasteningComponentØ  Value(daNm)
1aBoltCYLINDER HEADM9 x 1.253 + 90° + 90°
DescriptionCode
1bTorque wrench1.860.942.000
1. Position the cylinder head extension gasket on the cylinder head mating surface.2. Position the tappet retaining tools beneath the cylinder head extension, then place the cylinder head extension on the cylinder head and withdraw the tools.3. Use tool (3a) to tighten camshaft housing bolts (3b) to the specified torque.4. Refit the plugs and tighten to the specified torque.
DescriptionCode
2Tappet retaining tool1.860.988.000
DescriptionCode
3aSpanner1.860.834.000
FasteningComponentØ  Value(daNm)
3bHex-headed boltCYLINDER HEAD EXTENSIONM8 X 11.5
Fit the timing drive pulley by screwing in the bolt.1. Position tools (1a) in their seats on the 1st and 2nd cylinder. Tighten parts (1b) to a torque of 0.5 daNm.2. Turn the crankshaft in its normal direction of rotation until surface (2a) on the tool mobile part is aligned with surface (2b) on the part secured in the spark plug socket. When both tools positioned in the spark plug sockets are in this condition, the engine pistons will be aligned, i.e. half-away along their effective strokes.
The pistons were approximately aligned previously.
Crank the crankshaft. Proceed gradually to prevent the tool pins being expelled by compression of the pistons.
Camshaft timing was adjusted previously by applying tools (3b).
DescriptionCode
1aBearings1.860.992.000
DescriptionCode
3bLocating pins.1.860.985.000
1. Fit the timing belt by fitting firstly over the crankshaft gear (1a) and then over the water pump pulley (1b), the timing drive pulley (1c) and lastly the belt tensioner fixed pulley 1(d).
Ensure that this operation is performed with the camshaft pulley (1c) slack.
1. Use suitable round-nosed pliers to turn the automatic tensioner to the position of maximum tension, i.e. with the mobile reference (1a) located as shown in the figure. Then secure nut (1b) fastening the tensioner to the mount.
1. Use tool (1a) to tighten the camshaft pulley bolts (1b) to the specified torque.
DescriptionCode
1aSupport for counter-torque1.860.831.000
DescriptionCode
1aSpanner for rotating timing pullies1.860.831.002
FasteningComponentØ  Value(daNm)
1bBoltTIMING DRIVEN PULLIESM12 X 1.2512
Remove the tools postioned previously to adjust the timing and lock the camshaft and turn the crankshaft through two revolutions in its direction of rotation to settle the timing drive belt.
1. Loosen the nut securing the tensioner and align the mobile pointer (1a) with the fixed reference (1b), holding the tensioner with the round-nosed pliers at all times in order not to release the tension of the belt tensioner too suddenly.2. Once both references are aligned, tighten nut (2a) securing the tensioner to the specified torque.Turn the crankshaft through two revolutions in its normal rotation direction, then reposition the tools used to adjust engine timing and check the engine is in phase.Refit the cylinder head extension side plugs.
FasteningComponentØ  Value(daNm)
2aNutMOBILE TIMING TENSIONERM82.5
Refit the timing drive belt lower guard and upper guard.Fit the auxiliary drivebelt pulley to the crankshaft and tighten the bolts to the specified torque.
FasteningComponentØ  Value(daNm)
-BoltCRANKSHAFT PULLEYM82.2
Fit the rpm and TDC sensor and secure it using the bolt.Refit the oil dipstick.Refit the intake manifold complete with injectors and throttle body.Position the electrical wiring and connect the electrical connections.
DescriptionConnector
-Integrated throttle casing actuator    N75
DescriptionConnector
-Fuel vapour recovery solenoid valve    L10
DescriptionConnector
-Engine temperature sending unit    K36
DescriptionConnector
-Injector coupling    D81
DescriptionConnector
-Earth on engine    C40
DescriptionConnector
-Detonation sensor    K50
DescriptionConnector
-Engine oil pressure sensor (switch)    K30
DescriptionConnector
-Rpm sensor    K46
Position the relevant part of the wiring in the appropriate duct.    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE